Pipe Strand Bushing Casting With Integrated Longitudinal Sealing
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Solution Overview
Problem
Existing methods for attaching grommets to cable bundles in automotive applications face challenges in ensuring a reliable longitudinal seal during the casting process, requiring separate manual application of sealing elements, which is inefficient and not easily automated.
Innovation Solution
A two-stage casting process is employed where a first sealing material is introduced into an annular channel to form a sealing element, followed by a second sealing material to create a nozzle body, ensuring a longitudinal seal is achieved before forming the nozzle body, eliminating the need for separate manual application of sealing elements and allowing for automated assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sealing element is applied separately to the pipe assembly before casting, then a longitudinal seal can be achieved, but the manufacturing process becomes complex and difficult to automate
Solution Approach 1:
The sealing element formation and nozzle body casting are merged into a single integrated casting process. The mold includes both an annular channel for the sealing element and a main chamber for the nozzle body, allowing both components to be formed in one operation without separate manual application steps.
Solution Approach 2:
The sealing element is formed in advance within the mold's annular channel before the main casting operation. This preliminary formation ensures the seal is already in place and properly positioned before the nozzle body material is introduced, guaranteeing seal reliability while maintaining process integration.
2Reliability
If a sealing element is applied manually to ensure reliable sealing, then seal quality improves, but production efficiency decreases and automation becomes difficult
Solution Approach 1:
The mold structure itself provides the sealing function through its integrated annular channel design. The sealing element is formed automatically as part of the casting process, eliminating the need for separate manual sealing operations while maintaining high seal quality and enabling full automation.
Solution Approach 2:
The sealing operation is combined with the casting operation into a single integrated process. Both the sealing element and nozzle body are formed simultaneously in one casting cycle, dramatically improving productivity while maintaining seal reliability through the controlled casting process.
3Manufacturing precision
If the mold is opened after forming the sealing element to apply it, then the sealing element can be positioned correctly, but the manufacturing time increases
Solution Approach 1:
The positioning and formation of the sealing element are merged into the single casting operation. The annular channel in the mold automatically positions the sealing element correctly as it forms, eliminating the need for separate positioning steps that would require opening the mold and adding to cycle time.
Solution Approach 2:
The sealing element is formed and positioned in advance within the closed mold during the initial casting phase. This preliminary action ensures correct positioning is achieved automatically before the main nozzle body is formed, eliminating time-consuming intermediate steps.
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 method simplifies the attachment process, ensures a reliable longitudinal seal, and allows for automated manufacturing, particularly effective for thick cable strands, by integrating the sealing element formation within the casting process.
Implementation Method 1
the first sealing material is poured into the annular channel of the mold surrounding the pipe assembly, and the sealing element is formed through at least partial hardening
Implementation Method 2
the second sealing material is poured into the main chamber in a second casting step to form the nozzle body
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
According to the invention, the method for attaching a bushing (8) to a pipe strand (2) extending in an axial direction (A) comprises the following steps: - attaching a casting mould (8) around the pipe strand (2), wherein the casting mould (8) has at least one annular channel (22) separated from a main chamber (26), - forming a sealing element (10) with the aid of a first sealing material which is introduced into the annular channel of the casting mould (8), - subsequently filling the main chamber (26) and forming a bushing body (12) by introducing a second sealing material into the casting mould (8), wherein the previously formed sealing element (10) produces longitudinal sealing for the second sealing material in the axial direction (A). This enables fully automatic, simple attachment of a bushing on a pipe strand with good longitudinal sealing for the casting process.