Installation apparatus for pipe fittings and method of verifying proper installation

An installation apparatus for connecting a fluid fitting to a fluid element includes a tool mechanism having a first abutment surface and a second abutment surface that faces and is movable relative to the first abutment surface; a first sensor configured to detect a first property of the installation apparatus or fluid fitting and provide a first output corresponding to the first property; a second sensor configured to detect a second property of the installation apparatus or fluid fitting and provide a second output corresponding to the second property; and a processing unit that is configured to generate a first resulting data set based on the first output and second output, and compare the resulting data set with a first predetermined data set to determine if the first resulting data set is compliant with the first predetermined data set.

FIELD OF THE INVENTION

The present disclosure relates generally to installation apparatus for pipe fittings, and more particularly, methods of verifying proper installation of a pipe fitting with the installation apparatus.

BACKGROUND OF THE INVENTION

Generally, one type of fitting for fluid conduits, such as tubes or pipes, includes a connector body that fits over the fluid conduit and a swage ring which compresses and/or physically deforms the connector body against the outside surface of the fluid conduit to provide one or more seals around the fluid conduit that establish a strong and leak proof mechanical connection.

Prior art tools for assembling such a fitting to a fluid conduit often include a fixed jaw or frame, a movable jaw or frame, and one or more hydraulic cylinders for moving the movable frame toward the fixed frame. The frames can be configured to grip the swage ring and the connector body such that, upon actuation, the frames forcibly move the swage ring over the connector body thereby causing the connector body to compress or move radially into the fluid conduit to provide a seal and a mechanical connection. When the swaging is complete, hydraulic pressure in the one or more hydraulic cylinders is reduced to allow the tool to be removed from the fitting.

BRIEF SUMMARY OF THE INVENTION

The following presents a simplified summary of example embodiments of the invention. This summary is not intended to identify critical elements or to delineate the scope of the invention.

In accordance with a first aspect, an installation apparatus for connecting a fluid fitting to a fluid element includes a tool mechanism that is operable to connect said fluid fitting to said fluid element, the tool mechanism including a first abutment surface and a second abutment surface that faces and is movable relative to the first abutment surface; a first sensor configured to detect a first property of the installation apparatus or fluid fitting and provide a first output corresponding to the first property; a second sensor configured to detect a second property of the installation apparatus or fluid fitting and provide a second output corresponding to the second property; and a processing unit that is configured to generate a first resulting data set based on the first output and second output, and compare the resulting data set with a first predetermined data set to determine if the first resulting data set is compliant with the first predetermined data set.

In one example of the first aspect, the processing unit is configured to acquire the first output from the first sensor at discrete times to generate a first data set corresponding to the first property over time, and acquire the second output from the second sensor at the same discrete times to generate a second data set corresponding to the second property over time.

In another example of the first aspect, the processing unit is configured to correlate the first data set and the second data set with respect to the discrete times to generate the resulting data set, such that the first resulting data set corresponds to the first property versus the second property. In one example, the first predetermined data set includes a maximum data set and a minimum data set, the maximum data set corresponding to a maximum first property per second property, the minimum data set corresponding to a minimum first property per second property. In one example, the processing unit is configured to determine if the first resulting data set is compliant with the first predetermined data set by determining if the first resulting data set is between or equal to the maximum data set and minimum data set.

In yet another example of the first aspect, the processing unit is configured to provide an output based on whether the first resulting data set is compliant with the first predetermined data set.

In still yet another example of the first aspect, the first property corresponds to a force property and the second property corresponds to a spatial property.

In another example of the first aspect, the first property corresponds to a strain property and the second property corresponds to a spatial property.

In yet another example of the first aspect, the installation apparatus further includes a third sensor configured to detect a third property of the installation apparatus or fluid fitting and provide a third output corresponding to the third property, wherein the processing unit is configured to generate a second resulting data set based on the second output and third output, and compare the second resulting data set with a second predetermined data set to determine if the second resulting data set is compliant with the second predetermined data set. In one example, the processing unit is configured to provide an output based on whether the first resulting data set and second resulting data set are both in respective compliance with the first predetermined data set and second predetermined data set.

In accordance with a second aspect, a method is provided for connecting a fluid fitting to a fluid element with an installation apparatus that includes a tool mechanism, a first sensor, a second sensor, and a processing unit having an output device. The method includes operating the tool mechanism to connect the fluid fitting to the fluid element; operating the first sensor during the step of operating the tool mechanism, wherein the first sensor detects a first property of the installation apparatus or fluid fitting and provides the first output corresponding to the first property; operating the second sensor during the step of operating the tool mechanism, wherein the second sensor detects a second property of the installation apparatus or fluid fitting and provides the second output corresponding to the second property; and operating the processing unit. The processing unit generates the first resulting data set based on the first output and second output, compares the first resulting data set with the first predetermined data set to determine if the first resulting data set is compliant with the first predetermined data set, and electrically operates the output device to provide an output based on whether the first resulting data set is compliant with the first predetermined data set.

In one example of the second aspect, the processing unit acquires the first output from the first sensor at discrete times to generate a first data set corresponding to the first property over time, and acquires the second output from the second sensor at the same discrete times to generate a second data set corresponding to the second property over time. In one example, the processing unit correlates the first data set and the second data set with respect to the discrete times to generate the resulting data set, such that the first resulting data set corresponds to the first property versus the second property. In one example, the first predetermined data set includes a maximum data set and a minimum data set, the maximum data set corresponding to a maximum first property per second property, the minimum data set corresponding to a minimum first property per second property. In one example, the processing unit determines if the first resulting data set is compliant with the first predetermined data set by determining if the first resulting data set is between or equal to the maximum data set and minimum data set.

In another example of the second aspect, the output device includes an indicator light.

