Exhaust Gas Treatment Casing Sizing with Inserted Funnel
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Solution Overview
Problem
The existing manufacturing process for exhaust gas treatment devices is inefficient due to the need for varying funnels with different cross-sections to match the varying ultimate cross-sections of the casing after the sizing process, leading to high costs and time-consuming measurements.
Innovation Solution
Insert the funnel into the casing before reducing its cross-section, allowing the inside cross-section to match the funnel's outside cross-section, eliminating the need for post-sizing measurements and varying funnel selections, and enabling a simple, automated fixation without radial gaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the casing cross-section is reduced after inserting the exhaust gas treatment cartridge, then the cartridge is fixed in position and pre-stress is generated, but the ultimate cross-section varies due to manufacturing tolerances requiring multiple funnel sizes
Solution Approach 1:
The funnel is inserted into the casing before the cross-section reduction process. This preliminary positioning allows the funnel to serve as a reference object during sizing, ensuring that the ultimate cross-section is determined by the funnel dimensions rather than varying cartridge dimensions. The funnel acts as a predetermined reference that eliminates the need for multiple funnel sizes to accommodate different cartridge tolerances.
2Measurement precision
If the ultimate cross-section is measured after sizing to select an appropriate funnel, then the correct funnel can be chosen, but the process becomes time-consuming and cost-intensive
Solution Approach 1:
The funnel is selected and inserted before the sizing process based on nominal dimensions rather than actual measured dimensions. This eliminates the need for post-sizing measurements and iterative selection. The funnel choice is predetermined, and the sizing process automatically adapts to achieve the correct fit, thereby eliminating time-consuming measurement and selection steps.
3Adaptability or versatility
If a broad selection of funnels with different cross-sections is made available, then the correct funnel can be selected for each casing, but the expenditure increases
Solution Approach 1:
A single funnel size can be used for all casings regardless of variations in the exhaust gas treatment cartridge dimensions. The funnel serves as a universal component that works with any cartridge within the specified tolerance range. The sizing process adjusts the casing to match the fixed funnel dimensions, making the funnel system universal rather than requiring multiple specialized funnel sizes.
4Manufacturing precision
If the funnel is inserted after cross-section reduction, then the funnel can be selected to match the ultimate cross-section, but radial gaps remain requiring complex fixation
Solution Approach 1:
The funnel is inserted into the casing before the cross-section reduction process. During sizing, the casing is compressed to match the funnel's outside cross-section, ensuring that the funnel ends up with no radial gaps against the casing inner surface. This preliminary insertion combined with subsequent sizing achieves both precise fit and simple fixation, eliminating the need for complex adjustment or additional gap-filling operations.
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 approach reduces manufacturing costs by eliminating the need for multiple funnel selections and measurements, allowing for a standard funnel to be used across different devices with varying cartridges, while ensuring a gas-tight connection through a circumferential welding seam.
Implementation Method 1
the inside cross-section of the casing is reduced to the outside cross-section of the funnel in the end region, into which the respective funnel is inserted
Implementation Method 2
compress a supporting mat of the exhaust gas treatment cartridge that is wrapped around the circumference of a cartridge body in order to generate a pre-stress
Implementation Method 3
The funnel is subsequently fixed on the casing in a gas-tight fashion, particularly with the aid of a circumferential welding seam
Data Source
AI summary
A method for manufacturing an exhaust gas treatment device for an internal combustion engine comprises axially inserting an exhaust gas treatment cartridge into a casing, wherein the casing has an initial inside cross-section that is larger than an outside cross-section of the exhaust gas treatment cartridge. A funnel is axially inserted into an end region of the casing, wherein an outside cross-section of the funnel is smaller than the initial inside cross-section of the casing. The cross-section of the casing is subsequently reduced such that the casing ultimately has a first ultimate inside cross-section that is equal to the outside cross-section of the exhaust gas treatment cartridge in a region, in which the at least one exhaust gas treatment cartridge is arranged, and a second ultimate inside cross-section that is equal to the outside cross-section of the funnel in the respective end region, in which the respective funnel is arranged.