Conical Joining Element for Exhaust Tubular Component Welding
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Solution Overview
Problem
The existing methods for joining components in exhaust systems of internal combustion engines, particularly those involving tubular components, face challenges in achieving a high-quality, gas-tight joint due to varying shape and dimensional tolerances, leading to mechanical difficulties and the need for manual rework, which complicates automated manufacturing and can weaken the bearing structure.
Innovation Solution
A ring-shaped joining element with an outer cone is pressed into an axial end section of one component, widening it to create a flat contact surface for a circumferential weld seam, allowing for a high-quality, automated joint production, and optionally using an axial stop to define the cross-section and position of the weld seam.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the housing cross section is calibrated to match the insert with bearing mat, then the bearing mat achieves predetermined radial preload or compression, but the housing cross section varies within a wide range creating gaps that require manual rework
Solution Approach 1:
A joining element with a conical pressing-in section acts as an intermediary between the calibrated housing and the joining funnel. The conical section is pressed into the housing to create a localized enlarged cross section that provides a uniform bearing surface, mediating between the variable housing dimensions and the precise funnel requirements.
Solution Approach 2:
The joining process is segmented into distinct functional zones: the conical pressing-in section for creating the enlarged bearing area, the joining section for connection to the funnel, and the bearing section for supporting the housing. This segmentation allows each zone to optimize its specific function independently.
2Manufacturing precision
If manual rework is performed to close gaps between housing and funnel, then gas-tight joint quality improves, but manufacturing complexity and time increase
Solution Approach 1:
The conical pressing-in section is pre-formed on the joining element before assembly. This preliminary action creates the enlarged cross section in advance, ensuring that when the joining element is inserted into the calibrated housing, the uniform bearing surface is already prepared for direct welding to the funnel without manual gap closing.
3Volume of moving object
If axial transition regions are installed in the bearing pipe above the ceramic insert, then space requirements are reduced, but the carrying bearing length of the bearing mat is shortened weakening the bearing
Solution Approach 1:
The transition from the calibrated housing cross section to the joining funnel cross section is achieved radially through the conical pressing-in section, rather than axially. This radial expansion creates the necessary transition zone without consuming axial length, preserving the bearing mat's carrying length while still enabling the cross-sectional transition.
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
This method simplifies the production of high-quality, gas-tight weld joints between tubular components, reducing the need for manual rework and enabling more efficient automated manufacturing while maintaining the structural integrity of the bearing mat.
Implementation Method 1
ring-shaped joining element which comprises at least one outer cone with which it can be pressed into an axial end section of the one component of tubular design in such a manner that the end section of the one component is widened along this outer cone
Implementation Method 2
A circumferential weld seam can now be produced on this widened end section which joins the joining element with the one component
Data Source
AI summary
A method for joining two components, of which at least one is tubular in shape, more preferably of an exhaust system of an internal combustion engine. The joint can be produced in an easier manner with high quality if a ring-shaped joining element having an outer cone on at least one axial side with its outer cone is axially pressed into an axial end section of the one tubular component, as a result of which the end section of the one component widens along the outer cone when on its axial end of the widened end section and on the joining element a circumferential weld seam is produced and when the other component on an axial end section is joined with the joining element.