JPH0857549A - Production of corrugated sheet and device therefor - Google Patents

Abstract

PURPOSE: To highly precisely form the projecting and recessed parts of a corrugated sheet and to eliminate the deformation caused by the empty weight of a forming gear in a production method of the corrugated sheet and the device therefor for forming wavy projecting and recessed parts on a flat metal sheet using the forming gear. CONSTITUTION: Plural stages of a pair of gears 31, 33, 35 are arranged, the wave heights H1 , H2 , H3 , of the respective wavy projecting and recessed parts 31A, 33A, 35A formed with a pair of forming gears 31, 33, 35 are made gradually larger as a pair of gears 31, 33, 35 goes to a later stage. In this producing device, a pair of forming gears 31, 33, 35 are arranged over plural stages, and the wave heights H1 , H2 , H3 formed by a pair of forming gears 31, 33, 35 arranged in the later stage are made larger than the wave heights H1 , H2 , H3 formed by a pair of forming gears 31, 33, 35 arranged in the former stage.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a corrugated sheet manufacturing method and apparatus for forming corrugated irregularities on a metal flat plate using a molding gear.

[0002]

2. Description of the Related Art Generally, a catalytic converter for purifying exhaust gas is arranged in an exhaust system of an automobile, and, for example, a metallic corrugated plate and a flat plate are laminated in the catalytic converter. A metal catalyst carrier is contained.

Conventionally, as a method for producing such a metal catalyst carrier, for example, one disclosed in Japanese Patent Laid-Open No. 63-134061 is known. FIG. 7 shows a method for manufacturing the metal catalyst carrier disclosed in this publication, in which a flat plate 13 is formed by a pair of molding gears 11.
The corrugated sheet 15 molded from the sheet and the flat sheet 19 supplied by the roll 17 are alternately stacked in the winding section 21,
A cylindrical metal catalyst support is manufactured.

[0004]

However, in the conventional method for producing a metal catalyst carrier, a pair of molding gears 11 is used.
Therefore, since the corrugated unevenness 23 is formed on the flat plate 13 at one time, the distortion of the flat plate 13 during molding is large, and it is difficult to form the corrugated unevenness 23 with high accuracy.

Further, as the width of the flat plate 13 becomes larger, the length of the pair of molding gears 11 in the axial direction becomes longer, so that FIG.
As shown in FIG. 9, the center of the molding gear 11 is displaced downward due to the weight of the molding gear 11, and as a result, the molded corrugated sheet 15 has a curved shape as shown in FIG. .

The present invention has been made in order to solve such a conventional problem, and it is possible to form corrugated unevenness with high accuracy and to eliminate deformation of the forming gear due to its own weight. It is an object of the present invention to provide a manufacturing method and a device therefor.

[0007]

According to a first aspect of the present invention, there is provided a corrugated plate manufacturing method, wherein a metal flat plate is continuously supplied between a pair of molding gears, and the pair of molding gears form corrugated irregularities. In the method for manufacturing a corrugated plate, the pair of molding gears are arranged in a plurality of stages, and as the pair of molding gears in the subsequent stage is formed, the wave height of the corrugated unevenness formed by the pair of molding gears is sequentially increased. It is a thing.

According to a second aspect of the present invention, in the method of manufacturing the corrugated sheet according to the first aspect, one end of the pair of molding gears is moved in the traveling direction of the flat plate to form corrugated irregularities at right angles to the longitudinal direction of the flat plate. To do.

According to a third aspect of the present invention, in the corrugated sheet manufacturing method according to the first or second aspect, the clearances at one ends of the pair of molding gears are adjusted so that the speeds on both sides of the flat plate in the width direction are the same. .

According to a fourth aspect of the present invention, there is provided a corrugated plate manufacturing apparatus, wherein a flat plate made of metal continuously supplied between a pair of molding gears is molded by the pair of molding gears to form corrugated unevenness. In the manufacturing apparatus, the pair of molding gears are arranged in a plurality of stages, and the molding wave height of the pair of molding gears arranged in the subsequent stage is made larger than the molding wave height of the pair of molding gears arranged in the preceding stage. Is.

