JP2006239580A - Method for manufacturing metallic carrier - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing a metallic carrier, which comprises the steps of manufacturing a core part having high dimensional accuracy while detecting the time when the winding work of the core part is completed by a simple method without using an advanced arithmetic circuit and press-injecting the manufactured core part into an outer cylinder without enlarging the outer cylinder while leaving no space between the core part and the outer cylinder. <P>SOLUTION: The method for manufacturing the metallic carrier comprises the steps of: manufacturing the core part 4 having a honeycomb structure by winding a long flat plate 1 and a long corrugated plate 2 around a winding core 3 while superimposing the flat plate on the corrugated plate; press-injecting the manufactured core part 4 into the outer cylinder; and joining/integrating the injected core part to/with the outer cylinder. A marker 6 and a mark detector 7 are arranged respectively at a start point and an end point the distance between which is one-fourth length obtained by equally quartering the final peripheral length when the winding work of the core part 4 is completed. A mark 10 is put on the flat plate 1 by the marker 6. The mark 10 is detected by the mark detector 7. A winding angle of the flat plate to the winding core 3 is measured when the mark is detected. When the measured winding angle is smaller than 90°, the winding work is completed. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a method for producing a metal carrier.

  The metal carrier is wound around the core with a flat plate and corrugated plate, and when the circumference of the wound core reaches the final circumference, the winding operation is completed, and then the core is press-fitted into the outer cylinder. It is manufactured by brazing or diffusion bonding and integrating them.

  By the way, if the core part is larger than the outer cylinder, the core part cannot be inserted into the outer cylinder, and if the core part is too small than the outer cylinder, poor contact with the outer cylinder occurs, and Insufficient strength.

  Thus, since the final circumference of a core part has big influence on productivity, the method of controlling the final circumference of the core part is proposed conventionally (for example, refer to patent documents 1).

  The method described in Patent Document 1 counts the number of crests of the corrugated material to be moved at each start timing determined in accordance with a set rotation angle determined by dividing the circumference of the core portion into a plurality of parts, Corrugated sheet crest / set rotation angle is calculated corresponding to the start timing, and corrugated sheet crest / setting rotation angle is multiplied by the corrugated sheet pitch corresponding to each start timing. The virtual circumference variable of the core part is calculated by converting to one round, and when the virtual circumference variable of the core part corresponding to each start timing becomes the same as the set circumference of the core part, the corrugated plate The material and the flat material are cut.

In short, the method described in Patent Document 1 is a method of summing up the lengths wound up at a constant rotation angle for the entire circumference, and ending the winding up when reaching a constant value.
Patent No. 3431040 (pages 4 to 7, FIG. 1, FIG. 3 and FIG. 4)

  However, the method described in Patent Document 1 requires an advanced arithmetic circuit that measures the length at a set angle and integrates the length each time. Therefore, the cost for manufacturing the metal carrier increases.

  Therefore, the present invention has been made in view of the above-described actual situation, and without requiring an advanced arithmetic circuit, a core with high product dimensional accuracy by detecting the end of the winding operation of the core portion by a simple method. An object of the present invention is to provide a method of manufacturing a metal carrier that can be press-fitted into an outer cylinder without producing a core portion and without making the core portion too large.

  The invention according to claim 1 is to manufacture a core part of a honeycomb structure by overlapping a long flat plate and a corrugated sheet and winding them around a winding core, and press-fitting the core part into an outer cylinder so as to be joined and integrated. In the metal carrier manufacturing method, a stamper and a stamp detector are installed at the start and end points of 1 / N length obtained by dividing the final circumference when the core portion is finished into N, and the stamper The flat plate is marked with a mark, the mark is detected by the marking detector, the winding angle of the core is measured at the time of detection, and the winding operation is performed when the winding angle is less than 360 degrees / N. It is characterized by terminating.

  The invention according to claim 2 is a method of manufacturing a core part of a honeycomb structure by overlapping a long flat plate and a corrugated sheet and winding them around a winding core, and press-fitting the core part into an outer cylinder so as to be joined and integrated. In the metal carrier manufacturing method, a length measuring device for measuring the feeding length of the flat plate is provided in the middle of feeding the flat plate to the winding core, and the final circumference when the winding of the core portion is finished is defined as N. The divided 1 / N length is measured with the length measuring device, the winding angle of the winding core during the length measurement is measured, and the winding operation is performed when the winding angle is less than 360 degrees / N. It is characterized by terminating.

