Description:FIELD OF THE INVENTION

[0001] The present invention relates to a multi-stage hydraulic press that is capable of generating and amplifying force through sequential stages of pressure application, enabling efficient forming, shaping, or compressing of materials while ensuring enhanced operational control, safety, and performance across diverse industrial applications.

BACKGROUND OF THE INVENTION

[0002] Requirement for hydraulic press with multi-stage arises from the need to achieve high precision and force in metal forming, molding, and other industrial applications where single-stage means are inadequate. Multi-stage amplification allows efficient operation by combining fast positioning with high-pressure performance, reducing cycle times and improving productivity. However, users often face challenges such as excessive vibration, fluid leakage, and inconsistent pressure control, which affect accuracy and product quality. Heat buildup in the hydraulic means also lead to reduced efficiency and component wear. Additionally, safety risks from high-pressure operation and flying debris, along with difficulties in real-time monitoring and maintenance, make the process demanding without automated safety and control means.

[0003] Traditionally available presses include single-stage hydraulic presses, mechanical presses, and pneumatic presses, each with its own limitations. Single-stage hydraulic presses offer high force but operate slower, making them less efficient for applications requiring both speed and precision. Mechanical presses provide faster operation but lack the ability to generate very high pressures consistently and have limited stroke control. Pneumatic presses are quicker and simpler but not achieve the high force needed for heavy-duty forming tasks. Across these types, common drawbacks include high energy consumption, significant vibration, difficulty in maintaining consistent pressure, and limited adaptability for multi-stage operations. Additionally, many lack integrated safety features and autonomous monitoring, increasing operational risks and reducing production efficiency.

[0004] SU1431889A1 relates to the processing of metals by pressure and can be used to produce multi-stage products by the method of hydrostatic pressing. The goal is to reduce the power consumed during deformation by providing the possibility of alternately extruding the steps of the product and an increase in quality. products by reducing the number of alternating kinks of the metal in the shear strain planes. In the block of the matrix (M), they are formed with steps that form closed hydraulic cavities and are mounted with the possibility of axial displacement one relative to the other. At the initial moment, the lead-in cones M form a common cone with the smallest gage hole. After: pressing the workpiece through it for a predetermined length, the working fluid is fed into the hydraulic cavity between the first and second M. The second M nat moves towards the workpiece, and is pressed. The liquid is then fed into the cavity between the second M and the next M, and the next stage is pressed onto the workpiece. The device provides improved mechanical properties of products after processing.

[0005] US5673615 discloses about a hydraulic press for moving a slide up and down by the use of a hydraulic cylinder, the slide is lowered from a descending region to a molding region while its position is controlled on the basis of a position signal detected by slide position detector, and a pressure signal obtained from a pressure detector for detecting the pressing force of the slide is compared with a predetermined capacity set in accordance with a machining condition in this molding region. If the set capacity is not reached, the slide is made to continue its descent to a lower dead point while effecting successively the position control and holding it at that position for a set time. When the set capacity is reached, pressure control instead of position control is carried out and the pressure is held for the set time.

[0006] Conventionally, many presses are available in market for various forming, molding, and compression tasks; however, most lack the capability for precise multi-stage operation, autonomous monitoring, and enhanced safety features, thereby limiting efficiency, adaptability, and consistency in high-demand industrial applications requiring both speed and high-pressure performance.

[0007] In order to overcome the aforementioned drawbacks, there exists a need in the art to develop a press that requires to be capable of delivering multi-stage hydraulic amplification with precise control, reduced vibration, enhanced safety measures, efficient energy usage, and integrated real-time monitoring to ensure consistent performance, improved productivity, and operator protection in demanding industrial operations.

OBJECTS OF THE INVENTION

[0008] The principal object of the present invention is to overcome the disadvantages of the prior art.

[0009] An object of the present invention is to develop a press that is capable of delivering high-pressure output in multiple stages, enabling efficient shaping, forming, or compressing of various materials with improved force control and operational efficiency.

[0010] Another object of the present invention is to develop a press that is capable of maintaining stable operation by minimizing vibration and noise, ensuring consistent performance, reduced wear on machine parts, and increased safety during prolonged usage.

[0011] Another object of the present invention is to develop a press that is capable of achieving high accuracy in pressing operations through real-time monitoring, precise control of pressure and movement, and consistent repeatability across multiple production cycles.

[0012] Yet another object of the present invention is to develop a press that is capable of ensuring operator and workplace safety by preventing hazards from material ejection, mechanical recoil, or pressure bursts during high-force pressing processes.

[0013] The foregoing and other objects, features, and advantages of the present invention will become readily apparent upon further review of the following detailed description of the preferred embodiment as illustrated in the accompanying drawings.

SUMMARY OF THE INVENTION

[0014] The present invention relates to a multi-stage hydraulic press that is capable of amplifying pressure sequentially for diverse manufacturing applications. The developed press precisely exerts high force on a workpiece, with autonomous control and integrated safety features to ensure efficient and secure operations.

