Bulkhead Flange Clamp Assembly for One-Sided Hydraulic Service
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Solution Overview
Problem
Conventional four-bolt flange connections in bulkhead assemblies of work machines require disassembly from both sides, leading to increased weight, cost, and power consumption due to large manifolds and multiple fasteners, complicating assembly and service operations.
Innovation Solution
A flange clamp union assembly with a projecting portion that allows independent assembly and disassembly on one side, utilizing a bulkhead union plate with keyhole openings for alignment and retention, reducing the need for large manifolds and minimizing fastener usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional four-bolt flange connections are used in bulkhead assemblies, then reliable hydraulic connections are achieved, but weight increases due to large manifolds and multiple fasteners
Solution Approach 1:
The bulkhead assembly is segmented into modular components: a bulkhead plate with integrated keyhole openings, separate flange clamps with retaining portions, and individual fasteners. This segmentation allows each component to be optimized independently and reduces the need for large, heavy manifolds while maintaining connection reliability through distributed fastening points
Solution Approach 2:
The retaining portion is extracted as a separate functional element from the flange clamp body, designed to fit into the keyhole opening in the bulkhead plate. This extraction allows the connection system to use smaller, lighter fasteners while the retaining portion provides the necessary mechanical retention and alignment function
2Strength
If conventional four-bolt flange connections are used, then secure fastening is achieved, but device complexity increases due to multiple fasteners and assembly from both sides
Solution Approach 1:
Instead of requiring assembly from both sides of the bulkhead plate as in conventional designs, the retaining portion is designed to protrude from one side and fit into the keyhole opening on the same side. This inversion of the assembly approach allows all fastening operations to be performed from a single side, reducing complexity while maintaining fastening strength through the distributed bolt pattern and retaining mechanism
3Reliability
If large manifolds and multiple fasteners are used, then reliable connections are achieved, but manufacturing cost increases
Solution Approach 1:
The bulkhead plate integrates the keyhole openings directly into its structure, merging the retention feature with the bulkhead itself rather than requiring separate manifolds or brackets. This consolidation reduces the number of parts that need to be manufactured and assembled, lowering manufacturing costs while maintaining connection reliability through the integrated design
Solution Approach 2:
The bulkhead plate serves multiple functions: it provides the mounting surface for hydraulic connections, incorporates the keyhole openings for retention and alignment, and acts as the structural backbone for the entire assembly. This multi-functionality eliminates the need for separate manifolds and reduces the overall part count, decreasing manufacturing complexity and cost
4Strength
If conventional flange connections requiring disassembly from both sides are used, then secure fastening is achieved, but service time increases
Solution Approach 1:
The retaining portion is designed to engage with the keyhole opening from a single side of the bulkhead plate, inverting the conventional approach that requires access from both sides. This allows service personnel to perform all disassembly and reassembly operations from one side only, significantly reducing service time while maintaining fastening strength through the distributed fastener pattern and retaining mechanism
Data Source
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AI summary
A bulkhead assembly is disclosed. The bulkhead assembly comprising a bulkhead plate (600) and a flange clamp (512) for coupling a fluid connector (700) to the bulkhead plate (600), the flange clamp (512) comprising: a clamp body (514) having a curved inner surface configured to be engageable with a fluid connector (700); a plurality of openings (518, 520, 522) formed in the clamp body (514), the plurality of openings (518, 520, 522) including at least a first opening (518), a second opening (520), and a third opening (522); at least one extended body portion (536) integrally formed at an outer periphery of the clamp body (514); a retaining portion (534) integrally formed with the at least one extended body portion (536), the retaining portion (534) projecting away from the at least one extended body portion (536); wherein the retaining portion (534) is configured to be disposable within an opening formed in the bulkhead plate (600), where the retaining portion (534) is configured to selectively maintain an orientation of the clamp body (514) on the bulkhead plate (600). Further, a method of assembling such a bulkhead assembly is disclosed.