A novel motorcycle muffler

Abstract

This utility model discloses a novel motorcycle muffler structure, comprising a cylinder, a cover, and internal connecting plates embedded at both ends of the cylinder, with the cover fitted onto the internal connecting plates. The cover has an integrally stamped protrusion on its mating end face. When the cover and cylinder are mated, the end of the protrusion contacts the end face of the cylinder, thereby automatically forming a uniform welding gap. This structure fundamentally solves the problem of difficult gap control during the overlapping welding of multi-layer plates, effectively avoiding defects such as incomplete weld penetration and the need for secondary welding, significantly improving product welding quality, production efficiency, and pass rate, while simultaneously reducing production costs.

Description

Technical Field

[0001] This utility model relates to the field of motorcycle parts manufacturing technology, and in particular to a novel motorcycle muffler structure. Background Technology

[0002] Motorcycle mufflers typically employ a flush butt welding process for the cylinder body and front / rear cover. This structure usually consists of three layers of sheet metal: the cylinder body, an internal connecting plate, and an end cap. Specifically, the internal connecting plate is first fixed to the cylinder body, then the end cap is fitted onto the internal connecting plate and flush-butt-welded to the end face of the cylinder body. Finally, a circumferential weld is performed, and the finished product requires the weld bead to be ground until flush.

[0003] The core difficulty in welding these three plates lies in the fact that a suitable and uniform gap must be reserved at the joint between the end face of the cylinder and the end cap to ensure that the weld pool can simultaneously melt through the three plates and form a strong connection.

[0004] However, in existing technologies, the control of this gap largely depends on the experience of operators or auxiliary tooling, resulting in poor consistency and low stability: if the gap is too small, it will lead to incomplete welding, resulting in weak connection strength, abnormal product noise, or even scrap; if the gap is too large, two rounds of welding are required to fill it, resulting in low production efficiency, high cost, and subsequent grinding is prone to exposing defects such as pores and pits, leading to a high rework rate.

[0005] Therefore, in order to solve the above problems, it is necessary to develop a new type of motorcycle muffler that can ensure consistent gaps, completely eliminate the problems caused by inconsistent gaps, improve production efficiency and welding quality, and reduce production costs. Utility Model Content

[0006] To solve the above problems, the technical solution adopted by this utility model is as follows:

[0007] A novel motorcycle muffler, characterized in that it comprises a cylindrical body, a cover, and an internal connecting plate, wherein:

[0008] An internal connecting plate is provided between the cover and the cylinder;

[0009] The internal connecting plate is a hollow frustum structure with both ends connected, and a bridging section is provided at the large end of the internal connecting plate.

[0010] The internal connecting plates are respectively embedded at both ends of the cylinder via bridging sections;

[0011] The connecting ends of the cover are respectively fitted onto the bridging section, and the connecting end surface is provided with an integrally formed protrusion that protrudes from the connecting end.

[0012] When the cover and the cylinder are installed together, the ends of each of the protrusions contact the end face of the cylinder, so that a uniform welding gap is formed between the end face of the cover and the end face of the cylinder.

[0013] Preferably, the protrusion is one or a combination of a protrusion point, a boss, a flange, or a ridge.

[0014] Preferably, the protrusion is a plurality of protrusions.

[0015] Preferably, the number of protrusions is at least three.

[0016] Preferably, the plurality of protrusions are evenly distributed circumferentially along the end face of the cover.

[0017] Preferably, the height of the protrusion is configured to form a welding gap of 0.8 mm to 1.2 mm.

[0018] Preferably, the protrusion and the cover are integrally stamped structures.

[0019] Preferably, the cover is a front cover or a rear cover.

[0020] Preferably, the inner cavity of the internal connecting plate has a stepped structure.

[0021] Compared with the prior art, the beneficial effects of this utility model are as follows:

[0022] 1. By automatically ensuring the optimal welding gap through mechanical structure, the quality risks such as incomplete welding, abnormal noise, and insufficient strength caused by improper gap are completely eliminated, and the product yield is greatly improved.

[0023] 2. Automatic positioning during assembly eliminates the need for manual adjustment; ensuring completion with a single circumferential weld, significantly improving production efficiency.

