JP4906744B2 - Exhaust treatment device manufacturing method - Google Patents

Description

  The present invention relates to a method for manufacturing an exhaust treatment device.

  The exhaust treatment apparatus has a tubular member and a catalyst carrier inserted into the tubular member, and performs exhaust treatment by passing exhaust gas through the catalyst carrier. For example, Patent Document 1 discloses a method for manufacturing such an exhaust treatment device.

Here, first, the holding portion is formed by contracting a predetermined range in the axial direction of the cylindrical member. Then, after the buffer member is wound around the catalyst carrier, the catalyst carrier and the buffer member are press-fitted into the holding portion from the opening end of the cylindrical member. Then, it processes so that the cross section of an edge part may shrink gradually toward the opening end side of a cylindrical member, and a bottleneck part is formed.
JP 2003-38372 A

  However, in the manufacturing method as described above, the cylindrical member is easily stretched in the axial direction when the tubular member is contracted. For this reason, an error tends to occur in the axial dimension of the exhaust treatment device.

  An object of the present invention is to provide a manufacturing method capable of manufacturing an exhaust treatment apparatus with high dimensional accuracy.

  The manufacturing method of the exhaust treatment device according to the first invention includes the following steps.

(1) A step of forming a first flange portion and a second flange portion at both axial ends of the first tubular member,
(2) A step of sandwiching both ends of the first cylindrical member with a predetermined jig via the first flange portion and the second flange portion to restrict the movement of the first cylindrical member in the axial direction;
(3) forming a contracted tube portion by performing contraction processing in a predetermined range in the axial direction of the first cylindrical member in a state of being sandwiched by a jig;
(4) A step of press-fitting a cylindrical catalyst carrier into the contracted tube portion.

  In this exhaust processing apparatus manufacturing method, both ends of the first tubular member are clamped by a jig via the first flange portion and the second flange portion. For this reason, the deformation | transformation to the axial direction of the 1st cylindrical member in the case of a reduced tube process is suppressed. Thereby, the exhaust treatment device can be manufactured with high dimensional accuracy.

  The method for manufacturing an exhaust treatment apparatus according to the second invention is the method for manufacturing the exhaust treatment apparatus according to the first invention, and is between the first flange portion and the contracted tube portion and between the second flange portion and the contracted tube portion. Are provided with a first non-constricted tube portion and a second non-contracted tube portion in which the diameter of the first cylindrical member before the tube contraction is maintained. In this method for manufacturing the exhaust treatment device, the first restriction member and the second restriction member for restricting the movement of the catalyst carrier in the axial direction are inserted into the first non-constricted tube portion and the second non-constricted tube portion, respectively. And a step of fixing.

  In this method for manufacturing an exhaust treatment device, the first restricting member and the second restricting member are inserted and fixed to the first non-contracted tube portion and the second non-contracted tube portion, respectively. In the first non-contracted tube portion and the second non-contracted tube portion, the diameter before the tube contraction processing is maintained even after the first tubular member has undergone the tube contraction processing. For this reason, it is easy to align the dimensions of the first restricting member and the first non-constricted tube portion and to align the dimensions of the second restricting member and the second non-contracted tube portion.

  An exhaust processing apparatus manufacturing method according to a third aspect of the present invention is the exhaust processing apparatus manufacturing method of the first or second aspect, wherein the first flange portion and the second flange portion are formed, and the tube contraction processing is performed. This is done by spinning.

  In the method for manufacturing the exhaust treatment device, the first flange portion, the second flange portion, and the contracted tube portion are formed by spinning. For this reason, a big metal mold | die is unnecessary compared with the case where press work is performed.

  A method for manufacturing an exhaust treatment apparatus according to a fourth aspect of the present invention is the method for manufacturing an exhaust treatment apparatus according to any one of the first to third aspects, wherein the second cylindrical member is separate from the first cylindrical member. The method further includes a step of connecting the first tubular member and the second tubular member by fixing the third flange portion formed at the axial end portion and the first flange portion of the first tubular member. .

  In the method for manufacturing the exhaust treatment apparatus, the first flange portion can function as a portion for sandwiching the first cylindrical member with a jig at the time of contraction processing. The first flange portion can function as a portion for connecting the first tubular member and the second tubular member.

