CN105545426B - 预热型催化式转化器的焊接结构 - Google Patents

预热型催化式转化器的焊接结构 Download PDF

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CN105545426B
CN105545426B CN201510695675.7A CN201510695675A CN105545426B CN 105545426 B CN105545426 B CN 105545426B CN 201510695675 A CN201510695675 A CN 201510695675A CN 105545426 B CN105545426 B CN 105545426B
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梁大成
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Kia Corp
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/105—General auxiliary catalysts, e.g. upstream or downstream of the main catalyst
    • F01N3/106—Auxiliary oxidation catalysts
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    • F01N13/1805—Fixing exhaust manifolds, exhaust pipes or pipe sections to each other, to engine or to vehicle body
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    • F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
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    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
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    • F01N13/00—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00
    • F01N13/18—Construction facilitating manufacture, assembly, or disassembly
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Abstract

一种车辆的预热型催化式转化器(WCC)的焊接结构，所述焊接结构包括：连接到所述WCC的前锥的涡轮壳体的凸缘，所述WCC减少从发动机排出的废气；形成在所述凸缘中的通孔，废气从所述通孔流过；以及延伸部，其在废气从所述通孔流过的方向上延伸，所述延伸部形成在所述凸缘并与所述前锥面接触，其中所述前锥被焊接到所述延伸部以连接所述凸缘与所述前锥。

