Plug-In Insert Sleeve Forming to Cut Assembly Complexity
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Solution Overview
Problem
The production and assembly of existing plug-in inserts are complex, leading to high manufacturing costs due to the need for machining and assembly of individual parts.
Innovation Solution
A plug-in insert is designed using a punching-bending process to form a shell-like sleeve section from metallic flat material, incorporating a fixing element and release element, where the fixing element is secured in a form-fitting manner within the sleeve section, and a collar element is used to enhance stability and sealing, allowing for cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional machining and assembly methods are used to produce plug-in inserts, then manufacturing precision and reliability are maintained, but manufacturing complexity and costs increase significantly
Solution Approach 1:
The patent combines multiple components (sleeve, fixing element, release element) into a single integrated plug insert that is formed from one piece of flat metallic material through punching and bending processes. This merging eliminates the need for separate machining and assembly operations for each component, directly reducing manufacturing complexity while maintaining functional reliability
Solution Approach 2:
The invention changes the manufacturing parameter from traditional machining processes to punching and bending processes. This parameter change enables the production of complex three-dimensional forms from flat material, simplifying the manufacturing process and reducing the number of steps required while maintaining dimensional accuracy and component integrity
2Productivity
If multiple individual parts are machined and assembled, then functional reliability is ensured, but manufacturing time and production costs increase
Solution Approach 1:
The fixing element and release element are pre-formed as integral parts of the flat metallic material before the punching and bending process. This preliminary action eliminates the need for separate manufacturing and assembly steps, directly increasing productivity and reducing assembly time while ensuring proper positioning and fit
Solution Approach 2:
By merging multiple components into a single integrated structure formed from one piece of material, the patent eliminates sequential assembly operations. The fixing element, release element, and sleeve become unified, removing assembly time entirely while maintaining all necessary functions through the integrated design
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 process significantly reduces manufacturing effort and costs by eliminating the need for machining, while ensuring reliable fixation and sealing of tubular elements, suitable for applications with pressures up to 20 bar and diameters ranging from 2mm to 40mm.
Implementation Method 1
The wall element is formed by punching and bending a metallic flat material section into a shell-like or circumferentially closed element
Implementation Method 2
the fixing element can be pressed axially into the sleeve section and held in the plug-in sleeve by means of a snap mechanism
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention relates to a plug-in insert designed for insertion into a base body (3), wherein the plug-in insert (1) is designed for the releasable coupling of a tubular element (2) with the base body (3), wherein the plug-in insert (1) comprises a plug-in sleeve (5), a fixing element (6) and a release element (7), wherein the fixing element (6) is designed for the releasable fixing of a tubular element (2) inserted via an insertion opening in the plug-in sleeve (5) and the release element (7) interacts with the fixing element (6) in such a way that the fixing of the tubular element (2) is released by an axial displacement of the release element (7) relative to the plug-in sleeve (5), wherein the plug-in sleeve (5) has a sleeve section (5.1) comprising, which is formed from at least one wall element (5A, 5B), wherein the wall element (5A, 5B) is formed by punching and bending a metallic flat material section into a shell-like or circumferentially closed element, and wherein the fixing element (6) is enclosed by the sleeve section (5.1) and positively fixed in the sleeve section (5.1).