Hydraulic Manifold Plug Insert With Tapered Core Depth Control
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Solution Overview
Problem
Existing plug and sealing systems for manifolds are complex and costly to manufacture, and lack repeatable installation and depth control, particularly for hydraulic manifolds under high pressure.
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 and pull-rod mechanism for controlled radial expansion, allowing for easy handling and repeatable installation in a tray, and capable of withstanding high pressures.
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, a separate installation tool with a pull-rod mechanism is used to expand the plug after insertion, eliminating the need for a specially manufactured breakable stem and simplifying plug manufacturing
Solution Approach 2:
A separate installation tool acts as an intermediary device to perform the expansion function. The tool includes a pull-rod that engages with the plug's central hole and applies radial force to expand the plug, separating the installation function from the plug structure itself
2Manufacturing precision
If no depth control mechanism is provided during installation, then the installation process is simpler, but the installation depth cannot be controlled repeatably
Solution Approach 1:
The installation tool is configured with a predetermined stroke length that automatically controls the expansion depth. The pull-rod travels a fixed distance when actuated, ensuring consistent plug expansion depth without requiring complex control systems
Solution Approach 2:
The installation tool allows adjustment of the pull-rod stroke length or expansion force parameters. By changing these parameters, the same tool can accommodate different plug sizes and hole depths while maintaining repeatable installation results
3Productivity
If a complex stem breaking mechanism is used, then the plug installation can be achieved, but the installation process becomes slower and less efficient
Solution Approach 1:
The plug includes a central hole that automatically receives and engages the pull-rod from the installation tool. The plug's own geometry facilitates its installation by guiding the pull-rod into position, eliminating the need for complex alignment mechanisms
Solution Approach 2:
Instead of breaking the stem to release the plug (as in conventional rivet systems), the invention pulls the plug outward through the central hole to expand it. This inverted approach simplifies the release mechanism and speeds up installation
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 enables efficient, repeatable, and cost-effective installation of plugs in manifolds, ensuring reliable sealing and resistance to high pressures, such as those found in hydraulic systems, with adjustable depth control and enhanced sealing through ridges or ribs.
Implementation Method 1
the pull-rod is retracted by the drive to pull the core into the cylindrical sleeve thereby radially expanding the cylindrical sleeve against the hole
Implementation Method 2
The pull-rod may further pass through the bore and have a threaded end. An insert including a cylindrical sleeve and a core has a threaded hole. The pull-rod is threaded into the threaded hole and the pull-rod is retracted by the drive to pull the core into the cylindrical sleeve
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.