JP3601577B2 - Method and apparatus for manufacturing catalytic converter container - Google Patents

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a method for manufacturing a catalytic converter container and an apparatus for manufacturing the same, and more particularly, has a main body part, a cone part, and a connection part obtained by spinning a base material tube, and further includes a part from the cone part to the connection part The present invention relates to a method and an apparatus for manufacturing a catalytic converter container for forming a wall thickness so as to gradually increase from a main body portion toward a connection portion.
[0002]
[Prior art]
As is well known, catalytic converters are used to treat exhaust gases emitted from automobile engines. As shown in FIG. 3, a general container R of the catalytic converter has a relatively large-diameter main body r1 for accommodating the catalyst carrier S, and a relatively small-diameter connection portion r3 connected to the exhaust pipe E. It is constituted by a tapered cone r2 whose diameter gradually decreases from the main body r1 toward the connection portion r3. Such a catalytic converter container R generally has a cone r2 formed by spinning a base material tube having substantially the same diameter as the main body r1, and a cone r2 formed at both ends of a cylindrical main body r1 containing the catalyst carrier S. Each is constructed by joining.
[0003]
Incidentally, the connection part r3 of the cone r2 of the catalytic converter container R and the exhaust pipe E are generally connected by MIG welding or the like as shown in FIG. Reference sign B shown in FIG. 4 is a bead formed by MIG welding. The connecting portion between the connecting portion r3 of the cone r2 and the exhaust pipe E is placed under severe conditions, such as being rapidly heated and vibrated when the engine is started. Therefore, when the connection portion is fatigued and becomes fragile due to fatigue, and a hole is formed or a crack is generated, the exhaust gas leaks and the purification efficiency of the catalytic converter deteriorates. Therefore, it is necessary to provide a sufficient strength to the connection portion r3 of the cone r2. Therefore, as shown in FIG. 5, a reinforcing member Q is provided at the connection portion r3 of the cone r2 to increase the wall thickness and increase the rigidity.
[0004]
On the other hand, as disclosed in JP-A-57-48339, in a cone in which a large diameter portion is welded to a shell of a catalytic converter and a pipe and a flange are welded to a small diameter portion, the cone has a constant thickness. The large diameter portion is not thinner than the thickness of the base material tube, while the small diameter portion is processed and formed thicker than the thickness of the base material tube. There is known a cone for a catalytic converter container characterized in that: That is, as shown in FIG. 6, the cone for the catalytic converter container is formed so that the wall thickness gradually increases from the tapered surface (corresponding to the cone portion in the present invention) to the small diameter portion (connection portion). It is butt-welded to both ends of a shell (main body) containing the catalyst carrier.
[0005]
Japanese Patent Laying-Open No. 57-48339 discloses a method for manufacturing a cone for a catalytic converter container, which is a method for manufacturing a cone for a catalytic converter container by spinning a base material tube having a constant thickness. The base tube is inserted into a rotary forming die having a small-diameter circumferential portion and a large-diameter circumferential portion, and then rotated together with the rotary forming die, and a forming roller is abutted on the outer circumferential surface of the base material tube. It is disclosed that the rear end of the spinning contracted tube is cut by pressing and rolling from the tapered surface to the small diameter circumferential portion. In this manufacturing method, a stylus spin is copied to a template similar to a rotational molding die, a copy detection signal is input to a hydraulic control device, and a cross feed device is controlled by an X, Y conversion output signal to control a spinning roller. Is moved along the rotary mold, and the base material tube is pressed between the rotary mold and the spinning roller, and the cone is formed so that the wall thickness gradually increases from the tapered surface to the small diameter portion as described above. Is molded. In the spinning contraction tube apparatus used in this manufacturing method, a hydraulic cylinder is provided for moving the rotary mold forward and backward with respect to the base tube.
