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Publication numberUS3479725 A
Publication typeGrant
Publication dateNov 25, 1969
Filing dateMar 17, 1967
Priority dateMar 17, 1967
Publication numberUS 3479725 A, US 3479725A, US-A-3479725, US3479725 A, US3479725A
InventorsOrlando J Chiappe, Ralph J Haren, Gerald H Shaff, Frank R Smith
Original AssigneeWalker Mfg Co
Export CitationBiBTeX, EndNote, RefMan
External Links: USPTO, USPTO Assignment, Espacenet
Muffler manufacturing system
US 3479725 A
Abstract  available in
Images(1)
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Claims  available in
Description  (OCR text may contain errors)

Nov. 25, 1969 G, H, SHAFF ET AL 3,479,725

MUFFLER MANUFACTURING SYSTEM Filed March 17, 1967 A v ,y 75

farm/5x52 United States Patent O U.S. Cl. 29--430 5 Claims ABSTRACT OF THE DISCLOSURE A muler manufacturing method forms a muffler shell at one station, muler tubes at another station, and muffler partitions at still another station. The tubes and partitions are then combined into a skeleton and then the skeleton is inserted into the mufller shell and welded in place.

This invention relates to the method of making automotive exhaust mufllers or the like from sheet steel. y

It is the purpose of this invention to provide a muliler manufacturing arrangement that is well adapted to mass manufacture by automated equipment and procedures.

The invention accomplishes the foregoing and other objects =by dividing the component parts of a muffler into groups of similar parts that may be manufactured on substantially the same equipment. The groups of parts are then fed to an assembly area where they are assembled into a mutller and secured together.

The invention is illustrated in the accompanying drawings in which:

FIGURE 1 is a longitudinal cross section through a typical automotive exhaust muffler that may be manufactured in accordance with the invention; and

FIGURE 2 is a schematic diagram of a muffler manufacturing process embodying the principles of the invention.

The muffler 1 of FIGURE 1 comprises an outer shell 3 which is usually oval in cross section. Opposite ends of the shell 3 are closed by inlet and outlet headers in the form of transverse end walls '5 and 7 respectively which have peripheral flanges that fit inside and are welded to the ends of the shell.

The inside of the shell 3 is divided into a number of separate chambers 9, 11, 13, 15, 17, and 19 by means of transverse walls (acting with the end headers) in the form of partitions 21, 23, 25, 27, and 29 which have peripheral flanges that are Welded to the shell 3. Some of these partitions have holes or necked openings therein to provide communication between adjacent chambers as shown. They also have flanged openings to support the aligned gas inlet tubes 31 and 33, the gas outlet tube 35, and the tuning tube 37. The inlet tube 31 is welded inside and to an inlet bushing 39 that in turn is welded to a anged neck 41 in the inlet header 5 and the outlet tube is welded inside and to ran outlet bushing 43 that is formed in the outlet header 7.

Sections of the tubes are perforated or louvered as shown to allow communication between the insides of the tubes and the chambers through which they pass. Spit chamber shells 45 and 47 formed from complemental halves welded together along a midplane are positioned around louvered areas of tubes 31 and 35 to form high frequency sound attenuation or spit chambers.

It will be seen that the muffler 1 comprises the following groups of parts: (a) shell 3, (b) tubes 31, 33, 35, 37 and bushing 39, (c) spit chamber half shells 45 and 47, (d) partitions 21, 23, 25, 27, and 29, and (e) headers 5 and 7.

The processing layout of FIGURE 2 includes a line or conveyor for carrying a coil 51 of sheet steel to each of three stations 53, 5'5, and 57. Station 53 comprises suitable 3,479,725 Patented Nov. 25, 1969 equipment for cutting, blanking, forming, and connecting sheet steel from a coil 51 into a mufer shell 3 and for moving it on to a shell expanding station 59.

Station 55 comprises three substations 61, 63, and 65. Substation 61 comprises suitable equipment for cutting, perforating, forming, rolling, and connecting sheet steel from a coil 51 into tubes 31, 33, 35, and 37. Substation 63 comprises suitable equipment for cutting, perforating, forming, rolling, and connecting sheet steel from a coil `51 into bushings 39. Substation `65 comprises suitable equipment for cutting, blanking, and forming sheet steel from a coil 51 into the spit chamber shell halves 45 and 47.

Station 57 comprises two substations 67 and 69. Substation 67 comprises suitable equipment for cutting, blanking, piercing, drawing, and forming sheet steel from coil 51 into partitions 21, 23, 25, 27, and 29 while substation 69 is capable of performing similar operations to produce headers 5 and 7.

Each of the stations and substations includes suitable conveyor or moving means for moving the parts downstream toward and preferably on to the rotary assembly station 71. Station 55 includes a rotary subassembly station 55a to receive the parts for loading on to station 71 and for assembling the spit chamber shell halves 45 and 47 together on the tubes 31 and 35.