[0024] 3. The innovative structure is integrally molded during the manufacturing of the cover, achieving functionality with almost no increase in cost; at the same time, the scrap rate and rework rate are drastically reduced, greatly reducing the overall production cost.

[0025] 4. The assembly process is simplified, the skill requirements for workers are reduced, the operating efficiency is improved, and the product quality consistency is extremely high. Attached Figure Description

[0026] Figure 1 This is a three-dimensional structural diagram of the present invention;

[0027] Figure 2 This is a cross-sectional structural diagram of the present invention;

[0028] Figure 3 for Figure 2 Enlarged view of a portion of point A in the middle;

[0029] Figure 4This is a schematic diagram of the structure of the rear cover in this utility model;

[0030] Figure 5 This is a schematic diagram of the front cover structure in this utility model;

[0031] The components include: cylinder 1, cover 2, internal connecting plate 3, protrusion 4, welding gap 5, front cover 21, rear cover 22, bridging section 31, and protrusion 41. Detailed Implementation

[0032] To facilitate understanding of this utility model, a more complete description will be given below with reference to the accompanying drawings. Preferred embodiments of this utility model are shown in the drawings. However, this utility model can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to provide a more thorough and complete understanding of the disclosure of this utility model.

[0033] It should be noted that when a component is said to be "fixed to" another component, it can be directly attached to the other component or there may be an intervening component. When a component is said to be "connected to" another component, it can be directly connected to the other component or there may be an intervening component. The terms "vertical," "horizontal," "left," "right," "up," "down," "front," "back," and similar expressions used in this document are for illustrative purposes only.

[0034] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0035] The present invention will now be further described in conjunction with the accompanying drawings and specific embodiments:

[0036] like Figure 1-5 As shown, a novel motorcycle muffler includes a cylinder 1, a cover 2, and an internal connecting plate 3. The internal connecting plate 3 is provided inside the cover 2 and the cylinder 1.

[0037] The internal connecting plate 3 is a hollow frustum structure with both ends through it, and the large end of the internal connecting plate 3 is provided with a bridging section 31.

[0038] The internal connecting plates 3 are respectively embedded at both ends of the cylinder 1 via bridging sections 31;

[0039] The connecting ends of the cover 2 are respectively fitted onto the bridging section 31, and the connecting end surface is provided with an integrally formed protrusion 4 that protrudes from the connecting end.

[0040] When the cover 2 is installed in conjunction with the cylinder 1, the ends of each of the protrusions 4 contact the end face of the cylinder 1, so that a uniform welding gap 5 is formed between the end face of the cover 2 and the end face of the cylinder.

[0041] In this embodiment, the gap is mechanically determined by the integrally formed protrusion 4, eliminating welding quality risks (such as weak welding, abnormal noise, and insufficient strength) caused by too small or too large gaps, and significantly improving the product yield.

[0042] In this embodiment, the protrusion 4 structure is integrally formed with the cover 2, requiring no new steps in the existing process, resulting in extremely low cost for realizing the innovative function. Simultaneously, due to a significant reduction in scrap and rework rates, as well as savings in energy and time for secondary welding, the overall production cost is significantly reduced.

[0043] Furthermore, in order to meet the strength or welding requirements of different specifications and models of silencers, the protrusion 4 is one or a combination of a protrusion, a boss, a flange, or a ridge.

[0044] Furthermore, such as Figure 1 , 2 As shown in Figures 3, 4, and 5, while ensuring the uniformity of the welding gap 5, in order to save material costs and increase the number of weldable positions, the protrusion 4 consists of multiple protrusions 41.

[0045] Furthermore, such as Figure 2 , 3 As shown in Figures 4 and 5, in order to provide a stable and reliable support effect, the number of the protrusions 41 is at least three.

[0046] Furthermore, such as Figure 2 , 3 As shown in Figures 4 and 5, in order to ensure the optimal uniformity of the welding gap 5 and guarantee the consistency of the quality of the circumferential weld, the multiple protrusions 41 are evenly distributed circumferentially along the end face of the cover 2.

[0047] Furthermore, such as Figure 2 , 3 As shown in Figures 4 and 5, the height of the protrusion 4 is configured to form a welding gap 5 of 0.8 mm to 1.2 mm.

[0048] In this embodiment, the protrusion 4 consists of four protrusions 41 with a height of 1 mm, and the height of the protrusions 41 is controlled within a tolerance range of 1 mm ± 0.1 mm.