[0006]
[Problems to be solved by the invention]
However, in the method for manufacturing a cone for a catalytic converter container disclosed in the above-mentioned Japanese Patent Application Laid-Open No. 57-48339, a rotary mold is disposed in a base material tube, and a catalyst carrier cannot be inserted. However, there has been a problem that it is not possible to manufacture an integrated catalytic converter container in which a shell accommodating a catalyst carrier is continuously formed with a cone. Then, the manufactured cone must be butt-welded to both ends of the shell containing the catalyst carrier in a post-process, and there is a problem that the number of steps is increased and the manufacturing cost is increased. In addition, the butt-welded joint between the cone and the shell has a problem that it tends to be fatigued and brittle under severe conditions as described above.
[0007]
Further, in the spinning contraction tube apparatus used in the manufacturing method disclosed in the above-mentioned Japanese Patent Application Laid-Open No. 57-48339, a rotary molding die or a rotary molding die for advancing and retreating with respect to a base tube. A template or a stylus spin for moving the spinning roller along the hydraulic cylinder or the rotary mold is required, and the structure and control are complicated. Furthermore, in this spinning tube reducing device, the base tube is inserted and set in the rotary mold, and the thickness is automatically increased gradually from the tapered surface to the small diameter part by pressing and rotating the forming spinning roller. Therefore, there is also a problem that it is difficult to form such a portion so as to gradually increase with a desired set thickness.
[0008]
The present invention has been made in view of the above problems, and can be formed so that the thickness from the cone portion to the connection portion is gradually and reliably increased as desired from the main body portion to the connection portion. It is possible to easily manufacture an integrated catalytic converter container in which a cone portion formed so as to gradually increase in thickness toward a connection portion and a main body portion containing a catalyst carrier are continuously formed. An object of the present invention is to provide a method for manufacturing a catalytic converter container that can reduce the number of steps and reduce the manufacturing cost.
Another object of the present invention is to provide an apparatus for manufacturing a catalytic converter container which has a simple structure and can be easily formed with a desired thickness from a cone portion toward a connection portion.
[Means for Solving the Problems]
In order to solve the above-mentioned problems, the invention according to the method for manufacturing a catalytic converter container according to claim 1 is characterized in that a base material tube is spun to form a main body portion in which a catalyst carrier is accommodated and an end continuous from the main body portion. The cone part that is temporarily reduced in diameter toward the part and the connection part that is continuous with the end of the cone part to which the exhaust pipe is connected are integrally molded, and the thickness from the cone part to the connection part is further reduced to the body part A method for manufacturing a catalytic converter container formed so as to gradually increase from the direction toward the connection portion, wherein the cone portion and the connection portion are formed in the base material tube while rotating the base material tube around an axis. The forming roller is moved to reduce the diameter of the base material tube, and pressing means having a size equal to or larger than the end face of the base material tube is used. In the axial direction Is characterized in that the pressing.
[0010]
In order to solve the above-mentioned problems, the invention relating to the apparatus for manufacturing a catalytic converter container according to claim 2 is characterized in that a base material tube is spun to form a main body for accommodating a catalyst carrier and an end portion continuously from the main body. The cone part with a small diameter toward the end and the connection part connected to the end of the cone part for connecting the exhaust pipe are integrally molded, and the thickness from the cone part to the connection part is connected from the main body part A device for manufacturing a catalytic converter container formed so as to gradually increase toward a part, a rotation driving means for gripping and rotating the base material tube around an axis, and a cone part and a connection part in the base material tube. a forming roller moving means for the forming roller is moved Ru reduced in diameter substrate blank tube to form the substrate base tube in accordance with the degree of reduced diameter has an end face or the size of the substrate base pipe Pressing means for regulating or pressing the shaft in the axial direction. It is characterized in that the.
