Device and method for manufacturing the element with a honeycomb structure, in particular housing-media catalyst

 

(57) Abstract:

The application describes a device for the manufacture of an element with a honeycomb structure consisting of a set of typed at least one package to at least partially structured layers of sheet metal forming multiple channels for the passage of fluid. The device includes a pivotable around an axis acting on each package using a twisting device and the locking in solid form the core segments. The shape formed by at least two core segments. Each profile segment can rotate around a respective axis parallel to the axis of the twisting fixture, against the direction of rotation of the latter, thereby preventing deformation of the packages. 3 S. and 18 C.p. f-crystals, 19 ill.

The present invention relates to a device and method for manufacturing the element with a honeycomb structure having multiple channels for the passage of a fluid medium, in particular of the body of the carrier of the catalytic Converter.

To reduce emissions of harmful substances, in particular in exhaust gases of vehicles used catalytic neutralize the s with a honeycomb structure. Element with a honeycomb structure consists of typed in package set of at least partially structured metal sheets. This package is rolled into a roll by twisting in opposite directions around the Central zone. This embodiment of the element with a honeycomb structure is known, for example, from U.S. patent 4923109.

From the application WO 90/03220 known metal body vehicle catalytic Converter for vehicles, which consists of at least partially structured metal sheets. This case-storage media includes at least three pack of metal sheets, with at least three of them folded in half along the respective fold lines in the Central area of the element with a honeycomb structure and in such a state folded into a roll by twisting relative to each other in one direction around a Central area where the bend line.

The prior art also known device for the manufacture of such buildings vehicles catalytic converters, including rotating around its axis and acting on each package using a twisting fixture and mud in solid form profile is Oh its finally twisted condition. The most common form, which have elements with a honeycomb structure is cylindrical. In order to ensure the collapse in the coil packs around the Central zone of the core segments are moved toward the package in such a way that during the rotation of the fork twisting device package, respectively, adjacent packages (ut) to the edge of the core segments, and this region forms the arrester. At the end of the manufacturing process, the mold is completely closed, and the element with a honeycomb structure, thus, is given its final form.

Known devices have two specialized segments that can be moved rectilinearly in the direction towards each other and away from each other. During the process of closing the form, there is a danger that at least one profile segment will continue to move against the direction of movement of the plot package, which has yet to be collapsing into a roll, which can lead to undesirable deformation of the package, respectively packets. The deformation leads to the fact that the individual sheets are partially bent. As a consequence, the structure of the element is broken. First, suffers a strength element with a honeycomb structure, and secondly, prostene was based on the task to improve the known device for the manufacture of an element with a honeycomb structure thus so during the manufacturing process, there is no risk of deformation of the packets, respectively, a separate metal sheets. Next, you need to develop a method of manufacturing element with a honeycomb structure, prevent deformation of the individual packages.

According to the invention this task is solved by the device to the distinctive features of p. 1 of the claims. Preferred embodiments of the device are presented in the dependent PP. 2-18. Proposed according to the invention, the methods of manufacture of the element with a honeycomb structure described in paras. 19 and 20. A preferred variant of the method presented in the dependent p. 21.

The proposed device for the manufacture of an element with a honeycomb structure consisting of a set of typed at least one package to at least partially structured metal sheets forming multiple channels for the passage of fluid, includes a form that contains at least two core segments. Each profile segment can rotate around a respective axis parallel to the axis of the twisting fixture, against the direction of rotation of the latter. Thanks Povorotnaya one or more packets when closing the form. If there are more than two packets the number of profile segments in the device, which can be rotated against the direction of rotation of the twisting device preferably corresponds to the number of packages. The axis of rotation of the profile segments are predominantly located equidistant relative to each other in the envelope of the finished element with a honeycomb structure.

On dialed in package metal sheet element with a honeycomb structure effect of high load, which is caused by the design of the known device for manufacturing such element. The load on the sheets occurs, in particular, due to the fact that the arrester is located at some distance from the center of application of the forces. System arrester pack - leaves - the center of application of the forces are comparable to unilaterally fixed inlaid leaf spring. As is the case in such typesetting leaf springs between the individual layers of the package there are the forces of friction. These friction forces result in the collapse in the coil pack (s) to excessive power consumption. In addition, the curves have not yet collapsed section of each package, which makes the work of lateral deformation during compaction package.

