Sensor-Integrated Hydraulic Cylinder for Predictive Failure Detection
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Solution Overview
Problem
Mold immobilization in material injection installations leads to production delays and costly maintenance due to unforeseen breakdowns, particularly in hydraulic cylinders prone to stress-related failures and leaks, with no existing solution for automatic anticipation or adjustment of such failures.
Innovation Solution
A hydraulic cylinder equipped with a position sensor and a magnetically controlled sensor system that transmits real-time operational data to an external module, allowing for proactive identification and prevention of potential failures, integrated into an installation with a control module that communicates with solenoid valves and pressure sensors to manage the mold's operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hydraulic cylinders are used to eject molded parts, then the molding function is achieved, but the cylinders are prone to stress-related failures and leaks causing mold immobilization
Solution Approach 1:
The patent implements preliminary action by continuously monitoring cylinder operation parameters (position, pressure, temperature) and detecting anomalies before they cause complete failure. The control module identifies trends indicating potential rod breakage or seal leakage, allowing maintenance to be scheduled before the cylinder becomes completely inoperative, thus preventing mold immobilization.
Solution Approach 2:
The patent applies feedback by using sensors to continuously monitor cylinder position, pressure, and temperature, then feeding this information back to the control module. The control module analyzes this feedback data to detect abnormal patterns indicating developing failures, enabling proactive maintenance decisions that prevent complete cylinder failure and mold downtime.
2Reliability
If position sensors are added to monitor cylinder operation, then failure anticipation is enabled, but device complexity increases
Solution Approach 1:
The patent applies universality by designing a control module that performs multiple functions: it controls the hydraulic cylinder operation, processes sensor data from position/pressure/temperature sensors, detects anomalies, and generates maintenance alerts. This multi-functional approach consolidates monitoring and control functions into a single device, adding reliability through comprehensive monitoring while minimizing the increase in overall system complexity.
Solution Approach 2:
The patent merges the position sensor, pressure sensor, temperature sensor, and control module into an integrated monitoring system. By combining these elements that work together to detect cylinder health status, the patent reduces the complexity that would arise from separate independent systems while enhancing the ability to anticipate failures through comprehensive parameter monitoring.
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 real-time monitoring and anticipation of potential failures, reducing downtime and maintenance costs by providing operators with timely alerts and enabling corrective actions before complete immobilization, thus maintaining efficient production.
Implementation Method 1
a magnet is enclosed in said piston
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention relates to a hydraulic cylinder comprising a body (1) having a wall (3) defining a cylindrical housing (2), having an axis (X) of the cylindrical housing, in which a piston (4) is mounted for free movement, said piston (4) dividing said cylindrical housing (2) into two sealed chambers (5, 6) isolated from each other, the wall (3) of the body having at least two passages (7, 8) for introducing or expelling a fluid into each of the two said chambers (5, 6). The cylinder also comprises two end walls (17, 18) and a rigid rod (32), integral with the piston (4) and coaxial with the cylindrical housing (2), said rod passing through (32) an opening (20) formed in one of the two end walls (17, 18).The cylinder is remarkable in that it includes a position sensor (38) comprising a sensor head (39), a sensor rod (40) which is integral with the sensor head (39) and around which a magnet (41) is fitted, and a connector (42) connected to said sensor head (39).