Patent Application
20080028609
1. Field of the Invention
The present invention relates to a hollow member, a manufacturing method thereof, a fluid distribution system using the hollow member, and a forming apparatus of a hollow material.
2. Description of Related Art
A fluid distribution system for distributing a specific gas and changing its composition in the process of distribution is widely employed in various technical fields. By way of example, in a combustion engine such as an internal-combustion engine, an exhaust pipe for discharging exhaust gas into the atmosphere composes a fluid distribution system for purifying in the exhaust gas.
The exhaust pipe is connected to a catalytic converter for removing harmful matter contained in the exhaust gas. The catalytic converter is provided with a catalyst carrier in a catalyst container. As shown in
In a conventional art for manufacturing a catalytic converter comprising a catalyst container 101 in a shape having a single junction 101b at both ends and a catalyst carrier 2, as shown in
In such a manufacturing method, however, a high degree of control with respect to welding quality is required in order to maintain good airtightness at the butting portion of the members. To solve such problems, a manufacturing method as shown in
This manufacturing method will be briefly explained. First, as shown in
Further, for example, in order to form a hollow material for use in a housing of a silencer, as disclosed in Japanese Patent Application Laid-Open No. 11-324637, it is known that a square plate member is bent in a substantially cylindrical shape, and mutually opposing axial sides are overlaid and joined by mush seam welding between roller electrodes.
The hollow member used in a fluid distribution system or the like, in particular, the catalyst container of the catalytic converter for an internal-combustion engine of a vehicle, is required to be reduced in weight for the purpose of improving fuel economy. Also, to suppress generation of radiant noise or the like, it is desirable to form respective components of a hollow member such as the catalyst carrier installation portion 101a, junction 101b, cone portion 101c (see
However, the manufacturing method shown in
As shown in the graph in
One conceivable method for solving such problems is to increase the plate thickness of the hollow material WJ3 before the spinning process in consideration of loss of thickness so that the plate thickness may be t0 after thickness loss. With such measure, however, the plate thickness of the entire catalyst container is increased more than necessary and the weight of the catalyst container is increased.
Such problems similarly occur when spinning the hollow material formed as disclosed in Japanese Patent Application Laid-Open No. 11-324637. Further, when manufacturing a catalytic converter by using a hollow material formed as disclosed in Japanese Patent Application Laid-Open No. 11-324637, the catalyst carrier is inserted and installed in the hollow member as the catalyst container. In the inside of the hollow member, a mat is generally wound around. However, when the roundness is disturbed due to a step or the like formed in the peripheral direction of the junction of the hollow member, the fluid of exhaust gas or the like which needs to be treated may leak through the step without passing through the catalyst carrier. Further, there is a problem that the appearance of the product is poor when such a step is formed outside of the hollow member.
On the other hand, in the case of forming a hollow material by joining material plates to form a plate member and bending the plate member and joining the opposing sides, a mush seam welding machine for joining plate members, and another mush seam welding machine for joining the opposing sides of the bent plate member are provided individually, and there is a problem that the equipment for forming such a hollow material becomes large, and the manufacturing cost cannot be reduced.
In light of the foregoing problems, it is one object of the invention to facilitate control of plate thickness and control of shape when manufacturing a hollow member, for example, a container of a catalytic converter used in an exhaust pipe of a combustion engine. It is a further object to provide an apparatus for stably supplying a hollow member having good airtightness, and a fluid distribution system using such a hollow member, and also forming the hollow material easily (the relation between a hollow member and hollow material will be described in detail in “Description of the Preferred Embodiment”), by decreasing adverse effects of a hollow member due to insufficient control of plate thickness and a fluid distribution system using such a hollow member (by way of example, in a catalyst container, radiant noise increases due to exhaust resistance in the case of a decrease of plate thickness, or the weight of catalyst container increases in the case of an increase of plate thickness).
To solve the problems described above, a catalyst container having a sectional shape that is changed by a spinning process is provided. The container includes a hollow material formed from a plate member that is partially different in plate thickness or material, wherein the plate member that is partially different in plate thickness or material is formed by joining individual material plates that are different in plate thickness or material by mush seam welding, and the hollow material is formed by bending the plate member and joining the plate member in the axial direction by mush seam welding.
Using such a hollow member, in order that the characteristics of each part of the hollow material may be most suited to a spinning process when changing the sectional shape by a spinning process, the hollow material is integrally formed of plate materials that are partially different in plate thickness or material.
