Integrated Pump Heat Exchanger for Portable Post-Tensioning Jacks
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Solution Overview
Problem
Hydraulic fluid in post-tensioning jack systems becomes overheated, requiring external cooling systems that limit portability and increase system size and weight, and traditional heat exchangers are inefficient in maintaining optimal fluid viscosity.
Innovation Solution
A hydraulic pump unit with integrated cooling, featuring a coil and fan system for heat exchange with the atmosphere, allowing for a compact and portable design that maintains fluid temperature without external cooling systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional external cooling systems are used for hydraulic fluid, then heat dissipation is achieved, but system size and weight increase, and portability is limited
Solution Approach 1:
The cooling system is merged with the hydraulic pump by integrating the cooling coil directly into the pump housing. The coil is positioned to be in direct thermal contact with the hydraulic fluid passages within the pump, allowing heat exchange without requiring separate external cooling equipment. This integration eliminates the need for separate cooling system components, reducing overall system weight and size while maintaining effective heat dissipation.
2Temperature
If traditional external heat exchangers are used, then heat transfer is facilitated, but system complexity increases and portability is reduced
Solution Approach 1:
The cooling coil is integrated directly into the hydraulic pump housing, merging the heat exchange function with the pump structure. The coil is positioned to utilize existing hydraulic fluid passages within the pump, eliminating the need for separate external heat exchanger connections and reducing system complexity.
Solution Approach 2:
The hydraulic pump's own structure and fluid circulation system are utilized to provide cooling functionality. The existing pump housing and fluid passages serve dual purposes: hydraulic operation and heat exchange, allowing the system to cool itself without requiring additional external cooling infrastructure.
3Temperature
If large fluid reservoirs are used to dissipate heat, then acceptable working temperature is maintained, but system size and portability are compromised
Solution Approach 1:
The cooling coil is integrated into the pump housing, merging the heat exchange function with the pump structure itself. This eliminates the need for enlarged reservoirs and allows effective heat dissipation from a compact pump unit, maintaining portability and small form factor.
Solution Approach 2:
Instead of increasing reservoir volume to provide heat dissipation capacity, the solution transitions to a surface-area-based heat exchange approach using the integrated cooling coil. The coil provides extensive heat transfer surface area within the compact pump housing, achieving effective cooling without increasing system volume.
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
The integrated cooling system effectively manages fluid temperature, reducing the need for external cooling and enabling a smaller, lighter, and more maneuverable hydraulic pump unit.
Implementation Method 1
a cooling coil located directly beneath the fan and over the hydraulic pump and that is fluidly coupled to the hydraulic pump to allow for hydraulic fluid to flow through and exchange heat with the atmosphere
Implementation Method 2
a fan positioned over the cooling coil to force air through the cooling coil
Data Source
AI summary
The present disclosure relates to an improved hydraulic pump for maintaining acceptable operating temperatures for hydraulic fluid used in a post-tensioning jack system for post-tensioning concrete. Embodiments include a pump unit with a fan and a heat exchanger. The heat exchanger may be located directly below the motor for the pump and a fan unit; other embodiments include a heat exchanger may be located on a side of the pump with a co-located fan unit. The pump unit may be portable and battery powered. The pump unit may include a digital display for input and output of operating parameters.