JP2001276574A - Catalyst converter, method of manufacturing the same and processing apparatus used in manufacture of catalyst converter - Google Patents

Abstract

(57) [Problem] To provide a catalytic converter molded integrally without connecting a plurality of members to each other. SOLUTION: In the catalytic converter of the present invention, a circular flat plate-shaped work W is spinned in a plane direction, so that a joining portion 1b, a cone portion 1c, and a catalyst installing portion 1a are integrally formed in order from one end thereof ( b) A catalyst 2 such as a monolith is inserted into the catalyst installation portion 1a from the open other end (c), and the catalyst 2 is accommodated in the catalyst installation portion 1a by spinning so as to reduce the diameter of the other end. At the same time, the cone part 1c and the joint part 1b are formed integrally from the catalyst installation part 1a (d).

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

TECHNICAL FIELD The present invention relates to a catalytic converter,
The manufacturing method, and the processing apparatus used for the manufacturing, more specifically, a catalytic converter having an installation portion in which the catalyst is installed inside the catalyst container and one or more junctions at both ends, a manufacturing method thereof, And a processing device used for the production thereof.

[0002]

2. Description of the Related Art An exhaust pipe of a combustion engine such as an internal combustion engine is connected to a catalytic converter for removing harmful components contained in the exhaust gas. The catalytic converter has a catalyst installed inside a catalyst container. As shown in FIG. 27 (d), FIG. 28 (f) or FIG.
Is formed with a catalyst installation portion 101a in the center,
Cylindrical joints 1 that are joined at both ends to an inflow pipe from an internal combustion engine or an outflow pipe to a next processing section such as a muffler
01b is molded. The installation part 101a is formed with a relatively large diameter, and the joint part 101b is formed with a relatively small diameter.
Joint 101 provided at one end of catalyst container 101
The number b may be a single case (FIGS. 27 and 28) or a plurality of cases (FIG. 29) depending on the number of pipes to be joined. When a single joint 101b is provided at one end of the catalyst container 101, a funnel-shaped cone whose temporary diameter changes between a relatively large-diameter installation part 101a and a relatively small-diameter joint 101b is particularly preferable. The part 101c is formed. Further, when a plurality of joints 101b are provided at one end of the catalyst container 101, the catalyst container 101 has a branch portion 101d in which the plurality of joints 101b are formed. Such a catalytic converter needs to be formed airtight so that the exhaust gas does not leak outside the catalyst container 101.

[0003] As a conventional technique for manufacturing a catalytic converter including a catalyst container 101 and a catalyst 2 each having a single joining portion 101b at both ends, as shown in FIG. And a cone portion 1 formed by pressing or the like
01c and a member WJ forming a single joint 101b
2, or a member WJ2 'having a shape obtained by dividing this member WJ2 into half as required. Then, as shown in FIG. 27 (b), a half-split member WJ forming the cone portion 101c and the joint portion is formed.
In the case of 2 ′, the member WJ2 is formed by integrally joining the two members WJ2 ′ by welding or the like. Thereafter, the opening of the cone portion 101c of the integrally formed member WJ2 and one end of the cylindrical pipe member WJ1 forming the installation portion 101a are joined by welding or the like, and then, as shown in FIG. 27, a catalyst 2 such as a monolith is inserted and installed in a cylindrical pipe member WJ1, and finally, as shown in FIG. 27D, the opening of the cone portion 101c of the other member WJ2 and the cylindrical member are formed. By connecting the other end of the pipe member WJ1 by welding or the like, a catalytic converter having the catalyst 2 installed inside the catalyst container 101 has been manufactured.

As another conventional technique, a rectangular flat work WJ3 is prepared as shown in FIG. 28A, and the rectangular flat work WJ3 is prepared as shown in FIG. And joining the side edges WJ3a to each other by welding or the like to form a cylindrical shape as shown in FIG.
As shown in FIG. 28 (d), a catalyst 2 such as a monolith is inserted and installed inside a cylindrically shaped work WJ3, and one end is spinned as shown in FIG. 28 (e). The diameter of the cone portion 101c and the single joint portion 101b are reduced by processing or the like, and the other end is similarly reduced in diameter by spinning or the like to form the cone portion 101c and the single joint portion 101b as shown in FIG. By forming a single joint 101b, a catalytic converter in which the catalyst 2 is installed inside the catalyst container 101 has been manufactured. As a technique for forming the cone portion 101c and the joining portion 101b by reducing the diameter of the end of the work WJ3 formed into a cylindrical shape as described above, for example, a technique disclosed in Japanese Patent Application Laid-Open No. 9-112259 is disclosed. It has been known.

