EP0919703A2 - Procédé de fabrication d'un collecteur d'échappement isolé par une couche d'air pour un véhicule - Google Patents

Procédé de fabrication d'un collecteur d'échappement isolé par une couche d'air pour un véhicule Download PDF

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Publication number
EP0919703A2
EP0919703A2 EP98119975A EP98119975A EP0919703A2 EP 0919703 A2 EP0919703 A2 EP 0919703A2 EP 98119975 A EP98119975 A EP 98119975A EP 98119975 A EP98119975 A EP 98119975A EP 0919703 A2 EP0919703 A2 EP 0919703A2
Authority
EP
European Patent Office
Prior art keywords
pipe
exhaust
flange
tube
air
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP98119975A
Other languages
German (de)
English (en)
Other versions
EP0919703A3 (fr
EP0919703B1 (fr
Inventor
Pierre Bonny
Thomas Hülsberg
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Daimler AG
Original Assignee
DaimlerChrysler AG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by DaimlerChrysler AG filed Critical DaimlerChrysler AG
Publication of EP0919703A2 publication Critical patent/EP0919703A2/fr
Publication of EP0919703A3 publication Critical patent/EP0919703A3/fr
Application granted granted Critical
Publication of EP0919703B1 publication Critical patent/EP0919703B1/fr
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • 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
    • F01N13/1805—Fixing exhaust manifolds, exhaust pipes or pipe sections to each other, to engine or to vehicle body
    • F01N13/1811—Fixing exhaust manifolds, exhaust pipes or pipe sections to each other, to engine or to vehicle body with means permitting relative movement, e.g. compensation of thermal expansion or vibration
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • 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
    • F01N13/08—Other arrangements or adaptations of exhaust conduits
    • F01N13/10—Other arrangements or adaptations of exhaust conduits of exhaust manifolds
    • F01N13/102—Other arrangements or adaptations of exhaust conduits of exhaust manifolds having thermal insulation
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • 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
    • F01N13/1883—Construction facilitating manufacture, assembly, or disassembly manufactured by hydroforming
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2450/00—Methods or apparatus for fitting, inserting or repairing different elements
    • F01N2450/22—Methods or apparatus for fitting, inserting or repairing different elements by welding or brazing
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49398—Muffler, manifold or exhaust pipe making
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49826—Assembling or joining
    • Y10T29/49879—Spaced wall tube or receptacle

