KR101656403B1 - Method for manufacturing a catalytic converter with uniform gap bulk density - Google Patents

Abstract

A method of manufacturing a catalytic converter according to the present invention includes: a first step of measuring an outer diameter of a catalyst; A second step of measuring the weight of the sheet-shaped mat cut to a predetermined standard; A third step of placing a catalyst on the upper surface of the mat to wrap the mat on the outer surface of the catalyst; A fourth step of measuring the inner diameter of the can pipe and inserting a mat-wrapped catalyst into the can pipe; And a fifth step of calculating the gap volume and the density of the mat between the catalyst and the can pipe and then pressing down and downsizing the can pipe so that the GBD value is within the reference range. The downsizing ratio can be appropriately adjusted in the process of downsizing the can pipe even if the density of the supplied mat is different or an error occurs in the outer diameter of the catalyst and the inner diameter of the can pipe. The GBD value of the catalytic converter can be kept constant at all times.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] The present invention relates to a method of manufacturing a catalytic converter,

The present invention relates to a catalytic converter, and more particularly, to a method of manufacturing a catalytic converter including a step of pressurizing a can pipe such that a volume density value of a mat located in a gap between the catalyst and the can pipe is constant.

2. Description of the Related Art [0002] As widely known, an exhaust system of a vehicle is disposed on the lower surface of a floor of a vehicle to remove noise and impurities from various exhaust gases generated in the engine and discharge the exhaust gases to the outside. And at least one silencer for reducing noise by imparting a flow resistance to the exhaust gas discharged from the engine; and at least one silencer which reduces the harmful substances in the exhaust gas, carbon dioxide and nitrogen oxides, , A catalytic converter for converting nitrogen and oxygen, and the like.

Generally, the catalytic converter includes a cylindrical catalyst, a wrapped mat on the outer periphery of the catalyst, and a cylindrical can pipe accommodating a mat-wrapped catalyst. Particularly, the mat is composed of a heat-resistant fiber material and plays a role in securing the sealing property which is interposed between the catalyst and the can pipe so as to prevent the exhaust gas, which has been purified, from escaping between the catalyst and the housing, Support between the catalyst and the housing, and the like. Therefore, the role of the mat is very important to maintain the performance of the catalytic converter for a long time.

In manufacturing such a catalytic converter, first, a mat is wrapped on the outer circumferential surface of the catalyst and inserted into the inside of the can pipe, and then the can pipe is downsized by pressing the can pipe outer surface, .

In this case, since the mat is made of a fiber material, it can be uniformly manufactured, but it may be difficult to uniformly manufacture the density. Regardless of the density difference of the mat, if the can pipe is downsized in the same manner, The GBD (Gap Bulk Density) (hereinafter referred to as the GBD value) is varied, so that various problems may be caused. For example, if the GBD value is excessively high, there is a fear that the catalyst is excessively pressurized and damaged in the can pipe downsizing process, and when the GBD value is excessively low, there is a problem that the pressure leaks through the mat.

KR 10-0885665 B1

It is an object of the present invention to provide a method of manufacturing a catalytic converter capable of maintaining the GBD value constant by appropriately adjusting a downsizing ratio of a can pipe even if the density of the mat is different .

According to an aspect of the present invention, there is provided a method of manufacturing a catalytic converter, the method including: a first step of measuring an outer diameter of a catalyst; A second step of measuring the weight of the sheet-shaped mat cut to a predetermined standard; A third step of placing a catalyst on the upper surface of the mat to wrap the mat on the outer surface of the catalyst; A fourth step of measuring the inner diameter of the can pipe and inserting a mat-wrapped catalyst into the can pipe; And a fifth step of calculating the gap volume and the density of the mat between the catalyst and the can pipe and then pressing down and downsizing the can pipe so that the GBD value is within the reference range.

The GBD value is calculated by the following equation (1).

