Patent Publication Number: US-2015068022-A1

Title: Fluid coupling assembly and method of manufacture

Description:
RELATED APPLICATIONS 
     The present disclosure claims the right to priority based on, and is a divisional of, U.S. patent application Ser. No. 12/069,525 filed Oct. 30, 2009, which is fully incorporated herein. 
    
    
     TECHNICAL FIELD 
     The present disclosure relates generally to fluid coupling construction and manufacturing, and more particularly to the same as it relates to hydraulic coupling assemblies used for fluid connectivity through a reinforced hose. 
     BACKGROUND 
     Fluid couplings are commonly used in concert with flexible, elastomeric hoses to communicate fluid pressure between locales or to fluidly connect sources for the purpose of transporting fluid therebetween. Fluid couplings have broad utility across many industries relating to a wide variety of applications. Such couplings—typically connected by a flexible conduit or hose to form a hose assembly—are particularly useful in applications where one source may be moveable, or subject to vibration relative to another portion of a system, and where rigidly connected conduits may be compromised by such movement or vibration. Hose assemblies are commonly found in mobile machinery, electric power, refinery, mining and construction equipment industries. The equipment used in these industries often includes multiple instances where hose assemblies are employed to transport fluid (gaseous or liquid) commonly under high pressure and elevated temperature. Common examples of hose assembly usage in the mobile machinery and electric power industries include: connecting a high pressure hydraulic fluid source to pressure cylinders to animate implements, transporting fuel from a source to a fuel system within a combustion engine, communicating lubrication oil from a supply to moving or engaging parts such as, for example, gears in a transmission, transporting coolant from a source to a heat transfer element such as a radiator to cool the fluid and communicating fluid between pump/motor assemblies to transform fluid pressure to rotary motion. 
     A common form of fluid coupling includes a metallic stem portion which is structured to receive an end of a flexible elastomeric hydraulic hose and a metallic shell portion, which surrounds the hose, has inwardly directed barbs and is structured to provide a tight collar vis-à-vis the hose portion sandwiched between the stem and shell. 
     Although not part of the fluid coupling assembly, the hose is an element of the completed hose assembly and is commonly reinforced with a metallic wire weave or winding sandwiched between an inner elastomeric liner in concentric relation with an outer elastomeric cover portion to form a hose that is constructed to withstand high temperature and pressure application. A hard plastic sheath, overlaying and encasing the outer cover portion of the hose, may be provided to reduce damage caused by impact and abrasion related contact to the hose. 
     A common method to permanently affix the hose end with the coupling entails sliding the hose onto the stem of the coupling and thereafter deforming the metallic shell portion of the coupling via dies on a hydraulic press, for example, in order for the barbs of the shell to concentrically crush the hose between the shell and stem. This process is commonly referred to as “crimping” or “swaging”. There are two common types of couplings termed “skive” and “no-skive” couplings. As it relates to the skive coupling, the coupling assembly is not structured to address the cover of the hose. Therefore, the cover, including the outer abrasion resistant sheath if one exists, must be removed prior to the swaging operation to ensure that the barbs within the shell provide an adequate measure of compression to the reinforcement wire and the liner of the hose. As it relates to the non-skive coupling, the coupling assembly is structured to address (e.g., penetrate) the cover of the hose, thus little if any preparation to the hose is required and the cover does not need to be removed prior to the swaging operation. The barbs of the non-skive coupling are structured to penetrate the cover to provide a sufficient measure of compression to the reinforcement wire and the liner in sealing the liner with the stem. Non-skive couplings are typically preferable because the additional steps to remove the cover add expense and difficulty to the assembly process. 
     Unfortunately, hose assemblies heretofore utilizing swaged couplings may be subject to leakage and shortened life due to “over-compression” of the hose liner material in the vicinity of the barb tip. The swaging operation imparts a significant radial load that acts substantially along a circumferential line on the liner. At the site of the liner/barb interface and accompanying liner/stem interface, the elastomeric liner is often subject to complete compression—meaning the liner is completely compressed and is incompressible (e.g., a solid). In this state, the liner has little or no resiliency and as the liner wears any significant temperature or pressure variation may cause the liner to lose its seal with the stem resulting in premature leakage and shortened life. In response to this situation, fluid couplings employ multiple rows of barbs axially spaced within the shell to decrease the likelihood of fluid leaking past the multiple seals in serial arrangement. 
     As it relates to manufacturing and assembling the coupling assembly with the hose resulting in a finished hose assembly, manufacturers often suggest employing specialized equipment to provide a precisely swaged connection between the coupling assembly and hose. Since the goal in ensuring a fluid tight seal is to compress the hose liner near the barb tip to the point of incompressibility of the hose there is little if any margin for error when the shell of the coupling assembly is undergoing permanent deformation. In fact, near the point that the hose becomes incompressible any additional compression by the swaging device may cause deformation of the shell and stem resulting in scrapped parts, premature leakage or shortened life of the hose assembly at a significant expense. As a result, many hose assemblies are scrapped during the swaging process and it is not uncommon for the hose assembly to leak if the proper equipment has not been employed and proper procedures have not been meticulously followed. 
