Method and device for resizing a component shell with at least two different diameters

Abstract

Method for forming an exhaust system component comprising the following steps: Providing at least one first substrate (28) and one second substrate (30); Providing an outer shell (24) surrounding the first and second substrates (28, 30), wherein the outer shell (24) defines a central axis (A) extending in an axial direction; Forming at least one sensor hole (46) in the outer shell (24) at a location between the first and the second substrate (28, 30); and Surrounding a first end (40) of the outer shell (24) with a first plurality of fingers (56) for adapting the size of the first end (40) around the first substrate (28) to a first diameter (D1), wherein the first plurality of fingers (56) includes at least one extended finger (56a) which is longer in the axial direction than the other fingers (56) such that the extended finger (56a) at least partially covers the sensor hole (46) during the adaptation of the size of the first end (40).

Description

TECHNICAL FIELD

[0001] The present invention relates to a method and apparatus for adjusting the size of a shell of an exhaust system component having at least two different diameters. The present invention particularly relates to adjusting the size of a catalyst shell having a sensor hole located between shell sections that may have different diameters. BACKGROUND OF THE INVENTION

[0002] A vehicle exhaust system comprises various components that conduct exhaust gases generated by an internal combustion engine to an exterior outlet. One such exhaust system component is a catalytic converter with an outer shell defining an interior cavity that houses one or more catalyst substrates. The catalyst substrate can be formed as a single piece or divided into several parts called "bricks." Typically, the substrates are wrapped with an insulating material, such as an insulating mat, to reduce heat radiation to adjacent components in a vehicle underbody and to contain or support the substrate within the shell.

[0003] During vehicle operation, sensors are often used to monitor certain catalyst properties. For example, the catalyst often includes an oxygen sensor. The oxygen sensor is attached to a sensor protrusion mounted on the outer shell. In one known design, the sensor protrusion is attached to an outer shell that surrounds two substrates housed within the internal cavity.

[0004] The process for manufacturing this type of catalyst design typically involves measuring the substrates, weighing the mats, wrapping the mats around the substrates, and inserting the wrapped substrates into a cylindrical outer shell. The shell is then sized to a desired diameter, such as by reducing a shell diameter based on the measured substrate characteristics and the mat weight. Before the plugging step, at least one hole is typically punched into the outer shell at a location between the substrates. After the sizing process is complete, a sensor protrusion is attached to surround this hole. The sensor protrusion is typically welded to the outer shell around the location of the hole.

[0005] In certain designs, the outer shell may need to be resized to two different diameters to compensate for a component tolerance variation. It may be necessary to resize one end of the shell surrounding one substrate to a smaller diameter than an opposite end of the shell surrounding the other substrate. Conventional sizing processes for this type of design create a poor weld area around the sensor hole. The different diameters can result in large clearances between the boss and the shell at discrete locations around the circumference, which is undesirable.

[0006] US 2008 / 0041042 A1 discloses a catalyst having a pair of catalyst elements arranged in a housing along an axis of the housing.

[0007] US 6 317 976 B1 describes a process for producing catalysts with non-circular honeycomb-shaped substrates.

[0008] Furthermore, JP 4 856 618 B2 shows a diameter reducing die used in the manufacture of an elliptical catalyst.

[0009] US 2006 / 0 059 683 A1 discloses an exhaust system component having a tubular element with an outer wall and a drawing shape of the outer wall formed in the outer wall. SUMMARY OF THE INVENTION

[0010] In an exemplary embodiment, a method of forming an exhaust system component comprises providing at least a first substrate and a second substrate, providing an outer shell surrounding the first and second substrates, the outer shell defining a central axis extending in an axial direction, forming at least one sensor hole in the outer shell at a location between the first and second substrates, and surrounding a first end of the outer shell with a first plurality of fingers for resizing the first end around the first substrate to a first diameter, the first plurality of fingers comprising at least one extended finger that is longer in an axial direction than the other fingers such that the extended finger at least partially covers the sensor hole during resizing of the first end.