  In this exhaust processing apparatus manufacturing method, both ends of the first cylindrical member are clamped by a jig via the first flange portion and the second flange portion during the tube contraction process. For this reason, the exhaust treatment apparatus can be manufactured with high dimensional accuracy.

<Configuration of exhaust treatment device>
FIG. 1 shows a cross-sectional view of an exhaust treatment apparatus 1 manufactured by a method for manufacturing an exhaust treatment apparatus 1 according to an embodiment of the present invention. The exhaust treatment device 1 constitutes a part of a diesel particulate filter device that purifies exhaust gas discharged from an internal combustion engine such as a diesel engine. The exhaust treatment apparatus 1 includes a first tubular member 2, a filter 3, a heat insulating material 4, wire meshes 5a and 5b, and bucklings 6a and 6b.

  The first tubular member 2 is a metal member, and includes a first flange portion 21, a second flange portion 22, a contracted tube portion 23, a first non-contracted tube portion 24, and a second non-contracted tube portion 25. ing.

  The first flange portion 21 is provided at one end of the first tubular member 2 and has a shape protruding outward in the radial direction of the first tubular member 2. The first flange portion 21 is provided with a plurality of through holes 26a and 26b. When connecting the first tubular member 2 and a second tubular member 71 (described later), the through holes 26a, A bolt is passed through 26b.

  The second flange portion 22 is provided at the other end of the first tubular member 2. The second flange portion 22 has the same shape as the first flange portion 21 and protrudes outward in the radial direction of the first tubular member 2. Similarly to the first flange portion 21, the second flange portion 22 is also provided with a plurality of through holes 27 a and 27 b.

  The contracted tube portion 23 is provided in the central portion in the axial direction of the first tubular member 2 and has a cylindrical shape with a smaller diameter than the first non-contracted tube portion 24 and the second non-contracted tube portion 25. A filter 3 and a heat insulating material 4 are inserted into the contracted tube portion 23. The contraction tube portion 23 has an inner diameter slightly smaller than the outer diameter of the heat insulating material 4 and holds the filter 3 and the heat insulating material 4 inside.

  The first non-constricted tube portion 24 is provided between the first flange portion 21 and the contracted tube portion 23. The first non-constricted tube portion 24 has a shape extending along the axial direction of the first tubular member 2. Moreover, the connection part of the 1st non-constriction pipe part 24 and the contraction pipe part 23 is the curved R part.

  The second non-constricted tube portion 25 is provided between the second flange portion 22 and the contracted tube portion 23. The second non-constricted tube portion 25 has the same shape as the first non-contracted tube portion 24, and the axial direction of the second non-constricted tube portion 25 is along the axial direction of the first tubular member 2. It has an extended shape. Moreover, the connection part of the 2nd non-constriction pipe part 25 and the contraction pipe part 23 is the curved R part.

  The filter 3 is made of ceramic and is a catalyst carrier for purifying exhaust gas. The filter 3 has a cylindrical shape and is accommodated in the contracted tube portion 23.

  The heat insulating material 4 is a sheet-like member, and is wound around the filter 3 so as to cover the outer peripheral surface of the filter 3. The heat insulating material 4 holds the filter 3 and insulates heat from the filter 3. The heat insulating material 4 has substantially the same length as the filter 3 in the axial direction of the first tubular member 2. The filter 3 is press-fitted into the contracted tube portion 23 together with the heat insulating material 4.

  The wire meshes 5a and 5b include a first wire mesh 5a and a second wire mesh 5b, each having a ring shape. The first wire mesh 5 a is press-fitted into the first non-constricted tube portion 24, and the outer diameter of the first wire mesh 5 a is larger than the inner diameter of the contracted tube portion 23. Further, the inner diameter of the first wire mesh 5a is smaller than the outer diameter of the filter 3, and the movement of the filter 3 in the axial direction can be restricted. The second wire mesh 5 b has the same shape as the first wire mesh 5 a and is press-fitted into the second non-constricted tube portion 25.