  Invention of Claim 3 is a manufacturing method of the metal support | carrier of Claim 1 or Claim 2, Comprising: The circumference of the said core part winds up at high speed to about 95% of the said final circumference m. An operation is performed, and thereafter, the marking is performed by the marking device, or the length is measured by the length measuring device.

  According to the first aspect of the present invention, the stamper and the stamp detector are installed at the start point and the end point of the 1 / N length obtained by dividing the final circumference when the core portion has been wound into N, and the stamper The plate is engraved with a mark, the marking is detected by the marking detector, the winding angle of the winding core is measured at the time of detection, and the winding operation is finished when the winding angle is less than 360 degrees / N. By doing so, it is possible to always obtain the core portion having the final circumference.

  Therefore, according to the present invention, since the core portion can be manufactured without being longer or shorter than the final circumference, the core portion can be pressed into the outer cylinder without any gap, A sufficient bonding strength can be secured.

  According to the second aspect of the present invention, a length measuring device for measuring the feed length of the flat plate is provided in the middle of feeding the flat plate to the winding core, and the final circumference when the core portion is finished is divided into N Measure the 1 / N length with a length measuring instrument, measure the winding angle of the core during the measurement, and terminate the winding operation when the winding angle is less than 360 degrees / N. In this case, the core portion that is always the final circumference can be obtained.

  Therefore, according to the present invention, the core part can be manufactured without becoming longer or shorter than the final circumference, so that the core part can be press-fitted into the outer cylinder without a gap, and the joint between them can be produced. Sufficient strength can be secured.

  According to the invention described in claim 3, the core part is wound up at a high speed up to about 95% of the final circumference m, and then engraved with a stamp, or length measured with a length meter. Since it did it, the speed which manufactures a core part can be improved, and productivity can be improved.

  Hereinafter, specific embodiments to which the present invention is applied will be described in detail with reference to the drawings.

“First Embodiment”
FIG. 1 is a schematic view showing an example of a method for producing a cylindrical metal carrier, and FIG. 2 is a perspective view of a metal carrier obtained by press-fitting the produced core part into an outer cylinder and integrating them.

  To manufacture the metal carrier, first, as shown in FIG. 1, a long flat plate 1 supplied from one direction and a long corrugated plate 2 supplied from the other direction are overlapped to form a circle. A core portion 4 having a honeycomb structure is formed by winding around a columnar core 3.

  In order to form the core part 4, a core part manufacturing apparatus is used. The core part manufacturing apparatus includes a winding core 3, a winding angle detection means 5 that detects a winding angle of the winding core 3, and a stamp that marks the flat plate 1 at a stage before winding the flat plate 1 around the winding core 3. 6, a marking detector 7 for detecting the marking, and a flat plate cutting machine 8 and a corrugated sheet cutting machine for cutting the flat plate 1 and the corrugated plate 2 when the core portion 4 reaches the final circumferential length (product circumferential length). 9.

  The winding core 3 has a cylindrical shape with a predetermined diameter, and is driven to rotate by controlling its rotation speed by a stepping motor (not shown). A flat plate 1 and a corrugated plate 2 constituting the core portion 4 are wound around the surface of the core 3.

  The flat plate 1 and the corrugated plate 2 are made of a metal material constituting a metal carrier used in, for example, an automobile catalytic converter. The corrugated plate 2 is formed into a corrugated shape by corrugating a flat metal material.

  The winding angle detection means 5 detects the rotation angle of the winding core 3. The winding angle detection means 5 is composed of, for example, an encoder.

  The stamp 6 is provided before the flat plate 1 is wound around the core 3, and the stamp 10 is attached to the surface 1a of the flat plate 1. For example, a laser device, an ink application device, or a scratching device can be used as the marking device 6. When a laser device is used, the laser burns or a small hole becomes the marking 10. When the ink application device is used, the ink droplet becomes the stamp 10. When the scratch imparting device is used, the scratch becomes the stamp 10.

  The stamp detector 7 detects the stamp 10 attached to the surface 1 a of the flat plate 1 by the stamper 6. The stamp 6 and the stamp detector 7 are respectively installed at a start point and an end point of 1 / N length obtained by dividing the final circumference when the core portion 4 is wound into N parts. In the present embodiment, the marking device 6 and the marking detector 7 are placed at a position of a quarter length (hereinafter referred to as a quarter circumference) obtained by dividing the final circumference of the core portion 4 into four. Arranged respectively.

