Diesel Emission Control Core Replacement Using Hydraulic Pressing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for replacing cores in diesel emission control devices (DECDs) are inefficient and lack a systematic approach for removing and inserting cores of various shapes and sizes, leading to potential damage and increased operational costs.
Innovation Solution
A system comprising a core press station with a piston and control station, along with a decore and recore shaft, push plate, and adjustable wrapping station, enables precise removal and insertion of cores using hydraulic pressure and a two-handed sensor system for activation control, ensuring safe and efficient core replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If existing methods are used for replacing cores in DECDs, then the process is simple, but the efficiency is low and potential damage occurs
Solution Approach 1:
The system divides the core replacement process into distinct operational phases: removal phase using decore shaft and push plate, and insertion phase using recore shaft and stuffing funnel. This segmentation allows each tool to be optimized for its specific function, improving both efficiency and reliability without requiring complex multi-functional equipment.
Solution Approach 2:
The patent introduces intermediary components such as the push plate that interfaces between the hydraulic press and the core, and the stuffing funnel that guides the core during insertion. These intermediaries distribute forces evenly and prevent direct contact between pressing mechanisms and the core, thereby preventing damage while maintaining high replacement efficiency.
2Reliability
If a systematic approach with multiple components is implemented, then core replacement safety improves, but device complexity increases
Solution Approach 1:
The hydraulic press serves multiple functions within the system: it provides controlled forcing for core removal, supports the working platform during operations, and enables precise pressure application. This multi-functionality reduces the need for separate specialized equipment, thereby improving safety without proportionally increasing overall system complexity.
Solution Approach 2:
The system employs a working platform that provides stable support at a consistent height during both removal and insertion operations. This equipotential approach ensures that components remain properly aligned and supported throughout the process, improving safety through consistent positioning without requiring complex adjustment mechanisms.
3Manufacturing precision
If hydraulic pressure is used for core removal and insertion, then operational precision improves, but energy consumption increases
Solution Approach 1:
The hydraulic press applies force in controlled increments rather than continuous maximum pressure. The system uses just enough pressure to accomplish each stage of the operation (loosening the core, removing it, inserting the new core, compaction), avoiding excessive energy consumption while maintaining precise control over the core placement process.
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 system facilitates safe and economical refurbishment of DECDs by minimizing damage and optimizing the process of core removal and insertion, thereby extending the life and performance of diesel emission control devices.
Implementation Method 1
A system for removing an existing core from a DECD housing may comprise: a core press station having a piston and a working platform; a control station for controlling movement the piston; and a decore shaft connected to the piston, whereby movement of the piston is configured to push the existing core out of the DECD housing.
Implementation Method 2
a recore shaft connected to the piston; a stuffing funnel configured to couple to the DECD housing proximate an upper end of the DECD housing; whereby movement of the piston is configured to press the replacement core through the stuffing funnel and into the DECD housing
Data Source
AI summary
A system for removing an existing core from a diesel emission control device (DECD) housing and a system for installing a replacement core into the DECD housing. The system for removing the existing core comprising a core press station, a control station, and a decore shaft. The system for installing the replacement core comprising a core press station, a control station, and a recore shaft. A stuffing funnel and spacer may be used to install the replacement core. In certain embodiments, processes for removing the existing core and installing the replacement core may comprise the steps of pressing the existing core out of the DECD housing, collecting the existing core into a collection container, sealing the collection container, wrapping the replacement core with matting, lubricating the matting, and pressing together the replacement core and the existing DECD housing.