Patent Application
20060248939
1. Field of the Invention
The present invention relates to swaging devices and, in particular, to a swaging tool for swaging fittings.
2. Description of the Related Art
In hydraulic systems, swaged fittings connect ends of tubes together to form fluid-tight connections between the tubes. Swaged fittings in hydraulic systems of aircraft have been used for many years. During the swaging operation, tubes are inserted into a fitting, such as a cylindrical sleeve, and the fitting is then swaged or compressed radially inwardly by the swaging tool. Annular ridges on the outer surface of the fitting are flattened and transferred to the inner surface of the fitting, and form annular indentations in the tube to securely fasten it to the fitting.
The fittings to be swaged are often in locations that are difficult to reach. As a result, there has existed a need for a swaging tool that is compact enough to gain access to hard-to-reach fittings. Some conventional swaging tools provide a compact structure that supports an upper die held within a yoke and a lower die connected to the tool by a die holder. In some swaging tools, the yoke can be separated from the remainder of the tool for connection to the fitting.
There are numerous problems associated with conventional swaging tools. In some conventional swaging tools, the lower die has a tendency to rotate or wobble during swaging operations. Die rotation or wobble can damage the swaging tool and result in a defectively swaged fitting. Repeated improper use of the swaging tool over time could result in wear-related swaging problems. Thus, conventional swaging tools can become unreliable.
There is a need for a swaging tool that is versatile and compact to handle various swaging operations and that overcomes the drawbacks associated with conventional swaging tools.
The present invention provides a swaging device or tool for swaging hydraulic fittings and joining separate tubes together. In one embodiment, the swaging device includes a head assembly and a power unit assembly. The head assembly includes a head member and a first spring clip that retains a first die to a portion of the head member. The head assembly further includes a die block and a second spring clip that retains a second die to a portion of the die block. The power unit assembly includes a base member with a mounting portion that receives the die block and head member. The power unit assembly includes a moveable piston that engages the die block to move the second die towards the first die, and to thereby swage fittings and join tubes together.
Another embodiment of the invention is a swaging device having a head member with a first die coupled to a portion thereof, a die block having a second die coupled to a portion thereof, and a power unit assembly having a base member with a mounting portion that receives the die block and head assembly. The power unit assembly includes a moveable piston that engages the die block to move the second die towards the first die. The die block couples to the mounting portion of the base member in only one position, and the head member slidably engages the mounting portion of the base member in only one direction.
Another embodiment of the invention is a swaging device having a head assembly with a head member and a first spring clip that retains a first die to a portion of the head member. The head assembly includes a die block and a second spring clip that retains a second die to a portion of the die block. The swaging device further includes a power unit assembly having a base member with a mounting portion that receives the head assembly. The power unit assembly includes a moveable piston that engages the die block of the head assembly when the head assembly is received by the power unit assembly to move the second die towards the first die. The power unit assembly also includes a sleeve that secures the head assembly to the power unit assembly when the head assembly is received by the power unit assembly.
Another embodiment of the invention is a swaging device having a first and a second die, and a head member having a central portion interposed between first and second side portions. The first side portion includes a leg with a first contour, and the second side portion includes a leg with a second contour that is different from the first contour. A first spring clip retains the first die to a portion of the head member. The swaging device includes a die block and a second spring clip that retains the second die to a portion of the die block. The swaging device includes a power unit assembly having a base member with a mounting portion that receives the die block and head member. The power unit assembly includes a moveable piston that engages the die block to move the second die towards the first die. The mounting portion of the base member includes a first channel having a contour that slidably receives the leg of the first side portion of the head member and a second channel having a contour that slidably receives the leg of the second side portion of the head member.
Another embodiment of the invention is a swaging device having a first die with at least one slot, a head member, and a first spring clip having at least one tab that engages the at least one slot of the upper die to retain the first die to a portion of the head member. The swaging device includes a second die having at least one slot, a die block, and a second spring clip having at least one tab that engages at least one slot of the second die to retain the second die to a portion of the die block. The swaging device includes a power unit assembly having a base member with a mounting portion that receives the die block and head member. The power unit assembly includes a moveable piston that engages the die block to move the second die towards the first die.
These and other embodiments and advantages of the invention will become apparent from the following description and accompanying drawings.
