Flat Exhaust Flange Manufacturing with Common Spherical Matrix
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Solution Overview
Problem
The existing methods for manufacturing flat exhaust flanges require multiple tooling variations due to differing dimensions and orientations, leading to increased costs and complexity in producing flanges for various vehicle models.
Innovation Solution
A method involving a common base matrix of spherical shape for producing the mating face and heel, with a drilling step using a variable-diameter drilling tool to create orifices of specific dimensions and orientations, allowing for multiple flange variants from a single tool set.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple different striking tools are created for different flange dimensions and orientations, then manufacturing precision for specific flange variants is improved, but device complexity and tooling costs increase significantly
Solution Approach 1:
The patent applies universality by designing a single base matrix that can produce multiple flange variants with different dimensions and orientations. The base matrix includes a spherical heel that can accommodate different orifice configurations through adjustable positioning, eliminating the need for multiple specialized striking tools for each flange variant.
Solution Approach 2:
The patent utilizes parameter changes by allowing the drilling tool to vary its diameter and positioning parameters to create different orifices in the spherical heel. This enables a single base matrix to produce flanges with different dimensions and orientations by adjusting drilling parameters rather than creating new tools.
2Device complexity
If a single base matrix is used for multiple flange variants, then device complexity and tooling costs are reduced, but manufacturing precision for specific dimensions and orientations may be compromised
Solution Approach 1:
The patent applies dynamics by making the drilling process adjustable and adaptable. The drilling tool can dynamically change its diameter, position, and orientation based on the required flange variant, allowing precise control over the orifice dimensions and angles while using a single base matrix.
Solution Approach 2:
The patent uses preliminary action by pre-forming the spherical heel in the base matrix with appropriate curvature and positioning features. This preliminary shaping enables subsequent precise drilling operations to achieve accurate orifices for different flange variants without requiring tool modifications.
3Adaptability or versatility
If flanges are redesigned for each vehicle model, then adaptability to specific vehicle requirements is improved, but loss of time and manufacturing efficiency decrease
Solution Approach 1:
The patent applies universality by creating a base matrix that can serve multiple vehicle models through a single tool. The spherical heel design with adjustable drilling capabilities allows the same base matrix to produce flanges adapted to different vehicle models without requiring tool redesign or recreation.
Solution Approach 2:
The patent utilizes parameter changes by adjusting the drilling tool parameters (diameter, position, orientation) to match different vehicle model requirements. This enables rapid adaptation to new vehicle models by simply changing drilling parameters rather than redesigning the entire flange or creating new tools.
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 approach simplifies the manufacturing process, reduces tooling costs, and enables the production of flanges adaptable to different vehicle models without the need for frequent tool changes, enhancing manufacturing efficiency and reducing costs.
Implementation Method 1
a step of drilling the heel, to form said second orifice
Implementation Method 2
Said basic matrix is produced, for example by stamping, by means of a striking tool
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The method involves fabricating a coupling surface (11) and a heel of a flat exhaust flange from a base matrix whose spherical part (16) defines a part of the heel, where the matrix (15) is common to dimensions and different applications of the flange, and the thickness of the surface is comprised between 7-8 millimeters. The heel is bored using a boring tool for forming an orifice, where the diameter of the orifice is comprised between 40-60 millimeters. An independent claim is also included for a flat exhaust flange comprising a coupling surface.