Fundamentals of quick-acting couplings

Jan 1, 2012A staff report | Hydraulics & Pneumatics

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

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. Although simple in concept, many quick-acting couplings
are precisely engineered for specific fluid applications. Their widespread use over many
years has yielded a diverse variety of designs to serve not only specific, but general
industrial applications as well. Consequently, uncertainty can arise as to whether a specific
deign is best for a given application.

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.

Where they're used

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.

Valve arrangements

Among the many different designs of quick-acting couplings, either of tow types are used for
an application. Unvalved types have the advantage of low pressure loss through the
coupling, but make no provision to prevent fluid from escaping once the coupling is
disconnected. However, if pressure drop in the system must be held to a minimum, and
fluid draining from disconnected hoses can be tolerated, unvalved couplings would likely be
a designer's first choice.

Obviously, a coupling that does not leak when disconnected would be preferred for probably
all applications - all other factors being equal. Incorporating a shutoff valve into one or both
halves of the coupling allows fluid to flow through the coupling only when both halves are
connected. When the coupling is disconnected, a mechanical link between the coupling
halves is broken and causes the valve to close, blocking flow.

When only one coupling half is valved, it usually is located on the source (upstream) end of
the joint. Pneumatic systems generally employ this setup: the valved coupling half prevents
air loss from the system while the joint is disconnected, the unvalved coupling half allowed
downstream air to bleed off.

In hydraulic applications, both coupling halves often are valved. This practice not only
minimizes fluid leakage, but also limits the amount of air, dirt, and water that can enter the
system. When a coupling is disconnected, air can become trapped between valves and enter
the system when the joint is reconnected. So if the hydraulic system cannot tolerate air
inclusion, special provisions may be necessary to exclude air. To address these concerns,
many manufacturers now offer flat-faced couplings that reduce fluid spillage to a drop or
less every time the coupling is disconnected. Futhermore, mating surfaces of each coupling
half are flush when the coupling is disconnected. This minimizes air ingression and wiping
the mating surfaces clean before reconnecting them.

Valve considerations

While these valved designs offer the convenience of controlled fluid loss, there are tradeoffs.
First of all, valved couplings can generate a significantly higher pressure drop than unvalved
designs. The amount of this loss depends on the coupling size and design. Pressure drop can
be reduced somewhat by oversizing the coupling. There also may be some deviation in
pressure drop from one coupling design to another. If pressure drop is a concern, be sure to
check manufacturer's literature for appropriate data.

Other drawbacks to valved couplings include larger size and higher cost. The cost
differential will vary according to size and individual design. Generally, couplings designed
for low pressure drop, no fluid leakage, and no air entrapment carry a higher price tag.
However, manufacturers point out that the price differential is offset by higher productivity
gained by not having to clean up fluid spills.

Coupling types

There are over a dozen common designs of quick-acting couplings. This article covers the six
most popular locking mechanisms for fluid power applications.

Figure 1. Ball-lock couplings are the most popular quick-acting coupling in use today and are offered by many
manufacturers.

Ball-lock, Figure 1, 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 at the 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.

Figure 2. Roller-lock coupling design positions rollers circumferentially around the ID of the socket to grip the plug.

Roller-lock couplings, Figure 2, 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.
Figure 3. Pin-lock couplings use pins arranged in a truncated-cone formation to grip and hold the plug in the
socket.

Pin-lock couplings, Figure 3, allow push-to-connect joining using only one hand because the outer
sleeve does not need to be retracted to make a connection. In this design, pins are mounted around
the socket body ID in a truncated-cone-shaped formation. Pushing the plug into the socket moves
pins back and outward, due to a 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.

Figure 4. Flat-faced couplings can virtually eliminate spillage by limiting leakage to a drop of fluid or less upon
disconnection. The flat mating surfaces are also easy to keep clean, which prevents contaminating hydraulic fluid
upon reconnection.

Flat-face, no-spill couplings, Figure 4, 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.

Figure 5. A twist of the sleeve secures the plug once it has been inserted into the socket of the bayonet-type
coupling.

Bayonet couplings, Figure 5, 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 couplings 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.
Figure 6. Ring-lock couplings secure by pushing plug into socket; they disconnect by rotating the socket's outer
sleeve.

Ring-lock couplings, Figure 6, 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.

Figure 7. Folding back the levers on the cam-lock coupling secures the socket to the plug.

Cam-lock couplings, Figure 7, 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.
Figure 8. Multi-tube connectors quickly connect many lines of tubing in a specific orientation.

Multi-tube connectors, Figure 8, 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.
Coupling selection

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.
Materials of construction are another consideration. A wide variety of O-ring and seal
materials - elastomers, PTFE, etc. - are available to accommodate most any type of fluid at a
wide range of temperatures. Material chosen for the plug and socket also is important. Steel,
stainless steal, brass, and aluminum are common. In addition, many parts are made from
carbon steel and plated with a corrosion-resistant metal to keep material costs down.

Plastic may be used for many applications if pressure, temperature, and chemical
environment permit. Keep in mind that plastic couplings may contain internal metal
components that could be corroded by certain types of hydraulic fluid.

Pressure rating relates to values that provide optimum service life and maximum pressure
that can be tolerated without failure. Literature should include data for determining
pressure drop through the coupling at expected flows and pressures. Many of these
calculations are based on flow of water at 60 F.