Mush seam welding (also known as “mush-room welding”) is a type of resistance welding, and a method in which two material plates such as steel plates are overlaid slightly at the edges at a specific width and the overlapped portions are pressed and energized from upper and lower portions by circular revolving electrodes, and the work is relatively moved to weld continuously. A high welding strength and sealing effect can be obtained, and as a result of the press of the overlapped portions, the thickness of the overlapped portions can be smaller than the sum of the plate thicknesses of two material plates such as steel plates before welding. Therefore, by joining individual plates different in thickness or material by mush seam welding, a plate member with flat junctions and high welding strength can be obtained. Further, such mush seam welding may be also applied in the joining of mutually opposing axial side ends of plate materials when forming a hollow member with a bending plate member so that a hollow material of flat junctions may be formed without sacrificing welding strength or the like at the junctions.
The aforementioned object may further be achieved, for example, by a manufacturing method of a catalyst container comprising the steps of: bending a plate member that is partially different in plate thickness or material to form the hollow material, wherein the plate member that is partially different in plate thickness or material is formed by joining material plates that are a different in plate thickness or material by mush seam welding, and the hollow material is formed by bending the plate member and joining opposing sides thereof by mush seam welding; and changing the sectional shape of the hollow material by a spinning process.
In this invention, by forming plate members that are partially different in plate thickness or material, the characteristics of each part of the hollow material can be most suited to a spinning process by which the sectional shape of the hollow member integrated by bending and forming the plate members shown below is changed.
According to the manufacturing method, the plate members that are partially different in plate thickness or material are formed by joining a plurality of plates that are different in plate thickness or material by mush seam welding, and the hollow material is formed by bending the plate members and joining the opposing sides by mush seam welding.
According to a further aspect of the invention, the manufacturing method of the hollow member is characterized in that plate members that are partially different in plate thickness or material are formed by joining a plurality of plates that are different in plate thickness or material by mush seam welding, and the hollow material is formed by bending the plate members and joining the opposing sides by mush seam welding.
As mentioned above, by mush seam welding, a high welding strength and sealing effect can be obtained, and as a result of the press of the overlapped portions, the thickness of the overlapped portions can be smaller than the sum of plate thicknesses of two material plates such as steel plates before welding. Therefore, by joining plates different in thickness or material by mush seam welding, plate members of flat and smooth junctions and high welding strength can be obtained. Such mush seam welding may be also applied in the joining of mutually opposing axial side ends of a plate material when a hollow material is formed by bending plate members, so that a hollow material of flat and smooth junctions may be formed without sacrificing welding strength or the like at the junctions.
The hollow member obtained by this manufacturing method is tightly closed with the insert inserted inside, and holds the inserts appropriately.
According to another aspect of the invention, a forming apparatus for forming a hollow material for a catalyst container by disposing individual material plates that are different in plate thickness or material between electrodes, joining the material plates mutually by mush seam welding to form a plate member that is partially different in plate thickness or material, bending the plate member, disposing mutually opposing axial sides of the plate member between electrodes, and joining the mutually opposing axial sides of the plate member together by mush seam welding is provided. The forming apparatus includes: a flat plate holding device for holding individual material plates that are different in plate thickness or material so as to join the material plates by mush seam welding; a bend forming device for bending the joined plate member; a bent plate holding device for holding the mutually opposing axial sides of the bent plate member so as to join the bent plate member by mush seam welding; a first electrode, being one electrode for mush seam welding provided in the flat plate holding device; a second electrode, being one electrode for mush seam welding provided in the bent plate holding device; a third electrode, being another common electrode for mush seam welding in collaboration with both the first and second electrodes, respectively; and a mush seam welding direction moving device for moving the flat plate holding device holding the plate member and the bent plate holding device relatively close to and away from the other electrode in the mush seam welding direction.
According to such a forming apparatus, a plurality of material plates that are different in plate thickness or material are held by overlaying the junction sides by the flat plate member holding device, and are relatively moved in the mush seam welding direction with respect to the third electrode by the mush seam welding direction moving device. The mutually overlaid junction sides of the plate materials are continuously welded and joined while being squeezed between the first electrode and third electrode for mush seam welding provided in the flat plate member holding device, and plate members that are partially different in plate thickness or material are formed. The joined plate members are bent by the bend forming device, and held by overlaying the mutually opposing axial sides by the bent plate member holding means, and move relatively in the mush seam welding direction with respect to the third electrode by the mush seam welding direction moving device. The mutually opposing axial junction sides of the bent plate members are continuously welded and joined, being squeezed between the second electrode and third electrode for mush seam welding provided in the mush seam welding direction moving device so that the hollow material of high joining strength partially different in plate thickness or material is formed integrally. Since the other electrode (third electrode) of a pair of electrodes for mush seam welding is commonly used in the joining of material plates and in the joining of axial sides of bent plate members, and the forming apparatus of a hollow material is reduced in size.
