JP2008023533A - Method and apparatus for manufacturing metal carrier - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing a metal carrier, which method can apply tension to a metal plate by catching large wave portions even when the height of the wave has been increased, and can suppress the increase of ventilation resistance and the decrease of gas contacting surface area by eliminating a step at a final end portion of winding. <P>SOLUTION: When a first metal plate 1 having the large height of the wave formed in one direction and a second metal plate 2 having the smaller height of the wave than that of the first metal plate 1 or having a flat shape are formed to be cylindrical by winding them on a winding machine 14 respectively while supplying tension to them, the tension is applied to the first metal plate 1 by engaging the high wave portion 1A of the large wave shape with the tooth space portions 15A of worms 15 arranged above and below the first metal plate 1. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a method for manufacturing a metal carrier and a manufacturing apparatus therefor, and relates to a technique for applying tension to one metal plate that has been made into a high wave.

  For example, in a catalytic converter for automobiles, a corrugated plate and a flat plate or corrugated plates of different heights are overlapped and wound into a cylindrical shape, and the cylindrical core portion is press-fitted into an outer cylinder such as stainless steel. A metal carrier that is integrally joined is used.

  To manufacture such a metal carrier, a metal plate having a large wave with a high wave height and a metal plate or flat plate having a wave lower than the wave height are wound around a winding machine while applying tension. After the cylindrical shape is formed, the core portion of the cylindrical honeycomb structure is press-fitted into the outer cylinder.

  By the way, when manufacturing this metal carrier, in order to wind two metal plates in close contact with a hoisting machine, the metal plates are wound while applying tension to the metal plates (for example, Patent Document 1). Etc.)

  In the tension applying device described in Patent Document 1, as shown in FIG. 11, a roll gear 103 is disposed on one (upper side) of a metal plate 102 in which a high wave portion 101 having a high height is continuously formed on a thin plate such as stainless steel. At the same time, the roll gear 104 is disposed on the other side (lower side), and the gear portion 105 of the roll gear 104 has a tooth pitch and a tooth height that engage with the high wave portion 101, thereby applying tension to the metal plate 102. .

The roll gear 103 and the roll gear 104 are driven by a motor 106, and drive gears 107 and 108 provided on the roll gear 103 and the roll gear 104 are driven by the motor 106. 101 is hooked and tension is applied.
JP 2004-249361 A

  However, as shown in FIG. 12, the wave height Fh of the high wave part 101 formed on the metal plate 102 for improving the catalyst performance is made higher than the pitch Fp between the peaks of the high wave part 101. Furthermore, since the pitches of the teeth 109 and 110 of the drive gears 107 and 108 that rotate the roll gear 103 and the roll gear 104 are dense, the drive gears 107 and 108 are undercut, and the drive gears 107 and 108 interfere with each other ( Site surrounded by line A).

  Moreover, the high wave part 101 and the tooth | gear part 105 of the roll gear 104 engaged with it undercut and interfere.

  That is, when the height Fh of the high wave part 101 of the metal plate 102 and the pitch Fp of the high wave part 101 are Fh / Fp> 1, the drive gears 107 and 108 and the high wave part 101 and the roll gear 104 engaged therewith The tooth part 105 causes interference.

  On the other hand, when the surface of the roll gear 103 is a roll having a flat surface, it is not necessary to make the pitch of the teeth 109 and 110 of the drive gear dense, so there is no possibility that the drive gear interferes. However, the state in which the high wave portion 101 and the tooth portion 105 of the roll gear 104 engaged therewith are undercut and interferes with each other remains unchanged.

  Further, the core portion 111 manufactured by the method of Patent Document 1 has an increased height of the wave, so that the outer cylinder 112 is formed as shown in FIG. Concentrated stress acts from the step portion 113 at the time of press-fitting into the corrugated plate, and the corrugated sheet is deformed.

  As described above, when the corrugated plate is deformed, the catalyst applied to the core portion 111 after the press-fitting into the outer cylinder 112 is surplus, and the surplus catalyst fillet is increased, thereby increasing the airflow resistance. In addition, the surface area per unit volume of the corrugated plate in contact with the gas after the catalyst coating is reduced. The increase in the excess catalyst fillet and the reduction in the surface area of contact with the gas will reduce the purification efficiency of the metal carrier.