The main idea of the RA is ment with a honeycomb structure, having multiple channels for the passage of a fluid medium, in particular housing-carrier catalyst, more technological in the case when the arrester is directly adjacent to sternotomy in a roll package according to a rolled up into a roll packages. Not yet collapsed section of each package is free. Therefore, unlike the prior art, no load on it yet twisted plot package does not occur. Is not, therefore, a bending load on this has not yet collapsed section of the package.

This basic idea is implemented according to p. 5 claims in the device for manufacturing an element with a honeycomb structure having multiple channels for the passage of a fluid medium, in particular a catalytic Converter, comprising dialed in package set of at least partially structured metal sheets, where the device includes a pivotable around an axis and acting on the package using a twisting fixture and mud in integral form of the profile segments, and the axis of rotation is located on forming the arrester the end of the relevant segment, and each of the holder can be moved toward the axis and from the neo time clotting radial dimension of the twisted package increases. In order to implement this process arrester is designed so that it can move to the axis of the twisting device and from it. The arrester may adjoin the package with a certain contact force.

For the manufacture of an element with a honeycomb structure of at least three packages, each of which consists of a set of at least partially structured metal sheets and are twisted in the same direction around each other, a device in which the number of profile segments form corresponds to the number of packages. Each core segment is fixed on a rotation axis parallel to the Central axis, and forms at the end of one of the arrester. Profile segments can be rotated against the direction of rotation of the twisting device. Each of the arrester can be moved to the axis of the twisting device and from it. With the help of the device may be made as described in WO 90/03220 element with a honeycomb structure.

According to another preferred variant of the proposed device has a base plate with guide slots passing radially to the center. Each guide groove of octanone cross-section. Guide groove is preferably T-shaped cross-section or cross-section in the shape of a dovetail. The bolt has a head which is inserted in the guide groove. The guide grooves do not need to be in one-piece base plate. They can also be formed in different respectively molded plates.

Moving the holder in the direction of the axis and it is largely by means of an electric motor. For this purpose particularly suitable stepper motor, because it allows you to precisely control the movement of controvery relatively already rolled packages. Between the motor and a counter may be provided in the appropriate gear. You can also use other mechanisms, for example, a rack connected at one end with a counter and a member engages with a corresponding toothed wheel motor.

In a preferred embodiment of the device, each of the arrester is connected with the piston block. The piston unit may be a hydraulic or pneumatic actuator. You can apply the well-known standardized piston blocks.

According to one of prepective action of a spring force. This spring force can be created by spring tension or compression spring or a pair of such springs. In a preferred embodiment, the spring force with which the holder is attached to a twisted package can be adjusted. Due to this, the device can be adapted to different forms and background material element with a honeycomb structure. Preferably the spring force has a variable declining balance feature. This is based on the fact that the force with which the holder is attached to the package, due to the larger bend radius may be less than in the center of the curved package. The advantage of using spring is that they are standardized to the details that ensure safe and reliable operation.

For circuit form each core segment is connected with a driving unit that rotates the segment around the appropriate axis. This drive unit may be a piston unit with a hydraulic or pneumatic drive.

The following describes the manufacturing method of an element with a honeycomb structure having multiple channels for the passage of fluid formed by many at least partially structured metallic is s metal sheets. This package is placed in an open form. In the Central area of the package and forms the package is kept twisting device. Twisting device can be made fork. Then, the packet is folded in the roll twisting device. By turning the profile of the segments against the direction of rotation of the twisting device form interlocks. The form may impinge only upon reaching the required degree of curl. The package does not have to be rolled completely. The snapping process forms may begin when the size has not yet collapsed section of the package is less than the length of the perimeter of the core segment or equal to it. If the process circuit form begins when the above conditions, the process of twisting exercises each segment, since the locking of the segments of the pressure is not yet rolled sections in the direction of the axis. This method is manufactured item with a cellular structure known from EP 0245737. Such an element with a honeycomb structure known to experts in the art under the designation S-Kat.

For the manufacture of an element with a honeycomb structure having multiple channels for the passage of fluid formed by the set IU is trying to dial in multiple packages multiple at least partially structured metal sheets. Each package is folded in half along the line of its bend. After that, each packet is placed into the open, where he kept twisting device in the Central zone.

According to another preferred variant of the method proposed after the packet capture twisting device positioned on both sides of the package in the Central zone opposite each other on the holder with the contact to the package. Then pack roll roll through twisting in opposite directions. In the process of rolling each of the arrester extends radially from the Central zone, constantly adhering to the package. At the end of the process of twisting the core segments rotate around their respective axis, so the form is linked.