Moreover, the fluid distribution system, being a system in which a fluid is distributed inside, including the above-described catalyst container, is provided.
By containing such a container, a fluid distribution system optimum in rigidity, durability, shape or properties may be constituted.
The above and other objects, features, advantages, and technical and industrial significance of this invention will be better understood by reading the following detailed description of exemplary embodiments of the invention, when considered in connection with the accompanying drawings, in which:
FIGS. 2(a)-2(b) are essential sectional views of the catalyst container according to the embodiment of the invention;
FIGS. 6(a)-6(b) are schematic views showing a mush seam welding apparatus used in the embodiment of the invention;
FIGS. 8(a)-8(d) are process charts showing a procedure of manufacturing a catalytic converter by a spinning process from a circular flat work;
FIGS. 9(a)-9(e) are process charts showing another procedure of manufacturing a catalytic converter by a spinning process from a circular flat work;
FIGS. 10(a)-10(e) are explanatory diagrams showing types of shapes of catalyst containers obtained by the manufacturing procedures shown in
FIGS. 11(a)-11(e) are process charts showing still another procedure of manufacturing a catalytic converter by a spinning process from a circular flat work;
FIGS. 19(a)-19(c) are explanatory diagrams showing a mode of forming plate members by mush seam welding after chamfering junction sides of material plates;
FIGS. 20(a)-20(c) are explanatory diagrams showing a mode of positioning side edges by rolling and bending the formed plate members by bend forming means;
FIGS. 24(a)-24(b) are cross sectional plan views of clamp members provided with junction side overlaying means, for explaining a mode of pressing of one junction side of plate members;
FIGS. 25(a)-25(b) are explanatory diagrams showing the center of the press of electrodes to apply pressure to side edges of overlaid plate members, and the portions joined by mush seam welding;
FIGS. 26(a)-26(d) are explanatory diagrams showing an example of process for manufacturing a catalytic converter having junction and cone portion disposed at both ends in the conventional art;
FIGS. 27(a)-27(f) are explanatory diagrams showing another example of process for manufacturing a catalytic converter having junction and cone portion disposed at both ends in the conventional art;
In the following description and the accompanying drawings, the present invention will be described in more detail in terms of preferred embodiments.
An embodiment of the invention will be explained below according to the accompanying drawings, in which the fluid distribution system is an exhaust system for purifying the exhaust gas of a combustion engine such as an internal-combustion engine, and the hollow member is a catalyst container 1 of a catalytic converter for holding a catalyst carrier inside. Herein, the same parts as in the conventional art are identified with same reference numerals and detailed description is omitted. In this explanation, a cylindrical member in the process is called a “hollow material”, and a changed cylindrical member being drawn in the sectional shape after completion of the spinning process for forming the hollow material into a predetermined shape is called a “hollow member”.
In the embodiment of the invention, considering deformation by a spinning process, a hollow material W is formed from plate materials in which the plate thickness or material is partially changed, the sectional shape of the hollow material W formed from the plate materials is changed by the spinning process, and the catalyst container 1 of a predetermined shape is formed as a hollow member. Specifically, the plate thickness of the parts a and c of the junction 1b and cone portion 1c positioned at both ends of the catalyst container 1 of the hollow material W before the spinning process is t0, just as in the conventional art, but the plate thickness of the part b at the central catalyst installation portion 1a is t0′, being about 30% smaller than to (see
The plate thickness of each part of the hollow material W after a spinning process is unchanged at plate thickness t0′ (about 30% less than t0) in the part b at the catalyst installation portion 1a and is constant as shown in the graph in
Incidentally, the catalyst installation portion 1a of the catalyst container 1 is not required to be processed by a spinning process to deform the part b largely because the hollow material W is formed in a diameter the same as or slightly smaller than that of the catalyst installation portion 1a, and it is hardly necessary to consider plate thickness changes due to the spinning process, and further, since the shape is held by the catalyst carrier 2, there is no effect of lowering strength by reduction of the thickness t0′. Thus, in the portions free from the effects of lowering strength by reduction of the thickness by a spinning process, by decreasing the thickness beforehand, a reduction of weight of the catalyst container 1 may be promoted.
Further, as shown in
That is, by slightly increasing the thickness only in the portion reduced in wall thickness by a spinning process beforehand, the rigidity of the catalyst container 1 is maintained, and the capability of decreasing the radiant noise due to exhaust resistance can be sufficiently retained. By such an increase in wall thickness, the material rigidity in the spinning process is enhanced, and the forming speed is increased to enhance the efficiency, and the roundness of the catalyst container 1 can be improved at the same time.
