Radial Forging Machine Eccentric Shaft Hydraulic Cylinder
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Solution Overview
Problem
Radial forging machines are limited in their operational flexibility, as they can either function as swaging machines with short strokes and high frequencies or traditional forging presses with longer strokes and lower frequencies, and current systems are prone to overload issues and energy inefficiency.
Innovation Solution
A radial forging machine design that incorporates an eccentric shaft, connecting rod, and hydraulic cylinder system, allowing for both mechanical and hydraulic actuation modes, enabling operation as either a swaging machine or traditional forging press, with hydraulic chamber adjustments for overload protection and flexible stroke control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the machine operates as a swaging machine with short working strokes and high frequencies, then productivity is improved, but the machine lacks versatility for other forging operations
Solution Approach 1:
The system dynamically switches between two operational modes: mechanical actuation for high-frequency swaging operations and hydraulic actuation for low-frequency forging operations. The actuation mode is changed based on the specific operational requirements, allowing the machine to adapt its characteristics rather than being fixed in one mode
Solution Approach 2:
The forging machine is designed to perform multiple functions by incorporating both mechanical and hydraulic actuation systems. The same hammer mechanism can be actuated differently depending on the needs: mechanically for swaging and hydraulically for traditional forging, making the machine universal rather than dedicated to a single function
2Adaptability or versatility
If the machine operates as a traditional forging press with longer working strokes and lower frequencies, then adaptability is improved, but productivity decreases
Solution Approach 1:
The system dynamically switches between two operational modes: mechanical actuation for high-frequency swaging operations and hydraulic actuation for low-frequency forging operations. The actuation mode is changed based on the specific operational requirements, allowing the machine to adapt its characteristics rather than being fixed in one mode
Solution Approach 2:
A hydraulic actuation system is introduced to enable traditional forging press operations with longer strokes and lower frequencies. The hydraulic system provides controlled, slow movement for forging operations while the mechanical system handles high-frequency swaging, with the ability to switch between modes as needed
3Ease of operation
If a screw/nut-screw connection is used to modify cylinder length and hammer position, then ease of operation is improved, but the connection is prone to wear and failures under overload conditions
Solution Approach 1:
The screw/nut-screw connection is replaced with a hydraulic cylinder actuation system. The hydraulic system modifies the cylinder length and hammer position through fluid pressure control, eliminating the mechanical wear and failure issues associated with threaded connections while maintaining ease of adjustment through hydraulic control
4Force
If the hydraulic cylinder operates under overload conditions, then force capability is improved, but the screw connection suffers from wear and failures
Solution Approach 1:
The mechanical screw/nut-screw connection is replaced with a hydraulic actuation system that can handle overload conditions without wear. The hydraulic system transmits force through incompressible fluid, eliminating the friction and wear issues of threaded connections while maintaining or increasing force capability through hydraulic pressure
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
Enables high-frequency, short-stroke operation as a swaging machine and low-frequency, long-stroke operation as a traditional forging press, while protecting the machine from overloads and improving energy efficiency by switching between mechanical and hydraulic control modes.
Implementation Method 1
a first hydraulic chamber, arranged between piston and hollow body, allows to move the hollow body away from and/or towards said piston
Implementation Method 2
an eccentric shaft, adapted to rotate about a first axis... the hammer comprises a hydraulic cylinder provided with a hollow body... and a piston at least partially inserted within said hollow body and removably coupled to the connecting rod
Data Source
Figure 1
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AI summary
A forging machine with one or more hammers, comprising, for each hammer, an eccentric shaft (1) adapted to rotate about a first axis; a connecting rod (2), adapted to be actuated by the eccentric shaft operating as crank; a guiding frame (10); wherein the hammer is adapted to perform an alternating working movement within said guiding frame along a second axis perpendicular to the first axis; wherein the hammer comprises a hydraulic cylinder (8) provided with a hollow body (5), to which a forging member (15) is externally fixed, and with a piston (3) at least partially inserted within said hollow body and removably coupled to the connecting rod; wherein a first hydraulic chamber (6), arranged between piston and hollow body, allows to move the hollow body away from and/or towards said piston; wherein uncoupling means are provided for uncoupling the piston from the connecting rod.