[0011] In a further embodiment to the above, the method comprises surrounding a second end of the outer shell with a second plurality of fingers for resizing the second end around the second substrate to a second diameter, wherein the second plurality of fingers comprises at least one recessed finger aligned with the at least one extended finger during resizing of the second end.

[0012] In a further embodiment to any of the above, the method comprises simultaneously resizing the first end and the second end until the first or second diameter for the associated first or second end is reached, and wherein the resizing for the other of the first or second end is continued until the other of the first or second diameter is reached.

[0013] In a further embodiment to any of the above, the at least one elongated finger comprises a first finger body extending axially from a base to a first distal end having a protruding tip, and the at least one recessed finger comprises a second finger body extending to a second distal end having a recess corresponding in shape to a shape of the protruding tip, and the method comprises receiving the protruding tip within the recess during resizing of the first and second ends.

[0014] In another exemplary embodiment, a method for forming an exhaust system component comprises providing at least a first substrate and a second substrate, providing an outer shell surrounding the first and second substrates, the outer shell defining a central axis, forming at least one sensor hole in the outer shell at a location between the first and second substrates, surrounding a first end of the outer shell with a first plurality of fingers for resizing the first end around the first substrate to a first diameter, the first plurality of fingers including at least a first finger having a protruding tip that is longer than the other fingers of the first plurality of fingers such that the protruding tip at least partially covers the sensor hole during resizing of the first end,and surrounding a second end of the outer shell with a second plurality of fingers for adjusting the size of the second end around the second substrate to a second diameter, wherein the second plurality of fingers includes at least one second finger with a recessed tip within which the projecting tip is received during adjustment of the size of the first and second ends.

[0015] In a further embodiment to any of the above, the method comprises attaching one or more sensor protrusions to the outer shell at the sensor hole.

[0016] In another exemplary embodiment, an apparatus is provided for adjusting the size of an exhaust system component, comprising an outer shell defining a central axis extending from a first end of the shell to a second end of the shell, a first substrate disposed within the interior cavity at the first end of the shell, a second substrate disposed within the interior cavity at the second end of the shell, and at least one sensor hole formed in the outer shell between the first and second substrates.The device comprises a plurality of first fingers for encasing the first end of the shell and adjusting the size of the outer shell around the first substrate to a first diameter, and wherein each first finger of the plurality of first fingers extends in an axial direction and is circumferentially spaced from one another about the central axis, and wherein the plurality of first fingers extend axially from a base to a distal first finger end, and at least one first finger has a protruding portion at the distal first finger end that is longer than the distal first finger end of the other first fingers.

[0017] In a further embodiment to any of the above, the device comprises a plurality of second fingers for surrounding the second end of the shell and adjusting the size of the outer shell around the second substrate to a second diameter, and wherein the plurality of second fingers extend in an axial direction and are circumferentially spaced from each other about the central axis, and wherein each second finger of the plurality of second fingers extends to a distal second finger end and at least one second finger has a depressed portion at the distal second finger end that receives the projecting portion.

[0018] In another exemplary embodiment of any of the above, the protruding portion at least partially covers the at least one sensor hole when the plurality of first fingers surround the first end of the shell.

[0019] In a further exemplary embodiment to any of the above, the recessed portion comprises a curved notch, wherein the protruding portion has a rounded tip that covers the sensor hole and extends into the curved notch when the size of the first and second substrates is adapted to the first and second diameters.