Other advantages and features of the device and method are explained in more detail on the four examples with reference to the accompanying drawings on which is shown:

in Fig. 1 is a schematic top view of the first exemplary embodiment of the device in one package,

in Fig. 2 is a schematic top view of the device of Fig. 1 with a partially rolled into a roll package,

in Fig. 3 is a schematic top view of the device of Fig. 1 with soy

in Fig. 5 is a schematic top view of the device of Fig. 4 with partially twisted around each other packages

in Fig. 6 is a top view of the device of Fig. 4 with a closed form,

in Fig. 7-12 - schematic views from above of a third variant of the device run on different technological stages and

in Fig. 13-19 - schematic views from above of a fourth exemplary embodiment of the device.

In Fig. 1-3 depict a first exemplary embodiment of a device for manufacturing an element with a honeycomb structure from one package 1. Package 1 recruited from a variety of at least partially structured metal sheets, which in Fig. 1-3 are not depicted. At least partially structured metal sheets form in the finished element with a honeycomb structure multiple channels for the passage of fluid. The device includes a form 5, consisting of two core segments 6, 7. Each profile segment 6, 7 can be rotated around the respective axes 13, 14. The ends of each core segment 6, 7 are designed so that the closed form forms an almost continuous line. In the depicted example, the execution element 31 with a honeycomb structure has a circular cross-section. Two specialized ale is adopted not shown twisting device. Twisting fixture made fork and can be rotated around the axis 9 perpendicular to the plane of the drawing. The direction of rotation of the twisting device around the axis 9 is marked with the letter S. In Fig. 2 shows that the package 1 is partially rolled. Not yet rolled part of the package 1 has a length L, which corresponds to half the circumference of the envelope 32. At this stage of the method of the profile segments 6, 7 can be rotated in the direction of the arrow F around the respective axes 13, 14, closing thus form 5. The profiled segments 6, 7 are pressed on still rolled in the roll area of the package 1 in the direction towards the center.

In Fig. 4-6 shows a second exemplary embodiment of a device for manufacturing an element with a honeycomb structure of the three packages 1, 2 and 3. Packages 1, 2 and 3 are arranged symmetrically around the axis 9. To facilitate twisting device which holds and cranks each package 1, 2 and 3 in the direction of S, not shown. Twisting device can be performed, as already indicated, in the form of a clevis fixtures. Form 5 includes three profile segments 6, 7 and 8. Each profile segment 6, 7 and 8 are in the form of an arc of a circle. Each profile sego fixtures. To rotate each profile segment 6, 7 and 8 provides an appropriate drive unit 25, 26 and 27. As the drive units 25, 26 and 27 used piston blocks. Piston rods 28, 29 and 30 are connected respectively with the profile segments 6, 7 and 8. The connection is made rotatable. Each drive unit 25, 26, 27 are made stationary.

As a result of increasing pressure in the cylinder piston unit 25, 26, 27 corresponding to the piston rod 28, 29 and 30 is retracted allowing each segment 6, 7 and 8 are rotated around the respective axes 13, 14 and 15, and form 5 interlocks. Form closed up shown in Fig. 6.

In Fig. 7-12 presents the third exemplary embodiment of the invention. Device for the manufacture of an element with a honeycomb structure from one package 1 includes two core segments 6, 7, which can be rotated around the axis 13, 14 respectively. Each segment 6, 7 can be moved radially towards the axis 9 of the twisting device. In Fig. 7 depicts the location of the package in an open form 5. After placing the package in the form, and its capture is not shown twisting device profile segments 6, 7 are moved radially inwards in the direction of the arrow R to the Pak is and the axis 13, 14 rotation. The end of the relevant segment adjacent to the package 1, forms the arrester 10, 11. In the clotting process of the package 1 to the roll in the direction of rotation S of the profile segments 6, 7 are moved radially outward in the direction of the arrows, and controvery 10, 11 permanently attached to the package. This, in particular, can be seen in Fig. 9, 10 and 11. After almost complete collapse undertaken by twisting device, the profile segments 6, 7 are rotated around their respective axes 13, 14, and form 5 is closed. Fig. 11 and 12 correspond to Fig. 2 and 3, therefore, the description relating to these recent drawings, fully applies to this example implementation.