[0005] Among the catalytic converters having a catalyst 101 mounting portion 101a at the center of such a catalyst container 101 and a single joining portion 101b at both ends, as shown in FIG. In addition to (a) in which the axes of the joint 101a and the joints 101b are arranged concentrically,
1a and the axis of the other joint 101b are arranged so that the axis of the one joint 101b is concentric and intersects with these axes (b).
The axis of the other joint part 101b is arranged so that the axis of b is concentric and deviates from these axes (c), and the axis of the installation part 101a and the axis of both joints 101b intersect, respectively. (D), installation section 101a
(E) in which the axes of the two joint portions 101b are respectively deviated from the axis of (e).

On the other hand, as a conventional technique for manufacturing a catalytic converter having a branch portion 101d provided with a plurality of joint portions 101b at one end of a catalyst container 101, FIG.
As shown in (a), a cylindrical pipe member WJ1 forming the installation portion 101a, a member WJ2 forming the cone portion 101c and the single joint portion 101b, and a branch portion in which the joint portion 101b is formed respectively. A half-split member WJ4 'for forming 101d was prepared. Then, as shown in (b) of FIG. 29, the member WJ4 ′ divided and formed in a half-split shape is joined by welding or the like to form an integral member WJ4 forming a branch portion 101d having a plurality of joint portions 101b. Then, as shown in FIG. 29C, the opening of the member WJ4 and one end of the cylindrical pipe member WJ1 are connected by welding or the like, and the catalyst 2 such as a monolith is inserted into the cylindrical pipe member WJ1.・ Install,
Finally, as shown in FIG. 29D, the opening of the cone portion 101c of the member WJ2 and the other end of the cylindrical pipe member WJ1 are connected by welding or the like, so that the catalyst container 1
A catalytic converter having a branch 101d in which a catalyst 2 is provided inside 01 and a plurality of joint members 101b are provided on one side has been manufactured.

As a conventional technique for forming the joining portion 101b so as to protrude into a cylindrical shape, for example, as described in Japanese Patent Application Laid-Open No. 7-96332, burring is used. Are known. In Japanese Unexamined Patent Publication No. 7-96332, a mother tube (pipe member) formed in advance into a cylindrical shape is prepared, a pilot hole is provided in the parent tube, and burring is performed on the pilot hole.

[0008] In each of the catalytic converters manufactured as described above, since the catalyst container 101 is connected by welding or the like, an air leak inspection is performed to verify whether or not the welded portions are air-tightly connected. Had been Note that a gap is formed between the inner surface of the installation portion 101a of the catalyst container 101 and the outer periphery of the catalyst 2 housed and installed in the installation portion 101a so that the exhaust gas does not flow through the gap. Need to be in close contact with the outer periphery of the catalyst 2.

[0009]

However, of the prior art shown in FIG. 27, the quality of welding for connecting the respective constituent members WJ1, WJ2 or WJ2 ', WJ2' to each other is described. However, there is a problem that it is difficult to stabilize and a problem that it is necessary to perform an air leak inspection of a welded part of the manufactured catalyst container 101. Also,
In this case, there is also a problem that it is difficult to ensure product accuracy because welding distortion occurs. Further, in the case where half-shaped members WJ2 ′ and WJ2 ′ are prepared to form the cone portion 101c and the joint portion 101b, both the members WJ2 ′ divided into half-shapes are formed.
Since it is necessary to integrally connect WJ2 'by welding or the like, there is a problem that the number of steps is increased and the manufacturing cost is increased.

