A special-shaped integral end cone of a catalytic converter and a manufacturing method thereof

Abstract

The present invention discloses a special-shaped integral end cone for a catalytic converter, comprising a special-shaped integral end cone body, the end cone body being configured as a shell structure, the end cone body having two end ports, respectively, an intake flange interface and a catalyst shell interface, a sensor mounting hole being formed on the side of the end cone body, the two side edges of the end cone body being welded to form an end cone body weld bead, the intake flange interface being inserted into the intake flange and welded, and the catalyst shell interface being welded to the catalyst shell. The present invention has a simple structure, low manufacturing and use costs, and is easy to operate. Compared with conventional special-shaped butt-welded end cones, the manufacturing process is simpler, requiring only one step of stamping and then welding to complete the product manufacturing process. Compared with conventional cylindrical spun end cones, the product has high dimensional accuracy, meeting the requirements for component accuracy for automated welding.

Description

Technical Field

[0001] The present invention relates to the field of automobile engine exhaust system components, and in particular to a special-shaped integral end cone of a catalytic converter and a manufacturing method thereof. Background Art

[0002] The catalytic converter is an important component of the automobile exhaust system. It consists of a catalytic converter housing, exhaust cone end, intake cone end, intake flange, etc. Its performance directly affects the exhaust system's tail gas purification standards, noise, fuel consumption and other aspects.

[0003] There are two types of catalytic converter cones: cylindrical spun cones and clamshell (i.e., special-shaped) butt-welded cones. The cylindrical spun cones are formed by rolling the blank with a spinning roller. The rotating blank is gradually rolled along the die with the help of external force to produce plastic deformation, thus obtaining a rotating cone part. Figure 5 As shown, the clamshell-shaped butt-welded end cone typically utilizes a double-shell product structure. A single half-shell is stamped and formed through multiple steps, then butt-welded to form the edges. The cylindrical spun end cone suffers from low dimensional accuracy, uneven wall thickness distribution, poor surface corrosion resistance, and can only be a body of revolution. The clamshell-shaped butt-welded catalytic converter end cone is a complex process, requiring three stamping steps for a single shell. After forming, the two shells must be welded together in two steps. This multi-pass welding process inevitably produces defects such as pores and pinholes, leading to product leakage. Therefore, providing a special-shaped, integral end cone that overcomes the aforementioned shortcomings of existing catalytic converter cones has become a pressing challenge for those skilled in the art. Summary of the Invention

[0004] The purpose of the present invention is to provide a special-shaped integral end cone of a catalytic converter and a manufacturing method thereof, so as to solve the problems of high manufacturing cost, complex structure and inconvenient operation of the special-shaped integral end cone.

[0005] In order to solve the above technical problems, the present invention adopts the following technical solutions:

[0006] The present invention provides a special-shaped integral end cone of a catalytic converter, comprising a special-shaped integral end cone body, wherein the end cone body is configured as a shell structure, and the two end ports of the end cone body are respectively an intake flange interface and a catalyst shell interface, a sensor mounting hole is opened on the side of the end cone body, and the two side edges of the end cone body are welded to form an end cone body weld, the intake flange interface is embedded in the intake flange and welded, and the catalyst shell interface is welded to the catalyst shell.

[0007] Furthermore, the end cone body is made of 400 series stainless steel, and the end cone body is configured to have a clamshell shape.

[0008] Furthermore, the intake flange interface and the catalyst housing interface are both configured to be circular.

[0009] Furthermore, the diameter tolerance of the catalyst housing interface is within the range of ±0.5 mm, and the diameter of the catalyst housing interface is 4 times that of the intake flange interface.

[0010] Furthermore, a passivation layer is provided on the surface of the 400 series stainless steel plate.

[0011] Furthermore, the two side edges of the end cone body are arranged in parallel with a distance of 0.5 mm, and the two opposite edges are melted during welding. After welding is completed, the thickness of the weld must be no less than the thickness of the plate of the end cone body.

[0012] A method for manufacturing a special-shaped integral end cone of a catalytic converter comprises the following steps:

[0013] Step 1: Blanking: The original sheet material is cut or punched into a blank of a specific shape;

[0014] Step 2: Stretch forming: Install the forming die on the machine tool, place the blank in step 1 into the opened forming die, and when the machine tool drives the forming die to close, the blank is extruded and formed into an end cone body;

[0015] Step 3: Welding: The sides of the end cone body formed in step 2 at the opening are welded together.

