Bulbous Flow Tube Alignment for In-Tank Filter Connections
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Solution Overview
Problem
The assembly of tanks with integrated filter assemblies faces challenges in accommodating large tolerances, particularly in plastic rotomolded tanks, making it difficult to connect flow passages between the filter assembly and the tank.
Innovation Solution
A flow tube with bulbous-shaped walls is used to connect the filter head to a bulkhead fitting, featuring a hollow tube with one or both ends having bulbous-shaped walls and a straight section, allowing for alignment adjustments and secure sealing through o-ring seat grooves or integrated seals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a standard straight flow tube is used to connect the filter assembly to the tank, then the installation is simple, but the connection fails to accommodate large tolerances in plastic rotomolded tanks
Solution Approach 1:
The flow tube incorporates bulbous-shaped ends instead of straight cylindrical ends. These bulbous portions have curved, spherical-like geometries that can deform and adapt to misalignments between the filter assembly port and the tank bulkhead fitting. The curved surfaces allow the tube to compensate for tolerance variations in plastic rotomolded tanks, enabling successful connections despite manufacturing tolerances.
2Manufacturing precision
If the flow tube is designed with bulbous-shaped walls to accommodate misalignment, then tolerance accommodation improves, but the manufacturing complexity increases
Solution Approach 1:
The flow tube design changes the geometric parameters of the tube ends from uniform cylindrical dimensions to variable bulbous dimensions. The bulbous portions have varying diameters along their length, with the maximum diameter occurring at the center of the bulbous section and tapering toward the straight section. This parameter variation allows the tube to accommodate misalignments while remaining manufacturable through standard molding or forming processes.
3Ease of operation
If a blind installation method is used after filter assembly placement, then the assembly sequence is maintained, but the alignment accuracy deteriorates due to large tolerances
Solution Approach 1:
The bulbous-shaped ends are pre-formed on the flow tube during manufacturing, creating a self-aligning feature before installation. When the tube is inserted during blind installation, the bulbous portions naturally seek out the correct position by deforming to accommodate misalignments, eliminating the need for complex alignment procedures or adjustments during the blind installation process.
Data Source
AI summary
A flow tube for use connecting a filter head to a bulkhead fitting in a tank includes a hollow tube having a first open end and a second open end; and the tube having a first bulbous-shaped wall adjacent to at least one of the first open end or second open end. An in-tank hydraulic filter system uses the flow tube. The system includes a hydraulic tank having a surrounding wall defining an interior volume; the surrounding wall having a bulkhead fitting providing access to the interior volume; a filter assembly mounted in the interior volume of the tank; the filter assembly having a filter head with flow port; and the flow tube connecting the tank wall with the flow port.