  The back rings 6a and 6b include a first back ring 6a and a second back ring 6b, each of which is a metal ring-shaped member. The first buckling 6a is fixed to the first non-constricted tube portion 24, and is welded to the first non-constricted tube portion 24, for example. The first buckling 6a is located outside the first wire mesh 5a. The outer diameter of the first buckling 6 a is larger than the inner diameter of the contracted tube portion 23. Further, the inner diameter of the first buckling 6a is smaller than the outer diameter of the filter 3 and the inner diameter of the first wire mesh 5a, and the movement of the filter 3 and the first wire mesh 5a in the axial direction can be restricted. it can. The second buckling 6b has the same shape as the first buckling 6a. The second buckling 6b is fixed to the second non-constricted tube portion 25, and is welded to the second non-constricted tube portion 25, for example. The second buckling 6b is located outside the second wire mesh 5b.

<Method for Manufacturing Exhaust Treatment Apparatus 1>
Next, a method for manufacturing the exhaust treatment apparatus 1 will be described with reference to FIG.

  First, as shown to Fig.2 (a), the 1st cylindrical member 2 is prepared. In this state, the first cylindrical member 2 has a smooth cylindrical shape with no irregularities on the surface. The first cylindrical member 2 is formed, for example, by bending and welding a flat metal plate by pressing or the like.

  Next, as shown in FIG. 2 (b), the first flange portion 21 and the second flange portion 22 are respectively formed at both axial ends of the first tubular member 2. Here, the first flange portion 21 and the second flange portion 22 are formed by spinning. Here, as shown in FIG. 3, one end of the first tubular member 2 is fixed to the first jig 11. A mold 12 having a shape corresponding to the inner diameter of the first cylindrical member 2 is inserted into the first cylindrical member 2. The mold 12 supports the inside of a portion of the first tubular member 2 where no flange is formed. The 1st jig | tool 11 is rotationally driven by the drive means which is not shown in figure, and, thereby, the 1st cylindrical member 2 rotates. The first spinning roller 13 rotates and contacts the outer peripheral surface of the first cylindrical member 2, and moves in the axial direction of the first cylindrical member 2 while being in contact with the outer peripheral surface of the first cylindrical member 2. (See arrow A1). At the same time, the second spinning roller 14 contacts the inner peripheral surface of the first tubular member 2 while rotating. Then, when the second spinning roller 14 moves in the axial direction and the radial direction of the first cylindrical member 2 (see arrow A2), a flange is formed at the other end of the first cylindrical member 2. Thereafter, by changing the direction of the first tubular member 2 and performing this process again, the first flange portion 21 and the second flange portion 22 are formed at both ends of the first tubular member 2, respectively. .

  Next, as shown in FIG. 2C, the contracted tube portion 23 is formed. Here, the contracted tube portion 23 is also formed by spinning. Here, as shown in FIG. 4, both ends of the first cylindrical member 2 are sandwiched between the first jig 11 and the second jig 15 via the first flange portion 21 and the second flange portion 22. Thus, the movement of the first tubular member 2 in the axial direction is restricted. The first jig 11 fixes one end of the first cylindrical member 2, and the first cylindrical member 2 rotates as the first jig 11 rotates. The second jig 15 is movable in the axial direction of the first cylindrical member 2 (see arrow A5), and presses the first cylindrical member 2 in the axial direction. Specifically, the first flange portion 21 is in contact with the first jig 11, and the second flange portion 22 is in contact with the second jig 15. The distal end portion 15a of the second jig 15 has an outer diameter that is substantially the same as the inner diameter of the first tubular member 2 before being subjected to the tube contraction process. The second jig 15 has an enlarged diameter portion 15b having a larger diameter than the distal end portion 15a, and a step is provided between the distal end portion 15a and the enlarged diameter portion 15b. The second flange portion 22 is in contact with the step. A mold 16 is inserted inside the first tubular member 2. This mold 16 supports the inside of the portion of the first tubular member 2 that is subjected to spinning processing for forming the contracted tube portion 23. As shown in FIG. 5, the mold 16 is composed of a plurality of radially divided members 16a to 16h, and the outer diameter can be changed. When the spinning process is performed, the outer diameter of the mold 16 is set to a size corresponding to the outer diameter of the filter 3. Then, in a state where the first cylindrical member 2 is sandwiched between the first jig 11 and the second jig 15 and the first cylindrical member 2 is rotating, the first cylinder is rotating while the first spinning roller 13 is rotating. It moves to the axial direction of the 1st cylindrical member 2 in the state which contacted the outer peripheral surface of the cylindrical member 2, and contacted the outer peripheral surface of the 1st cylindrical member 2 (refer arrow A4). As a result, the reduced tube processing is performed on a predetermined range in the axial direction of the first tubular member 2, and the reduced tube portion 23 is formed. Further, the portion of the first tubular member 2 that has not undergone the tube contraction processing maintains the diameter of the first tubular member 2 before the tube contraction processing, and the first non-contracted tube portion 24 and the second non-contracted tube portion 2. It becomes the pipe part 25. Here, the position of the first spinning roller 13 can be changed in the radial direction of the first cylindrical member 2 (see arrow A3), and the size corresponding to the size of the filter 3 can be adjusted by adjusting the radial position. In addition, the outer diameter of the contracted tube portion 23 is adjusted. Further, by adjusting the moving distance and position of the first spinning roller 13 in the axial direction, the length of the contracted tube portion 23 is adjusted to a size corresponding to the axial length of the filter 3. Further, the lengths of the first non-constricted tube portion 24 and the second non-constricted tube portion 25 can be adjusted. A step is formed between the first non-constricted tube portion 26 and the constricted tube portion 23 and between the second non-constricted tube portion 25 and the constricted tube portion 23, and the inner surface of each step is curved. The contraction processing is performed so that the R portion is formed (see FIG. 1). Such an R portion can be easily formed by spinning.

