Spring-Loaded Accumulator for Hydroshaping Cycle Time
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Solution Overview
Problem
Current high-pressure hydraulic systems for hydroshaping hollow workpieces are too slow for series production and do not allow for efficient integration of subsequent mechanical operations like punching or cutting due to limitations in pressure control and cycle time.
Innovation Solution
A high-pressure shaping system with a piston-cylinder-spring unit that maintains pressure during and after shaping, enabling a pressure plateau for concurrent or subsequent manufacturing operations by using a spring-loaded pressure-storing cylinder connected to the hydraulic line, allowing additional operations like punching or cutting during the press stroke.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a hydraulic locking press with electronic and hydraulic pressure controllers is used to maintain pressure during hydroshaping, then the workpiece can be properly shaped, but the cycle time increases to 30-40 seconds making the system too slow for series production
Solution Approach 1:
The patent applies preliminary action by pre-charging the accumulator with hydraulic fluid at a predetermined pressure before the shaping operation. This allows the system to rapidly deliver the required pressure volume during shaping without needing to maintain continuous high pressure through complex control systems, thereby reducing cycle time while maintaining shaping precision.
Solution Approach 2:
The patent utilizes a spring-loaded accumulator as a hydraulic energy storage device that automatically maintains system pressure through mechanical spring force rather than electronic controls. This simplified hydraulic approach eliminates the need for complex electronic pressure controllers and valves, significantly reducing system response time and enabling series production while maintaining adequate shaping pressure.
2Manufacturing precision
If the dies are held closed for 5-10 seconds to complete hydroshaping, then the workpiece is properly formed, but additional manufacturing operations like punching or cutting cannot be performed during the same press stroke
Solution Approach 1:
The accumulator is pre-charged with sufficient hydraulic fluid volume and pressure before the shaping operation begins. This preliminary preparation allows the shaping process to complete rapidly using stored energy, creating a time window within the same press stroke to perform additional operations like punching or cutting without extending the overall cycle time.
Solution Approach 2:
The patent enables continuous useful action by maintaining system pressure through the accumulator during and after shaping. This continuous pressure availability allows multiple operations—hydroshaping followed immediately by punching, cutting, or other die operations—to be performed in sequence during a single press stroke, maximizing equipment utilization and production efficiency.
3Manufacturing precision
If a complex electronic and hydraulic pressure control system with multiple valves and sensors is used, then pressure can be maintained during shaping, but the system complexity increases and requires additional external energy sources
Solution Approach 1:
The patent replaces complex electronic and hydraulic pressure control systems with a mechanically self-regulating spring-loaded accumulator. The spring mechanism automatically maintains predetermined pressure through its mechanical properties alone, eliminating the need for electronic controllers, solenoid valves, and sensors. This mechanical approach simplifies the system while maintaining adequate pressure control for hydroshaping operations.
Solution Approach 2:
The accumulator serves itself by using the spring's inherent mechanical properties to automatically maintain system pressure without requiring external control systems. The spring expands and contracts based on system pressure needs, self-regulating the hydraulic fluid delivery to maintain shaping pressure without electronic intervention or additional energy input beyond the initial spring compression.
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 solution enables efficient integration of additional manufacturing operations during or after hydroshaping by maintaining high pressure levels, allowing for precise shaping and subsequent processing without external energy sources, significantly improving cycle times and operational efficiency.
Implementation Method 1
A spring-loaded pressure-storing cylinder is connected by a hydraulic line to the operating cylinder and to the workpiece
Implementation Method 2
A fluid line is connected between the cylinder and the interior of the workpiece and serves for internally pressurizing the workpiece
Data Source
AI summary
A high-pressure system for hydroshaping a hollow workpiece has a lower die and an upper die vertically shiftable above the lower die and forming therewith a cavity shaped to hold the workpiece. An upper actuating element bears downward via a vertically compressible hydraulic operating cylinder on the upper die. A spring-loaded pressure-storing cylinder is connected by a hydraulic line to the operating cylinder and to the workpiece. Downward shifting of the actuating element first closes the dies together, then internally pressurizes the workpiece via the line from the operating cylinder such that the workpiece deforms and shapes itself to the cavity, and then fills the spring-loaded pressure-storing cylinder. Subsequent upward shifting of the actuating element at first allows the pressure-storing cylinder to empty, and then entrains the upper die upward off the workpiece by the actuating element.