Head member 102 includes a U-shaped structure with a curved central portion 162 integrally formed between at least two side portions 166, 167. Curved central portion 162 includes an outer curved surface 170 that is adapted or contoured to receive an inner curved surface of first spring clip 112. Curved central portion 162 includes an inner curved surface 168 that is adapted or contoured to receive an outer curved surface of first die 110. Head member 102 includes shoulder portions 210 positioned at an inner portion of the intersection point of central portion 162 and side portions 166, 167. Head member 102 includes first and second leg portions 180, 182 formed at lower ends of first and second side portions 166, 167, respectively.
As shown in
Mounting portion 200 includes a protruding sidewall 206 that extends from upper surface 204 across the width of mounting portion 200. In one embodiment, as shown in
Base member 104 includes first and second channel portions 184, 186 formed on the sides of mounting portion 200 adjacent to upper portion 198 of base member 104. First leg portion 180 is contoured to slidably engage first channel portion 184 of base member 104, and second leg portion 182 is contoured to slidably engage second channel portion 186 of base member 104. Matching first leg portion 180 and corresponding first channel portion 184 along with matching second leg portion 182 and corresponding second channel portion 186 are contoured with different configurations so that head member 102 can engage base member 104 in only one direction. In one embodiment, this non-symmetrical configuration comprises a Murphy Strip configuration to provide a one way engagement between head assembly 101 and power unit assembly 103. If head assembly 101 is rotated relative to power unit assembly 103 such that leg portions 180, 182 of head member 102 do not properly align with corresponding channel portions 184, 186 of base member 104, head assembly 101 will not properly engage power unit assembly 103. That is, leg portion 180 cannot engage channel portion 186 and leg portion 182 cannot engage channel portion 184. In this manner, attachment of head assembly 101 to power unit assembly 103 in a wrong direction is prevented.
In one embodiment, as shown in
Power unit assembly 103 includes a sleeve or collar member 118 slidably engaged with upper portion 198 of base member 104. In one embodiment, sleeve member 118 is an annular ring having an inner surface that is adapted to engage the outer surface of cylindrical upper portion 198 so as to lock head member 102 in position to base member 104. After head member leg portions 180, 182 slidably engage base member channel portions 184, 186, sleeve member 118 is moved upwards towards head member 102 to secure or lock leg portions 180, 182 within channel portions 184, 186.
When in a secure or locked position, sleeve member 118 prevents head member 102 from being removed from base member 104 during swaging operations. Thus, sleeve 118 provides a positive fixed position to properly locate head assembly 101 during swaging, and prevents head assembly 101 from falling off if tool 100 is held at an angle other than vertical. Sleeve 118 acts as a guiding mechanism and eliminates the potential for head member 102 to be inadvertently offset (out of position) during swaging, which could induce an overstressed condition to elements of the swage tool components. Sleeve 118 also provides a means in which both the upper and lower dies are maintained in proper alignment with each other, to assure the fitting is swaged properly. As shown in FIGS. 3A-B, a spring may be provided within sleeve 118 to maintain or bias the sleeve in an extended position while head assembly 101 is engaged in a proper position with respect to the power unit. In one embodiment, sleeve member 118 retains head assembly 101 to power unit assembly 103 by use of a guiding mechanism.
As described above, a head alignment means is provided to align head assembly 101 with respect to power unit assembly 103, so that head member 102 properly engages and is secured to base member 104 before operation of swaging tool 100. This, in turn, assures proper alignment of first and second dies 110, 114 and thereby prevents incomplete or improper swaging which might occur if first die 110 is positioned in a reverse orientation with respect to second die 114.
As best shown in
As best shown in
First spring clip 112 includes curved portion 160 that is adapted to be positioned adjacent curved portion 162 of head member 102. First spring clip 112 includes side portions 164 that extend downward from end portions of the curved portion 160 thereof and extend over side portions 166, 167 of head member 102. First spring clip 112 includes flange portions 120, 122 that extend downward from a central portion of curved portion 160. Each flange portion 120, 122 includes tabs 152 that protrude inward to the inner portion of first spring clip 112 for secure spring clip retention of first die 110.