[0020] These and other features can best be understood using the following drawings and description. BRIEF DESCRIPTION OF THE DRAWINGS Fig. Figure 1 is a schematic representation of a vehicle exhaust system with a catalyst incorporating the present invention. Fig. Figure 2 is a schematic representation of the catalyst comprising two substrates and an outer shell sized to fit two different diameters. Fig. 3 is a schematic diagram of a sensor hole formed in the outer shell at a location between the two substrates. Fig. Figure 4 is a schematic representation of a tool used to adjust the size of the outer shell. Fig. Figure 5 is a perspective view of the tool showing multiple fingers with one finger extended. Fig. 6 is a plan view of a distal end of the extended finger relative to the sensor hole. Fig. 7 is a perspective view of another example of a tool used to adjust the size of the outer shell. Fig. Figure 8 is a schematic sectional view showing the tool and the outer shell of Fig. 7 shows. Fig. 9 is a Fig. 8 Similar view, but showing the two substrates. Fig. 10 is a plan view of a distal end of the extended finger of the tool of Fig. 7 relative to the sensor hole. Fig. Figure 11 is an example showing a substrate with an oval cross-section. Fig. Figure 12 is an example showing a cross-section of a package with more than one sensor hole at a location between substrates. DETAILED DESCRIPTION

[0021] Fig. 1 shows a vehicle exhaust system 10 that directs hot exhaust gases generated by an engine 12 through various upstream exhaust system components 14 to reduce emissions and mitigate noise in a known manner. The various upstream exhaust system components 14 may include one or more of the following elements: pipes, filters, valves, catalysts, mufflers, etc. In an exemplary embodiment, the upstream exhaust system components 14 direct exhaust gases into a catalyst 16 having an inlet 18 and an outlet 20. The outlet 20 directs exhaust gases to downstream exhaust system components 22. The various downstream exhaust system components 22 may include one or more of the following elements: pipes, filters, valves, mufflers, etc. The upstream 14 and downstream exhaust system components 22 may be mounted in many different configurations and combinations depending on the vehicle application and the available installation space.

[0022] As in Fig. 2, the catalyst 16 has an outer shell 24, which is also referred to as a container and defines an inner cavity 26. In the Fig. In the example shown in Figure 2, the catalyst 16 includes at least a first substrate 28 and a second substrate 30. The substrates 28, 30 are catalyst substrates and are received within the interior cavity 26. As is known, the catalyst substrate is a substance that accelerates a chemical reaction rate. In an automotive exhaust application, the catalyst substrate comprises an inert substance to which an active washcoat is applied. The catalyst substrate accelerates the oxidation of unconverted hydrocarbons, carbon monoxide, and nitrogen oxides to water, carbon dioxide, and hydrogen. The materials used for the inert substance and the active washcoat, as well as the operation of a catalyst, are well known and will not be described in further detail.

[0023] A first mat 32 surrounds the first substrate 28, and a second mat 34 surrounds the second substrate 30. The mats 32, 34 are compressed between the outer shell 24 and the respective substrates 28, 30 during the sizing process of the outer shell 24, as explained in more detail below. The outer shell 24 has an outer surface 36 and an inner surface 38 defining the inner cavity 26. The mats 32, 34 are pressed directly against the inner surface 38, providing insulation and promoting noise reduction. Any type of insulating mat material known in the art can be used for the mats 32, 34. The mats 32, 34 are preferably wrapped around the substrates 28, 30.

[0024] The outer shell 24 defines a central axis A extending from a first end 40 to a second end 42. At least one sensor hole 46 is formed in a region 44 on the outer shell 24 at a location between the first 28 and the second substrate 30 ( Fig. 3). In the example shown, the sensor hole 46 is circular. However, any other hole shape could be used, such as oval, square, rectangular, etc.

[0025] A sensor projection 48 is attached to the outer shell 24 and extends outwardly from the outer surface 36. The sensor projection 48 ( Fig. 11) is typically welded directly to the outer shell 24. The sensor boss 48 can be used for any type of exhaust gas sensor. However, the sensor boss 48 is preferably used for an oxygen sensor (not shown). Exhaust gas sensors are used to measure and monitor operating characteristics of a catalytic converter as needed. The operation of exhaust gas sensors, such as an oxygen sensor, is well known and will not be described in further detail.