     U.S. Pat. No. 6,447,017, to Gilbreath et al. issued Sep. 10, 2002 discloses a fluid coupling assembly employing a stem and shell combination that is swaged to sandwich a reinforced hose member therebetween. The stem is serrated, including a series of spaced grooves and the shell includes a plurality of spaced barbs. Radial displacement of the barb ends, caused by the swaging operation, displaces the reinforcement wire of the hose to substantially compress or “pinch” the liner material against the stem to form a generally circumferentially linear seal directly under each barb. Some barbs are positioned to overlay grooves of the stem and others may be positioned to overlay higher portions or “lands” on the stem. In some instances, the liner directly under each barb is compressed along a circumferential line on the stem to the point it is near “incompressibility” along this line and in other instances the barb may not adequately interact with the groove to provide an adequate seal. The overly compressed liner portions may be subject to premature leakage or shortened life when the liner is subject to natural degradation, thermal cycling or axial movement of the hose relative to the coupling assembly due to pressurization. 
     A fluid coupling which may overcome one or more of these limitations and one that would be readily manufacturable would be desirable. Furthermore, a non-skive fluid coupling assembly which does not significantly add cost relative to known fluid couplings, and one which may be readily adaptable to available reinforced hose members to form hose assemblies is highly desirable. 
     SUMMARY OF THE INVENTION 
     In one aspect, a coupling assembly for use with a wire-reinforced elastomeric hose member having reinforcement wire surrounding an elastomeric liner therein is provided and the coupling assembly comprises: a stem defining at least one groove, the groove includes first and second walls, a bottom portion and a pair of shoulder portions separated by a width. A shell is provided and at least partially encloses the stem and defines at least one barb. The barb includes a tip portion defining first and second edge portions. The tip of the barb is sized relative to the shoulder portions of the groove to transfer force developed by deflection of the reinforcement wire to sealingly compress the liner of the hose between the shoulder portions of the groove and the edge portions of the tip portion of the barb corresponding to a swaged state of the shell and stem members relative the hose. 
     In another aspect, a method of manufacturing a coupling assembly for use with a wire-reinforced elastomeric hose having reinforcement wire surrounding an elastomeric liner therein is provided. The coupling assembly comprises a stem defining at least one groove, the groove includes first and second walls, a bottom portion and a pair of shoulder portions separated by a width. The method comprises: providing a shell at least partially enclosing the stem and defining at least one barb. The barb including a tip portion defining first and second edge portions. The tip of the barb being sized relative to the shoulder portions of the groove to transfer force developed by deflection of the reinforcement wire to sealingly compress the liner of the hose between the shoulder portions of the groove and the edge portions of the tip portion of the barb corresponding to a swaged state of the shell and stem members relative the hose. The method also includes attaching the stem to the shell to form a coupling assembly wherein the coupling assembly comprises a size, the barb tip width, the barb height, the barb spacing, the groove width and the groove depth dimensions within dimension ranges provided in Table 1 or Table 2. 
     In another aspect, a method of manufacturing a hose assembly is provided. The method comprises: providing a wire-reinforced elastomeric hose having reinforcement wire surrounding an elastomeric liner therein, providing a coupling assembly, the coupling assembly comprises: a stem defining at least one groove, the groove including first and second walls, a bottom portion and a pair of shoulder portions separated by a width and a shell at least partially enclosing the stem and defining at least one barb. The barb includes a tip portion defining first and second edge portions. The tip of the barb is sized relative to the shoulder portions of the groove to transfer force developed by deflection of the reinforcement wire to sealingly compress the liner of the hose between the shoulder portions of the groove and the edge portions of the tip portion of the barb corresponding to a swaged state of the shell and stem members relative the hose. The coupling assembly comprises a size, the barb tip width, the barb height, the barb spacing, the groove width and the groove depth dimensions within dimension ranges shown in Table 1 or Table 2. The method also includes joining the hose with the coupling assembly through a swaging operation, wherein a size of the hose assembly and a shell diameter of the shell corresponding to a swaged state of the shell comprises a dimension within the dimension ranges shown in Table 3 or Table 4. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate an exemplary embodiment of the invention and, together with the description, serve to explain the principles of the invention. In the drawings, 
         FIG. 1  is a cross-sectional view of a coupling assembly in accordance with the present invention, additionally a sectioned hose is shown and is inserted on the stem in preparation for a permanent assembly operation between the coupling and hose; 
         FIG. 1A  is cross-sectional view of the coupling assembly of  FIG. 1  taken through line  1 A- 1 A. 
         FIG. 2  is the coupling assembly and hose of  FIG. 1 , permanently joined to form a hose assembly shown subsequent to a permanent assembly operation between the coupling assembly and the hose; 
         FIG. 3  is an enlarged view of the encircled area  3 , shown in  FIG. 2 ; 
         FIG. 4  is an enlarged view of the inner portion of the shell along line  4 - 4  of  FIG. 2 , with the hose removed, showing post-swage etching imparted by the hose reinforcement wire on the edge portions of the barbs; 
         FIG. 5  is an enlarged view of the encircled area  3  of  FIG. 2 , showing the force distribution along the distance −X to +X, imparted by the hose reinforcement wire on inner portions of the hose; 
         FIG. 6  are actual pressure test results (as a function of shell diameter, post-swage) for ⅜″ and ½″ diameter coupling assemblies and corresponding specified hose types using coupling configurations according to the present disclosure; and 
         FIG. 7  is a diagrammatic schematic of a hose assembly crimping apparatus in accordance with the present invention showing a clamping machine, controller and a measuring device. 
     
