Hydraulic Manifold Plug Insert With Pull-Rod Depth Control
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Solution Overview
Problem
Existing plug and sealing systems face challenges in easy installation, manufacturing complexity, and lack of depth control, particularly in sealing hydraulic manifolds under high pressure.
Innovation Solution
A plug system with a tapered core and cylindrical sleeve, secured by a pull-rod mechanism, allowing for controlled installation depth and radial expansion, facilitated by an installation device with depth stop and tray handling, suitable for high-pressure applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a rivet system with a stem is used to seal manifolds, then the plug can be installed in holes, but the manufacturing process becomes complicated and expensive due to the need for the stem to break off at appropriate force
Solution Approach 1:
The invention removes the complex stem break-off mechanism from the plug design. Instead of using a rivet system with a stem that must break at a specific force, the patent uses a simple insert that is pressed directly into the hole and secured by friction and interference fit, eliminating the need for specialized stem manufacturing and break-off control mechanisms
Solution Approach 2:
The insert is designed as a simple, inexpensive component that does not require complex manufacturing processes. The design accepts that the insert is a single-use component installed in the field, allowing for simpler materials and construction methods that reduce manufacturing complexity and cost
2Manufacturing precision
If manual activation tools are used for plug installation, then the tool can be simple, but there is no depth control for controlling the installation depth of the insert
Solution Approach 1:
The installation tool incorporates a depth control mechanism that acts as an intermediary between the operator and the insert. This mechanism provides visual or physical indicators (such as a depth stop or marked scale) that guide the operator to insert the component to the correct depth, achieving precision without requiring complex automated positioning systems
Solution Approach 2:
The insert design includes features such as a tapered portion or positioning elements that provide tactile feedback to the operator during installation. When the insert reaches the correct depth, these features engage with corresponding elements in the hole or provide resistance, allowing the operator to self-correct and achieve proper installation depth without complex tooling
3Ease of operation
If existing plug systems are used for high-pressure applications, then sealing can be achieved, but the installation process lacks repeatability and ease of installation
Solution Approach 1:
The insert is pre-designed with specific geometric features including a tapered portion and positioning elements that are prepared in advance during manufacturing. These features ensure that during installation, the insert will naturally align and seat at the correct depth and orientation, making the installation process repeatable and reliable without requiring skilled operators or complex procedures
Solution Approach 2:
The insert design incorporates a tapered portion that changes the dimensional parameters of the insert as it is installed. The taper allows the insert to be inserted easily and then expands or locks into place through controlled dimensional change, ensuring consistent installation results and reliable sealing under high-pressure conditions
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
Enables easy, repeatable, and secure installation of plugs in holes, providing effective sealing and resistance to high pressures up to 40,000 psi, with controlled depth and reduced manufacturing complexity.
Implementation Method 1
the core is pulled into the cylindrical sleeve to radially expand the cylindrical sleeve against the hole
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.