Segmented Hydraulic Cylinder for Radial Forging Force and Stroke Control
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Solution Overview
Problem
Radial forging machines require high drive power to achieve both high forces and long travel ranges, which is inefficient and energy-intensive.
Innovation Solution
A hydraulic cylinder is designed with divided partial spaces that can be controlled independently to optimize drive power, allowing for either fast piston feed with low force or slow feed with high force, using a variable ratio of sub-areas and a valve arrangement to manage fluid pressure, reducing the overall drive power required.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a hydraulic cylinder is designed to provide both high force and large stroke, then the drive power required increases significantly
Solution Approach 1:
The cylinder chamber is divided into two hydraulically separable sub-chambers (first and second sub-chambers) with different effective areas. This segmentation allows independent control of each sub-chamber's fluid pressure, enabling the system to achieve high force when needed while reducing drive power during normal operation by activating only one sub-chamber at a time.
2Productivity
If the piston member moves quickly to increase productivity, then the force output decreases
Solution Approach 1:
The valve arrangement enables dynamic switching between different operating modes by controlling fluid supply to different sub-chambers. The system can rapidly switch between high-speed low-force mode (one sub-chamber active) and high-force low-speed mode (both sub-chambers active), optimizing performance for different process requirements.
3Device complexity
If the hydraulic system is simplified to reduce complexity, then the ability to control different force and speed modes is reduced
Solution Approach 1:
The two sub-chambers serve multiple functions: they can operate independently or together, enabling the same hydraulic cylinder to perform both high-speed positioning and high-force forming operations. This multi-functionality is achieved through a relatively simple valve arrangement that controls fluid distribution to the different sub-chambers.
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 allows for flexible application of forces and stroke speeds, reducing energy consumption while maintaining productivity, especially when forming temperature-critical materials, and can be adapted for various forging strategies.
Implementation Method 1
both partial spaces can be acted upon by fluid under working pressure with resultant piston forces in the direction of action
Data Source
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AI summary
The invention relates to a hydraulic cylinder comprising a cylinder (2), a piston element (3) movably guided in the cylinder (2) in a working direction (W) and comprising an active surface (5, 7), and a first opening for feeding a fluid into a cylinder chamber (4, 6) by means of the active surface (5, 7). A working pressure of the fluid acting on the active surface (5, 7) drives the piston element (3) in the working direction (5, 7). The active surface comprises a first partial surface (5) and at least one second partial surface (7), the cylinder chamber being divided into a first sub chamber (4) with the first opening (4a) by means of the first active surface (5) and a second partial surface (6) with a second opening (6a) by means of the second partial surface (7), and the partial surfaces (4, 6) are hydraulically separated from each other at least in a selectable operating mode.