Radial Mounting System for Exhaust Aftertreatment Modules
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Solution Overview
Problem
The difference in thermal expansion between aftertreatment modules and their mounting surfaces, due to varying temperatures, leads to stress and potential damage from rigid attachment, which existing solutions like pivotable or elastomeric mounts fail to adequately address, especially for large modules under dynamic loads.
Innovation Solution
A mounting system with a radial and symmetric pattern of mounts, each allowing movement in a single direction aligned with the module's radial expansion, reducing complexity and stress concentration, and using an insulating plate to limit heat transfer and prevent excessive movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If rigid attachment is used to mount the aftertreatment module to the mounting surface, then structural stability is improved, but thermal expansion stress increases causing potential damage
Solution Approach 1:
The mounting system transitions from a static rigid attachment to a dynamic system where mounts can move radially outward to accommodate thermal expansion. The mounts are configured to allow controlled movement in the radial direction while maintaining attachment, enabling the system to adapt to changing thermal conditions without generating excessive stress.
Solution Approach 2:
The mounting system changes the physical state of the connection from fixed to movable by allowing radial displacement. The mounts are designed with movement capability that activates when thermal expansion occurs, changing the parameter of connection rigidity to accommodate dimensional changes in the aftertreatment module.
2Stress or pressure
If pivotable mounts are used to permit expansion, then thermal expansion stress is reduced, but device complexity increases
Solution Approach 1:
The mounting system divides the attachment function into multiple independent mounts arranged radially around the aftertreatment module. Each mount handles expansion in its specific radial direction, segmenting the complex thermal expansion problem into simpler, directionally-specific solutions that reduce overall system complexity.
Solution Approach 2:
The mounting system uses radial symmetry with mounts positioned at different angular locations around the module. Each mount is oriented asymmetrically to handle expansion in its specific radial direction, creating an overall symmetric system composed of asymmetric individual elements that simplifies the design of each component.
3Stress or pressure
If elastomeric mounts are used to accommodate expansion, then thermal expansion stress is reduced, but load-bearing capacity decreases under dynamic loads
Solution Approach 1:
The mounting system introduces an intermediary mechanism between the rigid aftertreatment module and the rigid mounting surface. The movable mounts act as intermediaries that can move radially to absorb thermal expansion while maintaining strong mechanical attachment, bridging the gap between the expanding module and the fixed surface without requiring compliant elastomeric materials.
Solution Approach 2:
The mounts are designed with dynamic movement capability that allows them to flex radially during thermal expansion while maintaining structural integrity. This dynamic behavior enables the mounts to accommodate expansion stresses without the need for soft elastomeric materials, preserving load-bearing capacity under dynamic conditions.
4Reliability
If multiple mounts are used in a radial pattern, then thermal expansion is accommodated effectively, but manufacturing complexity increases
Solution Approach 1:
The mounting system uses identical or similar mount designs positioned at different radial locations, making each mount a universal component that performs the same function in different orientations. This standardization simplifies manufacturing by allowing bulk production of identical parts, reducing the impact of having multiple mounts on overall manufacturing complexity.
Solution Approach 2:
The radial arrangement of identical mounts creates a symmetric overall pattern from asymmetric individual component orientations. This approach simplifies manufacturing by using the same component design repeatedly, while the radial positioning naturally accommodates thermal expansion in all directions without requiring complex custom-designed mounts for each location.
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 solution effectively mitigates thermal expansion stresses by allowing controlled movement while distributing loads and reducing the need for complex designs, making it more robust and cost-effective for large modules.
Implementation Method 1
using an insulating plate to limit heat transfer and prevent excessive movement
Implementation Method 2
The aftertreatment module may become hot during operation and expand but are often mounted on a surface that does not become as hot or expand as much. This difference in thermal expansion creates stress.
Data Source
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AI summary
An exhaust aftertreatment module (100) comprising a plurality of mounts (202) for connecting the module (100) to a surface (5). The mounts (202) are arranged in a radial pattern around a central location (204) of the module (100). The mounts (202) also have a direction of travel (208) aligned with a radial direction of expansion (210) that passes through the central location (204).