[0015] According to an aspect of the present invention, a multi-stage hydraulic press comprises of a pair of L-shaped frames, the bottom of L-shaped frames connected by a horizontal base and a horizontal cross-member connecting the top of the L-shaped frames, a pump is housed in a primary chamber, the primary chamber mounted by a compartment of hydraulic fluid, the compartment is integrated on the horizontal cross-member, a horizontal circular member is housed in a secondary chamber, the secondary chamber is integrated at the bottom of the primary chamber via a first solenoid direction control valve to perform the second stage of hydraulic pressure amplification, a hydraulic accumulator is connected on a lateral side of the secondary chamber via a third solenoid valve, to absorb excess hydraulic fluid from the secondary chamber.

[0016] The press further comprises of a vertical toggle is connected to the horizontal circular member of the secondary chamber to exert hydraulically generated pressure on a workpiece, a bottom pressing plate is mounted on the horizontal base, a sensor suite integrated in the hydraulic press for monitoring the operations in the hydraulic press, the sensors include two pressure sensors, a load sensor, a linear variable differential transformer (LVDT) displacement sensor and a temperature sensor, a transparent safety shield made of impact-resistant polycarbonate enclosed within a reinforced steel frame is integrated into the hydraulic press to enhance operator safety, a processing module coupled to the mechanical and electronic components of the hydraulic press for enabling multi-stage hydraulic amplification.

[0017] While the invention has been described and shown with particular reference to the preferred embodiment, it will be apparent that variations might be possible that would fall within the scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
Figure 1 illustrates an isometric view of a multi-stage hydraulic press.

DETAILED DESCRIPTION OF THE INVENTION

[0019] The following description includes the preferred best mode of one embodiment of the present invention. It will be clear from this description of the invention that the invention is not limited to these illustrated embodiments but that the invention also includes a variety of modifications and embodiments thereto. Therefore, the present description should be seen as illustrative and not limiting. While the invention is susceptible to various modifications and alternative constructions, it should be understood, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention as defined in the claims.

[0020] In any embodiment described herein, the open-ended terms "comprising," "comprises,” and the like (which are synonymous with "including," "having” and "characterized by") may be replaced by the respective partially closed phrases "consisting essentially of," consists essentially of," and the like or the respective closed phrases "consisting of," "consists of, the like.

[0021] As used herein, the singular forms “a,” “an,” and “the” designate both the singular and the plural, unless expressly stated to designate the singular only.

[0022] The present invention relates to a multi-stage hydraulic press that is capable of deliver high-pressure output in sequential stages, ensuring accurate, efficient, and safe material forming, shaping, or compression while maintaining operational stability, reducing vibration, and providing consistent performance for a wide range of industrial uses.

[0023] Referring to Figure 1, an isometric view of a multi-stage hydraulic press is illustrated, comprising a pair of L-shaped frames 101, the bottom of L-shaped frames 101 connected by a horizontal base 102 and a horizontal cross-member 103 connecting the top of the L-shaped frames 101, a primary chamber 104 mounted by a compartment 105 of hydraulic fluid, the compartment 105 is integrated on the horizontal cross-member 103, a pump 106 in primary chamber 104 is connected to the compartment 105 of hydraulic fluid via high-pressure hydraulic hoses 107 and also includes a second solenoid direction control valve 108, a horizontal circular member 109 is housed in a secondary chamber 125, the secondary chamber 125 is integrated at the bottom of the primary chamber 104 via a first solenoid direction control valve 110, a hydraulic accumulator 111 is connected on a lateral side of the secondary chamber 125 via a third solenoid valve 112, the hydraulic accumulator 111 includes of a cylindrical pressure vessel 111a equipped with two motorized, spring-controlled pistons 111b mounted vertically, one at the top and one at the bottom of the pressure vessel 111a on either side of the third solenoid valve 112.

[0024] Figure 1 further illustrates a vertical toggle 113 connected to the horizontal circular member 109 of the secondary chamber 125 via a swivel joint 114, a pressing plate 115 securely fixated to a distal end of the toggle 113, a bottom pressing plate 116 mounted on the horizontal base 102, a transparent safety shield 117 integrated into the hydraulic press, the horizontal base 102 is securely fixed to the ground with a plurality of bolts 118, a plurality of detachable wheels 119 are integrated with the horizontal base 102, a knob 120 integrated on the one of the L-shaped frames 101, the bottom pressing plate 116 arranged with the horizontal base 102 and integrated with motorised telescopic clamps 121 mounted on both sides of the plate 116, the transparency shield 117 is mounted on guided sliding rails 122 positioned in top periphery of the L-shaped frames 101 that is operated manually using a control knob 123 on the frames 101, the hydraulic press is equipped with vibration-damping pads 124, the secondary chamber 125 is integrated at the bottom of the primary chamber 104.

