High-Pressure Hose Crimp Verification Using Electrical Coupling
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Solution Overview
Problem
High-pressure hydraulic lines face safety risks due to inadequate quality control in the connection between the connection fitting and the hose section, which can lead to failures during operation, posing health and environmental hazards.
Innovation Solution
A method involving a test arrangement with two connections, where one is electrically or magnetically coupled to the connection fitting and the other to the reinforcement layer of the hose, using an electrical test signal to assess the connection quality by comparing the reaction signal with a stored target value range, allowing for detection of production errors and ensuring a secure connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a radial crimping method is used to join the fitting to the hose section, then a tight and permanent connection is achieved, but the quality of the connection cannot be reliably verified
Solution Approach 1:
The patent replaces mechanical verification methods with an electrical testing system. A test arrangement with two connections is used, where one connection is electrically coupled to the fitting and the other to the reinforcement layer. An electrical test signal is applied to detect the connection quality between the fitting and the hose section, enabling reliable verification of the crimping process without mechanical inspection.
Solution Approach 2:
The patent introduces an electrical test arrangement as an intermediary between the fitting and the reinforcement layer to verify connection quality. This test arrangement includes two connections: one electrically coupled to the fitting and another contactlessly coupled to the reinforcement layer, allowing indirect measurement of the connection integrity without direct physical contact between test points.
2Strength
If the hose is stripped externally and internally before joining, then a secure fit is achieved, but the risk of production errors and safety hazards increases
Solution Approach 1:
The patent implements a feedback mechanism through electrical testing after the crimping process. The test arrangement measures the electrical properties of the connection between the fitting and the hose section, providing feedback on connection quality. This allows detection of production errors such as insufficient crimping or improper stripping, enabling corrective actions before the product leaves the manufacturing line and reducing safety hazards.
3Productivity
If manual inspection methods are used to verify connection quality, then production speed is maintained, but measurement precision and reliability are insufficient
Solution Approach 1:
The patent replaces manual inspection with an automated electrical testing system. The test arrangement automatically applies electrical test signals and measures the connection properties, eliminating the need for manual verification while maintaining high production speed. This automated electrical measurement provides precise and objective quality assessment without the variability and limitations of human inspection.
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
This method enhances safety by reliably assessing the quality of the connection, detecting potential failures, and reducing production errors, thereby preventing accidents and ensuring operational integrity.
Implementation Method 1
a first connection (12) which is configured for electrical and/or magnetic coupling to the connecting fitting (4) and a second connection (16) which is configured for contactless electrical and/or magnetic coupling to the reinforcement layer (6)
Implementation Method 2
a first connection (12) which is configured for electrical and/or magnetic coupling to the connecting fitting (4) and a second connection (16) which is configured for contactless electrical and/or magnetic coupling to the reinforcement layer (6)
Implementation Method 3
the clear width of the annular gap of the connecting fitting (4) is reduced by radially pressing the crimp sleeve (9) with a press tool (1) having several press bodies (P) arranged around a press axis and movable radially to the press axis
Data Source
AI summary
In a method for producing a high-pressure hydraulic line, a connection fitting (4) is attached to the end of a multi-layer high-pressure hose (5), having at least one reinforcing layer (6, 7), in that a portion of a reinforced high-pressure hose (5) and a connection fitting (4) to be joined to it are provided, the connection fitting (4) is placed onto the end portion of the high-pressure hose (5) and a joining operation is carried out to form a sealed connection between the high-pressure hose (5) and the connection fitting (4). The quality of the connection of the connection fitting (4) to the high-pressure hose (5) is determined here by applying an electrical test signal to at least one connection (12; 16) of a testing arrangement (18) having two connections (12, 16), a first connection (12) of which is electrically and/or magnetically coupled to the connection fitting (4) and a second connection (16) of which is contactlessly electrically and/or magnetically coupled to the reinforcing layer (6), or at least one of the reinforcing layers (6, 7), of the high-pressure hose (5), an electrical response signal occurring in the testing arrangement is detected and the response signal is compared with a setpoint-value range stored in a memory of the testing arrangement (18) for the high-pressure-hose/connection-fitting pairing concerned.