  Therefore, the present invention has been made to solve the above-described problem, and even when the wave height is increased, the high wave portion can be hooked to apply tension to the metal plate, and the final winding can be performed. It is an object of the present invention to provide a metal carrier manufacturing method and a metal carrier capable of suppressing an increase in ventilation resistance and a decrease in gas contact surface area by eliminating a step at the end.

  The invention according to claim 1 is a first metal plate having a large wave shape with a high wave height with respect to one, and a small wave shape or a flat shape lower than the wave height of the first metal plate. In the method of manufacturing a metal carrier in which two metal plates are wound around a hoisting machine while applying tension to form a cylindrical shape, high waves having the large wave shape are formed in gear grooves of worm gears arranged above and below the first metal plate. A portion is hooked to give tension to the first metal plate.

  A second aspect of the present invention is the method of manufacturing the metal carrier according to the first aspect, wherein the worm gear is stopped from rotating in the vicinity of the end of winding of the first metal plate and the second metal plate. By winding up with a machine, the high wave portion of the first metal plate is extended to gradually reduce the wave height.

  According to a third aspect of the present invention, there is provided a first metal plate having a large wave shape with a high wave height relative to one, and a small wave shape or a flat shape lower than the wave height of the first metal plate. In the metal carrier manufacturing apparatus in which two metal plates are wound around a hoisting machine while being tensioned by respective tension applying means to form a cylindrical shape, the tension applying means for applying tension to the first metal plate is the first metal plate. It is characterized by comprising a worm gear that is arranged above and below the metal plate and that applies a gear groove portion to a high wave portion having a large wave shape formed on the first metal plate to apply tension.

  According to the first aspect of the present invention, the high wave portion formed on the first metal plate is hooked on the gear groove portion of the worm gear arranged above and below the first metal plate having a large wave shape. Tension can be applied to the metal plate. Further, according to the present invention, unlike the roll gear, a multi-row worm gear is used, so that a gear groove portion adapted to high waves can be formed.

  According to the second aspect of the present invention, in the vicinity of the end of the winding of the first metal plate and the second metal plate, the rotation of the worm gear is stopped and the hoisting machine is used to extend the high wave portion of the first metal plate. Since the height of is gradually reduced, the step at the final winding end can be made small.

  As a result, when the core obtained by winding into a cylindrical shape is press-fitted into the outer cylinder, deformation of the corrugated sheet can be prevented without intensive stress acting from the final end of the winding. As a result, it is possible to manufacture a metal carrier capable of improving purification efficiency that can suppress an increase in ventilation resistance and a decrease in gas contact surface area.

  According to the invention described in claim 3, as a tension applying means for applying tension to the first metal plate having a large wave shape, the tension is applied by engaging the gear groove portion with the high wave portion formed on the first metal plate. Since the worm gear to be applied is used and the worm gear is arranged above and below the first metal plate, the high wave portion can be hooked by the worm gear to apply tension to the first metal plate.

  Hereinafter, specific embodiments to which the present invention is applied will be described in detail with reference to the drawings.

  FIG. 1 is a line process diagram for manufacturing a metal carrier. The metal carrier purifies the exhaust gas by passing it through a cell coated with a catalyst on its surface. In order to form a cell, a corrugated plate made of a metal plate and a flat plate or corrugated plates of different heights are cylindrical. A core portion of a honeycomb structure in which a plurality of cells are formed by winding up into a shape is formed, the core portion is press-fitted into an outer cylinder, and then joined and integrated by diffusion bonding, and then coated with a catalyst.

  In the present embodiment, a first metal plate having a large wave shape with a high wave height relative to one, and a second metal plate having a small wave shape lower than the wave height of the first metal plate, respectively. It is assumed that a cylindrical core portion is formed by winding around a winding machine while applying tension.

  As shown in FIG. 1, the first metal plate 1 and the second metal plate 2 are wound in a coil shape, mounted on the uncoilers 3 and 4, and sent out to the respective paths. The first metal plate 1 sent out from one of the uncoilers 3 is sent to the piercing section 5 where it is formed by punching fine slit holes. In the piercing part 5, in addition to forming slit holes, oil is applied in order to improve moldability at the time of wave forming in the next process. Similarly, after the second metal plate 2 is fed out from the other uncoiler 4, a slit hole is opened at the piercing portion 6.