[0010] In the prior art shown in FIG. 28, when the rectangular flat work WJ3 is formed into a cylindrical shape, particularly, the connection at the longitudinal end is welded. It may be insufficient due to defects or cracks or scratches due to welding distortion or the like. These welding defects, cracks, scratches, and the like are often of a size that is difficult to visually confirm. Then, as shown in FIGS. 28E and 28F, these welding defects, cracks, flaws, etc. reduce the diameter of the longitudinal end by spinning or the like to reduce the cone 101c and the joint 101b. There is a problem that cracks may occur during molding, and therefore, as in the case shown in FIG. 27, there is a problem that it is necessary to perform an air leak test on the welded portion of the catalyst container 101 of the manufactured catalytic converter. Was. Further, in this case, in order to bend the rectangular flat work WJ3 and join its side edges WJ3a together to form a cylindrical shape,
Since the hardness of the joining portion of the side edge WJ3a is increased and the plastic deformability is different from other portions, there is a problem that it is difficult to form into a desired shape and a problem that the molding accuracy cannot be improved. Was.

Further, in the above-mentioned conventional technique, as shown in FIG. 29, in the case where a half-split member WJ4 'is formed in order to form a branch portion 101d in which a plurality of joining portions 101b are formed. As shown in FIG. 27, both the half-split members WJ4 'and WJ4' need to be joined together, so that the number of steps increases and the manufacturing cost increases. However, there is also a problem that it is difficult to stabilize and it is necessary to perform an air leak inspection of each welded portion, and further, it is difficult to secure product accuracy due to welding distortion.

In the prior art shown in FIGS. 27 to 29, all of the members WJ1 and WJ2
Since it is necessary to previously shape and process the shape of the work WJ3 into a cylindrical shape or a cone shape, the number of steps is large and the manufacturing cost cannot be reduced. In particular, FIG.
29, the components WJ1, WJ2, and WJ4 are connected to each other by welding or the like, and the connection causes a distortion in the installation portion 101a of the catalyst 2 to produce a perfect circle. The degree of deterioration deteriorates and the catalyst container 10
There was a problem that the inner circumference of 1 did not adhere to the outer circumference of the catalyst 2 and a gap was formed.

SUMMARY OF THE INVENTION The present invention has been made in view of the above-mentioned problems, and a plurality of members are integrally formed without being connected to each other by welding or the like. It is an object to provide a catalytic converter without any.

Further, the present invention has been made in view of the above-mentioned problems, and a catalyst container can be formed from a plate material without connecting a plurality of members to each other by welding or the like. An object of the present invention is to provide a method of manufacturing a catalytic converter in which a catalytic converter in which a branch part having a plurality of joints is integrally provided and a catalyst is installed in an installation part can be manufactured with a small number of steps with high accuracy and stable quality. And

Further, the present invention has been made in view of the above-mentioned problems, and a catalyst container can be formed from a plate-like work by using a plate-shaped workpiece without connecting a plurality of members to each other by welding or the like. Produces a catalytic converter with a catalyst installed in the installation part, with a small number of steps, with accurate and stable quality, and / or a hollow shape integrally formed with a branch part having multiple joints and / or It is an object of the present invention to provide a processing device that can perform the processing.

[0016] The invention relating to the catalytic converter of claim 1 is as follows.
In order to achieve the above object, an installation portion for installing a catalyst from a plate material is formed by spinning.

The invention relating to a catalytic converter according to claim 2 is as follows.
In order to achieve the above object, an installation part for installing a catalyst is formed from the plate by spinning in a plane direction of the plate.

[0018] The invention relating to a catalytic converter according to claim 3 is as follows.
In order to achieve the above object, in the invention according to claim 1 or 2, the plate is pre-drilled with a hole having a predetermined shape, and the circular opening forming the joint is formed by spinning the plate in the planar direction. It is characterized by being formed.

According to a fourth aspect of the present invention, there is provided a catalytic converter.
In order to achieve the above object, in the invention according to claim 1 or 2, the plate is provided with a plurality of holes having a predetermined shape in advance, and the plate is provided with a plurality of openings forming a joint by spinning the plate. The branch part is formed by molding.

According to a fifth aspect of the present invention, there is provided a catalytic converter comprising:
In order to achieve the above object, the invention according to claim 3 or 4 is characterized in that the opening is formed with a cylindrical joint by burring.

According to a sixth aspect of the present invention, there is provided a method for manufacturing a catalytic converter having a mounting portion on which a catalyst is installed, wherein the plate member is moved in a plane direction. The installation portion is formed by spinning.

According to a seventh aspect of the present invention, there is provided a method of manufacturing a catalytic converter according to the sixth aspect of the present invention, wherein a circular opening is formed when a plate material is spinned in a plane direction thereof. It is characterized in that a hole having a predetermined shape is preliminarily formed in a plate material.

