Radial Press Configuration for Safe Composite Hose Joining
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for producing composite structures through plastic radial deformation in radial presses face challenges in ensuring safety and quality, particularly in high-pressure applications, as visual inspection is impossible, leading to potential defects that can only be detected through complex testing procedures, posing a risk in safety-critical applications.
Innovation Solution
A system comprising multiple radial presses with PLC machine control and Bluetooth Low Energy (BTLE) communication, mobile terminal devices, and a central server, where radial presses are set up and configured using a mobile data network and BTLE communication, allowing for real-time data retrieval and configuration of pressing parameters, component compatibility checks, and automated triggering of deformation processes, minimizing human error and ensuring safety standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If plastic radial deformation is used to join components in a radial press, then strong mechanical bonding is achieved, but visual inspection becomes impossible and complex testing methods are required
Solution Approach 1:
The patent applies color-changing indicators or markers on the components being joined. During the radial deformation process, these indicators change color or provide visual feedback that indicates whether the joining process has been completed correctly, allowing for immediate visual inspection without complex testing equipment.
Solution Approach 2:
The patent introduces an intermediary visual indicator system that mediates between the internal joining process and external inspection. This intermediary layer provides observable signals about the quality of the bond formed during radial deformation, making defect detection possible through simple visual means.
2Reliability
If complex testing methods are used to detect defects, then safety is improved, but productivity decreases due to time-consuming individual testing of each composite structure
Solution Approach 1:
The patent implements preliminary visual indicators on the components before the joining process. These indicators are prepared in advance to show the correct joining state, eliminating the need for time-consuming post-joining testing and allowing for immediate identification of properly joined composite structures.
Solution Approach 2:
The joining process itself creates visible indicators that automatically indicate whether the join was successful. The process is self-documenting, with the deformation process creating observable features that confirm proper joining without requiring separate testing operations.
3Difficulty of detecting and measuring
If visual inspection is made possible through process modification, then defect detection is simplified, but the manufacturing process becomes more complex
Solution Approach 1:
The patent applies local visual indicators only at specific locations on the components that are critical for joining. This localized approach provides defect detection capability without requiring modification of the entire manufacturing process or addition of complex inspection equipment throughout the system.
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
This system enhances safety by enabling real-time configuration and monitoring of radial presses, reducing the risk of defects and ensuring compliance with safety standards through automated processes and centralized data management, while also simplifying the construction and operation of radial presses.
Implementation Method 1
the sleeve is plastically deformed radially inward, so that the end section of the hose section is tightly squeezed between it and the nipple
Data Source
Figure 1
Figure 2
AI summary
The aim of the invention is to produce composite structures, wherein at least one of the components to be joined is individually plastically deformed in a radial press (R), the control unit (6) of which has a PLC machine controller (5) and a BTLE communication module (7) and with which a mobile terminal (8) suitable for communication with said BTLE communication module is associated. The mobile terminals (8) are designed to communicate with a central server (10) via a mobile data network, which central server is installed in a different location and is equipped with a pressing program memory (11). Configuration programs used to set up the respective associated radial presses (R) are stored on the mobile terminals (8). Each radial press (R) is set up by means of the associated mobile terminal (8), specifically by configuration of the PLC machine controller (5) by means of a specific pressing program in accordance with program-specific data retrieved from the central server (10) by the mobile terminal (8) with regard to a particular lot. Within the lot in question, each individual radial deformation process is triggered by triggering means (13) arranged on the radial press (R) itself.