First die 110 includes a plurality of upper die retention slots 142, 144 formed adjacent to outer end portions of the first die 110. Upper die retention slots 142, 144 are adapted to receive tabs 152 of first spring clip 112 so as to engage therewith and form a secure attachment thereto. Retention slots 142, 144 allow first die 110 to be machined faster so as to reduce manufacturing and production costs. As shown in
Second spring clip 116 includes base portion 128 and side portions 124, 126 that upwardly extend therefrom to form an interior portion that is adapted to receive die block 106. Side portions 124, 126 of second spring clip 116 include tabs 156 and an elongated tab 158, respectively, that protrude inwardly to secure second die 114. Second spring clip 116 includes a tab 130 that extends from base portion 128 through aperture 132 adjacent side portion 124. Tab 130 allows the assembly of die block 106, second die 114, and second spring clip 116 to be positioned on mounting portion 200 of base member 104 in only one direction with respect to sidewall 206. Tab 130 interferes with sidewall 206 to prevent the assembly from being positioned on base member mounting portion 200 in an improper direction. For example, if the assembly of die block 106, second die 114, and second spring clip 116 was reversed, tab 130 would contact protruding sidewall 206 and would not allow this assembly to seat properly on mounting portion 200.
Second die 114 includes a plurality of lower die retention slots 146 formed adjacent to one end portion thereof and a lower die retention recess 148 formed adjacent to the other outer end portion thereof. Lower die retention slots 146 receive and engage tabs 156 of second spring clip 116 and forms a secure attachment thereto. Retention slots 146 allow second die 114 to be machined faster so as to reduce manufacturing and production costs. Lower die retention recess 148 receives and engages elongated tab 158 of lower spring clip 116 and forms a secure attachment thereto.
As described above, a lower die alignment means is provided for aligning the assembly of die block 106, second die 114, and second spring clip 116 with respect to base member 104 in a proper orientation prior to performing a swaging operation with swaging tool 100. Proper orientation of this assembly with respect to base member 104 provides proper orientation of second die 114 with respect to first die 110 to ensure proper swaging of a fitting with swaging tool 100. Mounting portion sidewall 206 and spring clip tab 130 allows this assembly to be seated on base member 104 in a preferred configuration and prevents this assembly from being seated on base member 104 in a wrong direction. Sidewall 206 and tab 130 also prevent undesirable wobble or rotation of this assembly with respect to base member 104 during swaging operations, thereby improving reliability and increasing the life of swaging tool 100.
During swaging, fitting 250 is compressed inwardly by dies 110, 114 so that fitting 250 forms an irregular contour along inner wall 262 and grips tube 254 tightly. Also, annular ridge 268 of fitting 250 is compressed inwardly to form an annular indentation on inner wall 262 of fitting 250. Tube 252 is correspondingly swaged to a configuration matching the inner wall 262 of fitting 250. Thus, swaging tool 100 provides a permanent leak-proof coupling of two tubes 252, 254.
As shown in
Side portions 166, 167 of head member 102 extend downward in a parallel manner. Side portions 166, 167 have substantially flat and parallel inner and outer surfaces which terminate at inwardly extending leg portions 180, 182. As previously described, leg portions 180, 182 are contoured to slidably engage channel portions 184, 186 to couple head member 102 with base member 104. Channel portions 184, 186 transverse the longitudinal axis of upper cylindrical portion 198 of base member 104. To mount head member 102 to base member 104, leg portion 180, 182 are inserted with a sliding motion into t channel portions 184, 186 until first die 110 is aligned directly over second die 114.
The sliding engagement of leg portions 180, 182 and channel portions 184, 186 enables a direct connection of head member 102 to base member 104 and reduces the need for posts, nuts, or various other fastening components to make or engage the connection. This sliding engagement results in a more reliable swaging tool since a secure connection between head member 102 and base member 104 can be achieved rapidly. Moreover, this sliding engagement reduces wobble and rotation of first die 110 with respect to second die 114 so as to improve performance and reliability of swaging tool 100.