[0049] Furthermore, such as Figure 4 , 5As shown, in order to improve the structural strength and reliability of the protrusion 4 and the cover 2, and reduce production costs, the protrusion 4 and the cover 2 are integrally stamped structures.

[0050] Furthermore, such as Figure 1 , 2 As shown, the cover 2 is either a front cover 21 or a rear cover 22.

[0051] In this embodiment, the front cover 21 and the rear cover 22 have different structures, but the protrusion 4 has the same structure.

[0052] Furthermore, such as Figure 2 As shown, in order to improve the support strength and the overall reliability of the muffler, the inner cavity of the internal connecting plate 3 has a stepped structure.

[0053] Manufacturing of cover 2: The cover 2 is made of metal sheet through multiple stamping processes. Its processing technology mainly includes: blanking, deep drawing, edge cutting and punching, and flanging.

[0054] Cutting: First, the metal sheet is punched into a circular piece.

[0055] Deep drawing: The sheet material is then deep drawn using a deep drawing die on a hydraulic press to form a bowl-shaped deep hole workpiece prototype.

[0056] Trimming and punching: Then, a set of special composite dies is used to process the deep-drawn workpiece; in one stamping stroke, the die simultaneously completes the trimming of the workpiece flash, the stamping of the central connecting hole, and the integral forming of four 1mm high protrusions 2, without adding extra costs.

[0057] Flanging and Flanging: Finally, the center connecting hole is folded using the folding and flanging die on the punch press, and the workpiece end is flanged to form a complete cover 2 that meets the assembly requirements.

[0058] During assembly, simply push the rear cover 22 / front cover 21 along the internal connecting plate 3 toward the cylinder 1 until the ends of all the protrusions 4 contact the end face of the cylinder 1 and then stop automatically; at this time, a uniform annular welding gap 5 is naturally formed between the end face of the rear cover 22 / front cover 21 and the end face of the cylinder 1.

[0059] Subsequently, with the help of the tooling, a one-time circumferential welding can be performed along this gap using an automatic welding gun; during welding, the molten pool can simultaneously melt through the rear cover 22 / front cover 21, the cylinder 1 and the internal connecting plate 3, so that the three are firmly joined; after welding and grinding, a high-quality silencer product can be obtained.

[0060] For those skilled in the art, various other corresponding changes and modifications can be made based on the technical solutions and concepts described above, and all such changes and modifications should fall within the protection scope of the claims of this utility model patent.

Claims

1. A motorcycle muffler of a new structure, characterized by, It includes a cylinder, a cover, and an internal connecting plate, characterized in that: An internal connecting plate is provided between the cover and the cylinder; The internal connecting plate is a hollow frustum structure with both ends connected, and a bridging section is provided at the large end of the internal connecting plate. The internal connecting plates are respectively embedded at both ends of the cylinder via bridging sections; The connecting ends of the cover are respectively fitted onto the bridging section, and the connecting end surface is provided with an integrally formed protrusion that protrudes from the connecting end. When the cover and the cylinder are installed together, the ends of each of the protrusions contact the end face of the cylinder, so that a uniform welding gap is formed between the end face of the cover and the end face of the cylinder.

2. A motorcycle muffler of new construction according to claim 1, characterized in that, The protrusion is one or a combination of a protrusion point, a boss, a flange, or a ridge.

3. A motorcycle muffler of new construction according to claim 2, characterized in that, The protrusion consists of multiple protrusions.

4. A motorcycle muffler of new construction according to claim 3, characterized in that, The number of protrusions is at least three.

5. A motorcycle muffler of novel construction according to claim 4, characterised in that, The multiple protrusions are evenly distributed circumferentially along the end face of the cover.

6. A novel motorcycle muffler according to claim 1 or 2, characterized in that, The height of the protrusion is configured to form a welding gap of 0.8 mm to 1.2 mm.

7. A novel motorcycle muffler according to claim 1, characterized in that, The protrusion and the cover are integrally stamped and formed.

8. A novel motorcycle muffler according to claim 1, characterized in that, The cover is either a front cover or a rear cover.

9. A novel motorcycle muffler according to claim 1, characterized in that, The inner cavity of the internal connecting plate has a stepped structure.

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