Radial Expansion Coupling for Distortion-Free Rigid Joints
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Solution Overview
Problem
Traditional bolted joints and adhesive mounting methods fail to provide a stress or distortion-free rigid joint, especially in optical systems under severe environmental conditions, and are prone to slip, misalignment, and rework difficulties.
Innovation Solution
A radial expansion coupling system using a plurality of wedge guides and expansion wedges that can be moved radially outward to apply a clamping force, allowing for easy disassembly and maintaining a stress-free joint, suitable for misaligned components and varying geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If traditional bolted joints are used to create a rigid joint, then joint rigidity is improved, but part distortion and stress increase
Solution Approach 1:
The coupling device is divided into multiple segments including a body portion, expansion portions, and wedge elements that can independently move and adjust. This segmentation allows the joint to achieve rigidity through controlled expansion rather than uniform clamping force, eliminating part distortion while maintaining joint stability.
Solution Approach 2:
The coupling device transitions from a static bolted joint to a dynamic expansion mechanism. The expansion portions can radially move outward when actuated by wedge elements, allowing the joint to adapt its rigidity level. This dynamic adjustment enables the joint to become rigid only when needed, avoiding continuous stress on the connected parts.
2Manufacturing precision
If traditional bolts with low preload are used to avoid part distortion, then part distortion is reduced, but the joint becomes susceptible to slip
Solution Approach 1:
The coupling device performs preliminary expansion action before the joint is fully assembled. The expansion portions radially move outward to engage the mating part's clearance hole, creating friction resistance against slip before any operational loads are applied. This preliminary engagement ensures reliable slip resistance without requiring high preload bolts that would cause distortion.
3Manufacturing precision
If adhesive mounting is used as a bolt substitute, then part distortion is avoided, but ease of disassembly is reduced
Solution Approach 1:
The coupling device uses a dynamic expansion mechanism that can be reversibly actuated. When disassembly is needed, the expansion portions can be caused to radially move inward, releasing the grip on the mating part. This dynamic reversibility provides easy disassembly similar to mechanical fasteners, unlike permanent adhesive bonds, while maintaining distortion-free assembly throughout the joint's service life.
4Stability of the object's composition
If the coupling device expands radially outward to apply clamping force, then joint rigidity is improved, but the complexity of the device increases
Solution Approach 1:
The coupling device employs a nested structure where expansion portions are integrated within the body portion, and wedge elements are contained within the expansion portions. This nesting allows the complex multi-component device to be compact and manageable, reducing the practical complexity despite the sophisticated expansion mechanism. The components fit within each other, making assembly and maintenance more feasible.
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 radial expansion coupling system provides a rigid, distortion-free joint that can be easily disassembled, maintaining alignment and stability in optical systems and other applications, while accommodating tolerance mismatches and misalignments without causing distortion or heat conduction.
Implementation Method 1
A radial expansion system can include a plurality of wedge guides and a plurality of expansion wedges. Each wedge guide can have at least one guide surface. The plurality of expansion wedges can be operable to be disposed between adjacent wedge guides such that the wedge surfaces interface with the opposing guide surfaces.
Data Source
AI summary
A radial expansion system for a fastener is disclosed. The radial expansion system can include a plurality of wedge guides. Each wedge guide can have at least one guide surface. The plurality of wedge guides can be operable to be movably arranged along an axis with the guide surfaces of adjacent wedge guides opposing one another. The radial expansion system can also include a plurality of expansion wedges. Each expansion wedge can have wedge surfaces configured to slidingly interface with the at least one guide surface. Each expansion wedge can also have a clamp surface operable to interface with an interior portion of a first component. The plurality of expansion wedges can be operable to be disposed between adjacent wedge guides such that the wedge surfaces interface with the opposing guide surfaces. A second component and the plurality of wedge guides can be operable to be drawn toward one another by a fastener to cause the plurality of expansion wedges to displace radially outward from the axis such that the clamping surfaces engage and apply a clamping force to the interior portion of the first component, and thereby couple the first and second components to one another.