Definitions

  • the invention relates to a method for producing a Air gap-insulated exhaust manifold of an exhaust system of a vehicle according to the preamble of claim 1.
  • a generic method is known from DE 195 11 514 C1. This describes the production of an exhaust manifold the one made up of several with a sliding seat Inner tubes and an outer jacket as well as input flanges and an outlet flange.
  • the outer jacket is half-shell construction executed, first the connector of the Inner pipes (pipe bend, T-piece, branch pipe with connection to the outlet flange) in a lower outer shell half-shell and then the upper half-shell is pressed onto the lower one and with the lower half-shell to form a flanged seam is welded between the inner tube ends.
  • the Plug connection of the inner tubes is carried out in a complex manner special spacer rings, which are pushed onto several inner tubes are centered within the outer jacket, the resulting gap forms the later air insulation gap.
  • the spacer rings consist of a heat, in particular decomposing and / or sublimating during engine operation Material.
  • those with manufacturing tolerances Individual pipes are displaceable against each other and due to the Assembly work from connector to connector different Have plug lengths and on the other hand the spacer rings on the one hand are subject to manufacturing tolerances themselves and secondly due to their design relative to the formation of the lower shell Manufacturing is rarely all-round of the entire exhaust manifold under these aspects alone Subject to tolerances.
  • the inner pipe with the branch connector is practically never included in the manufacturing tolerances mentioned the desired defined circumferential air gap within the Outer jacket. There is an exact reproducibility Not. When assembling, make sure that a certain minimum insertion length is observed so that the individual inner tubes do not slide apart.
  • the two outer shell half-shells lie not completely satiating by itself and therefore without any gaps on.
  • the upper shell of the outer jacket is therefore in the welding station placed on the lower shell and pressed against it.
  • the connector assembly is shaken or the displacement of the relative position of the branched inner tube in the outer jacket.
  • the shells of the outer jacket laser welded together. After releasing the contact pressure then act due to the non-uniformity of the contact surfaces the half-shells on the weld seam considerable tensile forces, what the durability of the assembly, in particular of the outer jacket and during operation of the exhaust system can even lead to component failure. Process security the production of the exhaust manifold is thus total seen not sufficiently guaranteed.
  • the welding of the half shells is forming one Flared seam is relatively complex, especially because of the transition for cutting out the outer jacket for the branch connector of the inner tube a triangular gusset arises due to edge radii, which has to be welded for process safety, what in in practice in a meaningful way only with the aid of an additional material goes.
  • the flanged seam is designed limited mechanical strength.
  • the inner tube on the outer jacket is also welded to form a circular seam, i.e. a circumferential fillet weld required in the end area of the branch connector, the end of the inner pipe of the socket opposite the opening of the outer jacket is somewhat set back.
  • the outer jacket is just because of the branched exhaust pipe spatially very expansive because of the manufacture the half-shells did not branch out by deep drawing can be and thus for a contoured training of a Outer jacket with regard to the design of the inner tube is not is suitable.
  • All inner tubes are made by one common outer jacket integrally enclosed, which due to of the uniform finish of the outer jacket approximately in the Level of the inlet flanges of relatively large-volume sheet metal sections of the outer jacket between those adjoining the input flanges Inner tubes are created that require considerable installation space, increase the weight of the branched exhaust pipe and additional unnecessary material expenditure mean. In addition, this is the formation of a defined uniformly uniform Air gap cannot be reached in the branched exhaust pipe.
  • the invention has for its object a generic To further develop methods in a simple manner a reliable and reproducible production of space-saving air gap-insulated exhaust manifolds achieved becomes.
  • a modular design of the exhaust manifold enables, in the simplest way from nested air gap insulated individual exhaust pipes with regard to their Extent and construction depth manufactured arbitrarily designed exhaust manifold can be, the outer tubes of the individual exhaust pipes welded together and the inner tubes together Sliding seat are positioned.
  • the individual modules form the individual exhaust pipes, which standard components and therefore inexpensive represent mass-produced goods. So by simple Joining of identical parts of the branched exhaust pipes for example, a 6 or 4 cylinder exhaust manifold 8-cylinder exhaust manifold can be manufactured. By using it The same assembly is essential for identical parts simplified.
  • the invention Manufacturing process achieved high process reliability because due to the internal high-pressure forming, on the one hand, no plug-in dissolving Sliding possibility of the inner tubes occurs and on the other hand the number of weld seams is minimized, whereby the exhaust manifold is designed to be simple only all-round, mechanically stressable fillet welds to be carried out for fastening the individual exhaust pipes to each other and required on the inlet flanges and on the outlet flange are.
  • FIG. 1 shows an air-gap-insulated exhaust manifold 1, that of a pipe bend 2, a T-branched Exhaust pipe 3 and a T-piece branched exhaust pipe 4 exists.
  • the ends facing the cylinder head 6 the exhaust pipes 2, 3 and 4 are connected to input flanges 5.
  • the illustrated separate input flanges 5 can also be integrated in a common flange.
  • the pipe bend is first 2, the exhaust pipe 3 and the final exhaust pipe 4 each from one straight double pipe ready for joining by means of internal high pressure forming manufactured.
  • the double pipe thus formed hereby consists of an inner tube 9 and one of these coaxially surrounding outer tube 10.
  • the two tubes 9 and 10 must not necessarily be straightforward in their training. It must only that for a uniformity of the later air insulation gap required coaxiality can be guaranteed, whereby the two tubes 9 and 10 at least at one end to each other must be concerned. So the tubes 9 and 10 can be plugged together at one end with the formation of an annular gap be spaced.
  • the inner tube 9 is inserted before Perforated at its ends.
  • the inner tube 9 consists of a high temperature resistant material, while the less temperature-loaded outer tube 10 from a cheaper less high temperature resistant material can.
  • the double pipe from which the pipe bend 2 is made pre-bent in a bending device which is also a hydroforming tool can be. That in one of the hydroforming tool separate bending device pre-bent Double tube is then placed in an internal high pressure forming tool, the engraving of which follows the course of the bending of the curved double tube is adapted, but following the End regions of the double tube is expanded concentrically, whereby an annular space between the engraving that serves as an expansion space and the inserted double tube is formed. After closing of the internal high pressure forming tool becomes the double tube sealed at the end by means of an axial ram and introduced filled with a pressure fluid via these stamps.
