Flexible Pipe Connector Assembly for Vibration-Resistant Welding
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Solution Overview
Problem
Existing flexible pipe connectors face issues such as incomplete welding, complex welding structures, increased manufacturing costs, and vulnerability to vibration-induced damage, leading to cracks and leaks, particularly in environments with continuous vibration.
Innovation Solution
A flexible pipe connector design that includes a corrugated pipe covered by a braided net, with a welding ring and end ring, allowing for a simplified welding process and stress relief through annealing heat treatment, ensuring secure coupling and vibration absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If gas silver brazing is used to weld components, then welding strength is achieved, but surface oxidation and welding stress occur during welding, and grain boundary carbide precipitation and stress corrosion cracking occur over time
Solution Approach 1:
The patent replaces traditional gas silver brazing (thermal welding process) with mechanical expansion fitting. The welding ring's expanded pipe portion mechanically expands to create a tight fit with the end ring and braided net, eliminating the need for thermal welding and its associated oxidation and stress problems.
Solution Approach 2:
The welding ring acts as an intermediary component between the end ring and the braided net. It provides a mechanical connection that distributes stress and prevents direct contact between components that would otherwise require welding, thereby eliminating welding-induced stress corrosion cracking.
2Strength
If multiple welding processes are performed to assemble components, then secure coupling is achieved, but manufacturing complexity and production time increase
Solution Approach 1:
The patent combines multiple assembly operations into a single mechanical insertion process. The welding ring with expanded pipe portion is inserted into the end ring, and the braided net is simultaneously secured, replacing multiple welding processes with one mechanical assembly step.
Solution Approach 2:
The welding ring is segmented into distinct functional portions: the expanded pipe portion for mechanical expansion and fitting, and the insertion portion for placement into the end ring. This segmentation allows for simplified assembly while maintaining coupling security.
3Strength
If the corrugated pipe is covered with a braided net to prevent stretching, then pipe strength is improved, but incomplete welding occurs between the braided mesh and base metal
Solution Approach 1:
The patent replaces welding (thermal process) with mechanical expansion fitting. The expanded pipe portion of the welding ring mechanically secures the braided net without requiring welding, thereby eliminating incomplete welding issues while maintaining the strength provided by the braided net coverage.
4Reliability
If vibration absorption is increased by improving corrugated pipe elasticity, then vibration damage is reduced, but bending flexibility increases causing accumulated processing stress and crack formation
Solution Approach 1:
The patent optimizes the hardness parameter of the corrugated pipe to a specific range (175-200 HV) through controlled heat treatment. This parameter change allows the pipe to absorb vibration while maintaining sufficient strength to prevent crack formation, resolving the contradiction between vibration resistance and structural integrity.
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 design enhances welding quality, reduces production costs, and prevents damage from vibration, extending the product's lifespan and improving reliability by simultaneously performing welding and stress relief in a single heating process.
Implementation Method 1
a phenomenon that vibration of a compressor that compresses a refrigerant gas is transmitted to a piping line of a closed circuit may occur. Specifically, stress corrosion occurs and hardness becomes 240 Hv or more due to welding stress (welding stress of a thin-walled straight pipe) and corrugation processing stress (martensite structure formation) generated in a manufacturing process for a corrugated pipe
Implementation Method 2
welding stress and processing stress can be removed through a manufacturing process further including the annealing heat treatment process in the related art
Implementation Method 3
an end portion of a metal corrugated pipe and a braided mesh covering the end portion of the corrugated pipe are severely abraded due to vibration, causing a crack in the end portion of the corrugated pipe
Implementation Method 4
a welding ring having an expanded pipe portion formed in one side portion, and inserted into the end ring so that an end portion of the braided net is disposed in a gap between the expanded pipe portion and the end ring
Data Source
AI summary
A flexible pipe connector according to an embodiment of the present invention includes a corrugated pipe, an end ring inserted into and welded to an end portion of the corrugated pipe, a circular ring disposed on the outer side of the end portion of the corrugated pipe, a braided net that covers a portion of an outer circumferential surface of the end ring, an outer circumferential surface of the corrugated pipe, and an outer circumferential surface of the circular ring, and a welding ring inserted into the end ring so thin the end portion of the corrugated pipe is disposed in a gap formed between the welding ring and the end ring, the end portion of the corrugated pipe being welded, in order to simplify a welding structure of the flexible pipe connector to which a fluid transport pipe is connected, improve welding quality, and minimize damage from friction due to vibration, thereby improving the reliability of a product and extending the life thereof.