JP2020037915A - Method for manufacturing assembly structure, assembly structure and vehicle - Google Patents

Abstract

To provide a method for manufacturing an assembly structure capable of more easily restricting injured operator at the time of assembly work.SOLUTION: The invention relates to a method for manufacturing an assembly structure to be mounted on an apparatus by assembling an assembly member to a to-be-attached member. In the method, at the time of the assembling, the assembling member is coated with a material that liquefies or vaporizes due to a change in the temperature of the to-be-attached member or the assembling member during operation of the apparatus.SELECTED DRAWING: Figure 2

Description

  The present disclosure relates to a method of manufacturing an assembly structure, an assembly structure, and a vehicle.

  In a vehicle manufacturing line, a vehicle as a final product is manufactured by a worker assembling parts such as an engine, an exhaust pipe, a door, and tires into a main body such as a vehicle body (for example, Patent Document 1 and Patent Document 2, etc.). Similarly, at the time of manufacturing another large-sized device or the like, one member (hereinafter, also simply referred to as “assembled member”) is replaced by another member (hereinafter, also simply referred to as “assembled member”). Production of end products by assembling to produce an assembled structure is widely performed.

JP-A-58-188766 JP-A-8-99658

  The to-be-attached member and the assembling member may have, for example, a region where a cut surface of a metal is exposed, for example, at an end of a pipe or an end surface of a metal plate. The cut surface may cause the worker to be injured by the careless contact of the worker during the assembling operation.

  In order to prevent the worker from touching the cut surface, the end portion or the end surface may be bent so that the cut surface is inside when manufacturing a large-sized device. However, if a process such as bending is to be performed on an end portion, an end surface, or the like, a mold for the bending process is separately required. Therefore, when the layout of the member to be assembled and the member to be assembled is changed according to the shape and operation of the final product, it is necessary to manufacture a mold having a different shape each time, and the manufacturing cost of the mold is reduced. There was a problem that it would take. In addition, even if a part that requires bending processing is found in the stage of actually performing an assembly test after manufacturing a part, it is not always possible to immediately manufacture a mold. As described above, there are various restrictions on the bending process for suppressing the injury of the worker.

  An object of the present disclosure is to provide a method of manufacturing an assembly structure, an assembly structure manufactured by the method, and an assembly structure that can more easily suppress damage to a worker during the assembly operation. To provide a vehicle having the same.

  A method of manufacturing an assembly structure according to one aspect is a method of manufacturing an assembly structure to be mounted on an apparatus by assembling an assembly member to a member to be assembled. The member is a method in which the member to be assembled or the member to be assembled is coated with a material that liquefies or vaporizes due to a change in temperature during operation of the device.

  Further, an assembly structure according to one aspect is an assembly structure mounted on an apparatus, which is obtained by assembling an assembly member to an assembly target member, wherein the assembly member is used when the apparatus operates. It is coated with a material that liquefies or vaporizes due to a change in temperature.

  Further, a vehicle according to one aspect includes the assembly structure.

  According to the present disclosure, a method of manufacturing an assembly structure, an assembly structure manufactured by the method, and the assembly structure, which can more easily suppress damage to a worker during the assembly operation, A vehicle is provided.

FIG. 1 is a schematic diagram illustrating an example of a configuration of an internal combustion engine and an intake / exhaust system included in a vehicle equipped with a diesel engine. FIG. 2 is a schematic diagram illustrating an example of a configuration of an exhaust pipe, an exhaust purification device, and a muffler provided in an exhaust system. FIG. 3 is a schematic diagram showing a cross-sectional shape of each pipe constituting the exhaust pipe.

  Hereinafter, embodiments of the present invention will be described in more detail. The embodiment described below is an example, and the present invention is not limited to the embodiment.

  FIG. 1 is a schematic diagram illustrating an example of a configuration of an internal combustion engine and an intake / exhaust system included in a vehicle equipped with a diesel engine.

  The vehicle 100 has an internal combustion engine (diesel engine) 110, an intake system 120, an exhaust system 130, a turbocharger 140, an exhaust purification device 150, and a muffler 160.

  The internal combustion engine 110 is a four-cylinder engine in the present embodiment, branches intake air from an intake system 120 into four combustion chambers, and introduces exhaust gas from the four combustion chambers into an exhaust system 130. Has a configuration to introduce.

