Hydraulic Stud Tensioning Adapter for Uniform Flange Bolt Preload
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Solution Overview
Problem
Conventional bolt tensioning systems require specialized tools and are inefficient, posing safety risks and taking excessive time due to the need for manual torqueing of bolts, which can lead to over-tightening or loosening under vibration, especially in flange connections.
Innovation Solution
A hydraulic tensioning adapter system that uses a flange housing, bolt support retainer, bolt tensioning piston, and retainer ring to apply uniform tension to multiple studs simultaneously without pneumatic, hydraulic, or hammer wrenches, utilizing hydraulic pressure to secure flange connections quickly and safely.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional hydraulic, pneumatic, or hammer wrenches are used to torque the bolts, then the connection is made, but the bolts may become loose due to vibration or over-tightened and rupture
Solution Approach 1:
The patent replaces conventional mechanical torqueing systems (hydraulic, pneumatic, or hammer wrenches) with a direct tensioning system that applies controlled tensile force to the studs. This substitution eliminates the indirect torque transmission mechanism that causes tension inaccuracies due to friction, and instead directly tensions the studs to the required preload, ensuring both connection reliability and manufacturing precision.
Solution Approach 2:
The patent utilizes a hydraulic tensioning system where hydraulic fluid is introduced into the tensioning device to generate controlled tensile force on the studs. The hydraulic mechanism provides smooth, controlled tension application that can be precisely regulated, avoiding both under-tightening and over-tightening issues associated with conventional mechanical wrenches.
2Manufacturing precision
If bolt tensioning systems are used to tension bolts, then accurate tension is achieved, but only one bolt can be tensioned at a time and special tools and modified nuts are required
Solution Approach 1:
The patent merges multiple individual tensioning functions into a single integrated device that can tension multiple studs simultaneously. The tensioning device incorporates multiple tensioning elements arranged to engage with multiple studs at once, allowing all studs in a flange connection to be tensioned in a single operation rather than requiring sequential tensioning of each bolt individually.
Solution Approach 2:
The tensioning device is designed with universal applicability to accommodate various stud configurations and flange types. It incorporates adjustable components and standardized interfaces that allow the same device to tension different numbers and sizes of studs without requiring specialized modified nuts or custom tooling for each application.
3Reliability
If heavy equipment is suspended overhead and personnel work in a closed environment making up equipment with flange connections, then the connection is made, but personnel are exposed to longer make-up times and increased safety risks
Solution Approach 1:
The tensioning device is pre-assembled and ready for immediate installation on the flange connection. The device incorporates pre-positioned tensioning elements and hydraulic components that are prepared beforehand, allowing for rapid installation and tensioning operation. This eliminates the need for sequential preparation and setup steps that extend make-up time in confined overhead environments.
Solution Approach 2:
The tensioning device incorporates self-contained hydraulic power and control mechanisms that do not require external equipment or additional personnel assistance during operation. The device can be independently operated by a single worker, reducing the need for multiple personnel in confined spaces and enabling rapid completion of flange connections without waiting for external support equipment.
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 reduces personnel exposure to injury and time spent on flange connections from hours to minutes, enabling accurate and uniform tensioning of bolts across various sizes and lengths, enhancing safety and efficiency while reducing the risk of over-tightening or loosening.
Implementation Method 1
Hydraulic fluid under pressure is applied to a port in the tensioning system housing and applies tension to all the bolts at the same time tensioning accurately and uniformly all the bolts
Data Source
AI summary
A hydraulic tension adaptor comprising a flange housing, a bolt support retainer, a bolt tensioning piston, a plurality of stud assemblies, and a retainer ring. The bolt tensioning piston houses a portion of the bolt support retainer. The bolt support retainer threadedly engages with the flange housing. The retainer ring threadedly engages with the bolt support retainer. Ports located on the bolt tensioning piston allow pressure to be exerted on the system via supply and bleed ports, thus applying tension to the plurality of stud assemblies simultaneously.