    
    
     Corresponding reference characters indicate corresponding parts throughout the several views. Although the drawings represent an embodiment of the present invention, the drawings are not necessarily to scale and certain features may be exaggerated in order to better illustrate and explain the present invention. The exemplification set out herein illustrates an embodiment of the invention in one form thereof, and such exemplification is not to be construed as limiting the scope of the invention in any manner. 
     DETAILED DESCRIPTION 
     Referring to  FIG. 1 , coupling assembly  10  includes a tubular stem  16  and a bell-shaped shell  18  which can be combined with hose  12  to create a “fluid-tight” hose assembly  14  ( FIG. 2 ). A first end  22  of stem  16  includes a T-shaped base  26  having a sealing interface  28  which is urged into contact with a complementary sealed nipple (not shown) as is customary when threaded portion  30  of nut  20  is threaded onto such nipple. It is envisioned that the sealing interface  28  of the first end  22  of stem  16  can alternatively include any conventional pipe-end connection such as a male pipe coupling, a JIC 37 degree flare coupling or an angled connection coupling. For example, it is envisioned that at least one type of sealing interface  28  alternative may be a male pipe-thread for example and therefore nut  20  would not be required. 
     Stem  16  includes a second end  24  which is a hollow nipple portion  32  having an inside diameter, d stem  and an outer diameter, D1. The outer diameter D1 may be sized to provide a slight radial clearance fit relative to the inside diameter of the hose  12 . Second end  24  of stem  16  includes two lands  34 ,  36  which are axially separated along stem  12  relative to groove  40 . Grooves  38 ,  42  are positioned outside of, and adjacent, groove  40 . A pilot land  44  is positioned about midpoint between first end  22  and second end  24  of stem  16 . Pilot land  44  includes diameter D2 which is slightly larger than the inner diameter of hose  12 . Positioned adjacent the pilot land  44  is stop  45  formed on stem  16  and is structured to abut an end  46  of hose  12  providing an affirmative stop for hose  12  when hose  12  is being assembled with stem  16 . 
     Stem  16  includes a male engagement portion  48  circumferentially formed on an outer surface  49  of stem  16 . Shell  18  includes a female engagement portion  50  formed on an inner bore  51  therein and is constructed to facilitate permanent engagement with the male engagement portion  48  to create a unitary coupling assembly  10 . Female engagement portion  50  of shell  18  may be fused with male engagement portion  48  through a swaging operation, an interference fit, welding or brazing or other suitable permanent engagement operation known by those with skill in the art of coupling manufacturing. 
     Referring to  FIG. 2 , shell  18  includes a tool portion  52 , which may be hexagonally shaped, ( FIG. 1A ) for example, for facilitating engagement with a tool or wrench. For example, as nut  20  on stem is tightened, shell  18  may have a tendency to rotate with stem  16  and in response a wrench may be applied to tool portion  52  of shell  18  to avoid unwarranted twisting of shell  18  and hose  12  which may compromise hose assembly  14 . Shell  18  includes a bell-shaped outer surface  54  and a toothed or barbed inner portion  56 . Inner portion  56  includes barbs  58 ,  60  and  62  that respectively align and are centered within grooves  38 ,  40  and  42 . An additional barb or seal barb  63  is located nearest an opening  65  of stem and is arranged to provide an additional seal at the site of the nipple  32  of stem  16  as is described in further detail below. Between barbs  58 - 60 ,  60 - 62  and  62 - 63  are annular wall portions  64  of shell  18 . A sloped end portion  66  of shell  18  is constructed to deform during crimping or swaging of shell  18  in order for barbs  58 ,  60  and  62  to align and center with respect to grooves  38 ,  40  and  42 . In fact, it may be seen—with reference to FIG.  1 —that before the swaging operation, shell  18  has a generally dilated posture, with barbs  58 ,  60  and  62  not aligning with respect to grooves  38 ,  40  and  42 . In contrast—with reference to FIG.  2 —the deformed shell  18  is smaller in diameter and elongated in the “post-swage” condition with barbs  58 ,  60  and  62  being aligned relative to grooves  38 ,  40  and  42 . 
     Referring to  FIG. 1 , hose  12  includes inner wall  68  which is the portion of hose  12  that is exposed to system fluid when hose assembly  14  ( FIG. 2 ) is in operation. Hose  12  includes liner  70  which is the inner core of hose  12  and is customarily manufactured from a pliable elastomeric material with temperature, pressure and chemical resistant properties contemplated to be compatible with the system fluid and operating conditions. Hose  12  also includes a reinforcement wire layer or “reinforcement wire”  72  comprised of more than one spiral or helically wound layers of wire. The reinforcement wire  72  surrounds and protects the liner  70  and may be manufactured from steel wire, having diameter, d wire  ( FIG. 3 ). Regarding the reinforcement wire  72 , it may be manufactured from alternating helically wound metallic wire layers with each successive layer being positioned at approximately a 54.7 degree angle relative the layer that it overlays. The number of wire layers of reinforcement wire  72  is typically dependent on the system requirements which specify temperature and pressure parameters. For example, a 6000 psi system fitted with a ⅜″ or ½″ diameter hose assembly may require the reinforced hose to include 4 layers of wound wire (as shown) having wire diameter, d wire  of 0.30 mm, for example. Hose  12  also includes a cover layer or “cover”  74  which comprises an inner portion  78  and a thin sheath  76 . Sheath  76  of cover  74  encases inner portion  78  and generally protects hose  12  from abrasion and impact. The inner layer  78  of cover  74  may be manufactured from a suitable flexible elastomeric material and sheath  76  may be manufactured from a high density polyethylene, for example. In an exemplary embodiment, hose  12  could be a hydraulic reinforced hose product manufactured and branded “ToughGuard™” by the assignee of the present application. Alternatively, the present invention hose coupling assembly contemplates compatibility with other suitable reinforced hose alternatives. 
     Coupling assembly  10  may be introduced to hose  12  by hand with little effort and without the need for additional tools, jigs or fixtures. Pilot land  44  of stem  16  is constructed to slightly interfere with an engagement portion  82  of the hose  12  while other portions of stem  16  are clearanced relative to the inside diameter of the hose  12  for ease of assembly and to ensure hose  12  is properly piloted on the coupling assembly  10  in preparation for the swaging operation. Clearance  80  is provided between the inner wall  68  of the hose  12  relative to nipple  32  and first and second lands  34 ,  36  of stem  16  in order for an assembler to mount the hose  12  on stem  16  with minimal effort. 
