Split Link Assembly for Flexible Tube Bending Mandrel
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Solution Overview
Problem
Existing link assemblies in rotary-draw tube-bending processes face issues with inconsistent wear rates leading to play or slop, requiring frequent replacement and complicating assembly, especially for split links which are more expensive and difficult to manufacture compared to poppet links.
Innovation Solution
A method for manufacturing a split link using two half-round sections of pre-hardened alloy steel or similar material, joined with set screws at an angled offset, allowing for easy assembly and machining into a flexible mandrel configuration, reducing manufacturing costs and improving durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If split link style is used, then durability and consistency are improved, but manufacturing complexity and cost increase
Solution Approach 1:
The link is divided into two separate halves that are joined together, allowing each half to be manufactured independently with consistent dimensions. This segmentation enables better control over wear characteristics while maintaining structural integrity through the joined construction.
Solution Approach 2:
Two link halves are merged together through joining mechanisms (such as welding, bonding, or mechanical fastening) to form a complete link assembly. This merging approach allows the benefits of split construction for wear consistency while achieving the durability needed for reliable operation.
2Ease of manufacture
If poppet style link is used, then manufacturing cost is reduced, but assembly difficulty increases
Solution Approach 1:
The link assembly is segmented into two halves that can be manufactured using simpler, more cost-effective processes compared to forming a single-piece poppet link. This segmentation reduces manufacturing complexity and cost while the joining mechanism ensures proper assembly.
Solution Approach 2:
The two link halves are prepared in advance with joining features (such as prepared surfaces, keys, or fastening mechanisms) that facilitate straightforward assembly. This preliminary preparation eliminates the need for complex field assembly operations required by traditional poppet links.
3Stability of the object's composition
If link halves are joined with keys, then longitudinal movement is prevented, but assembly complexity increases
Solution Approach 1:
The joining mechanism is segmented into discrete elements (such as individual keys or separate fastening components) that are integrated into the link halves. This segmentation allows for stable positioning while keeping each joining element simple and easy to install.
Solution Approach 2:
The link halves incorporate self-aligning or self-positioning features that automatically ensure correct positioning during assembly, eliminating the need for complex external alignment procedures or multiple adjustment steps.
Data Source
AI summary
A method for manufacturing a split link assembly having a split link (800C) that includes a first half link (801), a second half link (803) and a threaded aperture (805) formed in both the first half link (801) and second half link (803) for use in joining the first half link and second half link with a fastening device (807). The split link assembly is machined to include a head portion (811), shoulder portion (813), barrel portion (815) and base portion (817) for use in providing a highly flexible tube bending mandrel.