JP5604283B2 - Method for manufacturing catalyst device - Google Patents

Description

  The present invention relates to a method for manufacturing a catalyst device comprising a case member and a catalyst carrier inserted into the case member via a mat.

  2. Description of the Related Art A catalyst device that is attached to an exhaust system of a vehicle and purifies exhaust gas is known. The catalyst device is manufactured by winding a mat around a catalyst carrier and inserting the catalyst carrier and the mat into a case member. Various taper jigs used for inserting the catalyst carrier and the mat into the case member have been proposed (see, for example, Patent Document 1 (FIG. 3)).

Patent document 1 is demonstrated based on the following figure.
As shown in FIG. 12, the taper jig 100 is integrated with an inlet 103 into which the catalyst carrier 101 and the mat 102 are inserted, an outlet 104 through which the catalyst carrier 101 and the mat 102 are pushed out, and the outlet 104. It is formed of a fitting portion 106 that is formed and into which the tip of the case member 105 is fitted.
The tapered surface 107 is formed by gradually reducing the diameter from the inlet 103 toward the outlet 104.

  The catalyst carrier 101 around which the mat 102 is wound is put into the taper jig 100 and pushed in. By pushing in, the mat 102 is compressed between the catalyst carrier 101 and the tapered surface 107. The diameter of the outlet 104 of the taper jig 100 is formed smaller than the inner diameter of the case member 105. The diameter of the mat 102 extruded from the taper jig 100 is also smaller than the inner diameter of the case member 105. Since the inner diameter of the case member 105 is smaller, the catalyst carrier 101 and the mat 102 can be easily inserted into the case member 105. After being inserted into the case member 105, the compressed mat 102 expands and attempts to return to its original size. The catalyst carrier 101 can be held in the case member 105 by the restoring force. In this way, the catalyst device is manufactured.

  By pushing the catalyst carrier 101 and the mat 102 into the taper jig 100, the diameter of the mat 102 is compressed to a predetermined size. The catalyst carrier 101 and the mat 102 can be easily inserted into the case member 105 by being compressed to a predetermined size.

Incidentally, when the inclination angle θ0 of the taper surface 107 of the taper jig 100 is large, the frictional force generated between the mat 102 and the taper surface 107 increases. By increasing the frictional force, the mat 102 becomes difficult to move relative to the catalyst carrier 101. That is, the mat 102 tends to stay in place with respect to the catalyst carrier 101. When the mat 102 tries to stay in place, problems such as separation of the mat 102 from the catalyst support 101 and wrinkling of the mat 102 may occur. From the viewpoint of frictional force, it is desirable that the inclination angle θ0 of the tapered surface 107 of the taper jig 100 is smaller than a predetermined angle.
On the other hand, when the inclination angle θ0 is decreased, the overall length L1 of the taper jig 100 is increased, and the taper jig 100 is enlarged.

  It is desired to provide a manufacturing technique of a catalyst device that can reduce the taper jig while preventing the mat from peeling off.

JP 2003-293760 A

  An object of the present invention is to provide a technology for manufacturing a catalyst device that can reduce the size of a taper jig while preventing peeling of a mat.

The invention according to claim 1 is a method of manufacturing a catalyst device in which a catalyst carrier and a mat are inserted into a case member.
Preparing the columnar catalyst carrier, the belt-like mat, and the cylindrical case member;
Contacting the longitudinal center of the mat with the lower end of the catalyst carrier;
Causing two guide rods for winding the mat around the catalyst carrier to face below the mat;
Winding the mat around the catalyst carrier by moving the two guide rods along the left and right sides of the outer peripheral surface of the catalyst carrier;
Tilting each of the front ends of the mat along the catalyst support by a mat front end tilting mechanism while keeping the guide rod following the outer peripheral surface of the catalyst support;
Lowering the mat end pressing mechanism for pressing the front end of the mat toward the front end of the mat while retreating the mat front end tilting mechanism;
Before the leading edge of the mat returns, the leading edge of the mat is moved by a bending plate having a pressing surface formed along the mat in a state of being wound around the catalyst carrier. The process of holding,
Retreating the guide rod and the mat tip end tilting mechanism in a state where the tip end portion of the mat is pressed by the bending plate;
Moving the catalyst carrier on which the mat is wound to a mold for temporarily compressing the mat in a state where the leading end of the mat is pressed by the mat end pressing mechanism;
Pressing the mat toward the axis of the catalyst carrier from the entire circumference of the mat wound around the catalyst carrier, and temporarily compressing the mat;
A step of introducing the catalyst carrier on which the mat is wound into a taper jig having an inlet having a diameter larger than the outer diameter of the temporarily compressed mat and reducing the diameter from the inlet toward the outlet;
The catalyst carrier put in the taper jig is pushed toward the outlet having a diameter smaller than the outer diameter of the temporarily compressed mat, thereby main compressing the temporarily compressed mat,
And inserting the catalyst carrier around which the mat is wound into the case member disposed at the outlet of the taper jig,
In the step of temporarily compressing, a die for temporarily compressing the mat and retreating the bending plate with respect to the front end portion of the mat positioned directly above the catalyst carrier, The catalyst carrier is advanced from obliquely above .

