Working Cylinder Welded End Closure for High-Load Pressure Resistance
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Solution Overview
Problem
Existing working cylinders face challenges in achieving high load capacity, cost-effective production, and reliable operation due to the weakening effect of threads on the cylinder tube and difficulties in matching threads for precise angular positioning.
Innovation Solution
A working cylinder design featuring a cylinder tube and closure parts connected via a circumferential laser ring weld seam, with a specially designed coupling section that includes a tapered shaft portion and a circumferential ring weld seam, allowing for a hybrid form-fit and force-fit connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If threads are produced by shape-cutting operation, then connection between closure parts and cylinder tube is achieved, but tube wall thickness must be increased to compensate for thread weakening
Solution Approach 1:
The patent replaces the mechanical thread-cutting system with a laser welding system. Instead of cutting threads into the cylinder tube wall (which removes material and weakens the structure), the closure parts are connected directly to the cylinder tube ends via laser weld seams. This substitution eliminates the need for shape-cutting operations and the associated material removal, thereby maintaining tube wall thickness without compromising connection strength.
Solution Approach 2:
The patent changes the connection parameter from mechanical threading to thermal welding. By using laser welding with controlled energy input, the closure parts are fused directly to the cylinder tube ends, creating a strong joint without requiring increased wall thickness. The welding parameters (energy input per length, weld seam dimensions) are optimized to achieve high strength while minimizing thermal load on sensitive components.
2Strength
If tube wall thickness is increased to absorb forces during operation, then load capacity is improved, but final weight of working cylinder increases
Solution Approach 1:
The patent replaces the mechanical thread-cutting system with a laser welding system. Instead of cutting threads into the cylinder tube wall (which removes material and weakens the structure), the closure parts are connected directly to the cylinder tube ends via laser weld seams. This substitution eliminates the need for shape-cutting operations and the associated material removal, thereby maintaining tube wall thickness without compromising connection strength.
Solution Approach 2:
The patent changes the connection parameter from mechanical threading to thermal welding. By using laser welding with controlled energy input, the closure parts are fused directly to the cylinder tube ends, creating a strong joint without requiring increased wall thickness. The welding parameters (energy input per length, weld seam dimensions) are optimized to achieve high strength while minimizing thermal load on sensitive components.
3Ease of manufacture
If circumferential laser weld seam is used to connect closure parts, then production cost is reduced and load capacity is improved, but thermal load on seals and guides increases
Solution Approach 1:
The patent changes the connection parameter from mechanical threading to thermal welding. By using laser welding with controlled energy input, the closure parts are fused directly to the cylinder tube ends, creating a strong joint without requiring increased wall thickness. The welding parameters (energy input per length, weld seam dimensions) are optimized to achieve high strength while minimizing thermal load on sensitive components.
Solution Approach 2:
The patent uses laser welding to rapidly join the closure parts to the cylinder tube ends in a single, quick operation. The laser beam moves quickly along the weld seam, concentrating thermal energy in a localized area and minimizing the total thermal exposure time for seals and guides. This rapid welding process reduces the cumulative thermal load on thermally sensitive components compared to slower, more diffuse heating methods.
4Ease of operation
If threads are used for connection, then assembly is achieved, but precise angular positioning of closure parts is difficult
Solution Approach 1:
The patent replaces the mechanical thread-cutting system with a laser welding system. Instead of cutting threads into the cylinder tube wall (which removes material and weakens the structure), the closure parts are connected directly to the cylinder tube ends via laser weld seams. This substitution eliminates the need for shape-cutting operations and the associated material removal, thereby maintaining tube wall thickness without compromising connection strength.
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 achieves a high load capacity with a reliable, cost-effective, and efficient production process, minimizing material consumption and weight while ensuring precise angular positioning and high pressure resistance.
Implementation Method 1
both closure parts are coupled to the cylinder tube by a circumferential laser weld seam
Implementation Method 2
the laser weld seam must have a sufficiently strong dimension to be capable to absorb the forces
Implementation Method 3
causes an elastic circumferential expansion in a proximal zone of the coupling section
Data Source
AI summary
A working cylinder has a cylinder tube, a closure part and a further closure part disposed at cylinder tube ends. The closure part has a shaft portion and the cylinder tube has a cylinder tube end portion. The shaft portion and the cylinder tube end portion define a coupling portion where the shaft portion is axially inserted into the cylinder tube at the cylinder tube end portion. The shaft portion has a taper and is oversized, at least in part, relative to an inner diameter of the cylinder tube. The cylinder tube has an elastic circumferential expansion there. The coupling portion is constructed to axially couple the closure part and the cylinder tube. The cylinder tube end is bonded to the closure part by a circumferential annular weld seam that defines a sealing plane.