[0025] The press disclosed herein comprises the pair of L-shaped frames 101 are connected by the horizontal base 102 from the bottom, and the tops of which are joined by the horizontal cross-member 103. The horizontal base 102 mentioned above is equipped with multiple detachable wheels 119, each equipped with a locking assembly, are mounted beneath the horizontal base 102 to facilitate relocation of the press when required. Under normal operating conditions, when the press is in use, the horizontal base 102 is fixed securely to the ground using multiple bolts 118 manually, and the wheels 119 are retracted into a cavity formed beneath the horizontal base 102 to maintain maximum stability. The locking assemblies comprise a brake lever, locking pin, or cam-based clamp configured to restrict wheels 119 rotation and prevent unintended movement. When relocation of the press is required, the securing bolts 118 are removed manually, and a pneumatic lift associated with the wheels 119 is engaged to lower the wheels 119 from the cavity into an operational position.

[0026] The pneumatic lift generally comprises one or more air cylinders connected to a compressed air reservoir and controlled via a manual or electronically actuated valve. Upon valve activation, pressurized air is directed into the cylinders, causing the piston rods to extend and push the wheels 119 mounts downward until the wheels 119 make firm contact with the ground. In this state, the locking assemblies are disengaged, allowing the wheels 119 to rotate freely for movement. The weight of the press is then partially or fully transferred onto the wheels 119, and the locking assemblies are disengaged, allowing the press to be rolled to a desired location. Once repositioned, the valve is operated to release the compressed air, allowing the piston rods to retract under spring force or gravity, thereby lifting the wheels 119 back into the cavity in a non-operational position. The locking assemblies are re-engaged, and the base 102 is again bolted to the ground to ensure stable operation.

[0027] The press disclosed herein includes the compartment 105 containing the replaceable hydraulic fluid is mounted on the horizontal cross-member 103. The primary chamber 104, housing the pump 106, is positioned adjacent to and supported by this compartment 105. The pump 106 is fluidly connected to the hydraulic fluid compartment 105 through multiple high-pressure hydraulic hoses 107, the connection further incorporating check valves to prevent reverse flow and the second solenoid direction control valve 108 for regulating fluid delivery. The check valves are configured herein permits unidirectional flow of hydraulic fluid from the compartment 105 to the pump 106 while automatically preventing reverse flow, thereby maintaining pressure and avoiding backflow-induced damage to upstream components. Each check valve includes but not limited to, such as a spring-loaded poppet element seated against a valve seat, the poppet being displaced from the seat when the fluid pressure in the inlet exceeds the combined outlet pressure and spring force, thereby allowing forward flow. The second solenoid direction control valve 108 is operable to selectively direct hydraulic fluid from the compartment 105 into the primary chamber 104 or to block such flow based on control signals from a processing module associated with the press, serves as the central control unit. The solenoid valve 108 comprises an electromagnetic coil that, when energized, displaces an internal spool to align fluid passages for forward flow, and when de-energized, returns the spool to a closed position via a return spring, thereby isolating the primary chamber 104 from the compartment 105.

[0028] The pump 106 is configured to operate in a dual-speed mode, selectively adjustable by an operator in accordance with real-time operational requirements via the knob 120 integrated on one of the L-shaped frames 101. The dual-speed configuration comprises:
• Fast-Stroke Mode — In this mode, the pump motor operates at higher rotational speed with reduced displacement, enabling rapid transfer of hydraulic fluid from the compartment 105 to the primary chamber 104 with minimal resistance. This allows the pressing to be quickly positioned over a workpiece without exerting significant force, thereby reducing idle time between operations.
• Power-Stroke Mode — In this mode, the pump 106 operates at reduced rotational speed but with increased displacement, delivering hydraulic fluid at substantially higher pressure to the primary chamber 104. The elevated pressure is then transferred to the secondary chamber 125 for amplification, enabling the pressing to exert maximum force during the working cycle.

[0029] The pump 106 includes, but is not limited to, a drive motor, a crankshaft or cam-driven pump, an inlet port coupled to the hydraulic fluid compartment 105 via the check valves and the second solenoid direction control valve 108, and an outlet port connected to the high-pressure circuit leading to the primary chamber 104. During operation, the drive motor imparts rotary motion to the crankshaft or cam, which in turn converts the rotary motion into a reciprocating or rotary pumping action, depending on the pump type. This motion generates alternating low-pressure and high-pressure cycles within the pump chamber, enabling hydraulic fluid to be drawn through the inlet port during the suction stroke and forced through the outlet port during the discharge stroke. The check valves ensure that hydraulic fluid flows only in the intended direction by automatically opening when forward pressure exceeds spring resistance and closing when reverse pressure occurs, thus preventing backflow. The second solenoid direction control valve 108 governs the timing and routing of the fluid supply to the primary chamber 104, actuating its internal spool via an electromagnetic coil under commands from the processing module.