[0026] In an exemplary embodiment, the first end 40 of the outer shell is sized to a first diameter D1 around the first substrate 28, and the second end 42 is sized to a second diameter D2 around the second substrate 30, wherein the second diameter D2 is larger than the first diameter D1. The sensor hole 46 is formed, for example, in a stamping process prior to plugging the first end 40 and second end 42. The region 44 in which the sensor hole 46 is formed typically has a very short axial length between the two substrates 28, 30. In such a configuration, this region 44 around the sensor hole 46 deforms to some extent during the sizing processes, resulting in different diameters on opposite sides of the sensor hole 46. This complicates the welding of the sensor protrusion 48 to the outer shell 24.A large gap is often formed on one side of the sensor hole 46, which is undesirable. The present invention provides a method and apparatus for adjusting the size of the outer shell 24 to provide a better weld area around the sensor hole 46.

[0027] As explained above, the outer shell 24 surrounds the first and second substrates 28, 30, which are wrapped in the first mat 32 and second mat 34, respectively. The substrates 28, 30 can have variable diameters, and the mats 32, 34 can have variable weights. In the example shown, the first substrate 28 has a first substrate diameter D3, and the second substrate has a second substrate diameter D4 that is larger than the first substrate diameter D3. The diameters D3 or D4 can be identical with varying dimensions, possibly caused by differences in the mats 32, 34. Also, due to the component tolerance variation, any difference between the diameters D3, D4 is very small. The difference is as in Fig. 1 shown schematically, greatly enlarged for explanatory purposes only.

[0028] The extent of the size adjustment of the first end 40 and the second end 42 is determined based on properties of the components located within the outer shell 24. These properties may, for example, be related to specific component properties of the substrates and / or mats or other components located within the outer shell. In one example, the diameter of the substrates and the weight of the mats are used. This example is described in more detail below.

[0029] In an exemplary method for manufacturing the catalytic converter 16, the sensor hole 46 is formed in the outer shell, the diameters of the substrates 28, 30 are measured, and the mats 32, 34 are weighed. After these steps have been performed, the first mat 32 is wrapped around the first substrate 28 and the second mat 34 is wrapped around the second substrate 30. The wrapped substrates 28, 30 are then stuffed into the outer shell 24. The outer shell 24 has at least one sensor hole 46 punched into the outer shell 24 at a location between the substrates 28, 30 prior to the stuffing step.

[0030] The size of a first end 40 of the outer shell 24 is then adjusted to the first diameter D1 based on the measured diameter of the first substrate 28 and the weight of the first mat 32. The first end 40 refers to the portion of the outer shell 24 that surrounds at least the first substrate 28.

[0031] As in the Fig. 4 through 6, the sizing process utilizes a sizing tool 50 having a base 52 coupled to an actuator 54. A plurality of circumferentially spaced fingers 56 extend outwardly from the base 52. At least one of the fingers 56a is longer than the remaining fingers 56. In the preferred embodiment, only one extended finger 56a is longer than the remaining fingers 56. This extended finger 56a is oriented to extend over and at least partially cover the sensor hole 46 during the first end 40 sizing process. This forms a surface around one side of the sensor hole 46 sized to the first diameter D1. During the sizing process, the actuator 54 moves the fingers 56 radially inward toward the central axis A to apply a compressive force F to shrink the outer shell 24 to the specific first diameter D1.The functionality of the resizing tool for reducing the outer shell to the desired size is well known and will not be described in detail.

[0032] Once the first end 40 has been sized to the first diameter D1, the outer shell 24 is removed from the sizing tool 50, and the entire assembly is then flipped over for the second sizing process. The second end 42 of the outer shell 24 is then surrounded by the fingers 56 and sized to the second diameter D2 based on the measured diameter of the second substrate 30 and the weight of the second mat 34. The second end 42 refers to the portion of the outer shell 24 that surrounds at least the second substrate 30. The extended finger 56a is oriented to extend over and at least partially cover the sensor hole 46 during the second sizing process. This forms an area around an opposite side of the sensor hole 46 sized to the second diameter D2, which is larger than the first diameter D1.During the resizing process, the actuator 54 moves the fingers 56 radially inward toward the central axis A to reduce the outer shell 24 to the specific second diameter D2.