The rotary station 71 includes suitable fixtures 73 to support the various parts while the tubes, partitions, bushing, and headers are subassembled. The parts are welded together into a skeleton structure exclusive of the outer shell 3 as the station 71 rotates toward shell expanding station 59. At station 59 the shell 3 is loaded onto station 71 and the skeleton of tubes, partitions, spit chamber shells, and end headers positioned inside the shell. The combined shell and internal parts are then transferred to the weld station 75. Station 75 has a pre-chamber 77 and a post chamber 79 and a suitable Welder 81, such as an electron beam, intermediate theserchambers. The headers and partitions are welded to the shell in unit 81 and the completed muiller is then transferred to conveyor 83 for transfer to a desired area.

Modifications may be made in the specific procedures and arrangements of equipment disclosed without departing from the spirit and scope of the invention. It will be recognized that certain parts may be omitted in some mufller structures, such as bushings and spit chamber shells, :and that additional parts to those shown may be added.

We claim:

1. The method of making automotive exhaust muillers or the like which comprises passing sheet metal to a shell forming station and forming a shell at such station, passing sheet metal to a tube forming station and forming gas ow tubes at s-uch station, passing sheet metal to a transverse wall forming station and forming transverse walls at such station, passing the tubes and walls to an assembly station and combining them into a skeleton of parts, passing a shell to such assembly station and inserting said skeleton into the shell, passing the assembled shell and skeleton to Ia welding station and welding the walls to the shell to form a muffler.

2. A method as set forth in claim 1 including forming headers at said Wall forming station, passing the headers to said assembly station and combining them with the tubes into said skeleton, and welding the headers to the shell.

3. A method as set forth in claim 1 including forming said walls at said wall forming stataion in the shape of partitions, passing the partitions to said assembly station and combining them with the tubes into `said skeleton, and Welding the partitions to the shell.

4. A method as set forth in claim 1 including forming ICC said walls at said Wall forming station in the shape of partitions and headers, passing the partitions to said assembly station and combining them with the tubes into said skeleton, and welding the partitions and headers to the shell to form a substantially finished muffler.

5. The method of making automotive exhaust mulers or the like which comprises passing sheet metal to a shell forming station and forming a shell at such station, passing sheet metal to a tube forming station and forming gas flow tubes at such station, passing sheet metal to a transverse wall forming station and forming transverse walls at such station, passing the tubes and walls to an assembly station and combining them into a skeleton of parts, inserting said skeleton into the shell, and welding the Walls to the shell to form a mufller.

References Cited Y UNITED STATES PATENTS 1/ 1940 Powell 29l57 1/1945 Buck 29-157 11/1962 Powers etal 29-169.5 10/ 1963 Christman 29-430 10/ 1965 Brown 29-157 3/1966 Selig 29-157 4/1967 Selig 181-48 THOMAS H. EAGER, Primary Examiner U.S. C1. X.R.

Patent Citations
Cited PatentFiling datePublication dateApplicantTitle
US2187431 *Feb 3, 1938Jan 16, 1940Powell Herbert SMethod of assembling mufflers
US2367753 *Apr 29, 1940Jan 23, 1945Hayes Ind IncMethod of making mufflers and the like
US3064336 *Sep 16, 1959Nov 20, 1962Walker Mfg Company Of WisconsiMethod of making mufflers
US3108367 *Apr 6, 1959Oct 29, 1963Formacel IncContinuous method of manufacturing cellular cored panels
US3209438 *Oct 28, 1960Oct 5, 1965Walker Mfg CoMuffler manufacturing method
US3242558 *Jun 13, 1962Mar 29, 1966Oldberg Mfg CompanyMethod of making intermediate shell construction for silencer or muffler
US3315761 *Oct 14, 1965Apr 25, 1967Oldberg Mfg CompanyMuffler with spaced concentric tubular members
Referenced by
Citing PatentFiling datePublication dateApplicantTitle
US3613830 *Jul 18, 1969Oct 19, 1971Walker Mfg CoOne-piece tube and shell assembly for silencer
US3772752 *Nov 3, 1971Nov 20, 1973Small BApparatus and process for forming tubular bodies
US4486932 *Aug 6, 1982Dec 11, 1984Apx Group, Inc.Process for making a replacement muffler
US4516659 *Feb 6, 1984May 14, 1985Apx Group, Inc.Replacement muffler and process for making same
US4674594 *May 7, 1985Jun 23, 1987Johannes PedersenSilencer and a method of manufacturing the silencer
US4847965 *Oct 18, 1988Jul 18, 1989Ap Parts Manufacturing CompanyMethod of manufacturing stamp formed mufflers
US4901815 *Mar 20, 1989Feb 20, 1990Parts Manufacturing CompanyStamp formed mufflers
US4928372 *Apr 7, 1989May 29, 1990Ap Parts Manufacturing CompanyProcess for manufacturing stamp formed mufflers
US5042125 *May 24, 1990Aug 27, 1991Ap Parts Manufacturing CompanyApparatus for manufacturing stamp formed mufflers
EP0164155A1 *May 6, 1985Dec 11, 1985Pedersen, JohannesA silencer and a method of manufacturing the silencer
Classifications
U.S. Classification29/430, 29/890.8
International ClassificationB21D53/88, B21D53/00, F01N13/18
Cooperative ClassificationF01N2450/22, F01N13/18, F01N2470/02, B21D53/88, F01N2490/02, F01N2490/08
European ClassificationB21D53/88, F01N13/18