In yet another example of the second aspect, the first property corresponds to a force property and the second property corresponds to a spatial property.

In still yet another example of the second aspect, the first property corresponds to a strain property and the second property corresponds to a spatial property.

In another example of the second aspect, the installation apparatus further includes a third sensor that detects a third property of the installation apparatus or fluid fitting and provides a third output corresponding to the third property. Moreover, the processing unit generates a second resulting data set based on the second output and third output, and compares the second resulting data set with a second predetermined data set to determine if the second resulting data set is compliant with the second predetermined data set.

In yet another example of the second aspect, the fluid fitting includes a coupling body defining a bore for receiving the fluid element therein at an end of the coupling body, and a ring configured to fit over the end of the coupling body for mechanically attaching said coupling body to the fluid element, the coupling body including a seal portion for engaging the fluid element. Moreover, the method includes providing the fluid fitting in a pre-installed configuration wherein the drive ring is arranged over the end of the coupling body, arranging the fluid element within the bore of the coupling body, and arranging the fluid fitting relative to the tool mechanism while the fluid fitting is in the pre-installed configuration, such that the first abutment surface faces a surface of the coupling body and the second abutment surface faces a surface of the drive ring. The step of operating the tool mechanism axially forces the drive ring along a longitudinal axis such that the drive ring deforms elastically to an expanded condition and applies a compressive force to the seal portion sufficient to cause permanent deformation of the coupling body such that a tooth of the seal portion bites into the fluid element to thereby attach the fluid element to the coupling body in a non-leaking manner.

DETAILED DESCRIPTION

The following is a detailed description of illustrative embodiments of the present application. As these embodiments of the present application are described with reference to the aforementioned drawings, various modifications or adaptations of the methods and or specific structures described may become apparent to those skilled in the art. All such modifications, adaptations, or variations that rely upon the teachings of the present application, and through which these teachings have advanced the art, are considered to be within the spirit and scope of the present application. Hence, these descriptions and drawings are not to be considered in a limiting sense as it is understood that the present application is in no way limited to the embodiments illustrated. Moreover, certain terminology is used herein for convenience only and is not to be taken as a limitation. Still further, in the drawings, the same reference numerals are employed for designating the same elements.

Turning toFIG.1-3, an example fitting10is illustrated that can be connected to two or more fluid elements. For the purposes of this disclosure, a “fluid element” refers to a pipe, tube, fitting, or any other element that is configured to convey, deliver, and/or receive fluid). Moreover, a “fitting” refers to any element that can be connected to two or more fluid elements to fluidly couple the two or more fluid elements together.

FIGS.1-3show cross-sectional views of the fitting10taken along a plane that is parallel to and contains a longitudinal axis L1. The components of the fitting10as arranged inFIGS.1-3are generally symmetrical about the longitudinal axis L1such that they extend completely around the longitudinal axis L1in a symmetrical manner.FIG.1shows the components of the fitting10generally aligned along the longitudinal axis L1. Meanwhile,FIGS.2&3respectively show one side of the fitting10(i.e., the right side as viewed inFIG.1) in a pre-installed configuration and an installed configuration. It is understood that the opposite side of the fitting10(i.e., the left side as viewed inFIG.1) can comprise similar pre-installed and installed configurations that are mirrored along the longitudinal axis L1.

The fitting10in the present example includes a coupling body12and two drive rings14(sometimes referred to as “swage rings”) that can be slid over the coupling body12to join a pair of pipe bodies16to the fitting10, as discussed further below. The pipes16can be thin walled or thick walled pipes, such as those ranging in size from ¼″ NPS to 4″ NPS. However, other pipe sizes may also derive a benefit from the example fitting10. Moreover, fitting10can be similarly connected to other types of fluid elements such as flanges, tees, and other fittings.

As shown inFIGS.2&3, the coupling body12defines a bore18that extends through the coupling body12for receiving a pipe16therein at each end. The coupling body12extends symmetrically about a central axis X1of the bore18, and includes a sleeve portion20, a flange portion22, and a seal portion24. The flange portion22extends radially outward from the sleeve portion20and defines an annular abutment surface26that extends radial to and concentric with the central axis X1. Moreover, the seal portion24includes a main seal30, an inboard seal32, and an outboard seal34, wherein each seal30,32,34comprises one or more teeth that extend radially inward from the sleeve portion20. It is contemplated that the seal portion24could include other numbers and/or arrangements of seals. The coupling body12has an interior surface36that faces the bore18and defines an interior profile of the coupling body12, and an exterior surface38that faces away from the bore18and defines an exterior profile of the coupling body12.

The drive ring14is similarly an open-center body that defines a bore46extending through the drive ring14for receiving coupling body12therein. The drive ring14extends symmetrically about a central axis X2of the bore46, and includes an interior surface48that faces the bore46, an exterior surface50that faces away from the bore46, and an annular abutment surface52that extends radial to the central axis X2.

The coupling body12and drive ring14can be initially assembled in the pre-installed configuration shown inFIG.2. Specifically, the drive ring14can be arranged over the end of the coupling body12such that the central axes X1, X2of the coupling body12and drive ring14are collinear with the longitudinal axis L1and the coupling body12is arranged within the bore46of the drive ring14. In this configuration, the abutment surfaces26,52of the coupling body12and drive ring14will face away from each other, radial to and concentric with the longitudinal axis L1. Moreover, a ramped-up section54of the drive ring14will be adjacent, but slightly spaced relative to, a land section56of the coupling body12. Through an interference fit, the drive ring14can be maintained on the coupling body12in the pre-installed configuration and shipped to customers, which facilitates ease of use and installation by the ultimate end-users.

