Pressure Intensifier Piston Rod Control Without Check Valves
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Solution Overview
Problem
Conventional pressure intensifier devices for diecasting machines are prone to wear, require complex production processes, and suffer from delayed pressure rise times due to the use of check valves, which can lead to spring breakages and inefficiencies.
Innovation Solution
A pressure intensifier device without a check valve, where the piston rod can move unhindered into the outlet region to provide pressure increase, and is controlled independently of the pressure conditions in the piston/cylinder unit, allowing for early initiation of the forward motion and minimizing production complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a check valve is installed in the pressure intensifier device to prevent return flow, then the pressure medium can be prevented from flowing back to the reservoir, but the device complexity increases and reliability decreases due to wear and spring breakages
Solution Approach 1:
The patent removes the check valve from the pressure intensifier device entirely. Instead of using a mechanical check valve with moving parts that are prone to wear and failure, the invention uses the piston rod's position to control fluid flow. The piston rod in the advanced blocking position naturally blocks the fluid connection between inlet and outlet regions, eliminating the need for a separate check valve mechanism and its associated reliability issues.
2Reliability
If a check valve with spring mechanism is used to control pressure medium flow, then the return flow can be prevented, but the device becomes more complex and susceptible to wear and spring breakages
Solution Approach 1:
The invention extracts and eliminates the spring mechanism and check valve assembly from the pressure intensifier device. The piston rod itself serves the dual function of transmitting force and controlling fluid flow direction. By removing the spring-loaded check valve mechanism, the patent eliminates the complexity of assembling multiple components and reduces production steps while improving reliability through fewer moving parts.
3Productivity
If a check valve is used to control pressure rise, then the pressure medium flow can be controlled, but the pressure rise time is delayed due to valve operation delays
Solution Approach 1:
The patent implements preliminary action by positioning the piston rod in advance in the advanced blocking position before pressure buildup is needed. This pre-positioning of the piston rod immediately blocks the fluid connection between inlet and outlet regions, allowing pressure to rise without delay. The system is prepared in advance with the flow control mechanism already in the correct position, eliminating the time lag associated with check valve operation.
4Ease of operation
If a valve sleeve with conical valve cone seat is installed to form a check valve, then the pressure medium flow can be controlled, but the manufacturing precision requirements increase and device complexity increases
Solution Approach 1:
The patent removes the valve sleeve and conical valve cone seat components entirely. Flow control is achieved through the simpler geometry of the piston rod end portion and outlet region passage cross-section. The piston rod's cylindrical geometry and the outlet region's passage design provide adequate flow control without requiring high-precision conical surfaces or specialized valve components, thereby reducing manufacturing precision requirements.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design enhances the reliability and reduces wear of the pressure intensifier device, enabling faster pressure rise times and improved casting quality by eliminating the need for check valves and associated delays.
Implementation Method 1
a pressure intensifier device for increasing pressure in a pressurized fluid chamber of a piston/cylinder unit
Implementation Method 2
in an advanced blocking position, blocks this connection with a free end portion, with which it extends into the outlet region
Data Source
AI summary
A pressure intensifier device for increasing pressure in a pressurized fluid chamber of a piston/cylinder unit and a casting unit provided therewith for a diecasting machine, and also an associated operating method are provided. The pressure intensifier device has a pressure intensifier cylinder and a pressure intensifier piston, which is guided in an axially movable manner in the cylinder, wherein the pressure intensifier cylinder has an outlet region, an inlet region upstream of the outlet region and a piston guiding chamber, and the pressure intensifier piston has a piston part, which is guided in the piston guiding chamber, and a piston rod, which extends from the piston part to the inlet region, in a maximally retracted release position releases a fluid connection between the inlet region and the outlet region and, in a maximally advanced blocking position, blocks this connection with a free end portion, with which it extends into the outlet region. Over a portion that can be passed through by the free end portion of the piston rod during movement from the release position into the blocking position, the outlet region has a free passage cross section for the free piston rod end portion that is at least equal in size to a rod cross section of the free piston rod end portion. Advantageously, a pressure intensifier inlet valve can be controlled independently of a pressure in the pressurized fluid chamber of the piston/cylinder unit.