  In order to manufacture the core part 4 using this core part manufacturing apparatus, the flat plate 1 drawn out from one direction to the core 3 and the corrugated sheet drawn out from the other direction, which is the opposite direction, to the core 3. 2 is wound around the peripheral surface by rotating the winding core 3. Then, the flat plate 1 and the corrugated plate 2 are wound up at a high speed until the peripheral length of the core portion 4 is approximately 95% of the final peripheral length m.

  Thus, if the flat plate 1 and the corrugated plate 2 are wound around the core 3 at a high speed up to about 95% of the final circumferential length m, the manufacturing efficiency of the core portion 4 can be increased.

  Then, when the flat plate 1 and the corrugated plate 2 are wound around the core 3 to about 95% of the final circumference m, the stamp 10 marks the surface 1a of the flat plate 1 with the stamp 6. Next, the marking 10 is detected by a marking detector 7 provided at a position one quarter circumference away from the stamp 6. When the marking 10 is detected by the marking detector 7, the winding angle detection means 5 measures the winding angle of the core 3 at that time.

  When the winding angle detected by the winding angle detection means 5 becomes less than 360 degrees / 4 (90 degrees), the winding operation is terminated. That is, if the peripheral length of the core portion 4 is less than the final peripheral length, the winding angle exceeds 90 degrees even if the flat plate 1 is fed by a quarter peripheral length, but the peripheral length of the core portion 4 becomes the final peripheral length. When the winding angle is 90 degrees.

  Therefore, when the winding angle of the core 3 exceeds 90 degrees, the stamp 10 is again marked on the surface 1a of the flat plate 1 by the stamper 6 at the next quarter circumference. Then, the marking 10 is detected by a marking detector 7 provided at a position separated by a quarter circumference, and the winding angle of the winding core 3 at that time is measured by the winding angle detecting means 5. When it is detected that the winding angle is less than 90 degrees, the winding operation is terminated, the flat plate 1 is cut by the flat plate cutting machine 8, and the corrugated plate 2 is cut by the corrugated plate cutting machine 9.

  And after rotating the winding core 3 and winding up the flat plate 1 and the corrugated sheet 2 to a cut end surface, the core part 4 of the obtained honeycomb structure is press-fitted in the cylindrical outer cylinder 11 shown in FIG. Thereafter, the metal carrier 12 is completed by brazing or diffusion bonding the core portion 4 and the outer cylinder 11.

  As described above, according to the present embodiment, when the winding angle becomes less than 90 degrees, the core portion 4 always having the final circumference can be obtained by terminating the winding operation. Therefore, by adopting the method of the present invention, the core part 4 can be manufactured without becoming longer or shorter than the final circumference, and the core part 4 can be press-fitted into the outer cylinder 11 without a gap, A sufficient bonding strength between them can be ensured.

  Further, according to the present embodiment, since the winding angle detected by the winding angle detection means 5 is not calculated, the core portion 4 having the final circumference can be obtained reliably without using an advanced calculation circuit. And manufacturing costs can be greatly reduced.

  Further, according to the present embodiment, since the winding operation is performed at a high speed up to the peripheral length of the core portion 4 being approximately 95% of the final peripheral length m, the speed of manufacturing the core portion 4 can be improved. And increase productivity.

“Second Embodiment”
FIG. 3 is a schematic diagram showing an example of a manufacturing method of an elliptical metal carrier, FIG. 4 is an operation diagram showing a winding operation, and FIG. 5 is a metal carrier formed by press-fitting the manufactured core portion into an outer cylinder and joining them together. FIG.

  In 2nd Embodiment, the core part 14 is formed by making the winding core 13 into an ellipse shape, and winding the flat plate 1 and the corrugated sheet 2 on the elliptical winding core 3 so that it may overlap. The core portion 14 is different from the first embodiment in that the core portion 14 has an elliptical shape and the corrugated plate 2 is fed to the core 3 from the same direction as the flat plate 1. Since the other configuration is the same as that of the first embodiment, the same reference numerals are given and the description thereof is omitted.

