One-Piece Sheet Metal Probe Connector Design
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Solution Overview
Problem
Existing probe sockets for exhaust pipes are difficult to weld due to partial coverage of the connecting joint, leading to potential thermal distortion and flow resistance, and require complex manufacturing processes.
Innovation Solution
A one-piece sheet metal probe connector with a spatially separated inner sleeve for the measuring probe and outer sleeve for fastening, connected via an annular bridge, allowing independent design and reducing thermal distortion risks through an annular free space, and formed using deep-drawing and turning processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a solid ring-shaped probe socket is used to accommodate the measuring probe, then the probe can be securely mounted in different angular positions, but the connecting joint between the exhaust pipe and probe socket becomes partially covered and inaccessible for normal welding equipment
Solution Approach 1:
The probe socket is segmented into an inner sleeve (receiving area) and an outer sleeve (fastening area) that are spatially separated and connected only via an annular connecting web. This segmentation allows the outer sleeve to be welded to the exhaust pipe without the inner sleeve interfering with welding accessibility, while still providing secure probe mounting
2Reliability
If welding is performed on the outer sleeve to connect it to the exhaust pipe, then a closed weld seam is achieved for tightness, but thermal distortion occurs on the inside of the ring-shaped probe socket impairing probe installation
Solution Approach 1:
By separating the probe-receiving inner sleeve from the welding-performed outer sleeve through spatial separation and connecting them only via a thin annular web, the heat from welding the outer sleeve does not significantly affect the inner sleeve, preventing thermal distortion that would impair probe installation
Solution Approach 2:
The annular connecting web acts as a thermal buffer or intermediary between the outer sleeve (subject to welding heat) and the inner sleeve (sensitive to thermal distortion). This thin web structure allows mechanical connection while minimizing heat transfer to the probe-receiving area
3Reliability
If the probe socket protrudes into the exhaust pipe to provide receiving area, then the measuring probe can be accommodated, but flow resistance is undesirably increased
Solution Approach 1:
The probe receiving function is moved from the radial dimension (protruding into the exhaust pipe) to the axial dimension (inner sleeve extending along the pipe axis). The inner sleeve protrudes only minimally into the exhaust pipe flow path, significantly reducing flow resistance while still providing adequate probe accommodation space
4Adaptability or versatility
If complex shapes with very different wall thicknesses are used for connecting pieces, then functional requirements are met, but manufacturing processes become complex requiring casting, forging or welding
Solution Approach 1:
The design uses relatively uniform wall thicknesses for both the inner and outer sleeves, making the component suitable for sheet metal forming processes. This parameter change from variable to uniform thickness simplifies manufacturing while still meeting functional requirements through the spatially separated sleeve design
5Ease of manufacture
If sheet metal forming is used to produce the probe socket, then material and energy are saved and component strength is enhanced, but the receiving area and fastening area must be spatially separated
Solution Approach 1:
The inner sleeve and outer sleeve are merged into a single one-piece component formed from a single sheet metal blank through deep-drawing and turning operations. This merging maintains manufacturing economy while the spatial separation of functions (probe receiving vs. fastening) is achieved through the three-dimensional forming process
Data Source
Figure 1
Figure 2~3
AI summary
A testing probe connection piece (10) is made as one piece from a sheet of metal. An inner sleeve (12) forms a retaining area and an outer sleeve (14) forms a fastening area with a radial clearance from the inner sleeve. The inner and outer sleeves interlink via a connecting strip (16). The outer sleeve has an edge (18) that protrudes radially outwards and has a contact area (20) for resting on a main body.