Spring-Loaded Pilot Punch Assembly for Thrust Wire Installation
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Solution Overview
Problem
The installation of supply tubes with coupling fittings and thrust wires in gas turbine engines is a time-consuming and labor-intensive process, often requiring multiple technicians to prevent the pilot punch from slipping and causing damage.
Innovation Solution
A spring-loaded punch assembly with a sleeve that moves axially between compressed and extended positions, retained by a pin, and featuring a guide section to securely engage and install the thrust wire, allowing for single-technician operation by minimizing slippage and ensuring proper alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a standard pilot punch is used with a hammer to install thrust wire, then the thrust wire can be installed through the B-nut, but the pilot punch may slip off the wire and cause damage to surrounding areas, requiring two technicians to minimize this risk
Solution Approach 1:
The pilot punch assembly incorporates a spring-loaded mechanism that dynamically adjusts the positioning force applied to the thrust wire. The spring provides continuous pressure to maintain engagement between the pilot punch and the wire, adapting to variations in wire position and installation forces, thereby preventing slippage without requiring multiple technicians.
Solution Approach 2:
A sleeve component is introduced as an intermediary element between the hammer and the pilot punch. This sleeve absorbs and distributes impact forces, preventing direct transmission of erratic hammer blows that could cause the pilot punch to slip. The intermediary mechanism stabilizes the force application, enabling reliable single-technician operation.
2Reliability
If multiple technicians are used to operate the pilot punch assembly, then the risk of slippage and damage is reduced, but the installation process becomes more time-consuming and labor-intensive
Solution Approach 1:
The spring-loaded pilot punch assembly is designed to be self-regulating, automatically maintaining proper engagement force through the spring mechanism. This self-service capability eliminates the need for multiple technicians to manually monitor and adjust positioning, allowing a single technician to operate the tool efficiently while maintaining high reliability.
Solution Approach 2:
The invention changes the force application parameter from manual multi-technician control to spring-based automatic force delivery. The spring constant and pre-load are engineered to provide optimal engagement force, transforming the operational parameters to enable both high speed and high reliability with single-technician operation.
3Ease of operation
If a spring-loaded sleeve mechanism is added to the pilot punch assembly, then single-technician operation is enabled with reduced slippage risk, but the device complexity increases
Solution Approach 1:
The pilot punch assembly is segmented into distinct functional components: the pilot punch itself, the spring-loaded sleeve, and the retention mechanism. This segmentation allows each component to perform its specific function independently, simplifying the overall design while enabling complex functionality. The modular structure makes the device easier to manufacture, assemble, and maintain despite the added capability for single-technician operation.
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
Facilitates efficient and secure installation of coupling fittings and thrust wires, reducing the risk of damage and enabling a single technician to perform the task, thereby improving operational efficiency and safety.
Implementation Method 1
a spring over the spring section and between the pin punch section and the sleeve such that the sleeve is movable axially along the axis between a compressed position and an extended position
Implementation Method 2
a spring biased to the punch, the sleeve movable axially along the axis between a compressed position and an extended position
Data Source
AI summary
A punch assembly includes a punch that defines an axis and a sleeve that is spring biased to the punch, the sleeve movable axially along the axis between a compressed position and an extended position.