  Next, as shown in FIG. 2D, the filter 3 and the heat insulating material 4 are press-fitted into the contracted tube portion 23. Here, the filter 3 and the heat insulating material 4 are inserted into the contracted tube portion 23 in a state where the heat insulating material 4 is wound around the outer peripheral surface of the filter 3. At this time, as shown in FIG. 6, the auxiliary jig 18 is inserted into the first non-constricted tube portion 24 of the first cylindrical member 2, and the filter 3 and the heat insulating material 4 are placed inside the auxiliary jig 18. Is inserted. The filter 3 and the heat insulating material 4 are pressed by the pressing jig 19 (see arrow A6), and are thereby pressed into the contracted tube portion 23.

  Next, as shown in FIG. 2 (e), the first wire mesh 5 a and the second wire mesh 5 b are disposed in the first non-constricted tube portion 24 and the second non-contracted tube portion 25, respectively. And the 1st buckling 6a and the 2nd buckling 6b are each inserted in the 1st non-constriction pipe part 24 and the 2nd non-constriction pipe part 25, and are fixed by welding. Here, since the first non-constricted tube portion 24 and the second non-constricted tube portion 25 have not undergone the tube contraction processing, they have the same inner diameter as the inner diameter of the first tubular member 2 before the tube contraction processing. Yes. For this reason, it is easy to adjust the dimensions of the first back ring 6a and the first non-constricted tube portion 24 and to adjust the dimensions of the second back ring 6b and the second non-constricted tube portion 25. The same applies to the first wire mesh and the second wire mesh.

  As described above, the exhaust treatment apparatus 1 shown in FIG. 1 is manufactured.

  Further, as shown in FIG. 7, the exhaust treatment device 1 can be connected to another exhaust treatment device 7 (hereinafter, the exhaust treatment device 1 is referred to as “first exhaust treatment device 1”, and other exhaust treatment devices 1 are connected). The processing device 7 is referred to as “second exhaust processing device 7”). The second exhaust treatment device 7 has a second tubular member 71, and a third flange portion 72 is formed at one end of the second tubular member 71. The third flange portion 72 is provided with a plurality of through holes 72a and 72b, and the third flange portion 72 and the first flange portion 21 are fixed by bolts and nuts. Thereby, the 1st cylindrical member 2 and the 2nd cylindrical member 71 are connected. That is, the first exhaust treatment device 1 and the second exhaust treatment device 7 are connected. As described above, the first flange portion 21 can function as a portion that comes into contact with the first jig 11 when performing tube contraction processing, and can also function as a connection portion with the second cylindrical member 71. it can.