In the invention according to claim 1, the temporarily compressed mat is put into the taper jig.
If the inclination angle of the taper surface of the taper jig is constant, the length of the taper jig is proportional to the amount of diameter reduction of the mat.
In the present invention, since the mat is temporarily compressed, the diameter reduction amount of the mat with the taper jig is small. Since the diameter reduction amount of the mat is small, the taper jig can be shortened and the taper jig can be miniaturized. There is no need to increase the taper angle in order to reduce the size of the taper jig. That is, the taper jig can be reduced in size while preventing the mat from peeling off.
If the size of the taper jig is the same, the taper angle can be reduced. By reducing the taper angle, the press-fit load can be reduced.

It is a figure explaining the preparatory process which concerns on this invention. It is a figure explaining from the positioning of a catalyst carrier to the process of moving a mat. It is a figure explaining the process of winding a mat with a guide rod. It is a figure explaining the process from depressing the edge part of a mat with a cylinder, and pressing it with a mat edge part presser mechanism. It is a figure explaining the process of moving the catalyst support around which the mat was wound to the 1st compression type. It is a figure explaining a temporary compression process. It is a figure explaining the process of moving to a taper jig | tool after retracting a 2nd and 3rd temporary compression type | mold. It is a figure explaining a taper jig. It is a figure explaining a main compression and insertion process. It is sectional drawing of the catalyst apparatus which concerns on this invention. It is a figure which compares the taper jig concerning this invention with the taper jig concerning a comparative example. It is a figure explaining the basic composition of the conventional technology.

  Embodiments of the present invention will be described below with reference to the accompanying drawings. The drawings are viewed in the direction of the reference numerals.

Embodiments of the present invention will be described with reference to the drawings.
As shown in FIG. 1, first, a columnar catalyst carrier 11, a belt-like mat 12 wound around the outer peripheral surface of the catalyst carrier 11, and a cylindrical shape into which the catalyst carrier 11 and the mat 12 are inserted. The case member 13 is prepared.

The mat 12 has tip portions 12a and 12b in the longitudinal direction formed in a protruding shape.
When the catalyst carrier 11, the mat 12, and the case member 13 are prepared, the mat 12 is wound around the outer periphery of the catalyst carrier 11. Details will be described in the next figure.

As shown in FIG. 2A, the catalyst carrier 11 is positioned by the catalyst positioning mechanism 15.
The catalyst positioning mechanism 15 has V-shaped plates 17 and 17 fixed to the tips of a pair of moving rods 16 and 16, respectively.

  The moving rods 16 and 16 are advanced toward the outer peripheral surface of the catalyst carrier 11. By sandwiching the catalyst carrier 11 between the pair of V-shaped plates 17, 17, the outer peripheral surface of the catalyst carrier 11 comes into contact with a predetermined position of the V-shaped plates 17, 17 and the catalyst carrier 11 is positioned.

Next, as shown in (b), the positioned catalyst carrier 11 is held by the catalyst holding mechanism 21.
The catalyst holding mechanism 21 includes a front moving arm 22 that moves forward and backward along the axis 11a of the catalyst carrier 11, a front disk 23 that is fixed to the tip of the front moving arm 22 and contacts the catalyst carrier 11, and a front movement. A rear moving arm 24 provided with the catalyst carrier 11 sandwiched between the arm 22 and advancing and retreating along the axis 11a of the catalyst carrier 11; a rear disc 25 fixed to the tip of the rear moving arm 24 and in contact with the catalyst carrier 11; Consists of.