  The intake system 120 has an intake pipe 121 that sucks fresh air (air) from an upstream intake port 121 a and supplies the fresh air to the internal combustion engine 110. The intake system 120 is provided with an air cleaner 122, a compressor 142 of a turbocharger 140, an intake throttle valve 123, and the like in this order from the upstream intake port 121a to the combustion chamber of the internal combustion engine 110.

  The exhaust system 130 has an exhaust pipe 131 for discharging the exhaust gas after combustion discharged from the internal combustion engine 110 to the outside of the vehicle 100. In the exhaust system 130, an EGR device 132, a turbine 141 of a turbocharger 140, an exhaust purification device 150, a muffler 160, and the like are provided in this order from the internal combustion engine 110 toward the downstream side.

  The turbocharger 140 has a turbine 141 that rotates by the flow of exhaust gas, and a compressor 142 that rotates in conjunction with the turbine 141. The turbocharger 140 rotates the turbine 141 by the flow pressure of the exhaust gas. The intake air is compressed by the rotation of.

  The exhaust purification device 150 is a device that removes particulate matter (PM) from exhaust gas of the internal combustion engine 110 that is a diesel engine, and includes an oxidation catalyst (Diesel Oxidation Catalyst: DOC) 151, a PM filter (Diesel Particurate Filter). : DPF) 152 and an electric heater 153 for heating the exhaust gas to incinerate and remove (DPF regeneration) particulate matter accumulated in the PM filter 152.

  The silencer 160 expands and contracts the gas passing through the exhaust pipe 131 to provide a resistance to the exhaust gas, and reduces noise generated by the flow of the exhaust gas. In FIG. 1, the vehicle 100 has two mufflers, a first muffler 160a and a second muffler 160b, but the number of mufflers 160 may be one or three or more.

  The exhaust gas that has passed through the silencer 160 is discharged from the tail pipe 131g of the exhaust pipe 131 to the outside of the vehicle 110.

  FIG. 2 is a schematic diagram illustrating an example of the configuration of the exhaust pipe 131 and the exhaust purification device 150 and the muffler 160 provided in the exhaust system 130.

  As shown in FIG. 2, the exhaust pipe 131 has a tubular adapter 131a, a first pipe 131b, a second pipe 131c, and a third pipe 131, all of which are cylindrical members, connected from the upstream side to the downstream side. It has a pipe 131d, a fourth pipe 131e, a fifth pipe 131f, and a tail pipe 131g. The turbo adapter 131a, the first pipe 131b, the second pipe 131c, and the third pipe 131d connect the turbocharger 140 and the exhaust gas purification device 150, and the fourth pipe 131e connects the exhaust gas purification device 150 and the first silencer 160a. The fifth pipe 131f connects the first silencer 160a and the second silencer 160b. The pipe 131, the exhaust gas purification device 150, and the muffler 160 are fixed to the main body of the vehicle by brackets 133a, 133b, 133c, 133d, and 133e.

  FIG. 3 is a schematic diagram illustrating a cross-sectional shape of each pipe constituting the exhaust pipe 131. The exhaust pipe 131 is covered from both sides in the radial direction by two heat protectors 134a and 134b having a semicircular cross-sectional plate shape. The heat protector 134a and the heat protector 134b are attached to the exhaust pipe 131 via an attachment member 135 with bolts 135a and nuts 135b and the like. In FIG. 2, the exhaust gas purification device 150 is also covered with the same heat protector 154 from both sides in the radial direction. These heat protectors suppress deterioration or malfunction due to heat of the other members due to transmission of heat released from the exhaust pipe 131 and the exhaust gas purification device 150 to other members of the vehicle such as the main body. I do.

  At the time of assembly, a turbo adapter 131a is attached to the main body of the vehicle 100 in which the internal combustion engine 110 and the turbocharger 140 are disposed so as to be connected to the turbocharger 140, and the exhaust pipe 131 is connected to the second pipe via a bracket 133a. 131c, the exhaust purification device 150 is assembled via the bracket 133b and the bracket 133c, and the first silencer 160a is assembled via the bracket 133d and the bracket 133e. Further, a first pipe 131b connecting the turbo adapter 131a and the second pipe 131c is assembled, and a third pipe 131d connecting the second pipe 131c and the exhaust purification apparatus 150 is assembled, and the exhaust purification apparatus 150 and the first muffler are assembled. A fourth pipe 131e connecting the second pipe 160a to the second pipe 160a is assembled, and a fifth pipe 131f, a second silencer 160b, and a tail pipe 131g are assembled downstream of the first silencer 160a. However, these assembling orders are not limited to the above, and can be arbitrarily changed from the viewpoint of making the operation easier. These assembling operations are performed by an operator by driving a screw or the like.

