By: Jason Hayslip – Sr. Mechanical Engineer
Client: Anonymous
Re:Build AppliedLogix developed a semi-automated hand tool for lubricating and installing gaskets into fire suppression sprinkler pipe fitting joints. The customer had created a new product line of pipe fittings with integrated gaskets that previously required a manual installation process. This manual process involved removing individual gaskets from bulk bags, lubricating them, and installing them with hand tools, resulting in quality issues, lengthy installation times, and ergonomically challenging force requirements.
The custom-molded gaskets required specific orientation within the pipe fittings to ensure proper sealing. Installation depth was also critical: too deep could damage the seal, while too shallow would compromise joint integrity. The solution needed to be ambidextrous, supporting both left and right-handed use, and capable of installing at least 400 gaskets during an eight-hour shift. Additionally, the design required scalability to accommodate various gasket sizes.
Our Mechanical Engineering Team developed a specialized gasket installation tool that allows users to quickly and securely attach it to a pipe fitting. The tool features a simple manual mechanism to transfer a gasket from the built-in storage magazine into a lubrication chamber, followed by pneumatic insertion of the gasket into the pipe fitting’s groove. Once installation is complete, users can easily detach the tool without requiring additional equipment.
The solution includes a custom gasket cartridge designed to be pre-loaded at the supplier’s facility with gaskets in a specific orientation. This cartridge doubles as protective packaging for shipping and storage. Users can replace depleted magazines in the installation tool as needed, with gaskets being positively fed through an escapement mechanism during each installation cycle. The tool accommodates standard commercial grease cartridges for seal lubrication. The escapement mechanism precisely delivers a consistent amount of grease onto each gasket during its transition into the tool chamber.
The gasket installation tool is designed to be suspended in the proper orientation using a tool balancer. Compressed air and low-voltage signal quick-disconnects are positioned at the top of the tool, with lines and wires tethered to the balancer cable for management. Users control the tool via an ambidextrous urethane grip. The installation trigger is ergonomically positioned relative to the stabilization and locking handle, activating the gasket’s insertion into the pipe fitting. Connection and disconnection from the pipe fitting is accomplished by manually rotating the collet ring using the locking handle at the tool’s base.
Safety features are built into the tool to prevent improper operation sequences. For example, the gasket escapement cannot be activated until the tool is properly locked onto a pipe fitting, and the installation piston cannot be engaged until a gasket has been transferred to the chamber. These safeguards prevent tool damage and protect operator safety.
The design was scaled to accommodate three different gasket and pipe fitting sizes, maximizing component commonality across variations. Development trials confirmed installation rates exceeding the 400-per-shift requirement.
A tool manufacturer selected by the customer completed the prototype and subsequent production tools. Our team collaborated throughout the final design stages to ensure manufacturability aligned with their capabilities and optimized efficiencies in process and approach. The assembly process was jointly developed, resulting in successful and cost-effective tool delivery.
Our custom gasket installation tool features unique characteristics not currently available in the industrial marketplace:
The custom semi-automated seal installation tool integrates consistent seal delivery in an ergonomic package. The designed solution provides quick change feeding of gaskets and grease along with easy and secure connection to the pipe fittings in which the seal is being installed. The resulting design removes the burden from the user to establish secure connection to the pipe fitting, correct gasket orientation, lubrication, and installation force ensuring consistent quality installations. Ultimately the risk of repetitive motion injuries to the operators are also eliminated.
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