JP3578429B2 - Winding method of metal honeycomb body - Google Patents

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to winding of a metal honeycomb body using a shaft supporting structure that can reduce a winding load on a winding shaft when manufacturing a metal honeycomb body by stacking a metal flat foil and a metal corrugated foil. It is about the method.
[0002]
[Prior art]
For example, in recent years, there has been known a catalyst device that arranges a purification catalyst in an exhaust passage of an internal combustion engine such as an automobile and purifies harmful components such as HC, CO, and NOx in exhaust gas. In this type of catalyst device, a metal honeycomb body is used as a catalyst carrier.
[0003]
The metal honeycomb body 4 is formed, for example, as shown in FIG. 5, by laminating a flat foil 1 of corrugated metal and a corrugated foil 2 and winding it up in a spiral shape, as shown in FIG. Are formed with innumerable through holes 4a . The metal honeycomb body 4 is generally used by being inserted into the casing 3.
[0004]
As an apparatus for winding the flat foil 1 and the corrugated foil 2 of the metal foil when the metal honeycomb body 4 is manufactured, for example, there is one disclosed in Japanese Patent Application Laid-Open No. 4-371234. This winding device is generally configured as shown in FIG.
In FIG. 7, reference numeral 5 denotes a winding shaft that is rotated by a driving device (not shown). A pair of side clamps 6A and 6B are mounted on the winding shaft so that the distance between the pair of side clamps can be adjusted. Both ends of the metal flat foil 1 and the metal corrugated foil 2 wound on the winding shaft 5 can be supported under pressure.
The winding shaft 5 of this winding device has a slit 5o for inserting and locking the ends of the metal flat foil 1 and the metal corrugated foil 2, and three pressing rolls are provided outside the winding shaft. Ra, Rb, and Rc are arranged to be able to advance and retreat with respect to the winding shaft 5 by the driving device M.
[0005]
In this winding device, as shown in FIG. 8, the distal ends of the metal flat foil 1 and the metal corrugated foil 2 supplied from the transport device (not shown) are inserted and locked in the slit 5o of the winding shaft 5. Then, the take-up shaft 5 is rotated, and the three pressure rolls Ra, Rb, Rc are taken up from the outer periphery of the take-up of the metal foil while being lightly supported with a constant load, so that the metal honeycomb body 4 is manufactured. I have.
[0006]
In recent years, however, metal flat foils, metal corrugated foils, and the like for forming honeycomb bodies, such as carriers for diesel co-generators, double-size cutting carriers for cutting one carrier into two or three to reduce manufacturing costs, and the like. There is an increasing demand to make the metal foil to be longer (100 to 500 mm), and the width of the metal flat foil and the metal corrugated foil is increased and the rigidity is further increased. When manufacturing, there is concern about the rigidity of the winding shaft.
[0007]
That is, in this winding device, the winding shaft 5 forms the slit 5o for inserting the metal flat foil 1 and the metal corrugated foil 2 at the start of winding and inserting and locking the leading end thereof. The diameter of the winding shaft 5 is often as small as possible (for example, 5 mm) in order to make the diameter of the shaft hole formed in the center of the metal honeycomb body 4 obtained by winding as small as possible. It is easy to bend.
[0008]
In this winding device, in the winding process, the metal foil is lightly supported with a constant load from the outer peripheral side of the metal foil by the pressure roll, but the supporting load by the pressure roll is such that the outer peripheral surface of the metal foil is touched. It has a light load and hardly functions to reinforce the winding shaft.
Therefore, if the width of the metal foil is large, the strength (rigidity) of the winding shaft is reduced and the winding shaft is broken, so that winding becomes impossible, or the winding is twisted or bent, so that it becomes difficult to wind smoothly and the dimensional accuracy is increased. However, there is a problem in that the shape accuracy is reduced and it becomes difficult to manufacture a metal honeycomb body having stable quality with high productivity.
