Stacking Bolt Adapter Plate Tapered Bore Design
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Solution Overview
Problem
Existing valve stack arrangements in hydraulic control systems face issues with bolt stretching causing leaks, complex and expensive monolithic manifolds, and incompatibility with industry standard directional control valve patterns, leading to assembly challenges and potential leakage.
Innovation Solution
A stack assembly using a tapered adapter plate with a resilient annular insert to prevent rotation of stacking bolts, ensuring secure engagement and compatibility with standard mounting interfaces, and a stacking kit for easy maintenance and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If long bolts or tie rods are used to hold valve stack components together, then the components are firmly abutted against the manifold, but bolt stretching causes mating surfaces to separate and leak
Solution Approach 1:
The patent divides the single long tie rod into multiple shorter stacking bolts arranged in a circular pattern. Each bolt is independently positioned and secured, eliminating the stretching problem that occurs with long single bolts while maintaining the clamping force needed to keep valve envelopes firmly abutted against the manifold without causing separation or leakage.
Solution Approach 2:
The patent removes the problematic stretching characteristic from the fastening system by extracting the function of a single long tie rod and replacing it with multiple shorter bolts. This extraction eliminates the mechanism that causes mating surfaces to separate while preserving the essential function of holding components together.
2Ease of manufacture
If multiple stacking bolts in series are used to replace long tie rods, then assembly is simplified, but uncertainty about which threaded connection will loosen causes leakage after reassembly
Solution Approach 1:
The patent incorporates a locking mechanism that is pre-configured in the stacking bolt assembly. The locking feature is built into the bolt structure itself, ensuring that when bolts are tightened, they are automatically locked in place. This preliminary action prevents any uncertainty about which connection will loosen during disassembly and reassembly, eliminating the risk of leakage.
3Ease of repair
If a monolithic manifold containing all valve elements as cartridges is used, then individual cartridges can be removed for servicing, but design and machining costs are quite expensive
Solution Approach 1:
The patent segments the valve stack into individually removable valve envelopes that are stacked and secured with stacking bolts. Each valve envelope can be independently removed for servicing without disturbing other components, achieving the maintenance accessibility of a monolithic manifold while avoiding its complex design and expensive machining requirements.
4Adaptability or versatility
If standard directional control valve patterns are used, then compatibility with industry standards is achieved, but adapter plate hole diameter must be reduced to avoid interference
Solution Approach 1:
The patent applies different properties to different parts of the adapter plate. The outer diameter of the adapter plate maintains standard dimensions for industry compatibility, while the inner hole diameter is locally reduced only where needed to avoid interference with standard valve patterns. This localized modification achieves the required precision without compromising overall compatibility.
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
The solution provides a secure, leak-resistant, and cost-effective assembly of fluid components that is compatible with industry standards, reducing the risk of bolt loosening and leakage during disassembly and assembly, while simplifying the assembly process and reducing material waste.
Implementation Method 1
A resilient, annular insert is attached to the head of the stacking bolt, and therefore occupies the space between the head and the bore, thus preventing rotation of the stacking bolt when the fastening bolt is turned
Data Source
AI summary
A stack or assembly of fluid, mechanical, and/or electrical components permits removal of some components for maintenance, without compromising the fluid integrity of the remainder of the assembly. A fastening bolt, attached to at least one fluid component, is screwed into a stacking bolt, attached to another fluid component, the bolts being screwed together inside the bore of an adapter plate. A resilient insert sits between the head of the stacking bolt and the bore. At least a portion of the bore has a continuous taper, such that the diameter of the bore decreases in the vicinity of the insert. The taper creates a reduced diameter hole on one surface of the adapter plate, thus preventing interference between fluid ports on an adjacent fluid component. The taper also prevents loss of the insert during transportation and storage, and prevents undesired extrusion of material of the insert when the components are fastened together.