JP2005201123A - Method of manufacturing muffler for vehicle - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing a muffler for a vehicle, in which a material cost is reduced to reduce a manufacturing cost and its weight, and a dead space is eliminated to secure the volume in the muffler at a maximum with respect to a maximum diameter of the muffler. <P>SOLUTION: Opening edge parts on both ends of an outer shell 1 are risen in an outward inclined shape to form flange parts 11, opening end parts of a cylinder part 22 in each outer plate 2 are folded back in a outer face direction of the cylinder part 22 to form inclined flange parts 23 to be brought into contact with flange parts 11 of the outer shell 11. With overlapping the flange parts 23 of the outer plate 2 with the flange parts 11 of the outer shell, the flange parts 11 are connected with the flange parts 23 by seam welding, the connected flange parts 11, 23 are folded from their base on an outer plate 2 side and their diameter is reduced to be overlapped with outer face of the cylinder part 22, so that the outer shell 1 is connected and integrated with the outer plates 2, 2 without clearance. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a method for manufacturing a muffler for a vehicle, and more particularly to an improvement in a method for assembling and fixing an outer plate to an outer shell.

  Conventionally, as a method for assembling and fixing an outer plate to both end openings of a cylindrical outer shell in a vehicle silencer manufacturing method, for example, a cross-sectional view of FIG. 4 and process diagrams of FIGS. As shown in FIG. 2, the outer peripheral edge portion of the outer plate (end plate) 103 that closes the flange portion 102 formed by bending the opening end portion of the outer shell (cylindrical body) 101 outward and the opening portion of the cylindrical body 101. 104, and the cylindrical body 101 and the outer plate 103 are held by the cored bar 105 fitted to the inner surface of the end portion of the outer shell 101 and the receiving means 106 arranged on the outer side of the outer plate 103. A method is known in which the overlapping portion of the peripheral edge portion 104 is wound and connected and integrated (see, for example, Patent Document 1).

JP 2001-300666 A (page (3) of the specification, FIGS. 1 to 3)

  However, in the conventional manufacturing method, the outer plate 103 is connected and integrated with the outer shell 101 by winding the overlapping portion of the flange portion 102 and the outer peripheral edge portion 104 as described above. As a result, the material cost of the tightened portion formed long is not only wasted, but also increases in weight, and the tightened portion protrudes greatly to the outside of the outer shell 101. There was a problem that a dead space D was secured for securing the room capacity of the silencer with respect to the maximum outer diameter of the device.

  The problem to be solved by the present invention is to reduce the material cost and reduce the weight, to reduce the dead space, and to secure the maximum capacity of the silencer for the maximum outer diameter of the silencer. Another object of the present invention is to provide a method for manufacturing a vehicle silencer.

  In order to solve the above-mentioned problem, a method for manufacturing a muffler for a vehicle according to claim 1 is characterized in that an outer plate is formed with a flange portion projecting outward at both end opening edges of the outer shell and closing the both end opening portions of the outer shell. A flange portion that contacts the flange portion of the outer shell in a state of projecting outwardly is formed on the opening edge portion of the cylindrical portion formed on the outer periphery, and the flange portion of the outer plate is overlapped with the flange portion of the outer shell. Both the flange portions are connected by welding in the state, and both the outer shell and both outer plates are bent by bending the both flange portions integrated and connected from the root to the outer plate side so as to overlap the outer surface of the cylindrical portion. Are integrated with each other without a gap.

  The method for manufacturing a vehicle silencer according to claim 2 is the method for manufacturing a vehicle silencer according to claim 1, wherein the outer diameter of the cylindrical portion of the outer plate is the outer diameter of both opening edges of the outer shell. The means is characterized by being formed with a smaller diameter.

  The vehicle silencer manufacturing method according to claim 3 is the vehicle silencer manufacturing method according to claim 1 or 2, wherein the outer shell flange portion and the outer shell are assembled in a state before the outer plate is assembled to the outer shell. The flange portion of the plate is formed so as to be inclined toward the tube portion direction of the outer plate.

  The method for manufacturing a muffler for a vehicle according to claim 4 is the method for manufacturing a muffler for a vehicle according to any one of claims 1 to 3, wherein the flanges are welded over the entire circumference. It was set as the characteristic feature.

  In the vehicle silencer manufacturing method according to claim 1, as described above, both flange portions are connected by welding in a state where the flange portion of the outer plate is overlapped with the flange portion of the outer shell, and the connection is integrated. The outer shell and the outer plate are connected and integrated without any gaps by bending both flange portions from the root to the outer plate side and reducing the diameter so as to overlap the outer surface of the tube portion. Compared to the conventional example that requires a long flange for processing, the material cost can be reduced and the weight can be reduced, and there is no projecting part on the outer surface of the outer shell. As a result, the maximum volume of the silencer can be secured against the maximum outer diameter of the silencer. The effect is obtained that.

