Thin Plate Fluid Bulging with Double-Station Hydraulic Clamping
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Solution Overview
Problem
Existing fluid bulging equipment for thin plate parts is costly and inefficient, with high investment waste due to underutilization of general-purpose auxiliary components, particularly in applications like new energy vehicle batteries and 5G communication base stations that require high bulging forces.
Innovation Solution
The equipment incorporates a main mechanism with an ultra-high pressure generating device, hydraulic control system, and mobile working platforms with servo motors, allowing for adjustable pressure and increased efficiency through a booster cylinder and mold clamping force, while reducing costs by utilizing general-purpose equipment and enhancing automation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If standard hydraulic press equipment is used for fluid bulging, then the equipment can perform basic bulging operations, but the production efficiency is low and the cost is high
Solution Approach 1:
The equipment is divided into independent functional modules: mobile working platforms for mold loading/unloading, main mechanism for bulging operations, and mold opening mechanisms. Each module operates independently and can be serviced separately, improving production efficiency while maintaining manageable complexity through modular design.
Solution Approach 2:
The mobile working platforms and standardized mold opening mechanisms are designed to be universal components that can serve multiple functions across different bulging operations. The hydraulic system can perform both clamping and bulging functions, reducing the need for specialized equipment and improving overall productivity.
2Device complexity
If general-purpose hydraulic press equipment is used, then the equipment can handle various operations, but the cost is particularly high and investment is wasted
Solution Approach 1:
The equipment uses universal components such as standard hydraulic cylinders, mobile working platforms, and mold opening mechanisms that can be applied across different bulging operations. This multi-functionality reduces the need for specialized expensive equipment while maintaining the ability to handle various operations.
Solution Approach 2:
The equipment employs standardized, replicable components such as the mobile working platforms and mold opening mechanisms that can be copied and reused across different installations and operations, reducing manufacturing costs while maintaining versatility.
3Productivity
If standard hydraulic press with fixed molds is used, then the equipment structure is simple, but the production efficiency is low and auxiliary components are not utilized
Solution Approach 1:
The equipment introduces mobile working platforms that can dynamically move to and from the main mechanism, and mold opening mechanisms that actively participate in the bulging process. These dynamic components improve productivity by enabling continuous operation and better utilization of auxiliary components, while the modular design keeps the overall structure manageable.
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 configuration significantly increases production efficiency by at least 6 times, reduces costs by about 40%, and enables automatic double-station operation, meeting installation requirements in standard factory buildings.
Implementation Method 1
The main oil cylinder is connected to a master cylinder mold-locked booster cylinder through the oil circuit block
Implementation Method 2
an ultra-high pressure generating device is arranged in the hydraulic control system. The ultra-high pressure generating device is connected to the master cylinder mold-locked booster cylinder through a pipeline
Implementation Method 3
the left mobile working platform and the right mobile working platform are respectively connected to a servo motor, and the servo motor drives the left mobile working platform and the right mobile working platform to reciprocate along the slide rail
Implementation Method 4
a hydraulic cylinder is installed on the gantry, a slider is connected to an end of the hydraulic cylinder
Data Source
AI summary
The embodiment of the present disclosure provides fluid bulging equipment for thin plate parts, which includes a main mechanism, a left mold opening mechanism and a right mold opening mechanism located on both sides of the main mechanism, a left mobile working platform, and a right mobile working platform. The main mechanism includes a main frame and a main oil cylinder located under the main frame. The main oil cylinder is connected to a master cylinder mold-locked booster cylinder through an oil circuit block. A hydraulic control system is arranged above the main mechanism. An ultra-high pressure generating device is arranged in the hydraulic control system. The ultra-high pressure generating device is connected to the master cylinder mold-locked booster cylinder through a pipeline. The hydraulic control system is also connected to the left mold opening mechanism and the right mold opening mechanism.