Joint Flange Assembly Using Thickened Pipe Beads Instead of Welding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for assembling joint flanges require extensive assembly work and increased manufacturing costs due to the need for welding and machining of extruded products, leading to inefficiencies in production time and cost.
Innovation Solution
A joint flange using a thickness-increased and machined pipe, where the pipe's thickness is increased by compressing one end, and machining a locking bead and sealing part using universal equipment, followed by pressing and fixing the pipe to a die-cast flange, reducing production time and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional welding and machining processes are used for joint flange assembly, then coupling strength is achieved, but production time increases and manufacturing cost increases
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with a mechanical pressing and locking system. The pipe end is pressed into the flange mounting hole and locked by beads formed on the pipe circumference engaging with grooves in the flange, eliminating welding operations and significantly reducing production time while maintaining coupling strength
Solution Approach 2:
The pipe end is pre-formed with beads and a sealing groove before assembly. These features are created in advance during pipe manufacturing, so that during final assembly, the pipe simply needs to be pressed into the flange and the pre-formed beads automatically lock into place, eliminating the need for on-site machining and welding operations
2Strength
If conventional welding and machining processes are used for joint flange assembly, then coupling strength is achieved, but manufacturing cost increases
Solution Approach 1:
The patent replaces expensive welding operations and precision machining with a simpler mechanical pressing and locking system. The beads and grooves can be formed using standard pipe forming equipment, and assembly requires only pressing operations, eliminating the need for specialized welding equipment, operators, and post-weld inspection processes
Solution Approach 2:
The pipe end features (beads and sealing groove) are self-forming during the pressing operation. As the pipe is pressed into the flange, the beads automatically engage with the grooves to create the locking mechanism, and the sealing groove automatically positions the O-ring for sealing, eliminating the need for separate machining operations
3Productivity
If pipe thickness is increased by compression and machining is performed on circumferential portion, then assembly efficiency is improved, but pipe manufacturing complexity increases
Solution Approach 1:
The patent combines multiple operations into a single integrated pipe forming process. The compression to increase wall thickness and the bead forming are performed in one continuous operation using a specialized die, and the sealing groove is machined in the same setup, eliminating the need for separate operations and reducing overall manufacturing complexity
Solution Approach 2:
The patent uses parameter changes in the forming process to achieve multiple features simultaneously. By adjusting the die geometry and compression parameters, the pipe wall thickness is increased and beads are formed in one operation. The sealing groove machining parameters are optimized to work with the pre-formed pipe geometry, creating all features through coordinated parameter adjustments rather than multiple complex operations
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 approach decreases production time and reduces costs by simplifying the assembly process through increased pipe thickness and machining, allowing for efficient coupling and sealing without extensive welding, thereby improving the efficiency of pipe connection.
Implementation Method 1
increasing a thickness of one end of a pipe toward the inside and outside by compressing the one end
Data Source
AI summary
A method of manufacturing a joint flange using a thickness-increased, machined pipe is provided. The method includes a pipe cutting operation in which a pipe is cut to a predetermined length, a flange forming operation in which a flange having a mounting hole for installing the pipe is formed by die casting, a bump-forming operation in which a thickness-increased part, which is formed by increasing a thickness of one end of the pipe, is bumped to form a first bead locked to the flange, a machining operation in which a circumference of the thickness-increased part is machined to form a sealing groove having an O-ring installed, and a fixing operation in which the pipe is inserted in the mounting hole of the flange and the other end of the pipe is pressed to form a second bead so that the pipe is pressed to a lower end of the flange.