  In the method for manufacturing a muffler for a vehicle according to claim 2, as described above, a structure in which the outer diameter of the cylindrical portion of the outer plate is smaller than the outer diameter of both opening edge portions of the outer shell is used. As a result, when both of the flange portions that are connected and integrated are bent from the root to the outer plate side and reduced in diameter so as to overlap the outer surface of the cylindrical portion, the flange portion of the outer plate having a small diameter is bent from the root side as a base point. Therefore, the bent portion can be prevented from projecting to the outer surface of the outer shell.

  In the method for manufacturing a muffler for a vehicle according to claim 3, the flange portion of the outer shell and the flange portion of the outer plate are respectively directed toward the cylinder portion of the outer plate, which is a bending direction, before the outer plate is assembled to the outer shell. By using a configuration that is formed in an inclined state, the connecting and integrating flange portions are bent from the root to the outer plate side to reduce the diameter so as to overlap the outer surface of the cylindrical portion. Therefore, the work process is simplified and the diameter reduction rate is reduced by an amount corresponding to the inclination, so that workability can be improved and generation of wrinkles due to the diameter reduction process can be suppressed. become able to.

  In the vehicle silencer manufacturing method according to claim 4, as described above, both the flange portions are welded over the entire circumference, so that both outer plates are connected and integrated with the outer shell without a gap. It becomes possible to make it.

  Embodiments of the present invention will be described below with reference to the drawings.

The vehicle silencer manufacturing method of this embodiment corresponds to the inventions described in claims 1 to 4.
First, the manufacturing method of the silencer for vehicles of this Example is demonstrated based on drawing.

FIG. 1 is a longitudinal sectional view showing a state before assembly in a silencer to which the method for producing a vehicle silencer of this embodiment is applied, and FIG. 2 is a process explanatory view showing the method for producing the vehicle silencer of this embodiment. It is.
A silencer to which this vehicle silencer manufacturing method is applied includes an outer shell 1, outer plates 2 and 2, and a middle assembly assembly 3 as main components.

  More specifically, as shown in FIG. 1, the outer shell 1 before assembly is formed into a cylindrical shape by wrapping a plate material twice and spot-welding the end portions, and both end opening edges of the outer shell 1 are formed. The flange portions 11 and 11 are formed by raising the portion in an outwardly inclined manner.

  Further, the outer plates 2 and 2 close both end openings of the outer shell 1, and a main body part 21 in which a central part is inflated outward, and an outer periphery of the main body part 21 is defined as a bulging direction of the main body part 21. The cylindrical portion 22 is formed by bending in the opposite direction, and in the state before assembly, the opening edge portion of the cylindrical portion 22 is folded back to the outer surface direction of the cylindrical portion 22 and the outer shell 1 is An inclined flange portion 23 is formed so as to abut on the flange portion 11.

  In this embodiment, the outer diameter of the cylindrical portion 22 of the outer plate 2 is smaller than the inner diameter of both opening edge portions of the outer shell 1 by a size that is twice the thickness of the outer plate 2.

  The intermediate assembly 3 includes two inner plates 31 and 32, an inlet pipe 33, and an outlet pipe 34. The silencer chamber is divided into three chambers 1a and 1b by the two inner plates 31 and 32. 1c. The inlet pipe 33 is assembled so as to pass through the upstream outer plate 2 and the two inner plates 31, 32, and the outlet pipe 34 includes the two inner plates 31, 32 and the downstream outer plate. The plate 2 is assembled so as to penetrate the plate 2. The inner plates 31 and 32 are formed with a plurality of communication holes (not shown).

Next, a method for manufacturing the silencer configured as described above will be described based on the process explanatory diagram of FIG.
First, as shown in FIG. 2 (a), the assembly assembly product 3 is assembled by inserting the inlet pipe 33 and the outlet pipe 34 into the two inner plates 31, 32 so as to pass through.

  Next, as shown in FIG. 2B, the intermediate assembly product 3 is press-fitted into the outer shell 1, and the inner plates 31, 32 are fixed to the outer shell 1 by spot welding.

  Next, as shown in FIG. 2C, the flange portions 11 and 23 are connected by seam welding in a state where the flange portion 23 of the outer plate 2 is overlapped with the flange portion 11 of the outer shell 1.

  Finally, as shown in FIG. 2 (d), the flange portions 11 and 23 connected and integrated are bent from their roots to the outer plate 2 side and pressed so as to overlap the outer surface of the cylindrical portion 22 to reduce the diameter. As a result, the outer shell 1 and both outer plates 2 are connected and integrated without any gaps, thereby completing the manufacture of the silencer.

Next, the operation and effect of this embodiment will be described.
In the vehicle silencer manufacturing method of this embodiment, as described above, the flange portions 11 and 23 are connected by welding in a state where the flange portion 23 of the outer plate 2 is overlapped with the flange portion 11 of the outer shell 1. The outer shell 1 and the outer plates 2 and 2 are respectively connected to the outer shell 1 and the outer plates 2 and 2 by bending the flanges 11 and 23 connected and integrated from the base to the outer plate 2 side and reducing the diameter so as to overlap the outer surface of the cylindrical portion 22 By connecting and integrating without a gap, the outer shell 1 can be reduced in cost and weight by reducing the material cost, compared to the conventional example in which the flange portion needs to be formed longer for the tightening process. Since there is no portion protruding from the outer surface, the dead space D (see FIG. 5) is not formed, thereby increasing the maximum outer diameter of the silencer. Effect that was made the muffler chamber capacity can be ensured to the maximum extent.