  The front and rear moving arms 22 and 24 are advanced toward the catalyst carrier 11, respectively. The front and rear discs 23 and 25 are moved forward to contact the catalyst carrier 11 and hold the catalyst carrier 11 in a predetermined position by sandwiching the catalyst carrier 11. After the catalyst carrier 11 is held by the catalyst holding mechanism 21, the catalyst positioning mechanism (FIG. (A), reference numeral 15) is moved backward.

  When the catalyst carrier 11 is held by the catalyst holding mechanism 21, the mat 12 is moved toward the catalyst carrier 11 as shown in FIG. The mat 12 is moved using the mat moving mechanism 31.

  The mat moving mechanism 31 includes a moving rod 32 that moves up and down toward the lower part of the catalyst carrier 11 and a receiving plate 33 that is fixed to the tip of the moving rod 32 and on which the mat 12 is placed.

The mat 12 is placed on the receiving plate 33 so that the center part of the mat 12 in the longitudinal direction overlaps the lower part of the center of the catalyst carrier 11.
When the center portion of the mat 12 contacts the lower end portion 11 b of the catalyst carrier 11, the mat 12 is wound along the outer peripheral surface of the catalyst carrier 11. Details will be described in the following figures.

  As shown in FIG. 3A, when the center portion of the mat 12 comes into contact with the lower end portion 11 b of the catalyst carrier 11, the left and right guide rods 36 and 37 for winding the mat 12 around the catalyst carrier 11 are disposed below the mat 12. Let us face you.

  When the left and right guide rods 36 and 37 are exposed, the left and right guide rods 36 and 37 are moved along the outer peripheral surface of the catalyst carrier 11 as shown in FIG. The mat 12 is wound along the outer peripheral surface of the catalyst carrier 11 by moving the left and right guide rods 36 and 37.

  As shown in (c), the left and right guide rods 36 and 37 are moved to the vicinity of the upper end portion 11 c of the catalyst carrier 11. The movement of the left and right guide rods 36, 37 is terminated at a position where the upper end portions 36a, 37a of the left and right guide rods 36, 37 do not exceed the upper end portion 11c of the catalyst carrier 11. When the movement of the left and right guide rods 36 and 37 is finished, the tip portions 12 a and 12 b of the mat 12 are tilted along the catalyst carrier 11. Details are described in the following figure.

  As shown in FIG. 4A, the mat tip end tilting mechanisms 41 a and 41 b are lowered to the vicinity of the upper end portion 11 c of the catalyst carrier 11. The mat tip portion tilting mechanism 41a is a device for tilting the tip portion 12a, and the mat tip portion tilting mechanism 41b is a device for tilting the tip portion 12b. The mat front end part tilting mechanisms 41a and 41b are arranged so as to be shifted in the drawing front / back direction.

  The mat tip end tilting mechanisms 41a and 41b include moving rods 42a and 42b that can be moved up and down in the vertical direction, cylinder fixing portions 43a and 43b fixed to the tips of the moving rods 42a and 42b, and these cylinder fixing portions, respectively. And cylinders 44a and 44b fixed to 43a and 43b, respectively.

  When the mat tip end tilting mechanisms 41a and 41b are lowered, the cylinders 44a and 44b are operated as shown in FIG. The cylinders 44a and 44b are operated to advance the rods 45a and 45b. The rod 45a moves forward while tilting the tip 12a of the mat 12, and the rod 45b moves forward while tilting the tip 12b of the mat 12.

  The front end portions 12a and 12b of the mat 12 are made to run along the catalyst carrier 11 using the mat front end portion tilting mechanisms 41a and 41b. Since the mat front end tilting mechanisms 41a and 41b that directly tilt the front end 12a and 12b are used, it is possible to prevent the left and right guide rods 36 and 37 from interfering with the front end 12a and 12b. That is, by using the mat tip end portion tilting mechanisms 41a and 41b, the tip end portions 12a and 12b of the mat 12 can be surely aligned with the catalyst carrier 11.

