A disc spring-based flexible docking mechanism for hydraulic systems

Achieving rapid and reliable hydraulic connection and separation under dynamic conditions is critical in modern engineering machinery, emergency rescue equipment, and automated production lines. Traditional rigid oil circuit docking mechanisms suffer from poor fault tolerance, causing seal damage, leakage, and structural failure when subjected to misalignment. This study presents a nonlinear dynamic design of an adaptive flexible oil circuit docking mechanism employing disc springs, whose inherent nonlinear force-displacement characteristics enable robust compensation for multi-directional misalignments. Two structural configurations are evaluated, with detailed nonlinear parameter design conducted for the selected scheme. Nonlinear finite element simulations under multi-degree-of-freedom dynamic loading provide comprehensive insights into spring behaviour and mechanical performance during flat, rotational, and angular docking operations. Nonlinear stress-strain analysis and fatigue life prediction based on dynamic loading spectra validate the structural integrity, achieving a predicted service life exceeding 106 cycles. A prototype was fabricated and experimentally tested under realistic dynamic conditions, confirming the mechanism’s superior adaptability and reliability. This work establishes a theoretical and experimental framework for developing intelligent quick-change devices with enhanced fault tolerance and durability, advancing next-generation smart hydraulic interface technology.