Tube Expander Jaw Control for Uniform Copper Tube Expansion
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Solution Overview
Problem
Conventional tube expansion tools often result in non-uniform expansion of copper tubes, leading to potential cracking during the expansion process.
Innovation Solution
A tube expansion tool with a moving mechanism that varies the advance position of a wedge to control the opening angle of jaws, allowing for gradual and controlled expansion of the tube end portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the wedge advances to open the jaws at one time with maximum force, then the expansion operation can be completed quickly, but the end portion of the copper tube may be expanded non-uniformly causing cracks
Solution Approach 1:
The expansion operation is divided into multiple stages by controlling the wedge to advance to different positions sequentially. The controller moves the wedge to a first advance position to open jaws to a first opening angle, then to a second advance position for a second opening angle, achieving gradual uniform expansion rather than single-step expansion
Solution Approach 2:
The opening angle of the jaws is made dynamically adjustable through controlled wedge movement. The system transitions from static single-angle expansion to dynamic multi-angle expansion, allowing the jaws to adapt their opening angle based on the expansion stage to ensure uniform radial expansion
2Force
If the plurality of jaws are inserted deeply into the copper tube for one-time expansion, then the expansion force can be applied effectively, but the motor may rotate at high speed causing large inertial force and non-uniform expansion
Solution Approach 1:
The jaws are preliminarily positioned at different insertion depths corresponding to different wedge advance positions. The controller first moves the wedge to the first advance position with appropriate jaw insertion depth, then to the second advance position, ensuring each expansion stage applies force uniformly without excessive inertial effects
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 tool ensures uniform radial expansion of the tube end portion, preventing damage or cracking and allowing for efficient expansion to a target diameter.
Implementation Method 1
an approximately conical wedge (mandrel) arranged radially inward of the plurality of jaws is manually operated to advance (move forward). The plurality of jaws radially outward of the wedge is pushed by the wedge, which causes the plurality of jaws to open outward.
Implementation Method 2
a tube expansion tool that expands a PEX tubing made of PEX (cross-linked polyethylene) is driven by an electric motor is known. This kind of an electrical tube expansion tool for expanding a PEX tubing can be utilized for a copper tube.
Implementation Method 3
In contrast to the PEX tubing, a copper tube is plastically deformed. Accordingly, the copper tube may be expanded at one time by a large force.
Data Source
AI summary
A tube expansion tool for expanding a tube end portion includes a moving mechanism that moves a wedge in a front-rear direction, a plurality of jaws that mutually open radially outward when pushed by the wedge moving forward, a controller and a switch that transmits an on-signal to the controller when the switch is in an on-position. The tube expansion tool is configured such that when the controller receives the on-signal from the switch, the controller activates the moving mechanism to move the wedge (i) forward to a first advance position to open the plurality of jaws at a first opening angle, (ii) rearward to close the plurality of jaws, (iii) forward to a second advance position ahead of the first advance position to open the plurality of jaws at a second opening angle, and (iv) rearward to close the plurality of jaws.