JP4050259B2 - Honeycomb body manufacturing apparatus and manufacturing method - Google Patents

Description

  The present invention relates to a honeycomb body manufacturing apparatus and a manufacturing method that can be used for a metal carrier. This manufacturing method is particularly suitable for the case of manufacturing a metal carrier by diffusion bonding.

  A general honeycomb body is manufactured by winding a flat plate made of metal foil and a corrugated corrugated sheet in a spiral shape around a winding shaft. At this time, in order to bring the top portion of the corrugated plate and the flat plate into contact with each other, a tension in the rearward direction relative to the winding direction, that is, a rear tension is applied to the flat plate.

This backward tension is normally generated by the mechanism shown in FIG. In this mechanism, a flat plate W ₁ is wound around a foil material reel 80, and a brake 81 is provided on the shaft of the foil material reel 80. If by this mechanism, by operating the brake 81, is imparted a backward tension F in a plate W ₁ between the winding unit (not shown) with the foil material reel 80. Further, the rear tension may be generated by the mechanism shown in FIG. In this mechanism, a tension generating unit 82 composed of a cylinder or the like is provided between the foil material reel 80 around which the flat plate W ₁ is wound and the winding unit. In the case of this mechanism, a rear tension F is applied to the flat plate W ₁ by extending the rod of the cylinder.

As a method for measuring the generated rear tension F, the mechanism shown in FIG. 5 or 6 is usually employed. That is, the flat plate W ₁ is supplied horizontally from the foil material reel 80, and the three rollers 90 to 92 are provided so as to be rotatable around a horizontal rotation axis. The central roller 91 is provided via a load meter 93 such as a load cell. In the mechanism shown in FIG. 5, the flat plate W ₁ is provided so that the lower surface of the roller 90, the upper surface of the roller 91, and the lower surface of the roller 92 can be sequentially advanced. Further, in the mechanism shown in FIG. 6, the flat plate W ₁ is provided so that the upper surface of the roller 90, the lower surface of the roller 91, and the upper surface of the roller 92 can be sequentially advanced. During these periods, the rear tension F generated by the brake 81 or the like is measured by the load meter 93.

During this time, the rollers 90 to 92 cause the finely shaking, immobile but sometimes meandering horizontally, not shown meandering of such flat plate W ₁ relative to the corrugated sheet and the take-up shaft thereby tabular W ₁ is not shown It is corrected by a fixed guide that is placed on the base of the machine. Then, the deviation between the flat plate W ₁ and corrugated plate which can not be corrected by the fixed guides, is corrected by the pressing force of the application to the end face of the honeycomb body after winding.

The honeycomb body obtained in this way is joined by brazing the contact portion between the flat plate W ₁ and the corrugated plate so that the gap between the flat plate W ₁ and the corrugated plate forms a porous structure, and is housed in the outer cylinder. Used as a carrier. The metal carrier has a catalyst support layer formed on a porous inner surface, and serves as an exhaust gas purifying catalyst.

  However, in the above-described conventional manufacturing method, the rear tension measured by the load meter 93 is confirmed in the quality inspection of the honeycomb body after winding and heat treatment, and the rear tension is not changed during winding. Not. This is because in the conventional brazing honeycomb body, the contact portion between the flat plate and the corrugated sheet is joined by brazing in a later process, so that a high rear tension is not required and the rear tension is not required to be managed as much. Because. For this reason, in the conventional manufacturing method, the quality of the honeycomb body cannot be confirmed in the middle of winding, and a honeycomb body in which the contact between the flat plate and the corrugated sheet is not uniform may be manufactured.

  Moreover, in the said conventional manufacturing method, the meandering of a flat plate is only corrected by the fixed guide fixed to the fixed base. This is because the conventional brazing honeycomb body does not require such a high rear tension, so that it is easy to correct the meandering of the flat plate even with the fixed guide, and the slight deviation between the flat plate and the corrugated plate is after winding. This is because it is considered that correction is possible by applying a pressing force to the end face. However, if the swing of each roller increases due to long-term use, the flat plate meanders, and the flat plate and the corrugated plate are wound with a large deviation in the horizontal direction. Even if a pressing force is applied to the end face of the honeycomb body obtained in this way, a flat plate having low rigidity buckles and closes a part of the pores, resulting in a defective product.

