composite fitting range product overview · can by used with hytrel and nylon tubing (pa11/pa12) in...
TRANSCRIPT
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WABCO Confidential and Proprietary
1
COMPOSITE FITTING RANGE PRODUCT OVERVIEW
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WABCO Confidential and Proprietary 2
Agenda
• Composite System Introduction
• Product Information
• Product structure and function
• Assembly information
• General Information
2* Raufoss ABCTM system is called as Composite systems hereon.
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SYSTEM INTRODUCTION
Product Overview
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Current Brass System
The Raufoss BRK P5 System
Building
blocks
Push-in couplings
P5-Plug-in
swivels
• Approximately 200 different articles
• Since 20 years succesful in the market
• More than 100 million parts sold
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Composite System Introduction
A new generation of couplings based on composite materials in combination with leading
coupling technology.
BENEFITS OF COMPOSITE MATERIALS:
• Reduced system cost
• Reduced system weight
• Increased Design Flexibility
• Brass components secure structural integrity
The system will provide significant improvement in all essential coupling areas.
One standardized system for truck, Bus, Trailer & off-road applications
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Composite System Introduction (2)
The benefits & functionality of the Composite system is given through:
1. Extensive use of advanced composite materials.
2. Consequent focus on producibility, process stability and integrated
assembly.
3. Maximum modularity by
• high building flexibility with few articles.
• increased single article production volumes.
• one standardized system fulfilling different engineering philosophies.
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Composite System Components
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Different components from Composite System.
Composite System
Push-InComposite Building
Blocks
Tools and
Accessories
New Line
Push-In
Threadless
Push-In
Integral
Push-In
Composite
Blocks
Brass
Swivels
Standard
Release
Tool
Professional
Release
Tool
Standard
Circlip
Plier
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Product Structure and Function
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PRODUCT INFORMATION
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New Line Push-in Geometry
Cone element
‚Ring snap‘ press connection
Brass grip ring
Large section O-ring main seal
With integrated port seal One piece housing brass/composite
Support sleeve
Environmental seal
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Color of tubular stiffener
Standard Composite
WHY: Colored tubular stiffeners prevent from swapping different tube sizes.
Tubular stiffener
Pipe size Color of tubular stiffener
10x1.0 Light grey (RAL7035)
10x1.5 Dark grey (7030)
Others, incl. 10x1.25
Black
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‘First grip then seal’ functionality
Cut tube
Grip
Detail of ‚Grip‘
Seal
Distinct assembly feeling through clamping ring
Free distance after clamping ring and O-Ring ensures complete assembly and allows angles in tube cut
If the connection is sealed, no slip out of tubing is possible
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‘Check Valve’ functionality
From outside From inside
Local slot
Bore:
1,5 mm diameter
Tube can be re-pushed under pressure
O-Ring in Standard position
O-Ring in displacement
O-Ring in ‚whistle‘ position
Bypass
Whistle
Integrated security check for correct assembled tubes
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‘Feedback Signal’ functionality
The operator gets a distinct ‚Feed Back Signal‘ to verify correct
assembly of tube.
• Click element integrated in support sleeve
Tube
SnapperSnapper has clicked
Snapper
Support sleeve
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Composite Building Block System
Building block parts
Swivel
The composite building block system consists of two parts:
• Building block = 90°elbows, Union „F“, „L“, „T“,
three way blocks…
• Brass swivels for structural
integrity
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Composite Building Block Geometry
Snap arms for two step assembly
Female composite port
Male brass swivel for composite system
Sealing surface
Composite building block
Sealing O-Ring
Vibration damping ring
Integrated port sealing
Two grooves for two step assembly
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‘First grip then seal’ functionality
1. (safety) position 2. (seal) position
O-Rings not compressed
O-Rings compressed
Snap-arms in first groove
Snap-arms in second groove
Two-step assembly
Disctinct assembly feeling by passing first step
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‘First grip then seal’ functionality (2)
Safety position
Whistle
Swivel or Push-in
First (safety) position
Air whistle and small pressure drop in ‚End
of line test‘ indicates not complete
assembly.