  When the leading end portions 12a and 12b of the mat 12 are tilted by the mat leading end portion tilting mechanisms 41a and 41b, the mat end portions are moved back while the rods 45a and 45b of the mat leading end portion tilting mechanisms 41a and 41b are retracted as shown in FIG. The holding mechanism 51 is lowered toward the tip portions 12 a and 12 b of the mat 12.

The mat end pressing mechanism 51 includes a moving rod 52 that moves up and down toward the leading ends 12a and 12b of the mat 12, and a bending plate 53 that is fixed to the leading end of the moving rod 52 and presses the leading ends 12a and 12b of the mat 12. Become.
The pressing surface 53a of the bending plate 53 has a shape along the mat 12 wound around the catalyst carrier 11 so that the front end portions 12a and 12b of the mat 12 can be pressed.

As shown in (d), the bending plate 53 is lowered before the front end portions 12a and 12b of the mat 12 are returned, and the front end portions 12a and 12b of the mat 12 are pressed by the pressing surface 53a.
For example, the time from when the rods 45a and 45b are retracted to when the tips 12a and 12b of the mat 12 are returned can be derived by experiments. After deriving the time for the leading ends 12a and 12b of the mat 12 to return, the bending plate 53 is lowered at a timing sufficiently earlier than the leading ends 12a and 12b of the mat 12 return.
After the mat 12 is wound around the catalyst carrier 11, the mat 12 is temporarily compressed. Details will be described in the following figures.

As shown in FIG. 5 (a), when the mat 12 is wound around the catalyst carrier 11, the left and right guide rods (FIG. 4 (d), reference numerals 36, 37) with the front end portions 12a, 12b of the mat 12 being pressed. Then, the mat tip end tilting mechanism (FIG. 4D, reference numeral 41) is retracted.
Note that the diameter of the mat 12 wound around the catalyst carrier 11 at this time is D0.

  Next, as shown in (b), the mat 12 is wound in a state where the catalyst carrier 11 is held by the catalyst holding mechanism 21 and the end portions 12a and 12b of the mat 12 are pressed by the mat end pressing mechanism 51. The catalyst carrier 11 is moved toward the first mold 56.

After moving to the first mold 56, the catalyst carrier 11 and the mat 12 are set in the first mold 56 as shown in FIG.
The curvature radius r1 of the first die 56 is smaller than the radius r2 of the mat 12 wound around the catalyst carrier 11. The mat 12 is temporarily compressed by fitting into a mold having a radius of curvature r1 smaller than the radius r2 of the mat 12. Details are described in the following figure.

6A, after the catalyst carrier 11 and the mat 12 are set, the second die 57 is advanced toward the outer periphery of the mat 12, and the third die 58 is moved in the outer periphery of the mat 12. Move forward toward.
As shown in (b), as the second and third molds 57 and 58 move forward, the mat end pressing mechanism 51 rises and the catalyst holding mechanism 21 moves backward (moves in the front-rear direction of the drawing). .

As shown in (c), the second and third molds 57 and 58 are advanced to a position where they come into contact with the first mold 56. The second and third molds 57 and 58 are also brought into contact with each other. The mat 12 is temporarily compressed by the first to third molds 56, 57 and 58.
A temporary compression mold 59 for temporarily compressing the mat 12 is a three-part mold composed of first to third molds 56, 57 and 58.

  By temporarily compressing, the diameter of the mat 12 wound around the catalyst carrier 11 becomes D1. That is, D1 = 2 · r1. The temporarily compressed mat 12 is finally compressed and inserted into the case member (FIG. 1, reference numeral 13). Details will be described in the following figures.

As shown in FIG. 7A, the second and third molds 57 and 58 are retracted after the temporary compression.
When the second and third dies 57 and 58 are retracted, the first die 56 is moved toward the taper jig 60 for main compression as shown in FIG.
Details of the taper jig 60 will be described in the next figure.

  As shown in FIG. 8A, when the case member 13 is viewed from the axial direction of the catalyst carrier, the first die 56 is moved to a position overlapping the taper jig 60. That is, the first die 56 is moved so that the case member 13, the taper jig 60, and the catalyst carrier on which the mat is wound are positioned on the same axis.

  As shown in (b), which is a sectional view taken along the line bb of (a), the taper jig 60 has an inlet 61 having a diameter (inner diameter) D2 larger than the diameter (outer diameter) D1 of the temporarily compressed mat 12. And an outlet 62 having a smaller diameter (inner diameter) D3 than the diameter D1 of the temporarily compressed mat 12, and a fitting portion 63 provided integrally with the outlet 62 and into which the case member 13 is fitted.