  When the first metal plate 1 finishes slit hole processing and oil application at the piercing portion 5, the front and back are reversed at the reversing portion 7. Similarly, the 2nd metal plate 2 is also reversed by the inversion part 8 after slit hole processing.

  And the 1st metal plate 1 is sent to the large wave formation part 9, and is made into the large wave shape with a high wave height by passing between the upper and lower forming rollers. Next, the 1st metal plate 1 is sent to the drying part 10 provided adjacent to the large wave shaping | molding part 9, and the oil adhering to the surface is dried. On the other hand, the 2nd metal plate 2 is sent to the small wave shaping | molding part 11, and is made into the small wave shape with a low wave height by passing between the upper and lower forming rollers.

  Next, tension is applied to the first metal plate 1 having a large wave shape by the first metal plate tension applying mechanism 12 which is tension applying means. On the other hand, the second metal plate 2 having a small wave shape is given a tension by a second metal plate tension applying mechanism 13 which is also a tension applying means. And the 1st metal plate 1 and the 2nd metal plate 2 to which tension was given respectively are made into the core part which makes a cylindrical shape by being pinched and rolled up by the core rod of the winding machine 14.

  Particularly in the present embodiment, the structure of the first metal plate tension applying mechanism portion 12 that applies tension to the first metal plate 1 in the line process diagram is arranged above and below the first metal plate 1 as in the prior art. By changing from a structure in which tension is applied between the roll and the roll gear to a multi-row worm gear, the high wave portion is hooked on the gear groove portion of the worm gear to apply the tension.

  2 is a perspective view of the first metal plate tension applying mechanism portion using a worm gear, FIG. 3 is a side view of the first metal plate tension applying mechanism portion of FIG. 2 viewed from the direction of arrow A, and FIG. It is a front view when seeing the 1st metal plate tension | tensile_strength provision mechanism part from the arrow B direction.

  The first metal plate tension applying mechanism 12 includes a worm gear 15 that applies tension by engaging (hanging) the gear groove 15A with the high wave portion 1A having a large wave shape formed on the first metal plate 1. The first metal plate 1 is arranged in multiple rows in the plate width direction so as to sandwich the first metal plate 1 above and below the one metal plate 1. In the present embodiment, the worm gears 15 are arranged on both sides in the width direction intersecting the feed direction X of the first metal plate 1 and in the center, respectively, and three on the lower surface side of the first metal plate 1 and the upper surface side. Are arranged with three worm gears 15.

  The three worm gears 15 arranged on the lower surface side of the first metal plate 1 are rotated in synchronization by a first timing belt 18 hung over a pulley 17 attached to a rotating shaft 16. Similarly, the three worm gears 15 arranged on the upper surface side of the first metal plate 1 are rotated in synchronization by a second timing belt 19 hung over a pulley 17 attached to the rotary shaft 16. ing. Then, the three worm gears 15 arranged on the lower surface side of the first metal plate 1 and the three worm gears 15 arranged on the upper surface side of the first metal plate 1 are controlled by a servo motor 21 whose rotation is controlled by the control unit 20. Everything is rotated in synchronization.

  That is, the drive shaft 22 of the servo motor 21 is connected to the rotary shaft 16 that rotates the outermost worm gear 15 disposed on the lower surface side of the first metal plate 1, and further the upper surface of the first metal plate 1. A third timing applied to a pulley 23 provided adjacent to a pulley 17 attached to a rotary shaft 16 for rotating the outermost worm gear 15 arranged on the side and a pulley 24 attached to the drive shaft 22. All the worm gears 15 are rotated by the belt 25 in synchronization.

  The gear groove portion 15 </ b> A of the worm gear 15 is a groove corresponding to the shape of the high wave portion 1 </ b> A of the first metal plate 1, and further applies tension to the first metal plate 1 and supplies the first metal plate to the hoisting machine 14. It is formed in a spiral shape for feeding 1 and is formed so as not to crush the high wave portion 1A. The worm gear 15 applies tension to the first metal plate 1 by hooking a high wave portion 1A formed on the first metal plate 1 into the gear groove portion 15A.

