Exhaust Manifold Weld Bead Segmentation for Heat Control

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Solution Overview

Problem

The existing manufacturing methods for exhaust manifolds result in strength degradation due to excessive heat application at weld spots, caused by overlapping weld beads, which affects the structural integrity and ease of welding control.

Innovation Solution

The exhaust manifold is designed with a body portion composed of two split bodies with semi-cylindrical portions that are welded together, featuring first and second weld beads where the end portions of the second weld beads overlap but are separated from the first weld bead, preventing excessive heat application and improving welding control by maintaining symmetry.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If end portions of second weld beads overlap the first weld bead to ensure complete welding coverage, then welding coverage is improved, but strength degradation occurs due to excessive heat application

Engineering Contradiction:
Improvewelding coverageVSAvoidstrength degradation
Core Design Contradiction:
ReliabilityVSStrength

Solution Approach 1:

The patent applies different welding strategies to different locations: the first weld bead uses continuous welding for complete coverage, while the second weld beads use discontinuous segments with gaps at critical locations. This local differentiation ensures adequate welding coverage while preventing excessive heat accumulation at the first weld bead location, thereby resolving the contradiction between welding coverage and strength degradation.

Inventive Principle:
Principle #3Local quality

2Reliability

If multiple weld beads are applied to ensure complete welding coverage, then welding coverage is improved, but heat accumulation increases causing strength degradation

Engineering Contradiction:
Improvewelding coverageVSAvoidheat accumulation
Core Design Contradiction:
ReliabilityVSTemperature

Solution Approach 1:

The patent applies partial action by making the second weld beads discontinuous rather than continuous. The second weld beads are divided into multiple segments with gaps between them, particularly at locations where they would overlap with the first weld bead. This partial application of welding ensures adequate coverage while preventing excessive heat accumulation, thereby resolving the contradiction between welding coverage and heat accumulation.

Inventive Principle:
Principle #16Partial or excessive action

3Reliability

If continuous welding is used for complete coverage, then welding coverage is improved, but welding control difficulty increases due to heat management

Engineering Contradiction:
Improvewelding coverageVSAvoidwelding control
Core Design Contradiction:
ReliabilityVSEase of operation

Solution Approach 1:

The patent segments the second weld beads into multiple discontinuous portions rather than applying continuous welding. This segmentation allows for better heat management and easier welding control, as each segment can be independently controlled and the gaps between segments prevent heat accumulation. The segmented approach maintains adequate welding coverage while significantly improving welding control ease.

Inventive Principle:
Principle #1Segmentation

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 design effectively restrains strength degradation and enhances the ease of welding control, ensuring improved scanning performance and structural integrity of the exhaust manifold.

Implementation Method 1

the first weld bead welding the first semi-cylindrical portion and the second semi-cylindrical portion to each other from an outer surface side, the first semi-cylindrical portion and the second semi-cylindrical portion defining one of the branch pipes, the second weld beads welding an outer peripheral portion of the one of the branch pipes to an edge portion of the opening

Methodology Applied
Scientific EffectWelding: Welding

Data Source

PatentUS10526948B2Exhaust manifold and method of manufacturing the exhaust manifold
Publication Date: 2020.01.07 TOYOTA JIDOSHA KK
  • US10526948B2 patent drawing
  • US10526948B2 patent drawing
  • US10526948B2 patent drawing

AI summary

An exhaust manifold includes a body portion and a flange portion. The body portion includes a first split body having a plurality of semi-cylindrical portions, and a second split body having a plurality of semi-cylindrical portions. The semi-cylindrical portions of the first and second split bodies overlie each other, respectively, and define branch pipes. The exhaust manifold includes a first weld bead and a plurality of second weld beads. The first weld bead welds the semi-cylindrical portions defining one of the branch pipes to each other from an outer surface side. The second weld beads weld an outer peripheral portion of the one of the branch pipes to an edge portion of opening in the flange portion. At least one of the second weld beads partially overlaps the first weld bead. End portions of neighboring second weld beads overlap each other and are separated from the first weld bead.