For the manufacture of many at least partially structured metal sheets element with a honeycomb structure with many channels for the passage of a fluid medium, in particular of the body of the carrier catalyst containing three packages 1, 2 and 3 of sheet metal, and these three packages 1, 2 and 3 are folded in half along the respective lines 16, 17 and 18 fold in the Central zone 4 element with a honeycomb structure and in such folded folded into a roll by twisting one around-ear, closed the device, is depicted in Fig. 13-19. The device includes three brake unit 19, 20 and 21 to fold the packet in half. Each brake unit 19, 20 and 21 has a bending mandrel 33, 34 and 35. The bending mandrel 33, 34 and 35 can perform reciprocating motion. Each brake unit 19, 20 and 21 contains a double-leaf gates 36, 37 and 38. The gates 36, 37 and 38 have two shutters 41, 42, rotating about their respective axes 39, 40. The rotation of the valves takes place against the action of their clamping force. For folding of one package 1, 2 and 3, the latter have in parallel the corresponding shutter 36, 37 and 38. Symmetrically between the gates 41, 42 is the mandrel 33. In the application to the package 1 force generated by the frame 33, and the rotation of the valves 41, 42 package 1 is folded along the line 16 fold. Packages 1, 2 and 3 in the folded state shown in Fig. 14. In the process of folding packages 1, 2 and 3 is introduced into the Central zone 4 devices. Packages 1, 2 and 3 are placed symmetrically relative to the axis 9. At the end of the folded package is removing the mandrels 33, 34, 35 of the corresponding package. In the subsequent Fig. 15-19 bending devices 19, 20 and 21 for simplicity is not shown.

After the capture is not shown twisting remediate radially inwards towards the axis 9. The transfer process takes place until such time as formed on the end of each profile segment 6, 7 and 8 controvery 10, 11 and 12 will not run into the appropriate package 1, 2 and 3, as shown in Fig. 16. The clotting process may be started when controvery attached to the package 1, 2 and 3. In Fig. 17 shows the individual packages 1, 2 and 3 in the initial stage of the process of twisting. For closing the form 5 core segments 6, 7 and 8 can be rotated respectively about the axis 13, 14. Fig. 18 and 19 correspond to Fig. 5 and 6, therefore, the description relating to these recent drawings, fully applies to this example implementation.

Described in the examples of execution elements with a honeycomb structure have a circular cross-section. According to the invention can be manufactured and also elements with non-circular cross-section. This can be seen, for example, elements with a honeycomb structure, which have a cross-section in the form of an ellipse, as part of a circle or epitrochoid.

1. Device for the manufacture of an element with a honeycomb structure, in particular housing-carrier catalyst, consisting of many layers recruited at least one package (1, 2, 3) at least partially structures the creation includes a pivotable around a Central axis (9) in the direction (S), current per package (1, 2, 3) fork twisting device and the profile segments (6, 7, 8) which can be drawn together in a coherent form (5) corresponding to the external shape of the manufactured element with a honeycomb structure, characterized in that provided at least two core segments (6, 7, 8), each of which can be rotated around the respective axes (13, 14, 15) parallel to the Central axis (9), against the direction of rotation (S) twisting the device.

2. The device under item 1, characterized in that the axis (13, 14, 15) of rotation of each profile segment (6, 7, 8) is located near the outer contour line of the manufactured element with a honeycomb structure, preferably at the end of each profile segment (6, 7, 8).

3. The device under item 1 or 2, characterized in that to collapse in the coil element with a honeycomb structure made of more than two packets of the prescribed number of profile segments (6, 7, 8) corresponds to the number of packets (1, 2, 3).

4. The device under item 1, 2 or 3, characterized in that the axis (13, 14, 15) turning circle are equidistant relative to each other in the envelope of the finished element with a honeycomb structure.

5. The mouth of stuudy the arrester (10, 11, 12) end of the relevant segment (6, 7, 8) and each of the holder (10, 11, 12) can be moved in the direction towards the Central axis (9) and from it.

6. The device under item 5, characterized in that the device has a support plate with a passing radially to the center of the guide slots, each of which has slidable therein a bolt forming the axis of rotation.

7. The device according to p. 6, characterized in that each guide groove has a polygonal, preferably T-shaped cross section or a cross section in the form of a dovetail.