In particular, in recent years, a honeycomb body joined by diffusion bonding is being applied to a metal carrier in order to easily join a contact portion between a flat plate and a corrugated plate (JP-A-4-180839, etc.). When manufacturing this diffusion bonding honeycomb body, as described above, a flat plate to which backward tension is also applied,
A honeycomb body for diffusion bonding is manufactured by winding the corrugated sheet in a spiral shape around the winding shaft. The contact portion between the flat plate and the corrugated sheet of the obtained diffusion bonding honeycomb body is bonded by performing diffusion bonding. In this honeycomb body for diffusion bonding, it is necessary to ensure the contact surface pressure in order to increase the bonding strength between the flat plate and the corrugated sheet, and it is possible to stably apply a high rear tension according to the state of the honeycomb body during winding. is necessary.

  Here, when manufacturing the honeycomb body for diffusion bonding, similarly to the above-described conventional manufacturing method, it is possible to wind with applying a high rear tension while measuring the rear tension with three rollers or the like. Conceivable. In this case, it is also conceivable to correct the meandering of the flat plate with a fixed guide fixed to a stationary base, as in the conventional manufacturing method.

  However, as described above, when the diffusion bonding honeycomb body is manufactured by the conventional manufacturing method, it is easily affected by the minute swing of each roller due to the high rear tension, and the plate meandering manufactures the brazing honeycomb body. It will be bigger than if you do. If the meandering of the flat plate is corrected by a conventional fixed guide, the flat plate rides on the fixed guide or the end portion buckles by the fixed guide. In order to avoid this, if the width of the fixed guides is increased, the flat plate and the corrugated plate are wound with a larger displacement in the horizontal direction. The honeycomb body thus obtained is strongly wound, so that the honeycomb body itself has high rigidity and is not corrected by applying a pressing force to the end face, and the flat plate has a part of the porous hole closed. It is easy to produce.

  The present invention has been made in view of the above-described conventional situation, and an object of the present invention is to provide a method for manufacturing a honeycomb body that can prevent generation of defective honeycomb bodies based on meandering of flat plates. This purpose is particularly significant when manufacturing a diffusion bonding honeycomb body that requires high back tension.

(1) An apparatus for manufacturing a honeycomb body according to claim 1, wherein a flat plate to which a rearward tension is applied and a corrugated plate formed in a wavy shape are stacked, and the honeycomb body is wound around a winding shaft in a spiral shape. In a manufacturing apparatus of a honeycomb body to be manufactured, one current roller is provided by a roller which is provided on a flat plate by a cylinder so as to be moved up and down and contacts the flat plate with a slight pressure, and an encoder connected to the rotation shaft of the roller. Measuring means for measuring the amount of flat foil used per rotation, and measuring means, and predicting means for predicting the amount of flat foil used per rotation of the winding shaft in the future from the measured value, Comparing the measured value corresponding to the predicted value among the measured values, the predicted value, and determining whether the rear tension is normal and determining whether the winding quality of the honeycomb body is good, Further, the judging means is a winding operation of the honeycomb body based on the judgment result. It is characterized by controlling.
(2) The honeycomb body manufacturing apparatus according to claim 2 is the honeycomb body manufacturing apparatus according to claim 1, wherein the flat plate has a rear tension in which the flat plate is sandwiched between the upper plate and the lower plate facing each other, and the flat plate is tensioned. It is characterized by being applied by a tension generating unit to be applied.
(3) The honeycomb body manufacturing apparatus according to claim 3 is the honeycomb body manufacturing apparatus according to claim 1, wherein the measurement of the amount of foil used in the flat plate is synchronized with the rotation of the roller mounted in contact with the flat plate. It is measured by an encoder that measures the length of a flat plate.
(4) The honeycomb body manufacturing apparatus according to claim 4 is the honeycomb body manufacturing apparatus according to claim 1, wherein when the judging means determines that the winding quality of the honeycomb body is good, the winding operation of the honeycomb body is performed. When it is determined that the winding quality of the honeycomb body is negative, the winding operation of the honeycomb body is stopped.
(5) In the method for manufacturing a honeycomb body according to claim 5, the flat plate to which the backward tension is applied and the corrugated plate formed in a wavy shape are stacked, and the honeycomb body is wound around the winding shaft in a spiral shape. In the manufacturing method of a honeycomb body to be manufactured, one current roller shaft is provided by a roller provided on a flat plate by a cylinder so as to be brought into contact with the flat plate with a slight pressure, and an encoder connected to the rotating shaft of the roller. Measure the amount of flat foil used per rotation and measure it as a measurement value; predict the amount of flat foil used per rotation of the winding shaft in the future from the measured value; A determination step of comparing the measured value corresponding to the predicted value of the measured value with the predicted value, determining whether the rear tension is normal and determining whether the winding quality of the honeycomb body is good, and In the judgment process, the winding work of the honeycomb body is performed based on the judgment result. It is characterized in that Gosuru.

