JPH0775836A - Production of corrugated sheet for metal carrier - Google Patents

Abstract

PURPOSE:To provide the production method of a corrugated sheet for metal carrier so as to produce in a high precision the corrugated height of corrugated sheet constituting a metal carrier. CONSTITUTION:The relative distance of a pair of corrugated rollers 1,2 corrugating a flat sheet 8 is controlled based on an amount of factor measured by the means to directly or indirectly detect the factor affecting a height of a corrugated sheet 9, a sheet thickness of a flat sheet 8 detected by a detecting means 4, the output from the sensor detecting the relative distance of a pair of corrugatedrollers 1, 2, and the output from the sensor detecting the wave height corrugated with a pair of corrugated rollers 1, 2.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a corrugated plate of a honeycomb structure which is a main constituent element of a metal carrier used for an exhaust gas purifying catalyst or the like.

[0002]

2. Description of the Related Art As a honeycomb structure used for a metal carrier, a foil-shaped flat plate and a corrugated sheet obtained by processing the flat plate into a corrugated plate are stacked and wound in a roll shape. Usually, this honeycomb structure is press-fitted into a metal outer cylinder and finally integrated by a heat treatment process of brazing or diffusion bonding to form a metal carrier.

Here, a flat corrugated sheet (corrugated sheet)
Processed into a toothed roller (corrugated roller)
It is performed by a method of corrugating by rotating the rollers while feeding a flat plate which is a material between the pair of rollers by meshing the two.

[0004]

When the honeycomb structure is assembled to the outer cylinder by press fitting, the dimensional accuracy of the diameter (long circumference) of the honeycomb structure is important. If the diameter of the honeycomb structure is too small compared to the inner diameter of the outer cylinder, defective bonding occurs, and conversely, if the diameter of the honeycomb is too large compared to the inner diameter of the outer cylinder, the honeycomb structure is deformed or wax foil is formed. There is a problem that it peels off.

Therefore, in order to obtain the accuracy of the diameter of the honeycomb structure, a method of winding using a corrugated plate or a flat plate cut in advance to a predetermined length, or winding while measuring the amount of the flat plate or the corrugated plate used. The method of controlling the diameter of the honeycomb structure to be constant by rotating the honeycomb structure is used.
Since the dimensional accuracy of (1) greatly varies depending on the height of the corrugated plate and the change of the plate thickness of the flat plate, the dimensional accuracy of the wave height and the plate thickness needs to be as good as possible.

However, in the current corrugated sheet processing, a predetermined wave height is set by adjusting the axial distance between the two rollers used for the processing, and usually the axial distance is adjusted at the start of processing. The position of the roller is not adjusted during the subsequent operation.

Therefore, when the thickness of the flat plate to be supplied changes, the wave height after processing changes, so that there is a problem that a constant wave height cannot be obtained. Here, a metal flat plate having a thickness of 0.05 mm is manufactured by rolling, and there is a limit to the plate thickness accuracy, and currently there is a variation of ± 0.005 mm. Further, there is a problem that the distance between the axes of the two rollers changes with time due to the influence of heat generation of the apparatus main body due to continuous operation, and the wave height changes.

Further, due to the processing resistance generated during processing,
There is a phenomenon that a force for expanding the axial distance is applied to each of the two rollers, and the axial distance changes due to backlash or elastic deformation of the bearing portion in which the rollers are fitted.
In this case, if the width of the flat plate is different, the processing resistance changes,
Therefore, the amount of displacement of the distance between the axes changes. As a result, there is also a problem that the wave height also changes depending on the width dimension of the flat plate.
In addition, since the wave height changes even if the tip diameter of the roller is different, it is necessary to readjust the axial distance when the roller is replaced.