Herein, the forming procedure of the hollow material W in which the plate thickness or material is partially changed, and the procedure of forming the catalyst container 1 in a desired shape by performing a spinning process after inserting the catalyst carrier 2 into the hollow material W are explained while referring to
Step (1): As shown in
Step (2): As shown in
Step (3): The plate member W is rolled and bent, and mutually opposing axial side edges Wa are slightly overlaid at a specific width in the axial direction (see
Step (4): Mutually overlaid portions are joined in the axial direction by mush seam welding, and a hollow material W can be obtained (see
Step (5): To enhance the roundness of the hollow material, an operation of expanding the diameter of the hollow material W is performed by a spinning process or the like (see
Step (6): Leak inspection is performed as required at the respective junctions of mush seam welding (see
Step (7): A catalyst carrier 2 (an insert) such as a monolith is inserted and installed in the hollow material W (see
Step (8): One end is contracted by a spinning process or the like, and a cone portion 1c and a single junction 1b are formed (see
Step (9): The other end is similarly contracted by a spinning process or the like, and a cone portion 1c and a single junction 1b are formed. At this point, the catalyst carrier 2 is positioned with both ends in the axial direction (see
Step (10): The end of the junction 1b is cut to a predetermined length (see
Step (11): Leak inspection is performed as required, and a catalytic converter having the catalyst 2 installed inside the catalyst container 1 can be obtained (see
As an applied example of the method shown in
Step (i): Three different material plates W2, W4, and W5 are prepared. Material plates W2 and W4 are the same in thickness, but material plate W5 is thicker than material plates W2 and W4 (see
Step (ii): The respective material plates W2, W4, and W5 are joined by mush seam welding, and a plate member W0′ partially different in plate thickness is formed. In the invention, the mush seam welding for forming the plate member W0′ is used for joining not only the peripheral sides of the hollow material W as mentioned above, but also the axial sides (see
Step (iii): The plate member W0′ is rolled and bent, and mutually opposing axial side edges Wa′ are slightly overlaid in a specified width in the axial direction (see
Step (iv): The overlaid portions are joined in the axial direction by mush seam welding, and the hollow material W′ can be obtained (see
Step (v): To enhance the roundness of the hollow material, an operation of expanding the diameter of the hollow material W′ is performed by a spinning process or the like (see
Step (vi): Leak inspection is performed as required in the respective junctions of mush seam welding (see
Step (vii): A catalyst carrier 2 (an insert) such as a monolith is inserted and installed in the hollow material W′ (see
Step (viii): One end is contracted by a spinning process or the like, and a cone portion 1c′ and a single junction 1b′ are formed. At this time, since a thin part W4 has a lower rigidity than a thick part W5, as shown in the drawing, the cone portion 1c′ is eccentric in the direction of the thin part W4 before the spinning process, and the junction 1b is also formed eccentrically. As a result of the cone portion 1c′ being eccentric in the direction of the thin part W4 before the spinning process, the thick part W5 is increased in deformation and is reduced in thickness so as to be close to the thickness of the thin part W4. The subsequent process is same as shown in
Thus, by partially changing the plate thickness of the plate member W in the peripheral direction, the shape after a spinning process can be changed as required (eccentric, changed angle, etc.) while the applied force is kept constant in the peripheral direction at the time of the spinning process. That is, in the case of such eccentric, changed angle or the like, since the thickness of the part in the direction of the inside of bending is reduced due to a greater number of times of bending by roller for a spinning process, by increasing the plate thickness of this part at this time, a uniform thickness may be obtained on the whole.
A motor 17 is provided as the operating source for moving the hanger 13 by the linear guide 15, and the driving force of the motor 17 is transmitted to the hanger 13 through a ball screw 16. Further, a work chuck 14 is provided for fixing a rolled and bent plate member W0. Electric power from a power source 19 is supplied to the upper electrode 11 and lower electrode 12 through a transformer 18.
In the case of mush seam welding, first, the lower electrode 12 is moved to a position away from the upper electrode 11, and the rolled and bent plate member W0 is inserted into the lower electrode 12. The plate member W0 is fixed by the work chuck 14 so that the overlaid side edges Wa of the plate member W0 may contact with the upper surface of the lower electrode 12.