[0016] Furthermore, the forming mold includes a mold frame, an end cone mold core, an end cone die, a left forming mold and a right forming mold, and the end cone mold core, the end cone die, the left forming mold and the right forming mold are installed to the set position of the mold frame.

[0017] Furthermore, during operation, the end cone mold core moves under the drive of the oil cylinder on the machine tool, pressing the blank into the end cone die to form a preliminary outline; the pressure of the end cone mold core is kept unchanged, and the two sides of the blank are lifted up under the action of the installed end cone mold core and the end cone die, and then the left forming mold and the right forming mold are synchronously moved toward the end cone mold core, and the lifted part of the extruded blank is formed into the end cone body; finally, the openings of the end cone body are welded together.

[0018] Compared with the prior art, the present invention has the following beneficial technical effects:

[0019] The special-shaped integral end cone of the special-shaped catalytic converter of the present invention and the manufacturing method thereof include an end cone body, on which an intake flange interface, a sensor mounting hole, a catalyst housing interface and an end cone body weld are provided. Compared with the special-shaped integral end cone of the ordinary special-shaped catalytic converter, the special-shaped integral end cone is formed in one step through the organic action of five major parts: the end cone mold core, the sheet material, the end cone die, the left forming die and the right forming die. Only one welding is performed at the joint to complete the product manufacturing. The present invention has a simple structure, low manufacturing and use costs, and is easy to operate. Compared with the traditional special-shaped butt-welded structure end cone, the process is simpler, requiring only one step of stamping and forming, and then one step of welding to complete the manufacturing process of a product. Compared with the traditional cylindrical spinning end cone, the product has high external dimensional accuracy, meeting the requirements of automated welding for part accuracy. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The present invention will be further described below with reference to the accompanying drawings.

[0021] Figure 1 It is a front view of the special-shaped integral end cone of the catalytic converter of the present invention;

[0022] Figure 2 This is a schematic diagram of the blank structure of the present invention;

[0023] Figure 3 This is a diagram showing the forming principle of the present invention;

[0024] Figure 4 Schematic diagram of the special-shaped integral end cone of the catalytic converter of the present invention;

[0025] Figure 5 It is a schematic diagram of the existing technology structure;

[0026] Figure 6 This is a schematic diagram of the welding structure of the present invention;

[0027] Explanation of the reference numerals: 101, intake flange interface; 102, sensor mounting hole; 103, end cone body; 104, catalyst housing interface; 105, end cone body weld; 201, end cone mold core; 202, blank; 203, end cone die; 204, left forming die; 205, right forming die. DETAILED DESCRIPTION

[0028] like Figure 1As shown, a special-shaped integral end cone of a catalytic converter includes a special-shaped integral end cone body 103, wherein the end cone body 103 is arranged as a shell structure, and the two end ports of the end cone body 103 are respectively an intake flange interface 101 and a catalyst shell interface 104, and a sensor mounting hole 102 is opened on the side of the end cone body 103. The two side edges of the end cone body 103 are welded to form an end cone body weld 105, the intake flange interface 101 is embedded in the intake flange and welded, and the catalyst shell interface 104 is welded to the catalyst shell. The special-shaped integral end cone is welded together with the intake flange and the catalyst shell to form a complete catalytic converter. The catalytic converter has fewer welds, good strength, higher dimensional accuracy, and a certain extent, which extends the service life.

[0029] The end cone body 103 is made of 400 series stainless steel, the intake flange interface 101 and the catalyst housing interface 104 are both set to be circular, and the end cone body 103 is set to a clamshell shape to make the flow of exhaust gas smoother and prevent vortexes from being generated inside the catalytic converter.

[0030] The diameter tolerance of the catalyst housing interface 104 is within the range of ±0.5 mm, and the diameter of the catalyst housing interface 104 is four times that of the intake flange interface 101 .

[0031] The surface of the 400 series stainless steel plate is provided with a passivation layer to enhance the corrosion resistance.

[0032] like Figure 6 As shown, the two side edges of the end cone body 103 are arranged in parallel with a distance of 0.5 mm, and the end face is melted during welding. After welding, the weld thickness is not less than the plate thickness of the end cone body 103, so that the weight of the product is further reduced.