  At this time, a cut surface of a metal (such as stainless steel) generated by processing may be exposed at an end of each pipe (particularly, at a discharge port side of the tail pipe 131g). In addition, each pipe and each member (the exhaust gas purification device 150, the silencer 160, the bracket, the heat protector, and the like) may have a welded surface exposed on the surface. Further, the cut surface, the welding surface, and the like may be exposed on each pipe as an assembling member and also on a main body of a vehicle as an assembling member to which each member is assembled.

  The exposed cut surface and welded surface may have a large number of burrs, minute projections, and the like. The cutting surface and the welding surface having the burrs and the minute projections may be used when the worker who intends to assemble a certain pipe inadvertently contacts each of the already assembled pipes or members. There is a risk of injuries to members.

  Therefore, in the present embodiment, coating is applied to the cut surface, the weld surface, and the like, thereby suppressing damage to the worker caused by careless contact.

  The material of the coating is solid or semi-solid at the time of assembling. However, when the internal combustion engine 110 is started and the vehicle 100 is operated, the temperature of each pipe and each member due to the operation of the vehicle 100 (operation of the internal combustion engine 110) changes. Any material may be used as long as it is liquefied or vaporized and removed from the cut surface and the weld surface. Alternatively, the coating is solid or semi-solid at the time of assembly, but is liquefied or vaporized due to a temperature change of each pipe or each member due to operation of the electric heater 153 included in the exhaust gas purification device 150, and from the cut surface and the weld surface. The material to be removed may be used.

  In the present disclosure, “semi-solid” refers to a material having a predetermined fluidity, but having a very high viscosity (for example, it is difficult to measure the viscosity at 50 ° C. using a rotational viscosity system), It means that it has a sufficient shape retention property to stay in such as.

  Specifically, the coating material is preferably a material that is solid or semi-solid at 50 ° C. and liquid or gas at 200 ° C. Examples of such materials include hydrocarbons such as paraffin, terpenes such as camphor, high molecular weight polyethylene glycol (polyethylene oxide) or polypropylene glycol (polypropylene oxide), aliphatic higher alcohols, higher fatty acids and esters thereof. , Higher fatty acid amides, and various other waxes such as vegetable wax, animal wax, petroleum wax, mineral wax, synthetic wax and modified products thereof.

  Since the coating is solid or semi-solid at the time of assembly, it can cover the cut surface and the welded surface, etc., and can prevent the worker who comes into contact with them from being damaged. On the other hand, when the internal combustion engine 110 is operated (or the electric heater 153 included in the exhaust gas purification device 150 is operated) after assembly, the coating is liquefied or vaporized by increasing the temperature of each pipe or each member due to the heat. And is removed from the cut surface and the weld surface. Therefore, the above-mentioned coating does not require a removal operation, and does not cause a remarkable decrease in operation efficiency.

  From the viewpoint of suppressing contamination of the production line or the like due to the removed material, the coating material is preferably a material that is vaporized by the operation of the internal combustion engine 110 (or the operation of the electric heater 153 included in the exhaust gas purification device 150). . For example, the material is preferably a solid or semi-solid at 50 ° C and a gas at 200 ° C. Examples of such materials include paraffin and the like. Note that paraffin is preferable because it is easily available and has little effect on the human body.

  The coating may be applied to each pipe or each member as an assembly member, or a member or a pipe of a main body as a member to be mounted, at the time of assembling each pipe or each member. For example, before starting the assembling work, by immersing the ends and the welded surfaces of these pipes and members in a pool of the above-described material that has been heated and melted for a predetermined time, it is easy to perform the above operations. It is possible to apply the above coating. Alternatively, the coating may be applied by spraying the material dissolved by heating.

  The immersion can be performed, for example, by holding a pipe or a member to be coated with a robot arm and immersing it in a pool of the material. Further, the spraying can be performed, for example, by spraying the material from a sprayer mounted on the tip of the robot arm.

  When the assembly structure is manufactured in this manner, it is not necessary to bend the end portion to suppress the damage to the worker, and it is necessary to manufacture different molds according to the layout of the member to be assembled and the assembly member. There is no. Further, as described above, when coating is performed using the robot arm, the coating is easily applied to different positions according to the shape of the member to be assembled and the shape of the assembly member only by changing the program for operating the robot arm. be able to. Therefore, according to the above-described method, it is possible to reduce costs required for taking measures for suppressing damage to workers when changing the layout or the like.

