Exhaust Gas Heater Bracket Assembly for Vibration Durability
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Solution Overview
Problem
Exhaust system heaters for internal combustion engines face challenges in withstanding harsh environmental conditions such as vibration, mechanical shock, and temperature cycling, which can affect their performance and durability, particularly in diesel exhaust applications where vibrations are significant.
Innovation Solution
A modular heating apparatus with a bracket assembly that includes support components and a heater flange component, allowing for flexible dimension adjustments and enhanced mechanical support, combined with a smart heating system that incorporates temperature sensors for precise temperature control and diagnostic capabilities, ensuring efficient heat flux and reduced manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electric heaters are installed in exhaust pipes to increase exhaust temperature and activate catalysts, then the heating function is achieved, but the heaters are subjected to harsh environmental conditions such as vibration, mechanical shock, and temperature cycling which affect their durability
Solution Approach 1:
The heating apparatus is divided into separate modular components including a heater element, bracket assembly, and support components. This segmentation allows each component to be optimized independently for vibration resistance and thermal management, improving overall reliability in harsh exhaust environments
Solution Approach 2:
The bracket assembly and support components are designed with vibration-dampening features and secure mounting mechanisms that protect the heater element from mechanical shock and vibration before damage can occur. This preemptive protection approach ensures the heater withstands harsh environmental conditions
2Adaptability or versatility
If a modular heating apparatus with bracket assembly is used to provide mechanical support and flexibility, then adaptability is improved, but device complexity increases
Solution Approach 1:
The bracket assembly serves multiple functions simultaneously: it provides mechanical support for the heater element, enables dimensional adjustments for adaptability, and facilitates secure mounting in various exhaust system configurations. This multi-functionality reduces the need for separate components, managing complexity while enhancing versatility
3Measurement precision
If temperature sensors are incorporated for precise temperature control and diagnostic capabilities, then measurement precision is improved, but device complexity increases
Solution Approach 1:
Temperature sensors are integrated into the heating apparatus to provide real-time temperature feedback to the control system. This feedback enables precise temperature control and diagnostic capabilities, allowing the system to adjust heating parameters dynamically while monitoring system health, thereby improving measurement precision through intelligent control
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 solution provides enhanced durability and performance by accommodating vibrations and temperature variations, maximizing heat flux, and enabling diagnostic capabilities to compensate for manufacturing variances, thus improving the overall efficiency and reliability of the heating apparatus in exhaust systems.
Implementation Method 1
a heater element, and a bracket assembly that supports the heater element
Implementation Method 2
establishes a pathway for a flow of exhaust gas through the heating apparatus
Implementation Method 3
The flow of exhaust gases pass from the exhaust system into the heating apparatus through a pathway formed in the heating apparatus
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
A heating apparatus (1) and method for use in an exhaust gas system is provided that includes a container body (14) defining an exhaust gas pathway (30), a heater flange (20) component attached to an exterior of the container body (14), and a heater assembly disposed in the exhaust gas pathway (30) and secured to the heater flange (20) component. The heater assembly includes at least one heater element (35), a bracket assembly (40) that secures the at least one heater element (35) in the container body (14), and a conformal bracket for securing the at least one heater element (35) to the bracket assembly (40).