Abstract:
An axial swage alignment tool ( 11 ) having a bridge member ( 27 ) for axially and rotationally aligning a metal tube ( 21 ) and a fitting ( 31 ) is disclosed. The bridge member that is temporarily bonded to the exterior surfaces of the metal tube and the fitting. The bridge member eliminates the need to place any material between the metal tube and the fitting either prior to or after the swaging process.

Description:
TECHNICAL FIELD  
       [0001]     The present invention relates to alignment tools. In particular, the present invention relates to axial swage alignment tools.  
       DESCRIPTION OF THE PRIOR ART  
       [0002]     Many complicated machines require metal tubing for carrying pressurized fluids, such as fuel and hydraulic fluid. Often, this metal tubing is formed by assembling together several small metal tubes. This is particularly true for metal tubing that has curves, bends, joints, and other complicated shapes. When assembling the small metal tubes, the joints must be coupled together with fluid tight seals that can withstand the pressures required by the machine. Some applications, such as aircraft applications, require specialized couplings, or fittings, that must be swaged onto the metal tubes with high-precision swaging tools to provide proper, fluid-tight, metal-to-metal seals and ensure that the resultant metal tubing conforms to strict dimensional tolerances. These swaging tools are typically high-pressure hydraulic machines that are capable of slightly deforming the metal tubing and the specialized fittings. Once the tubes and fitting are swaged together, they cannot be separated without damaging the tubes and fittings.  
         [0003]     Often, due to space constraints, the swaging tool will not fit into the required location to swage the metal tubes and fittings. When this happens, the metal tubes and fittings must be removed from the machine, swaged remote from the machine, and then reinstalled onto the machine as assembled metal tubing. These parts must be temporarily fastened together so that the orientation between them is maintained while they are remotely swaged together. Both the rotational alignment and the axial alignment must be accurately maintained. If the proper orientation is not maintained, the resultant metal tubing will not fit properly when it is reinstalled onto the machine.  
         [0004]     Several problems arise when metal tubes and fittings must be removed from the machine and remotely swaged together. With one method, the tubes and fittings must be precisely marked with reference marks to ensure the proper axial and rotational orientation. This is a time consuming process that is prone to errors. Often, the marks are made by hand with dull markers. With another method, the metal tubes and fittings must be temporarily fastened together. This is typically done by driving small wedges between the metal tube and the fitting, or by using super glue between the metal tube and the fitting. Methods that require the placement of materials between the metal tube and the fitting are undesirable. Wedges do not work well, because they fall out when the assembly is moved. Adhesives do not work well, because they degrade the seal.  
         [0005]     Although there have been significant developments in the area of swaging metal tubing, considerable shortcomings remain.  
       SUMMARY OF THE INVENTION  
       [0006]     There is a need for an axial swage alignment tool that can accurately maintain the proper orientation between the swaged parts.  
         [0007]     Therefore, it is an object of the present invention to provide an axial swage alignment tool that can accurately maintain the proper orientation between the swaged parts.  
         [0008]     This object is achieved by providing an axial swage alignment tool having a bridge member that is temporarily bonded to the exterior surfaces of the metal tubing and the fitting. The tool does not require placing any material between the metal tube and the fitting.  
         [0009]     The present invention provides significant advantages, including: (1) the metal tubes and the fittings can be removed from the machine and accurately swaged remote from the tool; (2) specialized marking templates are not required; (3) the parts do not have to marked prior to removal; (4) the axial alignment of the fitting on the metal tube is adjustable, i.e., the metal tube does not have to be axially bottomed-out into the fitting; and (5) because the bridge member is only bonded to the exterior surfaces of the metal tube and the fitting, it is not necessary to place any material between the metal tube and the fitting.  
         [0010]     Additional objectives, features, and advantages will be apparent in the written description that follows. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0011]     The novel features believed characteristic of the invention are set forth in the appended claims. However, the invention itself, as well as, a preferred mode of use, and further objectives and advantages thereof, will best be understood by reference to the following detailed description when read in conjunction with the accompanying drawings, wherein:  
         [0012]      FIG. 1  is a perspective view of the axial swage alignment tool according to the present invention;  
         [0013]      FIG. 2  is a partial longitudinal cross-sectional view of the axial swage alignment tool of  FIG. 1 ;  
         [0014]      FIG. 3A  is a left side view of the bridge member of the axial swage alignment tool of  FIG. 1 ;  
         [0015]      FIG. 3B  is a cross-sectional view of the bridge member of  FIG. 3A  taken at A-A; and  
         [0016]      FIG. 3C  is a right side view of the bridge member of the axial swage alignment tool of  FIG. 1 . 