When mounted to base member 104, die block 106 is positioned between side portions 166, 167 of head member 102. Die block 106 is retained between side portions 166, 167 by ball 310 that is positioned within opening 312 in die block 106 and is biased outwardly by spring 314 into groove 316 of side portions 166, 167. Groove 316 extends in an axial direction a sufficient distance to allow second die 114 and die block 106 to move toward first die 110 during swaging while head member 102 and first die 110 remain stationary. Lower surface 172 of die block 106 abuts upper surface 204 of mounting portion 200 of base member 104.
As shown in
As shown in
The outer circumferential edges of end cap 320 include outwardly extending annular shoulder 332, which is positioned against an inwardly extending annular shoulder 334 on the inner surface of base member 104. End cap 320 includes an externally threaded outer surface 340 to engage internally threaded surface 342 of third chamber 326. Upon threaded engagement of end cap 320 into third chamber 326, shoulder 332 of end cap 320 abuts shoulder 334 of base member 104.
As shown in
Base portion 337 of end cap 320 includes mounting apertures 347 that are adapted to receive fasteners, such as screws, for securing snap ring 338 to end cap 320. When end cap 320 is threaded into position within base member 104 and snap ring 338 is positioned in recessed channel 345, fasteners may be inserted through apertures 351 formed in snap ring 338 and into mounting apertures 347 to secure snap ring 338 to end cap 320. This prevents end cap 320 from backing out of base member 104 during a swaging operation.
End cap 320 includes a pressure inlet port 390 formed in base portion 337. In one embodiment, pressure inlet port 390 of end cap 320 comprises a high pressure inlet port, such as, for example an MS port configuration with MS33649-2 threads, that facilitates mounting of a two-axis swivel 400 via an adapter 406 to power unit assembly 103. The high pressure inlet port configuration of pressure inlet port 390 reduces the stress of introducing pressurized fluid into power unit assembly 103 during a swaging operation. Swivel 400 includes first swivel joint 402 that allows swaging tool 100 to rotate in a plane that coincides with an axis of base member 104. As shown in
In one embodiment, externally threaded outer surface 340 of end cap 320 comprises tapered threads. In general, tapering the thread of either a male or female threaded component in a proper fashion improves thread load distribution as compared to conventional constant-pitch threads. Thus, tapered threads on outer surface 340 of end cap 320 may improve the strength of the threaded connection between end cap 320 and internally threaded surface 342 of base member 104. Threads 340 may be tapered outwardly such that the outer diameter of end cap 320 increases from upper portion 336 in a direction towards lower portion 337, while internal threads 342 of base member 104 are formed, for example, in a conventional constant-pitch manner.
Piston 350 of power unit assembly 103 includes a base portion 354 reciprocally retained within second chamber 324, a rod portion 356 extending through first chamber 322 and through an axial aperture 360 in upper portion 198 of base member 104, rod portion 356 having an upper head portion that abuts and engages die block 106 via retaining ring 362. In one embodiment, retaining ring 362 is formed of a Teflon material, but may comprise other materials without departing from the scope of the invention. The upper head portion of rod 356 includes a counter groove 173 that is received within recess 308 in mounting portion 200 of base member 104 and is secured to die block 106 with retaining ring 362. When head assembly 101 and power unit assembly 103 are coupled, retaining ring 362 retains die block 106 to piston 350 so that second die 114 remains aligned with first die 110 during movement of piston 350 in a swaging operation. Swaging tool 100 utilizes a single piston 350, which is an improvement over prior art swaging tools.
Annular shoulder 364 formed at the top of piston base portion 354 engages inwardly extending annular shoulder 366 on the inner surface of base member 104. Annular shoulder 366 functions as an internal stop to limit movement of piston 350 during swaging. During swaging, second die 114 is moved toward first die 110 by die block 106 and piston 350 within base member 104. Upon engagement, annular shoulder 366 of base member 104 abuts annular shoulder 364 of piston 350.
The lower portion of piston base portion 354 includes second seal member 374 that provides a fluid barrier between piston 350 and base member 104. Second seal member 374 is a ring-shaped structure that couples with piston base portion 354. Piston 350 includes a lip portion 359 that extends outwardly from the lower end of base portion 354 to trap second seal member 374 between lip portion 359 and base portion 354.
As previously discussed, first seal member 372 engages end cap 320 to provide a fluid barrier between end cap 320 and base member 104. First and second seal members 372, 374 trap fluid introduced into second chamber 324 of base member 104 between base portion 354 of piston 350 and head portion 336 of end cap 320.