     Referring to  FIG. 3 , barb  60  will now be described. Barb  60  includes height, h, a base  94  defined by a width, W base  and a tip  90  defined by a tip width, W tip . Barb  60  extends the entire inner perimeter of inner wall  64  of shell  18  and its tip  90  includes first and second annular edges  86 ,  88 . It may be seen that an annular opening  92  is created in cover  74  at the site of base  94  of barb  60  when the coupling assembly  10  undergoes swaging. Opening  92  in sheath  76  of cover  74  was created by tip  90  of barb  60  as it penetrated cover  74  during the swaging process, thus, eliminating the need for removing the cover—a process commonly referred to “skiving” the hose prior to the swaging operation. It is envisioned that barbs  58  and  62  ( FIG. 2 ) are of similar construct and similarly engage hose  12  as has been described relative to barb  60 . 
     Stem  16  includes annular groove  40  having a bottom  100 , first and second walls  102 ,  104  connected to bottom  100  and first and second shoulders  106 ,  108  respectively connecting walls  102 ,  104  to first and second lands  34 ,  36 . First and second walls  102 ,  104  are angled relative to an axially extending datum  105  that extends parallel relative to an axial centerline  107  of stem  16  ( FIG. 2 ). In an exemplary embodiment, second wall  104  may be angled at 45 degrees relative to horizontal datum  105  and first wall  102  may be angled at 135 degrees relative to datum  105 . Alternatively, it is envisioned that walls  102 ,  104  may be oriented from 90 degrees to other generally obtuse angles so as not to significantly affect sealing performance of the hose assembly  14 . The width of groove  40  may be defined as W groove  and is measured axially along stem  16  from the intersection of land  34  and first shoulder  106  to the intersection of land  36  and second shoulder  108 . The depth, d of groove  40  may be measured along axial centerline  107  ( FIG. 2 ) at the center of stem  16  beginning from horizontal datum  105  measuring axially to first land  34 . Grooves  38  and  42  ( FIG. 2 ) are of similar construct as has been described relative to groove  40 . 
     Referring now to  FIG. 2 , it may be seen that each barb  58 ,  60  and  62  is generally centered relative to its respective groove  38 ,  40  and  42  and each is sized and spaced at a distance, S, from adjacent barb to create a controlled deflection and resultant seal force in the reinforcement wire  72  as will be described in further detail below. In contrast, the seal barb  63  includes a height, h s , width, W sbase , and tip width, W stip  and lacks a corresponding groove as compared to barbs  58 ,  60  and  62 . 
     Referring to  FIG. 5 , the controlled deflection of reinforcement wire  72  and resultant seal force imparted on liner  70  will now be described. It may be seen that after shell  18  is permanently deformed through the swaging process, compression regions  110  and  111  develop in reinforcement wire  72  in the vicinity of first and second edges  86 ,  88  of barb  60  corresponding to the reinforcement wire  72  being slightly deformed annularly along two distinct perimeters, first engagement portion  96  and second engagement portion  98  of reinforcement wire  72 . In fact, as best seen in  FIG. 4  depicting a disassembled and sectioned shell  18  that had undergone swaging, permanent deformation is observed in edges  86 ,  88  of barb  60  as a result of engagement of barb tip  90  with engagement portions  96 ,  98  of wire  72 . In contrast, little if any deformation occurred along a center portion  99  of barb tip  90  ( FIG. 4 ), meaning the force transferred by the barb  60  after shell  18  has been swaged was through two edges  86 ,  88  of barb  60  to form two annular seals between liner  70  and stem  16  (as is described in detail below) and not through a single center portion  99  ( FIG. 4 ) of barb as is the case with prior art hose assemblies. 
     Referring again to  FIG. 5 , reinforcement wire  72  includes first and second deflection regions  112 ,  114  which correspond to portions of the reinforcement wire that are located outside of and adjacent compression regions  110 ,  111 . The deflection of reinforcement wire  72  within deflection regions  112 ,  114  generates localized loading  120 ,  122  acting along two annularly positioned bands  124  and  126  in the liner  70  at a position in the liner  70  in the vicinity of first and second shoulders  106 ,  108  of stem  16 . The loads  120 ,  122  generated by the reinforcement wire  72  act to compress the liner  70  in the regions  124 ,  126  of liner  70  which, in turn, compresses the liner  70  in the vicinity of shoulders  106 ,  108  to provide a resilient seal between liner  70  and stem  16 . Located adjacent deflection regions  112 ,  114  in reinforcement wire  72  are cantilevered regions  116 ,  118  that respectively cantilever or extend beyond shoulders  106 ,  108  of groove  40  within stem  16 . By allowing the reinforcement wire to cantilever significantly beyond the shoulders  106 ,  108  of groove  40  through control of barb distance, S, the deflection in deflection regions  112 ,  114  is preserved and, in turn, the loads  120 ,  122  generated by the deflecting reinforcement wire are not negatively impacted by adjacent barbs. It is envisioned that barbs  58  and  62  ( FIG. 2 ) and corresponding grooves  38  and  42  within stem  16  are of similar construct and similarly engage reinforcement wire  72  and liner  70  of hose  12  to form seals between liner  70  and stem  16  as has been described relative to barb  60  and its corresponding groove  40 . 
     INDUSTRIAL APPLICABILITY 
     Referring to  FIG. 1 , to assemble coupling assembly  10  with hose  12  to form hose assembly  14  ( FIG. 2 ) an assembler may grasp and advance hose  12  in order for end  46  of hose  12  to engage nipple  32  of stem  16  until end  46  of hose  12  abuts stop  45  on stem  16 . The slight interference fit between pilot land  44  and engagement portion  82  of flexible hose  12 , during this step, may be easily managed by hand and preferably without the need for tools or jigs. The pilot land  44  acts to ensure accurate placement and positioning of hose  12  relative to coupling assembly  10  in preparation for the swaging operation. The swaging operation may be accomplished by placing the aforesaid coupling assembly  10  and hose  12  combination in a suitable die  142  ( FIG. 7 ) within a hydraulic crimping apparatus  128  ( FIG. 7 ) to create a suitable swage diameter, D shell  of shell  18  ( FIG. 2 ) from a range of acceptable swage diameters (see Tables 3 and 4). Although various press and die products are commercially available, an exemplary press and die combination, such as a Crimputer II, Version 5 with appropriate dies is commercially available from the assignee of the present application and is suited to swage shell  18  to stem  16  to form coupling assembly  10 . It will be appreciated by those with skill in the art of coupling manufacture that the present invention enables a range of values for D shell  to be developed for each nominal size and type of coupling assembly  10 . Further, it should be understood that prior to the swaging operation, the outer features (D shell ) for each shell for each size coupling will vary requiring post-swage ranges for these outer features to be empirically developed for each specific coupling assembly. 