According to a fifth aspect of the present invention, in the apparatus for manufacturing a corrugated sheet according to the fourth aspect, the forming gear is arranged horizontally in the axial direction and meshed with a backup gear arranged below the center of the forming gear. It is a thing.

According to a sixth aspect of the present invention, in the fourth aspect of the present invention, the forming gear is arranged so that the axial direction is vertical.

[0013]

In the method for manufacturing a corrugated sheet according to claim 1, since the wave height of the wavy unevenness formed on the flat plate is successively increased, the flat plate at the time of molding is formed as compared with the case where the wavy unevenness is formed at a time. Less distortion.

In the method for manufacturing a corrugated plate according to claim 2, when the corrugated irregularities are not formed at right angles to the longitudinal direction of the flat plate, one end of the pair of molding gears is moved and adjusted in the advancing direction of the flat plate. Corrugated irregularities are formed at right angles to the longitudinal direction of the flat plate.

In the corrugated sheet manufacturing method of the present invention, when the speeds on both sides of the flat plate in the width direction become different, the clearances at one ends of the pair of molding gears are adjusted, whereby both sides of the flat plate in the width direction are adjusted. The speeds of are made the same.

In the corrugated sheet manufacturing apparatus of the fourth aspect, the pair of molding gears are arranged in a plurality of stages, and the molding wave heights of the pair of molding gears arranged in the rear stage are set to those of the pair of molding gears arranged in the front stage. Since the height is larger than the forming wave height, the wave height of the wavy unevenness formed on the flat plate is gradually increased.

In the corrugated sheet manufacturing apparatus of the fifth aspect, the backup gear prevents the forming gear from bending due to its own weight. In the corrugated sheet manufacturing apparatus of the sixth aspect, since the forming gear is arranged vertically, the forming gear does not bend due to its own weight.

[0018]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The details of the present invention will be described below with reference to the drawings. 1 and 2 show the first embodiment of the corrugated sheet manufacturing apparatus of the present invention.
FIG. 1 shows an enlarged detail of the essential parts of FIG.

In this embodiment, a pair of first-stage molding gears 31, a pair of second-stage molding gears 33 and a pair of third-stage molding gears 35 are arranged at predetermined intervals in the horizontal direction.

Each pair of molding gears 31, 33,
A flat plate 37 is continuously supplied between 35. In addition,
The flat plate 37 is used as a metal catalyst carrier, and is a foil material made of, for example, 20% Cr-5% Al ferrite stainless steel and having a wall thickness of 50 μm.

Then, each pair of molding gears 31, 33,
The tooth shape of 35 is such that the molding wave height H ₁ molded by the first-stage molding gear 31 is smaller than the molding wave height H ₂ molded by the second-stage molding gear 33, and the third-stage molding gear 3
The tooth shape is such that the molding wave height H ₃ molded by 5 is larger than the molding wave height H ₂ molded by the second stage molding gear 33.

Therefore, the tooth angle becomes smaller and the tooth height becomes higher in the order of the first stage forming gear 31, the second stage forming gear 33, and the third stage forming gear 35. In the corrugated sheet manufacturing apparatus of this embodiment, the first stage molding gear 31 and the second stage molding gear 3 are attached to the flat plate 37 that is continuously supplied.
3, wavy unevenness 31A, 3 in the order of the third-stage molding gear 35
3A, 35A are formed, and wavy unevenness 31A, 33A,
The wave heights H ₁ , H ₂ and H _{3 of} 35 A are sequentially increased,
In the step forming gear 35, predetermined corrugated irregularities 35A required as a corrugated plate are formed.