[0011]
In the method according to the first aspect of the present invention, the forming roller is repeatedly moved while rotating the base material tube having substantially the same diameter as the main body for housing the catalyst carrier around the axis. The cone and the connection are formed continuously and integrally with the tube. At this time, the base material tube which tends to expand in the axial direction with the diameter reduction is regulated or pressed in the axial direction by a predetermined force. The portion of the base material tube reduced in diameter by spinning is regulated or pressed against elongation in the axial direction, so that its thickness is increased. Then, by restricting or pressing the base material tube in the axial direction with a predetermined force in accordance with the degree of diameter reduction due to the repeated movement of the forming roller, the diameter of the base material tube from the tapered portion to the connection portion is reduced. The part will be formed to the desired thickness.
[0012]
In the invention related to the apparatus for manufacturing a catalytic converter container according to claim 2, the rotation driving means grips and rotates the base material tube having substantially the same diameter as the main body for housing the catalyst carrier around the axis, thereby forming roller moving means. Repeatedly moves the forming roller to continuously and integrally form the cone portion and the connection portion. At this time, the base material tube which tends to expand in the axial direction with the diameter reduction is regulated or pressed in the axial direction by a predetermined force by the pressing means. By regulating or pressing the portion of the base material tube reduced in diameter by the spinning process against expansion in the axial direction, the wall thickness is increased. Then, by restricting or pressing the base material tube in the axial direction with a predetermined force in accordance with the degree of diameter reduction due to the repeated movement of the forming roller, the diameter of the base material tube from the tapered portion to the connection portion is reduced. The part is formed to the desired thickness.
[0013]
BEST MODE FOR CARRYING OUT THE INVENTION
First, an embodiment of an apparatus for manufacturing a catalytic converter container according to the present invention will be described in detail with reference to FIGS. The same reference numerals in the drawings denote the same or corresponding parts.
[0014]
The apparatus for manufacturing a catalytic converter container according to the present invention generally includes a main body P1 for accommodating a catalyst carrier S by spinning a base tube P, and a small diameter for a while continuously from the main body P1 toward an end. And a connecting portion P3 connected to the end of the cone portion P2 for connecting the exhaust pipe E are integrally formed, and the thickness from the cone portion P2 to the connecting portion P3 is reduced to the body portion P1. And a rotary drive means 1 for gripping and rotating the base tube P about its axis C-C, the base unit being formed so as to gradually increase from the base to the connection part P3. Forming roller moving means (to be described later) for moving the forming roller 2 to form a cone portion P2 and a connection portion P3 on the pipe P; and pressing means 3 for regulating or pressing the base material pipe P in the direction of the axis CC. And
[0015]
The base material tube P is set to have substantially the same diameter as the main body portion P1 of the catalytic converter container to be molded, is made of a material suitable for the catalytic converter container, and can form the catalytic converter container by spinning. Any of a welded pipe and a seamless pipe can be used.
[0016]
The rotation driving means 1 includes a gripping mechanism 11 such as a chuck for gripping the base material pipe P provided on the spindle 10, and a motor (not shown) for driving the spindle 10 to rotate. The substrate tube P is gripped and rotated around its axis CC.
[0017]
The forming roller moving means comprises a servo mechanism (not shown) that can be numerically controlled. The forming roller moving means and the forming roller 2 are formed on the basis of the input data in order to form the base material tube P into a desired shape. The material tube P is relatively moved in the directions of the axis CC and the diameter D. In this embodiment, as shown in FIGS. 1 and 2, the forming roller 2 is configured to move with respect to the base material pipe P rotating around the axis CC.