To install the fitting10onto a pipe16, the pipe16can be located within the bore18of the coupling body12while the fitting10is in its pre-installed configuration (FIG.2). The drive ring14can then be forced axially along the longitudinal axis L1toward the flange portion22of the coupling body12until the fitting10assumes its installed configuration (FIG.3). The drive ring14and coupling body12have a predetermined ratio of interference, such that axial movement of the drive ring14to the installed configuration causes the coupling body12, drive ring14, and pipe16to deform, thereby creating a mechanical connection of these elements with a metal-to-metal seal between the pipe16and coupling body12.

More specifically, as the drive ring14is forced axially toward the flange portion22, it applies a compressive force to the coupling body12that causes radial deformation of the body12, forcing the tooth or teeth of its seals30,32,34to bite into the pipe16. The coupling body12in turn compresses the pipe16first elastically (i.e., non-permanent) and then plastically (i.e., permanent). This compression is sufficiently high to plastically yield the pipe16under the sealing lands, forming a 360° circumferential, permanent, metal-to-metal seal between the pipe16and the coupling body12. Simultaneous with the radial compression of the body12and the pipe16, the drive ring14expands radially outward. This radial expansion of the drive ring14is elastic, and results in a small increase in the diameter of the drive ring14.

Setting of a seal is considered complete (i.e., fully set) when the seal's tooth or teeth are completely forced into deforming contact with the pipe16(e.g., when an exterior surface58of the pipe16immediately opposite the seals30,32,34has no further radial movement as a result of being forced inward by a particular section of the drive ring14). Alternatively, full setting of a seal(s) can be defined as when the drive ring14has forced the tooth or teeth of the seal furthest into the pipe16or when an actuating taper of the drive ring14levels out to a diametrically constant cylindrical section as the drive ring14moves past the seal.

The pipe16becomes strained locally in proximity to the seals30,32,34as they bite into the pipe17. In particular, the pipe16typically becomes strained beyond its elastic limit as the seals30,32,34continue to bite into the surface and the pipe16begins to plastically deform or move radially inwardly resulting in permanent deformation. The teeth of the seals30,32,34bite into and deform the exterior surface58of the pipe16and may themselves be somewhat deformed. This functions to fill any rough or irregular surface imperfections found on the outside of the pipe16.

Once installed, the drive ring14will abut or engage the flange portion22(although it can be spaced from flange portion22in other examples). Moreover, because the drive ring14deforms elastically during installation such that it expands radially outward, the drive ring14will exert a continuous elastic force against the coupling body12and pipe16that is maintained after installation through the life of the fitting10, thereby preventing release of the metal-to-metal seal between the pipe16and the coupling body12. The coupling body12can thereby be attached to the pipe16in a permanent, non-leaking manner that is compliant with industrial standards.

It is to be appreciated that the fitting10can comprise other configurations for mechanical attachment to a fluid element without departing from the scope of this disclosure. For instance, the coupling body12and drive ring14described above extend symmetrically about their respective central axes X1, X2, such that their features extend circumferentially about and concentric to their associated central axis. However, one or more of those features (e.g., the abutment surfaces26,52) may extend only partially about and/or asymmetric to their associated central axis. Indeed, in some examples, the coupling body12and/or drive ring14can be an irregular body with minimal or no symmetry about a central axis. For instance, the coupling body12can be a T-shaped or Y-shaped body having multiple legs that do not extend symmetric to a common axis. The coupling body12and drive ring14can be any body defining a bore therethrough such that the coupling body12can receive a fluid element and the drive ring14can be forced over the coupling body12to mechanically attach the coupling body12to the fluid element. Various other example fittings with coupling bodies and drive rings are described in commonly owned U.S. Pat. Nos. 10,663,093; 8,870,237; 7,575,257; 6,692,040; 6,131,964; 5,709,418; 5,305,510; and 5,110,163, which are all expressly incorporated herein by reference in their entirety.

The terms “axial”, “radial”, and variations thereof have been used above in describing various features of the coupling body12, drive ring14, and pipe16. It is to be appreciated that those terms as used above (and further below) are relative to the central axis of the element being described unless clearly indicated otherwise. For example, the terms “axial”, “radial”, and variations thereof when describing features of the coupling body12are relative to the coupling body's central axis X1, when describing features of the drive ring14are relative to the drive ring's central axis X2, and when describing features of the pipe16are relative to the pipe's central axis, unless clearly indicated otherwise. Moreover, it is understood that in configurations wherein the central axes of the coupling body12, drive ring14, and pipe16are collinear with each other and a common axis (see e.g.,FIGS.1-3), the terms “axial”, “radial”, and variations thereof when describing features of the coupling body12, drive ring14, and pipe16will similarly be relative to the common axis and all central axes of the coupling body12, drive ring14, and pipe16.

Turning toFIG.4, an installation apparatus100is illustrated having a tool mechanism102that can be operated to connect the fitting10and pipe16as described above, although it is understood that the tool mechanism102could be useful for connecting other fittings and fluid elements. More particularly, the tool mechanism102can be operated to axially move or advance the drive ring14over the coupling body12of the fitting10while the pipe16is within the coupling body12to compress or plastically deform the coupling body12radially against the exterior surface58of the pipe16and provide the sealed mechanical connection between the coupling body12and pipe16.

FIG.5shows a top view of the tool mechanism102in further detail, which includes a first body130and a second body132that are movable relative to each other. In particular, the first body130is a stationary body having a base portion134that slidably supports the second body132such that the second body132is movable in a linear manner along a longitudinal axis L2of the tool mechanism102. The tool mechanism102can further include one or more adapters that are coupled to the first body130and/or second body132. For instance, the tool mechanism102in the present embodiment includes a first adapter140that is coupled to the first body130and a second adapter142that is coupled to the second body132such that the second adapter142is movable with the second body132relative to the first body130and first adapter140.