In the corrugated sheet manufacturing method and the corrugated sheet manufacturing apparatus described above, however, the first stage forming gear 31, the second stage forming gear 33, and the third stage forming gear 35 are arranged, and the flat plate 3 is arranged.
Since the wave heights H ₁ , H ₂ , and H ₃ of the wavy unevennesses 31A, 33A, and 35A formed in 7 are sequentially increased,
As compared with the case of forming the wavy unevenness 35A at one time, the distortion of the flat plate 37 during molding becomes smaller, and as a result,
The wavy unevenness 35A can be formed with high accuracy.

3 and 4 show a second embodiment of the corrugated sheet manufacturing apparatus of the present invention. In this embodiment, the flat plate 37 wound around the roll 41 is the guide rolls 43, 45.
Through the pair of first stage forming gears 31 and 2 to the second stage forming gears 33 and two pairs of the third stage forming gears 35, and further guided through the guide rolls 47.

FIG. 4 shows two pairs of second stage forming gears 33. The two pairs of second stage forming gears 33 are arranged at a predetermined interval in the vertical direction. Further, each second stage molding gear 33 is arranged horizontally in the axial direction.

Each second stage molding gear 33 is meshed with a backup gear 49 arranged below the second stage molding gear 33. The backup gears 49 are arranged on both sides and the center of the second stage molding gear 33.

The second-stage molding gear 33 can be finely moved in the advancing direction (arrow A direction) of the flat plate 37 separately by the vertical fine movement mechanism 51 shown in FIG.
Further, the second-stage molding gear 33 can be finely moved in the horizontal direction (arrow B direction) separately at both ends thereof by the clearance adjusting mechanism 53 shown in FIG.

In FIGS. 5 and 6, reference numeral 55 denotes a main body column, to which a servo motor 57 is fixed, and one end of a screw shaft 59 is connected to the servo motor 57. There is.

The other end of the screw shaft 59 is rotatably supported by a support member 61. As shown in FIG. 6, a nut member 63 is screwed onto the screw shaft 59. Nut member 6
Projections 65 are formed on both sides of the projection 3.
Is fitted in a rectangular hole 69 formed at the end of the gear support frame 67.

A pointer portion 73 for the potentiometer 71 is formed on the end surface of the gear support frame 67.
In FIG. 6, reference numeral 75 indicates an end plate. A servo motor 77 is fixed to the end plate 75, and one end of a screw shaft 79 is connected to the servo motor 77.

The other end of the screw shaft 79 is rotatably supported by a support member 81. The nut member 8 is attached to the screw shaft 79.
3 is screwed together. A gear support frame 85 on the other side is connected to the nut member 83.

The nut member 83 is biased toward the servomotor 77 by a spring 87. Reference numeral 89 is a potentiometer that detects the position of the nut member 83.

The two pairs of the third stage molding gears 35 are
Since it is configured similarly to the pair of second-stage molding gears 33, detailed description thereof will be omitted. Also, the first stage molding gear 3
1, second stage forming gear 33 and third stage forming gear 35
Since the tooth shape is the same as that of the first embodiment, detailed description will be omitted.

In the corrugated sheet manufacturing apparatus of this embodiment, the first stage forming gear 31, the second stage forming gear 33, and the third stage forming gear 3 are attached to the flat plate 37 continuously supplied from the roll 41.
5, wavy unevenness 31A, 33A, 35A is formed, and the wave height H _{1 of} the wavy unevenness 31A, 33A, 35A,
H ₂ and H ₃ are successively increased, and a predetermined corrugated unevenness 35A required as a corrugated plate is formed in the third stage molding gear 35.

In the corrugated sheet manufacturing method and the corrugated sheet manufacturing apparatus described above, however, the first stage forming gear 31, the second stage forming gear 33, and the third stage forming gear 35 are arranged and the flat plate 3
Since the wave heights H ₁ , H ₂ , and H ₃ of the wavy unevennesses 31A, 33A, and 35A formed in 7 are sequentially increased,
As compared with the case of forming the wavy unevenness 35A at one time, the distortion of the flat plate 37 during molding becomes smaller, and as a result,
Similar to the first embodiment, the wavy unevenness 35A can be formed with high accuracy.

