Exhaust Connector Assembly With Tilted Weld Joint Flexibility
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Solution Overview
Problem
Conventional exhaust systems for vehicles require different components and tools to discharge exhaust gas based on the specific configuration of the vehicle, leading to increased manufacturing costs.
Innovation Solution
A method and system that allows a single connecting piece to be used for different positions and orientations of the catalytic converter's outlet pipe by adjusting the tilt angle between the longitudinal axes of the connecting piece and outlet pipe, enabling a gas-tight connection through welding, and using a clamp for a detachable connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If exhaust gas components are fastened to the vehicle frame using conventional methods, then the exhaust gas system can be assembled, but the assembly requires multiple separate fastening operations and alignment steps which increases assembly time and complexity
Solution Approach 1:
The patent combines multiple fastening operations into a single integrated clamp mechanism. The clamp simultaneously secures the exhaust gas component to the vehicle frame and positions it correctly, eliminating the need for separate alignment and fastening steps. This merging of functions directly increases assembly productivity while reducing operational complexity.
Solution Approach 2:
The clamp is pre-configured with alignment features and positioning elements that automatically guide the exhaust gas component into the correct position during installation. This preliminary preparation of the fastening device eliminates the need for manual alignment operations during assembly, thereby increasing assembly speed and simplifying the process.
2Reliability
If multiple fastening points are used to secure exhaust gas components, then the reliability of the connection is improved, but the number of fastening operations and potential leak paths increases
Solution Approach 1:
The clamp integrates multiple fastening functions into a single continuous clamping action that secures the exhaust gas component at multiple points simultaneously. This creates a unified sealing interface rather than multiple separate connection points, maintaining connection reliability while reducing the number of potential leak paths.
Solution Approach 2:
The clamp design ensures uniform distribution of clamping force across the entire exhaust gas component interface. This homogeneous pressure distribution creates consistent sealing conditions throughout the connection, improving reliability while minimizing localized stress concentrations that could lead to leaks.
3Manufacturing precision
If the exhaust gas system is designed as a complete assembly from the manufacturer, then assembly precision can be ensured, but the weight of the exhaust gas components increases due to additional fastening elements
Solution Approach 1:
The patent divides the exhaust gas system into modular components that are precisely manufactured separately and then quickly assembled using the simplified clamp mechanism. This segmentation allows each component to be optimized for its specific function without requiring excessive fastening elements, maintaining assembly precision while reducing overall weight.
Solution Approach 2:
The clamp mechanism is designed with optimized geometric parameters and material properties that enable high-precision positioning with minimal material usage. By carefully selecting the clamp dimensions, wall thickness, and material strength, the design achieves the required assembly precision while minimizing the weight of the fastening components themselves.
Data Source
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AI summary
The invention relates to a method for assembling an exhaust gas system (100) for a vehicle, in particular a passenger car, having the steps of: a) providing an outlet tube (11) of a catalytic converter (10), b) providing a connecting piece (20) with a passage for conducting an exhaust gas flowing out of the outlet tube (11) when the exhaust gas system (100) is used as intended, c) providing a connecting element (30) with a passage for conducting the exhaust gas flowing out of the connecting piece (20) when the exhaust gas system (100) is used as intended, d) at least partly fitting the connecting piece (20) over the outlet tube (11) or at least partly inserting the connecting piece into the outlet tube, e) setting a specified tilting angle (+ α, - α) between a longitudinal axis (L2) of the connecting piece (20) and a longitudinal axis (L1) of the outlet tube (11), f) welding the outlet tube (11) and the connecting piece (20) at the set tilting angle (+ α, - α), and g) connecting the connecting element (30) to the connecting piece (20).