Silencer Sensor Mounting Structure for Easier Pipe Assembly
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Solution Overview
Problem
The assembly of exhaust gas sensors in silencers for combustion engines is prone to errors due to the radial penetration of the sensor through both the casing and pipe member, leading to complications in the assembly process.
Innovation Solution
A silencer design featuring an external shell member with a radially penetrating opening, an internal pipe with a cylindrical projection, and a cap that covers the external shell opening, allowing for simplified assembly by preventing the projection from getting caught during insertion, and compensating for potential misalignments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the exhaust gas sensor radially penetrates through both the casing and the pipe member, then the sensor can sense the oxygen concentration in the exhaust gas, but the assembly process becomes complicated and prone to errors
Solution Approach 1:
The silencer is divided into distinct components (external shell member, internal pipe, cap) with the sensor passing through only the internal pipe rather than penetrating both components radially. This segmentation simplifies the assembly process while maintaining sensing capability.
Solution Approach 2:
The cylindrical projection on the internal pipe acts as an intermediary feature that guides and positions the sensor during assembly, preventing misalignment and reducing assembly complexity without compromising the sensor's ability to measure oxygen concentration.
2Ease of manufacture
If the internal pipe is inserted into the external shell member, then the silencer chamber is formed, but the projection may get caught during insertion causing assembly difficulties
Solution Approach 1:
Instead of making the internal pipe fit tightly into the external shell member which would cause the projection to get caught, the design inverts the approach by ensuring the projection's outer radius is smaller than the shell's inner radius, allowing smooth insertion while maintaining structural integrity.
Solution Approach 2:
The critical parameter relationship is defined as: outer radius of projection < inner radius of external shell member. This parameter change ensures the projection passes through the shell opening without interference, simplifying the insertion process while maintaining proper positioning.
Data Source
AI summary
A silencer includes: an external shell member having a silencer chamber; and an internal pipe disposed in the silencer chamber. The external shell member has an external shell opening formed in a peripheral wall, and the internal pipe has a pipe opening is formed in a peripheral wall. The internal pipe includes a projection protruding radially outwards from the peripheral wall of the internal pipe. The projection is provided along the circumference of the pipe opening about the axis of the pipe opening. A sensor is positioned so as to plug the pipe opening. The silencer includes a cap covering the external shell opening. The cap is joined to a portion of the external shell member around the external shell opening and to the projection of the internal pipe. An outer radius dimension of the projection is set smaller than an inner radius dimension of the external shell member.