Ball Lock Pin Constriction via Vacuum-Assisted Bore Widening
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Solution Overview
Problem
The existing methods for manufacturing ball lock pins are costly and inefficient due to the difficulty in precisely forming constrictions to hold locking balls, requiring precise positioning and embossing processes that are unreliable and prone to material deformation and edge breakage.
Innovation Solution
A method involving a sleeve component with a bore smaller than the locking ball diameter, where the bore is widened by material removal to create constrictions, allowing locking balls to be inserted and held in place using vacuum pressure, eliminating the need for expensive finishing processes like grinding and enabling precise control over constriction geometry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the embossing process is used to form constrictions, then the locking balls can be held in the bore, but the manufacturing precision and reliability are low due to uncontrolled material deformation
Solution Approach 1:
The bore is pre-formed with a diameter smaller than the locking ball diameter before the locking balls are inserted. This preliminary action creates a controlled starting geometry that enables precise constriction formation through subsequent material removal, avoiding the uncontrolled deformation of embossing.
Solution Approach 2:
The embossing process (mechanical deformation) is replaced with a material removal process (milling or turning). This substitution provides controlled and precise constriction geometry by removing material in a controlled manner rather than deforming it, eliminating the reliability and precision problems of embossing.
2Manufacturing precision
If fine machining such as grinding is applied to the sleeve component, then the positioning accuracy during embossing is improved, but the manufacturing cost increases considerably
Solution Approach 1:
The bore is pre-formed with controlled dimensions before locking ball insertion. This preliminary precision in bore formation eliminates the need for subsequent fine machining of the sleeve outer surface, as the critical positioning is achieved during the bore creation process itself.
Solution Approach 2:
The expensive fine machining processes (grinding) are replaced with more cost-effective material removal methods (milling or turning) that achieve the required precision for constriction formation without the need for high-cost finishing operations.
3Reliability
If the embossing process is used to create constrictions, then the locking balls can be held, but the process allows little control over material deformation resulting in edge breakage
Solution Approach 1:
The embossing process that causes uncontrolled material deformation and edge breakage is replaced with a material removal process (milling or turning). This substitution creates constrictions by removing material in a controlled manner, eliminating the harmful deformation effects while maintaining reliable locking ball retention.
Solution Approach 2:
Instead of trying to control the harmful material deformation in embossing, the invention converts the approach by using material removal. The 'harm' of complex deformation control is transformed into the benefit of simple, controlled material removal that naturally avoids edge breakage while achieving the same functional result.
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 method allows for cost-effective and precise manufacturing of ball lock pins with reliable constriction formation, avoiding material deformation and edge breakage, and enabling the production of complex geometries with high strength.
Implementation Method 1
by applying a negative pressure to the at least one constriction relative to the guide receptacle, the at least one locking ball is pulled against the constriction
Data Source
Figure 1
Figure 2a~3b
Figure 4a~5
AI summary
The invention relates to a method for manufacturing a ball lock pin (1), wherein the method comprises the following steps: a) a sleeve component (2) is provided with a bore (11) extending transversely to its guide receptacle (3), which extends at least to the guide receptacle (3), wherein the diameter (DRB) of the bore (11) is smaller than the diameter (DSK) of the at least one locking ball (12a, 12b); b) the bore (11) is enlarged in an inner section (21) by material removal to a diameter (DWB) larger than the diameter (DSK) of the at least one locking ball (12a, 12b), wherein a constriction (10a, 10b) remains at at least one outer end of the bore (11);c) The at least one locking ball (12a, 12b) is inserted into the bore (11), in particular through the guide receptacle (3), and by applying a vacuum to the at least one constriction (10a, 10b) relative to the guide receptacle (3), the at least one locking ball (12a, 12b) is drawn against the constriction (10a, 10b); d) A plunger (4) is inserted into the guide receptacle (3) while the at least one locking ball (12a, 12b) is drawn against the constriction (10a, 10b) by the vacuum. The invention provides a method for manufacturing a ball lock bolt with which a locking ball can be mounted behind a precisely formed constriction in a cost-effective manner.