[0033] In another example, the plurality of fingers could include a first group of fingers and a second group of fingers, wherein each of the first and second groups of fingers includes at least one extended finger 56a. As such, a group of fingers as shown in Fig. 5 shown arranged at one end of the outer shell 24 and another group of fingers as in Fig. 5, arranged at an opposite end of the outer shell 24. The size of the first end 40 of the outer shell is adapted to the first diameter D1 with the first group of fingers, and the size of the second end 42 of the outer shell is adapted to the second diameter D2 with the second group of fingers. This embodiment may increase tooling costs because two separate groups of fingers are required, but the step of flipping the outer shell is eliminated.

[0034] Because the diameter of the second sizing is larger than that of the first sizing, in the example shown, the extended finger 56a does not touch the side of the sensor hole 46 sized to the first diameter D1, resulting in less deformation. Finally, the sensor protrusion 48 is then welded to surround the sensor hole 46. The area around the sensor hole 46 still has two different diameters. However, the surface has a better shape for welding than in conventional sizing processes.

[0035] The fingers 56 extend axially from the base 52 and are circumferentially spaced from each other about the central axis A. The fingers 56 are defined by an axial length L1 extending from the base 52 to a distal finger end 58. In one example, the axial length L1 extends to a location generally at a center of the sensor hole 46. The extended finger 56a has a greater axial length L2 than the other fingers 56. In one example, the longer axial length L2 is configured to extend past the sensor hole 46 by a predetermined minimum length, for example, 5 mm. The predetermined minimum length varies depending on the catalyst redesign, the size of the substrates, and the weight of the mats.

[0036] In one example, the distal finger end 58 has a portion that extends beyond the distal finger end 58 to completely cover the sensor hole 46. This shape of the portion 60 can vary. In the example shown, the fingers 56 are all defined in a circumferential direction by a common width W1. In one example, the portion 60 has a rounded portion that does not extend the entire width W1 of the extended finger 56a. In another example, the portion 60 could be rounded along its entire width. The extended portion with the difference in axial length (L2-L1) has a circumferential region surrounding a portion of the sensor hole 46. This provides a process that does not adversely deform the sensor hole 46 and does not result in excessive pressure being applied to the mats 32, 34.By having only one finger 56a extend past the sensor hole 46, as opposed to all fingers extending past it, a better weld area around the sensor hole 46 is achieved, as well as less deformation and the avoidance of excessive compression of the mat.

[0037] The Fig. 7 through 10 illustrate another exemplary method and apparatus for resizing an outer shell around two substrates. In this example, an outer shell 124 defines an interior cavity 126 including at least a first substrate 128 and a second substrate 130. A first mat 132 surrounds the first substrate 128, and a second mat 134 surrounds the second substrate 130. The mats 132, 134 are compressed between the outer shell 124 and the respective substrates 128, 130 during resizing of the outer shell 124 in the manner discussed above. The outer shell 124 has an outer surface 136 and an inner surface 138 defining the interior cavity 126. The mats 132, 134 are pressed directly against the inner surface 138, providing insulation and promoting noise reduction.

[0038] The outer shell 124 defines the central axis A, which extends from a first end 140 to a second end 142. In a region 144 on the outer shell 124 at a location between the first 128 and the second substrate 130, at least one sensor hole 146 ( Fig. 7). In the example shown, the sensor hole 146 has a circular shape. However, any other hole shape may be used, such as an oval, square, rectangular, etc. A sensor protrusion is attached to the outer shell 124 and extends outwardly from the outer surface 136 as described above.

[0039] As described above, the substrates 128, 130 may have variable diameters, and the mats 132, 134 may have variable weights. Also as described above, the extent of adjustment of the size of the first end 140 and the second end 142 is determined based on the properties of the components located within the outer shell 124.