The tool mechanism102further includes a first abutment surface146and a second abutment surface148that face each other and are separated by a distance D. In the present embodiment, the first abutment surface146is defined by the first adapter140and comprises a semi-annular surface that extends radial to the longitudinal axis L2, while the second abutment surface148is defined by the second adapter142and similarly comprises a semi-annular surface that extends radial to the longitudinal axis L2. Moreover, the first and second abutment surfaces146,148are both concentric with longitudinal axis L2. However, the first and second abutment surfaces146,148can be defined by other portions such as the first and second bodies130,132, respectively. Moreover, the first and second abutment surfaces146,148can comprise other shapes or orientations, and may not be concentric with the the longitudinal axis L2in some examples.

The first and second abutment surfaces146,148are movable relative to each other since they are respectively carried by the first and second bodies130,132. That is, movement of the second body132along the longitudinal axis L2will cause the second abutment surface146to similarly move along the longitudinal axis L2relative to the first abutment surface148. Thus, the distance D between the first and second abutment surfaces146,148can be adjusted by moving the first and second bodies130,132relative to each other along the longitudinal axis L2.

The tool mechanism102defines a channel152that can receive the fluid fitting10described above in its pre-installed configuration. In particular, the fluid fitting10can be nested within the channel152such that the longitudinal axes L1, L2of the fitting10and tool mechanism102are collinear. Moreover, the abutment surfaces26,52of the coupling body12and drive ring14can be located between the first and second abutment surfaces146,148of the tool mechanism102such that the abutment surfaces26,52of the coupling body12and drive ring14respectively face the first and second abutment surfaces146,148of the tool mechanism102.

The tool mechanism102can then be operated to move the second body132along the longitudinal axial L2toward the first body130, in turn causing the second abutment surface148to move towards the first abutment surface146. Eventually, both abutment surfaces146,148will respectively abut the abutment surfaces26,52of the coupling body12and drive ring14. Moreover, further movement of the second abutment surface148towards the first abutment surface146will axially force the drive ring14along the longitudinal axes L1, L2toward the flange portion22of the coupling body12, eventually assuming the installed configuration show inFIG.3.

Accordingly, the tool mechanism102can be operated to connect the fitting10to the pipe16as described above, thereby creating a mechanical connection of these elements with a metal-to-metal seal between the pipe16and coupling body12. That is, movement of the second abutment surface148towards the first abutment surface146will axially force the drive ring14along the longitudinal axis L1toward the flange portion22of the coupling body12. As the drive ring14is forced axially toward the flange portion22, it will apply a compressive force to the coupling body12that causes radial deformation of the body12, forcing the tooth or teeth of its seals30,32,34to bite into the pipe16. The coupling body12will in turn compress the pipe16first elastically (i.e., non-permanent) and then plastically (i.e., permanent), eventually forming a 360° circumferential, permanent, metal-to-metal seal between the pipe16and the coupling body12. Simultaneous with the radial compression of the body12and the pipe16, the drive ring14will elastically expand radially outward. Thus, once installed, the drive ring14will exert a continuous elastic force against the coupling body12and pipe16that is maintained through the life of the fitting10, thereby preventing release of the metal-to-metal seal between the pipe16and the coupling body12.

It is to be appreciated that the tool mechanism102can be configured to install additional or alternative fittings than the fitting10described above. For instance, in some examples, the first and/or second adapters140,142can be removed from the tool mechanism102so that it can accommodate a fitting with a larger coupling body and/or drive ring. In such cases, the first and/or second bodies130,132themselves can define abutment surfaces for engagement with the coupling body and/or drive ring. In other examples, the first and/or second adapters140,142can be removed and replaced with a different adapter to accommodate a different fitting. Broadly speaking, the tool mechanism102can be any mechanism having two abutment surfaces that are movable relative to each other such that the mechanism can be operated to connect a fluid fitting to a pipe. Various example toll mechanisms are described in U.S. Pat. Nos. 4,189,817; 5,305,510; 5,694,670; 6,434,808; and 9,278,441, which are all expressly incorporated herein by reference in their entirety.

Turning back toFIG.4, the installation apparatus100can include a drive assembly160that is operable to apply a driving force to the tool mechanism102to move the first and second bodies130,132relative to each other as described above. In the present example, the drive assembly160includes a hydraulic source164that is remotely positioned from the tool mechanism102, and a hose assembly166that fluidly connects the hydraulic source164to the tool mechanism102.

The hydraulic source164is a hydraulic pump that is configured to supply a pressurized, hydraulic fluid. The hydraulic source164can be driven by a manual actuator, a gas engine, or an electric motor. Moreover, the hose assembly166includes a plurality of hoses168a,168band connectors170a-dthat are fluidly coupled in series to form a fluid channel that conveys the pressurized, hydraulic fluid from the hydraulic source164to the tool mechanism102. In particular, the connector170ais connected directly to an outlet of the hydraulic source164, while the connector170dis connected directly to an input port174of the tool mechanism102. Furthermore, conventional male/female quick disconnects are provided as the connectors170a-d, for making readily disconnectable fluid connections with their mating components.

In operation, the drive assembly160will deliver the hydraulic fluid to a hydraulic cylinder (not shown) of the tool mechanism102, which in turn will exert a corresponding linear force F against the second body132. That force F will move the second body132along the longitudinal axis L2toward the first body130as described above, so long as it is greater than any total counter force being exerted against the second body132in the axial direction (e.g., a counter force being generated by the drive ring14, friction, or other elements).