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Assembly Information
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PRODUCT INFORMATION
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Push-in Forces
TubePush-in force
(average values)[N]
Push-in force (maximum values)
[N]
6x1 50 80
8x1 50 90
10x1 60 100
10x1.25 60 100
12x1.5 70 110
15x1.5 85 130
16x2 85 130
Low push-in forces secure correct assembly
Accepted by leading OEM manufacturers
Push-in forces are depending on:
• Tolerances of tube and coupling (O-Ring)
• Tube quality (‚y‘-quality = 10% higher push-in force
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Fastening torque HEX - 1
The straight push-in fittings, ABC connectors, counter nuts etc.
are mounted to the threat without any preparation (DIN 3852, ISO
6149, ISO 4039-1, ISO 4039-2, Voss Geometry).
Fastening torque is listed in the following table:
ThreatRecommended fastening
torque 1) 2)Max. fastening torque 2)
G 1/8” 15 Nm 18 Nm
G 1/4” 24 Nm 28 Nm
M 10 x 1.0 15 Nm 18 Nm
M 12 x 1.5 20 Nm 24 Nm
M 14 x 1.5 24 Nm 28 Nm
M 16 x 1.5 30 Nm 35 Nm
M 22 x 1.5 34 Nm 40 Nm
M 26 x 1.5 43 Nm 50 Nm
Explanation for 1) and 2) on next slide
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Fastening torque HEX - 2
Using push-in fittings and ABC connectors the following reduced fastening torque is effective.
ThreatRecommended fastening
torque 1) 2)Max. fastening torque 2)
M 10 x 1.0 10 Nm 12 Nm
M 12 x 1.5 14 Nm 16 Nm
M 16 x 1.5 20 Nm 24 Nm
1) The recommended fastening torque is not valid for pretreated threats. The recommended fastening torque is valid for threats of aluminum, brass, or steel. The application of a torque key is recommended.2) Please consider the permitted fastening torque of valve, air cartridge, etc.
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Distinct assembly feeling during tube push-in
Click feature
Main seal
Environmental seal ~ 35N
Grip ring
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‘Assembly’ Force
1. (safety) position 2. (seal) position
Push-in force
Push-in force: 70 N
Safety position: 0 N Distinct assembly feeling
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‘Pull-out’ Force
Pull-out force
Pull-out force
1875 N =
2x Rohr
12x1,5
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‘Fixed Orientation’
Standard ‚Building block‘
RotoLock
Building block
Can be fixed with 15°steps
In cases:
• A fixed orientation of the tube is requested
• Use of the Composite Building block between frame and axle
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Repair of Composite Building Block
Circlip plier not currently in WABCO portfolio
Standard circlip plier
• Straight
• 90°elbow
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Tube release tool
• It is possible to release the assembled tube from the coupling
• ‚Tube releaser‘ are available in two versions:
Standard release tool Professional release tool
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GENERAL INFORMATION
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Composite System (Brass Swivels) – Sizes
Threat (Depending on
size)
M10x1
M12x1,5
M14x1,5
M16x1,5
M22x1,5
Swivel / building
block size
Tube Comment
SMALL 6x1 / 8x1 Mainly for Truck / Bus OEM
REGULAR 8x1 / 12x1,5 Truck / Bus + Trailer OEM
HEAVY DUTY 15x1,5 / 16x2 Truck / Bus + Trailer OEM
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Composite Building Block – Program overview
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Composite Building Block – Samples
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Composite System Comparison Against Brass
System
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Composite System General InfoOperating temperature:
-40°C bis +100°C
Can by used with Hytrel and nylon tubing (PA11/PA12) in accordance with
DIN 74324 / 73378 – Polyamide tubings used in motorvehicles
ISO 7628 – Road vehicles, thermoplastic tubing for air braking systems
Sealing towards stadard ports:
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