Floating Multi-Coupling Alignment for Offset-Tolerant Line Connection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional multi-couplings face challenges in securely aligning and connecting multiple media lines under varying environmental conditions, especially with movable objects where conventional supply lines are impractical due to offset tolerances and harsh conditions.
Innovation Solution
The multi-coupling design features a floating coupling carrier with pre- and fine centering pins and a catch jaw mechanism that compensates for lateral and rotational offsets between coupling parts, utilizing springs for flexibility and actuators for alignment, allowing for secure and efficient connection of media lines across different orientations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional rigid coupling system is used, then alignment precision may be maintained, but the system cannot compensate for offset tolerances and is prone to damage under harsh conditions
Solution Approach 1:
The coupling system employs a dynamic multi-stage centering mechanism with pre-centering pins and fine-centering pins that can adapt their positions during the coupling process. The pre-centering pins with spherical heads and fine-centering pins with conical heads provide progressive alignment capability, allowing the system to compensate for offset tolerances while maintaining controlled complexity through structured mechanical design.
Solution Approach 2:
The alignment function is segmented into multiple independent stages: pre-centering pins for initial alignment and fine-centering pins for precise final alignment. This segmentation allows each component to perform a specific function, improving reliability through modular error compensation while keeping the overall device complexity manageable by dividing the alignment task into discrete steps.
2Reliability
If multiple media couplings are rigidly mounted, then structural simplicity is maintained, but shock loads and overload damage cannot be avoided
Solution Approach 1:
The media couplings are mounted in a floating manner on the coupling carrier, allowing them to move dynamically in response to shock loads and external forces. This dynamic mounting protects the couplings from overload damage while maintaining a relatively simple structural design through the use of floating supports rather than complex active control systems.
Solution Approach 2:
The floating mounting of media couplings provides beforehand cushioning against shock loads by allowing the couplings to move independently when subjected to external forces. This passive protection mechanism is built into the mounting structure itself, providing reliability without requiring additional complex protection systems.
3Manufacturing precision
If precision alignment mechanisms are used, then alignment accuracy is improved, but tolerance for manufacturing variations decreases
Solution Approach 1:
The alignment mechanism is segmented into pre-centering pins for coarse alignment and fine-centering pins for precise alignment. This segmentation allows the system to achieve high alignment accuracy while maintaining tolerance for manufacturing variations, as each stage handles a specific range of corrections without requiring absolute precision from all components.
Solution Approach 2:
The multi-stage centering mechanism provides dynamic adaptability to manufacturing variations. The pre-centering pins with spherical heads accommodate larger offset variations initially, while the fine-centering pins with conical heads provide precise final alignment. This dynamic progression allows the system to achieve high accuracy regardless of initial manufacturing tolerances.
4Manufacturing precision
If a simple single-stage centering mechanism is used, then device complexity is reduced, but alignment precision and error tolerance are insufficient
Solution Approach 1:
The centering mechanism is segmented into multiple functional stages with pre-centering pins for initial alignment and fine-centering pins for precise alignment. This segmentation achieves high alignment precision by dividing the alignment task into manageable steps, while the modular nature of the segmented design keeps the overall device complexity controlled through structured functionality.
Solution Approach 2:
The pre-centering pins perform preliminary alignment action before the fine-centering pins engage. This preliminary action reduces the alignment burden on the fine-centering mechanism, allowing higher overall precision without requiring the fine-centering stage to handle the full range of misalignment, thus managing device complexity through staged engagement.
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
This design ensures secure, fault-tolerant, and efficient alignment and connection of multiple media lines, minimizing wear and shock loads, while accommodating large offset tolerances and harsh conditions, ensuring reliable operation in heavy industry and transportation applications.
Implementation Method 1
at least one spring element (17) arranged between the coupling carrier (8) and the carrier base (16), which is pre-tensioned by tensioning means (18)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A multi-coupling (1) is described for coupling lines (2) with an alignment aid (5) assigned to a first coupling part (3) and a second coupling part (4) for compensating for offset tolerances during threading of the first coupling part (3) into the second coupling part (4) during coupling of medium couplings (6). In order to provide advantageous coupling conditions, it is proposed that at least one coupling part has a coupling carrier (8) mounted floatingly transversely with respect to the coupling direction (7), that the alignment aid (5) has, on one coupling part, a central precentring journal (9) protruding from a coupling carrier in the coupling direction (7), and at least one precision centring journal (11) protruding from the coupling carrier (8) in the coupling direction (7) and arranged radially around the precentring journal axis (10), wherein the precision centring journal head is set back in the coupling direction (7) with respect to the precentring journal head, and that the alignment aid (5) has, on the coupling socket side, a central jaw (12) which merges in the coupling direction (7) into a precentring guide (13) for the precentring journal (9) and is equipped with at least one precision centring guide (15), arranged around the precentring guide axis (14), for the precision centring journal (11).