Valve Cap Adapter With Torque Multiplier for Seized Cap Removal

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Solution Overview

Problem

Conventional methods for removing valve caps are inadequate when they become seized, making it difficult to inspect and service valves due to the lack of effective disassembly tools and techniques.

Innovation Solution

A method and arrangement involving a cap adapter with a coupling structure and a torque multiplier, where the cap adapter is coupled to the valve cap through attachment holes, and the torque multiplier increases the input torque to facilitate the removal of the valve cap by providing an output torque greater than the input torque, preventing relative rotation between the torque multiplier and the cap adapter.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If conventional disassembly tools and methods are used on seized valve caps, then the tool simplicity is maintained, but the ability to remove the valve cap deteriorates significantly

Engineering Contradiction:

Improvevalve cap removal capabilityVSAvoiddisassembly tool complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The disassembly system is divided into distinct functional components: a cap adapter that interfaces with the valve cap attachment holes, coupling rods that transmit force, and a torque multiplier mechanism. This segmentation allows each component to be optimized for its specific function while working together to solve the seized valve cap problem.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The cap adapter serves as an intermediary device that bridges the gap between the available attachment holes on the valve cap and the torque multiplier tool. It provides a interface that allows the torque multiplier to apply rotational force to the seized valve cap without requiring direct modification of the cap itself.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Force

If extreme exertion or unsafe methods are used to remove seized valve caps, then the removal force is increased, but the operator safety deteriorates

Engineering Contradiction:

Improvetorque application capabilityVSAvoidoperator safety risk

Core Design Contradiction:

ForceVSObject-affected harmful factors

Solution Approach 1:

The manual mechanical advantage system (levers, pry bars, and direct force application) is replaced with a torque multiplier mechanism that uses gear trains to amplify input torque. This substitution eliminates the need for operators to apply extreme physical force or use unsafe pry-bar methods, while still generating sufficient torque to break loose seized valve caps.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The torque multiplier changes the torque parameter by using gear reduction to multiply the input torque from the operator's hand tool. This allows a relatively small input torque to be transformed into a much larger output torque, enabling the removal of seized valve caps without requiring extreme physical exertion from the operator.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If valve caps are left seized and not removed, then the valve operational time is maintained, but the valve inspection and service capability deteriorates

Engineering Contradiction:

Improvevalve inspection efficiencyVSAvoidtime to remove valve cap

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The cap adapter is designed with coupling holes that align with the valve cap attachment holes, allowing the adapter to be pre-positioned on the valve cap before applying torque. This preliminary positioning ensures proper alignment and force distribution, enabling the torque multiplier to effectively break loose the seized cap without trial-and-error adjustments that would waste time.

Inventive Principle:

Principle #10Preliminary action

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

This solution enables efficient removal of valve caps, enhancing the ability to inspect and service valves without requiring extreme exertion or unsafe methods, thereby extending the operational life of the valves and improving safety.

Implementation Method 1

The torque multiplier includes a head containing a plurality of gears and an output drive, and an input engagement structure. The plurality of gears is configured to receive an input torque from the input engagement structure, and provide an output torque to the output drive, the output torque being greater than the input torque.

Methodology Applied

Scientific EffectGear mechanism: Gear

Implementation Method 2

exerting an input torque on the torque multiplier to rotate the cap adapter and the valve cap, the input torque exerted on the torque multiplier being increased by the torque multiplier such that an output torque exerted on the cap adapter is greater than the input torque.

Methodology Applied

Scientific EffectMechanical advantage: Mechanical Advantage

Data Source

PatentUS11274765B2Valve cap adapter and arrangement and method of removing a valve cap

Publication Date: 2022.03.15 CATERPILLAR INC

AI summary

Method of removing a valve cap threadedly engaged with a valve body includes inserting at least one coupling rod from a cap adapter through a valve cap attachment hole to couple the structures, coupling an output drive of a torque multiplier with the adapter, and exerting an input torque on the torque multiplier to rotate the adapter and valve cap, the input torque exerted on the torque multiplier being increased by the torque multiplier.