The present invention has been made to solve the above-mentioned problems in processing a flat plate of a honeycomb structure which constitutes a metal carrier into a corrugated plate. Change over time between roller axes due to heat generation,
It is possible to improve the dimensional accuracy of the wave height of corrugated corrugated plates by controlling the distance between the roller axes in response to changes in the width of the flat plate and changes in the tip diameter when the rollers are replaced. It is an object of the present invention to provide a method for manufacturing a corrugated plate for a metal carrier.

[0010]

As described above, there are many factors that affect the height of the corrugated sheet. Therefore,
With the idea of providing a means for directly or indirectly detecting the factor amounts of these factors affecting the height of the corrugated sheet and controlling the relative distance between the pair of corrugated rollers according to the factor amounts. The invention of claim 1 has been completed.

According to the invention of the method for producing a corrugated plate for a metal carrier of claim 1, when the flat plate is processed into a corrugated plate which constitutes a metal carrier by a pair of corrugated rollers, the height of the corrugated plate is influenced. The gist of the present invention is to provide means for directly or indirectly detecting the factor amount of the factor to be exerted to control the relative distance between the pair of corrugated rollers according to the factor amount.

According to the invention of the method for manufacturing a corrugated sheet for a metal carrier of claim 2, as a factor affecting the height of the corrugated sheet,
Focusing on the plate thickness of the supplied flat plate, when a flat plate is processed into a corrugated plate that constitutes a metal carrier by a pair of corrugated rollers, a detection means for detecting the plate thickness of the supplied flat plate is provided. The gist is to control the relative distance between the pair of corrugated rollers according to the detected plate thickness.

The method of manufacturing a corrugated sheet for a metal carrier according to claim 3 focuses on the relative distance between a pair of corrugated rollers for processing a flat sheet into a corrugated sheet as a factor affecting the height of the corrugated sheet. When a flat plate is processed into a corrugated plate that constitutes a metal carrier by a pair of corrugated rollers, a sensor for detecting the relative distance between the pair of corrugated rollers is provided, and the relative distance between the corrugated rollers is determined according to the output from the sensor. The point is to control.

The method for manufacturing a corrugated sheet for a metal carrier according to claim 4 focuses on the height of the processed corrugated sheet as a factor affecting the height of the corrugated sheet. When processing the corrugated plate that constitutes the metal carrier by the corrugated roller, a sensor for detecting the wave height processed by the pair of corrugated rollers is provided, and the relative distance between the pair of corrugated rollers is determined according to the output of the sensor. The point is to control.

[0015]

According to the invention of claim 1, the factor amount is measured by means for directly or indirectly detecting the factor amount of the factor affecting the height of the corrugated sheet, and the corrugated sheet is determined according to the measured factor amount. Since the relative distance between the pair of corrugated rollers that processes the corrugated sheet is controlled, the dimensional accuracy of the wave height of the corrugated plate corrugated by the corrugated roller can be improved.

According to the second aspect of the present invention, the detecting means for detecting the thickness of the flat plate supplied is provided, and the relative distance between the pair of corrugated rollers for corrugating is controlled according to the detected thickness of the flat plate. The dimensional accuracy of the wave height of the corrugated corrugated plate can be improved by the attached roller.

According to the third aspect of the present invention, a corrugated roller for corrugating a flat plate is provided with a sensor for detecting the relative distance between the corrugated rollers, and the relative distance between the corrugated rollers is controlled according to the output from the sensor. Thus, a corrugated corrugated plate with good dimensional accuracy of wave height can be manufactured.

According to a fourth aspect of the present invention, there is provided a sensor for detecting a wave height processed by a pair of corrugated rollers for corrugating a flat plate, and a pair of corrugated rollers for corrugating the flat plate according to an output of the sensors. Since the relative distance is controlled, the corrugated corrugated plate can be manufactured with high dimensional accuracy by the corrugated roller.