     Referring to  FIG. 5 , in operation, it may be seen that after shell  18  is permanently deformed through the swaging process, compression regions  110  and  111  develop in reinforcement wire  72  in the vicinity of first and second edges  86 ,  88  of barb  60  corresponding to the reinforcement wire  72  being slightly deformed annularly along two distinct perimeters, first engagement portion  96  and second engagement portion  98  of reinforcement wire  72 . Reinforcement wire  72  includes first and second deflection regions  112 ,  114  which correspond to portions of the reinforcement wire  72  that are located adjacent compression regions  110 ,  111 . The deflection of reinforcement wire  72  within deflection regions  112 ,  114  generates localized loading  120 ,  122  acting along two annularly positioned bands  124  and  126  in the liner  70  at a position in the liner  70  in the vicinity of first and second shoulders  106 ,  108  of stem  16 . The loads  120 ,  122  generated by the reinforcement wire  72  act to compress the liner  70  in the regions  124 ,  126  of liner  70  which, in turn, compresses the liner  70  in the vicinity of shoulders  106 ,  108  to provide a sustainable seal between liner  70  and stem  16 . Located adjacent deflection regions  112 ,  114  in reinforcement wire  72  are cantilevered regions  116 ,  118  that respectively cantilever or extend beyond shoulders  106 ,  108  of groove  40  within stem  16 . By allowing the reinforcement wire to cantilever significantly beyond the shoulders  106 ,  108  of groove  40  through control of barb distance, S ( FIG. 2 ), the deflection in deflection regions  112 ,  114  is preserved and, in turn, the loads  120 ,  122  generated by the deflecting reinforcement wire  72  are not negatively impacted by deformed reinforcement wire  72  associated with adjacent barbs  58 ,  62 . 
     It will be understood that the loads generated by reinforcement wire  72  at cantilevered positions −X and +X which correspond to locations  116 ,  118  within reinforcement wire  72  are relatively smaller than the loads  120 ,  122  generated at deflection points  112 ,  114  corresponding to positions in reinforcement wire  72  located overlaying shoulders  106 ,  108  of stem  16 . Similarly, the load generated by reinforcement wire  72  at compression location X 0  is relatively smaller than the loads generated at deflection points  112 ,  114  corresponding to positions in reinforcement wire  72  located overlaying shoulders  106 ,  108  of stem  16 . Therefore, loads  120 ,  122  generated by the reinforcement wire  72  in deflection locations  112 ,  114  act to compress the liner  70  in the circumferential regions  124 ,  126  of liner  70  which, in turn, compresses the liner  70  in the vicinity of shoulders  106 ,  108  to provide two distinct annular sealing bands between liner  70  and stem  16 . In so doing, the barbs  56 ,  58  and  60  and corresponding shoulders  106 ,  108  of respective grooves  38 ,  40  and  42  are sized to promote the proper degree of deflection in reinforcement wire  72  to cause liner  70  to be resiliently compressed by the reinforcement wire  72  along a pair of annular bands  124 ,  126  of liner  70  as opposed to prior art hose assemblies which often over-compress the liner at the barb tip resulting in leakage and shortened life of the hose assembly. 
     Referring now to  FIG. 6 , performance results for several variations of ⅜ and ½ inch nominal hose assemblies will be described. Impulse, leakage and bursts tests, according to Society of Automotive Engineering (SAE) Standard J343, were conducted for coupling assemblies constructed according to the present invention and were swaged in combination with a “XT” series hose, manufactured by Caterpillar Inc., to form the hose assembly test specimens. The test specimen hose assemblies are each identified by the letters “XN” however the nomenclature that proceeds these letters signifies the particular XT hose type as is set forth in  FIG. 6 . Each tested ⅜″ and ½″ hose assembly is shown in  FIG. 6  and described as follows: (1) XN6 ES (6000 psi XT hose with no sheath), (2) XN6 ES ToughGuard (6000 psi XT hose with sheath), (3) XN3 ES (4000 psi XT hose with no sheath), and (4) XN3 ES ToughGuard (4000 psi XT hose with sheath). 
     Regarding the XN6 ES hose assembly using an XT6 ES hose for use with the ⅜″ coupling assemblies, twenty-four hose assemblies in total were tested and of these, sixteen hose assemblies having the swage or crimp diameters for shell  18  (D shell ,  FIG. 2 ) of 24.75, 24.50 and 24.25 millimeter (mm) passed all three tests. The hose assemblies that had the smallest and largest crimp diameters (25.00 mm and 24.00 mm) failed the impulse test, however passed both the burst and leakage tests. It will be understood that a range of acceptable crimp diameters termed the “core crimp range” may include only those hose assemblies that passed all three tests or passed leakage and burst tests and experienced an impulse test failure after an extensive number of cycles. For example, a failure inside the core crimp range is allowable if the sample completes at least 800 k cycles (80% of requirement) and the average of all the samples in the core crimp range is at least 1 million cycles (pass/fail requirement). 
     In summary, based on the test data, the acceptable range of crimp diameters or core crimp range for the XN6 ES hose assembly using the XT ES hose may be identified as 24.75 mm-24.25 mm diameters. It is suggested that a statistically adequate number of tests be executed for each crimp diameter for each hose assembly to ensure the repeatability and integrity of the data. Similar results for the remaining ⅜ inch hose assemblies  10  according to the present invention are shown in  FIG. 6 . It may be seen that although the hose type varied for each ⅜ inch hose assembly the coupling assemblies were substantially similar with the specific coupling assembly dimensions provided by Table 1 below. 
     Regarding the XN6 ES hose assembly using the XT6 ES hose for use with the ½″ coupling assemblies, it may be seen that eight hose assemblies in total were tested and the specific couplings having the swage or crimp diameters for shell  18  (D shell ,  FIG. 2 ) of 29.00, 28.75, 28.50, 28.25 and 28.00 millimeter (mm) passed all three tests and were therefore considered candidates as core crimp range diameters. 
     In summary, based on the test data, the acceptable range of crimp diameters or core crimp range relating to the several ½ inch hose assemblies may be identified as 29.00 mm-28.00 mm. It is suggested that a statistically adequate number of tests be executed for each crimp diameter for each hose assembly to ensure the repeatability and integrity of the data. Similar results for the remaining ½ inch coupling assemblies  10  according to the present invention are shown in  FIG. 6 . It may be seen that although the hose type varied for each ½ inch hose assembly the coupling assemblies were substantially similar with the specific coupling assembly dimensions provided by Table 2 below. 
     The following tables provide exemplary information related to shell and stem dimensions for certain nominal size coupling assemblies. 
     
