Forged Swaged Wire Rope Fitting Without Post-Machining
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Solution Overview
Problem
Existing swaged fittings for wire ropes require subsequent material removal processes like grinding or EDM to achieve the desired shape and size, which is inefficient and may introduce contamination issues in clean room environments.
Innovation Solution
A swaged fitting is fixed to the wire rope through a forging operation, resulting in a straight-sided construct with parallel sides and perpendicular end surfaces, eliminating the need for further material removal and enhancing force-transfer capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a swaged fitting is fixed to the wire rope through conventional swaging operations, then the fitting can be securely attached to the wire rope, but subsequent material removal operations (grinding or EDM) are required to achieve the desired shape and size
Solution Approach 1:
The fitting is designed with pre-formed bosses that contain material intended to flow into the void spaces during the swaging operation. This preliminary configuration of material distribution eliminates the need for subsequent material removal operations, as the desired shape and size are achieved directly during the initial swaging process.
Solution Approach 2:
The invention changes the physical state and distribution of material within the fitting during swaging. By controlling material flow from the bosses into the void spaces, the material parameters (density, distribution, flow characteristics) are dynamically adjusted during the forming process to achieve the final desired geometry without post-processing.
2Manufacturing precision
If material removal operations like grinding or EDM are performed on the swaged fitting, then the desired shape and size are achieved, but contamination issues are introduced in clean room environments
Solution Approach 1:
The invention extracts or eliminates the harmful material removal operations from the manufacturing process. By designing the fitting with bosses that provide material for void filling during swaging, the process achieves the desired geometry through material addition/ redistribution rather than material removal, thereby eliminating contamination risks associated with grinding or EDM in clean room environments.
3Strength
If the fitting is designed to provide a strong force-transfer interface, then high forces can be withstood, but the construct may require larger dimensions
Solution Approach 1:
The invention applies local quality by concentrating material in specific locations (the bosses) that are strategically positioned to fill the void spaces between the fitting and wire rope during swaging. This localized material distribution creates strong force-transfer interfaces at critical points without requiring the entire fitting to be larger, thereby maintaining high strength while minimizing overall volume.
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 solution provides a strong and effective force-transfer interface for medical devices, allowing for high-dimensional accuracy and compatibility with clean room operations, while withstanding high forces and repeated applications without slippage, and enabling smaller end-effector devices without compromising performance.
Implementation Method 1
impacting an end surface of the fitting to cause material to flow into the aperture and into contact with the wire rope
Data Source
AI summary
A swaged fitting can be fixed to a wire rope while simultaneously providing a desired shape and size, thereby avoiding the need for subsequent material removal. In one application, the swaged fitting is fixed to the wire rope by a forging operation such that the fitting is securely fixed provides a straight-sided construct once fixed to the wire rope. After the forging operation and without further material removal, the straight sides of the finished fitting are generally parallel to the longitudinal axis of the wire rope, while the end surfaces of the fitting are generally perpendicular to this longitudinal axis. This arrangement provides a strong and effective force-transfer interface for, e.g., end-effectors in medical devices.