[0019]

Embodiments of the present invention will be described below with reference to the drawings. (Embodiment 1) FIG. 1 shows a corrugated sheet processing apparatus which detects the relative distance between a pair of corrugated rollers for corrugating a flat plate according to claim 3 and controls the relative distance between corrugated rollers based on the detected value. It is a schematic side view. Both of the two corrugated rollers 1 and 2 have teeth formed on their surfaces, and they mesh with each other and rotate by a driving device (not shown). A flat plate 8 is supplied between the two corrugating rollers, and corrugating rollers 1 and 2 are provided.
Is processed into a corrugated sheet 9.

The relative distance between the upper and lower corrugated rollers 1 and 2 is measured by using a roller distance measuring device 3 which is a laser type measuring device attached to each roller, and the measured inter-axis distance is given to the controller 10. Is entered. The control device 10 is composed of a well-known microcomputer including, for example, a CPU, a RAM and a ROM. A program for controlling the CPU is written in the ROM, and the CPU is input from the roller distance measuring device 3 according to the program. Data about the distance between the axes is taken in, data is exchanged with the RAM, arithmetic processing is performed, and a control signal is output to the roller distance driving device 12 as necessary.

FIG. 4 is a side view of the roller gap driving device 12. The lower corrugated roller 2 is pivotally supported in the middle of the frame 14, and the servomotor 6 is fixed to the upper part of the frame 14 with the drive shaft 18 facing the corrugated roller side. The upper corrugated roller 1 is axially supported at the lower end of the connecting member 16 which is linearly moved up and down by the linear guide 7 attached to the frame 14, and the drive shaft 18 of the servo motor 6 is provided in the cam hole at the upper end thereof. The attached cam 5 is fitted.
When the servo motor 6 rotates in response to a control signal from the control device 10, the cam 5 fitted in the connecting member 16 rotates and the connecting member 16 moves up and down, so that the axial distance between the corrugated rollers 1 and 2 is controlled. To be done. In FIG. 4, the roller gap drive device 12 is shown only on one side, but the same device is attached to the other side.

The operation of the apparatus of this embodiment will be described below.
First, after setting the axial distance between the upper corrugated roller 1 and the lower corrugated roller to a predetermined distance, the upper corrugated roller 1 and the lower corrugated roller 2 are rotated by a driving device (not shown), The flat plate 8 is supplied between the corrugated rollers, and the corrugated plate 9 is processed by the corrugated rollers 1 and 2. In the meantime, the relative distance between the upper and lower corrugated rollers 1 and 2 is measured using a roller distance measuring device 3 attached to each roller, and the measured distance between axes is input to the controller 10.

The CPU of the control unit 10 fetches the input data of the inter-axis distance according to the program written in the ROM, exchanges the data with the RAM to perform the arithmetic processing, the variation of the thickness of the flat plate, and the operation. When the inter-axis distance is widened due to changes over time between roller shafts due to internal heat generation, changes in the width of the flat plate, etc., a control signal for narrowing the inter-axis distance by a predetermined value is output to the roller interval drive device 12, On the contrary, when the distance between the shafts is narrow, a control signal for expanding the distance between the shafts by a predetermined value is output to the roller distance driving device 12.

When the roller gap driving device 12 receives a control signal from the control device 10, the servo motor 6 rotates a predetermined amount, so that the position where the cam 5 contacts the cam hole of the connecting member 16 changes, and the connecting member 16 moves. Ascend or descend. Therefore, the upper corrugated roller 1 axially supported by the lower end of the connecting member 16 rises or lowers, and the axial distance between the corrugated rollers 1 and 2 is controlled.

(Embodiment 2) FIG. 2 is an embodiment of the invention of claim 2 in which a detecting means for detecting the plate thickness of the supplied flat plate is provided, and the corrugated rollers are moved relative to each other according to the detected plate thickness. It is a schematic side view of the corrugated sheet processing apparatus which controls a distance. Both of the two corrugated rollers 1 and 2 have teeth formed on their surfaces, and they mesh with each other and rotate by a driving device (not shown). A flat plate 8 is supplied between the two corrugated rollers and processed into a corrugated plate 9 by the corrugated rollers 1 and 2.