     
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0017]     The present invention represents the discovery that metal tubes and fittings can be swaged together without placing adhesives and other materials between the metal tubes and the fittings. The alignment tool according to the present invention is particularly useful in applications in which the metal tubes and the fittings are swaged remotely from the machine on which they are to be installed.  
         [0018]     Referring to  FIG. 1  in the drawings, the preferred embodiment of an axial swage alignment tool  11  according to the present invention is illustrated. Tool  11  is preferably powered by a hydraulic system, but may be powered by other means, such as an electric motor. Tool  11  includes a hydraulic pump (not shown) for pumping high-pressure hydraulic fluid through a hydraulic line  13 . Hydraulic line  13  is coupled to a housing  15  and a ram member  17  by a coupling  19 . Ram member  17  is driven forward and backward in the direction of arrow B by a piston (not shown) that is in communication with the hydraulic fluid from hydraulic line  13 . Tool  11  is used to precisely align and axially swage a metal tube  21  to a fitting  23 , so that metal tube  21  can be coupled to an elbow  25  or other tube or component part. A bridge member  27  is used to align tube  21  and fitting  23 .  
         [0019]     Referring now  FIGS. 2 and 3 A- 3 C in the drawings, the assembly of metal tube  21 , fitting  23 , and elbow  25  is illustrated prior to swaging. As is shown, fitting  23  preferably includes a body portion  31  and a collar  33 . Fitting  23  may be any of a wide variety of fittings, including unions, elbows, and tees. Body portion  31  includes a radially outward extending flange  35 . One side of flange  35  may form a selected fillet radius  37  with body portion  31 . The opposing side of flange  35  is received by a recessed area  39  bored into the end of collar  33  upon swaging.  
         [0020]     Bridge member  27  is generally U-shaped having a first end  41 , a second end  43 , and a cross piece  45 . First end  41  includes a contact surface  47  that is curved to match the outside diameter of tube  21 . In a similar fashion, second end  43  has a contact surface that is curved to match the outside diameter of fitting  23 . In addition, second end  43  includes a fillet radius that matches fillet radius  37  of flange  35 . Cross piece  45  is configured to provide sufficient clearance between the inside surface of cross piece  45  and the outside surface of collar  33 , including any radially outward deformation that occur to collar  33 . Bridge member  27  is preferably made of steel, but may be made of other metallic or strong, rigid materials. Bridge member  27  eliminates the need to place any material between metal tube  21  and fitting  23  either prior to or after the swaging process.  
         [0021]     In operation, tube  21  is inserted into fitting  23 . Tube  21  may be axially located anywhere within fitting  23 . It is not necessary that tubing  21  bottom-out within fitting  23 . One significant advantage of the present invention is that tool  11  allows for both axial and rotational alignment of tube  21  and fitting  23 . Next, first end  41  of bridge member  27  is adhered to tube  21  and second end  43  of bridge member  27  is adhered to fitting  23 . In the preferred embodiment, first end  41  and second end  43  are adhered to metal tube  21  and fitting  23  with cyanoacrylate, or a similar high-strength adhesive for bonding smooth metal parts together. It is preferred that second end  43  butt-up against and be adhered to fillet radius  37  of flange  35 . This provides additional strength and stability to the assembly. Once assembled in this fashion, metal tube  21  and fitting  23  may be moved to any convenient location for carrying out the swaging process.  
         [0022]     In the swaging process, metal tube  21  is installed into a slot  51  in ram member  17 , and fitting  23  is installed into a slot  53  in housing  15  (see  FIG. 1 ). Slot  51  engages collar  33 , and slot  53  engages flange  35 . Tool  11  is then activated such that ram member  17  forces collar  33  in the direction of arrow C. This movement slightly deforms metal tube  21 , body portion  31 , and collar  33  and forms a metal-to-metal seal between metal tube  21  and fitting  23 . Then, bridge member  27  is pried off of tube  21  and fitting  23 . First end  41  and second end  43  of bridge member  27  may then be cleaned with acetone, alcohol, or any other suitable cleansing agent, and reused.  
         [0023]     It is apparent that an invention with significant advantages has been described and illustrated. Although the present invention is shown in a limited number of forms, it is not limited to just these forms, but is amenable to various changes and modifications without departing from the spirit thereof.