Alternate Stapleless Coupler

Stapleless Coupler Development
Gary Nauer
April 2013
Acknowledgements
2
Evolution of Stapleless Coupler
Stecko
Hard Square
section staple
1946 to date
3
‘D’ section Staple
Ductile ‘D’ section
+ 2007 / legacy
Stapleless coupler
2010 & future
HISTORY
Post Second World War
Hydraulics used in mines for control systems
1946 Kelle Patents first Staple based on 12 Mpa (1750 psi)
1950’s – 1970’s
Development of low seam Longwall type mining, using 6 leg supports (manually actruated)
Staple technology (Stecko) adopted in longwalls
1970’s – 1990’s
Roof support designs improved to 4 & 2 leg shields
1979 Greenwalt Patents ‘D’ section staple
Hydraulic pressure increased from 20 Mpa (3000 psi) to 35 Mpa (5000 psi)
1988 Hinksman Patents ‘Super Stecko’
In-bye Pantec / main gate drives increase pump flow requirements
Guaranteed set at 42 Mpa (6000 psi)
1990’s to date
Electro- hydraulic controls / actuation (significant duty cycle increase)
Out-bye pump stations + Monorails (increased flow)
Yield valve pressures raised to 52 Mpa (7500 psi)
DN63, 35 Mpa (5000 psi) Monorail supply
LASC - Longwall automation - further increases duty cycle of components
195
Incidents High Pressure Hydraulics
2007 to 2012 in NSW
98 (49%) Longwall incidents
2007 to 2012 in NSW
6
Standards & Standardization
Nominated
Working
Pressure
(bar)
STANDARDS
DN
A
± 0.5
B
± 1.0
C
± 0.5
D
+0.5
-0.0
E
+0.5
-0.0
F
+1.0
-0.0
G
SQUARE
G
WIRE Ø
H
± 0.25
a
θ
ref.
BS 6537
SQUARE SPRING
10
38
19
14
12.5
22.9
3
3.93
4.07
NA
4
10º
8º
380
10
41
26
14
13
25
3
3.93
4.07
NA
2.5
15º
20º
380
NA
20º
10º
380
BS 6537
SQUARE S/S
BS 6537
ROUND S/S
SAE J1467
NCB 638
DIN 20043
10
37
18
14
11.8
24.2
3
NA
4.78
4.72
DN
A
± 0.5
B
± 1.0
C
± 0.5
D
+0.5
-0.0
E
+0.5
-0.0
F
+1.0
-0.0
G
SQUARE
G
WIRE Ø
H
± 0.25
a
θ
ref.
10
NA
NA
NA
NA
NA
NA
4.07
3.93
4.78
4.72
NA
NA
NA
DN
A
B
± .25
ØC
D
E
F
± 1.0
- 0.0
G
SQUARE
G
WIRE Ø
H
a
θ
ref.
10
37
18
14.13
13.87
12.30
11.80
24.7
24.2
3
NA
4.78
4.72
NA
20º
10º
DN
A
+ 0,2
- 0.0
B
+ 1.0
- 0.0
C
D
± 0,5
E
± 0.2
F
MIN
G
SQUARE
G
WIRE Ø
H
± 0.25
a
θ
ref.
10
38
26
14
12.5
22.9
3
4
NA
-
NA
NA
TOLERANCES ARE
DIFFERENT FROM NCB 638 &
DIN 20043
TOLERANCES ARE
DIFFERENT FROM NCB 638 &
DIN 20043
TOLERANCES ARE
DIFFERENT FROM BS 6537,
SAE J1467 & DIN 20043
280
TOLERANCES ARE
DIFFERENT FROM BS 6537,
SAE J1467 & NCB 638
530
Known Staple limitations
FEA & FMEA
Deformation
8
FOS
Staple fatigue test
Staple fatigue test conclusion
• Stainless steel (420) staples best results
• ‘D’ profile most successful Staple
• DN20 least successful <50k cycles
• DIN20043 & BS 6537 male & female
are inter-changeable, but neither standard
adequate for staple demands at current
operating requirements
Stecko pressure ratings
Stecko with 'D' Staple
Stecko
Din
Dash
Pressur
e
Din
Dash
Super Stecko
SUPER Stecko with 'D' Staple
Pressure
Impulse
Din
Size
Pressure
Cycles
Cycles
4
450
6
4
450
10
6
400
10
6
420
12
8
362
12
8
20
12
280
20
25
16
280
32
20
40
50
Pressure
Size
Rating
(bar)
6
Dash
Impulse
Size
Rating
(bar)
Din
Impulse
Size
Rating
Dash
Impulse
Cycles
Rating
(bar)
Cycles
(bar)
6
6
200,000
10
10
420
250,000
12
8
518
12
8
518
12
350
1,000,000
20
12
420
20
12
420
25
16
350
25
16
380
25
16
420
1,000,000
210
32
20
350
32
20
350
1,000,000
32
20
420
1,000,000
24
210
40
24
350
40
24
350
750,000
40
24
420
1,000,000
32
170
50
32
210
50
32
350
500,000
50
32
420
1,000,000
65
65
per ISO
7751
per ISO
6803
65
per ISO
7751
per ISO
6803
65
per ISO
7751
per ISO
6803
per ISO
per ISO 6803
7751
Do’s + Don’ts for Staples
Based on metallurgical evaluation
Do’s
• Understand cyclical demand
• Use staples once ONLY
• Obtain material Certificate of Conformance
Don’ts
•
•
•
•
•
Hardness >40 HRC
Electroplated (Hydrogen embrittlement)
304 Stainless (sulphur resistance)
Barbed legs (broaching female)
Identification stamped on legs
42 MPa ‘D’ Staple standard
PROPOSED ISO SUBMISSION
Based on DIN 20043 / SAE 1467 / NCB 638 / BS 6537
420 bar Staple-lok fittings for hydraulic power-transmission circuits, primarily used in
mining applications.