[Formula 1]

(Gm: measurement mat weight, Am: measurement mat width, Dp: can pipe inner diameter, Dc: catalyst outer diameter)

The value obtained by dividing the difference between the inside diameter of the can pipe and the outside diameter of the catalyst by 2 is set smaller than the thickness of the original mat.

And the fifth step is configured to downward the can pipe by pressing the entire outer surface of the can pipe as a whole.

And a sixth step of laser marking the GBD value with the barcode on the can pipe.

The sixth step further includes a step of measuring an outer diameter of the can pipe.

The downsizing ratio can be appropriately adjusted in the process of downsizing the can pipe even if the density of the supplied mat is different or an error occurs in the outer diameter of the catalyst and the inner diameter of the can pipe. The GBD value of the catalytic converter can be kept constant at all times.

FIG. 1 is a flow chart of a method of manufacturing a catalytic converter according to the present invention, and FIG. 2 is a schematic view showing a process of manufacturing a catalytic converter using a method of manufacturing a catalytic converter according to the present invention.
3 is a cross-sectional view of the catalytic converter when the density of the supplied mat is low.
4 is a cross-sectional view of the catalytic converter when the density of the supplied mat is high.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Reference will now be made in detail to embodiments of the present invention, examples of which are illustrated in the accompanying drawings.

1 is a flowchart of a method for manufacturing a catalytic converter according to the present invention.

The present invention relates to a honeycomb structure having a cylindrical catalyst, a wrapped mat on the outer circumferential surface of the catalyst, and a cylindrical can pipe accommodating a mat-wrapped catalyst. The harmful materials contained in the exhaust gas include hydrocarbon, The present invention relates to a method of producing a catalytic converter for converting nitrogen oxides into carbon dioxide, water, nitrogen and oxygen, which are harmless to the human body through oxidation and reduction, The volume density of the inter-pipe space, that is, the gap volume density (GBD) value (GBD value) can be maintained within the reference range.

That is, a method for manufacturing a catalytic converter according to the present invention includes a first step (S10) of measuring the outer diameter of a catalyst, a second step (S20) of measuring the weight of the sheet- A third step (S30) of placing a catalyst on the upper surface of the catalyst to wrap the mat on the outer surface of the catalyst, a fourth step (S40) of inserting the mat-wrapped catalyst into the can pipe after measuring the inner diameter of the can pipe And a fifth step (S50) of calculating the gap volume between the catalyst and the can pipe and the density of the mat, and then pressing down the can pipe so that the GBD value is within the reference range.

In this case, the GBD value represents the density volume value between the catalyst and the can pipe, that is, the density per volume of the mat inserted between the catalyst and the can pipe, and is calculated by the following formula (1).

[Formula 1]

(Gm: measurement mat weight, Am: measurement mat width, Dp: can pipe inner diameter, Dc: catalyst outer diameter)

That is, the large GBD value means that there is no fear of atmospheric leakage due to high density of matte but it means that the catalyst may be damaged in the downsizing process. The small GBD value means that the catalyst is not damaged in the downsizing process. It means that there is a concern. Therefore, GBD values should be within the standard range when producing catalytic converters. Even if catalysts, mats and can pipes are manufactured to have the same size, if the density of the mat is varied, even if the can pipes are downsized, There is a problem that the value is different.

However, the method of manufacturing a catalytic converter according to the present invention is configured not to downsize the can pipe unconditionally at a preset ratio but to appropriately adjust the downsizing ratio of the can pipe by measuring the density of the mat in advance, It is advantageous that the GBD value of the finally produced catalytic converter can always be kept constant.

At this time, if a value obtained by dividing the difference between the can pipe and the catalyst, that is, the difference between the inside diameter of the can pipe and the outside diameter of the catalyst by 2, is larger than the thickness of the original mat, the mat is not squeezed between the can pipe and the catalyst, , The GBD value can not be normally calculated. Therefore, the value obtained by dividing the difference between the can pipe inner diameter and the catalyst outer diameter by 2 should be set smaller than the thickness of the first mat.