[0030] The processing module receives operator input through the knob 120 installed on the one of the L-shaped frames 101. Based on this, the processing module determines whether the press operate in fast-stroke mode—where the drive motor runs at higher speed with reduced displacement for rapid positioning—or in power-stroke mode—where the motor operates at reduced speed with increased displacement to generate maximum hydraulic pressure. The processing module transmits control signals to adjust motor speed, pump 106 displacements, and second solenoid valve 108 actuation, ensuring smooth transitions between positioning and pressing operations, while also managing operational safety limits and pressure thresholds.

[0031] The operator-actuated control knob is configured to facilitate selection between the fast-stroke mode and power-stroke mode of pump operation. The control knob 123 comprises an external rotary or push-selector handle mounted on one of the L-shaped frames 101, a position-sensing arrangement includes but not limited to, such as a rotary potentiometer, encoder, or discrete position switch, and an electrical coupling to the processing module. In operation, rotation or actuation of the control knob 123 changes the position of the internal sensing arrangement, generating an electrical signal corresponding to the selected mode. This signal is transmitted to the processing module, which interprets the input and adjusts pump 106 parameters accordingly. Upon detection of the operator’s selection, the processing module energizes the electromagnetic coil of the second solenoid direction control valve 108, causing the internal spool to shift into the open position. This action permits hydraulic fluid to flow from the compartment 105 through the high-pressure hoses 107 into the primary chamber 104, initiating the pressurization cycle. In fast-stroke mode, the processing module commands the pump motor to operate at higher speed with reduced displacement for rapid movement; in power-stroke mode, the processing module reduces motor speed and increases displacement to achieve high hydraulic pressure for pressing operations.

[0032] The horizontal circular member 109 is housed in the secondary chamber 125, the secondary chamber 125 is integrated at the bottom of the primary chamber 104 via the first solenoid direction control valve 110 to perform the second stage of hydraulic pressure amplification. Upon receipt of the hydraulic fluid, the first solenoid direction control valve 110 further amplifies the hydraulic pressure to achieve the required force for the pressing operation. The secondary chamber 125 is equipped with composite vibration isolators designed to prevent resonance and absorb incoming vibrational energy.

[0033] The composite vibration isolators integrated herein constructed from layered materials combining elastomers, viscoelastic compounds, and reinforced fiber composites, each selected for its ability to dampen specific frequency ranges. The elastomeric layer provides flexibility and deformation under load, absorbing low- to mid-frequency vibrations, while the viscoelastic layer converts vibrational kinetic energy into heat, thereby reducing transmitted energy. The reinforced composite layer adds structural rigidity, ensuring stability under the press’s operational forces. In the hydraulic press, the isolators are strategically positioned between the secondary chamber 125 housing and its mounting frames 101, creating a mechanical buffer that interrupts the direct transmission path of vibrations. As the horizontal circular member 109 in the secondary chamber 125 amplifies pressure, operational vibrations are generated and tend to propagate through the press’s structure. The composite isolators deform and shear microscopically in response to these vibrations, dissipating their energy and preventing harmonic buildup that causes resonance. This dual action of absorption and isolation not only enhances operational smoothness but also protects sensitive components, reduces noise, and prolongs the service life of the hydraulic press.

[0034] Activation of the secondary chamber 125 is regulated by the processing module, which receives real-time input from integrated pressure sensors positioned on the fluid output line of the primary chamber 104. Each pressure sensor comprises a sensing diaphragm or strain-gauge element in fluid communication with the pressurized hydraulic circuit. Variations in pressure cause minute deflections in the diaphragm, which are converted into proportional electrical signals by the strain-gauge or piezoelectric element. These signals are transmitted to the processing module for continuous monitoring. When the measured pressure reaches a pre-set threshold stored in the processing module’s memory, the processing module energizes the electromagnetic coil of the first solenoid direction control valve 110, causing its internal spool to shift and open the fluid passage between the primary and secondary chamber 125s. This allows the high-pressure fluid to flow into the secondary chamber 125, initiating the secondary stage of hydraulic amplification.

[0035] The first solenoid direction control valve 110 is configured to selectively control the transfer of high-pressure hydraulic fluid from the primary chamber 104 to the secondary chamber 125. The valve 110 comprises a cylindrical housing containing an internal spool or poppet arrangement, an electromagnetic coil assembly, a return spring, and fluid inlet and outlet ports. In operation, the electromagnetic coil is energized by the processing module when the pressure sensor in the primary chamber 104 detects that the pre-set activation threshold has been reached. Energizing the coil generates a magnetic field that exerts a force on an armature connected to the spool, causing the spool to shift from its default closed position to an open position. In the closed position, the spool blocks the fluid passage between the primary and secondary chamber 125s, preventing premature pressurization of the secondary chamber 125. In the open position, the spool aligns internal flow channels, enabling high-pressure hydraulic fluid to flow from the primary chamber 104 outlet port through the valve 110 body to the inlet of the secondary chamber 125. Upon de-energization of the coil, the return spring pushes the spool back to its default closed position, isolating the chambers and preparing for the next pressurization cycle. This controlled actuation ensures precise timing of fluid transfer, thereby optimizing the secondary stage of hydraulic pressure amplification and preventing hydraulic shock.