Forward:
This proposed standard applies to staple-lok fittings and adaptors, which are used to
connect hydraulic fluid based systems. The proposed standard seeks to clarify
minimum material and dimensional requirements for a 420 bar connection,
whilst maintaining a 4:1 factor of safety.
The proposed standard defines
minimum working pressure of the assembled fitting (including its staple)
relevant testing and conformance standards
arrangement of components & their individual dimensions
material specifications for the components
corrosion resistance of metal components
identification
minimum burst pressure
impulse requirements of the assembled fitting
Section 1/. Minimum working pressure
Table 1 Minimum working pressure of the assembled staple-lok fitting
based on 4:1 FOS per ISO 7751
‘D’ Section
staple
ACARP validation
ACARP funded evaluations have taken place over past 5 years to review causes and to clarify key failure modes
relating to longwall hydraulic components.
ACARP C17020 The aim of this project was to address the following important issues/gaps of knowledge identified in
the previous project:
a) Hydraulic hose assembly duty:
- establish effective fatigue life of hoses for selected longwall hose assemblies based on representative pressure history
data; and
- identify possible design improvements to LW hydraulic circuits/components to reduce any extreme loading conditions
identified.
b) Life cycle management strategies - develop fit-for-purpose specifications and selection criteria for hose assemblies.
The key objectives are:
- determine the extent of deterioration, in-service life and safety factors for a sample of aged hoses;
- verify the compliance of selected new and used/aged hoses with the applied safety and fatigue (design life)
requirements, based on in-service pressure profiles data; and
- determine the adequacy of current hose assembly burst and endurance tests pre-qualification criteria, which are
considered as some of the most important parameters used in hose performance specification.
ACARP C19011 This report documents the outcomes of testing aiming to scientifically establish the
fatigue performance characteristics of DN20 square section spring steel staples.
The testing demonstrated that hydraulic function can be maintained well beyond the point of
fatigue “failure”, but it is recommended for longwall operators to implement staple
replacement programs limiting DN20 spring steel square section staple usage beyond
2,750 cycles.
Step change required
15
Known Staple alternatives Showing area engaged
Typ. Staple lock
3 pin & Garter
16
SSKV
Crocbite / Coalmaxx
Clip-lok
UPTC
HPK
Clip-Lok Coupler
The coupling consists of four main
parts: female end (1), male end (2)
and Clip-lok (3) dust boot (4)
4
2
PUSH TO CONNECT
The female/male end provides
a hose connection, while the
male/female end connects to a
manifold or hose assembly.
The two ends are retained by
a
Clip-Lok (3) which
allows the assembly to align
with mating part & eliminate
hose twist.
1
3
UPTC Stapleless coupler
18
SSKV by Prange
Click Link
Longwall installation using Stapleless
coupler + Piping
Mono Rail Installation
InterChock and Within Roof Support
Polyflex HPK coupler
HPK Stapleless coupler
•
•
•
•
•
•
•
Easy & Fast connection
Integrally safe
No threads or tools required
DN10 to DN50, 560 bar rated to 1,000,000 cycles
4:1 FOS
Corrosion resistant
Port & adaptor options
HPK Hose Tail Detail
utilized Std Stecko Orings and Backups
HPK Stapleless coupler
Longwall Mining market focused
Market Potential (OEM & MRO) + Large
bore hose assembly implications
Replacing SteckO staple technology
Adapted Polyflex HPK patent
DN10 & DN50 tested to 1 million cycles
Excellent market support
(previewed Oct 22, 2012)
Cost competitive
DN50 HPK coupler test
HPK Stapleless Port Adaptor Detail
Fluid power
management is
more than just
another standard !
29
Thank You!