Tube swage process and system

Abstract

A connector creates a connection between one or more tubes swaged with a swaging tool and the connector, allowing in-place modifications to allow connection between the tubes and the connector. The swaging tool creates one or more annular bosses in the tubes which engage corresponding annular grooves of the connector to permanently connect one or more tubes. The tubes are rotatable about the connector. Optional through-holes in the connector allow wiring, fluids, or other materials to pass through and be protected by the swage tube assembly. Clamping, threaded and pivoting connection variants are disclosed.

1 . A tube swage system for connecting tubes, comprising:
 a swaging tool having a first support wheel and a second support wheel and a swaging wheel, the first and second support wheels opposed to the swaging wheel by a variable distance wherein the first and second support wheels and the swaging wheel rotate around a first one of the tubes having a first outer wall such that the first and the second support wheels and the swaging wheel rotate around the first outer wall while the variable distance between the first and second support wheels, and the swaging wheel is incrementally reduced, creating a first annular boss on a first inner wall of the first tube such that a connector fitting having a first annular groove, is engageable with the first tube by mechanically engaging the first annular groove with the first annular boss.   
     
     
         2 . The tube swage system for connecting tubes of  claim 1 , further comprising a spacer which aligns the swaging tool with a surface which is not parallel to the first tube, such that the annular boss is created a fixed distance from the surface relative to the first tube. 
     
     
         3 . The tube swage system for connecting tubes of  claim 1 , wherein the swaging tool also rotates around a second one of the tubes having a second outer wall such that the first and second support wheels and the swaging wheel are rotated around the second outer wall while the distance between the first and second support wheels and the swaging wheel is incrementally reduced, creating a second annular boss on a second inner wall of the second tube and the connector fitting has a second annular groove, the second annular groove engaging with the second annular boss. 
     
     
         4 . The tube swage system for connecting tubes of  claim 1 , wherein the swaging tool simultaneously creates a first group of annular bosses on the first tube comprising at least two annular bosses, and wherein the connector fitting has a first group of annular grooves comprising at least one annular groove which engage the first group of annular bosses. 
     
     
         5 . The tube swage system for connecting tubes of  claim 4 , wherein there are the same number of annular grooves in each group of annular grooves as there are annular bosses in each group of annular bosses. 
     
     
         6 . The tube swage system for connecting tubes of  claim 4 , wherein the number of annular grooves in either the first group of annular grooves or the second group of annular grooves does not correspond to the number of annular bosses in the corresponding first group of annular bosses or the second group of annular bosses. 
     
     
         7 . The tube swage system for connecting tubes of  claim 4 , wherein the distance between the first swaging wheel and the second swaging wheel is adjustable by a user. 
     
     
         8 . The tube swage system for connecting tubes of  claim 1 , further comprising a cutting wheel which can be interchangeably substituted for the swaging wheel by a user. 
     
     
         9 . The tube swage system for connecting tubes of  claim 1 , wherein the connector fitting has an o-ring groove on a connector fitting outer wall into which an o-ring can be inserted, the o-ring located between the connector fitting outer wall and the first inner wall of the first tube and/or the second outer wall of the second tube. 
     
     
         10 . The tube swage system for connecting tubes of  claim 1 , wherein a u-bolt having an inner u-bolt circumference, a first threaded end, and a second threaded end and a saddle bracket are placed tangent to the first annular boss with the u-bolt such that when the saddle bracket is placed onto the u-bolt, the saddle bracket presses the inner u-bolt circumference into the first tube above the first annular boss and an interior member having an inner member circumference fits within the saddle bracket such that when the saddle bracket is pressed against the interior member, the inner u-bolt circumference and the inner member circumference together surround substantially all of the first tube above the first annular boss and a first nut and a second nut secure the u-bolt around the first tube and compressing the saddle bracket into the interior member. 
     
     
         11 . The tube swage system for connecting tubes of  claim 10 , wherein there are one or more annular bosses on the first tube and each of the annular bosses is secured by a corresponding u-bolt. 
     
     
         12 . The tube swage system for connecting tubes of  claim 1 , wherein the connector fitting has a shoulder having a height, the shoulder height being such that the first tube cannot be pressed onto the connector fitting past the shoulder. 
     
     
         13 . A method for swaging and connecting tubes comprising:
 swaging a first swaging ring on a first tube with a swaging tool comprising a first support wheel, a second support wheel, and a swaging wheel, the swaging wheel in contact with a first outer wall of the first tube such that a first annular boss is formed on a first inner wall of the first tube; and   inserting a connector fitting having a first annular groove and a second annular groove into the first tube such that the first annular groove engages the first annular boss.   
     
     
         14 . The method for swaging and connecting tubes of  claim 13 , further comprising the steps of:
 swaging a second swaging ring on the first tube with the swaging tool at a fixed distance from the first swaging ring such that a second annular boss is formed on the first inner wall of the first tube; and   swaging a fourth swaging ring on the second tube with the swaging tool at the fixed distance from the second swaging ring such that a fourth annular boss is formed on the second inner wall of the second tube.   
     
     
         15 . The method for swaging and connecting tubes of  claim 13 , further comprising the steps of:
 securing the first tube to the connector fitting with a clamp, the clamp comprising a u-bolt, a saddle bracket, an interior member, a first nut, and a second nut, such that the u-bolt and the interior member surround the first annular boss when the first nut and the second nut are used to secure the saddle bracket.   
     
     
         16 . The tube swage system for connecting tubes of  claim 1 , wherein the connector fitting is solid. 
     
     
         17 . The tube swage system for connecting tubes of  claim 1 , wherein the connector fitting has an interior connecting space communicating with an interior of the first tube. 
     
     
         18 . The tube swage system for connecting tubes of  claim 1 , wherein the connector fitting has a chamfered opening communicating with an interior of the first tube. 
     
     
         19 . The tube swage system for connecting tubes of  claim 1 , wherein a compound having adhesive and/or sealant properties is applied to the annular grooves in the first tube. 
     
     
         20 . A tube swage tool for swaging and connecting tubes comprising:
 a first support wheel;   a second support wheel;   a swaging wheel, the first and second support wheels opposed to the swaging wheel by a variable distance wherein the first and second support wheels and the swaging wheel rotate around a tube having a first outer wall such that the first and the second support wheels and the swaging wheel rotate around the first outer wall while the variable distance between the first and second support wheels, and the swaging wheel is incrementally reduced, creating a first annular boss on a first inner wall of the tube.