However, the drive assembly160can include various other structure for providing a driving force to the tool mechanism102. For instance, the tool mechanism102may require more than one input of hydraulic fluid. In such cases, the hose assembly166can deliver hydraulic fluid to a manifold, which distributes hydraulic fluid to multiple input ports on the tool mechanism102. In other examples, the hydraulic source164may be directly connected to the tool mechanism102without any intermediate hose assembly. Still further, the drive assembly160can use electro-mechanical means of applying force to the tool mechanism102without any use of a hydraulic fluid. Broadly speaking, the drive assembly160can comprise any conventional means that is operable to apply force to an object (e.g., the second body132) in order to move it linearly.

As described below, the installation apparatus100can further include a diagnostic system that is configured to detect one or more properties of the installation apparatus100or fluid fitting10during installation and determine a quality of the attachment between the fluid fitting10and the pipe16based on the one or more detected properties.

More specifically, the diagnostic system can include one or more sensors that are each configured to detect an associated property of the installation apparatus100or fluid fitting10and provide an output corresponding to the detected output. For example, the diagnostic system can include a first sensor182(shown schematically inFIG.4) that is configured to detect a force property of the installation apparatus100or fluid fitting10and provide an output corresponding to the force property (for the purposes of this disclosure, a “force property” of an object refers to a force being applied by or to the object, either in absolute terms or per unit area). The sensor182in the present embodiment is a pressure sensor that is connected in line with the hoses168a,168bof the hose assembly166(via connectors170c,170d) such that it can detect a pressure of the hydraulic fluid being delivered to the tool mechanism102and provide an electrical output (e.g., voltage or radio frequency output) corresponding to the detected pressure. It is understood that the pressure detected by the sensor182(and its output) will correspond to the linear force F that is ultimately exerted on the second body132of the tool mechanism102, since that force F can be extrapolated knowing either of those values and how the hydraulic pressure is transferred to the second body132as linear force. However, the sensor182can comprise other means for detecting a force property of the installation apparatus100. For example, the sensor182can be load cell that is configured to directly measure the linear force F.

The diagnostic system can further include a second sensor184(shown schematically inFIGS.4&5) that is configured to detect a spatial property of the installation apparatus100or fluid fitting10and provide an output corresponding to the spatial property (for the purposes of this disclosure, a “spatial property” of an object refers to a specific location of the object or a distance that the object travels). The sensor184in the present embodiment is an electrically operated sensor in the form of a linear transducer that is configured to detect a distance d that the second body132(and second abutment surface148coupled thereto) moves from an initial position, and provide an electrical output (e.g., voltage or radio frequency output) corresponding to the detected distance d. It is understood that the distance d detected by the sensor184(and its output) will correspond to the distance D between the first and second abutment surfaces146,148, since the distance D can be extrapolated knowing either of those values and the initial position of the second body132relative to the first body130.

However, the second sensor184can comprise other means for detecting a spatial property of the installation apparatus100or fluid fitting10. For example, the sensor184can be a proximity sensor that detects when a portion of the second body132(e.g., the second abutment surface148) arrives at a particular location. As another example, the sensor184can be a device that directly detects the distance D between the first and second abutment surfaces146,148. As yet another example, the sensor184can be a device that directly detects a distance that the drive ring14of the fluid fitting10moves.

Optionally, the diagnostic system can further include a third sensor186(shown schematically inFIGS.1-3) that is configured to detect a strain property of the installation apparatus100or fluid fitting10and provide an output corresponding to the strain property. For instance, the sensor186in the present embodiment is an electrically operated strain gauge that is configured to detect strain in a portion of the fitting10and produce an electrical output (e.g., voltage or radio frequency output) corresponding to the detected strain. Specifically, the sensor186is fixed to the exterior surface50of the drive ring14and is configured to detect strain that is present in the drive ring14. As discussed above, the drive ring14will expand radially during installation, thereby generating strain in the drive ring14that can be measured by the sensor186. This detectable strain is directly related to the deformation of the body12and/or pipe16. Depending upon the strain gauge used, and the orientation of its strain sensing element, the detected physical strain of the drive ring14can be any of circumferential strain or hoop strain, axial strain, or radial strain. It is further contemplated that combinations of these can be detected.

The third sensor186can be applied at various locations along the longitudinal axis L1of the fluid fitting10(i.e., body12, drive ring14). It is preferable for the sensor186to be located at a region that experiences relatively high strain at the installed configuration, or at potential failure points. In many cases, such a location can be found near or in alignment with one of the main seal30, inboard seal32, and/or outboard seal34. For example, the physical strain in the material of the drive ring14, due to its elastic expansion during installation, is relatively high in the position over the location of the main seal30because this is a location of high deformation of the coupling body12and pipe16. Thus, the sensor186can be located generally in radial alignment with at least one of the seals30,32,34, such as the main seal30, relative to the longitudinal axis X1of the fitting10. However, it is contemplated that the third sensor186can be affixed to various other parts of the fitting10, interior or exterior, including the body12or pipe16. Moreover, the sensor186can correspond to any of the example sensors described in U.S. Pat. No. 10,663,093.

The sensors182,184,186above can be configured to detect other types of properties than those described above, such as acceleration, vibration, temperature, etc. Moreover, the detected properties can be properties of the fitting10or installation apparatus100. For instance, in one example, the third sensor186can be configured to detect a strain property of the installation tool102instead of the fitting10, and may be positioned on a portion of the installation tool102, for example on either or both of the first body130or second body132.

Furthermore, the diagnostic system may include additional and/or alternative sensors that are configured to detect additional and/or alternative properties. For instance, any or all of the sensors182,184,186described above can be used alone or in various combinations with each other and/or other sensors. Broadly speaking, the diagnostic system can include any configuration of one or more sensors, wherein each sensor is configured to detect a property of the installation apparatus100or fluid fitting10and provide a corresponding output.

