Hydraulic Manifold Plug Insert With Controlled Expansion Depth
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Solution Overview
Problem
Existing plug and sealing systems for manifolds are complex and costly to manufacture, and lack repeatable and efficient installation methods, particularly for hydraulic manifolds under high pressures.
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 stem that breaks off during installation is used, then the plug can be installed in a hole, but the manufacturing process becomes complicated and expensive
Solution Approach 1:
The invention removes the complex stem-breaking mechanism from the plug design. Instead, it uses a simple threaded rod that screws into a threaded hole in the plug body, eliminating the need for complicated stem manufacturing and break-off mechanisms while maintaining reliable installation.
Solution Approach 2:
The installation system is divided into separate components: a plug with an internal threaded hole, a separate threaded rod, and an expansion mechanism. This segmentation simplifies manufacturing of each individual part while enabling reliable assembly through threading, avoiding the need for integrated complex mechanisms.
2Productivity
If a manual tool without mechanical power is used for installation, then the tool is simple, but the installation process lacks efficiency and productivity
Solution Approach 1:
The installation device is designed as a multi-functional tool that can perform multiple operations: it holds the plug, provides depth control, enables controlled expansion through the threaded rod mechanism, and ensures proper seating. This universal design improves installation efficiency without requiring multiple separate tools.
Solution Approach 2:
The installation device incorporates dynamic elements including the threaded rod that can be rotated and extended, and the expansion mechanism that dynamically adjusts during installation. This allows the tool to adapt to different installation stages, improving efficiency while maintaining manageable complexity.
3Manufacturing precision
If a tool without depth control is used for installation, then the tool is simple, but the installation depth of the insert cannot be controlled repeatably
Solution Approach 1:
The installation device incorporates a depth stop that is pre-set to the correct depth before installation begins. This preliminary action ensures that the plug is installed to the precise required depth, enabling repeatable installation without requiring complex real-time measurement systems during the installation process.
4Ease of manufacture
If a complex stem-breaking mechanism is used, then the plug can be installed, but the manufacturing process becomes expensive
Solution Approach 1:
The invention uses a simple threaded rod that can be easily manufactured at low cost, replacing the expensive stem-breaking mechanism. The threaded rod serves its purpose during installation and can be discarded or reused simply, significantly reducing manufacturing costs while maintaining ease of operation.
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, while simplifying the manufacturing process.
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 core includes a threaded hole to releasably secure the insert to the installation device
Implementation Method 3
A tapered core and a cylinder... The core includes a tapered outer wall
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.