  Here, the amount of flat foil used per rotation of the current winding shaft can be detected by the encoder.

In particular, as described above as a problem of the prior art, in the manufacture of a honeycomb body (for example, a diffusion bonding honeycomb body) that requires high backward tension, it is provided on a base that corrects meandering in a horizontal plane of a flat plate. The rear tension of the flat plate needs to be accurately managed in relation to a fixed guide (not shown). In that respect, in the manufacturing apparatus of the present invention, first, the measuring means measures the amount of flat foil used per one rotation of the take-up shaft to obtain a measured value. And in a prediction means, the foil usage-amount of the flat plate per rotation of a future winding shaft is estimated from a measured value, and it is set as a predicted value. Thereafter, in the determination means, the actual value corresponding to the predicted value among the measured values is compared with the predicted value. If the actual value is within the predicted value range set based on the predicted value, the rear tension is Since it is normal, the winding quality of the honeycomb body is good. When the measured value is out of the predicted value range, the rear tension is abnormal, and the winding quality of the honeycomb body is determined to be negative. In this way, the quality of the winding quality during the winding of the honeycomb body can be determined.

  Here, the predicted value can be determined on the estimated line by obtaining an estimated line satisfying the relational expression from the two measured values in the relationship between the number of circulations and the circumferential length (foil usage). In addition, the predicted value is obtained by previously obtaining a plurality of estimated lines under the same conditions in relation to the number of laps and the circumference (foil usage), and obtaining a specific estimated line from one measured value. It can also be determined.

  Moreover, in the manufacturing method of this invention, in the measurement process, the foil usage-amount of the flat plate per rotation of the present winding shaft is measured, and it is set as a measured value. Next, in a prediction process, the foil usage of the flat plate per rotation of the future winding shaft is predicted from the measured value to obtain a predicted value. Thereafter, the measured value corresponding to the predicted value among the measured values is compared with the predicted value, and the quality of the winding quality is determined. If the winding quality is managed in this way, the winding quality of the honeycomb body can be confirmed during the winding.

If the honeycomb body is manufactured by the manufacturing apparatus and the manufacturing method of the present invention, the measurement of the back tension does not use three rollers as in the conventional case, but only one roller that contacts the flat plate with a slight pressure. Further, the meandering of the flat plate due to the shaking of the roller can be prevented, the distance between the tension generating unit and the winding unit can be shortened, and the meandering of the flat plate can be reduced as compared with the prior art. Furthermore, since the winding operation of the honeycomb body is controlled while confirming the rear tension in the middle of winding, it is possible to prevent the occurrence of defective products based on meandering flat plates and defective products based on excessive or excessive rear tension .
In particular, these inventions have great significance when manufacturing a diffusion bonding honeycomb body that requires a high rear tension.

  Examples to which the present invention is applied will be described below.

DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments embodying the present invention will be described below with reference to the drawings.
Overview of a manufacturing apparatus used for the manufacturing method, as shown in FIG. 1, the flat plate W ₁ have been made can be supplied horizontally from the foil material reel (not shown), the tension generating unit 1 in the feeding direction of the flat plate W ₁ The circumference measuring unit 2 and the winding unit 3 are sequentially arranged, and the tension generating unit 1 and the like are connected to the microcomputer 4.

