Segmented Hydraulic Block Layout for Compact Pump Integration
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Solution Overview
Problem
Conventional hydraulic blocks are heavy, require large installation spaces, have increased assembly efforts, and suffer from difficult ventilation due to dead volume in auxiliary bores, and are costly to produce.
Innovation Solution
A hydraulic block is designed into three horizontal sections: a foot section with tank connections, a middle section with a pump engine, and a head section with valves and consumer connections, produced using 3D printing, which allows for cost-effective and simplified manufacturing, reduced material usage, and improved accessibility during maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a hydraulic block is produced by machining a cubic metal body, then the structural strength and sealing reliability are improved, but the weight increases, installation space increases, assembly effort increases, and machining time increases
Solution Approach 1:
The hydraulic block is divided into three distinct block sections (foot section, middle section, head section) arranged vertically. Each section serves specific functions: the foot section contains the suction connection, the middle section houses the pump drive unit, and the head section contains valves and consumer connections. This segmentation allows for optimized material distribution, reducing overall weight while maintaining structural integrity and sealing reliability in each functional zone.
Solution Approach 2:
The patent transitions from traditional horizontal machining approaches to a vertical arrangement of block sections. The foot section, middle section, and head section are stacked vertically, with connections and components arranged in the vertical dimension. This dimensional reorganization reduces the horizontal footprint (installation space) and allows for more efficient material usage, thereby reducing weight while maintaining all necessary functional capabilities.
2Stability of the object's composition
If a hydraulic block is produced by machining a cubic metal body, then the structural integrity is improved, but the installation space increases and production costs increase
Solution Approach 1:
The hydraulic block is segmented into three vertical sections, each optimized for its specific function. The foot section (with suction connection), middle section (with pump drive unit), and head section (with valves and consumer connections) are arranged vertically, reducing the horizontal installation footprint while maintaining structural integrity through careful design of connection interfaces and support structures between sections.
Solution Approach 2:
Multiple functional elements are merged into compact vertical arrangements. The pump drive unit is integrated into the middle section, valves are consolidated in the head section, and all connections are arranged vertically. This merging of functions into a compact vertical structure reduces installation space while maintaining structural integrity through unified design and optimized material distribution.
3Ease of operation
If auxiliary bores are included in the hydraulic block, then fluid distribution is improved, but ventilation becomes difficult due to dead volume
Solution Approach 1:
The block sections are designed with locally optimized fluid channels and bores. Rather than uniform auxiliary bores throughout, the patent implements specific channel geometries in each section (foot, middle, head) that minimize dead volume while ensuring adequate fluid distribution to all connection points. The vertical arrangement allows for gravity-assisted fluid flow and improved ventilation pathways.
4Device complexity
If the hydraulic block is designed with integrated pump drive unit, then device complexity is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The pump drive unit is merged into the middle section of the hydraulic block, eliminating the need for separate pump housings and reducing overall device complexity. The integration is achieved through unified manufacturing of the middle section that incorporates both the hydraulic block structure and pump mounting features, reducing assembly steps while maintaining necessary manufacturing precision for hydraulic connections and pump alignment.
Solution Approach 2:
The middle section serves multiple functions: it provides structural support for the hydraulic block, houses the pump drive unit, and contains fluid channels for suction and discharge. This multi-functionality reduces overall device complexity by consolidating components that would traditionally require separate housings and mounting structures, while the universal design maintains adequate 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
The design reduces weight and installation space, simplifies assembly and maintenance, and lowers production costs while enhancing fluid flow and sealing reliability, allowing for compact and robust system design.
Implementation Method 1
a mold with a core and at least one wall surface of an external geometry of the hydraulic block is produced using the 3D sand core printing method
Data Source
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AI summary
A hydraulic block is disclosed, divided into three horizontal sections. One block section is designed as a base section, which has tank connections, particularly on the underside. One block section is designed as a middle section, in or on which a pump drive can be arranged. Another block section is designed as a top section, which serves for the connection of at least one valve and at least one hydraulic connection.