In succession, the hanger 13 is moved, and the upper electrode 11 is pushed to contact from one end in the axial direction of the plate member W0. While pressing and energizing the overlaid edges Wa of the plate member W0 between the upper electrode 11 and lower electrode 12, the plate member W0 is moved at a constant speed, thereby welding continuously. In
The operational effects obtained by the embodiment of the invention having such configuration are as follows. First, in the embodiment of the invention, since the plate member W0 for forming the hollow material W is formed to be partially different in plate thickness or material, the characteristics of the individual parts of the hollow material W, W′ may be adjusted to be most suited for the spinning process. Moreover, the thickness and shape of the hollow member obtained by spinning the hollow material (step (8) in
In the examples shown in
In the embodiment, the plate member W0 partially different in plate thickness or material is mainly explained, but the invention is not limited to this embodiment. In the catalytic converter shown in
As mentioned above, when the plate member W0 for forming the hollow material is made a plate member that is partially different in plate thickness, the rigidity of the plate can be controlled by changing the plate thickness in each part, and the shape obtained by spinning the hollow material can be optimized. Or when the plate member W0 for forming the hollow material W is made a plate member partially different in material, the rigidity and durability can be controlled by varying the material in each part. In any case, the shape obtained by spinning the hollow material may be optimized, and the quality of hollow member completed as a product can be optimized. When a plate member different in both plate thickness and material are combined, the merits of both members can be obtained. Thus, “plate members partially different plate in thickness or material” of the invention includes not only both members different in either plate thickness or material, but also members different in both plate thickness and material.
Further, as shown in
In the embodiment of the invention, by joining individual material plates different in plate thickness or material, W1, W2 and W3 (or W2, W4 and W5), mush seam welding is performed when forming a plate member W0 partially different in plate thickness or material (step (1) in
Moreover, since any junctions are joined by mush seam welding, when the catalyst container 1 is formed, no protrusion increasing the resistance of exhaust is formed inside the duct. Therefore, in spite of the technique of manufacturing the catalyst container by welding a plurality of material plates, the degree of closure is high, the exhaust resistance is low, and an appropriate strength is obtained at the proper parts.
By forming the cone 1c and a single junction 1b by contracting the diameter of the hollow material W by a spinning process (step (8) in
Owing to these reasons, the exhaust system of the internal-combustion engine having the catalytic converter according to the embodiment of the invention is characterized by light weight, high airtightness, high durability, low noise, and low exhaust resistance, and is hence extremely suitable as an exhaust treatment system of high efficiency loaded in a mobile body such as automobile, for example. When the intake system of the internal-combustion engine is composed by using a hollow member having a similar structure formed by the same procedure as in the embodiment of the invention, in the intake system, the same operational effect as when applied to the exhaust system can be obtained. That is, according to the embodiment of the invention, in the fluid distribution system of an internal-combustion engine including the intake system and exhaust system, the same operational effect can be obtained. In the embodiment of the invention, the diameter of the hollow material W is contracted by a spinning process, but depending on the shape of the required hollow member, the diameter can be expanded by the spinning process.
The catalytic converter and manufacturing method thereof according to the embodiment of the invention may be also applied to the catalytic converter and manufacturing method thereof disclosed by the present inventors in Japanese Patent Application No. 2000-101111. The manufacturing method of the catalytic converter is briefly explained below while referring to
In the method shown in
By forming the circular work W shown in
The method shown in
By forming the cylindrical work W shown in
The method shown in
Further, by forming the circular work W shown in
As described herein, the embodiment of the invention is suited to control plate thickness or control shape at a high precision in the case of manufacture of a hollow member having a necessary sectional shape by a spinning process.
An embodiment of the apparatus of the invention for forming a hollow material used in a hollow member or the like constituting the catalyst container 1 is specifically described below while referring to
As shown in
Further, in the forming apparatus of a hollow material of the invention, the bend forming means 25 includes a roll 28 positioned inside of the plate member W0 to be bent, extending in the axial direction of the hollow material W, and rotatably supported at one end, and also a free end support mechanism 29 for supporting, in which one electrode 23 for mush seam welding disposed in the bent plate holding means 26 is formed in the shape of a bar having one end fixed and supported, which is detachably engaged with at least one free end of the roll 28 of the bend forming means 25 and the bar-shaped electrode 23 of the bent plate holding means 26.
The forming apparatus of a hollow material of the invention further comprises chamfering means 30 for chamfering side edges Wa to be formed as junctions to join by mush seam welding, in which the bent plate holding means 26 includes junction side overlaying means 31 for overlaying mutually opposing axial sides (edges) Wa, Wa of the bent plate member W0 so as to join by mush seam welding, and inserting means 32 for inserting an insert such as catalyst carrier 2 inside of the formed hollow material W.