In the method for manufacturing the corrugated plate described above, the second method
By rotating one end of the step forming gear 33 and the third step forming gear 35 in the traveling direction of the flat plate 37 by rotating the screw shaft 59 of the vertical fine moving mechanism 51, the flat plate 37 is corrugated at right angles to the longitudinal direction. Since it becomes possible to form the irregularities 33A and 35A, it is possible to reliably prevent the flat plate 37 from being twisted.

Further, in the above-described corrugated plate manufacturing method, the screw shaft 79 of the clearance adjusting mechanism 53 is rotated to adjust the clearances at one ends of the second stage forming gear 33 and the third stage forming gear 35. Since the flat plate 37 has the same speed on both sides in the width direction, the flat plate 37 can be reliably prevented from being twisted.

Further, in the above-described corrugated plate manufacturing apparatus, the backup gear 49 can surely prevent the molding gears 33, 35 from bending due to their own weight. Furthermore, in the above-described corrugated sheet manufacturing apparatus, the second stage molding gear 3
Since the 3rd and 3rd stage forming gears 35 are arranged in pairs, the 2nd stage forming gear 33 and the 3rd stage forming gears 35 arranged on the front side are arranged.
By adjusting the vertical fine moving mechanism 51 and the clearance adjusting mechanism 53 of the step forming gear 35, the second step forming gear 33 and the third step forming gear 3 arranged on the rear side are adjusted.
It becomes possible to supply the flat plate 37 to the plate 5 with high positional accuracy.

In particular, in the above-described second embodiment, it becomes possible to surely form the wavy unevenness 35A on the wide flat plate 37. That is, for example, in a metal catalyst carrier for an industrial engine, the flat plate 37 has a width of 270.
When the metal catalyst carrier is manufactured by cutting the parent metal catalyst carrier into a plurality of pieces, the width of the flat plate 37 of the parent metal catalyst carrier becomes very wide, so that each molding gear Although the deformation of 33, 35 due to its own weight becomes large, in the above-described embodiment, the backup gear 49 prevents the forming gears 33, 35 from bending due to its own weight, so that the wavy unevenness 35A is formed with high accuracy. be able to.

When the width of the flat plate 37 becomes wider, the flat plate 3
Waveform unevenness 31A, 33A, 35 perpendicular to the longitudinal direction of 7
It becomes difficult to form A, and it becomes difficult to make the speeds on both sides of the flat plate 37 in the width direction uniform,
Although the flat plate 37 is likely to be twisted, in the above-described embodiment, these problems are solved by adjusting the vertical fine movement mechanism 51 and the clearance adjusting mechanism 53, and the wide flat plate 37 is provided with wavy unevenness. 35A can be molded with high precision.

In the embodiment described above, an example in which the axial directions of the molding gears 31, 33, 35 are arranged horizontally is described, but the present invention is not limited to such embodiment. Each molded gear may be arranged vertically,
In this case, the molded gear does not bend due to its own weight, so that the backup gear is unnecessary.

[0042]

As described above, in the method for manufacturing a corrugated sheet according to claim 1, since the wave height of the corrugated irregularities formed on the flat plate is successively increased, it is compared with the case where the corrugated irregularities are formed at one time. As a result, distortion of the flat plate during molding becomes small, and as a result, wavy unevenness can be molded with high accuracy.

In the corrugated sheet manufacturing method of the present invention, by moving and adjusting one end of the pair of molding gears in the traveling direction of the flat plate, it is possible to form corrugated irregularities at right angles to the longitudinal direction of the flat plate. Therefore, it is possible to reliably prevent the flat plate from being twisted.

In the method for manufacturing a corrugated sheet according to claim 3, the clearance at one end of the pair of molding gears is adjusted,
Since the speeds on both sides of the flat plate in the width direction are the same, it is possible to reliably prevent the flat plate from being twisted.

