Modular Pipe Fitting Segmentation for Cost Reduction
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Solution Overview
Problem
Existing pipe fitting technologies require numerous variants for different pipe cross-sections, leading to high production costs and complexity, and lack a simplified, detachable connection method for plastic or plastic-metal composite pipes.
Innovation Solution
A modular fitting system comprising a base body and a connection body with telescoping contact surfaces and a flexible, incompressible locking element, allowing for various connection technologies and pipe diameters, and enabling easy assembly and disassembly without on-site pressing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a complete fitting is produced by drop forging or casting for each pipe cross-section, then the fitting achieves high strength and reliability, but the tool costs increase and manufacturing complexity increases
Solution Approach 1:
The fitting is divided into two separate parts: a base body and a connection body. The base body is produced by drop forging or casting to ensure high strength, while the connection body can be manufactured using simpler, more cost-effective methods. These segmented parts are then assembled together to form the complete fitting, thus maintaining strength requirements while reducing overall manufacturing costs and tooling requirements.
Solution Approach 2:
The base body is designed as a universal component that can accommodate multiple different connection bodies for various pipe cross-sections and connection technologies (compression, sliding, screw sleeve). This multi-functionality allows a single base body design to serve multiple purposes, reducing the need for specialized tools and fixtures for each variant, thereby lowering manufacturing costs while maintaining the required strength through the robust base body.
2Reliability
If a complete fitting is produced as a single piece for each pipe cross-section, then the fitting achieves high reliability, but the number of variants increases and device complexity increases
Solution Approach 1:
The fitting system is segmented into a standardized base body and interchangeable connection bodies. This segmentation allows the complex variations to be confined to the connection bodies, while the base body remains standardized and simple. The modular structure reduces device complexity by organizing variants in a systematic way, while reliability is maintained through the robust, standardized base body design.
Solution Approach 2:
The base body is designed as a universal platform that can work with multiple types of connection bodies for different pipe dimensions and connection methods. This universality reduces the overall system complexity by eliminating the need for completely different base body designs for each variant, while maintaining high reliability through the consistent, well-tested base body structure.
3Reliability
If pipe connection is performed on-site, then the fitting achieves proper installation, but the installation time increases and loss of time increases
Solution Approach 1:
The connection body is pre-assembled with the pipe in a controlled environment (workshop or factory) before being transported to the installation site. This preliminary action allows for precise alignment and connection preparation under optimal conditions, ensuring high installation quality. At the actual installation site, only the final connection to the base body is required, significantly reducing on-site installation time while maintaining proper installation standards.
4Reliability
If a traditional locking mechanism is used with projections into the receiving space, then the locking is secure, but the access space becomes blocked and ease of operation deteriorates
Solution Approach 1:
Instead of having the locking element interact with projections that extend into the receiving space (which would block access), the design is inverted: the access space is maintained open and clear, and the locking mechanism engages with the outer surfaces of the base body and connection body. This allows the locking element to be easily inserted and removed through the unobstructed access space while still achieving secure locking through the inverted engagement geometry.
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 modular system reduces production costs by allowing a few base bodies to cover a wide range of nominal widths, simplifies installation by allowing off-site connection preparation, and provides a secure, fluid-tight connection with adjustable locking mechanisms.
Implementation Method 1
a flexible, essentially incompressible locking element can be inserted into the receiving space from the outside
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The fitting for a pipe, in particular a plastic pipe or plastic-metal composite pipe, is provided with a base member (12) with a passage (14) for a fluid, a connecting member (16) that is removably connectable to the base member (12) and that also comprises a passage (17) for a fluid, wherein a pipe can be connected to said connecting member. Both members (12, 16) comprise contact surfaces (26, 28) that can slide inside of one another, said surfaces comprising at least one pair of recesses (30, 32) opposite one another, said recesses forming a receptacle space (34). The fitting is further provided with a flexible, substantially incompressible locking element (44) that can be led into the receptacle space (34) for fixing the two members (12, 16) onto one another. At least one of the two members (12, 16) comprises an access space (36, 38) extending between an outer surface (40) of the respective member (12) and the receptacle space (34). The access space (36, 38) abuts against the receptacle space (34) substantially in extension thereof. The locking element (44) comprises a blocking protrusion (68) at one of the opposite ends of said locking element for blocking the locking element (44) on the outside at at least one of the two members (12,16) so that the locking element (44) is prevented from unintentionally sliding out of the receptacle space (34).