Power unit assembly 103 includes one or more return springs 370 that are positioned in first chamber 322 around piston rod portion 356 and above piston base portion 354. Spring 370 biases piston 350 against end cap 320 in the absence of fluid pressure in base member 104. After swaging is complete, piston 350 retracts against end cap 320 due to the biasing effect of return spring 370. Conversely, the engagement of annular shoulders 364, 366 within base member 104 during swaging provides an internal stop to prevent over-compression and fatigue of return spring 370. These limits to movement of piston 350 results in a more reliable operation and performance of swaging tool 100.
In one embodiment, return spring 370 includes one or more disc springs that carry the same load in much less space than a significantly larger helical spring. A stack of disc springs is smaller in diameter, lighter in weight, carries larger loads, and provides faster return of piston 350 than a conventional helical spring. This features contributes to a reduced size and weight of swaging tool 100.
Some components of swaging tool 100, including head member 102, base member 104, die block 106, first die 110, second die 114, end cap 320, snap ring 338, and piston 350, are preferably formed from high tensile strength materials. Other components may be formed or constructed from cold rolled steel or free machined steel. Return spring 370 may be formed of spring steel.
An axial passageway 380 extending through adapter 406 permits fluid communication with piston 350. Fluid from passageway 380 enters end cap 320 through axial aperture 330 and snap ring 338 to push piston 350, die block 106, and second die 114 towards first die 110. Passageway 380 may include a beveled edge 382 to facilitate introduction of fluid into central axial aperture 330. As fluid reaches piston 350 via passageway 380, the fluid moves piston 350, which in turn moves die block 106 and second die 114 towards first die 110. Fluid is then dispersed rapidly behind base portion 354 of piston 350. This configuration utilizes the surface area of piston base portion 354 to provide substantial force for movement of piston 350 against upper die block 106. Thus, piston force is increased without increased fluid pressure. A smaller sized piston arrangement may be utilized, which results in a more compact and lighter swaging tool.
Operation of the swaging tool 100 is as follows. A fitting 250 is positioned between first and second dies 110, 114. This is accomplished by removing head assembly 101 from power unit assembly 103, positioning fitting 250 in the curved region of second die 114, and then replacing head assembly 101 on power unit assembly 103 so that fitting 250 is positioned between first and second dies 110, 114. Sleeve member 118 is then moved into lock position to lock leg portions 180, 182 within channel portions 184, 186 of base member 104.
After fitting 250 is properly positioned and sleeve member 118 secured, pressurized fluid is admitted into base member 104 through end cap 320 and snap ring 338. The pressurized fluid forces piston 350 against die block 106 to move second die 114 toward first die 110. Compression of dies 110, 114 continues until shoulder 210 of head member 102 abuts shoulder 212 of die block 106. After fluid pressure is released and spring 370 returns piston 350 to a retracted position, swaging is complete and fitting 250 may be removed from tool 100.
In some instances, the assembled swaging tool 100 may be inserted directly onto a fitting, such as fitting 250, if one of tubes 252, 254 to be swaged has a free end to permit access in this manner. In other circumstances, it may be necessary to remove head assembly 101 from power unit assembly 103 to position head assembly 101 around the fitting between the free ends of the side portions 166, 167 or leg portions 180, 182. In the latter situation, the sliding engagement of head assembly 101 and power unit assembly 103 permits rapid assembly of swaging tool 100 and is especially useful in swaging fittings in difficult-to-access locations, such as overhead or in confined spaces. After swaging of the fitting, head assembly 101 may be rapidly removed from power unit assembly 103 to swage a next fitting.
From the foregoing, it will be appreciated that improved swaging tool 100 is adapted to swage fittings, such as fitting 250 for connecting tubes 252, 254, especially fittings located in difficult-to-access areas. Tool 100 provides effective means for ensuring proper connection, alignment, and orientation of first die 110 with respect to second die 114, and various improved features over known swaging tools to contribute to a more reliable swaging tool than heretofore developed.
Although preferred embodiments of the invention have been shown and described, it will be understood that modification may be made by those skilled in the art without departing from the spirit and scope of the invention, as defined by the appended claims.
