Mixing Element for Dual-Flow Exhaust Sensor Reduction
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Solution Overview
Problem
The functional monitoring of catalytic converter arrangements in dual-flow exhaust systems is costly due to the high expense of sensors and evaluation circuits required for each exhaust line.
Innovation Solution
A mixing element is inserted into the dual-flow exhaust system with two inlet and two outlet openings, allowing exhaust gases from one inlet to exit through both outlets, creating a gas mixture that can be analyzed by a single sensor downstream, reducing the need for multiple sensors and associated costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate sensor is arranged in each exhaust line downstream of the catalytic converter arrangement, then the functional monitoring of catalytic converter arrangements is accurate and reliable, but the manufacturing costs and device complexity increase significantly
Solution Approach 1:
The patent merges the monitoring functions of both exhaust lines into a single sensor location downstream of the mixing element. The mixing element combines exhaust gases from both lines, allowing one sensor to monitor both catalytic converter arrangements simultaneously, thereby reducing the number of sensors and evaluation circuits from two to one while maintaining monitoring reliability
Solution Approach 2:
The mixing element acts as an intermediary device that receives exhaust gases from both exhaust lines and delivers a combined stream to a single sensor. This intermediary structure enables the sensor to indirectly monitor both catalytic converter arrangements by analyzing the mixed exhaust gas composition
2Device complexity
If a mixing element is introduced to combine exhaust gases from both exhaust lines, then the number of sensors required is reduced to one, but additional device complexity and flow resistance are introduced
Solution Approach 1:
The mixing element is segmented into multiple ducts (first and second ducts) that separately convey exhaust gases from different inlet openings to different outlet openings. This segmentation allows for controlled mixing while minimizing flow resistance by providing dedicated flow paths rather than forcing gases through a single constricted channel
3Device complexity
If a mixing element is introduced to combine exhaust gases from both exhaust lines, then the number of sensors required is reduced to one, but the device complexity and manufacturing complexity increase
Solution Approach 1:
The mixing element is designed as a universal component that can be integrated into dual-flow exhaust systems with catalytic converter arrangements. It performs multiple functions: combining exhaust gases from both lines, maintaining predetermined mixing ratios, and enabling single-sensor monitoring of both catalytic converters, thereby reducing overall system complexity despite its own manufacturing requirements
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 solution allows for the detection of malfunctions in catalytic converter arrangements using a single sensor, reducing manufacturing costs and enabling efficient monitoring of both exhaust lines while maintaining a predetermined mixing ratio and minimizing flow resistance.
Implementation Method 1
a mixing element (4) for a dual-flow exhaust system (1), which can be inserted into the two exhaust lines (2, 3) of a dual-flow exhaust system (1) via two inlet openings (5, 6) and two outlet openings (7, 8), the four openings mentioned in the mixing element (4) being interconnected in such a way that each inlet opening (5, 6) can be connected to both outlet openings (7, 8)
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The present invention relates to a mixing element (4) and an exhaust system (1) equipped therewith for an internal combustion engine, in particular for a motor vehicle. The mixing element (4) has two inlet openings (5, 6) and two outlet openings (7, 8), wherein each inlet opening (5, 6) is commuting with both outlet openings (7, 8).