[0018]
In the case of this embodiment, the pressing means 3 is provided so as to be relatively close to and away from the end face of the base material pipe P, and is located on the rotation axis CC of the spindle 10 of the rotary driving means 1. It has a disk-shaped member 31 rotatably supported so as to rotate synchronously with or follow the rotation of the base tube P. In this embodiment, the board-shaped member 31 is configured to move in the direction of the axis CC with respect to the end face of the base material pipe P. In this embodiment, the gripping mechanism 11 of the rotary drive unit 1 includes the board-shaped member 31 of the base material tube P so that the base material tube P is not moved in the direction of the axis CC. A bottom part 11a is formed, with which the end face opposite to the end face to be abutted abuts. Further, in this embodiment, the pressing means 3 will be described by a case where the disc-shaped member 31 is configured to move in the direction of the axis CC with respect to the end face of the base pipe P. However, the present invention is not limited thereto, and the gripping mechanism 11 gripping the base tube P may be configured to move in the direction of the axis CC with respect to the pressing means 3. In addition, the pressing means 3 is rotatably supported so as to rotate synchronously or drivenly with the rotation of the base material tube P, and is capable of regulating or pressing the base material tube P in the axial direction. The configuration is not limited to the plate-like member 31 and may be the same as the configuration of the gripping mechanism 11 of the rotary drive unit 1.
[0019]
Next, an embodiment of a method for manufacturing a catalytic converter container according to the present invention will be described in detail by using a manufacturing apparatus configured as described above. The same reference numerals in the drawings denote the same or corresponding parts.
The manufacturing method of the catalytic converter container of the present invention is generally a method of spinning a base tube P to form a main body portion P1 in which a catalyst carrier S is housed, and continuously from the main body portion P1 to an end portion for a while. A cone part P2 having a small diameter and a connection part P3 connected to an end of the cone part P2 to which the exhaust pipe E is connected are integrally formed, and the thickness from the cone part P2 to the connection part P3 is determined by the main body. A method for manufacturing a catalytic converter container formed so as to gradually increase from a portion P1 to a connection portion P3, wherein a cone portion P2 and a connection portion are formed on a base material tube P while rotating the base material tube P around an axis. The molding roller 2 is moved so as to form P3, and the base material tube P is regulated or pressed in the axial direction.
[0020]
First, the forming roller 2 and the plate-shaped member 31 are retracted so that the holding mechanism 11 of the rotation driving means 1 can hold the base material tube P. Then, the base tube P is inserted into the holding mechanism 11 of the rotation driving means 1, and the inserted end face is brought into contact with the bottom 11 a of the holding mechanism 11. I do. Next, the cone section P2 and the connecting portion P3 are continuously connected to the base material tube P while rotating the base material tube P around an axis at a predetermined rotation speed by rotating a motor (not shown) of the rotation drive means 1. Numerical control is performed based on the data set and input by the forming roller moving means so that the forming roller 2 is moved with respect to the base material tube P in this embodiment to reduce the size of the base material tube P. Diameter forming. The movement of the forming roller 2 depends on the angle of the cone portion P2 formed in a tapered shape and the size of the diameter of the connecting portion P3 formed in a small diameter, in the direction inclined with respect to the axis of the base material pipe P and It is repeated in a parallel direction and fed at a predetermined feed speed corresponding to the peripheral speed of the base material tube P. Note that, as shown in FIG. 1, the portion where the diameter of the base material tube P is reduced can be formed at an end portion of the base material tube P which is located on the board-like member 31 side. As shown in the figure, the cone portion P2 can be formed substantially at the center of the base material tube P so that the cone portion P2 is symmetrical with the connection portion P3 interposed therebetween.
[0021]
The base material pipe P tends to expand in the axial direction as the diameter of the base material pipe P is reduced. However, in the present invention, when the diameter of the base material tube P is reduced, the board-shaped member 31 of the pressing means 3 restricts the base material tube P from extending and moving its end face in the axial direction. Alternatively, the end face of the base material tube P is pressed against the extension force in the direction of the axis CC. For this reason, in the base material pipe P, the thickness of the main body portion P1 is maintained, and the thickness from the tapered cone portion P2 to the connection portion P3 formed with a relatively small diameter is reduced by the forming roller 2. The diameter gradually increases from the main body P1 toward the connection portion P3 according to the degree of the diameter formation and the regulation or pressing by the board-shaped member 31.
