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Eight quick ways to incorporate couplings

Aug. 9, 2007
Quick-acting couplings provide a fast, convenient way to repeatedly connect and disconnect fluid lines.

More than a dozen common designs of quick-acting couplings exist. Here is a brief look at eight of the most popular locking mechanisms used in fluid power applications.
Regardless of the manufacturer, all quick-acting couplings have some elements in common. All have two parts: a plug and a socket. The plug is the male half and the socket is the female half. When connected properly, these parts seal and lock the joint effectively to contain internal pressures and resist any tensile forces that tend to pull the joint apart. The parts are easily disconnected without tools by disengaging a locking mechanism and separating parts.

1. Ball-lock is the most common design and has the widest range of applications. A group of balls is positioned in holes located around the ID of the socket body. These holes normally are tapered or stepped to reduce their diameter atthe socket body ID, so the balls do not fall into the cavity vacated by the plug when the coupling is disconnected. A spring-loaded sleeve around the socket body's OD forces balls toward the socket body ID. To connect the plug, the sleeve is pushed back, which opens clearance so the balls are free to move outward. Once the plug is in place, releasing the sleeve forces the balls inward against a locking groove on the OD of the plug. To disconnect, pushing the sleeve back provides the balls with clearance to move outward and allow the plug to be removed.
2. Flat-face, no-spill couplings have a poppet-style shutoff valve on each mating half. Most limit leakage during uncoupling to only a film of oil on the coupling's mating surfaces and prevent air ingression during coupling. They are also designed for minimum flow restriction, which minimizes pressure drop during equipment operation.
3. Pin-lock couplings allow push-to-connect joining using only one hand because the outer sleeve does not need to be retracted to make aconnection. In this design, pins are mounted aroundthe socket body ID in a truncated-cone-shaped formation. Pushing the pluginto the socket moves pins back and outward, due toa ramp on the plug. Shear across pins locks the plug into the socket. Retracting the springloaded sleeve, which forces the pins back out of the locking groove, releases the plug from the socket.

4. Roller-lock couplings use locking rollers or pins spaced end-to-end in grooves or slots around the socket's ID. As the plug is inserted, a ramp on the plug OD pushes the rollers outward. Once the plug is inserted the prescribed distance, the rollers slip into a retention groove on the plug's OD. Retracting the locking sleeve, which allows the ramp on the plug OD to move the rollers outward, releases the plug.

5. Bayonet couplings rely on the familiar twist locking arrangement and are widely used in a variety of applications, especially in plastic couplings for lighter-duty pneumatic equipment. To join the coupling halves, lugs on the OD of the plug engage slots in the socket sleeve as the plug is pushed into the socket. A quick turn locks the lugs into position. Turning the plug in the opposite direction allows the halves to be pulled apart.

6. Ring-lock couplings use a split ring seated in a groove and slot in the socket. Pushing the plug into position causes a ramp on the plug to spread the ring apart at the split until the ring snaps closed behind a retention shoulder on the plug. Rotating an external sleeve expands the ring, thus releasing it from the retention shoulder so the halves can be pulled apart. This design provides maximum flow in a small envelope for normal shop air applications. A variation of this design uses jaws instead of a split ring to lock the parts together.

7. Cam-lock couplings lock the socket to the plug when two external levers are folded back against the sides of the socket. These are most common in larger sizes and generally require more spaces than comparable couplings of the same size. Moreover, the locking mechanism can wear if lines are connected or disconnected frequently, which can allow leakage.

8. Multi-tube connectors are the fluid equivalent to electrical Cannon-style connectors. They quickly and easily connect or disconnect several tubing lines, while maintaining a correct line orientation and discrete flow paths during reconnection.

 Photos courtesy of Hansen Couplings Div. of Eaton Hydraulics Group.

Where should quick-acting couplings be used?
If a hose or tube in a fluid power system will be connected and disconnected more frequently than once a week, then chances are a quick-acting coupling will pay for itself rapidly by improving productivity. The more frequently hoses must be connected and disconnected, the more valuable quick-acting couplings become. They also become more critical as machine productivity increases.

One common application is in assembly workstations, where a worker may have to rapidly switch from impact wrench to drill to riveter. With one quick-acting coupling half on every tool and the mating half on the air line, tool changing is accomplished in seconds. Without the couplings, separate air lines would be needed for each tool; the mass of tools and lines would clutter the workstation and could slow down production.

On hydraulic test stands, quick-acting couplings eliminate bottlenecks by slashing the time required to test each assembly. Just a quick push/pull, and the assembly is ready to test. In contrast, testing time would skyrocket if technicians had to tap into systems using fittings and a wrench for each test procedure.

Selection considerations
Before selecting a coupling, questions must be answered regarding its expected performance. These questions focus not only on the coupling, but the fluid medium as well. For example, what fluid will flow through the coupling? Characteristics of the fluid — viscosity, corrosivity, etc. — will influence the type of coupling that should be used. Other questions concerning the fluid deal with temperature (high, low, or wide variation), pressure, and flow rate.

Knowing details on the fluid, questions must be answered about the coupling's construction. How often will the coupling be connected and disconnected? What type and diameter of hose or tubing will be used to contain the fluid? Will the coupling or hose be subjected to abuse such as impact from falling objects, severe vibration, or contamination from the environment?

Once these questions have been answered, a preliminary selection of coupling type can be made: one, two, or no shutoff valves, and the type of connect/disconnect mechanism. Keep in mind that one style may offer the greatest convenience in service, but a different model's lower pressure loss may be more desirable for the application.

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