  Also, the outer diameter of the cylindrical portion 22 of the outer plate 2 is set to be smaller than the inner diameter of both opening edges of the outer shell 1 by a size that is twice the thickness of the outer plate 2. Thus, when the flange portions 11 and 23 that are connected and integrated are bent from the root to the outer plate 2 side and reduced in diameter so as to overlap the outer surface of the cylindrical portion 22, the root of the flange portion 11 in the outer plate that has a small diameter. Since it can be bent with the side as a base point, the bent portion can be prevented from projecting to the outer surface of the outer shell 1.

  Further, as shown in FIG. 1, the flange portion 11 of the outer shell 1 and the flange portion 23 of the outer plate 2 are in the bending direction of the outer plate 2 before the outer plate 2 is assembled to the outer shell 1, respectively. By using the structure that is formed so as to incline toward the bottom, the flanges 11 and 23 that are connected and integrated are bent from the root to the outer plate 2 side so as to overlap the outer surface of the cylindrical portion 22. Since the work of reducing the diameter to the diameter is only a process of pressing in the radial direction, the work process is simplified, and the diameter reduction rate is reduced by an amount corresponding to the inclination. The generation of wrinkles can be suppressed.

  Further, since both the flange portions 11 and 23 are welded over the entire circumference thereof, both the outer plates 2 and 2 can be connected and integrated with the outer shell 1 without a gap.

Although the present embodiment has been described above, the present invention is not limited to the above-described embodiment, and design changes and the like within a scope not departing from the gist of the present invention are included in the present invention.
For example, in the embodiment, the outer shell is formed by wrapping the plate material twice in the embodiment, but it may be formed in a single layer.

  In the embodiment, the intermediate assembly product 3 is press-fitted and assembled into the outer shell 1 formed in a cylindrical shape in advance. However, the outer shell 1 is formed by winding a plate around the outer periphery of the intermediate assembly assembly 3. You may do it.

  In the embodiment, before the outer plate 2 is assembled to the outer shell 1, the flange portion 11 of the outer shell 1 and the flange portion 23 of the outer plate 2 are inclined toward the cylindrical portion 22 of the outer plate 2, which is the bending direction. However, as shown in the enlarged cross-sectional view of the main part in FIG. 3, it is also possible to use a structure in which both flange portions 11 and 23 are vertically erected. .

  In the embodiment, the outer diameter of the cylindrical portion 22 of the outer plate 2 is smaller than the inner diameter of both opening edges of the outer shell 1 by a size that is twice the thickness of the outer plate 2. However, it is not limited to this dimension, For example, it can set arbitrarily, such as 1 to 2 times.

In the embodiment, the flange portions 11 and 23 are connected by seam welding, but may be connected by laser welding or plasma arc welding.
Further, the configuration of the intermediate assembly product 3 is arbitrary.

It is a longitudinal cross-sectional view which shows the state before the assembly | attachment in the silencer to which the manufacturing method of the silencer for vehicles of the Example was applied. It is process explanatory drawing which shows the manufacturing method of the silencer for vehicles of an Example. It is a principal part expanded sectional view which shows the other example of a flange part. It is sectional drawing of the manufacturing method of the silencer for vehicles of a prior art example. It is a principal part expanded sectional view which shows the manufacturing method of the silencer for vehicles of a prior art example.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Outer shell 1a Chamber 1b Chamber 1c Chamber 11 Flange part 2 Outer plate 21 Main body part 22 Cylinder part 23 Flange part 3 Middle assembly assembly 31 Inner plate 32 Inner plate 33 Inlet pipe 34 Outlet pipe

Claims (4)

A flange portion projecting outward is formed at both end opening edges of the outer shell, and the outer shell protrudes outward from the opening edge portion of the cylindrical portion formed on the outer periphery of the outer plate that closes the both end opening portions of the outer shell. Form a flange part that contacts the flange part of the outer shell,
With the flange portion of the outer shell overlapped with the flange portion of the outer shell, both flange portions are connected by welding,
The outer shell and the outer plate are connected and integrated without gaps by bending both the connected and integrated flange portions from the root to the outer plate side and reducing the diameter so as to overlap the outer surface of the cylindrical portion. A method for manufacturing a muffler for a vehicle, characterized by comprising:   The method for manufacturing a vehicle silencer according to claim 1, wherein the outer diameter of the cylindrical portion of the outer plate is smaller than the outer diameters of both opening edge portions of the outer shell. Manufacturing method.   3. The method for manufacturing a vehicle silencer according to claim 1 or 2, wherein the flange portion of the outer shell and the flange portion of the outer plate are respectively directed toward the cylinder portion of the outer plate in a state before the outer plate is assembled to the outer shell. A method for manufacturing a muffler for a vehicle, wherein the muffler is formed to be inclined.   The method for manufacturing a vehicle silencer according to any one of claims 1 to 3, wherein the both flange portions are welded over the entire circumference thereof. Method.

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