Segmented Annular Body Static Mixer for Exhaust Systems
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Solution Overview
Problem
The existing production methods for static mixers in exhaust systems are costly and time-consuming, involving multiple steps to form an annular body with guide blades from a single sheet metal body.
Innovation Solution
The annular body is assembled from multiple part bodies, each with guide blades, produced in a single forming operation, and connected without expensive joining methods like soldering or welding, using coupling protrusions and receptacles for a strong, cost-effective assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the annular body with guide blades is produced from a single sheet metal body through multiple forming steps, then the structural integrity is maintained, but the production cost and time increase significantly
Solution Approach 1:
The annular body is divided into multiple separate guide blade elements that can be produced independently and then assembled together. This segmentation allows each element to be manufactured through simpler, more cost-effective processes while maintaining the overall structural integrity of the mixer.
Solution Approach 2:
Multiple separately produced guide blade elements are combined to form the complete annular body. This merging approach enables parallel production of components, reducing total manufacturing time and cost while achieving the same functional result as a single-piece construction.
2Productivity
If multiple part bodies are assembled to form the annular body, then the production cost decreases, but the assembly complexity increases
Solution Approach 1:
The mixer is segmented into multiple identical or similar part bodies that can be produced simultaneously through standardized processes, increasing productivity while the modular nature simplifies assembly through repetition of proven connection methods.
Solution Approach 2:
The coupling protrusions and receptacles are designed with universal compatibility, allowing the same connection mechanism to be used for assembling all part bodies. This universality reduces assembly complexity despite the increased number of components.
3Ease of manufacture
If traditional joining methods like soldering or welding are used to connect part bodies, then the connection strength is high, but the manufacturing cost increases
Solution Approach 1:
The part bodies are designed with self-joining features (coupling protrusions and receptacles) that enable direct mechanical connection without requiring external joining processes like soldering or welding. This self-service approach eliminates costly and complex joining operations while maintaining adequate connection strength.
Solution Approach 2:
The coupling elements are designed as simple, inexpensive mechanical features that can be easily manufactured into the part bodies themselves, replacing expensive joining methods with cost-effective integrated design features.
Data Source
AI summary
The present invention relates to a static mixer (9) for installation in a fluid line, in particular exhaust line (5) of a combustion engine (1), with an annular body (10) comprising at least one blade row (11) with a plurality of guide blades (12) standing away from the annular body (10) to the inside.A cost-effective producibility is obtained when the annular body (10) in the circumferential direction (13) consists of at least two part bodies (14), when part bodies (14) adjacent in the circumferential direction (13) are fastened to one another and when each part body (14) comprises a plurality of guide blades (12).