[0009]
[Problems to be solved by the invention]
The present invention supplements the shaft rigidity of a winding shaft and prevents breakage, twisting, and bending of the winding shaft when manufacturing a wound metal honeycomb body by stacking a metal flat foil and a metal corrugated foil on the winding shaft. In addition, another object of the present invention is to provide a method for winding a metal honeycomb body capable of manufacturing a metal honeycomb body having high shape accuracy and stable quality with high productivity.
[0010]
[Means for Solving the Problems]
The gist of the present invention is a metal having a winding shaft for stacking and winding a metal flat foil and a metal corrugated foil, and a pair of side clamps for pressing and supporting the side edges of the metal flat foil and the metal corrugated foil during winding. In the winding method of the metal honeycomb body using the winding device of the honeycomb body, the central region of the winding shaft in the winding process is supported by three or more support rollers from the winding outer peripheral side of the metal foil, The support reaction force at that time is supported in the range of 1 to 5 kg / cm from the start of winding up to a winding angle of about 360 degrees, and then the support reaction force is set to 0.2 kg / cm or less. A method for winding a metal honeycomb body, wherein winding is performed while reducing a winding load on a winding shaft . Further, in this method , a range in which the central region of the winding shaft in the winding process is supported by three or more support rollers through the outer periphery of the metal foil includes at least a central region of the foil width, Is preferably in the range of 20% or more.
[0011]
BEST MODE FOR CARRYING OUT THE INVENTION
In the present invention, in the process of laminating the metal flat foil and the metal corrugated foil with the winding shaft, the central region of the winding shaft is supported by three or more support rollers from the outer peripheral side of the metal foil being wound. The shaft rigidity of the take-up shaft can be compensated for in the central region of the metal foil width, preventing breakage and bending of the take-up shaft, thereby extending the life of the take-up shaft and reducing equipment costs. In addition, it is possible to stably maintain the shape accuracy of the core portion and improve the productivity of manufacturing a metal honeycomb body having stable quality.
[0012]
In the present invention, in the case of manufacturing a wound metal honeycomb body by stacking a thin metal flat foil and a metal corrugated foil using a winding device, the metal flat foil and the metal corrugated foil are formed in the slits of the winding shaft 5. When the winding shaft is rotated and wound, the three or more supporting rollers support the slit forming area of the winding shaft from the outer periphery of the winding of the metal foil to increase the rigidity of the winding shaft. compensate.
[0013]
It is preferable that the support range of the support roller is at least a region of 20% or more of the metal foil width including at least a central region of the metal foil width so that the support can be symmetrically supported left and right from the center of the metal foil width. If the supporting range is less than 20%, the winding shaft is displaced in the non-supported portion because the film is locally supported, and the winding shaft is broken. If the supporting range is 100% or more, it interferes with the side clamp during the winding process, and causes trouble in the clamp.
[0014]
The supporting reaction force of the support roller is set to 1 to 5 kg / cm until the tip of the metal flat foil and the metal corrugated foil is inserted into the slit 5o of the winding shaft 5 and the winding shaft is rotated to make one rotation. It is preferable that the supporting reaction force after that is set to 0.2 kg / cm or less for supporting. Here, the support reaction force is a support load (kg) per unit length (cm) of the support roller.
[0015]
When the winding core is formed, the winding is performed with a relatively small tension. However, since the winding shaft 5 has a small diameter and a slit in the center and has low rigidity, the winding shaft 5 is supported by three or more support rollers. Unless the reaction force is 1 to 5 kg / cm, the rigidity of the winding shaft cannot be sufficiently compensated. If the supporting reaction force exceeds 5 kg / cm, the winding resistance is increased, and the metal foil is broken or the corrugated foil shape is undesirably deteriorated.
[0016]
Then, the leading ends of the metal flat foil and the metal corrugated foil are inserted into the slits of the winding shaft 5, and the supporting reaction force after rotating the winding shaft by 360 degrees (one rotation) exceeds 0.2 kg / cm. In such a case, the metal corrugated foil is crushed and the shape accuracy of the metal honeycomb body is reduced, which is not preferable.