Keep in mind that pressure drop for oil will be higher because of its higher viscosity.
Calculations for air are more complex because a gas's density varies widely with its pressure
and temperature. A rule of thumb for air to estimate maximum air flow at 100 psig inlet and
5-psi pressure drop is to multiply flow coefficient of the coupling by 25. Often, literature
contains more detailed data on maximum air flow at prescribed inlet pressures and pressure
drop. Therefore, precise valves for pressure drop for specific couplings should be obtained
from the manufacturer.

Also be aware that couplings may be subjected to pressures well above the maximum
operating pressure. Sudden shifting of valves or abrupt application of heavy loads can cause
system pressure to quickly rise and fall within milliseconds. These pressure spikes often go
undetected in a system, but still can damage seals and locking elements of the coupling.
Ultimately, then, the coupling would develop leaks, become difficult to disconnect or
reconnect, or any combination of these. To prevent these problems from occurring, select a
coupling with a pressure rating substantially higher than the anticipated maximum
operating pressure.

Depending on the application, the coupling may be subjected to vibration or relative

rotation between the mating halves while pressurized. In most cases, these conditions will
shorten the expected life of the coupling by causing leakage or difficulties in connecting or
disconnecting. Therefore, check with the manufacturer to determine if the coupling will
tolerate these conditions.
A few words on substitution

The various designs of quick-acting couplings available differ not only in how the two halves
connect to each other, but also in the valve arrangement to prevent fluid from escaping while the
coupling is disconnected. Several designs are fairly standard and may be interchangeable from one
manufacturer to another.

These standardized couplings are based on designs for which patents expired year ago. Still, some
manufacturers warn against interchanging standard designs between manufacturer because the loose
tolerances of one product line may cause problems if it is mated with another product requiring
tighter tolerances. The couplings may match based on nominal size but they may not mate or operate
properly together.

Thoughts on applying pneumatic quick-acting couplings

Jun 27, 2006Hydraulics & Pneumatics

Safety and productivity continue to be key factors when selecting components for almost
any industrial application. Simple pneumatic quick-acting couplings are among the
components that can have a significant effect on both. These products are available in
regular and safety styles but where should each be used?

Safety couplings were designed primarily to reduce possible injuries and damage from hose
ends whipping about. Hose whip can take place when a pressurized air hose is disconnected
via a regular quick-disconnect coupling. When air in the hose suddenly has a large opening
through which it can escape, it instantaneously expands and rushes out. This rapid
discharge of energized air, which is accompanied by a loud pop and a hissing sound, can
cause the end of the hose with the metal nipple still attached to whip dangerously out
of control.

The force of the whipping action and the noise level are both directly related to the pressure
level and the volume of air in the hose. The higher the pressure and the larger the volume of
air in of the hose, the greater the potential whipping force and the louder the noise that is
generated during disconnection.
 While short-lived noise may be only disconcerting, whipping hoses have caused serious
injury to workers as well as costly damage to nearby products or equipment. There have
been many cases where companies could have converted all of their air-supply couplings
from regular to safety styles for a fraction of the costs they incurred as a result of a hose
whip incident.

Safety couplings incorporate a 2-stage disconnection process. In the first stage, the initial
disconnection action closes a valve in the coupling. Downstream pressurized air inside the
hose then quietly vents from at a controlled, reduced rate while the nipple remains
connected with the coupling. In the second stage, the operator mechanically releases the
nipple from the coupling by performing a separate secondary disconnection action.

Installing safety quick couplings in place of regular couplings at air drops greatly reduces
the chance of dangerous hose whip occurrences. In addition, safety couplings dramatically
reduce the noise level when hose assemblies are disconnected. The difference in noise levels
between disconnecting a hose from a regular coupling and a safety coupling at 100 psi can
be as much as 19 dBa.

Safety couplings should also be considered for hose assemblies that occasionally have other
hose extensions connected to them. Hose whip can occur when any hose extension is
disconnected-from a supply hose that doesnt have a safety coupling.

Of course, regular air couplings have their place in industry as well. They should be installed
at the ends of air hoses that connect to pneumatic tools. Regular couplings are
recommended at this location for these reasons:

there is no danger of hose whip at the tool end

their lighter weight reduces operator fatigue

they cost less than safety couplings, and

they are easier and quicker to disconnect when changing tools.

Finally, anyone who specifies pneumatic quick-acting couplings should consider these
points before selecting a particular component:

Will the rated flow of the couplings and hose assemblies meet the applications demand?
 Are the couplings easy to operate? Some regular couplings are difficult to connect and
disconnect, and may actually reduce productivity. Some safety couplings are complicated to operate
and/or may not engage their safety feature automatically, thereby putting employees at risk

Do the couplings seal reliably? Compressed air leaks are still a leading waste of energy.

Are the couplings durable? Some quick couplings are susceptible to failure due to impact or
contamination. If the applications requirements and shop conditions warrant it, you may benefit by
selecting a more rugged quick coupling.

Note that hose safety valves also can be installed upstream from any style pneumatic
coupling as an additional precaution. If a hose ruptures, this valve automatically blocks air
flow, allowing the damaged hose to be removed safely.

John Joniak, regional manager, Prevost Corp., Greenville, S.C., contributed this
discussion. Phone his company at (800)-845-7220 or visit www.prevost-ltd.com.

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