In order to visually confirm the GBD value of the finally produced catalytic converter, a sixth step (S60) of laser marking the GBD value with a barcode may be added to the can pipe. The process of laser marking a GBD value with a bar code will be described in detail below with reference to another drawing.

Hereinafter, a process of actually manufacturing the catalytic converter by the method of manufacturing the catalytic converter according to the present invention will be described in detail.

2 is a schematic diagram showing a process of manufacturing a catalytic converter using the method of manufacturing a catalytic converter according to the present invention.

When the catalyst 10 converter is to be manufactured, the laser sensor 100 for measuring the catalyst is irradiated onto the outer surface of the catalyst 10 while the cylindrical catalyst 10 is first raised and rotated and lowered, (110) calculates the outer diameter of the catalyst (10) by calculating the distance measured by the laser sensor (100) for measuring the catalyst during one revolution of the catalyst (10).

When the calculation of the outer diameter of the catalyst 10 is completed, the cylindrical catalyst 10 is laid down horizontally and aligned, the weight of the mat 20 is measured by placing the mat 20 on the weighing device 200, The control unit 400 receiving the weight value of the mat 20 calculates the density of the mat 20. At this time, since the width and the length and thickness of the mat 20 can be always constant, the density of the mat 20 can be calculated by measuring the weight of the mat 20 only. Meanwhile, each corner of the mat 20 is supported by a separate stopper 210 so that it can be held in a fixed state without being shaken during the weight measurement.

When the weight of the mat 20 is measured, the mat 10 is placed on the upper surface of the mat 20 and the mat 20 is wrapped on the outer surface of the catalyst 10. In this way, The process of lapping the mat 20 on the side surface is also applied to the conventional manufacturing method of the catalyst 10 converter, so a detailed description of the lapping process of the mat 20 is omitted.

After the lapping of the mat 20 is completed, the catalyst 10 having the mat 20 wrapped therein is inserted into the can pipe 30, and then the outer surface of the can pipe 30 Thereby down-sizing the can pipe (30). At this time, if only a part of the outer surface of the can pipe 30 is pressed, the shape of the can pipe 30 may be distorted. Therefore, when downsizing the can pipe 30, It is preferable to evenly press the entire outer surface.

Meanwhile, while the can pipe 30 is down-sizing, the mat 20 positioned between the can pipe 30 and the catalyst 10 is squeezed so that the catalyst 10 and the can pipe 30 In this process, the mat 20 becomes thinner as the inner diameter of the can pipe 30 becomes smaller, thereby increasing the density.

At this time, the method of manufacturing a converter (10) according to the present invention is not limited to downsizing the can pipe (30) at all times when pushing down the can pipe (30) The operation of the pressurizing apparatus 300 is controlled by the control unit 400 so that the downsizing ratio of the can pipe 30 varies depending on the density of the can 20. That is, when the density of the mat 20 at the time of the initial supply is high, the can pipe 30 is slightly downsized, and when the density of the mat 20 at the time of the initial supply is low, The GBD value of the finally produced catalyst 10 converter is uniformly formed.

When the GBD value of the catalyst 10 to be finally manufactured is uniformly formed, it is possible to prevent the shape of the catalyst 10 from being damaged during downsizing of the can pipe 30, It is possible to prevent the phenomenon in which the pressure is leaked through the valve.

On the other hand, even if the GBD value of the finally produced catalyst 10 converter falls within a certain range, a slight GBD value difference (tolerance within an allowable range) may be generated for each converter 10 of the catalyst 10 , And the marking device 600 can be used to mark the GBD value on the outer surface of the finally produced catalyst 10 converter.

The downsizing ratio of the can pipe 30 is set differently depending on the density difference of the mat 20 when the converter 10 of the catalyst 10 is manufactured by the method of manufacturing the converter 10 according to the present invention. A difference in the outer diameter size of the finished can pipe 30 is generated. At this time, even if the downsizing ratio of the can pipe 30 is slightly changed, a large difference in GBD value is generated, so that there is not a large difference in the outer diameter of the finally manufactured can pipe 30. However, if the density of the mat 20 at the time of the initial supply has a large difference from the reference value, the downsizing ratio of the can pipe 30 is also slightly changed to some extent so that the outer diameter of the can pipe 30, May occur.

