Segmented Compression Jaw Assembly for Precise Tube Deformation
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Solution Overview
Problem
Existing compression jaw assembly units for tubular metal parts in exhaust systems of internal combustion engines face challenges in achieving precise deformation without generating undesired deformations, often requiring thick materials that increase manufacturing costs and weight.
Innovation Solution
The compression jaw assembly unit features a combination of fixed and movable segments with a prestressing device, allowing for a distributed circumferential spacing that reduces the risk of deformation by minimizing the size of partial spacings, enabling the use of thinner materials and accommodating complex geometries like oval or elliptical housings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thick material is used for the housing, then the risk of undesired deformations is reduced, but manufacturing costs and weight increase
Solution Approach 1:
The compression jaw is divided into multiple segments (first compression jaw segment, second compression jaw segment, third compression jaw segment) that can move relative to each other. This segmentation allows the compression force to be distributed more evenly across the housing, reducing stress concentrations that would otherwise require thicker material to prevent deformation.
Solution Approach 2:
The compression jaw segments are designed to be movable relative to one another during the compression process. This dynamic configuration allows the jaw to adapt to the housing geometry and distribute compression forces more uniformly, eliminating the need for excessive material thickness to prevent undesired deformations.
2Ease of operation
If circumferential spacing is provided between compression jaw assembly units, then radial movement is enabled, but folds and shape deviations occur in the housing
Solution Approach 1:
The compression jaw is segmented into multiple movable segments that can independently adjust during compression. This segmentation allows the jaw to maintain continuous contact with the housing even when circumferential spacing exists between assembly units, preventing folds and shape deviations while preserving radial movement capability.
Solution Approach 2:
The movable compression jaw segments can dynamically adjust their positions relative to each other during the compression process. This dynamic adaptation allows the jaw to bridge the circumferential gaps between assembly units, ensuring uniform compression without creating folds or shape deviations in the housing.
3Adaptability or versatility
If movable compression jaw segments are provided, then complex geometries can be accommodated and material thickness reduced, but device complexity increases
Solution Approach 1:
The compression jaw is divided into multiple segments that can move relative to each other, enabling the jaw to adapt to complex housing geometries such as oval or elliptical shapes. The segmented structure achieves versatility without requiring an entirely different jaw design for each geometry type.
Solution Approach 2:
The movable compression jaw segments provide dynamic adaptability to various geometries through their relative motion capability. This dynamic configuration allows a single jaw assembly design to handle multiple geometry types, reducing the need for specialized designs while maintaining versatility.
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 configuration allows for precise and controlled deformation of tubular metal parts with reduced risk of deformation, lowering manufacturing costs and weight, while enabling the processing of parts with complex circumferential structures.
Implementation Method 1
a prestressing device (biasing device), which prestresses the at least one movable compression jaw segment in the direction of movement away from the fixed compression jaw segment
Data Source
AI summary
A compression jaw assembly unit for a compressing device for compressing tubular metal parts includes a compression jaw carrier (17) and a compression jaw (16), provided at the compression jaw carrier (17), with a compressing surface (18) that is oriented essentially facing away from the compression jaw carrier (17) and is curved transversely to a compression jaw longitudinal direction (LB) in a compression jaw transverse direction (QB). The compression jaw (16) includes a fixed compression jaw segment (22), which is fixed to the compression jaw carrier (17) and provides a compressing surface segment (24), and at least one movable compression jaw segment (26, 28) providing a compressing surface segment (30, 32). The at least one movable compressing surface segment (26, 28) can be moved in a direction of movement (B) in relation to the fixed compressing surface segment (22) against the prestressing action of a prestressing device (42).