  • the pressure fluid is clamped up to about 700-1000 bar, whereupon the double tube expands in a simple manner.
  • the inner tube 9 is clamped circumferentially at both ends with the outer tube 10.
  • the outer tube 10 in the area of the expansion chamber directly with pressurized fluid acts, whereby this expands and addresses to the concentrically expanded portion of the engraving creates while due to the pressure equalization between inner tube 9 and outer tube 10 in this section, the shape of the inner tube 9 of a Forming remains undisturbed.
  • the branched exhaust pipe 3 is produced in two Steps. Starting from the double pipe mentioned, this will not bent, but remains straight in its course.
  • the first Step is the double tube in a first hydroforming tool introduced, the engraving of a radial branch having. After closing the first forming tool and sealing both ends of the double tube, the ring of holes of the Inner tube is also sealed, respectively Pressurized fluid introduced into the inner tube 9 and under high pressure set. Under high pressure, according to the engraving form a double-walled branch pipe 12 from the double pipe blown out. After the branch connector 12 is formed, the The pressure is released and the branched T-shaped double pipe from the first internal high pressure forming tool removed.
  • the second Step was the branched double tube in a second hydroforming tool brought in, its engraving accordingly the formation of the double tube is T-shaped, however following the three end regions of the T-shaped double tube is expanded concentrically.
  • the end areas are each with game in the engraving.
  • the engraving limits thus a T-shaped with the double tube between its end regions Expanding space.
  • the second hydroforming tool is now closed and the open ones facing each other End areas of the double pipe sealed, the perforation of the inner tube 9 is released.
  • the three end regions of inner tube 9 and Outer tube 10 are against each other and against the high pressure Engraving pressed, the inner tube 9 and the outer tube 10th jam together there.
  • the now branched air gap insulated Exhaust pipe 3 is after the forming and Relaxation and discharge of the pressure fluid and subsequent Opening the second forming tool removed from this.
  • the This opening can also be made by milling, turning, Stamping, drilling or similar processes are carried out. It is at the formation of the branched air-gap insulated exhaust pipe 3 and 4 otherwise conceivable, the two-forming steps in one sequence single forming tool simultaneously or in succession allow. In this case, the forming tool would then have to be two in a reliable manner Have engravings formed at a distance from one another.
  • the manufacture of the final exhaust pipe 4 is the same as that of the branched exhaust pipe 3 just described. Regarding the formation of its slightly curved end 7 the exhaust pipe 4 may be pre-bent or by the internal high pressure forming in the first step according to the Engraving shape take its bending shape.
  • both the exhaust pipe 4 and the exhaust pipe 3 are made by laser cutting trimmed so that the air insulating gap 13 is opened there.
  • the pipe bend 2 is cut at one end, whereby its air insulation gap 11 opens at this point becomes.
  • the end 14 whose inner tube 9 in an end 15 of the inner tube 9 of the open End of the exhaust pipe 3 and the end 16 there Outer tube 10 of the pipe bend 2 in one end 17 of the outer tube 10 of the exhaust pipe end inserted there with a sliding seat.
  • the two outer tubes 10 are then from the outside on their Overlap point forming a circumferential fillet weld 18 welded by laser welding.
  • the ends 6 of the exhaust pipes 3 and 4 that is, the ends of the branch pipe 12 in tapered air isolation gaps 24 of short straight lines air gap-insulated exhaust pipes 25 inserted, which open to the connector with the branch connector 12 serving End 26 with its inner tube 9 with a sliding fit into the inner tube 9 of the branch connector 12 is inserted.
  • the on the outer tube 10 of the respective exhaust pipe 25 inside double-walled End 6 of the branch pipe 12 is then with its outer tube 10th by laser welding to form the aforementioned rotating Fillet weld 36 welded.
  • the air insulation gap 24 of the exhaust pipes 25 also by means of internal high pressure forming in the same way as the elbow 2, but under No bending of the double tube, trained.
  • the inner tubes 9 of the exhaust pipes 25 and the pipe bend 2 remain on still connection-free ends 6 and 27 with the outer tubes 10 jammed, whereby the air insulating gap 24 and 11 closed there and the inner pipe plug-in assembly within the outer pipe plug-in welded assembly set in its centered position remains.
  • inner tube 9 and outer tube To provide 10 of different lengths, according to which Do not close the ends flush.
  • ends 6 and 27 on the opening wall 37 of the Through opening 38 of the respective input flange 5 are only two thin welds are required, each forming a fillet weld, the inner tube 9 at its end on the inside of the outer tube 10 and the end of the outer tube 10 on the opening wall 37 of the input flange through opening 38 is welded.
  • Ends 6.27 of the exhaust pipes 2.27 on a cylindrical die Plug through opening 38 surrounding extension 28 and to be welded all around on the extension. This alternative is, however, of limited suitability because of the weld is difficult to access with the welding laser.
  • the other ends of the exhaust pipes 2,3,4 or 25 have to be have inner tubes 9 and outer tubes 10 clamped together, where the air insulation gap 11 and 13 and 24 closed is. Then the respective exhaust pipe 2, 3, 4 or 25 attached to the input flange 5, whereby the inner tubes 9 in the Outer tubes 10 centrally and thus permanently air gap insulated are set. After that, the other ends, being like this the end 7 of the exhaust pipe 4 may be exempted Cut exhaust pipes 2, 3, 4 or 25 so that the respective air insulation gap 11 and 13 or 24 is opened. Only now the joining step mentioned above in the first variant, in which the inner and outer tubes 9, 10 are inserted into one another and then the outer tubes 10 are laser welded all around become.
  • the output flange is joined 8, the end 7 of the final exhaust pipe 4, that of the last the one from the pipe bend 2 in the row next to each other branched exhaust pipes 3,4 is formed in the through opening 29 of the flange 8 is inserted.
  • the Through opening 29 is initially a stepped cylindrical extension 30 on, the circumference of that of the outer tube 10 of the final exhaust pipe 4 corresponds so that when inserting the pipe end 7 the outer tube 10 with its outer side 31 on the circumference the extension 30 is present.
  • the outer tube 10 can also rest with its end face 32 on the step of the extension 30, whereby the outer tube 10 is defined by the stop Has relative plug position in the output flange 8.
  • the end 7 the final exhaust pipe 4 is trimmed such that the clamping of the tube 4 is lifted and the air insulating gap 13 is open. Furthermore, the inner tube 9 protrudes from the outer tube 10 out.
  • the stage of extension 30 survives the outer tube 10 radially inwards by the dimension of the width of the air insulation gap 13.
  • the outer tube 10 is inserted from the outside using a laser or the like Beam welding process at the output flange 8 all around Formation of a fillet weld 36 welded.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Exhaust Silencers (AREA)
EP98119975A 1997-11-28 1998-10-22 Procédé de fabrication d'un collecteur d'échappement isolé par une couche d'air pour un véhicule Expired - Lifetime EP0919703B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE19752773 1997-11-28
DE19752773A DE19752773C2 (de) 1997-11-28 1997-11-28 Verfahren zur Herstellung eines luftspaltisolierten Abgaskrümmers einer Fahrzeugabgasanlage

