Self-aligning Exhaust Sensor Joint Using Tapered Pipe and Nut Assembly
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Solution Overview
Problem
The installation of exhaust pressure sensors is complicated by alignment constraints between tubing assemblies and fixed bases, leading to potential misalignment, increased stress, and subsequent degradation of the sensor, which can result in longer installation times and higher costs due to the need for realignment and re-welding.
Innovation Solution
A self-aligning exhaust sensor joint system comprising a tapered pipe with a flange, a nut assembly with a conical inner cavity, and a boss with a threaded inner cavity, allowing the pipe to be freely rotated and aligned before being secured by the nut assembly, reducing stress and eliminating the need for precise initial alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the tubing assembly includes a press washer with a protrusion that matches a notch in the fixed base to ensure precise alignment, then the alignment precision is improved, but the device complexity and installation time increase
Solution Approach 1:
The patent eliminates asymmetric alignment features (protrusions and notches) in favor of a symmetric design where the tubing assembly can rotate freely within the fixed base. The universal joint allows the tubing to align itself with any orientation, removing the need for precise pre-alignment features that increase complexity.
Solution Approach 2:
The patent introduces a dynamic alignment mechanism where the tubing assembly can rotate and adjust its orientation freely within the fixed base during installation. This dynamic capability allows the system to self-align without requiring precise static alignment features, thereby reducing complexity while maintaining precision.
2Manufacturing precision
If the tubing assembly is constrained to a single orientation to ensure proper alignment, then the alignment precision is improved, but the ease of operation and installation ease deteriorate
Solution Approach 1:
The universal joint mechanism enables the tubing assembly to dynamically adjust its orientation during installation, allowing installers to easily position the tubing at any angle while maintaining proper alignment. This dynamic freedom of movement greatly simplifies the installation process compared to rigid fixed-orientation constraints.
Solution Approach 2:
The tubing assembly self-aligns with the fixed base through free rotation within the universal joint, eliminating the need for complex alignment procedures or specialized tools. The system automatically achieves proper alignment through its own mechanical freedom, making installation straightforward and intuitive.
3Manufacturing precision
If the tubing assembly is misaligned and torqued to force alignment, then the alignment precision is improved, but the stress on the tubing assembly increases leading to sensor degradation
Solution Approach 1:
The universal joint provides dynamic alignment adjustment, allowing the tubing to achieve proper orientation without forced torquing. By enabling free rotation and self-alignment during installation, the system eliminates the need to apply excessive torque to correct misalignment, thereby protecting the tubing and sensor from stress-induced degradation.
4Manufacturing precision
If the fixed base is removed, realigned, and re-welded to correct misalignment, then the alignment precision is improved, but the loss of time and productivity increase
Solution Approach 1:
The universal joint mechanism allows alignment corrections to be made dynamically during installation by simply rotating the tubing assembly, eliminating the need to remove and re-weld the fixed base. This dynamic adjustment capability maintains high installation productivity while achieving proper alignment.
Solution Approach 2:
The patent separates the alignment function from the fixed base structure by incorporating a universal joint that allows independent rotation of the tubing assembly. This segmentation enables alignment adjustments without affecting the welded connection, preventing the need for time-consuming removal and re-welding operations.
Data Source
AI summary
Systems and methods are provided for a self-aligning exhaust sensor joint. In one example, a system may include a tapered pipe having a flange at its wider end; a nut having a head, an externally threaded bottom, and a tapered inner cavity that is adapted to fit around the tapered pipe; and a boss having a threaded inner cavity that is adapted to engage with the threaded bottom of the nut and having an engagement cavity for receiving the flange. By inserting the flange into the engagement cavity, mating the externally threaded bottom of the nut with the threaded inner cavity of the boss, and torquing the nut until a bottom surface of the externally threaded bottom pushes against the flange, a seal may be formed between the tapered pipe and the boss.