A surface connecting the inlet 61 to the outlet 62 is a tapered surface 64 that gradually decreases in diameter from the inlet 61 toward the outlet 62.
The inner diameter D4 of the case member 13 is larger than the diameter D3 of the outlet 62 of the taper jig 60.

A catalyst charging device 66 for extruding the catalyst carrier 11 wound with the mat 12 toward the taper jig 60 is disposed so as to face the inlet 61 of the taper jig 60.
It is desirable to use an air cylinder for the catalyst charging device 66. Since air, which is a compressible fluid, is used as power, air is compressed when a predetermined resistance is applied. By compressing the air, it is possible to prevent excessive movement of the cylinder. When the catalyst carrier 11 and the mat 12 are put into the taper jig 60, the catalyst carrier 11 is prevented from being pushed to the outlet 62 side more than necessary.

A stopper device 67 for the catalyst carrier 11 is provided so as to overlap the end of the case member 13 in a cross-sectional view. When the catalyst carrier 11 is pushed into the case member 13, the catalyst carrier 11 can be prevented from protruding due to being pushed too much. It is desirable to use a hydraulic cylinder for the stopper device. This is because it is desirable to use an incompressible fluid as power in order to prevent the protrusion.
Details of the insertion of the catalyst carrier 11 and the mat 12, the main compression, and the insertion into the case member 13 will be described with reference to the following drawings.

As shown in FIG. 9A, the catalyst charging device 66 is operated, and the catalyst carrier 11 around which the mat 12 is wound is loaded into the taper jig 60.
When the catalyst carrier 11 and the mat 12 are loaded, the catalyst loading device 66 and the first mold 56 are moved backward as shown in FIG.

After the catalyst charging device 66 and the first die 56 are retracted, the catalyst pushing device 68 is lowered as shown in FIG.
The catalyst pushing device 68 is a device for pushing the catalyst carrier 11 and the mat 12 toward the outlet 62 and inserting the catalyst carrier 11 and the mat 12 into the case member 13.
The catalyst pushing device 68 is desirably a servo cylinder.

  By operating the catalyst pushing device 68, the catalyst carrier 11 and the mat 12 are pushed toward the outlet 62 as shown in FIG. By passing through the outlet 62, the catalyst carrier 11 and the mat 12 are inserted into the case member 13.

  The diameter is gradually reduced from the inlet 61 toward the outlet 62. The mat 12 is compressed by gradually narrowing the gap between the outer peripheral surface of the catalyst carrier 11 and the tapered surface 64. The compression at the tapered surface 64 of the taper jig 60 is the main compression.

The diameter of the outlet 62 of the taper jig 60 (FIG. 8D, symbol D3) is smaller than the inner diameter of the case member 13 (FIG. 8D, symbol D4). Since the diameter of the outlet 62 of the taper jig 60 is small, the catalyst carrier 11 and the mat 12 can be easily inserted into the case member 13.
The catalyst carrier 11 and the mat 12 are pushed by the catalyst pushing device 68 until the end on the inlet 61 side of the catalyst carrier 11 is accommodated in the case member 13. Details will be described in the next figure.

As shown in FIG. 10, the catalyst carrier 11 and the mat 12 are inserted into the case member 13, and after a while, the compressed mat 12 is restored. The mat 12 is restored and the catalyst carrier 11 is held by frictional force with the mat 12, whereby the catalyst device 70 is completed.
Details of the effect of the manufacturing method of the catalyst device 70 will be described with reference to the following drawings.

In the manufacturing method according to the comparative example shown in FIG. 11 (a), the mat 112 (diameter D5) wound around the catalyst carrier 111 is compressed by a thickness of 2 · a using only the taper jig 110 to obtain the diameter D7. To do. That is, D5-2 · a = D7.
The taper angle of the taper jig 110 needs to be θ2 so that the load applied to the catalyst carrier 111 and the mat 112 does not become excessive. In order to compress the thickness 2 · a with the taper jig 110 having the taper angle θ2, the length of the taper jig 110 needs to be L2. Moreover, the height of the taper jig | tool 110 becomes h2 by making the diameter of an entrance larger than D5.

