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Relevant weight savings through the use of stamped sheet metal parts

Laser-welded exhaust dampers reduce expenses and costs

 

 

 

Exhaust dampers - modern valve technology helps reduce CO2 emissions and improve acoustics and vehicle performance

  1. Air filter
  2. Air mass sensor
  3. Turbocharger
  4. Intercooler
  5. Throttle valve
  6. High pressure EGR valve
  7. Cylinder
  8. EGR radiator valve
  9. EGR radiator
  10. DOC + DPF
  11. NOx adsorber
  12. Exhaust damper
  13. H2S catalytic converter

Exhaust dampers are an important component in modern systems to reduce pollution and increase comfort

They are involved in reducing the volume level of exhaust systems, as well as in reducing weight. These electro-mechanical valves are useful especially in controlling exhaust gas recirculation at low pressure and effects related to exhaust heat recovery. They can be used to reduce the path of the exhaust, making the tailpipe much shorter and lighter. In addition, they also allow fuel to be used more efficiently. Exhaust dampers are being used more often in near-engine applications as a result of legal requirements to reduce noise and pollution.

  • DeNOx adsorbers
  • Low pressure exhaust gas recirculation
  • Optimise exhaust gas system acoustics (e.g. cylinder deactivation)
  • Increase performance through resonance effects
  • Reduce noise
  • Use in the heating system
  • Register turbocharging

 

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20% weight savings through the use of sheet metal assemblies

Valve production for high and ow pressure exhaust gas purification

The current standard for EGR valve housings is to produce them as cast components. Using stamped sheet metal parts in the form of pipe sections, shells, connection brackets or turned parts like bearing bushings and internal mandrels can help achieve weight savings in this area.  

Simply switching to pressed sheet metal parts can result in weight savings of up to 20%.

 

In addition to joining and laser technology, weil technology offers extensive expertise in clamping device development

The different assembly and welding tasks are divided into individual steps. This makes it possible to find the optimal position for each assembly or welding task through a combination of tool, workpiece and laser axes. 

Based on our long-term experience in welding shift forks, fittings, bypass valves, etc., we have developed tool components that can turn the welded material to an optimal position for the laser beam. Depending on requirements, each seam position, from longitudinal to non-linear 3D seams on a workpiece, can be completed with a combination of optical axes (lasers) and mechanical axes (clamping tool, workpiece axes). The modules in the overall system allow us to position the component using a linear axis, a rotational axis with counter bearing, a rotational axis (for welding horizontal round seams), and rotational and pivot axes for more complex components with different seam geometries. Modules with less axes are available for simple round or longitudinal seams.

 

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Laser: Non-contact welding at high speeds

In comparison to a classic welding process, laser welding and heat conduction welding offer the option of deep welding: Create streamlined, deep weld diameters with a minimal heat-affected zone and low warping in a non-contact, high-speed process.

The laser seam requires a design appropriate for laser welding, significantly improving process and workpiece parameters. Joint tolerances must be complied with, and automatic clamping devices make it possible to precisely reproduce positions.

Optimise material flows with parallel loading and removal processes

Material flow concepts and loading and unloading processes are drafted for each system as part of the overall process, allowing for parallel loading and processing. The goal is to coordinate component architectures and clamping concepts, automate loading and unloading processes as far as possible, and increase production through processing appropriate for laser welding. This results in large quantities of high-quality components with low warpage that require little reworking.

Dividing the production process into individual steps makes it possible to use standardised modules for workpiece mounting and laser processing. Chaining with a workpiece carrier system allows for parallel processing of multiple modules. Since each module can be used and configured “individually,” complex assemblies can be produced. The clamping tools are easy and quick to exchange, allowing for flexible part production.

The module system not only makes it possible to use multiple optics per module, but also to include mechanical processing stations. Leak testing stations, laser engraving stations, and palletising systems can be integrated with the chained workpiece carrier system.

  • Parallel processes
  • Sturdy clamping devices
  • Division of individual process steps allows for a custom adjustment to detailed work

 

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Laser welding module for producing laser-welded exhaust dampers

  1. Insert and weld bearing to housing
  2. Weld internal mandrel and cover plate
  3. Join engine bracket and engine console
  4. Mount engine bracket to housing and weld
  5. Assemble valve plate and inlay, weld the valve plate on the internal mandrel and inlay to the housing
  6. Inspection station and installation control
  7. Torque rotational angle test, leak testing
  8. Labelling
  9. Palletising

 

A Fitting the workpiece carrier system
B Insertion controlling
C Suction
D Laser
E Radiator
F Spring assembly

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