Exhaust Sensor Carrier Unit for Precise Multi-Sensor Mounting
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Solution Overview
Problem
Existing exhaust systems for internal combustion engines face challenges in efficiently and precisely integrating multiple sensors onto exhaust gas-carrying elements, leading to potential damage and increased manufacturing complexity due to individual sensor attachment requirements.
Innovation Solution
A sensor carrier unit is designed to be fixed on the exhaust gas-carrying element, featuring multiple sensor sockets with precise positioning and connection mechanisms, such as welding, to simplify sensor installation and ensure a stable, gas-tight connection, reducing the risk of damage and manufacturing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple sensors are attached individually to the exhaust gas-carrying element, then each sensor can be positioned precisely, but the manufacturing complexity and time increase significantly
Solution Approach 1:
The invention introduces a sensor carrier unit as a separate module that houses multiple sensor sockets. This segmentation allows the sensor carrier to be pre-assembled and tested independently, then mounted as a single unit on the exhaust gas-carrying element, reducing overall manufacturing complexity while maintaining positioning precision through the carrier's integrated design
Solution Approach 2:
The sensor carrier unit acts as an intermediary component between the exhaust gas-carrying element and the sensors. It provides a standardized interface with multiple pre-positioned sensor sockets, eliminating the need to attach each sensor directly to the exhaust element, thereby simplifying the manufacturing process while ensuring precise sensor positioning relative to the exhaust flow
2Reliability
If multiple sensors are attached individually to the exhaust gas-carrying element, then each sensor connection can be optimized, but the risk of damage during installation increases
Solution Approach 1:
The sensor carrier unit serves as a protective intermediary that shields the sensors and their connections from direct exposure to harsh exhaust conditions and mechanical damage during installation. By mounting sensors to the carrier rather than directly to the exhaust element, the carrier absorbs thermal and mechanical stresses, reducing the risk of damage to the sensitive sensor components
3Adaptability or versatility
If multiple sensors are attached individually to the exhaust gas-carrying element, then sensor installation flexibility is maintained, but the manufacturing time increases
Solution Approach 1:
The sensor carrier unit is pre-assembled with multiple sensor sockets and their connections established beforehand in a controlled environment. This preliminary action allows for optimized sensor positioning and connection setup prior to final installation on the exhaust system, significantly reducing on-site manufacturing time while maintaining the flexibility to accommodate different sensor configurations through the carrier's modular design
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 sensor carrier unit allows for precise and stable mounting of multiple sensors, simplifying the manufacturing process and reducing the risk of damage during installation, while ensuring a secure connection under thermal and mechanical loads, thereby enhancing the operational efficiency of the exhaust system.
Implementation Method 1
the sensor carrier element has a sensor carrier element contour that is adapted to an outer peripheral contour of the exhaust gas-carrying element
Implementation Method 2
such as welding, to simplify sensor installation and ensure a stable, gas-tight connection
Data Source
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AI summary
An exhaust system, in particular for an internal combustion engine in a vehicle, comprises at least one sensor carrier unit (20) carried on an exhaust-carrying element (14), wherein the sensor carrier unit (20) comprises a sensor carrier element (22) fixed to the exhaust-carrying element (14) and on the sensor carrier element (22) a plurality of sensor nozzles (24, 26, 28) equipped or capable of being equipped with sensors, each with at least one sensor receptacle/measuring opening (30) formed therein.