       
         
           
               
               
               
               
             
               
                 TABLE 1 
               
               
                   
               
               
                 Coupling 
                   
                   
                   
               
               
                 Size 
                   
                 Dimension 
                 Dimension 
               
               
                 (inch) 
                 Shell and Stem Element 
                 (mm) 
                 Range (mm) 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
               
               
            
               
                 ⅜ 
                 Barb width @ base (W base ) 
                 2.39 
                 2.52-2.26 
               
               
                   
                 Barb width @ tip (W tip ) 
                 0.71 
                 0.84-0.58 
               
               
                   
                 Height of barb (h) 
                 3.05 
                 3.18-2.92 
               
               
                   
                 Seal barb width @ tip (W stip ) 
                 1.17 
                 1.30-1.04 
               
               
                   
                 Height of seal barb (h s ) 
                 2.67 
                 2.80-2.54 
               
               
                   
                 Spacing of barbs (S) 
                 7.21 
                 7.34-7.08 
               
               
                   
                 I.D. of stem (d stem ) 
                 6.00 
                 6.13-5.87 
               
               
                   
                 O.D. of stem, nipple land (D1) 
                 9.52 
                 9.65-9.39 
               
               
                   
                 O.D. of stem, pilot land (D2) 
                 9.91 
                 10.04-9.78  
               
               
                   
                 Width of stem groove (W groove ) 
                 3.75 
                 3.88-3.62 
               
               
                   
                 Depth of stem groove (d) 
                 0.33 
                 0.46-0.20 
               
               
                   
               
            
           
         
       
     
     
       
         
           
               
               
               
               
             
               
                 TABLE 2 
               
               
                   
               
               
                 Coupling 
                   
                   
                   
               
               
                 Size 
                   
                 Dimension 
                 Dimension 
               
               
                 (inch) 
                 Shell and Stem Element 
                 (mm) 
                 Range (mm) 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
               
               
            
               
                 ½ 
                 Barb width @ base (W base ) 
                 2.49 
                 2.62-2.36 
               
               
                   
                 Barb width @ tip (W tip ) 
                 0.76 
                 0.89-0.63 
               
               
                   
                 Height of barb (h) 
                 3.23 
                 3.36-3.10 
               
               
                   
                 Seal barb width @ tip (W stip ) 
                 1.14 
                 1.27-1.01 
               
               
                   
                 Height of seal barb (h s ) 
                 2.84 
                 2.97-2.71 
               
               
                   
                 Spacing of barbs (S) 
                 7.44 
                 7.57-7.31 
               
               
                   
                 I.D. of stem (d stem ) 
                 8.50 
                 8.63-8.37 
               
               
                   
                 O.D. of stem, nipple land (D1) 
                 12.70 
                 12.83-12.57 
               
               
                   
                 O.D. of stem, pilot land (D2) 
                 13.08 
                 13.21-12.95 
               
               
                   
                 Width of stem groove (W groove ) 
                 3.75 
                 3.88-3.62 
               