In the forming apparatus of a hollow material of the invention, a pair of guide rails 35, 35 are provided parallel on a base 33. At least at one side of the base 33, a ball screw shaft 34 is disposed as mush seam welding direction moving means 27 so as to extend parallel to the guide rail 35, and a ball screw nut 37 provided in a bracket 36 is engaged with the ball screw shaft 34, and a motor 38 is connected so as to control and rotate about the ball screw shaft 34. The bracket 36 is detachably connected as required either to the flat plate holding means 24 and bent plate holding means 26. Inside the base 33, the other electrode 21 for mush seam welding is elevatably supported by driving a cylinder 39. The electrode 21 is formed like a roller or disk, and is supported so that its side may be parallel to the guide rail 35, that is, the rotation central axis 21C may be nearly orthogonal to the guide rail 35.
The flat plate holding means 24 comprises, as shown in
In this embodiment, moreover, a support member 47 is disposed at one side edge of the frame 40, and a guide rail 48 is disposed on the top so as to be parallel to the side edges of the material plates W1, W2, W3 and the like held by the clamp 41. On the guide rail 48, a slider 50 is slidably mounted so as to be moved parallel (see arrow Y in
In the thus composed flat plate holding means 24, first as shown in
Next, by driving the cylinder 42, the movable member 41b of the clamp 41 is brought closer to the fixing member 41a so as to overlay the material plates W1, W2, W3 different in plate thickness at a specified width. Until this time, as shown in
By preliminarily chamfering the thicker material plates W1, W3 out of the material plates W1, W2, W3, a fused portion is formed near the boundary of the material plates W1 and W2, or W3 and W2, so that the material plates W1 and W2, or W3 and W2 can be mutually joined at a specified welding speed, and moreover since they are squeezed between the electrodes 22 and 21, junctions of the material plates W1 and W2, or W3 and W2 different in plate thickness can be formed smoothly.
When manufacturing the catalyst container 1 mentioned above, by chamfering the side edges of relatively thick material plates W1, W3, as shown in
Next, an embodiment of the bend forming means 25 in the forming apparatus of a hollow material of the invention will be explained mainly by referring to
The roll 28 is disposed so as to extend in the axial direction of the hollow material W to be formed, and the end at the opposite side of the bent plate holding means 26 is detachably supported on a rotary shaft (not shown) of a support bracket 57 provided on the base 33. The free end of the roll 28 is provided with a bearing 58 detachably engaged and supported to the free end support mechanism 29 (described later).
Both ends of the auxiliary rolls 52, 52 are rotatably supported so that the interval may be adjusted with respect to the roll 28 and/or each other depending on the size of the diameter of the hollow material W to be manufactured by manipulating a handle 59 (see
The guide plate 53 is bent in the peripheral direction depending on the diameter of the hollow material W to be manufactured, and one end thereof is supported by the support bracket 57.
The transmission mechanism 55 in this embodiment is composed by mounting pulleys 61, 62 on a rotary shaft supporting the roll 28 and a rotary shaft of the motor 54, and applying a belt 63 between the both pulleys 61, 62.
The opening position detecting means 56 is provided with a sensor 64 including a proximity switch disposed between the auxiliary rolls 52, 52, and a positioning member 60 provided elevatably as shown in FIGS. 20(a) to 20(c). The sensor 64, as shown in
As indicated by chain double-dashed line in
Next, an embodiment of the bent plate holding means 26 in the forming apparatus of the hollow material of the invention will be explained by referring mainly to
The engaging portion 67 for engaging so as to cut off the bent plate clamp portion 65 and electrode holding portion 66 includes, in the case of the embodiment shown in
The bent plate clamp portion 65 comprises a pair of clamp members 71, 71 for gripping the rolled and bent plate member W0, an actuator 72 such as cylinder for driving to open or close the clamp members 71, and a guide 73 for guiding the opening and closing action of the clamp members 71, and a frame 74 thereof is detachably provided with the bracket 36 of the mush seam welding direction moving means 27. On the other hand, the electrode holding portion 66 holds one end of the opposite side of the bend forming means 25 of the bar-shaped electrode 23 disposed to extend in the axial direction of the hollow material W. The bent plate clamp portion 65 comprises the roll 28 of the bend forming means 25, and the free end support mechanism 29 for supporting by detachably engaging with the free end of the bar-shaped electrode 23 of the electrode holding portion 66, and one of the clamp members 71 is provided with the junction side overlaying means 31 for laying the mutually opposing axial sides (side edges Wa) of the rolled and bent plate member W0 so as to join by mush seam welding. At the side end of the bend forming means 25 of the both clamp members 71, 71, a guide 75 (see
As shown in
The free end support mechanism 29 comprises, as shown in
In this embodiment, as shown in
When rolling and bending the plate member W0, as shown in
When the side edge of the rolled and bent plate member W0 is subjected to mush seam welding, the working rod 68a of the cylinder 68 of the engaging portion 67 is disengaged from the engaging hole 69a, and can be separated from the electrode holding portion 66, and only the bent plate clamp portion 65 is moved close to the bend forming means 25 by driving of the mush seam welding direction moving means 27, and the plate member W0 in a rolled, bent and positioned state is received, and the bent plate clamp portion 65 is brought again closer to the electrode holding portion 66 by driving of the mush seam welding direction moving means 27 to be engaged with the engaging portion 67, and the arm 82 is positioned at the support position so that the engaging member 82a is engaged with the engaging hole 23a of the electrode 23, as shown in
On the other hand, as shown in
The junction side overlaying means 31 in the embodiment shown in
In the junction side overlaying means 31 having such configuration, in the embodiment shown in
Next, using the bend forming means 25 and bent plate holding means 26 having such a configuration, the operation for forming the hollow material W from the plate member W0 will be explained.