[0036] The hydraulic accumulator 111 is connected on a lateral side of the secondary chamber 125 via the third solenoid valve 112, to absorb excess hydraulic fluid from the secondary chamber 125. The hydraulic accumulator 111 includes of the cylindrical pressure vessel 111a equipped with two motorized, spring-controlled pistons 111b mounted vertically, one at the top and one at the bottom of the pressure vessel 111a on either side of the third solenoid valve 112, upon detection of the pressure in the secondary chamber 125 by the integrated pressure sensor exceeding a predefined threshold, the processing module activates the third solenoid valve 112 to open, allowing high-pressure fluid to flow into the accumulator 111.

[0037] The third solenoid valve 112 is configured to regulate the flow of hydraulic fluid between the secondary chamber 125 and the hydraulic accumulator 111. The valve 112 comprises a valve body housing an internal spool or poppet arrangement, an electromagnetic coil, a return spring, and fluid inlet and outlet ports. Under normal conditions, the valve 112 remains closed, with the return spring maintaining the spool or poppet in a position that blocks fluid flow between the secondary chamber 125 and the accumulator 111. When the processing module detects that the pressure in the secondary chamber 125 exceeds a predetermined threshold stored in the memory, the processing module energizes the electromagnetic coil of the third solenoid valve 112. The resulting magnetic field shifts the spool or poppet against the return spring force, opening the fluid passage and allowing excess high-pressure fluid to flow from the secondary chamber 125 into the accumulator 111. Conversely, when the pressure sensor indicates a drop below the threshold, the processing module de-energizes the coil, allowing the return spring to close the valve 112 and isolate the accumulator 111. This controlled actuation ensures the accumulator 111 only receives excess fluid when necessary and maintains hydraulic press stability by preventing pressure surges and fluctuations.

[0038] The motorized spring-controlled pistons 111b within the hydraulic accumulator 111 are configured to regulate volume of hydraulic fluid stored in the cylindrical pressure vessel 111a and maintain pressure within predetermined limits. Each pistons 111b comprises a cylindrical body fitted with seals to prevent fluid leakage, a motorized driver for vertical displacement, and an integrated compression spring that applies force opposite to the direction of pistons 111b movement. During operation, when excess high-pressure fluid enters the accumulator 111 via the open third solenoid valve 112, the fluid pressure overcomes the spring force, causing the pistons 111b to retract vertically toward the ends of the pressure vessel 111a. The motorized drive assists or controls the pistons 111b movement, ensuring smooth retraction and preventing abrupt motion that causes hydraulic shock. Conversely, when the pressure sensor detects a drop below the threshold in the secondary chamber 125, the processing module activates the motorized drives to extend the pistons 111b vertically, forcing the accumulated fluid back through the solenoid valve 112 into the secondary chamber 125. The compression springs provide a restoring force, aiding pistons 111b extension and maintaining consistent pressure against the hydraulic fluid.

[0039] The hydraulic pressure generated in the primary chamber 104 and subsequently amplified in the secondary chamber 125 is transmitted to the workpiece through the vertical toggle 113, which is operatively connected to the horizontal circular member 109 of the secondary chamber 125 via the robust swivel joint 114, ensuring smooth transfer of force while accommodating minor angular adjustments during operation. The pressing plate 115 is securely fixed to the distal end of the vertical toggle 113, providing a stable interface for direct contact with the workpiece. The swivel joint 114 incorporates an integrated torsion spring that serves a dual purpose—facilitating controlled movement of the toggle 113 during the pressing cycle and enabling automatic retraction once the hydraulic pressing operation is complete.

[0040] The torsion spring integrated into the swivel joint 114 functions by storing and releasing rotational energy to control the movement of the vertical toggle 113. The torsion spring is composed of a coiled helical body with two projecting arms or ends, designed to work by twisting around its axis. In the hydraulic press, one arm of the spring is fixed to the swivel joint 114 housing, while the other arm is connected to the vertical toggle 113 linkage. During the pressing operation, as the toggle 113 is driven downward by hydraulically amplified force from the secondary chamber 125, the torsion spring’s coils are twisted, causing the spring to store potential energy in the form of torque. Once the hydraulic pressure is released at the end of the pressing cycle, the stored torque is discharged, rotating the toggle 113 back in the opposite direction. This retraction resets the toggle 113 and pressing plate 115 to their initial positions, preparing the hydraulic press for the next operation without manual adjustment. The integration of the torsion spring with these operational components ensures consistent cycle timing, reduces wear on moving parts, and improves overall efficiency.

