Robust Design of a Catalytic Converter With Material and Manufacturing Variations

Document Number: 2002-01-2888

Date Published: October 2002

Author(s):
Andreas Vlahinos - Advanced Engineering Solutions LLC
Danet Suryatama - DaimlerChrysler Corp.
Mustafa Ullahkhan - DaimlerChrysler Corp.
Jay T. TenBrink - DaimlerChrysler Corp.
Ronald E. Baker - DaimlerChrysler Corp.

Abstract:
A design is robust when the performance targets have been achieved and the effects of variation have been minimized without eliminating the causes of the variation such as manufacturing tolerances, material properties, environmental temperature, humidity, operational wear, etc. In recent years several robust design concepts have been introduced in an effort to obtain optimum designs and minimize the variation in the product characteristics. In this study, a probabilistic design analysis was performed on a catalytic converter substrate in order to determine the required manufacturing tolerance that results in a robust design. Variation in circularity (roundness) and the ultimate shear stress of the substrate material were considered. The required manufacturing tolerance for a robust design with 1,2 and 3 sigma quality levels was determined. The same manufacturing tolerance for a reliability based design with reliability levels of 85%, 90% and 95% was also determined and compared. The methodology for implementing robust design used in this research effort is summarized in a reusable workflow diagram.

File Size: 285K
Product Status: In Stock

See other papers presented at SAE Powertrain & Fluid Systems Conference & Exhibition, October 2002, San Diego, CA, USA, Session: Diesel Emission Control Technologies

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