Tapered Helical Coil Extractor for Deep Mounting Holes
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing helical coil extraction devices are inadequate for removing deeply embedded helical coils, which are often installed more than three to five thread pitches below the surface of a mounting hole, requiring full disassembly of brake actuators for removal.
Innovation Solution
A helical coil extraction device featuring a custom blade with a tapered design and specific geometric ratios, coupled to a shaft, allows the blade to traverse deeply into mounting holes without contacting the sides, enabling effective engagement and removal of deeply embedded helical coils through rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If off-the-shelf helical coil extraction devices are used, then the device structure is simple and easy to manufacture, but they cannot extract deeply embedded helical coils and require full disassembly
Solution Approach 1:
The extraction device is divided into distinct functional segments: a shaft for insertion, a tapered blade for engagement, and a slot for blade reception. This segmentation allows each component to perform its specific function optimally while maintaining overall device simplicity.
Solution Approach 2:
The blade is designed with a tapered geometry that extends radially from the shaft, creating a three-dimensional engagement structure. The taper angle and radial extension allow the blade to reach deeply embedded coils at angles and depths that standard straight extraction devices cannot achieve.
2Ease of manufacture
If a standard extraction device is used, then manufacturing is simple, but it causes damage to the surrounding housing when attempting to remove deeply embedded coils
Solution Approach 1:
The blade features a tapered geometry with varying width along its length, creating local quality differences. The narrower distal end allows precise engagement with the helical coil, while the wider proximal end provides structural support. This localized geometry optimization enables extraction without excessive force that would damage surrounding housing.
Solution Approach 2:
The blade's tapered geometry changes the physical parameters of engagement. The taper angle and radial extension create a progressive engagement profile that distributes extraction forces, preventing sudden force spikes that could damage the housing while maintaining manufacturing simplicity.
3Ease of operation
If the blade width is increased to engage deeply embedded coils, then extraction capability improves, but the blade contacts the side of the mounting hole causing damage
Solution Approach 1:
Instead of increasing blade width in a straight line, the blade extends radially outward from the shaft at a taper angle. This dimensional change allows the blade tip to reach deeply embedded coils without the full blade width contacting the mounting hole sides, preventing damage while maintaining engagement capability.
Solution Approach 2:
The tapered geometry of the blade performs preliminary action by gradually engaging the helical coil as it is inserted. The taper allows the blade to progressively cut into and grip the coil, establishing secure engagement before full extraction force is applied, preventing sudden movements that could damage the mounting hole.
4Length of moving object
If the blade is made longer to reach deeply embedded coils, then extraction depth capability improves, but the blade becomes more difficult to manufacture and harder to control
Solution Approach 1:
The blade is segmented into functional zones along its length: a tapered engagement zone for coil gripping, a transition zone for stress distribution, and a root zone for shaft connection. This segmentation allows each section to be optimized for its specific function while maintaining manufacturability through standard fabrication processes.
Solution Approach 2:
The blade's cross-sectional parameters change along its length through the taper, creating a geometry that is long yet manufacturable. The gradual parameter change from root to tip allows the blade to achieve the necessary length for deep engagement while maintaining structural integrity and compatibility with standard manufacturing processes.
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 device enables efficient extraction of deeply embedded helical coils without damaging the surrounding components, reducing the need for full disassembly of brake actuators and improving the overall removal process.
Implementation Method 1
the blade is hardened via a hardening process that includes: wrapping the blade in heat treatment foil; heat treating the blade at a first temperature; performing a first air quenching the blade at a second temperature that is less than the first temperature; performing a first tempering at a third temperature, wherein the third temperature is less than the first temperature and more than the second temperature
Data Source
AI summary
A device for extracting a deeply embedded helical coil is provided. The device includes a shaft, the shaft comprising a proximal end and a distal end; and a blade coupled to the distal end of the shaft, wherein the blade is configured to traverse into a mounting hole to engage the deeply embedded helical coil free of contact with a side of the mounting hole and wherein the deeply embedded helical coil is at least three to five thread pitches below a surface of the mounting hole.