[0040] In the Fig. 7 through 10, the sizing process utilizes a sizing tool 150 having a base 152 associated with a controller / actuator 154. A plurality of circumferentially spaced first fingers 156 extend axially outward from the base 152. At least one of the fingers 156a includes a protruding portion 160 that is longer than a distal end of the remaining fingers 156. The protruding portion 160 may be configured to have varying profiles. In the preferred embodiment, only one extended finger 156a includes a protruding portion 160. This extended finger 156a is oriented to extend over and at least partially cover the sensor hole 146 during the sizing process of the first end 140. This creates an area around the sensor hole 146 sized to match the first diameter D1.During the resizing process, the actuator 154 moves the fingers 156 radially inward toward the central axis A to apply a compression force F to reduce the outer shell 124 to the specific first diameter D1. The operation and control of the resizing tool with a controller and actuator to reduce the outer shell to the desired size are well known and will not be described in further detail.

[0041] In this example, the device includes a plurality of circumferentially spaced second fingers 170 extending axially outward from the associated base 152 in a direction toward the first fingers 156. At least one of the fingers 170a includes a recessed portion 172 that receives the protruding portion 160 when the first 156 and second fingers 170 surround the outer shell 124. In the preferred embodiment, only one finger 170a includes a recessed portion 172 for aligning with the protruding portion 160.

[0042] In this example, the size adjustment of the first end 140 and the second end 142 occurs simultaneously. Thus, there are two independent size adjusters / actuators 154, both of which adjust the size of the outer shell 124 at the same time and at the same speed. Whichever end has the larger diameter stops first, and the other size adjuster continues to operate until the desired smaller diameter is reached. In this embodiment, the deformation around the sensor hole 146 is reduced compared to the Fig. 2 to 6 shown designs are even further minimized.

[0043] As in Fig. 10, the at least one extended finger 156a includes a first finger body 180 extending to a first distal end 158 having a protruding tip 184. The at least one recessed finger 170a includes a second finger body 190 extending to a second distal end 192 having a recess 194 that generally corresponds in shape to a shape of the protruding tip 184. The protruding tip 184 is received within the recess 194 during resizing of the first end 140 and the second end 142.

[0044] In one example, the recess 194 includes a curved notch, and the protruding tip 184 includes a rounded portion that covers the sensor hole 146 and extends into the curved notch when the size of the first and second substrates is adjusted to the first and second diameters. Other shapes for the protruding and depressed portions may also be used.

[0045] In the Fig. In the examples shown in Figures 2 to 10, the substrates have a circular cross-section. However, the substrates could also have other cross-sectional shapes. For example, the substrates could be as shown in Fig. 11 shown at 200 have an oval cross-section.

[0046] In the Fig. In the examples shown in Figures 2 to 10, the outer shell also has a sensor opening or a sensor hole. Fig.12 shows an example in which an outer shell 224 has at least two openings 246. In this example, one of the first and second groups of fingers has a second protruding tip, while the other of the first and second groups of fingers has the corresponding recessed portion. Additional openings 246 may be included if desired. For each hole in the outer shell, there is a corresponding pair of protruding and recessed fingers. Reference symbol 10 Vehicle exhaust system 12 Engine 14 exhaust system components 16 Catalyst 18 Entrance 20 Outlet 22 exhaust system components 24 Outer shell 26 Internal cavity 28 first substrate 30 second substrate 32 first mat 34 second mat 36 exterior area 38 inner surface 40 first end 42 second end 44 Area 46 Sensor hole 48 Sensor projection 50 Resize tool 52 Base 54 Actuator 56 fingers 56a extended finger 58 Finger end Section 60 124 Outer shell 126 Internal cavity 128 first substrate 130 second substrate 132 first mat 134 second mat 136 exterior area 138 interior surface 140 first end 142 second end 144 Area 146 Sensor hole 150 Resize tool 152 Base 154 Control device / actuator 156 first fingers 156a extended finger 158 End Section 160 170 second fingers 170a recessed finger Section 172 180 first finger body 184 lace 190 second finger body 192 End 194 Deepening 224 Outer shell 246 openings

