Hydraulic Manifold Plug Insert for Repeatable Depth-Controlled Sealing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing plug and sealing systems face challenges in easy installation, manufacturing complexity, and ensuring repeatable installation in holes, particularly in hydraulic manifolds, where high pressures and inconsistent hole sizes complicate the sealing process.
Innovation Solution
A plug system featuring a tapered core and cylindrical sleeve with a threaded hole, secured to an installation device that includes a depth stop for controlled installation depth, allowing for radial expansion against the hole surface, and a tray for handling multiple inserts, enabling easier and repeatable installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a rivet system with a breakable stem is used to install the plug, then the plug can be installed in the hole, but the manufacturing process becomes complicated and expensive
Solution Approach 1:
The invention removes the complex breakable stem from the plug design entirely. Instead, it uses a separate installation tool with an extraction mechanism that pulls the plug into the hole and then extracts itself, leaving no stem remnants. This eliminates the need for complicated stem manufacturing processes while achieving the same installation function.
Solution Approach 2:
The invention introduces an intermediary installation tool that facilitates plug installation without becoming part of the final assembly. The tool includes a driver that engages with the plug during installation and then extracts itself, serving as a temporary mediator that simplifies the overall process by removing the need for permanent stem structures.
2Ease of operation
If manual activation is used for installing the plug, then the installation process is simple, but depth control and repeatability are insufficient
Solution Approach 1:
The installation tool incorporates a depth control mechanism that is pre-configured with a stop feature. This preliminary action ensures that the plug is installed to the correct depth automatically during the installation process, eliminating the need for manual measurement and adjustment while maintaining ease of operation.
Solution Approach 2:
The installation tool includes a depth control mechanism that provides feedback during installation through a stop feature. When the plug reaches the predetermined depth, the stop mechanism engages to prevent further insertion, ensuring repeatable and precise installation depth control while keeping the operation simple.
3Productivity
If a plug system without depth control is used, then the installation process is simple, but consistent installation depth cannot be ensured
Solution Approach 1:
The depth control mechanism is pre-configured in the installation tool with a stop feature set at the precise depth required. This preliminary action allows installers to quickly install plugs without manual measurement, maintaining high productivity while ensuring consistent depth across all installations through the automatic stop mechanism.
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 system provides reliable sealing under high pressures, withstands up to 40,000 psi, and ensures consistent installation depth, reducing manufacturing costs and complexity while accommodating varying hole sizes and pressures.
Implementation Method 1
radial expansion against the hole surface
Data Source
AI summary
The present disclosure relates to an insert and system of installing the same. The insert includes a tapered core and a cylinder. The core releasably secures to an installation device which includes a depth stop or a depth control to control the installation depth of the insert. The insert may be provided in a tray that allows for easier handling of the inserts and installation thereof in installation holes, for example in a hydraulic manifold. In some cases, the core includes a threaded hole to releasably secure the insert to the installation device, thus allowing the installation device to pull the core into the cylinder. The core and cylinder may be made of metallic materials such as steels, steel alloys and others. In some cases the insert can withstand blow out pressures of 40,000 psi or higher.