Exhaust Sensor Nozzle Joining by Flow Drilling
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Solution Overview
Problem
Existing methods for producing exhaust systems for internal combustion engines lack a simple and efficient way to arrange sensors for monitoring exhaust gas parameters like temperature and composition, requiring additional processing steps and openings in the system.
Innovation Solution
A method involving a metal sensor mounting socket with a tapered connection area that penetrates into a metal exhaust gas routing component using a flow drill method, creating a material-locking connection without the need for additional machining or welding, allowing sensors to be securely attached without pre-existing openings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sensor receiving nozzle is attached to an exhaust gas routing component using conventional methods (welding, additional machining), then the sensor can be securely fixed, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The patent combines the sensor receiving nozzle attachment process with the existing exhaust gas routing component manufacturing process. The flow-drilling process that creates openings in the exhaust component simultaneously receives and secures the sensor nozzle, merging two operations into one. This eliminates separate welding or machining steps, reducing manufacturing complexity while maintaining secure sensor fixation.
Solution Approach 2:
The sensor receiving nozzle design includes self-centering features where the nozzle automatically positions itself during the flow-drilling process. The tapered geometry and matching tolerances allow the nozzle to self-align and self-secure in the drilled opening without requiring additional alignment operations or complex fixtures, enabling the component to service its own attachment process.
2Ease of manufacture
If openings are pre-formed in the exhaust gas routing component for sensor installation, then sensor mounting is simplified, but additional processing steps are required
Solution Approach 1:
The patent incorporates the opening creation and sensor nozzle installation into a single preliminary action during the flow-drilling process. Rather than pre-forming openings separately and then installing nozzles, the process performs both functions simultaneously - the flow-drilling creates the opening and the nozzle is inserted and secured in the same operational sequence, eliminating redundant steps.
Solution Approach 2:
The flow-drilling process is given multiple functions: it creates the opening in the exhaust gas routing component, provides the mounting location for the sensor nozzle, and secures the nozzle in place. This multi-functional approach eliminates the need for separate dedicated opening creation and sensor mounting operations, improving manufacturing efficiency.
3Strength
If welding or additional fastening measures are used to attach the sensor nozzle, then a secure connection is achieved, but the manufacturing time and process complexity increase
Solution Approach 1:
The patent extracts the welding and additional fastening operations from the sensor attachment process. By designing the flow-drilling process and nozzle geometry to create a secure mechanical interference fit, the need for thermal processes like welding is eliminated. This extraction of unnecessary operations reduces manufacturing cycle time while maintaining connection strength through the optimized mechanical fit.
Solution Approach 2:
The patent replaces thermal joining methods (welding) with a mechanical joining approach using the flow-drilled interference fit. The mechanical system of tapered nozzle geometry and corresponding opening creates sufficient connection strength without requiring external heat sources or additional fastening hardware, reducing both time and process complexity.
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
Enables secure, gas-tight attachment of sensors to the exhaust system without additional processing, allowing for efficient monitoring of exhaust gases and reducing emissions by simplifying the sensor installation process.
Implementation Method 1
Due to the pressure and rotation of the sensor receiving nozzle and the resulting frictional interaction between the sensor receiving nozzle and the wall of the exhaust gas routing component, the wall of the exhaust gas routing component is primarily melted
Implementation Method 2
the wall of the exhaust gas routing component is primarily melted, allowing the sensor receiving nozzle to penetrate it
Implementation Method 3
at the end of the joining process, when the sensor receiving nozzle has reached its intended installation position relative to the wall of the exhaust gas routing component and the rotation is stopped, the material of the sensor receiving nozzle forms a material-bonded connection with the material of the wall of the exhaust gas routing component
Data Source
Figure 1~2
Figure 3~4
AI summary
A method for manufacturing an exhaust system, in particular for an internal combustion engine of a vehicle, comprises the following measures: a) providing an exhaust system component (26) with a wall (38) made of metal material; b) providing a sensor receiving nozzle (22) made of metal material, which is to be fixed to the wall (38) of the exhaust system component (26), wherein the sensor receiving nozzle (22) comprises a sensor receiving area (28) to be positioned outside the exhaust system component (26) and a connecting area (34) to be positioned engaging in the wall (38) of the exhaust system component (26); c) pressing the sensor receiving nozzle (22) with its connecting area (34) against an outer surface (40) of the wall (38) of the exhaust system component (26) in a fastening area (39) of the wall (38) provided for fixing the sensor receiving nozzle (22), and thereby rotating the sensor receiving nozzle (22) about a Longitudinal axis of the nozzle (A) such that,that at least the connection area (34) of the sensor receiving nozzle (22) penetrates the structural material of the wall (38) of the exhaust gas routing component (26) and a material-bonded connection is formed between the metal material of the wall (38) and the metal material of the sensor receiving nozzle (22).