Hydraulic Hose Crimping With Electrical Joint Quality Detection
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Solution Overview
Problem
The existing methods for producing high-pressure hydraulic lines lack effective quality control measures to ensure the integrity of connections between connecting fittings and hoses, posing safety risks during high-pressure operations.
Innovation Solution
An electrical test signal is applied between a terminal coupled to the connecting fitting and another terminal in contactless relation to the reinforcing layer of the hose, with the response signal compared to a target range to assess the connection quality, allowing for detection of defects and ensuring a secure connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If radial pressing is used to join connecting fitting to hose, then connection strength is improved, but quality control capability deteriorates
Solution Approach 1:
The patent applies electrical testing before the radial pressing operation to detect defects in the hose and connecting fitting. By performing the measurement action in advance, the system can identify potential connection quality issues before they occur during the pressing process, enabling preventive quality control rather than post-processing inspection
Solution Approach 2:
The patent replaces mechanical quality inspection methods with electrical testing. Instead of using mechanical probes or visual inspection to assess connection quality, the system uses electrical signals to detect defects in the hose structure and connecting fitting, providing more precise and reliable quality control capability
2Measurement precision
If electrical testing is added to the production process, then quality control capability is improved, but device complexity worsens
Solution Approach 1:
The radial press is designed to perform multiple functions: it conducts the radial pressing operation to join the connecting fitting to the hose, and simultaneously performs electrical testing to detect defects. By integrating these functions into a single device, the system improves quality control capability without proportionally increasing device complexity
Solution Approach 2:
The patent combines the electrical testing system with the radial press structure. The testing components (electrical signal source, measurement devices) are integrated into the press mechanism, allowing quality control functions to be performed within the existing production equipment framework rather than requiring entirely separate testing apparatus
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 evaluating the connection quality, detecting defects, and controlling the production process to prevent hazardous failures, thereby improving occupational and industrial safety.
Implementation Method 1
applying an electrical test signal to at least one terminal of a test arrangement having two terminals, of which a first terminal is coupled electrically and/or magnetically to the connecting fitting and a second terminal is coupled electrically and/or magnetically in contactless relationship to the reinforcing layer
Implementation Method 2
radial pressing of a pressing sleeve of the connecting fitting in such a way that the hose—which is usually peeled beforehand on the outside and/or inside—is squeezed securely, durably and media-tightly in the annular gap that exists between the pressing sleeve (surrounding the hose on the outside) and a nipple (pressed into the inside of the hose)
Data Source
AI summary
When producing a high-pressure hydraulic line, a connection fitting is attached to a multi-layer high-pressure hose having a reinforcing layer. A portion of a reinforced high-pressure hose and a connection fitting to be joined to it are provided. The connection fitting is placed onto the end portion of the high-pressure hose and a joining operation is carried out to form a sealed connection. The quality of the connection is determined by applying an electrical test signal to at least one connection of a testing arrangement having two connections. A first connection is electrically and/or magnetically coupled to the connection fitting and a second connection is contactlessly electrically and/or magnetically coupled to a reinforcing layer of the high-pressure hose. An electrical response signal is detected and the response signal is compared with a setpoint-value range stored in a memory of the testing arrangement.