  The second metal plate tension applying mechanism portion 13 is different in configuration from the first metal plate tension applying mechanism portion 12 and allows the second metal plate 2 to pass between the two felts 26 so that tension is applied. It comes to grant.

  After applying tension to each of the first metal plate 1 and the second metal plate 2, as shown in FIG. 5, the first metal plate 1 and the second metal plate 2 are sandwiched between the core rods 27 of the hoisting machine 14, A winding motor (not shown) is driven and the core rod 27 is rotated to wind up the first metal plate 1 and the second metal plate 2 into a cylindrical shape.

  At this time, an encoder (not shown) for detecting the required discharge amount of the first metal plate 1 (high wave) from the rotational speed of the core rod 27 is provided, and when the necessary rotational speed is detected by this encoder, the winding motor stops. The drive is controlled by the control circuit. When the first metal plate 1 and the second metal plate 2 are wound up, the servo motor 21 of the worm gear 15 and the winding motor of the winder 14 are rotated synchronously so that tension is always applied to the first metal plate 1.

  When the discharge amount of the first metal plate 1 is detected by the encoder, both the servo motor 21 of the worm gear 15 and the hoisting motor of the hoisting machine 14 are stopped. Then, the first metal plate 1 and the second metal plate 2 being assembled are temporarily fixed by the spot welder 28.

  Next, as shown in FIG. 6, while the operation of the servo motor 21 of the worm gear 15 is stopped, the hoisting motor of the hoisting machine 14 is driven and wound up on the core rod 27 while pulling the first metal plate 1. Then, when the encoder detects the necessary rotation speed, the operation of the winding motor is stopped. At this time, when the hoisting motor is operated in a state where the rotation of the worm gear 15 is stopped, the circumference of the high wave part 1A of the first metal plate 1 between the worm gear 15 and the hoisting machine 14 is constant. Is gradually extended from the state shown in FIG. 6 as shown in FIG. Thereby, the core part 30 can be rolled up, relieving the level | step difference amount of the high wave part 1A.

  When the discharge amount of the first metal plate 1 is detected by the encoder, both the servo motor 21 of the worm gear 15 and the hoisting motor of the hoisting machine 14 are stopped. Then, the first metal plate 1 and the second metal plate 2 being assembled are temporarily fixed by the spot welder 28.

  Next, the servo motor 21 that rotates the worm gear 15 and the hoisting motor of the hoisting machine 14 are synchronously rotated again, and as shown in FIG. 8, the remaining relaxed first metal plate 1 is sent out, and the core part 30 is completely hoisted. Let Then, as shown in FIG. 9, when the unrelieved high wave part 1A approaches the core part 30, a proximity switch 29 is provided so that the worm gear 15 and the hoisting motor stop, and finally the core part 30 does not collapse. The first metal plate 1 is cut by spot welding. And if a series of work is completed, it will return to the process shown in the said FIG. 5, and will make the above continuous operations.

  As shown in FIG. 10, the core portion 30 obtained by winding the core rod 27 as described above has a cylindrical shape without a step at the final winding end portion 31. In this way, if the core portion 30 having a cylindrical shape without a step at the final winding end 31 is pressed into the outer cylinder in the next process, there is no step, so that no intensive stress acts and deformation of the corrugated sheet is achieved. Can be prevented. Therefore, the surplus fillet due to the catalyst applied to the core portion 30 after press-fitting into the outer cylinder is reduced, and the ventilation resistance can be reduced. Further, the purification performance can be improved without reducing the surface area per unit volume of the corrugated plate with which the gas after catalyst coating comes into contact.

  According to the method of the present invention, it is possible to apply tension to the first metal plate 1 by hooking the high wave portion 1A to the gear groove portion 15A of the worm gear 15 arranged above and below the first metal plate 1, and unlike the roll gear. By using the multi-row worm gear 15, the gear groove portion 15 </ b> A matched to the high wave portion 1 </ b> A can be formed.

  Further, according to the method of the present invention, in the vicinity of the end of the winding of the first metal plate 1 and the second metal plate 2, the rotation of the worm gear 15 is stopped and the winding is performed by the winder 14, whereby the high wave portion of the first metal plate 1. Since the height of the wave is gradually reduced by extending 1A, the step at the final winding end can be made small.

