In pursuit of continuous process improvement, Gestamp has embraced recent recommendations we presented on integrating stamping and assembly processes solutions. In collaboration with the BIW Gestamp Design team, we hosted two webinars that brought together teams overseeing each plant. These sessions demonstrated the profits and results achieved by each team through the application of our software. Additionally, we sought to provide insights to improve internal processes.

During the webinars, we prioritized knowledge sharing and the introduction of tools applicable across different facilities. The goal was to ensure that each production unit grasped how the presented solutions could be adapted to improve their operations, promoting a more comprehensive understanding of potential implementations and their impactful results.

The first webinar focused on the Digital Twin process, illustrating how simulation is used throughout the development cycle of a stamped part, from product engineering to tool construction approval. A critical first step is to evaluate the formability of the product, as shown in Figure 1. This stage allows users to quickly analyze the imported data for part geometry, material data, and the optimal stamping balance. The software provides feasibility analysis tools that suggest modifications to the product geometry to mitigate specific issues, minimizing rework and future delays.

Figure 1: Product feasibility analysis

Following this evaluation, the next step is to develop the process and estimate the cost to manufacture the tooling. By parameterizing the stamping processes—whether tandem, transfer or progressive—the geometry to be developed should clearly defined at this stage. This data will inform the sizing of the blanks and components within the chosen process, as shown in Figure 2. Following these analyses, it becomes feasible to organize operations, determining the number of stamping stages required and their distribution within each operation.

Figure 2: Process development and budget

After the process validation and cost analysis associated with the tooling construction, the next stage involves evaluating the performance of the previously defined process. The software provides tools to facilitate automatic variations, such as altering the height of segmented stretchers, drawing wall inclinations, punch and die entrance radii, pressure, size, and position of the blank. In this phase, feasibility evaluation is crucial, as are compensations for the material’s springback, as shown in Figure 3. After these stages are validated, the next step is the tooling design.

Figure 3: Project and compensation

As the engineering progresses from development to the release of tooling for construction, several factors can significantly affect the stability of the production process. Variations in the material’s mechanical properties, including its thickness, can pose challenges. Leveraging the software’s features, we can integrate all established tolerances to ensure assertive results directly in production. When changes in the raw material occur, the software quickly identifies the source of any issues, thereby reducing downtime in the press lines. Through robustness analysis, it is possible to identify which variable is influencing a certain region of the product. An analysis illustrated in Figure 4 shows that material thickness is a determining factor in determining the quality and dimensions of the final product.

Fig. 4: Thinning sensitivity analysis of process parameters

With significant reductions in reworks, quicker problem detection, and improved product quality, Gestamp has demonstrated the applications of advanced engineering, as shown in Figure 5. This encompasses everything from feasibility assessments and process plan definitions to tooling costs for single parts in cold forming, hot forming, assembly joining, and production support. 

Figure 5: Gestamp’s process cycle

The feasibility and assembly dimensions of this process are crucial to the smooth operation of the production line. By analyzing the assembly’s initial joining process, we can assess the overall layout, identify parts with greater influence, and suggest possible geometry changes to optimize efficiency and manufacturing quality. 

We explore comprehensive understanding of the Assembly and Hemming modules to evaluate assembly processes. This includes different hemming and spot welding systems and considers nominal, formed, and digitized parts. We also perform a dimensional evaluation of the final assembly, taking into account the combined springback effects of the different parts.

In process engineering, it is important to consider the effects of springback and, if necessary, adapt the joining processes. Identifying the necessary adjustments and defining try-out parameters are crucial steps to ensure satisfactory results. The assembly software features the VAR (Virtual Assembly Reference) concept to achieve this end—a powerful tool capable of performing geometric compensation of a single part based on the assembly results. Figure 6 illustrates the assembly comparison between the uncompensated products (on the left) and the result with compensation applied to the inner panel (on the right).

Figure 6: Compensation – Virtual Assembly Reference (VAR)

Try-out support involves addressing assembly issues related to the sequence of part insertion into the device or even the stability of single items. This process enables necessary changes to be applied as required. Meanwhile, production support focuses on solving emerging challenges, reducing downtime, and minimizing errors during production to improve process efficiency. The assembly module also enables existing assemblies to be analyzed, considering digitization for more precise analysis and definition of appropriate production parameters to ensure manufacturing excellence. Recognizing these details contributes significantly to the success of the project and customer satisfaction.