Claims

[1] A method for forming an exhaust system component comprising the following steps: Providing at least a first substrate (28) and a second substrate (30); Providing an outer shell (24) surrounding the first and second substrates (28, 30), the outer shell (24) defining a central axis (A) extending in the axial direction; Forming at least one sensor hole (46) in the outer shell (24) at a location between the first and second substrates (28, 30); and Surrounding a first end (40) of the outer shell (24) with a first plurality of fingers (56) for adjusting the size of the first end (40) around the first substrate (28) to a first diameter (D1), wherein the first plurality of fingers (56) comprises at least one extended finger (56a) that is longer in the axial direction than the other fingers (56) such that the extended finger (56a) at least partially covers the sensor hole (46) during the adjustment of the size of the first end (40). [2] The method of claim 1, comprising surrounding a second end (42) of the outer shell (24) with a second plurality of fingers (56) for resizing the second end (42) around the second substrate (30) to a second diameter (D2), wherein the second plurality of fingers (170) includes at least one recessed finger (170a) aligned with the at least one extended finger (56a) during resizing of the second end (42). [3] The method of claim 2, wherein the adjustment of the size of the first end (40) and the adjustment of the size of the second end (42) occur simultaneously until the first or second diameter (D1, D2) for the associated first or second end (40, 42) is reached, and wherein the size adjustment for the other of the first and second ends (40, 42) is continued until the other of the first and second diameters (D1, D2) is reached. [4] The method of claim 2, wherein the first or second diameter (D1, D2) is larger than the other of the first and second diameters (D1, D2), and the method further comprises, prior to inserting the first and second substrates (28, 30) into the outer shell (24), wrapping the first substrate (28) with a first mat (32) and wrapping the second substrate (30) with a second mat (34). [5] The method of claim 4, wherein the first substrate (28) has a first substrate diameter (D3) and the second substrate (30) has a second substrate diameter (D4) different from the first substrate diameter (D3), and the method comprises measuring the first and second substrate diameters (D3, D4) prior to wrapping the first and second substrates (28, 30) with the first and second mats (32, 34). [6] The method of claim 5, including weighing the first and second mats (32, 34) prior to wrapping the first and second mats (32, 34) around the first and second substrates (28, 30). [7] The method of claim 6, including adjusting the size of the first end (40) of the outer shell (24) to the first diameter (D1) based on a measured diameter of the first substrate (28) and the weight of the first mat (32) and adjusting the size of the second end (42) of the outer shell (24) to the second diameter (D2) based on a measured diameter of the second substrate (30) and the weight of the second mat (34). [8] The method of claim 7, including aligning the extended finger (56a) to completely cover the sensor hole (46) during the adjustment of the size of the first end (40). [9] The method of claim 2, wherein the at least one recessed finger (170a) extends axially from a base (52) to a second distal end (192), and wherein aligning the extended finger (56a) to at least partially cover the sensor hole (46) and positioning a protruding portion (160) of the extended finger (56a) within a recess (194) in the second distal end (192) of the recessed finger (170a) during the resizing of the first end (40). [10] The method of claim 9, comprising attaching a sensor protrusion (48) to the outer shell (24) at the sensor hole (46). [11] The method of claim 2, wherein the at least one extended finger (56a) comprises a first finger body (180) extending axially from a base (52) to a first distal finger end (58) having a projecting tip (184), and wherein the at least one recessed finger (170a) comprises a second finger body (190) extending axially from the base (52) to a second distal end (192) having a recess (194) corresponding in shape to a shape of the projecting tip (184), and wherein the method comprises receiving the projecting tip (184) in the recess (194) during resizing of the first and second ends (40, 42). [12] A method for forming an exhaust system component comprising the following steps: Providing at least a first substrate (128) and a second substrate (130); Providing an outer shell (124) surrounding the first and second