Modular Coupling Device for Media Conduits
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Solution Overview
Problem
The existing coupling devices for hose and pipeline connections, particularly in vehicle technology, require complex and costly manufacturing due to customer-specific designs and specialized holding means, leading to increased development and production costs.
Innovation Solution
The coupling device features separate, cartridge-like retaining inserts that are standardized and inserted into receptacles within the coupling carriers, simplifying the design and allowing for identical receptacles across different applications, reducing the need for custom injection molds and enabling cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If customer-specific coupling carriers are designed with specialized holding means for plug-in coupling parts, then the coupling device can securely retain and lock plug and socket parts, but the manufacturing complexity and production costs increase significantly
Solution Approach 1:
The coupling device is divided into modular components: standardized holding inserts that can be universally used, and customer-specific coupling carriers that only need simple receptacles. This segmentation allows the complex holding function to be separated from the application-specific carrier design, reducing overall manufacturing complexity while maintaining secure retention through the standardized inserts.
Solution Approach 2:
The holding inserts are designed as universal components that can be used across different coupling carrier versions. Each insert contains the specialized holding means (locking arms, retaining projections) that work with various plug-in coupling parts, eliminating the need to redesign these features for each customer-specific application and significantly reducing tooling costs.
2Manufacturing precision
If separate injection molding tools are produced for each version of coupling carrier with custom holding contours, then the coupling device can be precisely manufactured for specific applications, but the development and production costs increase
Solution Approach 1:
The manufacturing process is segmented into two parts: a standardized holding insert that uses a universal mold, and a customer-specific coupling carrier that uses a simplified mold. Only the carrier requires customization, and even then, only the receptacle geometry needs to be custom-molded, not the complex holding features, which are pre-formed in the standardized insert.
Solution Approach 2:
The holding inserts are pre-manufactured using a standardized mold before the customer-specific coupling carriers are produced. This allows the complex holding features to be prepared in advance using a single tool, eliminating the need to create custom molds for each application and significantly reducing development and production costs.
3Device complexity
If coupling carriers are designed as one-piece molded parts with integrated holding means, then the structure is simplified, but the injection molds become complex and expensive to produce
Solution Approach 1:
The coupling carrier is designed as a one-piece molded part with a structurally simple receptacle, while the holding insert is a separate component with the complex holding features. This segmentation allows the carrier mold to remain simple and inexpensive, while the complex holding features are contained in the separately manufactured insert, which uses a standardized, amortized tool.
Data Source
Figure 1~2
Figure 3~7
Figure 8~11
AI summary
The coupling device (1) has two plate-shaped coupling supports (20) that are connected with each other and have receiving openings (22,24) for fixed mounting of inserted plug-in coupling portions. each receiving opening is formed together with the holding units (28) in a separate holding element (32,34), where each holding element is inserted in an assigned receiver (36,38) of the coupling supports. Each holding element is seated in a defined rotational direction in the corresponding receiver of the coupling supports.