[0041] The bottom pressing plate 116 is securely mounted on the horizontal base 102 of the hydraulic press. The bottom pressing plate 116 is further integrated with motorized telescopic clamps 121 positioned on both lateral sides of the plate 116. Each telescopic clamps 121 comprises a multi-segment extendable arm assembly, actuated by an electric motor—usually a stepper or servo motor—coupled with a precision lead screw or belt driver that converts rotary motion into linear movement for smooth and controlled extension and retraction. The motor receives real-time control signals from the processing module, enabling automated adjustment of clamps 121 position based on predefined workpiece dimensions or operator input.

[0042] The telescopic design allows the clamps 121 to extend outward to accommodate larger workpieces and retract when securing smaller or irregularly shaped items. Gripping pads or jaws, made of wear-resistant, non-marring materials such as polyurethane or rubber composites, are mounted at the distal ends of the clamp arms to ensure firm yet gentle holding without damaging the workpiece surface. Integrated position sensors—such as linear encoders, Hall effect sensors, or potentiometers—provide continuous feedback on the exact position and movement of each clamp arm, enabling closed-loop control for precision positioning and force application. Additionally, torque or current sensors monitor the motor load to detect the clamping force applied, allowing the processing module to regulate and maintain optimal gripping pressure, preventing over-clamping or slippage. The clamps 121 also automatically release and reset after each pressing cycle, facilitating rapid workpiece exchange and increasing operational efficiency. Safety interlocks and limit switches are incorporated to prevent over-extension or mechanical collision, protecting both the clamps 121 and the workpiece.

[0043] A sensor suite integrated within the hydraulic press comprises two pressure sensors, a load sensor, a linear variable differential transformer (LVDT) displacement sensor, and a temperature sensor, each serving to monitor critical operational parameters. The two pressure sensors, installed respectively on the fluid output lines of the primary and secondary chamber 125s, usually employ strain gauge or piezoelectric sensing elements. These sensors operate by converting the mechanical deformation caused by hydraulic fluid pressure on a sensing diaphragm into proportional electrical signals, enabling precise measurement of fluid pressure within the chambers. The load sensor embedded in the bottom pressing plate 116 generally consists of strain gauges affixed to a deformable structural element; it measures the force applied during each pressing cycle by detecting minute strain variations that correspond to the load exerted on the plate 116. The LVDT displacement sensor mounted on the cylindrical ram comprises a primary coil and two secondary coils surrounding a movable ferromagnetic core attached to the ram. As the ram moves linearly, the position of the core changes relative to the coils, causing a differential voltage output proportional to the displacement, thus providing accurate and contactless linear position tracking. The temperature sensor inserted into the hydraulic accumulator 111 is commonly a thermistor or resistance temperature detector (RTD), which operates by varying its electrical resistance in response to temperature changes. This variation is translated into temperature readings that allow real-time monitoring of the hydraulic fluid temperature, ensuring operations in safe thermal limits. The electrical signals from all these sensors are transmitted continuously to the processing module for real-time analysis, control, and safety management.

[0044] The transparent safety shield 117, constructed from impact-resistant polycarbonate and enclosed within a reinforced steel frame, is integrated into the hydraulic press to enhance operator safety. The safety shield 117 is mounted on the guided sliding rails 122 positioned along the top periphery of the L-shaped frames 101, allowing smooth vertical movement. The transparent safety shield 117 operated manually via the control knob 123 located on the frames 101 or remotely through a communicatively coupled a user interface. The control knob 123 operates in the same manner as the knob disclosed above, enabling the operator to deploy the transparent safety shield 117. The shield 117 provides effective protection against flying debris, shattered materials, and potential hydraulic fluid bursts, thereby ensuring safe operation for the operator.

[0045] The guided sliding rails 122 supporting the transparent safety shield 117 are designed to enable smooth, controlled vertical movement along the top periphery of the L-shaped frames 101. Each rails 122 assembly comprises a rigid track, fabricated from hardened steel or aluminum, and a matching sliding carriage or runner equipped with low-friction bearings or rollers to minimize resistance during motion. The carriage is securely attached to the safety shield 117, allowing it to glide vertically within the confines of the rails 122. The rails 122 include guide channels or grooves that maintain lateral stability and prevent undesired wobbling or misalignment of the shield 117 during operation. Manual operation is facilitated by the control knob 123 mechanically linked to a lead screw or rack-and-pinion arrangement, which translates rotary input into linear vertical movement of the shield 117. For remote operation, an electric actuator integrated with the rails 122 assembly receives commands from the processing module, driving the shield’s motion smoothly and precisely. Safety stops or limit switches are installed at the upper and lower ends of the rails 122 to prevent overtravel, ensuring the shield 117 remains within safe operational boundaries. This guided sliding rails 122 provides reliable, easy-to-use, and precise positioning of the safety shield 117, enhancing both usability and operator protection.