Turning toFIG.6, the diagnostic system can further include a processing unit192that can acquire the outputs of sensors182,184,186and generate one or more resulting data sets for comparison with one or more predetermined data sets to determine a quality of the attachment between the fluid fitting10and the pipe16.

More specifically, the processing unit192in the present embodiment is a handheld unit having a user interface194and display196. Each sensor182,184,186can be in electrical communication with the processing unit192via an electronic wire or cable (e.g., a USB cable). Alternatively, communication between the processing unit192and one or more sensors182,184,186may be established wirelessly. For instance, one or more sensors182,184,186can include an RFID tag that is configured to transmit an RF signal corresponding to its detected property. The RFID tag typically includes an antenna that transmits RF signals relating to the identification and/or information stored within the RFID tag. The processing unit192can provide power to the RFID tag, in whole or in part, whereby a wireless communication transceiver of the RFID tag is passively powered by an electromagnetic field from the processing unit192. The processing unit192can be configured to probe or interrogate the RFID tag, and can include a transmitter and receiver for exchanging RFID information with the RFID tag wirelessly. Optionally, the processing unit192can be in wireless communication with the one or more sensors182,184,186via other wireless data communication protocols, such as any of Wifi, Bluetooth, NFC, cellular (analog or digital, including all past or present iterations), etc.

While installing the fitting10with the tool mechanism102as described above, the processing unit192can be configured to acquire the output from the first sensor182at discrete times to generate a first data set202(seeFIG.7) corresponding to the sensor's detected property over time. The X-axis inFIG.7represents a specified time interval during operation of the tool mechanism102and the Y-axis represents the linear force F applied to the second body132applied to during the time interval (it is understood that the linear force F corresponds to the pressure detected by the sensor182, as discussed above, or other linear force data that is ultimately exerted on the second body132obtained by an alternative variation of sensor182).

The first data set202includes various crests and troughs which correlate to specific moments as the drive ring14traverses over and interacts with the coupling body12. Specifically, crest “a” occurs as a result of the outboard seal34of the coupling body12engaging and biting into the pipe16, since this is the first seal that is compressed by operation of the drive ring. As the drive ring14is forced over the coupling body12by the second abutment surface148of the tool mechanism102, the outboard seal34will engage and press against the pipe16, thereby requiring an increase in linear force F to continue moving the drive ring14over the coupling body12. The linear force F will thus increase until the pipe16yields to compression by the outboard seal34, at which point the linear force F required for further movement of the drive ring14will decrease. This fluctuation of linear force F corresponds to crest “a”.

The linear force F will continue to decrease until the next seal is compressed, which in this example is the main seal30of the coupling body12that engages and presses against the pipe16, thereby requiring another increase in linear force F to continue moving the drive ring14over the coupling body12. This fluctuation of linear force F corresponds to trough “b”. The linear force F will continue to increase until the pipe16yields to compression by the main seal30, at which point the linear force F required for further movement of the drive ring14will decrease. This fluctuation of linear force F corresponds to crest “c”.

Again, the linear force F will continue to decrease until the next seal is compressed, which in this example is the inboard seal32of the coupling body12that engages and presses against the pipe16, thereby requiring another increase in linear force F to continue moving the drive ring14over the coupling body12. This fluctuation of linear force F corresponds to trough “d”. The linear force F will continue to increase until the pipe16yields to compression by the inboard seal32, at which point the linear force F required for further movement of the drive ring14will decrease. This fluctuation of linear force F corresponds to crest “e”.

During installation, the processing unit192can be further configured to acquire the output from the second sensor184(corresponding to a spatial property of the tool mechanism102) at the same discrete times in which the output from the first sensor182was acquired. The processing unit192will then generate a second data set204(seeFIG.8) corresponding to the detected property of the second sensor184over those same discrete times. The X-axis inFIG.8represents a specified time interval during operation of the tool mechanism102and the Y-axis represents the distance d that the second body132(and second abutment surface148coupled thereto) moves to during the time interval.

After the processing unit192creates the first and second data sets202,204, the processing unit192can be further configured to correlate the first and second data sets202,204with respect to their discrete times to generate a resulting data set208(seeFIG.9) that corresponds to the first property detected by the first sensor182versus the second property detected by the sensor184. The X-axis inFIG.9represents the distance d that the second body132(and second abutment surface148coupled thereto) moves to during the time interval, and the Y-axis represents the linear force F applied to the second body132applied during the movement (it is understood that the linear force F corresponds to the pressure detected by the first sensor182, as discussed above).

In some examples, the processing unit192can store a predetermined data set that can then be compared against the resulting data set208to determine if resulting data set208is compliant. More specifically, as shown inFIG.9, the predetermined data set can include a maximum data set210and a minimum data set212respectively corresponding to a maximum first property (e.g., linear force F) per second property (e.g., distance d) for the installation apparatus100and a minimum first property per second property. In other words, the maximum and minimum data sets210,212represent upper and lower limits for the resulting data set208that would yield a proper installation of the fitting10. The limits can be predetermined based on known properties for the fitting10and pipe16(e.g., materials, dimensions, etc.) and/or experimental data.

Accordingly, the processing unit192can determine if the fitting10has been installed properly by determining if the resulting data set208is between or equal to the maximum data set210and minimum data set212. As can be seen inFIG.9, the resulting data set208is between the maximum and minimum data sets210,212, indicating that the fitting10has been installed properly. By contrast,FIG.10shows a comparative resulting data set214having segments S1, S2that fall outside of the acceptable limits, indicating a possible failure in the installation process. Moreover, the specific locations in which the resulting data set214fall outside of the acceptable limits can provide further indication of the specific type of failure.

