Exhaust Probe Support Assembly with Chamfered Weld Joint
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Solution Overview
Problem
Existing probe support assemblies for exhaust systems of internal combustion engines are not structurally simple and are not resistant to thermomechanical stresses.
Innovation Solution
A probe support assembly with a probe nozzle connection surface designed like a chamfer, using austenitic material for the nozzle and ferritic material for the wall, connected by a weld seam, and a connecting plateau formed by reshaping the wall to provide a stable and thermally resistant connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the probe nozzle is bonded to the wall by a weld seam or formed integrally, then the connection strength is improved, but the device complexity increases and installation space is required
Solution Approach 1:
The probe nozzle is inserted into the wall opening and fixed with connecting material, creating a nested structure where the nozzle fits within the wall opening. This eliminates the need for external mounting brackets or complex attachment mechanisms, reducing device complexity while maintaining connection strength through the ferritic connecting material.
Solution Approach 2:
The probe nozzle and wall are merged through the connecting material that bonds the nozzle outer peripheral surface to the wall inner peripheral surface. This merging creates a unified structure that resists thermomechanical stresses without requiring separate mounting components, thereby reducing device complexity.
2Stability of the object's composition
If austenitic material is used for the probe nozzle and ferritic material for the wall, then the thermal expansion compatibility is improved, but the connection strength may be reduced without proper connecting material
Solution Approach 1:
The ferritic connecting material acts as an intermediary between the austenitic probe nozzle and the ferritic wall. This intermediate layer provides compatible thermal expansion characteristics with both materials, ensuring stable connection under thermal cycling while maintaining strong bonding through weld seams or adhesive bonding.
Solution Approach 2:
The connection assembly forms a composite structure combining austenitic nozzle material, ferritic connecting material, and ferritic wall material. This composite construction leverages the complementary properties of different materials to achieve both thermal expansion compatibility and high connection strength.
3Strength
If the probe nozzle connection surface is designed like a chamfer with material removal, then the connection strength is improved, but the manufacturing complexity increases
Solution Approach 1:
The probe nozzle is pre-formed with a chamfered connection surface during manufacturing, preparing the surface in advance for optimal connecting material application. This preliminary preparation ensures proper geometry for strong bonding without requiring complex post-processing or assembly operations, maintaining ease of manufacture.
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 assembly achieves increased connection strength and resistance to thermomechanical stresses with reduced installation space, ensuring stable attachment under varying thermal conditions.
Implementation Method 1
the connecting material is provided by a weld seam
Implementation Method 2
considering the different thermal expansion behaviors of these two bodies
Data Source
Figure 1~3
Figure 4~5
AI summary
A probe support assembly, in particular for an exhaust system of an internal combustion engine, comprises a probe support body (14) with a wall (18), wherein a wall opening (44) surrounded by an outer wall surface (22) is provided in the wall (18) on an outer wall side (20), and a probe socket (24) fixed to the outer wall surface (22) in the region of the wall opening (44), wherein a probe socket (24) is provided in the probe socket (24) which penetrates the probe socket (24) in the direction of a probe receiving opening longitudinal axis (L) from a distal axial end (30) of the probe socket (24) positioned away from the wall (18) to a proximal axial end (32) of the probe socket (24) positioned close to the wall (18) and is open towards the wall opening (44).In the region of the proximal axial end (22) of the probe socket (24), a probe socket connecting surface (38) is provided which surrounds the probe receiving opening (24) in a ring-like manner and is angled with respect to the probe receiving opening longitudinal axis (L) with a radial distance from the probe receiving opening longitudinal axis (L) decreasing in the direction away from the distal axial end (30) of the probe socket (24), wherein the probe socket (24) is fixed to the wall (18) by connecting material (50) which is connected to the probe socket connecting surface (38) and to a connecting section (48) of the wall outer surface (22).