Patent Application
20110181037
Embodiments described herein relate to a device, system and method for accurately aligning two components at a mating joint. More specifically, embodiments described herein relate to an alignment device, system and method for aligning two components in a rotational position relative to each other.
Exhaust systems of vehicles typically include multiple components that are joined together to form a fluid passageway. The multiple components are attached to each other to have a particular rotational orientation with respect to each other so that the attached components can be located within the packaging of the vehicle. One example of exhaust system components that have a particular rotational alignment are turbocharger downpipes. When the exhaust system components have an accurate alignment, the components are located in their predetermined locations, and there is reduced stress on the exhaust system.
Often the exhaust system components are generally cylindrical in shape. Referring to
The components are typically aligned by including a dowel pin on the first component, and including a hole for receiving the dowel pin on the second component. However, this solution can only be used when the casting is thick enough to accommodate the dowel pin and the hole. Another way that the components are aligned is by providing a non-symmetric flange on the first component and the second component, however the flanges are fixedly cast to the components, take up space, and can interfere with the packaging of other vehicle components. Further, time is spent bolting the flanges together.
An alignment clamp that aligns a pair of tubular members in a fixed, end to end relationship includes a clamp member having a longitudinal axis, and also having a substantially annular interior surface facing the longitudinal axis. The interior surface includes a discontinuous raised surface and at least one radial gap between portions of the raised surface. At least one indicator key is disposed on the at least one radial gap.
An alignment clamp system for aligning a pair of tubular members in a fixed, end to end relationship includes a clamp member having a longitudinal axis. The clamp member also has a substantially annular interior surface facing the longitudinal axis, and at least one indicator key disposed on the interior surface of the clamp member. The system includes first and second tubular members having a suitable diameter such that they can be positioned in a fixed, end to end relationship within the clamp member. The first and second tubular members each have an exterior surface having an alignment indicator. The first and second tubular members are alignable with respect to each other by aligning the alignment indicator of the first tubular member with the indicator key of the alignment clamp, and aligning the alignment indicator of the second tubular member with the indicator key of the alignment clamp.
A method of aligning a pair of tubular members in a fixed, end to end relationship includes the steps of attaching the first and second tubular members together in an end to end relationship. Both the first and the second tubular members have an alignment indicator on their respective exterior surfaces. The method also includes the step of providing an alignment clamp having a longitudinal axis, a substantially annular interior surface facing the longitudinal axis, and at least one indicator key disposed on the interior surface of the alignment clamp. The alignment clamp is engaged around the first and the second tubular members, and the first and second tubular members are rotationally aligned with respect to each other by aligning the alignment indicator of the first tubular member with the indicator key of the alignment clamp, and aligning the alignment indicator of the second tubular member with the indicator key of the alignment clamp.
Referring to
The alignment clamp 10 used to clamp and align a first tubular member 16 with a second tubular member 18 (see
As shown in
The first and second tubular members 16, 18 have a suitable diameter such that they can be positioned in a fixed, end to end relationship, and the first and second tubular members can be longitudinally positioned within the clamp member 12. The interior surface 26 of the clamp member 12 is in clamped engagement with the exterior surface 46 of the tubular members 16, 18 adjacent to the ends of the tubular members when the latch 24 engages and closes the latch ends 20, 22 in the latched position.
The interior surface 26 may include a first substantially annular lip 28 and a second substantially annular lip 30. A recessed inner surface 32 may be disposed between the first lip 28 and the second lip 30, such that the lip 28, the recessed surface 32 and the lip 30 generally form a raised surface 33 having a general “V”-shape or a general “U”-shape, although other shapes are possible. The lips 28, may be discontinuous or segmented along the interior surface 26, leaving at least one radial gap 34 along the interior surface 26 and between portions of the raised surface 33. In the alignment clamp 10, there are three radial gaps 34 along the clamp member 12, however other numbers are possible.
The at least one alignment key 14 is located on the interior surface 26 of the alignment clamp 10 between the latch ends 20, 22. On an exterior surface 36 of the alignment clamp 10, and at the same radial position as the alignment key 14, may be an alignment key location indicator 38, such as a notch 40 or any other visual indicator. The alignment key location indicator 38 indicates on the exterior surface 36 where the alignment key 14 is located on the interior surface 26.
The alignment clamp 10 has at least one alignment key 14 on the interior surface 26. The alignment clamp 10 may have three alignment keys 14 disposed at about 90-degree radial increments and disposed in the radial gaps 34 around about the interior surface 26 of the alignment clamp, however other numbers of alignment keys and other radial increments are possible.
The alignment key 14 may be protruded or a male-shaped member, such as a tab 41, or may be recessed or a female-shaped member. Further, the alignment key may be a visual indicator, such as a painted line or indentation. It is possible that the alignment key 14 may have a stamped, welded, brazed or integrally formed construction, or any other construction that indicates the particular location on the interior surface 26 as a key for alignment of components 16, 18. In the embodiment where the alignment key 14 is the tab 41, the tab may protrude from the interior surface 26 at the radial gaps 34.
The first tubular member 16 includes at least one tubular alignment indicator 42, such as a slot 44 or any other visual indicator, on an exterior surface 46 of the tubular member 16. The tubular alignment indicator 42 may be recessed or female-shaped, or may be protruded or male-shaped. It is possible that the tubular alignment indicator 42 may have a stamped, welded, brazed or integrally formed construction, or any other construction.
In an embodiment where the alignment key 14 is male-shaped (such as tab 41), the indicator 42 may be female-shaped (such as slot 44), and in an embodiment where the alignment key is female-shaped, the indicator may be male-shaped, such that the alignment key 14 mechanically engages with the tubular alignment indicator. Alternatively, the alignment key 14 and the tubular alignment indicator 42 may not mechanically engage, but instead, the alignment key can be visually aligned with the tubular alignment indicator.
Referring now to
When the second tubular member 18 is attached to the first tubular member 16, the second tubular member is positioned between the annular receiving surface 48 and the interior surface 26 of the alignment clamp 10, and abuts the abutting surface 52. The rotational position of the second tubular member 18 can be rotationally aligned relative to the first tubular member 16 by aligning the tubular alignment indicator 42 on the second tubular member 18 with the alignment key 14 on the alignment clamp 10.
In one embodiment, if the tubular alignment indicators 42 on the first tubular member 16 and the second tubular member 18 are both slots 44, both slots can be aligned with the same tab 41 of the alignment key 14, such that one alignment clamp 10 can align and clamp both the first tubular member 16 and the second tubular member 18. In this embodiment, the tab 41 engages in both the slot 44 on the first tubular member 16 and the slot 44 in the second tubular member 18. In another embodiment, the tubular alignment indicators 42 may be visual markings that are aligned with the indicator key 14.
While
The alignment clamp 10 may be formed of a cast metal such as a steel or ductile iron alloy, among other metals. Lighter alternatives such as aluminum alloys could also be employed to cast the alignment clamp 10. It is also possible that other materials can be used to form the alignment clamp.
The integrated alignment key 14 allows accurate rotational alignment of mating first and second tubular members 16, 18 in an end-to-end relationship so that the exhaust system assembly as a whole can have accurate alignment. When the assembly is accurately aligned, the components are more likely to function properly and there is reduced stress on the assembly.
