Exhaust Housing Deformation Using Segmented Jaws for Axial Length Control
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Solution Overview
Problem
Existing methods for manufacturing exhaust gas carrying devices, such as catalytic converters and diesel particulate filters, face challenges with axial deformation of the outer housing during the clamping process, leading to tolerance issues and the need for subsequent machining operations.
Innovation Solution
A method using a tool with segment-like jaws featuring indentations or projections that form a continuously surrounding indentation or projection upon closure, allowing for precise deformation and stabilization of the outer housing without requiring additional machining, by accommodating material within these features during the clamping process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If segment-like pressure jaws are used to deform the outer housing during clamping, then the insert is securely clamped in the outer housing, but the outer housing lengthens in the axial direction causing tolerance problems
Solution Approach 1:
The pressure jaws are equipped with locally differentiated surface features (protrusions or indentations) that create corresponding local deformations on the outer housing. These localized features allow the material to be redistributed in specific areas, accommodating axial shortening while maintaining overall clamping stability. The local quality change enables the housing to be shorter without compromising the clamping function.
Solution Approach 2:
The axial stops are positioned in advance to define the target axial length before the clamping process begins. During jaw closure, the housing is deformed and shortened until it contacts the stops, which then maintain the precise axial dimension. This preliminary positioning of stops ensures the housing achieves the correct length during the forming process itself, eliminating the need for subsequent machining.
2Stability of the object's composition
If the outer housing is deformed by closing segment-like jaws, then the insert is clamped securely, but subsequent machining operations are required to achieve precise axial length
Solution Approach 1:
The clamping function and the length-defining function are merged into a single integrated process. The pressure jaws not only clamp the insert but also deform the housing to the correct length, while the axial stops simultaneously define and maintain the target dimension. This merging of functions eliminates the need for separate machining operations, simplifying the manufacturing process while ensuring both clamping stability and precise axial length.
Solution Approach 2:
The housing itself serves to define its own final length through the interaction with the axial stops during the clamping process. The stops act as self-contained reference elements that automatically establish the correct axial dimension without requiring external machining operations. The process is self-regulating, as the housing deforms until it contacts the stops, which then maintain the precise length.
3Length of moving object
If protrusions or indentations are created on the outer housing during clamping, then the axial length is reduced and stability is improved, but the jaw design becomes more complex
Solution Approach 1:
The pressure jaws are divided into functional segments: the main clamping surface that contacts the housing, and the localized protrusion/indentation features that create the axial shortening effect. This segmentation allows each part of the jaw to perform its specific function independently, making the complex geometry manageable through modular design principles.
Solution Approach 2:
The pressure jaws feature asymmetric geometry with protrusions or indentations on one side but not the other, creating the necessary unilateral deformation pattern on the housing. This asymmetric design is essential for generating the localized material redistribution that shortens the axial length while maintaining clamping effectiveness. The asymmetry is deliberately introduced to achieve the specific deformation pattern required for the invention's purpose.
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 simplifies and enhances the precision of the machining process, reduces axial length, and increases the stability of the outer housing, eliminating the need for subsequent machining and ensuring consistent axial length across devices.
Implementation Method 1
deforming the outer housing by closing the jaws to clamp the insert in the outer housing; and producing a surrounding projection or a surrounding indentation on the outer jacket remote from the ends thereof when closing the jaws
Data Source
AI summary
A method of manufacturing an exhaust gas carrying device, in particular an exhaust gas purification device, and a tool provided therefor include segment-like jaws that are used to deform an outer housing. The jaws have indentations or projections adjacent to each other, and which are complementary to form a continuously surrounding indentation/projection. The reshaped outer housing is provided with one or more surrounding projections or indentations by the deformation.