[0017]
When the winding shaft is a split shaft and the diameter is 5 to 7 mm, and the metal foil width is 100 to 200 mm, the supporting roller has a diameter of 15 to 20 mm (3 to 5 times the winding shaft diameter) and arranges 3 to 4 rollers. In addition, it is desirable that the distance between the adjacent support rolls in contact with the winding shaft is equal to or smaller than the diameter of the winding shaft. When the diameter of the support roller is 15 mm or less, the support roller easily bends, so that a uniform support effect cannot be obtained and the effect of reinforcing the rigidity of the winding shaft is insufficient. If the diameter of the support roller is 20 mm or more, interference occurs between adjacent support rollers at a stage where the winding diameter is small, and stable support cannot be performed.
[0018]
When the number of the support rollers is less than three, it is difficult to balance the support of the winding shaft, and the winding shaft is displaced and deformed, so that the winding cannot be performed smoothly and the winding shaft is easily broken. When the number of the support rollers is four or more, it is not preferable because at the stage where the winding diameter is small, interference occurs between adjacent support rollers and stable support cannot be performed. Further, if the distance between the adjacent support rolls (the distance of the closest part) is equal to or larger than the diameter of the winding shaft, the support balance tends to be lost, which is not preferable.
[0019]
This support roller may be driven, but it is not indispensable to drive it, and the equipment cost is greatly increased due to the drive effect. Therefore, it is advantageous to use a non-driven and rotatable roller.
The support range of the support roller may be divided into a plurality of parts in the axial direction of the winding shaft and arranged side by side so as to be intermittently held.
[0020]
The present invention will be conceptually described together with an example of a winding apparatus for a metal honeycomb body for carrying out the present invention shown in FIGS.
In FIG. 1, reference numerals 10a and 10b denote supports, and a take-up shaft 5 is slidably inserted between the supports 10a and 10b via a slide mechanism 12 arranged on a support member 11. The take-up shaft 5 is slidably inserted into the center of the small-diameter support portions 6a and 6b of a pair of side clamps 6A and 6B that press and support the side end surfaces of the metal honeycomb body 4.
[0021]
A spline is formed in the side clamp insertion portion of the winding shaft 5, and the small-diameter support portions 6 a and 6 b of the side clamp rotate together with the winding shaft 5. The support portions 6c and 6d of the side clamps simultaneously slide in the axial direction with the small-diameter support portions 6a and 6b, but are in a loose fit state and do not rotate together.
[0022]
That is, the large-diameter support portion 6c of one side clamp 6A has a structure in which the large-diameter support portion 6c is slidably supported by the slide mechanism 13 provided on the support 11 and does not rotate, and slides together with the small-diameter support portions 6a and 6b. To adjust the distance b between the pair of side clamps.
The large-diameter support portion 6d of the other side clamp 6B is fixed to the support 10b, and has a structure that does not slide or rotate.
[0023]
Gears 14a and 14b are provided on the small-diameter support portions 6a and 6b of the pair of side clamps 6A and 6B, and these gears are respectively rotated by a drive device 15 via a transmission shaft 16 and a gear 17. , And is coaxially rotated by a driving device to transmit rotation to the winding shaft 5 via the small-diameter support portions 6a and 6b of the pair of side clamps 6A and 6B.
[0024]
In the vicinity of the take-up shaft 5 between the pair of side clamps 6A, 6B, three support rollers 7a, 7b, 7c are provided so as to be able to advance and retreat from a side orthogonal to the take-up shaft. As shown in FIGS. 2 and 3, these support rollers are rotatably supported at the distal end of a support rod 19 attached to the support base 8 via a pneumatic cylinder 9, and are supported by the winding shaft 5. On the other hand, it can move forward and backward.