According to an eighth aspect of the present invention, in order to achieve the above object, in the invention according to the sixth aspect, a plurality of holes having a predetermined shape are previously formed in the plate material.
The plate material is formed by spinning in the plane direction to form a branch portion having a plurality of openings.

According to a ninth aspect of the present invention, in order to achieve the above object, in the invention of the seventh or eighth aspect, the opening is subjected to burring to form a cylindrical joint. It is characterized by the following.

According to a tenth aspect of the present invention, in order to achieve the above object, in the invention according to any one of the sixth to ninth aspects, the reduced diameter portion at the end is further formed by spinning. It is characterized by being molded.

On the other hand, in order to achieve the above object, the invention according to an eleventh aspect of the present invention provides a spinning process in which a flat work is revolved relative to a flat work and the work is flattened from a flat work to a hollow work. And a spinning roller attitude adjusting means for adjusting the attitude of the spinning roller in accordance with the shape of a workpiece plastically deformed from a flat plate shape to a hollow shape.

According to a twelfth aspect of the present invention, in order to achieve the above object, in the eleventh aspect of the present invention, the holding means for holding the work can be replaced according to the shape of the work to be plastically deformed. It is characterized by having.

According to a thirteenth aspect of the present invention, in order to achieve the above object, in the invention of the eleventh or twelfth aspect, the flat work is pre-drilled with a hole of a predetermined shape, and the spinning is performed. It is characterized by comprising control means for controlling the movement of the spinning roller so as to remove the splash near the hole of the work caused by the processing.

According to a fourteenth aspect of the present invention, in order to achieve the above object, in the thirteenth aspect of the present invention, a flat work is further formed from a pre-drilled hole by spinning a work. A burring means for burring the formed circular opening to form a cylindrical joint is provided.

According to the first aspect of the present invention, the installation part for installing the catalyst from the plate material and the joint part as necessary are integrally formed by spinning, and there is no need to connect a plurality of members. Provided is a catalytic converter which is stable in quality accurately and does not require air leak inspection.

According to the second aspect of the present invention, the installation portion for installing the catalyst from the plate material and the joining portion as necessary are integrally formed by spinning in the plane direction, and there is no need to connect a plurality of members. Provided is a catalytic converter in which the quality is stabilized accurately with a small number of processes and no air leak inspection is required.

According to a third aspect of the present invention, in the first or second aspect of the present invention, an installation portion for installing a catalyst is formed integrally from a plate material in which holes of a predetermined shape are formed in advance by spinning. A catalytic converter is provided in which a circular opening forming a joint is formed from a hole of a predetermined shape formed in advance in a plate material.

According to a fourth aspect of the present invention, in the first or second aspect of the present invention, a branch portion having a plurality of openings forming a joint portion is integrally formed with a mounting portion for mounting a catalyst from a plate material by spinning. An improved catalytic converter is provided.

According to a fifth aspect of the present invention, in the third aspect of the present invention, the opening is formed by burring from the opening.
There is provided a catalytic converter in which a cylindrical joint is integrally formed.

According to the sixth aspect of the present invention, since the plate material is spinned in the plane direction to integrally form the installation portion and, if necessary, the joint portion, there is no need to connect a plurality of members, which is small. A method for manufacturing a catalytic converter that does not require an air leak test by providing stable quality with high accuracy in the number of steps is provided.

According to a seventh aspect of the present invention, in the sixth aspect of the present invention, a hole having a predetermined shape is formed in the plate material in advance, thereby spinning the plate material in a plane direction to form an installation portion. In this case, there is provided a method for manufacturing a catalytic converter in which a circular opening forming a joint is integrally formed.

According to an eighth aspect of the present invention, in accordance with the sixth aspect of the present invention, a plurality of holes having a predetermined shape are formed in the plate material in advance, and a plurality of openings are provided by spinning the plate material in a plane direction. A method for manufacturing a catalytic converter in which a branch is integrally formed is provided.

According to a ninth aspect of the present invention, there is provided a method of manufacturing a catalytic converter in which a cylindrical joint is formed by subjecting an opening to burring according to the seventh or eighth aspect.

