Exhaust Pipe Connection Member Integrating Sensor Boss
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Solution Overview
Problem
Existing exhaust system structures for internal combustion engines face challenges in improving sensor detection accuracy and reducing manufacturing costs, particularly due to the need for additional components like separate bosses for sensor attachment and the complexity of exhaust flow affecting sensor positioning.
Innovation Solution
A connection member with an integrally formed flange, boss, and attachment portion that allows for direct attachment of sensors and heat protectors to the exhaust pipe, reducing the number of parts and optimizing sensor placement for improved detection accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a separate boss is added to the flange for sensor attachment, then the sensor can be attached to the exhaust pipe, but the number of parts increases and manufacturing cost increases
Solution Approach 1:
The boss portion is integrated into the flange portion as a single integral structure, combining the connection function and sensor attachment function into one component. This eliminates the need for separate boss parts while maintaining both the exhaust pipe connection capability and the sensor mounting capability.
Solution Approach 2:
The flange portion is designed with multiple functions: it serves as the connection interface for the exhaust pipe, provides structural support through the boss portion for sensor attachment, and maintains structural integrity. This multi-functional design reduces the overall number of components needed in the system.
2Ease of operation
If a separate boss is added to the flange for sensor attachment, then the sensor can be attached to the exhaust pipe, but manufacturing cost increases
Solution Approach 1:
The boss portion is integrated into the flange portion as a single integral structure, combining the connection function and sensor attachment function into one component. This eliminates the need for separate boss parts while maintaining both the exhaust pipe connection capability and the sensor mounting capability.
Solution Approach 2:
The flange portion is designed with multiple functions: it serves as the connection interface for the exhaust pipe, provides structural support through the boss portion for sensor attachment, and maintains structural integrity. This multi-functional design reduces the overall number of components needed in the system.
3Ease of operation
If the sensor is positioned downstream in the exhaust pipe, then it is easier to install, but the exhaust flow pattern becomes complex and detection accuracy decreases
Solution Approach 1:
The boss portion is designed to extend in the exhaust flow direction, creating a flow-guiding structure before the sensor is positioned downstream. This preliminary structural arrangement helps organize the exhaust flow pattern, ensuring more uniform flow conditions reach the sensor despite its downstream location.
Solution Approach 2:
The boss portion adds a structural dimension to the exhaust flow path, creating a three-dimensional flow guidance structure that modifies the two-dimensional flow pattern. This dimensional addition helps straighten and uniformize the flow before it reaches the sensor measurement point.
Data Source
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AI summary
A connection member (1) for connecting an exhaust manifold (2) and an exhaust pipe (4) of an internal combustion engine (40), includes a flange portion (10), a boss portion (20) and an attachment portion (30). The flange portion (10) has a plate shape with an opening (11) configured to be fixed to the exhaust pipe (4) in a state where the opening (11) communicates with the exhaust pipe (4). The boss portion (20) is provided to bulge from the flange portion (10) on an outside of the opening (11) in a radial direction of the opening (1), is configured so that a sensor (5) configured to detect components of the exhaust is attached to the boss portion (20), and is configured to be fixed to a portion of an outer circumferential surface of the exhaust pipe (4). The attachment portion (30) protrudes from the flange portion (10) and is configured so that a protection member (8) which covers the exhaust pipe (4) is attached to the attachment portion (30).