Development of exhaust system

Today's automotive exhaust systems are developed to deliver minimum noise, emissions and maximum durability. In addition, they must also meet requirements including artistic appearance, user-friendly packaging, safety and health, flow rates, lower system restriction, high temperature compatibility, corrosion resistance, easy serviceability and cost effectiveness. All of these should be based on the legislative and performance requirements. These challenging requirements cannot be met effectively without a systems approach. Development of exhaust system undoubtedly covers many fields worth pondering and the following contents will give you an avalanche of cutting-edge information: what we aim for, what areas we take into account when it comes to development of automotive exhaust systems.

Initial aims of development of exhaust system

Development of automotive exhaust components and systems

Development of production processes of exhaust systems

Initial aims of development of exhaust system

The design and development of the products conform to the requirements shared by our customers. With the client-oriented business model, automotive industry spares no efforts to satisfy their needs. And besides, by utilizing optimized design tools and simulation to make early decisions on specification, materials or structures of products, manufacturers are able to reduce development time, thus increasing efficiency and saving costs.

Development of automotive exhaust components and systems

1. Optimized design and calculations: by mounting the exhaust system onto the engine, we test exhaust sounds and vibration noise and tune exhaust sounds through simulation for each vehicle's needs. A design is then created that optimizes both vehicle performance and gas mileage. Lightweight, non-metallic exhaust systems can provide higher engine operating efficiencies, improved handling of high-performance automobiles, and opens the design envelope to manufacture designs difficult with typical metal designs. System design specifications are elaborated with reference to performance, durability, legislation, installation, manufacturing / assembly / service considerations, etc.

2. Durability: we use simulation to test and evaluate whether there are any influences on the durability and tone or vibrations from the engine transmitted to the car interior. We use heat cycling to assess the durability for the exhaust manifold. We conduct durability and thermal fatigue tests to evaluate exhaust systems assembled onto the engine. Quality tools like design review, DFMEA, PFMEA and DVPR for exhaust systems are worth paying heed to with an aim to achieve performance, quality and durability requirements.

3. Exhaust sound inspection: we perform evaluations on the exhaust sound clarity and sound quality from both the inside and outside of the vehicle. The vehicle is placed on the chassis dynamometer where we utilize several external microphones in order to evaluate the external noise with an actual running vehicle. To reduce the released noise, resonators and mufflers are developed taking into account the packaging of the car.

Development of production processes of exhaust systems

1. Pipe manufacturing: 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.

2. Assembly operations: we achieve high-quality welding results, even for complex shaping. We also utilize production sequencing in order to meet customer requirements. 

3. Varied and small volume production system: we are able to manufacture multiple products on a single line. The inspections are focused on meeting the criteria for weld quality and airtightness.

We pursue performance that can be enjoyed from the moment the engine starts. We closely follow industry trends in order to create a harmony between environmental performance and functionality. If you want more information about development of exhaust systems, please call or email us.