Universal Doser Mount for Exhaust Mixer Shells
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Solution Overview
Problem
The proliferation of different doser mounts for various mixer shell sizes in vehicle exhaust systems increases costs and complexity due to the need for specific mounts for each size, leading to inefficiencies in manufacturing and assembly.
Innovation Solution
A single, universal doser mount with a curved body and multiple mating surfaces is designed to accommodate mixer shells of different dimensions, featuring a center boss with a doser opening and a swirl chamber, allowing the same mount to be used across various mixer shell sizes, thereby reducing the need for multiple mounts and simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If different doser mounts are used for different mixer shell sizes, then each mixer shell size can have a dedicated mount, but the number of parts increases and manufacturing cost increases
Solution Approach 1:
The doser mount is designed with multiple mating surfaces that can accommodate different mixer shell sizes (e.g., 2.5-inch, 3-inch, 3.5-inch, 4-inch shells) using a single universal mount design. This eliminates the need for multiple size-specific mounts, directly resolving the contradiction by maintaining reliable dedicated fits while reducing the total number of parts.
Solution Approach 2:
The doser mount body is segmented into multiple mating surfaces, each configured for a specific mixer shell size. This segmentation allows the single mount to interface with different shell dimensions while maintaining a unified component structure, thereby reducing part proliferation.
2Manufacturing precision
If different doser mounts are used for different mixer shell sizes, then each configuration can be optimized, but manufacturing cost increases due to part proliferation
Solution Approach 1:
The universal doser mount incorporates multiple mating surfaces that maintain optimized configurations for different mixer shell sizes within a single component. This approach preserves the manufacturing precision benefits of dedicated optimized mounts while achieving economies of scale in production, directly addressing the cost issue.
Solution Approach 2:
Multiple size-specific mount designs are merged into a single universal doser mount component. By combining the functional requirements of different sized mounts into one part, the invention maintains configuration optimization while reducing manufacturing costs through part consolidation.
3Reliability
If multiple doser mount designs are maintained for different mixer sizes, then each size can have a perfect fit, but inventory complexity and assembly time increase
Solution Approach 1:
The doser mount's multiple mating surfaces enable a single component to achieve perfect fits across different mixer shell sizes. This universality eliminates the need for assembly personnel to select from multiple different mount designs, directly improving assembly efficiency while maintaining fit accuracy.
Solution Approach 2:
The mating surfaces are segmented to accommodate different shell sizes, allowing the single doser mount to provide accurate fits for various configurations. This segmentation within a unified component simplifies inventory management and accelerates the assembly process.
Data Source
AI summary
A component for a mixer of a vehicle exhaust system, according to an exemplary aspect of the present disclosure includes, among other things, a doser mount comprising a curved body having a center boss with a doser opening defining a doser axis. The curved body includes at least a first mating surface configured to receive a first mixer shell defined by a first dimension and a second mating surface configured to receive a second mixer shell defined by a second dimension different than the first dimension.