Multi-Disc Quick Coupler Layout for Standard-Wrench Assembly
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Solution Overview
Problem
Conventional quick couplers require custom-made hexagon socket wrenches due to the need for longer attachment bolts, increasing production costs and limiting the use of conventional wrenches for assembly.
Innovation Solution
A multi-disc quick coupler design with an axisymmetric structure and articulated connectors, utilizing at least three arc-shaped discs connected by bolt and articulated connectors, allowing for minimal deformation and reduced bolt length, enabling assembly with conventional wrenches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the attachment bolt length is increased to ensure smooth expansion of the pipe sleeve, then the pipe sleeve can be smoothly expanded for pipe insertion, but the conventional hexagon socket wrenches are not deep enough to tighten the nuts, requiring custom-made deep wrenches which greatly increases product cost
Solution Approach 1:
The clamp is segmented into at least three arc-shaped discs that can independently rotate relative to each other via articulated connectors. This segmentation allows the clamp to expand in a distributed manner, reducing the required expansion distance for any single bolt connection, thereby enabling the use of standard-length bolts and conventional wrenches.
Solution Approach 2:
The articulated connectors enable dynamic rotation between adjacent arc-shaped discs during the expansion process. This dynamic mechanism allows the clamp to gradually increase its inner diameter through controlled rotation, achieving smooth pipe insertion without requiring excessively long bolts that would necessitate custom wrenches.
2Ease of operation
If the gap between separate pipe sleeves or rings is enlarged to facilitate pipe insertion, then the pipe can be smoothly inserted, but the attachment bolt needs to be provided with a relatively larger length which requires custom-made deep wrenches
Solution Approach 1:
By dividing the clamp into multiple arc-shaped discs connected by articulated connectors, the expansion gap requirement is distributed across multiple rotation joints. This segmentation allows for gradual expansion that facilitates pipe insertion while maintaining standard bolt lengths and eliminating the need for custom-made deep wrenches.
3Productivity
If conventional quick coupler design is used with separate unions or rings, then the connection can be achieved by deforming the housing, but the attachment bolts require custom-made deep wrenches due to the need for larger length
Solution Approach 1:
The clamp is divided into multiple arc-shaped discs that can rotate independently. This segmentation enables the quick coupling function to be achieved through controlled rotation of discs rather than requiring large deformation of a single housing structure, thereby reducing bolt length requirements and eliminating the need for custom-made deep wrenches while maintaining high connection efficiency.
Solution Approach 2:
The articulated connectors provide dynamic rotation capability between arc-shaped discs, enabling the quick coupling mechanism to function through controlled rotational movement rather than static deformation. This dynamic approach maintains productivity while reducing the need for custom wrenches.
Data Source
AI summary
A multi-disc quick coupler includes a clamp, a bolt connector and an articulated connector, the clamp includes at least three arc-shaped discs, the clamp is of an axisymmetric structure, and the articulated connector or the bolt connector is mounted between adjacent arc-shaped discs to connect them. The articulated connector includes rotary parts fixed to the arc-shaped disc and a connecting part hinged with the rotary parts, two rotary parts are provided corresponding to the adjacent arc-shaped discs, two ends of the connecting part are respectively rotatably connected to the two rotary parts. The design method therefor includes S1: determining a basic design size; S2: formulating design variables; S3: establishing a Cartesian coordinate system; S4: establishing a polar coordinate system; S5: calculating coordinates after rotation; S6: calculating the minimum value of Δθ; S7: deriving, by the computer, a curve of Δθ with design variables.