Compact Grease Coupler Locking for High-Pressure Uncoupling
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Solution Overview
Problem
Conventional grease couplers face difficulties in positive coupling and uncoupling under high pressure, leading to wear, leakage, and hydraulic lock issues, and are often bulky, making them inefficient and hard to use at tight greasing points.
Innovation Solution
A grease coupler design featuring an outer and inner sleeve with a collar and nozzle system, utilizing springs and locking balls to facilitate easy and secure coupling and uncoupling, along with a ball check valve for adjustable flow control, allowing for efficient operation under pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If conventional couplers are used under high grease pressure, then grease delivery is maintained, but positive coupling and uncoupling becomes difficult requiring noticeable physical effort
Solution Approach 1:
The coupler is divided into an outer sleeve and an inner sleeve that can move independently relative to each other. The inner sleeve carries the nozzle and locking mechanism, while the outer sleeve provides structural support. This segmentation allows the locking balls to be distributed between the two sleeves, enabling positive locking without requiring excessive coupling force.
Solution Approach 2:
Locking balls act as intermediaries between the inner and outer sleeves to transmit and distribute the locking force. These balls engage with corresponding grooves in both sleeves, providing a mechanical advantage that secures the coupling without requiring high manual force from the operator.
2Quantity of substance
If conventional couplers are used under high grease pressure, then grease flow is maintained, but wear and tear and component failure occur
Solution Approach 1:
By separating the nozzle (on the inner sleeve) from the main body (outer sleeve), the design isolates the high-wear components. The nozzle can be easily replaced if worn, while the outer sleeve remains intact. This segmentation prevents catastrophic failure and extends component durability.
Solution Approach 2:
The inner sleeve is designed to move dynamically within the outer sleeve, allowing the nozzle to adjust its position automatically in response to pressure changes. This dynamic adjustment prevents binding and reduces wear on the locking mechanism, enhancing reliability under high pressure.
3Quantity of substance
If conventional couplers are used under high grease pressure, then grease delivery continues, but leaking and spurting of grease occurs
Solution Approach 1:
The design incorporates a gradual engagement mechanism where the inner sleeve moves incrementally into the outer sleeve during coupling. This gradual engagement allows the sealing surfaces to make contact progressively, cushioning the pressure buildup and preventing sudden grease spitting. The locking balls engage in stages, distributing the pressure load and preventing leakage.
4Productivity
If conventional quick-release couplers are used, then coupling speed is improved, but the coupler becomes bulky posing access problems
Solution Approach 1:
The inner sleeve is nested within the outer sleeve, with the nozzle positioned inside the outer sleeve's bore. This nested configuration allows the coupler to maintain a compact overall size while still incorporating all necessary locking and sealing mechanisms. The locking balls are housed within grooves in both sleeves, minimizing the radial dimension without compromising the quick-release functionality.
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 enables reliable and effortless coupling and uncoupling of grease nipples, minimizing leakage and hydraulic lock issues, while being compact enough for easy access to tight spaces.
Implementation Method 1
a collar spring on the inlet end of the inner sleeve between the collar and the connection body to axially bias the collar toward the outlet end of the outer sleeve
Implementation Method 2
a nozzle spring in the inner sleeve between the nozzle and the connection body; pushing the grease nipple inside the outlet end of the outer sleeve initially moves the nozzle axially away from the jaws to unlock the jaws and compress the nozzle spring, and subsequently moves the nozzle axially toward the grease nipple under spring pressure by the nozzle spring to thereby relock the jaws
Data Source
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AI summary
A grease coupler, comprising: an outer sleeve; an inner sleeve; a connection body; a collar; a collar spring; jaws to lock and unlock with a grease nipple; a nozzle; a nozzle spring; a collar ball groove; and an inner ball groove; sleeve locking balls; a nozzle ball groove; and nozzle locking balls.