               
                   
                 Depth of stem groove (d) 
                 0.33 
                 0.46-0.20 
               
               
                   
               
            
           
         
       
     
     Referring to  FIG. 1 , the crimping of shell  18  to stem  16  to form coupling assembly  10  will now be described. In an exemplary embodiment, both stem  16  and shell  18  are originally separate pieces and the stem may be machined from solid carbon steel bar stock using a computer numerically controlled machine or a screw machine; the shell  18  may be machined from a carbon steel extrusion on a machining center, for example. The inner portion  56  of shell  18 , including barbs  58 ,  60 ,  62  and  63 , may be machined in the same operation as female engagement portion  50  to ensure that shell  18  is substantially concentrically oriented relative to stem  16  in preparation for assembly with hose  12 . Accordingly, the barb features (W base , W tip  h, W sbase , W stip  and h s ), the barb spacing (S), and the stem features (d stem , D1, D2, W groove  and d) may be machined prior to an operation where shell  18  is being permanently fused or joined to stem  16 . The stem and shell may be annealed. For example, if the shell is manufactured from extruded carbon steel stock such as a 1010 or 1010 Ca steel and the stem is manufactured from a 12L14 or 1215 steel then the shell and stem may be annealed at 1900 degrees F. minimum resulting in a Rockwell B hardness reading within the range of 45 to 65 Annealing the stem and shell is necessary in preparation for attaching the stem to the shell and to ensure satisfactory swaging of the completed coupling assembly with hose. It will be understood that the pre-swage stem  16  and shell  18  dimensions may include a common tolerance for a majority of machined aspects of the stem and shell such as ±0.13 mm, for example. 
     Tool portion  52  of shell  18  may be a hexagonal shape in a finished condition to facilitate engagement by a tool (not shown) and be formed from a generally cylindrical shape in a “green condition” prior to the finish operation, through machining or preferably by a die forming operation such as a forging process, for example. Stem  16  and shell  18  may then be fused or permanently joined by a crimping operation by permanently deforming tool portion  52  of shell  18  to stem  16 , using 6 die segments (not shown) in a press (not shown) structured to exert force in a circumferential manner on said dies, for example. Prior to fixing shell  18  with stem  16 , nut  20  may be placed on stem  16 . The tool portion  52  of shell  18  is located in the same vicinity as the joined combination of male and female engagement portions  48 ,  50  to consolidate functional features of shell  18  resulting in an appropriate sized shell  18  and corresponding stem  16  as compared to known coupling assemblies. The fusing of shell with stem may be carried out as taught by US Patent Application No. 2008/0185840, to Menor, filed Feb. 7, 2007 which is assigned to the assignee of the present application and is hereby incorporated herein by reference. The swaging of coupling assembly  10  with hose  12  to create a hose assembly may be carried out as taught by U.S. Pat. No. 5,799,383, issued to Baldwin et al., Sep. 1, 1998 which is assigned to the assignee of the present application and is hereby incorporated herein by reference. 
     The crimping of coupling assembly  10  to hose  12  to form a hose assembly  14 , according to the present invention, will now be described. Referring to  FIG. 7 , a hose assembly crimping apparatus  128  for crimping a coupling assembly  10  on the end of hose  12  includes a clamping machine  130  and a controller  132 . Clamping machine  130  has first and second portions  134 ,  136 . While the following components of clamping machine  130  may be mounted on either first portion  134  or second portion  136 , as shown herein, die fixture  138  is advantageously attached to second portion  136 , a conical-shaped die holder  140  to first portion  134  and a conical-shaped split die  142  is mated to die holder  140 . Hydraulic rams  144 ,  145  driven by hydraulic motor  146  are connected to first and second portions  134 ,  136  and cause second portion  136  to move relative to first portion  134  in response to operator input at hydraulic ram control valve  148 . Die  142  and die holder  140  move vertically in response to the clamping or releasing movement of die fixture  138  through portions  134 ,  136  while die  142  moves also horizontally inside die holder  140  upon being compressed or uncompressed by die fixture  138 . 
     A first measuring device  150 , such as a linear potentiometer, is attached to second portion  136  of clamping machine  130  and electronically connected to controller  132 . However, first measuring device  150  could be mounted on first portion  134  of clamping machine  130  if desired. First measuring device  150  delivers a signal to controller  132  representative of the linear distance between first and second portions  134 ,  136  of clamping machine  130 . Controller  132  stops the relative movement between portions  134 ,  136  in response to a signal from first measuring device  150  once the signal reaches a predetermined setting corresponding to a particular hose  12  type and size. A second measuring device  152 , such as a digital caliper as is well known in the industry, is operatively connected to controller  132  and reports measured diameters of crimped coupling assemblies  10  thereto, as is later described. Controller  132  compares the measured diameters to a database of predetermined nominal connector diameters and calculates a differential magnitude. If the differential magnitude is out-of-tolerance (e.g., not within the range provided by Table 3 for a ⅜″ coupling), controller  132  adjusts the relative movement of first and second portions  134 ,  136  according to the die  142  type and the hose  12  size and type. A foot pedal device  154  signals the controller  132  to record an output from second measuring device  152 . Controller  132  has a menu-driven set of operator communications, as is customary, for simplifying the crimping process. 
     Again, referring to  FIG. 7 , an operator of crimping apparatus  128  may be prompted by a user interface (not shown) as part of controller  132  to commence a crimping operation. The operator may then select from a menu of hose types and sizes. The operator may then be instructed to install a particular die  142  into die holder  140  being based upon the selection. The operator then calibrates the relative vertical positions of first and second portions  134 ,  136  of clamping machine  130  by lowering second portion  136  until die fixture  138  seats upon first portion  134  and die holder  140 . 