The relative distance between the upper and lower corrugated rollers 1 and 2 is measured by using a roller distance measuring device 3 which is a laser type measuring device attached to each roller, and the measured distance between axes is controlled by the controller 10. Is entered. Further, the plate thickness of the supplied flat plate 8 is the plate thickness measuring device 4 which is a laser type measuring device.
Is measured, and the measured plate thickness is input to the control device 10.

Controller 10 and roller spacing controller 1
Since the configuration of No. 2 is exactly the same as that of the first embodiment, the description will be omitted. Explaining the operation of the apparatus of this embodiment, first, the axial distance between the corrugated roller 1 on the upper side and the corrugated roller on the lower side is set to a predetermined interval in accordance with the plate thickness of the flat plate 8, and then the upper unit is driven by a driving device not shown. The corrugating roller 1 and the lower corrugating roller 2 are rotated, the flat plate 8 is supplied between the two corrugating rollers, and the corrugated plate 9 is processed by the corrugating rollers 1 and 2.

In the meantime, the relative distance between the upper and lower corrugated rollers 1 and 2 is measured by using the roller distance measuring device 3 attached to each roller, and the measured distance between axes is input to the controller 10. Further, the plate thickness of the supplied flat plate 8 is also measured by the plate thickness measuring device 4 and input to the control device 10.

The CPU of the control unit 10 takes in the data of the input distance between axes and the data of the thickness of the flat plate to be supplied according to the program written in the ROM, and exchanges the data with the RAM to perform the calculation. After processing, the inter-axis distance according to the thickness of the flat plate is calculated, and when the inter-axis distance is wider than the inter-axis distance, a control signal for narrowing the inter-axis distance by a predetermined value is output to the roller interval drive device 12. On the contrary, when the distance between the shafts is narrow, a control signal for expanding the distance between the shafts by a predetermined value is output to the roller distance driving device 12.

When the roller spacing driving device 12 receives a control signal from the control device 10, the servo motor 6 rotates by a predetermined amount, so that the position where the cam 5 contacts the cam hole of the connecting member 16 changes, and the connecting member 16 moves. Rises or falls. Therefore, the upper corrugated roller 1 axially supported by the lower end of the connecting member 16 moves up or down, and the corrugated rollers 1 and 2
The inter-axis distance of is controlled.

(Embodiment 3) FIG. 3 shows an embodiment of the invention of claim 4 in which a sensor for detecting the wave height of a corrugated plate processed by a corrugated roller is provided, and the pair of sensors is provided according to the output of the sensor. It is a schematic side view of a corrugated sheet processing apparatus that controls the relative distance of the corrugated roller. Both of the two corrugated rollers 1 and 2 have teeth formed on their surfaces, and they mesh with each other and rotate by a driving device (not shown). A flat plate 8 is supplied between the two corrugated rollers and processed into a corrugated plate 9 by the corrugated rollers 1 and 2.

A corrugated sheet height measuring device 20 composed of a laser type measuring device for measuring the wave height is attached above and below the processed corrugated sheet 9, and the measured corrugated sheet height is controlled by the controller 1.
Input to 0. Since the configurations of the control device 10 and the roller gap drive device 12 are exactly the same as those of the first embodiment, the description thereof will be omitted.

The operation of the apparatus of this embodiment will be described below.
First, after setting the axial distance between the upper corrugated roller 1 and the lower corrugated roller to a predetermined distance, the upper corrugated roller 1 and the lower corrugated roller 2 are rotated by a driving device (not shown), The flat plate 8 is supplied between the corrugated rollers, and the corrugated plate 9 is processed by the corrugated rollers 1 and 2. The wave height of the processed corrugated sheet is measured using the attached corrugated sheet height measuring device 20, and the measured wave height of the corrugated sheet is input to the control device 10.