Description

预热型催化式转化器的焊接结构
技术领域
本发明涉及一种预热型催化式转化器(warm-up catalytic converter，WCC)的焊接结构，特别涉及一种WCC的焊接结构，其中WCC的前锥(front cone)焊接到涡轮壳体的凸缘。
背景技术
车辆的预热型催化式转化器(WCC)净化从车辆发动机排出的废气，其具有焊接到涡轮壳体的入口部(inlet portion)。
如图1和图3所示，涡轮壳体的凸缘101被焊接在WCC的前锥102及102’的入口部，使得从涡轮增压器的涡轮排出的废气进入到WCC。
用于将前锥102和102’焊接到凸缘101的方法能够分为如图1和图2所示的内周焊接方法以及如图3和图4所示的外周焊接方法。
所述内周焊接方法通过将前锥102的入口部插入到凸缘101上形成的通孔中并在通孔内将前锥102焊接到凸缘101，来将前锥102固定到凸缘101。内周焊接方法在凸缘101与前锥102的外周面之间的间隔G1狭窄从而焊接工具不能够进入所述间隔时使用。因此，排气系统能够被最小化。由于排气系统的小尺寸，提高了动态刚度(dynamic stiffness)，改善了噪声，振动，和声振粗糙度(NVH：noise，vibration，and harness)并缩短了排气通道，由此催化剂在早期就能被活化。然而，由于焊接部103被直接暴露在高温废气中，收缩与膨胀应力会作用于凸缘101，这就导致了对抗热疲劳的耐久性的下降。
在外周焊接方法中，前锥102’的入口部被插入到凸缘101的通孔中，并在前锥102’的外周面与凸缘101相会处进行焊接。由于焊接部103形成于排气通道的外侧，外周焊接方法能够降低暴露温度并分散收缩与膨胀应力，但由于增加了排气通道以及前锥102’的尺寸导致催化剂容量降低和动态刚度以及NVH恶化。
发明内容
本发明一方面提供一种车辆的WCC的焊接结构，其通过在凸缘与前锥的焊接部面接触的状态下将催化式转化器的前锥焊接到涡轮壳体的凸缘，能够分散焊接部的应力集中并且增加对抗热疲劳的耐久性。
本发明另一方面提供一种车辆的WCC的焊接结构，其通过使前锥的内周中的前锥的焊接部的厚度比凸缘的主体的厚度薄，能够改善焊接性。
本发明又一方面提供一种车辆的WCC的焊接结构，其由于前锥的焊接部形成在从凸缘延伸的部分的后部，而能够最小化在高温废气中的暴露。
本发明的其他目的和优点能够通过下文的描述来理解，并参考本发明的实施例，这些其他目的和优点将变得显而易见。此外，对本发明所属领域的技术人员显而易见的是，本发明的目的和优点能够通过权利要求的装置及其组合来实现。
根据本发明的实施例，一种车辆的预热型催化式转化器(WCC：warm-up catalyticconverter)的焊接结构，包括：连接到所述WCC的前锥的涡轮壳体的凸缘，所述WCC减少从发动机排出的废气；形成在所述凸缘中的通孔，废气从所述通孔流过；以及延伸部，其在废气从所述通孔流过的方向上延伸，所述延伸部形成在所述凸缘并与所述前锥面接触，其中所述前锥被焊接到所述延伸部以连接所述凸缘与所述前锥。
所述延伸部可以包括从所述通孔延伸并与所述前锥的内周面接触的内周延伸部。所述内周延伸部可以被焊接到所述前锥。
所述内周延伸部的端部可以被焊接到所述前锥的内周面。
所述前锥的外周面的端部可以被焊接到所述凸缘。
所述内周延伸部的厚度可以比所述凸缘的厚度薄。
所述延伸部还可以包括从所述通孔延伸并与所述前锥的外周面接触的外周延伸部。所述外周延伸部被焊接到所述前锥。
所述外周延伸部的端部可以被焊接到所述前锥的外周面。
所述外周延伸部的厚度可以比所述凸缘的厚度薄。
所述前锥可以由不锈钢材料形成。
附图说明
图1为利用现有技术的内周焊接方法使涡轮壳体的凸缘与WCC的前锥相互焊接的WCC的立体图。
图2为图1的A部分的局部放大图。
图3为利用现有技术的外周焊接方法使涡轮壳体的凸缘与WCC的前锥相互焊接的WCC的立体图。
图4为图3的B部分的局部放大图。
图5为根据本发明的一个示例性实施例将涡轮壳体的凸缘与WCC的前锥相互焊接的WCC的入口部的焊接结构的截面图。
图6和图7为图5的C部分的局部放大图，其中图6是示出废气的流动方向的截面图，以及图7是应力分布的截面图。
图8为根据本发明另一个示例性实施例将涡轮壳体的凸缘与WCC的前锥相互焊接的WCC的入口部的焊接结构的截面图。
图9和图10为图8的D部分的局部放大图，其中图9是示出废气的流动方向的截面图，以及图10是应力分布的截面图。
具体实施方式
以下，将结合附图对本发明的示例性实施例的车辆的WCC的焊接结构进行详细的描述。
如图5到图7所示，在本发明的示例性实施例的车辆的WCC的入口部的焊接结构中，凸缘11被安装到涡轮壳体10并且连接到WCC的前锥12，其减少从发动机排出的废气。通孔11c形成在凸缘11中使得废气从中流过。延伸部在形成有凸缘11的通孔11c处在废气流动的方向上延伸，并与被焊接到所述延伸部以连接凸缘11和前锥12的前锥12面接触。
通孔11c是形成在凸缘11中的用于排出从涡轮壳体侧经其排出的废气的通道。内周延伸部11a在废气从通孔11c流动的方向上，即在前锥12的连接方向上延伸。内周延伸部11a在废气从凸缘11的通孔11c流动的方向上，即以预定义长度向前锥12延伸，并且接触前锥12的内周面，即内周。
前锥12被插入到内周延伸部11a的外侧，因此，凸缘11与前锥12以内周延伸部11a的延伸长度相互重叠。
凸缘11与前锥12通过焊接相互固定。即，凸缘11的内周延伸部11a与前锥12的内周面相互焊接。在此情况下，前锥12的内周面被焊接到内周延伸部11a的端部。如图6与图7所示，前锥12的内周面在内周延伸部11a的端部被焊接到内周延伸部11a，以形成内焊接部13a。
内周延伸部11a的厚度可以比凸缘11薄。
前锥12的外周面在其端部被直接焊接到凸缘11的主体。前锥12的外周面被焊接到凸缘11的主体，以形成外焊接部13b。
在此，前锥12的材料可以使用与一般的铸钢材料相比质量更轻而且耐久性和加工性更高的不锈钢。
如前所述，当前锥12的内周面被焊接到从凸缘11延伸到前锥12的内周面的内周延伸部11a的端部时，如图6所示，内焊接部13a在废气的流动方向上形成在前锥12的下部，因此，能够将暴露在高温废气中的部分最小化。
而且，内周延伸部11a的厚度比凸缘11薄，因此，焊接性出色并且焊接部的耐久性得以改善。
图7为凸缘11和前锥12的连接部的热应力分布。其中，热膨胀应力从内周延伸部11a和内焊接部13a作用于前锥12的内周面，并且热收缩应力从外焊接部13b作用于前锥12的内周面。所述热膨胀应力被分散在前锥12的内周面，多达内周延伸部11a的延伸长度，因此，增加了对抗热疲劳的耐久性。
图8至图10为本发明另一示例性实施例的车辆的WCC的入口部的焊接结构。
根据本发明的另一示例性实施例，除了上述实施例中的部件外，还追加形成有从凸缘11延伸并与前锥12的外周面接触的外周延伸部11b。
外周延伸部11b形成在废气从凸缘11流过的方向上，即与内周延伸部11a相同的方向。
与内周延伸部11a类似，外周延伸部11b的的厚度比凸缘11薄。
前锥12被插入在内周延伸部11a和外周延伸部11b之间，并且前锥12被焊接到内周延伸部11a和外周延伸部11b。即，如图所示前锥12的内周面和外周面分别焊接到内周延伸部11a和外周延伸部11b的端部。
根据本发明的另一示例性实施例，从凸缘11延伸到前锥12的内周面和外周面的内周延伸部11a和外周延伸部11b的端部分别焊接到前锥12的内周面和外周面。因此，内焊接部13a和外焊接部13b形成在废气的流动方向的下游处，从而使废气中的暴露最小化。而且，外周延伸部11b的厚度比凸缘11薄，因此，焊接性出色并且焊接部的耐久性得以改善。
图10为凸缘11和前锥12的连接部的热应力分布。在此，热膨胀应力通过内周延伸部11a和内焊接部13a的全部长度作用于前锥12的内周面，热收缩应力从外焊接部13b作用于外焊接部13b和前锥12的外周面，从而提高了对抗热疲劳的耐久性。
根据如上所述的本发明示例性实施例的WCC的入口部的焊接结构，通过将前锥焊接到WCC的前锥和涡轮壳体的凸缘与从凸缘延伸的内周延伸部和外周延伸部面接触的内周延伸部和外周延伸部，将由于高温废气的流动导致凸缘发生热膨胀时产生的热应力从内周延伸部和外周延伸部传递到前锥，由此能够提高对抗热疲劳的耐久性。
而且，通过使内周延伸部和外周延伸部的厚度比凸缘11薄，能够改善焊接部的焊接性，由此增加焊接部的耐久性。
此外，由于内周延伸部形成在内周延伸部的下部，当高温气体流过时，能够使焊接部在高温废气中的暴露最小化。
前述示例性实施例仅是示例性的，以使本发明所属领域技术人员能够容易实施本发明。因此本发明不局限于上述示例性实施例及附图，因此本发明的范围不限于前述示例性实施例。因此，对本领域技术人员显而易见的是，在不脱离由所附权利要求所限定的本发明的精神和范围的情况下，能够做出替代、变形和改变，并且这些替代、变形和改变也属于本发明的范围。