  In FIG. 7, the second exhaust treatment device 7 contains the filter 73 inside, as with the first exhaust treatment device 1, but may be a cylindrical member that does not contain the filter 73. . Further, the flange portion of another exhaust treatment device may be connected to the second flange portion 22 instead of the first flange portion 21.

<Features>
In this method for manufacturing the exhaust treatment apparatus 1, even if the filter 3 is made of a highly brittle material such as ceramic, the filter 3 is damaged at the time of manufacturing by performing the contraction processing before the filter 3 is press-fitted. This can be prevented.

  The ceramic filter 3 has a relatively large dimensional error because it is difficult to process. However, in the method for manufacturing the exhaust treatment device 1, since the contracted tube portion 23 is formed in a size corresponding to the outer diameter of the filter 3, the gap between the first tubular member 2 and the filter 3 can be reduced. it can. Further, both ends of the first tubular member 2 are clamped by the first jig 11 and the second jig 15 via the first flange portion 21 and the second flange portion 22 during the tube contraction processing. For this reason, the deformation | transformation to the axial direction of the 1st cylindrical member 2 is suppressed, and the precision of the axial direction dimension of the 1st cylindrical member 2 can be improved.

<Other embodiments>
(A)
Specific shapes of the first jig 11 and the second jig 15 are not limited to those described above, and other shapes may be used as long as both ends of the first cylindrical member 2 can be sandwiched.

(B)
In the above embodiment, the ceramic filter 3 is used, but a catalyst carrier made of other materials may be used.

(C)
In the above embodiment, the contracted tube portion 23 is formed by spinning processing, but the contracted tube portion 23 may be formed by other processing methods. However, it is desirable to perform spinning processing in that a large mold is not required. In particular, spinning is effective for manufacturing a large exhaust treatment apparatus.

  The present invention has an effect of improving the dimensional accuracy of an exhaust treatment apparatus, and is useful as a method for manufacturing an exhaust treatment apparatus.

Sectional drawing of an exhaust-gas treatment apparatus. The figure which shows the manufacturing process of an exhaust-gas treatment apparatus. The figure which shows the formation process of a flange part. The figure which shows the formation process of a reduced tube part. VV sectional drawing in FIG. The figure which shows the press injection process of a filter. The figure which shows the connection process of a 1st exhaust processing apparatus and a 2nd exhaust processing apparatus.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Exhaust treatment device 2 1st cylindrical member 3 Filter (catalyst carrier)
6a First buckling (first regulating member)
6b Second buckling (second regulating member)
11 1st jig | tool 15 2nd jig | tool 21 1st flange part 22 2nd flange part 23 Shrinkage part 24 1st non-shrinkage part 25 2nd non-shrinkage part 72 3rd flange part 71 2nd cylindrical member

Claims (4)

Forming a first flange portion and a second flange portion at both axial ends of the first tubular member,
Sandwiching both ends of the first tubular member with a predetermined jig via the first flange portion and the second flange portion to restrict the movement of the first tubular member in the axial direction;
Forming a contracted tube portion by performing contraction processing on a predetermined range in the axial direction of the first cylindrical member in a state of being sandwiched by the jig;
A step of press-fitting a cylindrical catalyst carrier into the contraction tube portion;
A method for manufacturing an exhaust treatment apparatus comprising: Between the first flange portion and the contracted tube portion and between the second flange portion and the contracted tube portion, a first dimension in which the diameter of the first tubular member before the tube contraction is maintained is maintained. A non-constricted tube portion and a second non-constricted tube portion are provided,
A step of inserting and fixing a first restricting member and a second restricting member for restricting the movement of the catalyst carrier in the axial direction in the first non-constricted tube portion and the second non-contracted tube portion, respectively;
The method for manufacturing an exhaust treatment device according to claim 1. The formation of the first flange portion and the second flange portion, and the contraction processing are performed by spinning processing.
The method for manufacturing an exhaust treatment device according to claim 1 or 2. By fixing the third flange part formed at the axial end of the second cylindrical member separate from the first cylindrical member, and the first flange part of the first cylindrical member, A step of connecting the first tubular member and the second tubular member;
The method for manufacturing an exhaust treatment device according to any one of claims 1 to 3.

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