     After raising second portion  136  the operator installs a particular die or die group  142  into die holder  140  based upon the hose  12  type and size. The operator next inserts hose  12  and coupling assembly  10  into die group  142 . The operator lowers second portion  136  of clamping machine  130  by moving lever (not shown) to activate hydraulic ram control valve  148 . The lowering of second portion  136  is stopped by controller  132  at a predetermined setting, which is a function of type and size of hose  12 . Since the diameter, D shell  ( FIG. 2 ) of shell  18  is derived—accessed via the controller&#39;s memory—once the linear distance of the die fixture  138  is measured during the crimping operation, the compressing of D shell  to the final diameter may be stopped in response to a signal from the linear potentiometer  150  which is operatively connected to the controller  132 . It is envisioned that second measuring device  152  may be an electronic caliper and be incorporated into crimping apparatus  128  as may be contemplated by those of ordinary skill; perhaps embedded into first portion  136  of clamping machine  130  to take direct electronic measurements of crimped shell diameter D shell  and communicate the same to controller  132 . Yet another alternative may be to manually apply electronic caliper  152  to measure shell diameter and communicate (e.g., key-in) the same to controller for the purpose of verifying that shell diameter, D shell , is within a prescribed range, examples of which may be seen in Tables 3 and 4. It will be understood that the present invention provides a coupling assembly construct and associated manufacturing method that provides a range of acceptable shell diameters for ease of manufacture and assembly and to reduce incidences of scrap. 
     The operator then raises second portion  136  of clamping machine  130  and removes hose assembly  14  consisting of coupling assembly  10  permanently fixed with hose  12 . Prior to removing finished hose assembly  14 , operator may be prompted by controller  132  to measure the crimped coupling assembly  10 . If operator chooses “no”, controller  132  may then prompt operator to decide whether another coupling assembly  10  and hose  12  pair of identical size and type is to be crimped. 
     If the operator answers “yes” to measure the crimped coupling assembly  10  of the hose assembly  14  the operator may be prompted by controller  132  to decide whether the crimped measurements should be recorded by measuring device  152  such as a digital or electronic caliper, for example. If the operator answers “yes”, the controller may initiate measuring sequence by calibrating the digital caliper  152 . Calibration is performed by adjusting the digital caliper  152  to read “zero” when closed. Measurements may be manually taken with digital caliper  152  at D shell  and then input by operator into the controller  132 . Alternatively, crimping apparatus  128  may have digital caliper  152  or any alternative measuring device with electronic output incorporated into crimping apparatus  128 . Measurements are taken from the outer diameter, D shell , of crimped shell  18  of coupling assembly  10  and communicated to controller  132 . More than one measurement may be taken, such as four, and then averaged to calculate the final value of the crimped shell  18 . The controller  132  may then present this value through an electronic output of controller, as is customary, for operator to acknowledge. The measurements are then entered into the controller  132  and stored in memory as is customary for comparison with acceptable predetermined values within acceptable ranges as set forth in Tables 3 and 4, for example. 
     The operator may then be notified by the controller  132  whether the crimped value is within the predetermined acceptable range. If the crimp value is not within an acceptable range the controller  132  initiates adjustment of vertical travel of second portion  136  of clamping machine  130  in accordance with predetermined nominal diameter relationships programmed into the memory of controller  132  and corresponding to particular dies  142  and hose  12  types and sizes to maintain the crimped diameters within the acceptable predetermined range. 
     In summary, coupling assembly  10  is crimped onto the end of hose  12  and the diameter, D shell  of crimped coupling assembly  10  is automatically maintained within the acceptable range. This is done by inputting controller  132  of hose assembly crimping apparatus  128  with the relative limit distance between first and second portions  134 ,  136  of the clamping machine  130 ; assembling coupling assembly  10  and end of hose  12  in the conical-shaped die  142  of the clamping machine  130  in preparation for crimping; and operating the clamping machine  130  so that the first and second portions  134 ,  136  move towards each other thereby compressing the conical-shaped die  142 , the compressing action being stopped in response to a signal from the linear potentiometer  150  which is operatively connected to the controller  132 . 
     The following tables provide exemplary information related to post swage shell dimensions D shell  for certain nominal size hose assemblies. 
     
       
         
           
               
               
               
               
             
               
                 TABLE 3 
               
               
                   
               
               
                 Hose Assembly 
                   
                 Dimension 
                 Dimension 
               
               
                 Size (inch) 
                 Shell Element 
                 (mm) 
                 Range (mm) 
               
               
                   
               
             
            
               
                 ⅜ 
                 Post swage diameter of shell 
                 24.50 
                 24.75-24.25 
               
               
                   
                 (D shell ) 
               
               
                   
               
            
           
         
       
     
     
       
         
           
               
               
               
               
             
               
                 TABLE 4 
               
               
                   
               
               
                 Hose Assembly 
                   
                 Dimension 
                 Dimension 
               
               
                 Size (inch) 
                 Shell Element 
                 (mm) 
                 Range (mm) 
               
               
                   
               
             
            
               
                 ½ 
                 Post swage diameter of shell 
                 28.50 
                 29.00-28.00 
               
               
                   
                 (D shell ) 
               
               
                   
               
            
           
         
       
     
     It should be understood that the above description is intended for illustrative purposes only, and is not intended to limit the scope of the present invention in any way. Thus, those skilled in the art will appreciate that other aspects of the invention can be obtained from a study of the drawings, the disclosure and the appended claims.