Publications (3)

Publication Number Publication Date
EP0919703A2 true EP0919703A2 (fr) 1999-06-02
EP0919703A3 EP0919703A3 (fr) 2003-03-12
EP0919703B1 EP0919703B1 (fr) 2003-11-26

Family

ID=7850096

Family Applications (1)

Application Number Title Priority Date Filing Date
EP98119975A Expired - Lifetime EP0919703B1 (fr) 1997-11-28 1998-10-22 Procédé de fabrication d'un collecteur d'échappement isolé par une couche d'air pour un véhicule

Country Status (4)

Country Link
US (1) US6343417B1 (fr)
EP (1) EP0919703B1 (fr)
DE (2) DE19752773C2 (fr)
ES (1) ES2210643T3 (fr)

Cited By (3)

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GB2349915A (en) * 1999-05-10 2000-11-15 Ford Global Tech Inc Hybrid exhaust manifold for i.c. engines
EP2075432A1 (fr) * 2007-12-24 2009-07-01 J. Eberspächer GmbH & Co. KG Collecteur de gaz d'échappement et son procédé de fabrication
US8375707B2 (en) 2007-12-24 2013-02-19 J. Eberspaecher Gmbh & Co. Kg Exhaust gas collector

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DE102004021196B4 (de) * 2004-04-29 2006-10-05 J. Eberspächer GmbH & Co. KG Luftspaltisolierter Abgaskrümmer
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USD779559S1 (en) * 2015-02-09 2017-02-21 Dixon Valve & Coupling Company, Inc. Intake manifold
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Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2349915A (en) * 1999-05-10 2000-11-15 Ford Global Tech Inc Hybrid exhaust manifold for i.c. engines
US6425243B1 (en) 1999-05-10 2002-07-30 Ford Global Tech., Inc. Hybrid exhaust manifold for combustion engines
GB2349915B (en) * 1999-05-10 2003-12-03 Ford Global Tech Inc Hybrid exhaust manifold
EP2075432A1 (fr) * 2007-12-24 2009-07-01 J. Eberspächer GmbH & Co. KG Collecteur de gaz d'échappement et son procédé de fabrication
US8375707B2 (en) 2007-12-24 2013-02-19 J. Eberspaecher Gmbh & Co. Kg Exhaust gas collector

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US6343417B1 (en) 2002-02-05
DE59810260D1 (de) 2004-01-08
DE19752773C2 (de) 1999-09-02
DE19752773A1 (de) 1999-06-02
EP0919703A3 (fr) 2003-03-12
ES2210643T3 (es) 2004-07-01
EP0919703B1 (fr) 2003-11-26

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