  Further, the coating can be easily applied to the end portion, the welded portion, and the like even when the member to be assembled or the assembly member has a complicated shape in which the end portion is difficult to bend.

  Immediately after production, the above-mentioned coating remains on each pipe and each member (assembly member) or the main body (assembly member to be assembled) of the vehicle on which the assembly structure thus manufactured is mounted. ing. The coating may be removed during a test operation (test operation) before shipment, or may be removed during full operation after shipment. That is, when a test operation is performed before shipping, the coating may be completely removed by the test operation, or may remain without being partially removed.

  In the above description, an example in which coating is performed at the time of assembling on each pipe and each member constituting the exhaust system of an internal combustion engine that is a diesel engine has been described, but it is needless to say that the scope of the present disclosure is not limited thereto. No.

  For example, the exhaust system may have a SCR (Selective Catalytic Reduction) catalyst downstream of the exhaust purification device.

  Further, the internal combustion engine may be a gasoline engine or a jet engine other than the diesel engine, and the assembled structure having the internal combustion engine may be mounted not only on a vehicle but also on a ship or an airplane.

  Further, the device on which the assembly structure is mounted is not limited to the device having the internal combustion engine, and any device that changes the temperature of the assembly member or the member to be assembled by operation of the device and removes the coating. For example, it may be an external combustion engine such as a steam engine, a combustion device such as a boiler or an incinerator, or a building material installed near these.

  According to the method of manufacturing an assembly structure of the present disclosure, it is possible to suppress damage to an assembling worker, and to easily cope with a change in layout of the assembly member and the member to be assembled. Therefore, the method of manufacturing the assembled structure of the present disclosure is expected to improve the working environment of the assembling worker.

REFERENCE SIGNS LIST 100 vehicle 110 internal combustion engine 120 intake system 121a intake port 121 intake pipe 122 air cleaner 123 intake throttle valve 130 exhaust system 131 exhaust pipe 131a turbo adapter 131b first pipe 131c second pipe 131d third pipe 131e fourth pipe 131f fifth Piping 131g Tail pipe 132 EGR device 133a, 133b, 133c, 133d, 133e Bracket 134a, 134b Heat protector 135 Mounting member 135a Bolt 135b Nut 140 Turbocharger 141 Turbine 142 Compressor 150 Exhaust purification device 151 Oxidation catalyst 152 PM filter 153 Heat protector 160 silencer

Claims (12)

A method of manufacturing an assembly structure to be mounted on an apparatus by assembling an assembly member to an assembly target member,
At the time of the assembling, the assembling member is coated with a material that liquefies or vaporizes due to a change in temperature of the to-be-attached member or the assembling member during operation of the apparatus.
A method of manufacturing an assembly structure.   The method of manufacturing an assembled structure according to claim 1, wherein the material is a material that is solid or semi-solid at 50 ° C and liquid or gas at 200 ° C. The assembly member is a tubular member or a plate-like member,
The cylindrical member or the plate-shaped member has an end or a welding surface coated with the material,
A method for manufacturing the assembled structure according to claim 1.   The assembly according to any one of claims 1 to 3, wherein the assembly member is a pipe that forms an exhaust system connected to an internal combustion engine, or a heat protector that covers a pipe or a member that forms the exhaust system. A method for manufacturing an attached structure.   The method for manufacturing an assembled structure according to any one of claims 1 to 4, wherein the material is paraffin. An assembly structure to be mounted on an apparatus, wherein the assembly member is assembled to an assembly member,
The assembly member is coated with a material that liquefies or vaporizes due to a temperature change during operation of the device.
Assembly structure.   The assembly structure according to claim 6, wherein the material is a material that is solid or semi-solid at 50 ° C and liquid or gas at 200 ° C. The assembly member is a tubular member or a plate-like member,
The cylindrical member or the plate-shaped member has an end or a welding surface coated with the material,
The assembly structure according to claim 6.   At least one of the member to be assembled and the assembly member is a pipe that forms an exhaust system connected to an internal combustion engine, or a heat protector that covers a pipe or a member that forms the exhaust system. The assembly structure according to any one of the above.   The assembly structure according to any one of claims 6 to 9, wherein the material is paraffin.   The assembly structure according to any one of claims 6 to 10, which has an internal combustion engine.   A vehicle having the assembly structure according to claim 11.

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