Gestamp was a pioneer in implementing assembly in Brazil. With the results obtained, it has been developing procedures and requirement specifications to advance and guarantee the stability of the parts in assembly, focusing on the quality and dimensional accuracy.

By identifying issues in the engineering phase, companies can avoid unnecessary waste from product development to final assembly and the layout of support points that influence dimensionality during the welding process. Once again, Gestamp has provided comprehensive and high-quality content, showcasing some process applications in development that have led to great satisfaction among the team.

From the Second BiW Development Engineering: “In simulations in assembly mode, we test and improve manufacturing processes at the conception stage, allowing us to deal with more realistic schedules that guarantee a significant reduction in delivery times and the creation of production shortcuts that help reduce errors. The advantages of this are improved productivity, quality, efficiency, cost savings, shorter development times, adjustments and, most importantly, innovation for Gestamp.”

We are very grateful to Leandro Pedracolli for his trust and initiative in promoting digital twins at Gestamp. Atair Cainan Figueiredo Bello Lopes played a key role in coordinating the presentations. We also extend our appreciation to Leonardo Fernandes Dompieri and Leonardo Freitas Oliveira for sharing their experiences and contributions with us during the webinars. We value the collaboration and participation of everyone involved.

What Is an Oxygen Detector Spacer?

They exist typically inaugurated between the O2 detector and the exhaust manifold or downpipe. The structure process of O2 detector spacers changes, counting on the precise automobile and spacer placement.

Generally, they exist threaded or included onto the O2 detector, completing a gap or length between the detector and the exhaust streamlet.

Oxygen sensor spacers, likewise known as oxygen detector spacers or O2 detector attachments, are undersized motorized machines created to modify the assignments of the oxygen (O2) detector in an automobile’s exhaust procedure.

Further, they are glorified as possible answers for “inspection machine” lights rendered by O2 detector mistakes.

While these advantages exist often asserted, their significance may deviate counting on the specific automobile, its machine managing strategy, and further aspects. Some spacers feature built-in motivations or further elements to exploit the detector’s homework.

The immediate position of O2 detector spacers is to change the feedback delivered by the O2 detector to the automobile’s machine management unit.

The O2 detector recreates an important role in surveying the oxygen stations in the exhaust gases, which enables the ECU to resolve the optimal air-to-fuel ratio for the explosion. Similarly, the legality of utilizing O2 detector spacers must exist carefully evaluated to confirm submission with emissions restrictions and the associated permitted substances.

Proponents of O2 detector spacers commandeer several advantages associated with their service. The numerous central assertion is that spacers can change the O2 detector lessons to complete a more wasted air-to-fuel proportion, which some acknowledge can output boosted horsepower, enhanced power economizing, and sweetened throttle answer.

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Do Oxygen Detector Spacers Work?

Nonetheless, the advancement intention portion counts on the automobile class and the height of the spacer utilized. Besides, it’s necessary to guarantee that the automobile obeys provincial emissions restrictions.

In some possibilities, the growth in energy economizing can be the tiniest. Besides, O2 detector spacers can boost exhaust emissions, so it’s necessary to guarantee that the automobile obeys provincial emissions restrictions.

Nonetheless, it’s necessary to explore the class of automobile and spacer size before seating them, as the piece of advancement will change depending on the circumstances.

The quick response is yes, O2 detector spacers can enhance machine interpretation and energy economizing.

Overall, O2 detector spacers can be fee-sufficient to enhance machine interpretation and energy scrimping.

1. Takes Out The Oxygen Sensor

Therefore, the sensor intention cannot discern the improved oxygen station in the tube. The spacer intention accepts the oxygen sensor from the exhaust tube. Thus, the inspection motor light choice termination is illuming.

2. Locks Open Loops

This advanced fragment of oxygen will expand the fuel-to-air ratio, forming an unobstructed loop. As a consequence, this intention initiates the inspection machine light to wink.

Hydrocarbons of gasoline again cause an immense portion of dampness. The spacer intention reads the gaunt shape in the exhaust streamlet and completes the open loop.

