Flexible Collet Cup Plug Insertion Tool Centering
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Solution Overview
Problem
Current cup plug press operations in automotive applications experience high failure rates during post-operation leak tests, primarily due to excessive press force leading to miscentering and potential deformation or removal of the cup plug during tool retraction.
Innovation Solution
A cup plug insertion tool featuring a cylindrical collet with radial flexible segments that flex inward to securely engage and center the cup plug, providing frictional hold without deforming the plug, and allowing for easy release after insertion, utilizing a chamfer and vacuum assistance for precise alignment and securement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a tight tolerance between the tool outer diameter and cup plug inner diameter is used for centering, then the cup plug is effectively centered, but the cup plug may deform and tightly grab the tool, causing it to be pulled out upon tool retraction
Solution Approach 1:
The collet is divided into multiple flexible segments by longitudinal slots, allowing the segments to independently flex and adapt to the cup plug inner diameter. This segmentation enables effective centering through controlled interference fit while preventing excessive gripping that would cause the cup plug to be pulled out during retraction
Solution Approach 2:
The collet transitions from a rigid structure to a dynamic flexible structure where segments can radially move. During insertion, the segments flex outward to engage the cup plug for centering, then flex inward during retraction to release the cup plug, preventing it from being pulled out while maintaining centering precision
2Ease of operation
If significant relief between the tool outer diameter and cup plug inner diameter is used, then the cup plug can be easily inserted, but the centering is completely dependent on vacuum and friction, causing droop and gouging effects
Solution Approach 1:
The collet's outer diameter parameter is made variable through the flexible segments. The segments can expand to provide sufficient interference fit for positive centering during insertion, then contract to reduce friction and allow easy release after insertion, resolving the contradiction between insertion ease and centering precision
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
Ensures accurate centering and secure insertion of the cup plug without risk of removal during tool retraction, minimizing stress and ensuring a proper seal, while allowing for easy tool release and reduced likelihood of leaks.
Implementation Method 1
the flexible segments are adapted to flex radially inward under force, thereby reducing the outer diameter of the first section of the collet
Implementation Method 2
the flexible segments push radially outward to frictionally engage the inner diameter of the cup plug and hold the cup plug thereon
Implementation Method 3
the vacuum tube adapted to engage a cup plug to provide additional force to secure the cup plug onto the distal end of the collet
Data Source
AI summary
A cup plug insertion tool comprises a cylindrical base and a cylindrical collet extending from the base and including at least two longitudinal slots that divide the collet into at least two flexible segments adapted to flex radially inward under force, an annular groove formed adjacent the base, the annular groove adapted to allow the flexible segments to flex radially inward, further wherein, the force necessary to flex the flexible segments radially inward is tunable based on a width and depth of the annular groove, a first section defining a circumferential outer diameter and a circumferential inner diameter, a second section defining a circumferential outer diameter that is larger than the circumferential outer diameter of the first section, a tip positioned at the distal end of the collet, and a chamfer formed between the outer diameter of the first section and the tip.