Patent ID: 8661671
Filing Date: 2014-03-04
Classification: B23P,C04B,F01N,Y10T

Abstract:
1. A hard stuff method for making catalytic converters with automated substrate crack detection, comprising the following steps: forming a rigid housing with a hollow interior into a predetermined final size and shape; providing a catalytic converter substrate having an exterior surface and a predetermined size and shape similar to the final size and shape of the housing to define a gap of predetermined width between the substrate and the housing when the same are assembled; forming a mat having a size and shape configured to cover the exterior surface of the substrate, a predetermined thickness which is greater than the width of the gap, and a radially compressible construction that is compressed inwardly against the exterior surface of the substrate to a predetermined final assembled mat density that creates a tight friction fit and seal between the housing and the substrate when the same are assembled into a finished catalytic converter; wrapping the mat around the outer surface of the substrate to define a wrapped substrate; radially compressing the wrapped substrate to the predetermined final assembled mat density to define a compressed wrapped substrate; hard stuffing the compressed wrapped substrate axially into the interior of the housing with the predetermined final size and shape using a reciprocating ram which extends at a predetermined, constant speed to define the finished catalytic converter without resizing the housing; regularly measuring the force applied by the ram to the compressed wrapped substrate during said hard stuffing step; regularly recording the ram force and the associated position of the ram during said hard stuffing step; after said hard stuffing step is fully completed to define the finished catalytic converter, comparing the ram force as a function of the position of the ram to define an array of data; after said hard stuffing step is fully completed to define the finished catalytic converter, analyzing the array of data and ascertaining the existence of any abrupt change in the ram force as a function of the position of the ram above a predetermined ratio which indicates a crack in the fully assembled compressed wrapped substrate portion of the finished catalytic converter; and unstuffing the fully assembled compressed wrapped substrate from the housing upon detection of a crack in the substrate during said data analyzing step.