[0046] In an embodiment of the present invention, a communication module is operatively linked with the processing module to establish a wireless connection between the processing module and a computing unit (including, but not limited to, a smartphone, tablet, or laptop). The communication module is integrated with a user interface that is accessed by the user to provide input commands for controlling and monitoring the operation of the hydraulic press, such as deployment of the transparency shield 117. The communication module includes, but is not limited to, a Wi-Fi (Wireless Fidelity) module, a Bluetooth module, or a GSM (Global System for Mobile Communication) module. Preferably, the communication module is a Wi-Fi module comprising a hardware component that enables the processing module to connect wirelessly with the computing unit. The Wi-Fi module operates by utilizing radio waves to transmit and receive data over short distances, in accordance with the IEEE 802.11 standards that define the protocols for wireless local area networking (WLAN). Once a secure connection is established, the module facilitates bidirectional communication, enabling the processing module to send and receive operational data through data packets, thereby allowing remote control, status updates, and diagnostics in real time.

[0047] The hydraulic press is fitted with vibration-damping pads 124 used for absorbing and dissipating kinetic energy generated during pressing operations, thereby minimizing structural noise and reducing recoil forces transmitted through the frames 101. These pads 124 are composed of layered materials such as high-density rubber, viscoelastic polymers, and fiber-reinforced composites, each selected for their high damping coefficient and durability under repetitive loading. The rubber layer provides elasticity and deformation capability to absorb low-frequency vibrations, while the viscoelastic polymer layer converts vibrational motion into heat energy through internal molecular friction. The fiber-reinforced layer ensures dimensional stability and distributes the load evenly across the mounting surface. In operation, the pads 124 are positioned between the horizontal base 102 of the press and the floor, acting as a mechanical buffer that interrupts direct transmission of vibrational energy into the supporting structure. When the press exerts force on a workpiece, sudden reactive forces and shock loads are generated; the pads 124 compress slightly under these loads, dissipating the impulse energy and preventing it from reflecting back into the press components. This not only reduces operational noise and floor vibration but also protects sensitive mechanical parts from fatigue, improves operator comfort, and enhances the overall stability of the hydraulic press during high-force operations.

[0048] Lastly, a battery (not shown in figure) is associated with the press to supply power to electrically powered components which are employed herein. The battery is comprised of a pair of electrode named as a cathode and an anode. The battery uses a chemical reaction of oxidation/reduction to do work on charge and produce a voltage between their anode and cathode and thus produces electrical energy that is used to do work in the press.

[0049] The present invention work best in the following manner, where the multi-stage hydraulic press operates by generating hydraulic pressure in the primary chamber 104 which is mounted on the hydraulic fluid compartment 105 integrated into the horizontal cross-member 103 connecting the L-shaped frames 101 connected together via the horizontal base 102. The pump 106 in the primary chamber 104, connected via high-pressure hoses 107 with check valves and the second solenoid direction control valve 108, delivers pressurized fluid for either the fast stroke or the power stroke, selected by the operator through the knob 120. Upon reaching the preset pressure threshold, the processing module triggers the first solenoid direction control valve 110 to open, allowing high-pressure fluid to enter the secondary chamber 125. The horizontal circular member 109 in the secondary chamber 125 further amplifies the pressure, with composite vibration isolators preventing resonance and absorbing vibrational energy. Excess hydraulic fluid is managed by the hydraulic accumulator 111, which consists of the cylindrical pressure vessel 111a with two motorized, spring-controlled pistons 111b, regulated by the third solenoid valve 112 based on pressure sensor feedback. The amplified pressure is transferred to the workpiece through the vertical toggle 113 connected to the horizontal circular member 109 via the swivel joint 114, with the pressing plate 115 fixed to the toggle’s distal end. The swivel joint 114 incorporates the torsion spring to retract the toggle 113 post-operation. The bottom pressing plate 116, mounted with motorized telescopic clamps 121, positions the workpiece and supports interchangeable tooling. The sensor suite, comprising pressure sensors, load sensor, LVDT displacement sensor, and temperature sensor, enables real-time monitoring, while the transparent safety shield 117 on sliding rails 122 ensures operator protection from debris and hydraulic bursts.

[0050] Although the field of the invention has been described herein with limited reference to specific embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternate embodiments of the invention, will become apparent to persons skilled in the art upon reference to the description of the invention. , Claims:1) A multi-stage hydraulic press comprising:

a) a pair of L-shaped frames 101, the bottom of L-shaped frames 101 connected by a horizontal base 102 and a horizontal cross-member 103 connecting the top of the L-shaped frames 101;
b) a pump 106 housed in a primary chamber 104, the primary chamber 104 mounted by a compartment 105 of hydraulic fluid, the compartment 105 is integrated on the horizontal cross-member 103;
c) a horizontal circular member 109 housed in a secondary chamber 125, the secondary chamber 125 is integrated at the bottom of the primary chamber 104 via a first solenoid direction control valve 110 to perform the second stage of hydraulic pressure amplification;
d) a hydraulic accumulator 111 connected on a lateral side of the secondary chamber 125 via a third solenoid valve 112, to absorb excess hydraulic fluid from the secondary chamber 125;
e) a vertical toggle 113 connected to the horizontal circular member 109 of the secondary chamber 125 to exert hydraulically generated pressure on a workpiece;
f) a bottom pressing plate 116 mounted on the horizontal base 102;
g) a sensor suite integrated in the hydraulic press for monitoring the operations in the hydraulic press, the sensors include at least two pressure sensors, a load sensor, a linear variable differential transformer (LVDT) displacement sensor and a temperature sensor;
h) a transparent safety shield 117 made of impact-resistant polycarbonate enclosed within a reinforced steel frame and integrated into the hydraulic press to enhance operator safety; and
i) a processing module coupled to the mechanical and electronic components of the hydraulic press for enabling multi-stage hydraulic amplification,
wherein the diameter of the primary chamber 104 is large as compared to the diameter of the secondary chamber 125.