[0025]
The support rollers 7a, 7b (7b is omitted) 7c have a support width a of 20% or more of the metal foil width b, and are arranged so as to be symmetrically supported in the central region of the metal foil. As shown in FIG. 4, the winding shaft 5 having the slit 5o can be contacted and supported at an interval of 120 degrees from the outer peripheral side, and the closest approach distance x between the adjacent supporting rollers has a margin in the height of the metal corrugated foil. It is arranged so as to have a plus dimension.
[0026]
When the support is performed by the support rollers, the support reaction force of the support rollers 7a, 7b, and 7c is controlled in accordance with the winding angle (diameter) during the winding process of the metal foil. A rotation pulse generator 20 is arranged on the shaft 5 and, as shown in FIG. 2, a rotation pulse from the rotation pulse generator is counted, and a calculation for controlling the reaction force supported by the pneumatic cylinder (elevating device) 9 is performed. A pressure adjusting device 22 for adjusting the pressure adjusting valve 22v is provided.
[0027]
A change pattern of the support reaction force according to the winding angle from the start of winding is set in the arithmetic unit 21, and the support reaction force is controlled according to the change in the winding angle. For this purpose, here, the pneumatic cylinder 9 is connected to the compressed air circuit 91 via a pressure regulating valve 22v and a solenoid valve Mv. The pressure can be switched between a pressure P1 for reverse movement, a pressure P2 for obtaining a single-turn support reaction force by the support roller, and a pressure P3 for obtaining a support reaction force after one turn of the support roller.
Here, an air pressure feedback circuit 22p that feeds back the air pressure after the pressure adjustment valve 22v to the pressure adjustment device 22 is provided.
[0028]
Here, the metal flat foil 1 is supplied between the support roller 7a and the support roller 7b via the flat foil supply guide 23, and the metal corrugated foil 2 is connected to the upper surface of the metal flat foil 1 via the corrugated foil supply guide 24 and the support roller. It is supplied between 7a.
[0029]
In the figure, 25 is a foil cutting machine. Reference numeral 26 denotes a tip bending jig which bends the tip of the metal flat foil inserted into the slit 5o of the winding shaft 5 when forming the winding core, and is movable forward and backward with respect to the winding shaft 5 by an elevating mechanism 27. Are located in
[0030]
Reference numeral 28 denotes a spot welding machine for fixing the metal flat foil 1 and the metal corrugated foil 2 at an appropriate time during the winding completion process. Reference numeral 30 denotes a storage table of the unloading device 31 for the metal honeycomb body 4 obtained after the completion of the winding, and is disposed to be able to advance and retreat to a lower portion between the pair of side clamps 6A and 6B.
[0031]
In the winding apparatus for a metal honeycomb body according to this embodiment configured as described above, when the metal flat foil 1 and the metal corrugated foil 2 are overlapped to manufacture the wound metal honeycomb body 4, the flat metal foil body 2 passes through the flat foil supply guide 23. The tip of the supplied metal flat foil 1 is inserted into the slit 5o of the winding shaft 5, as shown in FIG.
[0032]
Then, after the distal end is bent by the distal end bending jig 26 and locked on the winding shaft 5, the distal end of the metal corrugated foil 2 supplied through the corrugated foil supply / supply guide 24 is connected to the winding shaft 5 and the metal flat foil 1. The take-up shaft 5 is rotated by the driving device 15 through the small-diameter support portions 6a and 6b of the side clamps 6A and 6B, and the pneumatic cylinder 9 is controlled to support the support rollers 7a, 7b and 7c. After winding once while supporting the supporting reaction force at 1 to 5 kg / cm by the surface, the supporting reaction force by the supporting roller is reduced to 0.2 kg / cm or less, and winding is performed until the winding diameter becomes about 30 mm. Then, both ends are pressurized (pressed) by side clamps, and subsequently wound up to a predetermined winding diameter (angle).
[0033]
After cutting the metal flat foil 1 and the metal corrugated foil 2 with a predetermined diameter with a cutting machine 25, both ends of the obtained metal honeycomb 4 are pressed (pressed) by a pair of side clamps 6A and 6B to align both end faces. The metal flat foil 1 and the metal corrugated foil 2 are spot-welded by a spot welding machine to produce a metal honeycomb body 4.