In some examples, the processing unit192can be configured to correlate the second data set204(corresponding to a spatial property of the tool mechanism102over time) with other properties of the fitting10or tool mechanism102as an alternative or redundant means of determining whether the fitting10has been installed correctly. For instance, in some examples, the processing unit192can be configured to acquire the output from the third sensor186(corresponding to a strain property of the fitting10) at the same discrete times in which the output from the second sensor184was acquired. The processing unit192will then generate a third data set216(seeFIG.11) corresponding to the strain property over those same discrete times. The X-axis inFIG.11represents a specified time interval and the Y-axis represents the strain detected by the sensor186during the time interval.

The third data set216inFIG.11similarly includes various changes in slope which correlate to specific moments as the drive ring14traverses over and interacts with the coupling body12. Specifically, crest “f” occurs as a result of the outboard seal34of the coupling body12engaging and biting into the pipe16. As the drive ring14is forced over the coupling body12by the second abutment surface148of the tool mechanism102, the outboard seal34will engage and press against the pipe16, thereby increasing strain in the fitting10. The strain will increase until the pipe16yields to compression by the outboard seal34, at which point the strain will decrease. This fluctuation of strain corresponds to crest “f”.

The strain in the fitting10will continue to decrease as the drive ring14moves over the coupling body12until the main seal30of the coupling body12engages and presses against the pipe16, again causing strain in the fitting10to increase. This fluctuation of strain corresponds to trough “g”. The strain will continue to increase until the pipe16yields to compression by the main seal30, at which point the strain will decrease. This fluctuation of strain corresponds to crest “h”.

Again, the strain in the fitting10will continue to decrease as the drive ring14moves over the coupling body12until the inboard seal32of the coupling body12engages and presses against the pipe16, causing strain in the fitting10to increase. This fluctuation of strain corresponds to trough “i”. The strain will continue to increase until the pipe16yields to compression by the inboard seal32, at which point the strain will decrease. This fluctuation of strain corresponds to crest “j”.

After the processing unit192creates the second and third data sets204,216, the processing unit192can be configured to correlate the second and third data sets204,216with respect to their discrete times to generate a resulting data set218(seeFIG.12) that corresponds to the second property detected by the second sensor184versus the third property detected by the third sensor186. The X-axis inFIG.12represents the distance d that the second body132(and second abutment surface148coupled thereto) moves to during the time interval, and the Y-axis represents the strain experienced by the fitting10during the movement.

The processing unit192can similarly store a predetermined data set that can then be compared against the resulting data set218to determine if resulting data set218is compliant. More specifically, as shown inFIG.12, the predetermined data set can include a maximum data set226and a minimum data set228respectively corresponding to a maximum third property (e.g., strain) per second property (e.g., distance d) and a minimum third property per second property. In other words, the maximum and minimum data sets226,228represent upper and lower limits for the resulting data set218that would yield a proper installation of the fitting10. The limits can be predetermined based on known properties for the fitting10and pipe16(e.g., materials, dimensions, etc.) and/or experimental data.

Accordingly, the processing unit192can determine if the fitting10has been installed properly by determining if the resulting data set218is between or equal to the maximum data set226and minimum data set228. As can be seen inFIG.12, the resulting data set218is between the maximum and minimum data sets226,228, indicating that the fitting10has been installed properly. Although not shown inFIG.12, the processing unit192could likewise determine a failure of the installation process if resulting data set218has any segments that fall outside of the acceptable limits (i.e., data sets210,212).

Although the data sets202,204,208,210,212,214,216,218,226,228described above have been illustrated inFIGS.7-12in graphical form, it is to be appreciated that the data sets can be represented in other forms such as, for example, tabular.

In some examples, the processing unit192can include one or more output devices (e.g., speakers, lights, the display196, etc.) that can be electrically operated to provide an output (e.g., sound output, indicator light, video image, electrical signal, vibration, etc.) based on compliance of one or both of the resulting data sets208,218with their respective maximum and minimum data sets, thereby indicating whether the fitting10has been installed correctly.

For example, the processing unit192(seeFIG.6) can include first and second indicator lights230,232. The processing unit192can be configured to illuminate the first indicator light230(e.g., green) if the resulting data set208is compliant with the maximum and minimum data sets210,212, thereby indicating that the fitting10was installed correctly. Moreover, the processing unit192can be configured to illuminate the second indicator light232(e.g., red) if the resulting data set208is not compliant, thereby indicating that the fitting10was not installed correctly. It is understood that the indicator light230when unlit can thereby indicate that the resulting data set208is not compliant, while the indicator light232when unlit can thereby indicate that the resulting data set208is compliant. It is further contemplated that compliant or non-compliant notices could also be presented on other output devices (e.g., speakers, lights, the display196, etc.).

In another example, the processing unit192can be configured to illuminate the indicator light230if the resulting data set218is compliant with the maximum and minimum data sets226,228, or illuminate the indicator light232if the resulting data set218is not compliant. It is understood that the indicator light230when unlit can thereby indicate that the resulting data set218is not compliant, while the indicator light232when unlit can thereby indicate that the resulting data set218is compliant.

As a further example, the processing unit192can be configured to illuminate the indicator light230if both of the resulting data sets208,218are compliant with the their respective maximum and minimum data sets, or illuminate the indicator light232if at least one of the resulting data sets208,218is not compliant with its respective maximum and minimum data sets. It is understood that the indicator light230when unlit can thereby indicate that at least one of the resulting data sets208,218is not compliant, while the indicator light232when unlit can thereby indicate that both of the resulting data sets208,218are compliant.

The processing unit192can include any number and configuration of output devices that can be electrically operated to provide one or more outputs based on compliance of one or both of the resulting data sets208,218with their respective maximum and minimum data sets.

