Repairable Manifold Thread Insert Assembly for Safe Thread Replacement
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Solution Overview
Problem
Existing fluid distribution manifolds in space missions face maintenance challenges due to thread wear and fatigue, leading to potential failure and difficulty in re-seating components, which astronauts cannot safely address through drilling and tapping repairs.
Innovation Solution
A repairable thread insert assembly with a shaft, elastic ring, and washers that lock within a noncircular borehole, allowing easy removal and replacement using simple hand tools, eliminating the need for drilling and tapping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If drilling and tapping repair is performed on the manifold, then thread damage can be repaired, but the repair is difficult or impossible for astronauts to perform safely while on mission
Solution Approach 1:
The thread repair function is segmented from the manifold body and placed into a removable insert assembly. This allows the threading function to be replaced independently without affecting the manifold structure, enabling astronauts to simply remove a damaged insert and install a new one without performing complex drilling and tapping operations.
Solution Approach 2:
The insert assembly is designed as a disposable or limited-life component that can be easily replaced. Rather than attempting to repair the threaded hole in the manifold, the entire insert (including threads) is replaced as a unit, simplifying the repair process for astronauts while ensuring reliability.
2Ease of repair
If drilling and tapping repair is performed on the manifold, then thread damage can be repaired, but the material becomes weak or runs out entirely after limited repairs
Solution Approach 1:
The threading function is segmented into a separate insert assembly that does not require modifying the manifold material. Each insert contains its own threads, eliminating the cumulative weakening effect of repeated drilling and tapping operations on the manifold body.
Solution Approach 2:
The insert is designed as a consumable component with a limited service life. Once the insert's threads become damaged or worn, the entire insert is replaced rather than repaired, preventing degradation of the manifold material while maintaining thread functionality.
3Adaptability or versatility
If traditional manifold components are used, then the system can be maintained by aggregating components in one place, but thread wear and fatigue result in the inability to re-seat components
Solution Approach 1:
The threading function is segmented into a replaceable insert assembly, allowing the manifold to maintain its component aggregation advantage while eliminating thread wear issues. The insert can be independently replaced when threads become damaged, ensuring continuous reliable seating capability.
Solution Approach 2:
The threading interface is changed from integral manifold threads to insert-based threads. This parameter change allows the threading function to be renewed by replacing the insert rather than the entire manifold, maintaining reliability while preserving the manifold's component aggregation benefits.
4Ease of repair
If thread insert assemblies are made removable for repair purposes, then maintenance becomes easier, but the locking mechanism must ensure secure retention during operation
Solution Approach 1:
The insert retention system uses a dynamic locking mechanism with a spring-loaded elastic ring that automatically adjusts to maintain secure retention. The elastic ring provides continuous radial force against the borehole wall, ensuring the insert remains firmly locked during vibration and operation while still allowing controlled removal when needed.
Solution Approach 2:
The elastic ring is pre-compressed during insert installation, storing mechanical energy that provides immediate and secure retention. This preliminary action ensures the insert is firmly locked in place before any operational stresses are applied, eliminating the need for complex secondary locking mechanisms.
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
Enables safe, efficient, and unlimited thread replacements, enhancing system maintainability and preventing metal chips, while improving repair speed and safety.
Implementation Method 1
an elastic ring compressed between a head of an assembly fastener and a first end surface of the shaft
Data Source
Figure 1A~1B
Figure 1C~1D
Figure 2A~2B
AI summary
A manifold having a borehole (190); and a repairable thread insert assembly, including: a shaft (230) inserted in the borehole, the shaft defining: first and second end surfaces (240, 250) spaced apart from each other, wherein the shaft is shorter than the borehole; a threaded through hole extending between the end surfaces; and an outer surface extending between the end surfaces and defining an outer boundary shape that is complementary to the shape of the borehole; an elastic ring (280); an assembly fastener having a head that compresses the elastic ring between the head (300) of the assembly fastener (290) and the first end surface of the shaft such that the outer surface of the ring is pressed against the borehole, whereby the shaft is locked within the borehole.