Pinned Head Swage Tool with Sawtooth Interlocks
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Solution Overview
Problem
Conventional swage tools wear down over time due to vibration, leading to reduced performance and the need for frequent replacement, especially at the tongue and groove connections, resulting in unreliable fittings.
Innovation Solution
A swage tool design featuring a pinned head with sawtooth interlocks and a double piston configuration, allowing for quick assembly and operation, with modular components like threaded inserts and disc springs to reduce wear and facilitate easy maintenance, and quick-release pins for secure yet easy attachment of the head to the die block holder.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a tongue and groove configuration is used to connect the head to the cylinder, then assembly is enabled, but wear occurs over time due to vibration and relative sliding movement
Solution Approach 1:
The connection between head and cylinder is segmented into modular components: the head with sawtooth portion, the cylinder with sawtooth portion, and removable pins. This segmentation allows individual replacement of worn parts while maintaining the overall connection mechanism, resolving the contradiction between assembly ease and connection reliability over time.
Solution Approach 2:
The connection system transitions from a static tongue-and-groove design to a dynamic pinned connection where pins can be inserted and removed. This dynamic design allows the connection to be secured during operation and easily disassembled for maintenance, preventing wear accumulation and maintaining reliability.
2Ease of operation
If clearance is provided between mating surfaces of tongues and grooves to allow relative sliding movement, then assembly is facilitated, but surfaces become roughened over time
Solution Approach 1:
The pins act as consumable components that can be replaced when worn. Instead of attempting to maintain the precision of the sawtooth mating surfaces indefinitely, the design accepts that these surfaces will wear and provides an economical replacement mechanism through the pin system, resolving the contradiction between assembly ease and surface finish maintenance.
3Stability of the object's composition
If the head is securely attached to the die block holder, then stability during swaging is improved, but replacement of the head becomes difficult
Solution Approach 1:
The connection between head and die block holder is made dynamic through the use of removable pins. During swaging operations, the pins secure the head firmly to ensure stability. When replacement is needed, the pins can be quickly removed to facilitate easy head replacement, thus resolving the contradiction between operational stability and repair ease.
4Productivity
If conventional swage tools are used, then initial swaging operations are effective, but the tool becomes unreliable over time due to wear
Solution Approach 1:
The swage tool is divided into separable modular components (head, cylinder, die block holder, pins) that can be independently inspected and replaced. This segmentation maintains productivity by allowing continuous operation with minimal downtime for maintenance and ensures long-term reliability through easy replacement of worn components without replacing the entire tool.
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 design enhances reliability, reduces manpower requirements, and allows for easier maintenance by enabling the replacement of individual parts rather than the entire tool, resulting in a more efficient and cost-effective swaging process with improved ergonomics and reduced wear.
Implementation Method 1
The sawtooth portion of the head interlocks with the sawtooth portion of the die block holder
Implementation Method 2
The pins are slidably inserted though a sawtooth portion of the head and a sawtooth portion of the die block holder
Implementation Method 3
A piston inside a cylinder moves the second die toward the first die
Implementation Method 4
A first clip retains the first die to the head. A second clip retains the second die to the die block
Data Source
AI summary
A swage tool includes a first die coupled to a portion of a head and a second die coupled to a portion of a die block. A die block holder holds the die block and the second die. A piston inside a cylinder moves the second die toward the first die. At least two pins couple the head to the die block holder. When one of the pins is coupled to the head and to the die block holder, the head rotates about an axis transverse to a longitudinal axis of the cylinder.