In the manufacturing method according to the embodiment shown in (b), the mat 12 having a diameter D5 is temporarily compressed by a thickness of 2 · b to a diameter D6, and then compressed by 2 · c using a taper jig 60, The diameter is D7. That is, D5-2 · b = D6, D6-2 · c = D7.
Note that b + c = a and the mat 12 having the diameter D5 is finally compressed to the diameter D7 in the same manner as the comparative example. The taper angle is the same at θ2.

  Since c <a and the amount compressed by the taper jig 60 is smaller than that of the comparative example, the overall length L3 of the taper jig 60 can be made shorter than that of the taper jig according to the comparative example. Further, since the diameter of the inlet only needs to be larger than D6, the height h3 of the taper jig 60 can be reduced. That is, the taper jig 60 can be downsized.

In other words, it can be said as follows.
The temporarily compressed mat 12 is put into the taper jig 60.
If the inclination angle θ2 of the taper surface 64 of the taper jig 60 is constant, the length L3 of the taper jig 60 is proportional to the diameter reduction amount of the mat 12.
In the present invention, since the mat 12 is temporarily compressed, the diameter reduction amount of the mat 12 in the taper jig 60 is reduced. Since the diameter reduction amount of the mat 12 is small, the taper jig 60 can be shortened, and the taper jig 60 can be downsized. It is not necessary to increase the angle of the tapered surface 64 in order to reduce the size of the taper jig 60. That is, the taper jig 60 can be reduced in size while preventing the mat 12 from peeling off.

  Although the catalyst carrier and the mat are inserted into the taper jig and the catalyst carrier and the mat are pushed into the taper jig using separate devices, for example, the catalyst is pushed in from the time when the taper jig is loaded. An apparatus can also be used. That is, the present invention is not limited to the case of using separate devices.

  The method for manufacturing a catalyst device of the present invention is suitable for manufacturing a vehicle catalyst device.

  DESCRIPTION OF SYMBOLS 11 ... Catalyst carrier, 12 ... Matt, 13 ... Case member, 60 ... Taper jig | tool, 61 ... Inlet, 62 ... Outlet, 70 ... Catalyst apparatus.

Claims (1)

In the manufacturing method of the catalyst device in which the catalyst carrier and the mat are inserted into the case member,
Preparing the columnar catalyst carrier, the belt-like mat, and the cylindrical case member;
Contacting the longitudinal center of the mat with the lower end of the catalyst carrier;
Causing two guide rods for winding the mat around the catalyst carrier to face below the mat;
Winding the mat around the catalyst carrier by moving the two guide rods along the left and right sides of the outer peripheral surface of the catalyst carrier;
Tilting each of the front ends of the mat along the catalyst support by a mat front end tilting mechanism while keeping the guide rod following the outer peripheral surface of the catalyst support;
Lowering the mat end pressing mechanism for pressing the front end of the mat toward the front end of the mat while retreating the mat front end tilting mechanism;
Before the leading edge of the mat returns, the leading edge of the mat is moved by a bending plate having a pressing surface formed along the mat in a state of being wound around the catalyst carrier. The process of holding,
Retreating the guide rod and the mat tip end tilting mechanism in a state where the tip end portion of the mat is pressed by the bending plate;
Moving the catalyst carrier on which the mat is wound to a mold for temporarily compressing the mat in a state where the leading end of the mat is pressed by the mat end pressing mechanism;
Pressing the mat toward the axis of the catalyst carrier from the entire circumference of the mat wound around the catalyst carrier, and temporarily compressing the mat;
A step of introducing the catalyst carrier on which the mat is wound into a taper jig having an inlet having a diameter larger than the outer diameter of the temporarily compressed mat and reducing the diameter from the inlet toward the outlet;
The catalyst carrier put in the taper jig is pushed toward the outlet having a diameter smaller than the outer diameter of the temporarily compressed mat, thereby main compressing the temporarily compressed mat,
And inserting the catalyst carrier around which the mat is wound into the case member disposed at the outlet of the taper jig,
In the step of temporarily compressing, a die for temporarily compressing the mat and retreating the bending plate with respect to the front end portion of the mat positioned directly above the catalyst carrier, A method for manufacturing a catalyst device, wherein the catalyst carrier is advanced from obliquely above .

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