In certain embodiments, the processing unit192may be integrated with a computer system. The processing unit192preferably has on-board non-transient computer memory to store the data sets202,204,208,210,212,214,216,218,226,228described above for later retrieval, analysis, or transmission. Additionally, the processing unit192preferably is capable of communication on a local network (LAN) or wide-area network (WAN), including the internet and world-wide web. Preferably, the processing unit192itself is capable of wireless data communication, such as via Wifi, Bluetooth, NFC, cellular (analog or digital, including all past or present iterations), or other similar techniques. Further, the processing unit192preferably has a programmable microprocessor that can include various features and capabilities. For example, the microprocessor includes a programmable computing core that is capable of executing any or all of the processing steps described above, including generating, storing, and comparing the data sets202,204,208,210,212,214,216,218,226,228as described above. The programmable computing core can be capable of performing any or all of processing commands, making calculations, tracking/reading data, storing data, analyzing data, adjusting/manipulating data, receiving new commands or instructions, etc.

In some examples, the diagnostic system can include an additional or alternative processing unit in the form of a remote database300(seeFIG.6), which can receive data from the processing unit192and/or sensors182,184,186for storage and/or performing one or more of the diagnostic procedures described above (e.g., generating data sets, comparing data sets, and/or providing an output indicating compliance of a data set). The remote database300may be a remote central computer server database (e.g., a network-connected or internet-connected computer, sometimes referred to as “in the cloud”) that is local to the site of the field installation or the controlling company, local to the manufacturer of the fitting, and/or “cloud-based” in that it is maintained at a remote, internet-connected server. Such a “cloud-based” internet-connected server could provide data storage and retrieval capabilities, and/or may further provide computational capabilities to transform, analyze, and/or report upon the cataloged data. Regardless of location, this database300can be maintained by the manufacturer of the fitting10, by a service company that inspects the fitting10, and/or by the end user of the fitting10for use by the associated quality assurance personnel. The data obtained from the processing unit192and/or sensors182,184,186can be catalogued over time to help both the manufacturer and end customer track performance of the fitting10and installation tool102for purposes of installation help, maintenance, replacement, warranty claims, etc.

In one example, data from the third sensor186described above can be captured at the time that the fitting10is installed upon the pipe16(immediately before, during, and/or after). This reading can provide a baseline reference for the state of the drive ring14at the ambient environment where it will be installed (although, installation could also be performed at the manufacturer or other location). It can be especially useful to store the installation sensor readings to the remote database300for future use.

In this manner, both the manufacturer and the end-user can keep track of and otherwise understand the performance of the fitting10in the field so that all parties involved have a high degree of confidence that the fitting10will perform to its specifications. Alternatively, if the sensed readings indicate that the fitting installation trended out of specifications (i.e., still acceptable but moving towards being unacceptable) or is out of specification (i.e., unacceptable), all parties with access to the central computer database300can be informed of the status. This can enable the manufacturer to contact the end-user, or the end-user to contact the manufacturer, to arrange maintenance or replacement of the fitting10. Data trends can further be understood and identified by observing the information, such as what effect particular fittings, customers, installation techniques, environmental factors, etc. have on the installation, performance, and long-term function of the fitting10in the field. For example, data indicative of strain cracking, micro strain, or other pre-fail or failure modes can be cataloged and correlated, and then be used as a comparison against other fluid fittings in the field to determine predictive failures and identify potential remedy actions. The remote database300can store, analyze, transform, and report on various types of data, including some or all of historical installation sensor readings, comparison of installation sensor readings (current vs. historical), minimums/maximums, data offsets, calculations, etc. With regards to reporting, it is contemplated that the remote database300can be passive, in that the data and/or reports may be compiled but the user ultimately takes action based upon the data, or can be partially or wholly active, in which the remote database300can take further steps such as preemptively report potential problems to the manufacturer, end-user, service company, etc. based upon an analysis of the data input. Such active operation can be partially or fully automatic.

In another example, it is possible that the maximum and minimum data sets indicating that the fluid fitting10is installed correctly for its intended purpose may change over time. This may occur for various reasons, including further research and development, a better understanding of lifetime performance of the fluid fitting10in different environments, changes in manufacturing, etc. Through the use of a cloud computing environment, the maximum and minimum data sets can be easily changed in the remote database300and automatically applied to the data for past, present (real-time), or future sensor readings. For example, based upon experience it may be determined that a data set is too low or too high; thus, by changing the data set in a single remote database300, it can be quickly applied across all past, present (real-time), or future sensor readings. Similarly, based upon industry or customer demand, unique or different maximum and minimum data sets can be applied to only a subset of products (i.e., only certain products of a particular customer or industry), which may change from time to time.

It is to be appreciated that the processing unit192and remote database300can be collectively described as a processing unit that performs the diagnostic procedures described above (e.g., acquiring outputs, generating data sets, comparing data sets, and/or providing an output indicating compliance of a data set). Indeed, the diagnostic procedures can be split amongst the processing unit192and remote database300such that some procedures are performed by the processing unit192while others are performed by the remote database300. Moreover, the diagnostic system in some examples can exclude the processing unit192, while the remote database300is configured to perform the diagnostic functions of the processing unit192.

The diagnostic system as described above thus can determine whether the fitting10has been properly installed by monitoring at least two parameters of the fitting10and installation tool102(e.g., linear force F applied to the tool mechanism102and the distance d that the second body132moves from an initial position) to generate two data sets, correlating those two data sets to generate a resulting data set, and comparing that resulting data set to a predetermined data set for compliance. However, it is to be appreciated that the two properties monitored and correlated can vary by embodiment. Moreover, the diagnostic system can monitor more than two parameters and compare multiple resulting data sets with respective predetermined data sets for the purposes of redundancy. Broadly speaking, the diagnostic system can be any system that monitors at least two parameters of the fitting10and installation tool102and correlates those parameters for comparison with one or more predetermined data sets to determine whether the fitting10has been properly installed.