Weld Cup Fastener Removal for Broken Bolt Extraction
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Solution Overview
Problem
Existing fastener removal devices are time-consuming, ineffective, and prone to breaking during use, especially when dealing with damaged fasteners, and often cause damage to surrounding surfaces.
Innovation Solution
A weld-on fastener removal device with a weld cup and detachable handle, featuring a deep concave form, a hex-shaped outer surface, and a cone-shaped protrusion for alignment, allowing efficient welding and removal of damaged fasteners without damaging surrounding surfaces, suitable for both threaded and non-threaded fasteners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a helical ridge extractor tool is used to remove broken fasteners, then the extractor can engage with the drilled bore, but the process becomes time-consuming and the extractor tends to break during use
Solution Approach 1:
The invention performs preliminary action by welding the removal device directly to the exposed end of the broken fastener before any drilling or extraction operations. This eliminates the need to drill a bore into the broken fastener, saving time and preventing extractor tool breakage. The device is prepared in advance by attaching a handle and welding cup to the fastener end, creating a secure connection point for removal.
Solution Approach 2:
The invention extracts the problematic drilling and extractor insertion steps from the removal process. By welding directly to the exposed fastener end, the method eliminates the need to drill into the broken fastener and insert helical extractors, thereby removing the sources of time consumption and tool failure.
2Ease of manufacture
If welding is performed without proper positioning, then the weld cup can be attached to the fastener, but surrounding surfaces may be damaged
Solution Approach 1:
The handle serves as an intermediary component between the operator and the weld cup positioning. It provides a stable reference structure that helps position the weld cup correctly over the fastener end, preventing welding damage to surrounding surfaces while maintaining ease of attachment.
Solution Approach 2:
The handle is attached to the fastener end before welding operations begin, establishing proper positioning and alignment in advance. This preliminary positioning ensures that subsequent welding is performed accurately without damaging surrounding surfaces.
3Adaptability or versatility
If a weld-on device is designed for versatility with different fastener types, then it can remove both threaded and non-threaded fasteners, but the device structure becomes more complex
Solution Approach 1:
The weld cup and handle combination creates a universal removal device that works with both threaded and non-threaded fasteners. The simple cup-shaped structure with central opening provides a standardized interface that adapts to different fastener types without requiring complex adjustments or multiple specialized tools.
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 device enables rapid and effective extraction of damaged fasteners, including threaded and non-threaded types, with minimal damage to surrounding surfaces, using common tools like wrenches or pry bars, and is cost-effective to manufacture.
Implementation Method 1
welding the device to the fastener around the perimeter of the hole
Data Source
AI summary
A weld-on damaged fastener removal device has a weld cup with a deep concave form, and a detachable handle attached to the weld cup. The weld cup has a base and sidewalls that define a hex-shaped outer surface for accommodating a drive tool for rotating the device. A circular hole extends through the base, and a cone-shaped protrusion surrounds the hole. In use, the weld cup is positioned with the hole in the base of the weld cup aligned with the fastener, and the cone-shaped protrusion protruding toward and engaging the exposed end of the fastener. The handle is used to position and hold the weld cup on the fastener while welding the device to the fastener around the perimeter of the hole. A wrench or pry bar can then be used to apply a rotating or pulling force to the weld cup to remove the damaged fastener.