Catalyst Unit Vibration Fixation via Bearing Mat Density
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Solution Overview
Problem
Exhaust gas catalytic converters for large engines, particularly in non-stationary applications like ships, face issues with catalyst bodies being dislodged or detached due to vibrations and oscillations, necessitating a secure fixation method.
Innovation Solution
A catalyst unit design with defined dimensions for the catalyst body and housing, including a gap dimension dependent on the bearing mat density, and projections to enhance sealing and fixation, ensuring the catalyst body remains securely in place under vibration loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a catalyst body is fixed in a housing using bearing mats for non-stationary applications, then the catalyst unit can be assembled, but the catalyst body is dislodged or detached due to vibrations and oscillations
Solution Approach 1:
The patent applies parameter changes by establishing a specific mathematical relationship between the gap dimension (s) and bearing mat density (p), expressed as s ≤ p × 5. This quantitative parameter optimization ensures that the bearing mat has sufficient density to withstand vibration and oscillation forces while maintaining the required gap dimension for proper catalyst body positioning and exhaust gas flow.
Solution Approach 2:
The patent implements preliminary anti-action by pre-defining the gap dimension between the catalyst body and housing based on the bearing mat density before the unit is subjected to vibration loads. This pre-calculated gap dimension (s ≤ p × 5) creates a stable configuration that proactively counteracts the harmful effects of vibrations and oscillations, preventing catalyst body dislodgment before it occurs.
2Reliability
If the gap dimension is reduced to prevent catalyst body dislodgment, then fixation stability improves, but exhaust gas flow may be restricted
Solution Approach 1:
The patent resolves this contradiction through parameter optimization by establishing the relationship s ≤ p × 5, which calculates the maximum acceptable gap dimension based on bearing mat density. This ensures the gap is small enough to prevent catalyst body dislodgment under vibration loads while remaining large enough to maintain adequate exhaust gas flow through the catalyst unit.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The catalyst unit effectively prevents dislodgment and detachment of the catalyst body during operation, maintaining stability and ensuring efficient exhaust gas flow while reducing the risk of mechanical failure.
Implementation Method 1
a bearing mat, which is positioned in a gap between the catalyst body and the housing of the respective catalyst unit
Implementation Method 2
the gap between the margins of the catalyst body and the metallic housing seen perpendicularly to the through-flow direction of the catalyst body having a dimension determined according to the following relationship: S≤p*5
Data Source
AI summary
A catalyst unit includes: a ceramic catalyst body through which exhaust gas flows and having a substantially cuboid contour with a substantially rectangular inflow side and a substantially rectangular outflow side; a housing that at least partially encloses the catalyst body, and at least one bearing mat positioned in a gap formed between the catalyst body and the housing. Borders or edges of the catalyst body, which delimit the inflow side and the outflow side, each have dimensions of between 210 mm and 280 mm. The gap between the catalyst body and the housing, seen perpendicularly to the throughflow direction of the catalyst body, has a dimension determined according to the following relationship: s≤p*5, s being the dimension of the gap in mm and p the dimensionless amount of the density of the or each bearing mat expressed in kg/m2.