3. Read Average Status Of CO2

The Engine Control Unit volition noticed it as a defect and triggered the assessment machine light. Occasionally, this expanded gas flow will produce the oxygen sensor to discern a developed status of carbon dioxide.

Then the sensor spacer will read the average status of carbon dioxide and choice improve this problem.

4. Passes Emission Examination

Consequently, connecting a sensor spacer downstream choice support passes the emission examination. Especially the downstream sensor scans the cat output and whether the voltage stays steady.

5. CAT Efficacy Test

The sensor spacer intercepts gases from the cat and from getting the sensor. Thus, it intention hand the cat usefulness test.

Naturally, ECU intention stands confident about a functional catalytic converter (cat) when the downstream voltage is flatline somewhere about 450mV.

Consequently, the downstream voltage choice was arranged at about 450 mV, revealing the cat’s force.

6. Energy Economy

This exists fantastic for energy economizing. When you employ an oxygen spacer upstream, it intentionally reads the oxygen status at a decreased status. To reimburse for this, it intention depend on the air power ratio.

7. Tricks the ECU

Therefore, it takes a period for the sensor to discern the modifications in the gaseous combination. Occasionally, operating an oxygen sensor spacer hinders the instant reading power of the sensor. Due to this slow variation in the result stream reading, the ECU presumes that the cat is working appropriately.

8. Solves the CAT Efficacy Mistake

Otherwise, your strength maintains to encounter an efficiency mistake in the cat. The post-cat sensor must read more worn than the pre-cat oxygen sensor to settle this matter.

The center and pre-cat oxygen sensor assist should have significant difference alignments. And an oxygen sensor spacer in the post-cat exhaust tube translates this problem.

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Functions of the Oxygen Sensor Spacer

The leading position of it is to complete the unrestricted loop and troubleshoot the spark pin by the diagnostic machine. Additional than this, it is likewise employed in the pursuit.

1. Detach the Oxygen Sensor

The spacer disconnects the oxygen sensor from the exhaust tube so that the sensor intention does not exist competent to notice the high oxygen status in the stripe. Therefore, the assessment machine’s light intention contains illuminating.

2. Lock the Open Loops

As a development, this generates the machine light to flash. Hydrocarbons from gasoline again force surplus dampness, and this improved part of oxygen raises the power into the air, forming an empty loop.

So the spacer reads the creep state in the drain and approaches the unobstructed loop.

3. Observe the Correct Volume of Carbon Dioxide

The Engine Control Unit (ECU) catches a blemish and disturbs the assessment machine light. Occasionally the updraft demands the oxygen sensor to discern the extended status of carbon dioxide.

The area sensor reads the accurate amount of carbon dioxide and repairs this problem at that location.

4. Saves Fuel

This exists exemplary for energy conservation.

Employing an oxygen spacer beyond the dampness story reads lowers oxygen stations. To reimburse for this, it pauses the air-energy ratio.

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What Are The Oxygen Sensor Spacer Installation Procedures?

Thus, you can establish the sensor spacer by obeying occasional, straightforward steps. The building function of the oxygen sensor spacer is concise.

1. Let The Engine Cool Down

If you drive the automobile, wait 30 min until it evolves cold. You can’t persist with the methodology if the machine exists nonetheless desirable. The oxygen sensor is commonly connected to the exhaust procedure, and it willpower obtain hot when the machine is operating or hot.

2. Lifting The Auto

This intention completes sufficient space beneath the auto so you can proceed efficiently there. You ought to lift them by utilizing a jack. Construct infallible you are jacking it appropriately, and the jack bracket is sturdy.

3. Locating The Oxygen Sensor

Normally, an automobile can contain one to considerable oxygen sensors. If your automobile includes two oxygen sensors, you intention discover one around the machine cylinder.

Now, you maintain to encounter the oxygen sensor. A raven and stout wire intention arrive outward from that domain. Now, you can effortlessly access the oxygen sensor around the Catalytic converter.

Another intention exists someplace near the catalytic converter on the exhaust manifold.

Naturally, your choice maintain to fasten oxygen sensor spacers on the rearward oxygen sensor. Therefore, creeping down underneath the automobile, you intentionally discover a spark-pin-like element.