Claims (7)

1.一种车辆的预热型催化式转化器的焊接结构，所述焊接结构包括：
连接到所述预热型催化式转化器的前锥的涡轮壳体的凸缘，所述预热型催化式转化器减少从发动机排出的废气；
形成在所述凸缘中的通孔，废气从所述通孔流过；以及
延伸部，其在废气从所述通孔流过的方向上延伸，所述延伸部形成在所述凸缘并与所述前锥面接触，
其中所述前锥被焊接到所述延伸部以连接所述凸缘与所述前锥，
其中，所述延伸部包括：
从所述通孔延伸并与所述前锥的内周面接触的内周延伸部，并且
所述内周延伸部被焊接到所述前锥；和
从所述通孔延伸并与所述前锥的外周面接触的外周延伸部，并且所述外周延伸部被焊接到所述前锥。
2.如权利要求1所述的焊接结构，其中，所述内周延伸部的端部被焊接到所述前锥的内周面。
3.如权利要求1所述的焊接结构，其中，所述前锥的外周面的端部被焊接到所述凸缘。
4.如权利要求1所述的焊接结构，其中，所述内周延伸部的厚度比所述凸缘的厚度薄。
5.如权利要求1所述的焊接结构，其中，所述外周延伸部的端部被焊接到所述前锥的外周面。
6.如权利要求1所述的焊接结构，其中，所述外周延伸部的厚度比所述凸缘的厚度薄。
7.如权利要求1所述的焊接结构，其中，所述前锥由不锈钢材料形成。
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