Telescopic Cylinder Sealing Set for Variable Rod Diameters
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Solution Overview
Problem
Existing sealing elements fail to maintain optimal leakage within specified limits in telescopic hydraulic cylinders with non-standard rod diameters and surface roughness, particularly in high-pressure systems, and are prone to deformation under axial loads, leading to inefficient sealing performance.
Innovation Solution
A sealing set comprising a seal ring, energizer ring, guide element, and back-up ring with specific geometric structures and materials, designed to accommodate variable rod diameters and pressures, ensuring minimal leakage and stable operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If standard sealing elements are used in telescopic cylinders with non-standard rod diameters and surface roughness, then the sealing element structure remains simple and easy to manufacture, but the leakage control fails to meet the required limit values (maximum 80 cc/min)
Solution Approach 1:
The sealing element is divided into multiple functional segments: a seal ring for primary sealing, an energizer ring for maintaining contact pressure, a guide element for alignment, and a back-up ring for structural support. This segmentation allows each component to be optimized for its specific function, enabling the sealing set to meet the stringent leakage requirement of maximum 80 cc/min while accommodating non-standard rod diameters and surface roughness.
Solution Approach 2:
The sealing set utilizes composite material construction with the seal ring made from wear-resistant material, the energizer ring from elastic material for pressure compensation, and the back-up ring from structurally strong material. This composite approach enables the sealing system to simultaneously handle the non-standard rod surface conditions and maintain reliable sealing under high pressure, resolving the contradiction between sealing performance and structural simplicity.
2Adaptability or versatility
If the sealing gap is increased to accommodate rod diameter tolerances (up to +0.59 mm deviation), then the sealing set can adapt to manufacturing variations, but the leakage amount increases beyond acceptable limits
Solution Approach 1:
The energizer ring is designed with elastic properties that allow it to dynamically adjust and maintain constant contact pressure between the seal ring and the rod surface, regardless of rod diameter variations within the tolerance range (including +0.59 mm deviation). This dynamic pressure compensation ensures that the sealing gap remains effective across the full range of manufacturing tolerances while maintaining leakage below the 80 cc/min threshold.
Solution Approach 2:
The sealing set incorporates parameters such as the energizer ring's elastic modulus, the seal ring's cross-sectional area, and the contact pressure magnitude that can be adjusted to optimize performance. By carefully selecting these parameters, the sealing system achieves adaptability to rod diameter tolerances up to +0.59 mm while simultaneously maintaining leakage control within the required limits, effectively resolving the contradiction between adaptability and reliability.
3Reliability
If the sealing set deforms under axial loads to close the sealing gap, then sealing performance improves, but metal-to-metal contact occurs causing system deformation and part damage
Solution Approach 1:
The back-up ring serves as an intermediary structural element that supports the seal ring and distributes axial loads across a larger area. This prevents excessive localized deformation that would lead to metal-to-metal contact between the seal ring and rod, while still allowing sufficient deformation to maintain the sealing gap closure. The guide element also acts as an intermediary to ensure proper alignment and reduce eccentric loading, thereby protecting part integrity while maintaining sealing performance.
Solution Approach 2:
The back-up ring is positioned beforehand to provide structural cushioning and support to the seal ring before axial loads are applied. This pre-positioned support prevents the seal ring from deforming excessively under load, thereby avoiding metal-to-metal contact and potential damage to the rod or seal components, while still allowing the necessary deformation for effective sealing.
4Reliability
If multiple sealing parts are integrated into a compact set for high-pressure systems, then the sealing effectiveness increases, but the manufacturing precision requirements for contact and pressure transfer become more critical
Solution Approach 1:
Each component of the sealing set is designed with local quality optimizations: the seal ring has enhanced material properties and geometric features at the contact surface for optimal sealing; the energizer ring has specific elastic properties localized to the pressure transmission zone; the back-up ring has reinforced structure at critical load-bearing points. These localized quality enhancements ensure that each component performs its specific function effectively, maintaining high sealing effectiveness while managing manufacturing precision requirements through targeted design rather than uniform high precision across all components.
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 sealing set effectively maintains minimal leakage of 80 cc/min and stable operation across varying rod diameters and pressures, enhancing sealing performance and preventing fluid leakage.
Implementation Method 1
The sealing set can close this gap in the cylinder by deforming under pressure
Implementation Method 2
The guide element (33) is the element that is positioned in the sealing set groove (21) of the piston (20) in the x-axis and that presses against the groove flanks (211) against the pressure effect force (F) in the x-axis
Data Source
AI summary
Disclosed is a seal ring, which is located in a double-acting telescopic cylinder having a plurality of nested rods and sealing elements between the piston moving in the rod and the rod, an energizer ring which provides the contact of the seal ring with the rod by applying pressure to the sealing set, a back-up ring which is positioned mirrored on both sides of the seal ring, and a sealing set which is positioned mirrored in the sealing groove of the piston in the x-axis and which contains the guide element.