  Even when the core 3 has an elliptical shape, as in the case where the core 3 has a cylindrical shape, the stamper 6 is marked at the start and end points of the 1 / N length obtained by dividing the final circumference of the core portion 14 into N. The stamp detector 7 is installed, the flat plate 1 is marked with the stamp 6 (not shown), the stamp is detected by the stamp detector 7, and the winding angle of the core 3 at the time of detection is measured. If the winding operation is performed when the winding angle is less than 360 degrees / N, the core portion 14 always having the final circumference can be obtained.

  Therefore, by adopting the method of the present invention, the core portion 14 can be manufactured without becoming longer or shorter than the final circumference, and the core portion 14 can be press-fitted into the outer cylinder 15 without a gap. The metal carrier 16 that can sufficiently secure the bonding strength between them can be manufactured.

  Further, even when the winding core 13 has an elliptical shape, as in the first embodiment, by performing the winding operation at a high speed up to about 95% of the final circumferential length of the core portion 4, The speed which manufactures the core part 4 can be improved, and productivity can be improved.

“Third Embodiment”
FIG. 6 is a schematic diagram showing an example in which a length measuring device measures the 1 / N length obtained by dividing the final circumference when the core portion is wound into N parts.

  In the first and second embodiments, the 1 / N circumference is detected using the stamp 6 and the stamp detector 7, but in the third embodiment, the plate 1 is sandwiched up and down. The 1 / N circumference is measured with a pair of roll-shaped length measuring devices 17 provided.

  In the third embodiment, as in the first and second embodiments, the length measuring device is obtained by calculating the 1 / N length obtained by dividing the final circumference when the core portions 4 and 14 are wound into N by N. The length is measured at 17, and the winding angle of the winding cores 3 and 13 at the time of the measurement is measured. When the winding angle is less than 360 degrees / N, the winding operation is finished.

  In this way, it is possible to obtain the core portions 4 and 14 that always have the final circumference, and the core portions 4 and 14 having high dimensional accuracy can be press-fitted into the outer cylinders 11 and 15 without gaps, It is possible to ensure a sufficient bonding strength between the two.

It is the schematic which shows an example of the manufacturing method of the metal carrier made into the cylindrical shape. It is a perspective view of the metal carrier formed by press-fitting the manufactured core part into the outer cylinder and joining and integrating them. It is the schematic which shows an example of the manufacturing method of the metal carrier made into the ellipse shape. It is an operation | movement figure which shows winding-up operation | movement. It is a perspective view of the metal carrier formed by press-fitting the manufactured core part into the outer cylinder and joining and integrating them. It is the schematic which shows the example which measures the 1 / N length which divided the final circumference at the time of finishing a core part into N with a length measuring device.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Flat plate 2 ... Corrugated sheet 3, 13 ... Core core 4, 14 ... Core part 5 ... Winding angle detection means 6 ... Stamping machine 7 ... Stamping detector 8 ... Flat plate cutting machine 9 ... Corrugated sheet cutting machine 10 ... Stamping 11, 15 ... outer cylinder 12, 16 ... metal carrier

Claims (3)

In the manufacturing method of a metal carrier formed by stacking a long flat plate and a corrugated sheet to be wound around a core to produce a core part of a honeycomb structure, and press-fitting the core part into an outer cylinder and joining and integrating them,
A stamper and a stamp detector are installed at the start point and end point of 1 / N length obtained by dividing the final circumference when the core portion is wound into N,
When the plate is marked with the stamp, the stamp is detected by the stamp detector, the winding angle of the core at the time of detection is measured, and when the winding angle is less than 360 degrees / N A method for manufacturing a metal carrier, characterized in that the winding operation is terminated. In the manufacturing method of a metal carrier formed by stacking a long flat plate and a corrugated sheet to be wound around a core to produce a core part of a honeycomb structure, and press-fitting the core part into an outer cylinder and joining and integrating them,
In the middle of feeding the flat plate to the core, a length measuring device for measuring the feed length of the flat plate is provided,
The 1 / N length obtained by dividing the final circumference when the core portion is finished into N is measured with the length measuring device, and the winding angle of the winding core at the time of the measurement is measured. The metal carrier manufacturing method is characterized in that the hoisting operation is terminated when the angle becomes less than 360 degrees / N. It is a manufacturing method of the metal carrier according to claim 1 or 2,
The circumference of the core part is wound up at a high speed to approximately 95% of the final circumference m, and then engraved with the stamp or length measured with the length measuring device. A method for producing a metal carrier.

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