When forming the hollow material W from the plate member W0, first as shown in
In this state, by rotating and driving the roll 28 by the motor 54 through the transmission mechanism 55, as shown in
Driving the motor 38 of the mush seam welding direction moving means 27, the bent plate holding means 26 is spaced from the bend forming means 25, and the bearing 58 provided at the free end of the roll 28 is released from the leading end fitting portion 82a of the arm 82, and by the retreat driving of the cylinder 80, the rotary shaft 79 is moved back so that the arm 82 may rotate by 90 degrees to move to the retreat position. The working rod 68a is released from the engaging hole 69a by the actuator 68 of the engaging portion 67, and the bent plate clamp portion 65 of the bent plate holding means 26 and the electrode holding portion 66 are separated, and only the bent plate clamp portion 65 of the bent plate holding means 26 is moved closer to the bend forming means 25. Release of the working rod 68a from the engaging hole 69a is detected by the detecting means 70. In succession, while keeping both clamp members 71 open, the motor 38 of the mush seam welding direction moving means 27 is driven, and only the bent plate clamp portion 65 of the bent plate holding means 26 is moved closer to the position where the clamp members 71 are adjacent to the rolled and bent plate member W0 of the bend forming means 25. Since being separated from the bent plate clamp portion 65, the electrode holding portion 66 does not move closer to the bend forming means 25 so that interference of the roll 28 and the bar-shaped electrode 23 can be avoided.
The clamp members 71 are driven so as to be closed by driving the cylinder 72. At this time, as mentioned above, by driving to retreat the working rod 87a of the actuator 87 of the junction side overlaying means 31, and projecting the pressing member 85 from the holding face 71a of one clamp member 71, one of the side edges (junction sides) Wa of the plate member W0 rolled and bent, and positioned by the positioning member 60 is securely pressed to the inside in the radial direction than the other side edge Wa so that collision of the ends of both side edges Wa can be avoided. Upon completion of holding of the rolled and bent plate member W0, by driving to extend the working rod 87a of the actuator 87, when the pressing members 85 are retreated from the holding faces 71a of the clamp members 71, since the side edges Wa in the axial direction are held by the clamp members 71 after being rolled and bent, and positioned by the positioning member 60, as shown in
When the clamp members 71 hold the rolled and bent plate member W0, the motor 38 of the mush seam welding direction moving means 27 is driven, and the bent plate clamp portion 65 is separated from the bend forming means 25, and is combined with the electrode holding portion 66 as shown in
Between the bar-shaped electrode 23 and roller-shaped electrode 21 disposed in the electrode holding portion 66 of the bent plate holding means 26, the electrode pressing force by the cylinder to the plate member, the current value to be energized, and welding speed by driving of motor 38 of the mush seam welding direction moving means can be appropriately controlled depending on the plate thickness of the side edges Wa of the plate member W0 to be joined, just as in the above case of forming the plate member W0 by joining material plates W1, W2, W3.
When joining by mush seam welding, the side edges Wa of the plate member W0 are pressed between the bar-shaped electrode 23 and roller-shaped electrode 21, and are moved to escape in the opening direction mutually. However, the escape of the side edges Wa is limited by the holding faces 71a forming a circle of the both clamp members 71, being pressed to the holding faces 71a so that the roundness of the formed hollow material W to be formed is enhanced. Moreover, since the preliminarily chamfered side edges are joined by mush seam welding, as shown in
Next, inserting means 32 for inserting an insert into the hollow material W formed by the forming apparatus of a hollow material of the invention will be explained mainly by referring to
The inserting means 32 comprises a guide 75 for supporting to guide the catalyst carrier 2, which is an insert to be detachably fitted to the end faces of the clamp members 71, into the hollow material W, a pressing member 88 disposed to advance on the base 33 and retreat in the base 33, and axial direction moving means (described later) for moving the clamp members 71 having the guide 75 attached and the pressing member 88 relatively in the axial direction.