[0022]
Note that the position of the pressing means 3 in the direction of the axis CC of the board-shaped member 31 corresponds to the end face of the base material pipe P from the start of spinning according to the thickness formed from the cone part P2 to the connection part P3. At the start of the spinning process, the end surfaces of the base pipes P can be brought into contact with each other when the end surface of the base tube P extends in the axial direction by the spinning process. During spinning, the position of the board-shaped member 31 in contact with the end face of the base tube P in the direction of the axis CC is determined by the axial extension force of the end surface of the base tube P. Or the plate-like member 31 is moved forward toward the gripping mechanism 11 side so as to positively press the so-called base material pipe P. The plate-like member 31 can be moved backward so as to be separated from the gripping mechanism 11 at a speed lower than the axial movement speed due to the extension of the end face of the end face, and so-called passive pressing can be performed.
[0023]
In this manner, the cone portion P2 and the connection portion P3 have desired wall thicknesses depending on the amount of diameter reduction by the forming roller 2 and the degree of restriction or pressing in the direction of the axis CC by the plate-shaped member 31. Can be adjusted.
[0024]
Thereafter, a cutter (not shown) is brought into contact with a desired portion of the connection portion P3 while a motor (not shown) of the rotation driving means 1 is rotated, so that the connection portion P3 has a length set in the axial direction. As described above, when the end portion of the base material pipe P is reduced in diameter, it is cut as shown by a broken line in FIG. 1, and when the diameter of the center of the base material pipe P is reduced. If so, it is cut as shown by the broken line in FIG.
[0025]
Subsequently, as shown in FIG. 1, when one end of the base material tube is reduced in diameter, the rotation by the rotation driving means is stopped and the base material tube is once taken out from the gripping mechanism, and the cone is taken out. The cone portion and the connection portion are formed in a predetermined shape by reducing the diameter of the end portion where the portion and the connection portion are not formed by performing the above-described steps in the same manner. The catalyst carrier S is first housed in a portion to be the main body P1 of the base tube P, and then the above-described steps are repeated to form cones at both ends of the main body P1 in which the catalyst carrier S is housed. The diameter of the portion P2 and the connection portion P3 can be reduced. Also, after the cone part P2 and the connection part P3 are first reduced in diameter at one end of the main body part P1 by the above-described process, the catalyst carrier S is inserted from the other end where the cone part P2 and the connection part P3 are not formed. On the other end, the cone portion P2 and the connection portion P3 can be formed with a reduced diameter.
[0026]
On the other hand, as shown in FIG. 2, when the diameter of the substantially central portion of the base material tube P is reduced, the catalyst carrier S is first placed near both ends to become the main body portion P1 of the base material tube P first. Then, by performing the above-described steps, the cone portion P2 and the connection portion P3 are symmetrically reduced in diameter at substantially the center of the base material tube P in which the catalyst carrier S is stored. Almost the center of the connection portion P3 of the base material tube is cut, the rotation by the rotation driving means 1 is stopped, and the base material tube P is once taken out from the gripping mechanism 11, and cut off in the same manner as shown in FIG. A cone portion P2 and a connection portion P3 can be formed at the other end of the base material pipe P, which has not been reduced in diameter. First, by performing the above-described steps, the cone portion P2 and the connecting portion P3 are symmetrically reduced in diameter at substantially the center of the base material tube P, and the center of the connecting portion P3 of the base material tube P is cut. Then, the rotation by the rotation driving means 1 is stopped, and the base material tube P is once taken out from the gripping mechanism 11, and then the catalyst carrier S is separated from the other end of the cut base material tube P which has not been reduced in diameter. The cone part P2 and the connecting part P3 can be formed in the other end of each of the base tubes P by reducing the diameter. Further, the above-described process is performed to cut substantially the center of the connection portion P3 located between the substantially central cone portions P2 and P2 of the base material pipe P, and thereafter, the single catalyst carrier S is cut. It is also possible to insert the other ends of the base pipes P that have not been reduced in diameter into one another and to join the other ends of the base pipes P cut together by, for example, TIG welding. In this case, it is not necessary to join the cones r2 to both ends of the main body r1 as in the related art (see FIG. 3), and only one joining is required.