The CPU of the control unit 10 fetches the input wave height data of the corrugated sheet in accordance with the program written in the ROM, exchanges the data with the RAM and performs arithmetic processing to calculate the wave height of the corrugated sheet. When the wave height is low, a control signal for narrowing the shaft distance by a predetermined value is output to the roller interval driving device 12. Conversely, when the wave height of the corrugated plate is high, a control signal for expanding the shaft distance by a predetermined value is output. Output to the drive device 12.

When the roller spacing driving device 12 receives a control signal from the control device 10, the servo motor 6 rotates by a predetermined amount, so that the position at which the cam 5 contacts the cam hole of the connecting member 16 changes, and the connecting member 16 moves. Ascend or descend. Therefore, the upper corrugated roller 1 axially supported by the lower end of the connecting member 16 rises or lowers, and the axial distance between the corrugated rollers 1 and 2 is controlled.

In any of the above examples, the relative distance between the rollers, the plate thickness of the flat plate, and the wave height of the flat plate were measured using the laser type measuring device. You may use the measuring instrument of.

[0037]

According to the invention of claim 1, the factor amount is measured by means for directly or indirectly detecting the factor amount of the factor affecting the height of the corrugated sheet, and the factor amount is measured according to the measured factor amount. According to the invention of claim 2, a detecting means for detecting the thickness of the supplied flat plate is provided, and the invention of claim 3 is a pair of corrugated rollers for corrugating the flat plate according to the detected thickness of the flat plate. According to the output from this sensor, a sensor for detecting the wave height processed by a pair of corrugated rollers corrugating a flat plate is provided, and this sensor is provided. Since the relative distance between the pair of corrugated rollers for processing the corrugated sheet is controlled according to the output of the above, the dimensional accuracy of the wave height of the corrugated sheet corrugated by the corrugated roller can be improved.

[Brief description of drawings]

FIG. 1 is a schematic side view of a corrugated sheet processing apparatus according to a third aspect of the invention.

FIG. 2 is a schematic side view of a corrugated sheet processing apparatus according to a second aspect of the invention.

FIG. 3 is a schematic side view of a corrugated sheet processing apparatus according to a fourth aspect of the invention.

FIG. 4 is a side view of the roller gap driving device 12.

[Explanation of symbols]

1 Upper corrugated roller 2 Lower corrugated roller 3 Roller interval measuring device 4 Plate thickness measuring instrument 5 Cam 6 Servo motor 8 Flat plate 9 Corrugated plate 10 Control device 12 Roller spacing driving device 14 Frame 16 Connecting member 18 Servo motor drive Axis 20 corrugated plate height measuring instrument

Claims (4)

[Claims] 1. When a flat plate is processed into a corrugated plate that constitutes a metal carrier by a pair of corrugated rollers, a means for directly or indirectly detecting a factor amount of a factor affecting the height of the corrugated plate is provided. A method of manufacturing a corrugated sheet for a metal carrier, comprising controlling a relative distance between the pair of corrugated rollers according to the factor amount. 2. When a flat plate is processed into a corrugated plate that constitutes a metal carrier by a pair of corrugated rollers, a detection means for detecting the plate thickness of the flat plate supplied is provided, and depending on the detected plate thickness. A method of manufacturing a corrugated sheet for a metal carrier, comprising controlling a relative distance between the pair of corrugated rollers. 3. A corrugated roller is provided with a sensor for detecting the relative distance between the pair of corrugated rollers when the flat plate is processed into a corrugated plate that constitutes a metal carrier by a pair of corrugated rollers. A method for producing a metal carrier, which comprises controlling the relative distance between the two. 4. When a flat plate is processed into a corrugated plate that constitutes a metal carrier by a pair of corrugated rollers, a sensor is provided for detecting the wave height of the corrugated plate processed by the pair of corrugated rollers. A method for manufacturing a corrugated sheet for a metal carrier, comprising controlling a relative distance between the pair of corrugated rollers according to an output.