[0033] A method for manufacturing a special-shaped integral end cone of a catalytic converter comprises the following steps:

[0034] Step 1, blanking: the original sheet material is cut or punched by a blanking die to obtain a blank 202 of a specific shape;

[0035] Step 2: stretching: the forming die is mounted on a machine tool, and the blank 202 in step 1 is placed in the opened forming die. When the machine tool drives the forming die to close, the blank is extruded and formed into the end cone body 101;

[0036] Step 3: Welding: The sides of the opening of the end cone body 101 formed in step 2 are welded together.

[0037] like Figure 3As shown, the forming mold includes a mold frame, an end cone mold core 201, an end cone die 203, a left forming mold 204 and a right forming mold 205, and the end cone mold core 201, the end cone die 203, the left forming mold 204 and the right forming mold 205 are installed to the set position of the mold frame.

[0038] During operation, the end cone mold core 201 moves under the drive of the oil cylinder on the machine tool to press the blank 202 into the end cone die 203 to form a preliminary outline; the pressure of the end cone mold core 201 is kept unchanged, and the two sides of the blank 202 are lifted up under the action of the installed end cone mold core 201 and the end cone die 203, and then the left forming die 204 and the right forming die 205 are synchronously moved toward the end cone mold core 201, and the lifted part of the extruded blank 202 is formed into the end cone body 101; finally, the openings of the end cone body 101 are welded together.

[0039] The embodiments described above are merely descriptions of preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Without departing from the spirit of the present invention, various modifications and improvements made to the technical solutions of the present invention by persons skilled in the art should fall within the scope of protection defined by the claims of the present invention.

Claims

1. A method for manufacturing a special-shaped integral end cone of a catalytic converter, characterized by: The special-shaped integral end cone of the catalytic converter comprises a special-shaped integral end cone body (103), the end cone body (103) is configured as a shell structure, the two end ports of the end cone body (103) are respectively an intake flange interface (101) and a catalyst shell interface (104), a sensor mounting hole (102) is opened on the side of the end cone body (103), two side edges of the end cone body (103) are welded to form an end cone body weld bead (105), the intake flange interface (101) is embedded in the intake flange and welded, and the catalyst shell interface (104) is welded to the catalyst shell; The method comprises the following steps: Step 1, blanking: the original sheet material is cut or punched with a blanking die to obtain a blank of a specific shape (202); Step 2: stretching and forming: installing the forming die on a machine tool, placing the blank (202) in step 1 into the opened forming die, and when the machine tool drives the forming die to close, the blank is extruded and formed into an end cone body (101); Step 3: Welding: welding the sides of the opening of the end cone body (101) formed in step 2 together; The forming die comprises a die frame, an end cone die core (201), an end cone die (203), a left forming die (204) and a right forming die (205); the end cone die core (201), the end cone die (203), the left forming die (204) and the right forming die (205) are installed at a set position of the die frame; During operation, the end cone die core (201) moves under the drive of the oil cylinder on the machine tool, pressing the blank (202) into the end cone die (203) to form a preliminary outline; the pressure of the end cone die core (201) is kept constant, and both sides of the blank (202) are tilted under the action of the installed end cone die core (201) and the end cone die (203); then the left forming die (204) and the right forming die (205) are synchronously moved toward the end cone die core (201), and the tilted part of the extruded blank (202) is formed into the end cone body (101); finally, the openings of the end cone body (101) are welded together.

2. The method for manufacturing a special-shaped integral end cone of a catalytic converter according to claim 1, characterized in that: The end cone body (103) is made of 400 series stainless steel and is configured in a clamshell shape.

3. The method for manufacturing a special-shaped integral end cone of a catalytic converter according to claim 1, characterized in that: The air intake flange interface (101) and the catalyst housing interface (104) are both configured to be circular.

4. The method for manufacturing a special-shaped integral end cone of a catalytic converter according to claim 1, characterized in that: The diameter tolerance of the catalyst housing interface (104) is within the range of ±0.5 mm, and the diameter of the catalyst housing interface (104) is four times that of the intake flange interface (101).

5. The method for manufacturing a special-shaped integral end cone of a catalytic converter according to claim 2, characterized in that: A passivation layer is provided on the surface of the 400 series stainless steel plate.

6. The method for manufacturing a special-shaped integral end cone of a catalytic converter according to claim 2, characterized in that: The two side edges of the end cone body (103) are arranged in parallel with a distance of 0.5 mm, and the two opposite sides are melted during welding. After welding, the thickness of the weld is not less than the thickness of the plate of the end cone body (103).

Images