In the corrugated sheet manufacturing apparatus of the fourth aspect, the pair of molding gears are arranged in a plurality of stages, and the molding wave heights of the pair of molding gears arranged in the subsequent stage are set to those of the pair of molding gears arranged in the preceding stage. Since it is larger than the molding wave height, the wave height of the wavy unevenness formed on the flat plate is sequentially increased, so the distortion of the flat plate at the time of molding becomes smaller compared to the case where wavy unevenness is formed at a time. The wavy unevenness can be formed with high accuracy.

In the corrugated sheet manufacturing apparatus of the fifth aspect, the backup gear can surely prevent the forming gear from bending due to its own weight. In the corrugated sheet manufacturing apparatus of the sixth aspect, since the forming gear is arranged vertically, there is an advantage that the forming gear does not bend due to its own weight.

[Brief description of drawings]

FIG. 1 is an explanatory diagram showing a main part of a first embodiment of a corrugated sheet manufacturing apparatus of the present invention.

FIG. 2 is an explanatory diagram showing the entire corrugated sheet manufacturing apparatus of FIG.

FIG. 3 is a side view showing a second embodiment of the corrugated sheet manufacturing apparatus of the present invention.

4 is an explanatory view showing a second stage forming gear of the corrugated sheet manufacturing apparatus of FIG. 1. FIG.

FIG. 5 is a side view showing a vertical fine movement mechanism.

FIG. 6 is a front view showing a clearance adjusting mechanism.

FIG. 7 is a perspective view showing a conventional method for producing a metal catalyst carrier.

FIG. 8 is an explanatory view showing the deformation of the molding gear.

FIG. 9 is an explanatory diagram showing deformation of a flat plate on which wavy unevenness is formed.

[Explanation of symbols]

 31 First Stage Forming Gear 33 Second Stage Forming Gear 35 Third Stage Forming Gear 37 Flat Plate 49 Backup Gear

Claims (6)

[Claims] 1. A flat plate (37) made of a metal is continuously supplied between a pair of molding gears (31, 33, 35), and the pair of molding gears (31, 33, 35) corrugates unevenness ( 31A, 33A, 35A) in the method of manufacturing a corrugated plate, the pair of molding gears (31, 33, 35) are arranged in a plurality of stages, and the pair of molding gears (31, 3) in the rear stage are arranged.
3, 35), a pair of molding gears (3
1, 33, 35), the wavy unevenness (31
A, 33A, 35A) wave heights (H ₁ , H ₂ , H ₃ ) are successively increased, and a corrugated sheet manufacturing method is characterized. 2. The method for manufacturing a corrugated plate according to claim 1, wherein one end of the pair of molding gears (31, 33, 35) is
The flat plate (37) is moved in the moving direction of the flat plate (37).
Wavy irregularities (31A, 33A, 35
A method of manufacturing a corrugated plate, which comprises forming A). 3. The method of manufacturing a corrugated plate according to claim 1, wherein the clearances at one ends of the pair of molding gears (31, 33, 35) are adjusted so that both sides of the flat plate (37) in the width direction are adjusted. A method for manufacturing a corrugated sheet, characterized in that the speeds are the same. 4. A pair of molding gears (31, 33, 35)
Manufacture of corrugated plate for forming corrugated unevenness (31A, 33A, 35A) by molding a metal flat plate (37) continuously supplied between the two by the pair of molding gears (31, 33, 35) In the apparatus, the pair of molding gears (31, 33, 35) are arranged over a plurality of stages, and the molding wave heights (H ₁ , H) of the pair of molding gears (31, 33, 35) arranged at the rear stage are arranged.
₂ , H ₃ ) and a pair of molding gears (3
₁ , 33, 35) and a wave height (H ₁ , H ₂ , H ₃ ) of the forming wave. 5. The apparatus for manufacturing a corrugated plate according to claim 4, wherein the forming gears (31, 33, 35) are arranged horizontally in the axial direction, and the center of the forming gears (31, 33, 35) is located below the center. An apparatus for manufacturing a corrugated plate, which is meshed with a backup gear (49) arranged at. 6. The corrugated plate manufacturing apparatus according to claim 4, wherein the forming gear is arranged vertically in the axial direction.