In the tension generating unit 1, the lower plate 11 is fixed to a stationary base (not shown), and the upper plate 12 facing the lower plate 11 is fixed to a rod of the cylinder 13. The cylinder 13 is connected to the control valve 14, and the control valve 14 is connected to the microcomputer 4. The flat plate W ₁ is supplied between the lower plate 11 and the upper plate 12, and is sandwiched between the lower plate 11 and the upper plate 12 by extension of the rod of the cylinder 13, and a rear tension F is applied. It has become so.

In the circumference measuring unit 2, a roller 21 that can come into contact with the upper surface of the flat plate W ₁ is provided so as to be rotatable around a horizontal rotation axis, and this rotation axis is provided so as to be movable up and down by a cylinder 22. An encoder 23 is connected to the rotation shaft of the roller 21, and the encoder 23
Is connected to the microcomputer 4.
In the winding unit 3, the winding shaft 31 is provided so as to be rotatable around a horizontal rotation shaft, and the winding shaft 31 is driven by a motor 35 via gears 32 and 33. A corrugated plate (not shown) is supplied to the winding shaft 31 from between the circumference measuring unit 2 and the winding unit 3.

The configured manufacturing apparatus as described above, by rotating the motor 35, the winding shaft 31 is rotated in the drawing counterclockwise rotation, while overlapping a flat plate W ₁ and the corrugated plate, around the winding shaft 31 Wind in a spiral. Since the roller 21 of the circumference measuring unit 2 is in contact with the flat plate W ₁ with a relatively small pressure, the meandering of the flat plate W ₁ does not occur. Thus, a diffusion bonding honeycomb body is manufactured.

Next, an implementation method of the measurement process, the prediction process, and the determination process according to the present invention will be described.
"Measurement process"
In this manufacturing apparatus, first, the microcomputer 4 uses the input signal of the encoder 23 for each rotation of the take-up shaft 31, as shown in FIG. 2, to indicate the current take-up shaft 31 (when the number of turns is n-2). The amount of foil used on the flat plate W ₁ per rotation is measured, and the measured value is L _n-2 . Then, similarly, the current (number of turns when n-1) measuring the foil usage of the flat plate W ₁ per one rotation of the winding shaft 31, a measured value L _n-1. Similarly, the amount of foil used on the flat plate W ₁ per rotation of the winding shaft 31 at the current time (when the number of turns is n) is measured and set as a measured value L _n .

"Prediction process"
And the circumference when the number of turns is n-2; L _n-2 , the length when the number of turns is n−1; L _n−1 , the length when the number of turns is n; L _n , Radius to the outer periphery of the honeycomb body when the number of rounds is n-2; r, radius that increases with each round of rounds (the sum of the amplitudes of the flat plate W ₁ and the corrugated plate W ₂ );
L _n−2 = 2πr (1) Formula L _n−1 = 2π (r + s) (2) Formula L _n = 2π (r + 2s) (3) Formula. here,
2 × 2π (r + s) −2πr = 2π (r + 2s) (4) Since the equation (4), the measured value L _n−2 and the measured value L _n−1 are
L _n = 2L _n−1 −L _n−2 (5) is established. On the estimated line that satisfies this equation (5), the foil usage amount of the flat plate W ₁ per one rotation of the winding shaft 31 in the future (when the number of turns is n) is predicted and set as a predicted value L _n . The predicted value L _n is given a predetermined management width to obtain a predicted value range L.

"Judgment process"
Thereafter, the measured value L _n calculated in the measurement step is set as the actual measured value L _n ′, and the actual measured value L _n ′ is compared with the predicted value range L. Here, if the measured value L _n ′ is within the predicted value range L, the rear tension F is good and the operation is continued. On the other hand, if there is no measured value L _n ′ within the predicted value range L, the rear tension F is negative, and an abnormal signal is issued to stop the work.