The metal honeycomb body 4 thus obtained is stored in the storage table 30 of the unloading device 31 and is unloaded to a predetermined place.
[0034]
In the winding method of the metal honeycomb body of the present invention, in the winding process, the slit forming area of the winding shaft is supported by three to four support rollers to supplement the rigidity of the winding shaft and improve the shaft life. At the same time, the shape accuracy and the winding density of the core portion of the metal honeycomb body can be secured stably, and the quality such as the shape characteristics and the structural characteristics of the entire metal honeycomb body can be stabilized.
[0035]
The winding device for carrying out the present invention is not limited to the above embodiment. For example, the structure (shape) and drive mechanism of the winding shaft and the pair of side clamps, the structure of the support roller, the structure of the support reaction force control, the arrangement, the supply direction of the metal flat foil and the metal corrugated foil, etc. The present invention is changed within a range in which the present invention according to claims 1 to 3 can be carried out according to the diameter of the metal honeycomb body, winding operation conditions, and the like.
[0036]
【Example】
Using the winding apparatus for a metal honeycomb body of the present invention shown in FIGS. 1 to 4 and changing the support width and support reaction force of the support roller, a flat foil and a corrugated foil of stainless steel (SUS304) foil are stacked and wound. Then, a production experiment of a metal honeycomb body was performed. Regarding the durability of the winding shaft and the quality evaluation of the metal honeycomb body, the results will be described together with the results of the conventional example.
[0037]
"Experiment conditions"
Flat foil width: 170mm, thickness: 50μm
Wave foil width: 170 mm, thickness: 50 μm, wave height: 1.25 mm, wave pitch: 2.5 mm
Winding axis: diameter 5 mm, slit width 0.4 mm, slit forming area 200 mm
Winding speed (1) Winding core formation (winding diameter up to 30 mm): 3 m / min
(2) Main winding (winding diameter after 30 mm): 10 m / min
Winding tension (1) Winding core part formation (winding diameter up to 30 mm): 0.2 kgf / mm ²
(2) Main winding (winding diameter after 30 mm): 1 kgf / mm ²
Effective side clamp diameter: 30mm
Number of support rollers: 3, support roller interval x is about 1.7 mm
Material: General structural carbon steel (SS41)
Diameter: 20mm
Support width a: 10 to 170 mm (width to metal foil 6 to 100%)
Support reaction force winding angle up to 360 degrees: 0 to 10 kg / cm
Winding angle after 360 degrees: 0 to 10 kg / cm
[0038]
In the examples satisfying all the conditions defined in the present invention , no deformation such as breakage, twisting or bending of the winding shaft was recognized in the winding process. The shape and winding density of the obtained metal honeycomb body were examined. The dimensions, shape, and winding density were all within a tolerance (± 1 mm) with respect to a predetermined dimension, and the winding quality was high. It was good.
[0039]
On the other hand, although the other conditions are satisfied, in the embodiment in which the support width of the support roller is less than 20% at the central portion, the winding shaft is displaced at the non-support portion, and the winding shaft is broken, twisted or bent. In some cases, the winding work could not be performed.
[0040]
Although the other conditions are satisfied, in the embodiment in which the support reaction force of the support roller up to the winding angle of 360 degrees is set to 7 kg / cm, the load on the winding shaft becomes large, and the winding drive may stop. there were.
[0041]
Although the other conditions are satisfied, in the embodiment in which the supporting reaction force of the supporting roller up to a winding angle of 360 degrees is set to 0.5 kg / cm, the winding shaft is displaced, and the winding shaft is broken, twisted, or the like. Deformation such as bending was observed, and the winding operation could not be performed in some cases.
[0042]
Further, other conditions are satisfied, but in the embodiment in which the support reaction force of the support roller after the winding angle of 360 degrees is set to 1 kg / cm, the winding shaft is not broken, twisted or bent. However, the metal corrugated foil sometimes collapsed and did not become a product.
