Hose Coupling Press Fitting Design for High-Pressure Hydraulic Systems
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Solution Overview
Problem
Existing hose couplings for high-pressure hydraulic systems, particularly in heavy hydraulics, face inefficiencies due to pressure losses and inability to handle tensile loads, leading to reduced energy efficiency and risk of hose disconnection under strong forces.
Innovation Solution
A hose coupling design featuring a press fitting with distinct securing and sealing areas, utilizing differently dimensioned wall deformations and materials to ensure a strong, non-positive connection between the hose and coupling element, preventing collapse and maintaining inner diameter for increased volume flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a press fitting is used to connect hydraulic hoses, then a tight connection is achieved, but the connection cannot withstand high tensile loads in heavy hydraulics
Solution Approach 1:
The press fitting is divided into two distinct areas: a securing area with larger wall deformations for tensile load bearing, and a sealing area with smaller wall deformations for tight sealing. This segmentation allows each area to specialize in its function, resolving the contradiction between connection reliability and tensile strength.
Solution Approach 2:
Different wall deformation dimensions are applied locally to different areas of the press fitting. The securing area has larger wall deformations optimized for mechanical strength and tensile load resistance, while the sealing area has smaller wall deformations optimized for sealing performance. This local differentiation resolves the contradiction by providing both strength and reliability in appropriate locations.
2Stress or pressure
If hydraulic pipes are used instead of hoses, then high pressures can be handled, but the system becomes rigid requiring multiple bends and fittings
Solution Approach 1:
The hose coupling design enables flexible hoses to universally replace rigid hydraulic pipes by providing a press fitting that can withstand high pressures (up to 1000 bar) while maintaining hose flexibility. This multi-functionality allows a single hose-based solution to replace complex pipe systems with multiple bends and fittings, reducing overall system complexity.
3Quantity of substance
If the press fitting expands axially during pressing, then material can be taken up, but the clear width of the hose nipple is reduced
Solution Approach 1:
The press fitting design redirects material flow from the axial dimension to the radial dimension through strategically positioned larger wall deformations in the securing area. These deformations absorb excess material radially during pressing, preventing axial expansion that would reduce the clear width of the hose nipple, thus maintaining volume flow capacity.
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 achieves a secure and efficient connection that maintains inner diameter, enhancing energy efficiency by allowing higher volume flow and withstanding high pressures and impulse loads without hose disconnection.
Implementation Method 1
The press fitting is designed with a material and wall thickness that enable it to absorb the pressing force without collapsing the hose nipple. The press fitting may be designed with a slightly larger wall thickness than the hose wall thickness to ensure sufficient strength and stability during pressing.
Data Source
Figure 1
Figure 2
AI summary
The coupling (10) has a press holder (20) provided with a wall deformation unit (21) that is aligned and running radial to a high pressure hydraulic hoseline (11), in a safety region (A). A recess is provided at an outer side of the press holder in an area of the deformation unit. The deformation unit is made of material same as material of another wall deformation unit (24) in a sealing region (B). A hose nipple (31) in the safety region has a groove-like bulge (34) lying opposite to the former deformation unit. The holder exhibits uniform wall thicknesses in the safety- and sealing regions.