A Systems Approach to Automotive Exhaust System Development 2003-26-0029
Today's automotive exhaust systems are developed to deliver minimum noise, emissions and maximum durability based on the legislative and performance requirements. In addition, they must also meet requirements of packaging, safety, flow rates, lower system restriction, high temperature compatibility, corrosion resistance, easy serviceability and cost effectiveness. These challenging requirements cannot be met effectively without a systems approach.
The exhaust system development process starts with selection of design methodology and evolution of checklists for system design specifications and definition of targets. System design specifications are elaborated with reference to performance, durability, legislation, installation, manufacturing / assembly / service considerations, etc. Checklists for exhaust system clearance and design review are given. Exhaust pipe material, silencers, glass wool, noise shields, after treatment devices, heat shields, flanges, gaskets, isolators, flexible bellows and exhaust routing are discussed.
This paper reviews the requirements, design considerations and developments in the field of exhaust systems for automotive application. It emphasizes the importance of quality tools like design review, DFMEA, PFMEA and DVPR for exhaust systems, which are elucidated with an aim to achieve performance, quality and durability requirements.