[0027]
【The invention's effect】
According to the first aspect of the present invention, while rotating the base material tube around the axis, the forming roller is moved so that the base material tube has a desired shape, and the base material tube is restricted or controlled in the axial direction. By pressing, the cone portion can be formed so as to increase the thickness of the cone portion reliably and easily as desired toward the connection portion, and further, the cone portion is formed so that the thickness gradually increases toward the connection portion. A catalyst capable of easily manufacturing an integrated catalytic converter container in which a cone portion and a main body portion containing a catalyst carrier are continuously formed, thereby reducing the number of manufacturing steps and reducing manufacturing costs. A method for manufacturing a converter container can be provided.
[0028]
According to the invention of claim 2, rotation driving means for gripping and rotating the base material tube around an axis, forming roller moving means for moving a forming roller to form the base material tube into a desired shape, A pressurizing means for restricting or pressing the base material tube in the axial direction, so that the catalytic converter can be easily and gradually formed with a desired thickness from the cone portion toward the connection portion by a simple structure. An apparatus for manufacturing a container can be provided.
[Brief description of the drawings]
FIG. 1 is an explanatory view showing an embodiment of a catalytic converter container manufacturing apparatus according to the present invention.
FIG. 2 is an explanatory view showing another embodiment of the manufacturing apparatus of the catalytic converter container of the present invention.
FIG. 3 is a perspective view showing a conventional catalytic converter container.
FIG. 4 is a sectional view showing a state where an exhaust pipe is connected to a cone of a conventional catalytic converter container.
FIG. 5 is a cross-sectional view showing a conventional catalytic converter container in which a reinforcing member is provided to increase the rigidity of a connection portion with an exhaust pipe and the wall thickness is increased.
FIG. 6 is a sectional view showing a conventional cone formed so as to gradually increase the thickness toward a small diameter portion.
[Description of sign]
DESCRIPTION OF SYMBOLS 1 Rotation drive means 2 Forming roller 3 Pressing means P Base material pipe P1 Main body part P2 Cone part P3 Connection part E Exhaust pipe S Catalyst carrier C Rotation axis

Claims (2)

By spinning the base material tube, the main body portion in which the catalyst carrier is accommodated, the cone portion that is temporarily reduced in diameter from the main body portion toward the end, and the cone portion to which the exhaust pipe is connected A method for manufacturing a catalytic converter container, wherein a connection part continuous to an end is integrally formed, and further, the thickness from the cone part to the connection part is formed so as to gradually increase from the main body part toward the connection part,
While rotating the substrate base tube about its axis, together with the forming roller is moved so as to form a connecting portion and the cone portion in the substrate raw tube to shrink the substrate base tube, the end face of the substrate base pipe A method for manufacturing a catalytic converter container, wherein the pressing means having the above-mentioned size restricts or presses the base material tube in the axial direction according to the degree of diameter reduction from the start of spinning . Spinning of the base tube, body part to accommodate the catalyst carrier, cone part continuously smaller from the body part toward the end, and the end of the cone part to connect the exhaust pipe A catalytic converter container manufacturing apparatus, which is integrally formed with a continuous connecting portion, and further formed so that the thickness from the cone portion to the connecting portion gradually increases from the main body portion toward the connecting portion,
A rotation driving means for rotating gripping the substrate mother tube axis, forming rollers which move the forming roller to form a connecting portion and the cone portion on the substrate base pipe and Ru reduced in diameter substrate element tube Moving means, and pressing means having a size equal to or larger than the end face of the base material tube and restricting or pressing the base material tube in the axial direction according to the degree of diameter reduction, Equipment for manufacturing catalytic converter containers.

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