2) The multi-stage hydraulic press as claimed in claim 1, wherein the horizontal base 102 is securely fixed to the ground with a plurality of bolts 118, if the hydraulic press is to be relocated, a plurality of detachable wheels 119 with locking assemblies are integrated with the horizontal base 102, the detachable wheels 119 become operational once the securing bolts 118 are removed, the hydraulic press is equipped with vibration-damping pads 124 to prevent structural noise and recoil.

3) The multi-stage hydraulic press as claimed in claim 1, wherein the pump 106 in primary chamber 104 is connected to the compartment 105 of hydraulic fluid via high-pressure hydraulic hoses 107 and also includes check valves and a second solenoid direction control valve 108, the pump 106 is operable in dual-speed mode as chosen by an operator based on real-time requirement of operation, the two modes correspond to fast stroke for quick positioning and power stroke for pressure generation, on turning of a knob 120 integrated on the one of the L-shaped frames 101, the hydraulic fluid is dispensed via the second solenoid valve 108 to the primary chamber 104.

4) The multi-stage hydraulic press as claimed in claim 1, wherein the horizontal circular member 109 in the secondary chamber 125 receives high-pressure fluid from the primary chamber 104 and further amplifies the pressure, the secondary chamber 125 is integrated with composite vibration isolators to prevent resonance and absorb incoming vibrational energy, activation of the secondary chamber 125 is regulated by the processing module , upon the pressure reaching a pre-set threshold the first solenoid valve 110 between the primary and secondary chamber 125 is triggered to open, allowing high-pressure fluid to enter the secondary chamber 125.

5) The multi-stage hydraulic press as claimed in claim 1, wherein the hydraulic accumulator 111 includes of a cylindrical pressure vessel 111a equipped with two motorized, spring-controlled pistons 111b mounted vertically, one at the top and one at the bottom of the pressure vessel 111a on either side of the third solenoid valve 112, upon detection of the pressure in the secondary chamber 125 by the integrated pressure sensor exceeding a predefined threshold, the processing module activates the third solenoid valve 112 to open, allowing high-pressure fluid to flow into the accumulator 111, upon receiving the excess fluid, the pistons 111b retract vertically toward the top and bottom of the pressure vessel 111a, upon detection of low pressure in the secondary chamber 125 by the pressure sensor , the processing module activates the pistons 111b to extend vertically to force the accumulated fluid back through the third solenoid valve 112 into the secondary chamber 125.

6) The multi-stage hydraulic press as claimed in claim 1, wherein the hydraulic pressure generated in the primary chamber 104 and increased in the secondary chamber 125 is transferred to the workpiece by the vertical toggle 113 connected to the cylindrical member of the secondary chamber 125 via a swivel joint 114, a pressing plate 115 is securely fixated to a distal end of the toggle 113.

7) The multi-stage hydraulic press as claimed in claim 6, wherein the swivel joint 114 connecting the vertical toggle 113 to the horizontal circular member 109 of the secondary chamber 125 includes a torsion spring to enable the vertical toggle 113 to retract post finishing of the hydraulic press operation.

8) The multi-stage hydraulic press as claimed in claim 1, wherein the bottom pressing plate 116 is integrated with motorised telescopic clamps 121 mounted on both sides of the plate 116 for accurately positioning the workpiece during operation and enables interchangeability with tooling dies, molds, or fixtures depending on the workpiece.

9) The multi-stage hydraulic press as claimed in claim 1, wherein the one of the pressure sensor is installed on the fluid output line of the primary chamber 104 and the second pressure sensor is installed on the fluid output line of the secondary chamber 125, the load sensor is embedded within the bottom pressing plate 116 to measure the total force applied during each pressing cycle, the LVDT displacement sensor is mounted on the side of the cylindrical ram for accurate linear tracking, the temperature sensor is inserted into the hydraulic accumulator 111 to monitor the fluid temperature in real time.

10) The multi-stage hydraulic press as claimed in claim 1, wherein the transparency shield 117 is mounted on guided sliding rails 122 positioned in top periphery of the L-shaped frames 101 that is operated manually using a control knob 123 on the frames 101 or remotely via a communicatively coupled user-interface, the shield 117 offers protection against flying debris, shattered material, or hydraulic bursts, ensuring safe operation by the operator.