Therefore, a process for measuring the outer diameter of the finally manufactured can pipe 30 using the can sensor laser sensor 500 and the can outer diameter calculator 510 is added ≪ / RTI > A method of measuring the outer diameter of the can pipe 30 using the can sensor 500 and the can outer diameter calculator 510 is a method of measuring the outer diameter of the can pipe 30 using the catalyst sensor 100 and the catalyst outer diameter calculator 110, Is substantially the same as the method of measuring the outer diameter of the base 10.

On the other hand, the process of measuring the outer diameter of the finally manufactured can pipe 30 is configured to be performed together with the process of laser marking the bar code on the can pipe 30 so as to shorten the length of the entire production line .

3 is a cross-sectional view of the catalyst 10 when the density of the supplied mat 20 is low and FIG. 4 is a sectional view of the catalyst 10 when the density of the supplied mat 20 is high.

3 (a) and 4 (a), when the density of the mat 20 is low as in the case of FIG. 3, The mat 20 is compressed so that the thickness of the mat 20 becomes very thin (the density becomes very high) as shown in FIG. 3 (b) by increasing the downsizing ratio of the mat 20, . On the other hand, when the density of the mat 20 is high as in the case of FIG. 4, even if the mat 20 is slightly compressed, the GBD value falls within the reference range. The thickness of the mat 20 is slightly compressed as shown in (b) of FIG.

That is, even if the density of the mat 20 supplied for the first time is different, the downsizing ratio of the can pipe 30 can be appropriately adjusted so that the final GBD value can be adjusted within a certain range Therefore, it is possible to prevent the product defect due to the density difference of the mat 20 from being obtained. Of course, when the densities of the first mat 20 are different, the thickness of the final mat 20 varies as shown in FIGS. 3 (b) and 4 (b) ) There is no problem in disassembling the function of the converter.

On the other hand, a value obtained by dividing the difference between the inner diameter of the can pipe 30 and the outer diameter of the catalyst 10 by 2 is set to be smaller than the thickness of the initial mat 20.

While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it is to be understood that the scope of the present invention is not limited to the disclosed exemplary embodiments. It will also be appreciated that many modifications and variations will be apparent to those skilled in the art without departing from the scope of the invention.

10: catalyst 20: mat
30: Can pipe 100: Laser sensor for measuring catalyst
110: catalyst outer diameter calculation unit 200: weight measuring device
210: stopper 300: pressure device
400: Control unit 500: Laser sensor for can measurement
510: can outer diameter calculation part 600: marking device

Claims (6)

A laser for measuring the catalyst is irradiated onto the outer surface of the catalyst while the cylindrical catalyst is rotated and rotated, and the distance measured by the laser sensor for measuring the catalyst during one rotation of the catalyst is calculated to calculate the outer diameter of the catalyst Stage 1;
A second step of measuring the weight of the mat by raising a sheet-shaped mat cut to a predetermined standard on a weighing apparatus;
A third step of placing a catalyst on the upper surface of the mat to wrap the mat on the outer surface of the catalyst;
A fourth step of measuring the inner diameter of the can pipe and inserting a mat-wrapped catalyst into the can pipe;
Calculating a gap volume between the catalyst and the can pipe and a density of the mat and then downsizing the can pipe by uniformly pressing the outer surface of the can pipe evenly so that the GBD value is within the reference range; And
Measuring the outer diameter of the can pipe, and laser marking the GBD value with a bar code on the can pipe;
, ≪ / RTI &
Wherein the GBD value is calculated by the following formula (1).
[Formula 1]

(Gm: measurement mat weight, Am: measurement mat width, Dp: can pipe inner diameter, Dc: catalyst outer diameter) delete delete delete delete delete

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