If the rear tension F is managed in this way, a stable high rear tension F can be applied while confirming the quality of the honeycomb body in the middle of winding according to the state of the honeycomb body in the middle of winding. Therefore, according to this manufacturing method, generation | occurrence | production of the inferior goods based on the back tension too small or too large can be prevented.
In addition, since the conventional three rollers are not used, the distance between the tension generating unit (mechanism) and the winding unit can be made narrower than before, thereby preventing the meandering of the flat plate W ₁ as compared with the conventional _one. can do.

Therefore, according to the manufacturing device and a manufacturing method, it is possible to prevent the occurrence of defective products, such as flat plate W ₁ is closed a portion of the porous.
Note that thus obtained honeycomb body, after being housed in the outer tube, the gap between the flat plate W ₁ and the corrugated plate is so as to constitute a porous, it is a metal carrier diffusion bonded. This metal carrier has a catalyst support layer formed on a porous inner surface, and serves as an exhaust gas purifying catalyst.

It is a schematic block diagram of the manufacturing apparatus which concerns on the manufacturing method of the Example of this invention. It is a graph which concerns on the manufacturing method of the Example of this invention, and shows the relationship between the frequency | count of circumference | surroundings and circumference (foil usage-amount). It is a schematic block diagram which shows the generation | occurrence | production mechanism of the back tension which concerns on the conventional manufacturing method. It is a schematic block diagram which shows the generation | occurrence | production mechanism of the back tension which concerns on the conventional manufacturing method. It is a schematic block diagram which shows the measurement mechanism of the back tension which concerns on the conventional manufacturing method. It is a schematic block diagram which shows the measurement mechanism of the back tension which concerns on the conventional manufacturing method.

Explanation of symbols

F: Back tension W ₁ ... Flat plate W ₂ ... Corrugated plate 31 ... Winding shaft T ... Winding shaft torque L ... Perimeter, foil usage r ... Radius

Claims (5)

In a honeycomb body manufacturing apparatus for manufacturing a honeycomb body by winding a flat plate provided with a back tension and a corrugated corrugated sheet while winding the spiral plate around a winding shaft,
It is provided on the flat plate by a cylinder so as to be movable up and down, and comprises one roller that contacts the flat plate with a slight pressure, and an encoder connected to the rotary shaft of the roller . Measuring means for measuring the amount of foil used on the flat plate, and a measuring means,
Predicting means for predicting the amount of foil used on the flat plate per one rotation of the winding shaft in the future from the measured value,
A judgment means for comparing an actual measurement value corresponding to the predicted value of the measured value with the predicted value, determining whether the rear tension is normal, and determining whether the winding quality of the honeycomb body is good or not; , And
Further, the determination means controls the winding operation of the honeycomb body based on the determination result.   The said back tension of the said flat plate is provided with the tension | tensile_strength generation unit which clamps the said flat plate with the upper plate and lower plate which mutually face, and provides tension | tensile_strength to this flat plate. An apparatus for manufacturing a honeycomb body.   The measurement of the amount of foil used on the flat plate is measured by an encoder that measures the length of the flat plate in synchronization with the rotation of a roller attached in contact with the flat plate. Honeycomb body manufacturing apparatus.   The determination means continues the winding operation of the honeycomb body when it is determined that the winding quality of the honeycomb body is good, and performs the winding operation of the honeycomb body when it is determined that the winding quality of the honeycomb body is negative. The apparatus for manufacturing a honeycomb body according to claim 1, wherein the apparatus is stopped. In a method for manufacturing a honeycomb body, a flat plate provided with a back tension and a corrugated sheet formed in a wavy shape are wound around a winding shaft in a spiral shape to manufacture a honeycomb body.
The flat plate per one rotation of the current winding shaft is provided by a cylinder, which can be moved up and down on the flat plate, and is in contact with the flat plate with a slight pressure, and an encoder connected to the rotary shaft of the roller. Measuring the amount of foil used and measuring the measurement value;
Predicting the amount of foil used in the flat plate per revolution of the winding shaft in the future from the measured values,
A determination step of comparing the measured value corresponding to the predicted value of the measured value with the predicted value, determining whether the rear tension is normal, and determining whether the winding quality of the honeycomb body is good or not; With
Furthermore, the determining step controls the winding operation of the honeycomb body based on the determination result.

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