[0043]
From these examples, it can be said that it is more preferable that all the conditions defined in the present invention be satisfied at the same time . On the other hand, in a conventional example having no shaft rigidity reinforcing structure such as a support roller or a support in the slit forming region of the winding shaft, the winding shaft often shifts and the winding operation cannot be performed.
[0044]
【The invention's effect】
In the present invention, in the process of laminating the metal flat foil and the metal corrugated foil with the winding shaft, the central region of the winding shaft is optimally adjusted from the outer peripheral side of the metal foil being wound by three or more support rollers. The range of support allows the shaft rigidity of the take-up shaft to be compensated for in the central region of the metal foil width, thereby preventing breakage, twisting and bending of the take-up shaft, thereby extending the life of the take-up shaft. As a result, the cost of equipment can be reduced, and the shape accuracy of the core portion can be stably maintained, and the productivity of manufacturing a metal honeycomb body having stable quality can be improved.
[Brief description of the drawings]
FIG. 1 is a front conceptual explanatory view showing an example of a winding device for a metal honeycomb body embodying the present invention.
FIG. 2 is an explanatory side view conceptually showing an example of the arrangement of support rollers in an example of a winding device for a metal honeycomb body embodying the present invention.
FIG. 3 is a partially enlarged front conceptual explanatory view showing an example of a support structure of a support roller in FIG. 2;
FIG. 4 is a partially enlarged side view conceptually showing a winding shaft supported by a support roller in FIG. 2;
FIG. 5 is a three-dimensional conceptual explanatory view showing an example of a conventional winding method of a metal honeycomb body.
FIG. 6 is a plan conceptual explanatory view showing an example of a conventional metal honeycomb body.
FIG. 7 is a front conceptual explanatory view showing an example of a conventional metal honeycomb winding device.
FIG. 8 is a partially cutaway side view conceptual diagram showing an example of a core forming structure in an example of a conventional winding apparatus for a metal honeycomb body.
[Explanation of symbols]
Reference Signs List 1 metal flat foil 2 metal corrugated foil 3 casing 4 metal honeycomb body 5 winding shaft 5o slits 6A, 6B side clamps 6a, 6b small-diameter support portions 6c, 6d large-diameter support portions 7a, 7b, 7c support roller 8 support base 9 empty Pressure cylinder 91 Compressed air circuit Mv Solenoid valve 10a, 10b Support 11 Support member 12 Slide mechanism (for winding shaft)
13 Slide mechanism (for side clamp)
14a, 14b Gear 15 Drive 16 Transmission Shaft 17 Gear 18 Relay Gear 19 Support Rod 20 Rotary Rotary Pulse Oscillator 21 Computer 22 Pressure Regulator 22v Pressure Regulator 22p (Air Pressure) Feedback Circuit 23 Flat Foil Supply Guide 24 Corrugated Foil Supply guide 25 Foil cutting machine 26 Tip bending jig 27 Elevating mechanism 28 Spot welding machine 29 Elevating device 30 Storage table 31 Unloading device

Claims (2)

A winding device for a metal honeycomb body including a winding shaft for winding a metal flat foil and a metal corrugated foil on top of each other, and a pair of side clamps for pressing and supporting the side edges of the metal flat foil and the metal corrugated foil during winding. In the winding method of the metal honeycomb body using the above, the central region of the winding shaft in the winding process is supported by the three or more support rollers from the outer peripheral side of the winding of the metal foil, and the supporting reaction force at that time Is supported in a range of 1 to 5 kg / cm from the start of winding up to a winding angle of about 360 degrees, and thereafter, the support reaction force is set to 0.2 kg / cm or less to support the winding shaft. A method for winding a metal honeycomb body, wherein winding is performed while reducing a winding load. The range in which the central region of the winding shaft in the winding process is supported by the three or more support rollers via the outer periphery of the metal foil includes at least the central region of the foil width, and is at least 20% of the metal foil width. The method for winding a metal honeycomb body according to claim 1, wherein:

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