EGR Pipe Repair Kit In-Situ Fastener Alignment
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Solution Overview
Problem
The current methods for repairing EGR pipes and manifolds are time-consuming, costly, and prone to damage due to corrosion, contamination, and thermal expansion, often requiring the removal of multiple engine components, which exposes internal components to dirt and increases the risk of breaking fasteners.
Innovation Solution
A device with a rhomboid body, repair holes, mounting pins, and an expandable flange that securely attaches to the EGR pipe, allowing for precise alignment and machining of new fasteners without removing the EGR assembly from the vehicle, facilitating in-situ repairs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If traditional methods are used to repair EGR pipes, then fasteners can be replaced, but multiple engine components must be removed which increases repair time and complexity
Solution Approach 1:
The repair device serves as an intermediary tool that interfaces with the EGR pipe flange and provides mounting holes for fastener repair. This intermediary device eliminates the need to remove engine components while still allowing access to damaged fasteners, thereby reducing repair time and complexity.
2Ease of repair
If traditional repair methods are used, then fasteners can be accessed, but the risk of damaging components and fasteners increases due to corrosion and contamination
Solution Approach 1:
The repair device allows technicians to perform fastener repair without removing the EGR assembly from the vehicle. The device mounts directly to the EGR pipe flange and provides self-contained mounting holes that enable fastener access and replacement while the assembly remains in place, reducing the risk of contamination and damage.
3Ease of repair
If EGR assembly is removed for repair, then fasteners can be accessed, but internal components are exposed to dirt and contaminants
Solution Approach 1:
The repair device acts as an intermediary that provides access to fasteners without requiring removal of the EGR assembly. By mounting to the flange and providing external access points, it allows fastener repair while keeping the EGR assembly sealed and protected from contaminants.
4Ease of repair
If extensive disassembly is performed to repair EGR pipes, then damaged fasteners can be replaced, but the complexity and cost of the repair process increases
Solution Approach 1:
The repair device is segmented into distinct functional components: a body with mounting holes, a flange for attachment to the EGR pipe, and separate fastener access mechanisms. This segmentation allows the device to perform multiple functions (mounting, alignment, fastener access) without requiring complex integration, thereby reducing overall repair process complexity.
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
Enables efficient and cost-effective repair of EGR pipes and manifolds by allowing precise alignment and machining of new fasteners in place, reducing the need for extensive disassembly and minimizing the risk of component damage.
Implementation Method 1
an expandable flange that securely attaches to the EGR pipe
Data Source
AI summary
An improved apparatus for repairing pipes and tubes, such as EGR pipes, is disclosed. The apparatus can be readily mounted to the pipe or tube via a flange that fits inside the pipe or tube and thus generally avoids the need to remove any adjacent components. The apparatus further provides holes or bushings that allow for the precise alignment of various repair tools.