Spun Extrusion Side Entry Muffler Inlet
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Solution Overview
Problem
The existing press and die method for forming side entry muffler exhaust inlets interrupts the production flow on high-speed lines, leading to increased costs and material thinning issues, limiting its use to low-volume dedicated lines and reducing extrusion durability.
Innovation Solution
A spun extrusion method is used to form the exhaust inlet, allowing the muffler shell to be completely assembled and end caps attached on a high-speed production line without interruptions, with minimal thinning at the base radius area, using a spinning tool that engages the inner circumferential area for line contact and pulls the outer shell material outward to form the extruded surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If press and die method is used to form extrusion, then exhaust inlet connection interface is created, but production flow is interrupted and material thinning occurs
Solution Approach 1:
The patent replaces the traditional press and die mechanical system with a spinning tool system that uses rotational motion to form the extrusion. The spinning tool rotates against the shell material, using friction and plastic deformation to create the extruded portion, eliminating the need for offline pressing operations and maintaining continuous production flow.
Solution Approach 2:
The extrusion is formed during the shell forming process itself, before the shell moves to subsequent assembly stations. The spinning tool creates the extruded portion as the shell is being formed, so that when the shell reaches the stuffing station, the exhaust inlet connection interface is already ready, eliminating interruptions in the production sequence.
2Ease of manufacture
If press and die method is used to form extrusion, then exhaust inlet connection interface is created, but material thinning reduces extrusion durability
Solution Approach 1:
The patent replaces the compressive pressing mechanism with a rotational spinning mechanism. The spinning tool rotates against the shell material, distributing material flow more evenly through plastic deformation. This process maintains material density and structural integrity at the base radius area, creating a stronger extrusion that is less prone to failure.
3Ease of manufacture
If extrusion is formed before stuffing internal components, then exhaust inlet connection interface is available, but production line efficiency decreases
Solution Approach 1:
The patent merges the extrusion formation operation with the shell forming operation. Both processes occur at the same location and time on the production line, using the shell forming process to create the base structure and the spinning tool to create the extrusion simultaneously. This eliminates the need for separate offline pressing operations and allows continuous flow to the stuffing station.
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
Enables continuous production of side entry mufflers on high-speed lines with improved extrusion durability and allows for subsequent offline connections, such as attaching tail pipes, without the material thinning issues associated with traditional methods.
Implementation Method 1
The spinning tool engages an inner circumferential area of the exhaust inlet at a line contact interface. The spinning tool is also pulled in a direction generally parallel to the axis to pull outer shell material outwardly to form the spun extruded portion.
Data Source
AI summary
By using a spun extrusion method to form a side entry exhaust inlet, a muffler can be completely stuffed and end caps can be spun onto opposing ends of the muffler on a high speed production line without interruptions. The side entry exhaust inlet is formed within a muffler shell at a position between the opposing ends. A spinning tool engages an internal peripheral area of the side entry exhaust inlet to form a spun extruded surface that extends outwardly from the muffler shell.