Exhaust Shell Sizing Tool With Interlocking Fingers For Sensor Hole Protection
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Solution Overview
Problem
Traditional sizing methods for exhaust component shells with varying diameters result in poor weld areas around sensor holes due to differential diameters, leading to large gaps and undesirable deformations during the manufacturing process of catalytic converters.
Innovation Solution
The method involves using a plurality of fingers with extended and recessed tips to size the shell ends to different diameters, where at least one extended finger partially covers the sensor hole during sizing, ensuring a better welding area by minimizing deformation and maintaining a consistent shape around the sensor hole.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional sizing methods are used to size the shell to two different diameters, then the shell can accommodate substrates with tolerance variation, but the weld area around the sensor hole becomes poor with large gaps
Solution Approach 1:
The sizing tool applies different diameters to different ends of the shell while protecting the sensor hole area. The extended finger covers the sensor hole during sizing of the first end to a smaller diameter, while the recessed finger allows the second end to be sized to a larger diameter. This creates local quality differences in the shell diameter while preserving the weld area quality around the sensor hole.
Solution Approach 2:
The extended and recessed fingers act as intermediaries between the sizing force and the shell. These fingers control where the sizing force is applied, allowing differential sizing while protecting the sensor hole area from deformation that would compromise weld quality.
2Adaptability or versatility
If the shell is sized to different diameters at opposite ends, then substrate tolerance variation is compensated, but large gaps appear between the boss and shell at discrete circumferential locations
Solution Approach 1:
The sizing tool applies local quality by differentiating which ends of the shell receive sizing force. The extended finger protects one end's sensor hole area while the recessed finger allows the other end to be sized differently, achieving tolerance compensation without creating circumferential gaps.
3Ease of manufacture
If sensor boss is welded after sizing, then the welding process can be performed, but poor weld area with large gaps results
Solution Approach 1:
The sizing operation is performed preliminarily with protection of the sensor hole area, ensuring that the weld area is prepared in advance with proper geometry. The extended and recessed fingers create the appropriate shell shape before welding, eliminating gaps and improving weld reliability.
Data Source
AI summary
An apparatus sizes an exhaust component that includes an outer shell that surrounds first and second substrates. At least one sensor hole is formed in the outer shell at a location between the first and second substrates. A first end of the outer shell is surrounded with a plurality of first fingers to size the first end around the first substrate to a first cross-section. At least one first finger has a protruding portion at a first finger distal end that is longer than first finger distal ends of the other first fingers. A plurality of second fingers surrounds the second shell end to size the outer shell about the second substrate to a second cross-section. At least one second finger has a recess portion at a second finger distal end that receives the protruding portion of the at least one first finger.