substrates (128, 130), the outer shell (124) defining a central axis (A); Forming at least one sensor hole (146) in the outer shell (124) at a location between the first and second substrates (128, 130); Surrounding a first end (140) of the outer shell (124) with a first plurality of fingers (156) for adjusting the size of the first end (140) around the first substrate (128) to a first diameter (D1), wherein the first plurality of fingers (156) includes at least one first finger (156a) having a protruding tip (184) that is longer than the other fingers of the first plurality of fingers (156) such that the protruding tip (184) at least partially covers the sensor hole (146) during the adjustment of the size of the first end (140); and Surrounding a second end (142) of the outer shell (124) with a second plurality of fingers (170) for adjusting the size of the second end (142) around the second substrate (130) to a second diameter (D2), the second plurality of fingers (170) comprising at least one second finger (170) having a recess (194) within which the projecting tip (184) is received during adjustment of the size of the first and second ends (140, 142). [13] The method of claim 12, comprising simultaneously resizing the first end (140) and the second end (142) with the first and second plurality of fingers (156, 170), respectively. [14] The method of claim 12, wherein the first or second diameter (D1, D2) is larger than the other of the first and second diameters (D1, D2). [15] A device for adjusting the size of an exhaust system component, comprising an outer shell (24) defining a central axis (A) extending from a first end (40) of the outer shell (24) to a second end (42) of the outer shell (24), a first substrate (28) disposed within the internal cavity (26) at the first end (40) of the outer shell (24), a second substrate (30) disposed within the internal cavity (26) at the second end (42) of the outer shell (24), and at least one sensor hole (46) formed in the outer shell (24) between the first and second substrates (28, 30), the device comprising: a plurality of first fingers (56) for surrounding the first end (40) of the outer shell (24) and for adjusting the size of the outer shell (24) around the first substrate (28) to a first diameter (D1), and wherein the plurality of first fingers (56) extend in an axial direction and are circumferentially spaced from one another about the central axis (A); and wherein each first finger (56) of the plurality of first fingers (56) extends axially from a base (52) to a first distal finger end (58), and at least one first finger (56a) has a protruding portion (60) at the first distal finger end (58) that is longer than the first distal finger end (58) of the other first fingers (56). [16] The device of claim 15, comprising a plurality of second fingers (170) for surrounding the second end (42) of the outer shell (24) and adjusting the size of the outer shell (24) around the second substrate (30) to a second diameter (D2), and wherein the plurality of second fingers (170) extend in an axial direction and are circumferentially spaced from each other about the central axis (A); and wherein each second finger of the plurality of second fingers (170) extends to a second distal end (192), and at least one second finger (170) has a recess (194) at the second distal end (192) that receives the projecting portion (60). [17] The device of claim 16, wherein the protruding portion (60) at least partially covers the at least one sensor hole (46) when the plurality of first fingers (56) surround the first end (40) of the outer shell (24). [18] The device of claim 16, wherein to reduce the first end (40) of the outer shell (24) to the first diameter (D1), the plurality of first fingers (56) are moved radially inward toward the central axis (A) by an actuator (54) and to reduce the second end (42) of the outer shell (24) to the second diameter (D2), the plurality of second fingers (170) are moved radially inward toward the central axis (A) by an actuator (54), wherein the first or second diameter (D1, D2) is larger than the other of the first and second diameters (D1, D2). [19] The device of claim 16, wherein the recess (194) has a curved notch and the protruding portion (60) has a rounded tip (184) covering the sensor hole (46) and extending into the curved notch when the size of the first and second substrates (28, 30) is adapted to the first and second diameters (D1, D2). [20] The apparatus of claim 16, including control means (154) for actuating said first and second plurality of fingers (156, 170) for radially inward movement during said resizing.

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