Crimp Ferrule Hinge Structure for High-Pressure Hose Couplings
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Solution Overview
Problem
Crimp couplings for high-pressure applications require complex manufacturing processes and are expensive due to the need for positive engagement structures that cannot be easily produced by deep drawing and stamping, unlike those for low-pressure applications which rely on frictional engagement.
Innovation Solution
A crimp coupling design featuring a crimping ferrule with a tapering hinge section that pivots during crimping to create a positive engagement with the fitting, allowing for a simple and cost-effective manufacturing process, where the ferrule is formed by deep drawing and includes a flange and cylindrical section with a groove for enhanced engagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex positive engagement structures are used in crimping ferrules for high-pressure applications, then the connection reliability is improved, but the manufacturing complexity and cost increase significantly
Solution Approach 1:
The ferrule incorporates a dynamic hinge section that pivots during the crimping process. This hinge section transitions from a parallel orientation to an angled orientation, enabling the ferrule to actively engage with the groove on the fitting. The dynamic movement allows a simple ferrule structure to achieve positive engagement and reliable connection under high pressure without requiring complex pre-formed structures.
Solution Approach 2:
The hinge section changes its geometric parameters during crimping. The angle between the hinge section and the ferrule axis transitions from approximately 0 degrees (parallel) to a larger angle as the ferrule is deformed. This parameter change enables the ferrule to transform from a simple deep-drawn shape into one that provides positive engagement, resolving the contradiction between simplicity and reliability.
2Ease of manufacture
If simple deep-drawn ferrules are used for low-pressure applications, then the manufacturing cost is reduced, but the connection reliability under high loads is insufficient
Solution Approach 1:
The hinge section provides dynamic adaptability during crimping. As the ferrule is deformed radially inward, the hinge section pivots and the flange rotates, enabling the simple deep-drawn ferrule to automatically achieve positive engagement with the fitting's groove. This dynamic behavior allows the ferrule to transition from a simple manufactured shape to a functionally complex engagement state, maintaining ease of manufacture while improving reliability.
Solution Approach 2:
The ferrule structure performs part of the engagement function automatically during the crimping process. The hinge section's pivotal movement and the flange's rotation are self-driven by the crimping forces, requiring no additional manufacturing steps or complex pre-formed structures. The simple deep-drawn ferrule essentially serves itself to create the positive engagement needed for high-pressure applications.
3Device complexity
If frictional engagement is used for crimp couplings, then the manufacturing process is simplified, but the coupling cannot withstand high pressure or tensile forces
Solution Approach 1:
The hinge section creates a dynamic engagement mechanism that transitions during crimping. As the ferrule is deformed, the hinge section pivots and the flange rotates to engage with the groove, transforming the engagement type from purely frictional to positive mechanical engagement. This dynamic transformation enables the coupling to withstand high pressure and tensile forces while keeping the ferrule structure relatively simple and manufacturable by deep drawing.
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
The crimp coupling achieves a secure, positive engagement with the fitting, enabling reliable connections under higher loads while maintaining cost-effectiveness by using a ferrule that can be easily manufactured, addressing the manufacturing complexity and cost issues of previous high-pressure crimp couplings.
Implementation Method 1
a tapering hinge section is formed, which hinge section is formed in a tapering manner starting at a larger radius to the ferrule axis at the adjoining cylindrical section to a smaller radius at the adjoining end of the flange in such a manner that the hinge section is, due to the diameter reduction of the cylindrical section during crimping, pivoting with its end carrying the flange in outward direction
Implementation Method 2
the crimping ferrule is deformed by means of radially inwardly acting crimping tools, such that the end of the hose located within the crimping ferrule is clamped between the crimped crimping ferrule and the pipe end of the fitting
Implementation Method 3
a metal sheet is first brought by deep drawing into the shape of a cup, i.e., a substantially cylindrical shell having a closed bottom side
Data Source
AI summary
A crimp coupling includes a crimping ferrule for connecting a hose to a fitting. The fitting includes an outwardly projecting stop collar and a groove which extends circumferentially around the fitting at a constant axial distance to the stop collar. The crimping ferrule, which can be slid onto the fitting, includes a flange, a tapering hinge section, and a cylindrical section. A distance between the stop collar and the groove of the fitting is dimensioned such that the flange, when abutting the stop collar, has a lower edge facing away from the stop collar above the groove. Due to a diameter reduction of the cylindrical section and the tapering hinge section, during crimping, the flange is pivoted such that the lower edge of the flange is turned into the groove by the pivotal movement of the flange.