Semi-Circular Alignment Tool for Flexible Exhaust Tube Mounting
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Solution Overview
Problem
Flexible exhaust tubes in heavy vehicles are subjected to severe mechanical stress and heat due to vibrations and relative movement, leading to frequent replacements and increased maintenance costs.
Innovation Solution
A semi-circular alignment tool with a diameter and length matching the flexible tube, which holds the tube in a straight state during mounting between pipe ends using attachment means like cable ties or reusable straps, minimizing stress and deflection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a flexible tube is used to connect pipe ends subject to relative movement, then the system can accommodate vibrations and movement, but the flexible tube is exposed to severe mechanical stress and heat
Solution Approach 1:
The alignment tool is used before mounting the flexible tube to pre-align the pipe ends. This preliminary alignment ensures that the pipe ends are in the correct position and orientation before the flexible tube is installed, preventing misalignment that would cause mechanical stress during operation.
Solution Approach 2:
The alignment tool acts as an intermediary device between the pipe ends during mounting. It provides a reference structure that mediates the positioning of pipe ends, ensuring they are properly aligned before the flexible tube is connected, thereby reducing subsequent mechanical stress.
2Ease of operation
If the flexible tube is mounted without proper alignment, then installation is simpler, but the tube experiences increased mechanical stress and deflection
Solution Approach 1:
The alignment tool is designed to be self-aligning through its semi-circular body that fits over the flexible tube. The tool automatically provides alignment references without requiring complex measurement or adjustment procedures, making the alignment process as simple as attaching the tool to the tube.
Solution Approach 2:
The alignment tool includes visual indicators (such as marked positions or colored references) that show when pipe ends are properly aligned. This visual feedback simplifies the alignment process by eliminating the need for complex measurements or expert judgment.
3Productivity
If the flexible tube is mounted in a non-straight state, then installation is faster, but side forces and deflection increase during use
Solution Approach 1:
The alignment tool is attached to the flexible tube before mounting to pre-establish the correct straight-line position. This preliminary positioning ensures that the tube is installed in the optimal straight state, minimizing subsequent deflection and side forces during operation.
Solution Approach 2:
The alignment tool replaces complex mechanical alignment procedures with a simpler geometric reference system. The semi-circular body provides inherent geometric references that guide pipe end positioning, substituting elaborate alignment mechanisms with a straightforward geometric approach.
Data Source
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AI summary
An alignment tool (1) and method for mounting a flexible tube (8) between a first pipe end (9) and a second pipe end (10), where the alignment tool (1) is adapted to be used to align the first pipe end (9) to the second pipe end (10), where the alignment tool (1) is provided with a semi-circular body (2) having a diameter corresponding to the diameter of the flexible tube (8), where the length of the alignment tool (1) corresponds to the length of the flexible tube (8), and that the alignment tool (1) is adapted to bear on the flexible tube (8) during the mounting of the flexible tube between the first pipe end (9) and a second pipe end (10).