8. Device according to any one of paragraphs.5 to 7, characterized in that each axis (13, 14, 15) of rotation can be moved in the direction towards the Central axis (9) and using the electric motor.

9. The device under item 8, characterized in that each axis (13, 14, 15) turn connected to the stepper motor.

10. Device according to any one of paragraphs.5 to 7, characterized in that each axis (13, 14, 15) of rotation can be moved in the direction of the axis (9) and from it using a piston unit (22, 23, 24).

11. The device according to p. 10, characterized in that each piston unit (22, 23, 24) has a hydraulic or pneumatic actuator.

12. The device according to lubasi (9) against the action of spring force.

13. The device according to p. 12, characterized in that the spring force against which each axis (13, 14, 15) of rotation can be moved in the direction from the Central axis (9) is adjustable.

14. The device under item 12 or 13, characterized in that the characteristic curve of the spring has a variable declining balance.

15. The device according to p. 12, 13 or 14, characterized in that each axis (13, 14, 15) of rotation can be moved in the direction from the Central axis (9) against the action of at least one tension spring.

16. Device according to any one of paragraphs.12 to 15, characterized in that each axis (13, 14, 15) of rotation can be moved in the direction from the Central axis (9) against the action of compression springs.

17. Device according to any one of paragraphs.1 to 16, characterized in that each profile segment (6, 7, 8) to rotate around a respective axis (13, 14, 15) is connected with a driving unit (25, 26, 27).

18. The device under item 17, characterized in that the drive unit (25, 26, 27) is a hydraulic or pneumatic piston block.

19. A method of manufacturing element with a honeycomb structure having multiple channels for the passage of fluid from multiple layers at least partially of structuresof avannah metal sheets, put (1) in an open form (5), formed from the corresponding external shape of the manufactured element with a honeycomb structure of the profile segments (6, 7, 8) and hold it in the Central zone of the twisting device, roll in roll package (1) in the direction of rotation (S) and close the form (5) by turning the profile segments (6, 7, 8) against the direction of rotation (S) twisting device for achieving the required degree of curl.

20. A method of manufacturing element with a honeycomb structure having multiple channels for the passage of fluid, composed of multiple layers of at least partially structured metal sheets, which are gaining a lot of packages (1, 2, 3) multiple layers of at least partially structured metal sheets, each package (1, 2, 3) fold in half with the appropriate line (16, 17, 18) bend, put the packages (1, 2, 3) in an open form (5), formed from the corresponding external shape of the manufactured element with a honeycomb structure of the profile segments (6, 7, 8) and hold it in the Central zone of the twisting device, packets (1, 2, 3) roll into a roll by twisting around each other in the direction of rotation (S), close up of molded achieving the required degree of curl.

21. The method according to p. 19 or 20, in which the relevant holder (10, 11, 12) constantly abuts against each of the packages (1, 2, 3) in the Central zone, and in the clotting time of packets in a roll by twisting around each other each arrester (10, 11, 12) radially away from the Central zone (4), and the holder is permanently attached to the package (1, 2, 3).

 

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The invention relates to a device and method for manufacturing the element with a honeycomb structure consisting of a set of at least partially structured metal sheets forming multiple channels for the passage of fluid

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FIELD: production of honeycomb substrates for catalyst converters for two-wheeled or diesel vehicles.

SUBSTANCE: the invention is dealt with production of honeycomb substrates made out metal sheets piled or rolled in a package and minimized to the honeycomb elements used first of all as honeycomb substrates for catalyst converters in the systems of exhaust gas (EG) neutralization. There is a description of a honeycomb element (1) first of all as a honeycomb substrate for a catalyst converter for systems of two-wheeled vehicles exhaust gas neutralization. The honeycomb substrate for catalyst converter consists of some layers of metal sheets (2, 3) packed as a package or minimized in a roll, which are at least on separate sections are structured or profiled in such a manner, that they form for EG flowing channels (4). At that the metal sheets (2, 3) represent the sheets of high-quality steel of more than 0.08 mm thick with a share of aluminum from 6 up to 12 mass % multiplied by 0.02 mm and divide by "d" - thickness of the metal sheets (2, 3). The technical result - a possibility to use metal sheets depending on the share of aluminum in them and their thickness, that allows to use the sheets taken from production process of manufacture of a material subjected to a hot aluminization.

EFFECT: the invention ensures a possibility to use metal sheets for the purpose depending on the share of aluminum in them and their thickness.

5 cl, 1 dwg

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