Parallel Partial Silencers for Compact Exhaust Systems
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Solution Overview
Problem
Existing exhaust systems for commercial vehicles are not compact enough in both height and length, leading to installation challenges and high manufacturing costs, as they require adaptation for each vehicle type and individual component customization.
Innovation Solution
The design features two partial silencers that can be arranged parallel to each other or stacked, sharing a single supply and discharge line, allowing for easier maintenance and reduced heat shielding, with the option to combine multiple silencers and use standardized components of varying sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If exhaust systems are designed with series-connected pre-silencer and main silencer for each vehicle type, then the exhaust aftertreatment function is achieved, but the system complexity and manufacturing costs increase due to customization for each vehicle type
Solution Approach 1:
The patent applies universality by designing a standardized main silencer module that can be used across different vehicle types. The main silencer is equipped with multiple connection flanges that allow it to serve as both a series-connected component and a parallel-connected component, enabling the same component to function in different system configurations without customization.
Solution Approach 2:
The patent segments the exhaust aftertreatment system into independent functional modules: pre-silencer, main silencer, and after-silencer. These modular components can be independently designed, manufactured, and assembled. The main silencer module in particular is designed as a self-contained unit with integrated catalysts and multiple connection options, allowing flexible system assembly.
2Length of stationary object
If parallel arranged partial silencers are used to reduce installation height, then the installation height is reduced, but the installation length increases leading to new installation problems
Solution Approach 1:
The patent transitions from a longitudinal arrangement (series connection increasing length) to a transverse arrangement (parallel connection reducing height). By utilizing the vertical dimension and arranging silencers side-by-side with transverse connection lines, the system reduces installation height while keeping the installation length comparable to the original series arrangement.
Solution Approach 2:
The patent employs asymmetric connection line routing where the supply and discharge lines are positioned at different heights and connect to different faces of the main silencer. This asymmetric arrangement allows optimal use of available space and enables compact packaging of the parallel silencer configuration.
3Device complexity
If multiple supply lines and discharge lines are provided for parallel partial silencers, then the parallel arrangement is achieved, but the manufacturing costs and heat shielding requirements increase
Solution Approach 1:
The patent merges the supply lines and discharge lines by having them converge at common connection points on the main silencer. The multiple partial silencers share common supply and discharge manifolds, reducing the total number of individual line connections required and simplifying the overall piping system.
Solution Approach 2:
The main silencer acts as an intermediary component that receives exhaust gas from multiple partial silencers through its multiple connection flanges. This central hub approach consolidates the flow paths and reduces the complexity of connecting lines compared to a direct peer-to-peer connection system.
Data Source
AI summary
Commercial vehicle with an internal combustion engine and an exhaust system (1) comprising a silencer and an exhaust aftertreatment device integrated into the silencer for the purpose of aftertreating the exhaust gas. In the exhaust system (1), the engine exhaust gas is fed to the silencer via an inlet (2) and the cleaned exhaust gas is discharged via a outlet (3). The silencer is divided into two partial silencers (6; 7) arranged parallel to each other and each connected to the inlet (2) and outlet (3) via a flanged distributor (4; 5). Each partial silencer (6; 7) has an exhaust aftertreatment device.