In the embodiment shown in
The pressing member 88 is formed in an L-shape, and its vertical section is connected to an elevation driving actuator 89 comprising a cylinder or the like. The elevation driving actuator 89 lowers the pressing member 88 beneath the guide rail 35 of the base 33 so as not to interfere with the bent plate holding means 26 or flat plate holding means 24 moving on the base 33 by the mush seam welding direction moving means, and raises to advance onto the base 33 so as to be positioned coaxially with the catalyst carrier 2 supported by the guide 75 when inserting the catalyst carrier 2 into the formed hollow material W.
The axial direction moving means, in this embodiment, moves the catalyst carrier 2 supported by the guide 75 and the hollow material W held by the clamp members 71 in the axial direction with respect to the pressing member 88 raised on the base 33, and as mentioned above, the mush seam welding direction moving means 27 configured so as to move the bent plate holding means 26 in the axial direction functions as the axial direction moving means.
In the inserting means 32 thus configured, when inserting the catalyst carrier 2 into the formed hollow material W, by clearing the engaging portion 67 of the bent plate holding means 26 so that the bent plate clamp portion 65 may be separated from the electrode holding portion 66, the motor 38 of the mush seam welding direction moving means 27 is driven, and the bent plate clamp portion 65 is moved to the right in
In the forming apparatus of a hollow material of the invention, the roller-shaped electrode 21 can be used commonly for forming a plate member W partially different in thickness or material by joining material plates W1, W2, W3 different in plate thickness or material, and joining the mutually overlaid side edges Wa of the rolled and bent plate member W0, and the bar-shaped electrodes 22, 23 are moved together with the material plates W1, W2, W3, or side edges Wa of the plate member W0 with respect to the roller-shaped electrode 21, and therefore the apparatus is reduced in size and lowered in cost. Moreover, since the bar-shaped electrode 23 is used for joining of mutually overlaid side edges Wa of the rolled and bent plate member W0, even if manufacturing a hollow material W of a small diameter, the desired hollow material W can be integrally manufactured easily and reliably. Further, since the side edges (junction sides) Wa of the rolled and bent plate member W0 are joined by mush seam welding in a state held by holding faces 71a forming a circle of clamp members 71, a hollow material W of high roundness can be manufactured. A chamfered material plate W2 or a plate member W0 is joined by mush seam welding, and the junction in the peripheral direction (junctions of material plates W1, W2, W3) is smooth in the axial direction, and a junction in the axial direction (junction of the side edges Wa of the rolled and bent plate member W0) is smooth in the peripheral direction, and therefore no impact is applied if pressing the forming rolls during the spinning process, the appearance is excellent, the junction strength is high, and when used in the catalyst container 1, there is no gap created between the inner circumference and the mat 20 wound around the catalyst carrier 2 inserted inside, thus allowing no exhaust gas to escape, and the plates are formed in a specified thickness after spinning.
The forming apparatus of a hollow material of the invention is not limited to the illustrated embodiments, and may be used, for example, when forming a hollow material Wa′ as shown in
In summary, according to the invention, individual plate members of a different plate thickness or material are joined together by mush seam welding to form a hollow material, and the rigidity is controlled in individual parts. By spinning the hollow material, a junction and a cone are formed in an optimum shape, and a hollow member is manufactured. Thus, the hollow member smooth in junction and high in welding strength is obtained in spite of thin plate material. When this hollow member is used in a catalyst container, the sealing performance is excellent without being accompanied by an increase in radiant noise or an increase in weight.
While the invention has been described with reference to preferred embodiments thereof, it is to be understood that the invention is not limited to the preferred embodiments or constructions. To the contrary, the invention is intended to cover various modifications and equivalent arrangements. In addition, while the various elements of the preferred embodiments are shown in various combinations and configurations, which are exemplary, other combinations and configurations, including more, less or only a single element, are also within the spirit and scope of the invention.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2000-270255 | Sep 2000 | JP | national |
| 2001-182065 | Jun 2001 | JP | national |
This is a Division of application Ser. No. 10/362,834 filed Feb. 27, 2003. The disclosure of the prior application is hereby incorporated by reference herein in its entirety. This application is the U.S. National Stage of PCT/IB01/01617, filed Sep. 5, 2001, which claims priority from JP2000-270255, filed Sep. 6, 2000, and JP2001-182065, filed Jun. 15, 2001, the disclosures of which are incorporated herein in their entireties by reference thereto.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 10362834 | Feb 2003 | US |
| Child | 11892537 | Aug 2007 | US |
