Helical Coil Extraction Blade for Deep Mounting Holes

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Solution Overview

Problem

Off-the-shelf helical coil extraction devices are inadequate for deeply embedded helical coils, as they are designed for shallowly installed coils, leading to difficulties in removing coils that are at least three to five thread pitches below the surface of the mounting hole, often requiring full disassembly of brake actuators.

Innovation Solution

A custom helical coil extraction device featuring a shaft with a blade that tapers from a wider to a narrower end, allowing engagement with deeply embedded helical coils without contacting the mounting hole sides, and a heat treatment process to enhance the blade's strength for effective removal.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Length of moving object

If off-the-shelf extraction devices are used, then the device structure is simple and easy to manufacture, but the device cannot reach deeply embedded helical coils (at least three to five thread pitches below surface)

Engineering Contradiction:

Improveblade lengthVSAvoiddevice structure

Core Design Contradiction:

Length of moving objectVSDevice complexity

Solution Approach 1:

The blade is divided into multiple sections with different functions: a first portion for engagement and a second tapered portion for traversal. This segmentation allows the blade to reach deep into mounting holes while maintaining structural integrity and ease of manufacture through modular design.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The blade incorporates a tapered second portion that transitions from a first width to a second width, creating a dimensional gradient that enables the blade to traverse deeply into mounting holes without contacting the sides, thereby reaching embedded helical coils without increasing overall device complexity.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Strength

If the blade is made wider to engage the helical coil, then the engagement strength increases, but the blade cannot traverse deeply into the mounting hole without contacting the sides

Engineering Contradiction:

Improveengagement strengthVSAvoidblade insertion depth

Core Design Contradiction:

StrengthVSLength of moving object

Solution Approach 1:

The blade features local quality variation through its tapered design: the first portion has a larger width for strong engagement with the helical coil, while the second portion tapers to a smaller width for deep traversal. This local differentiation allows the blade to achieve both deep insertion and strong engagement simultaneously.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

Instead of making the entire blade wide for engagement, the design inverts the approach by making the engagement portion wide and the traversal portion narrow through tapering. This inversion allows the blade to traverse deeply first, then engage the helical coil with maximum strength at the appropriate location.

Inventive Principle:

Principle #13The other way round (Inversion)

3Length of moving object

If the blade is made narrower to reach deep into the mounting hole, then the blade can traverse without contacting sides, but the engagement strength with the helical coil decreases

Engineering Contradiction:

Improveblade insertion depthVSAvoidengagement strength

Core Design Contradiction:

Length of moving objectVSStrength

Solution Approach 1:

Inventive Principle:

Principle #3Local quality

4Strength

If a custom heat treatment process is applied, then the blade strength and hardness increase for effective extraction, but the manufacturing complexity and time increase

Engineering Contradiction:

Improveblade strengthVSAvoidmanufacturing time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

The heat treatment process modifies the physical parameters of the blade material through controlled heating and cooling cycles, transforming the microstructure to achieve the required strength and hardness for extracting deeply embedded helical coils while managing manufacturing time through optimized treatment parameters.

Inventive Principle:

Principle #35Parameter changes

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 effectively extracts deeply embedded helical coils by biting into them, allowing for removal without damaging the brake actuator hub, ensuring efficient and secure extraction processes.

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

Methodology Applied

Scientific EffectHeat treatment: Heat Treatment

Implementation Method 2

performing a first air quenching the blade at a second temperature that is less than the first temperature

Methodology Applied

Scientific EffectAir quenching:

Implementation Method 3

performing a first tempering at a third temperature, wherein the third temperature is less than the first temperature and more than the second temperature

Methodology Applied

Scientific EffectTempering:

Data Source

PatentUS11872677B1Deeply embedded helical coil extraction device

Publication Date: 2024.01.16 GOODRICH CORP

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.