  According to the apparatus of the present invention, the worm gear 15 that applies tension by engaging (hanging) the gear groove portion 15A with the high wave portion 1A formed on the first metal plate 1 is used, and the worm gear 15 is used as the first metal plate. 1, the worm gear 15 can hook the high wave portion 1 </ b> A to apply tension to the first metal plate 1.

  Although specific embodiments to which the present invention is applied have been described above, the above-described embodiments are examples of the present invention and are not limited to these embodiments.

  For example, in the above-described embodiment, the first metal plate 1 and the second metal plate 2 having different heights are wound around the core rod 27 to form the cylindrical core portion 30, but the first metal plate having the high wave portion 1A is used. Of course, the same effect can be obtained by winding the first metal plate 2 and the second metal plate 2 made of a flat plate around the core rod 27 to form the cylindrical core portion 30.

It is a line process figure which manufactures a metal support | carrier. It is a perspective view of the 1st metal plate tension provision mechanism part which uses a worm gear. It is a side view when the 1st metal plate tension | tensile_strength provision mechanism part of FIG. 2 is seen from the arrow A direction. It is a front view when the 1st metal plate tension | tensile_strength provision mechanism part of FIG. 2 is seen from the arrow B direction. It is a process figure which winds up a metal plate by synchronizing the servomotor of a worm gear, and the winding motor of a winding machine. It is a process figure which stops the servomotor of a worm gear, drives the winding motor of a winding machine, and extends the high wave part of a 1st metal plate gradually. It is process drawing which shows the state which stopped the servomotor of the worm gear and driven the winding motor of the winding machine, and extended the high wave part of the 1st metal plate. It is process drawing which shows the state which rolled up the site | part which extended the high wave part and finally finished winding. FIG. 5 is a process diagram for sending out the first metal plate and the second metal plate by synchronizing the servo motor of the worm gear and the winding motor of the winding machine again. It is a top view of the core part manufactured by the method of this invention. It is a figure which shows the conventional tension | tensile_strength provision apparatus. It is a figure which shows the gear part of the drive gear in the conventional tension application apparatus. It is a figure which shows the metal support | carrier obtained by press-fitting in the outer cylinder the core part wound up with the tension | tensile_strength by the conventional tension application apparatus.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... 1st metal plate 1A ... High wave part 2 ... 2nd metal plate 12 ... 1st metal plate tension provision mechanism part (tension provision means)
DESCRIPTION OF SYMBOLS 14 ... Winding machine 15 ... Worm gear 15A ... Gear groove part 20 ... Control part 21 ... Servo motor 27 ... Core rod 30 ... Core part

Claims (3)

On the other hand, a first metal plate (1) having a large wave shape with a high wave height, and a second metal plate having a small wave shape or a flat shape lower than the wave height of the first metal plate (1). (2) In a method for producing a metal carrier that is wound around a winder (14) while applying tension to each other to form a cylindrical shape,
The high wave portion (1A) having the large wave shape is hooked on the gear groove portion (15A) of the worm gear (15) arranged above and below the first metal plate (1), and tension is applied to the first metal plate (1). A process for producing a metal carrier, characterized in that It is a manufacturing method of the metal carrier according to claim 1,
In the vicinity of the end of the winding of the first metal plate (1) and the second metal plate (2), the rotation of the worm gear (15) is stopped, and the first metal plate ( A method for producing a metal carrier, comprising extending the high wave part (1A) of 1) to gradually reduce the wave height. On the other hand, a first metal plate (1) having a large wave shape with a high wave height, and a second metal plate having a small wave shape or a flat shape lower than the wave height of the first metal plate (1). (2) and a metal carrier manufacturing apparatus in which a cylindrical shape is formed by winding a winding machine (14) while applying tension with each tension applying means (12, 13).
The tension applying means (12) for applying tension to the first metal plate (1) is disposed above and below the first metal plate (1), and has a large wave shape formed on the first metal plate (1). A metal carrier manufacturing apparatus comprising a worm gear (15) for applying a tension by engaging a gear groove (15A) with the high wave portion (1A).

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