4. Disconnecting The Sensor

Employ a twisting and rotate it anti-clockwise to sever it from the procedure. You can likewise employ a heat gun to heat its cables and ground to complete the reference yield.

Periodically, the sensor can exist adhered, which is hard to remove. To unfasten the sensor from the exhaust manifold, you control to unscrew the sensor.

You can involve any intelligent petroleum on the sensor to unravel this matter. Then, you intend to wait 5-10 minutes, and the lubricant’s intention operates as a lubricating mechanism.

5. Establishing The Sensor Spacer

Before inaugurating the spacers, you control to seal up the tack which connects to the catalytic converter. Nowadays, keep circling it clockwise to tense the extension. After that, operate a wrench to complete the extension firm.

In this manner, your intention facilitates the gamble of it dropping inside the exhaust. Nowadays, behind dismissing the sensor, you ought to establish the sensor spacer on the bank-2 exhaust tube. Position the spacer on the pinpoint where the oxygen sensor was.

6. Attach The Oxygen Sensor

While extracting the sensor, you circled it anti-clockwise. Therefore, you must spin it clockwise while binding it to the oxygen sensor spacer. Behind depending it until the previous cable, you have to operate a twisting to tense its branch.

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Can Oxygen Detector Spacer Cause Problems?

Inaugurating an oxygen detector spacer on the exhaust tube may complete some penalties. Here exist those.

• Occasionally, the automobile could handle in a too-lean shape which stands dangerous. If you establish the spacer before the cat, it intends to maintain your vehicle’s air or energy ratio.
• You may likewise experience a loss in the torque of the subordinate back
• This may generate powerful harm to your motor in destiny. Establishing the spacer intention misleads the ECU into considering that the cat exists, operating precisely when it exists not.
• Although you can translate the inspection machine light point by this, it can ensure the factual situation is cracked
• At this location, exhaust gas won’t arrive in communication with the detector Thus, if, for some unpredictable grounds, the air-fuel ratio differences, the detector intention does not feel that. Establishing an oxygen spacer is assembling a dead area in the exhaust tube. As a development, you intend to understand unresponsiveness or misfires from your automobile’s machine
• This represents the front detector adhering to the posterior shape. 90° oxygen detector spacers stand sensitive to delivering a p2196 code. This transpires because 90° spacers determine the exhaust gas from contacting the center cat oxygen detector

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Conclusion

The main objective of an O2 sensor is to estimate the portion of oxygen in the exhaust gases, which permits the machine’s computer to complete adjustments for optimal fuel-to-air ratio.

So when temperatures decrease, the more inconsequential possibility is that these dimension choices are skewed due to increased heat stations reaching out of your machine.

Because the oxygen sensor spacer enables to decrease in prevailing exhaust gas temperatures, it can likewise support enhanced power economizing.

This indicates your automobile intention to employ more diminutive gas altogether, and you can maintain banknotes on power expenses over the duration.

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Frequently Asked Questions (FAQ)

What Is an Oxygen Detector Spacer?

The O2 spacer extends the gap between the o2 sensor and the exhaust gases, with an increased gap, it will provide a lower Co2 reading. … However, 90% of the time they will work provided the original o2 sensor is not faulty.

What Are O2 Sensor Spacers?

This Spacer is designed to space the oxygen sensor out of the hot exhaust gases just enough that it helps eliminate the check engine light (CEL) that is caused by dying catalytic converters or catless exhausts. There are two versions available, Straight and 90 Degree Angled Spacer.

How Do 02 Sensor Spacers Work?

So, What do O2 sensor spacers do? Mainly, oxygen sensor spacers pull the oxygen sensor out from the exhaust pipe. As a result, the increased oxygen level in the exhaust flow can’t manipulate the oxygen sensor. Thus, the ECU keeps thinking everything is alright with the cat system.

What Do O2 Sensor Spacers Do?

The primary function of oxygen sensor spacers is to close the open loop and solve the check engine light flashing issue.

Can O2 Sensor Spacer Cause Problems

If you put the spacer on the upstream sensor it would see the reduced O2 as a rich condition and compensate by leaning out the AFR. That might be better for the economy but also a possible risk of bad things happening if too lean.