Hydraulic Manifold Plug Installation With Depth-Controlled Expansion
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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 with a tapered core and cylindrical sleeve, where the core is secured to an installation device with a depth stop and threaded hole, allowing for easy handling and installation using a pull-rod mechanism that radially expands the sleeve against the hole, providing secure sealing and handling in a tray for multiple inserts.
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 mechanism from the plug design. Instead of having the stem break during installation, the plug uses a simple pull-rod that remains intact and provides a threaded interface for secure attachment to the installation device, eliminating manufacturing complexity while maintaining installation functionality
Solution Approach 2:
The plug is divided into distinct functional components: an expansion sleeve for sealing, a core providing structural support, and a threaded interface for tool attachment. This segmentation allows each component to be optimized independently, simplifying manufacturing while achieving the desired installation and sealing functions
2Manufacturing precision
If no depth control mechanism is provided during installation, then the installation process is simpler, but the installation depth of the insert cannot be controlled
Solution Approach 1:
A depth stop feature is pre-configured on the installation device that limits the insertion depth of the pull-rod before expansion occurs. This preliminary depth control ensures consistent installation depth without requiring complex active control mechanisms during the expansion process
Solution Approach 2:
The depth stop acts as an intermediary mechanical element between the installation device and the plug. It provides passive depth control by physically limiting how far the pull-rod can be inserted, achieving precision without adding complex active control systems
3Reliability
If a complex stem breakage mechanism is used, then the plug can be installed, but the installation process becomes less repeatable
Solution Approach 1:
The threaded interface on the pull-rod automatically engages with the installation device, providing self-aligning and self-retaining functionality. This eliminates the need for complex breakage control mechanisms and ensures repeatable installation through consistent mechanical engagement
Solution Approach 2:
Instead of using a stem that breaks to indicate installation completion, the invention uses a threaded interface that requires controlled torque application. The installation is complete when the threaded connection is fully engaged, providing a more reliable and repeatable endpoint for the installation process
4Manufacturing precision
If the distal surface dimension is larger than the hole dimension, then the insert can be properly positioned, but the insert cannot be inserted into the hole
Solution Approach 1:
The installation system separates the positioning function from the insertion function. The distal surface of the installation device (not the insert itself) provides the positioning reference with its larger dimension, while the insert's leading edge remains small enough to be inserted into the hole first, then expanded to the final sealed position
Solution Approach 2:
The installation device is pre-positioned on the workpiece surface using its distal surface as a reference before the actual insert insertion occurs. This preliminary positioning ensures accurate placement, after which the insert is inserted and expanded at the predetermined location
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 easier and repeatable installation of plugs in holes with high-pressure resistance, ensuring reliable sealing and handling of multiple inserts, with the system capable of withstanding pressures up to 40,000 psi.
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
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.