According to a tenth aspect of the present invention, in the invention according to any one of the sixth to ninth aspects, the reduced diameter portion at the end is integrally formed with the installation portion and the joining portion for installing the catalyst from the plate material by spinning. A method for manufacturing a catalytic converter is provided.

According to the eleventh aspect of the present invention, the spinning roller revolves relatively to the work to perform spinning in a planar direction to plastically deform the work from a flat plate to a hollow shape. The spinning roller attitude adjusting means adjusts the attitude of the spinning roller in accordance with the shape of the workpiece plastically deformed into a shape, thereby providing a processing device capable of appropriately plastically deforming the workpiece from a flat plate to an integrated hollow shape. Is done.

According to a twelfth aspect of the present invention, in accordance with the eleventh aspect of the present invention, by replacing the holding means for holding the work in accordance with the shape of the work to be plastically deformed, the work can be appropriately held and plastically deformed. Provided is a processing apparatus capable of causing the processing apparatus to perform the processing.

According to a thirteenth aspect of the present invention, in the eleventh or twelfth aspect of the present invention, the plate-shaped work is provided with a hole of a predetermined shape in advance, and the spinning roller revolves relatively to the work. By performing spinning in the plane direction, a splash occurs in the vicinity of the hole, but a processing device capable of controlling the movement of the spinning roller by control means and removing the splash generated in the vicinity of the hole has been developed. Provided.

According to a fourteenth aspect of the present invention, in the thirteenth aspect of the present invention, since a burring means is provided, a circular work formed from a hole formed in advance by spinning a flat work. A processing device capable of forming an opening into a cylindrical joint is provided.

[0044]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS First, an embodiment of a catalytic converter manufactured according to the present invention will be described in detail with reference to FIGS. In the catalytic converter manufactured according to the present invention, a relatively large-diameter catalyst mounting portion 1a for mounting the catalyst 2 is formed at the center of the catalyst container 1, and relatively small-diameter joining portions 1b are formed at both ends. . Then, as shown in each of FIG. 1 (d) and FIG. 2 (e) or FIG. 3, the joining portion 1b is provided as a single unit, and as shown at one end in FIG. 4 (e). In some cases.

When the joint 1b is provided singly,
As shown in FIG. 1 (d) and FIG. 2 (e), a funnel-shaped cone portion 1c which temporarily reduces in diameter from a relatively large-diameter catalyst installation portion 1a to a relatively small-diameter joint portion 1b is formed, respectively. Molded.

Further, in a catalytic converter in which the catalyst container 1 has a single joint 1b at both ends, FIG.
As shown in (a), the axis of the catalyst installation part 1a and both joints 1b are arranged concentrically (a), the axis of the installation part 1a and one joint 1b are concentric and intersect with these axes The other joint 1b is arranged such that the axis of the other joint 1b is arranged such that the axis of the catalyst installation part 1a and the axis of one joint 1b are concentric and deviate from these axes. (C), the axis of the catalyst installation part 1a and both joint parts 1b
(D), and (e) are arranged such that the axes of both joints 1b deviate from the axis of the catalyst installation part 1a.

On the other hand, when a plurality of joints 1b are provided, as shown in FIG. 4E, a branch 1d provided with the plurality of joints 1b is formed.

In the catalytic converter of the present invention, in any case where one or a plurality of joints 1b are provided in the catalyst container 1, an installation part for installing a catalyst from a flat work (plate material) W by spinning is integrally provided. It is formed.

That is, when manufacturing a catalytic converter in which a single joint 1b is formed at both ends of the catalyst container 1, as shown in FIG. 1, a flat work is formed into a circular shape (a), By spinning the flat work W in the plane direction, the joining portion 1b, the cone portion 1c,
And the catalyst installation part 1a is integrally molded in order (b). At this time, the end face of the joining portion 1b formed at one end is constituted by the central portion of the circular flat work W before spinning, and the end face is in a closed state.
The other end is constituted by the peripheral portion of the circular flat work W before spinning, and at this stage, the cone portion 1c and the joint portion 1b are open without being formed. As described above, the other end in the open state without being reduced in diameter is used when the joint 1b is formed later, as shown in FIG.
Is inclined at a predetermined angle (declination) with respect to the axis of the catalyst installation part 1a like the right end joint 1b of the right side, or the right end joint of FIG. 3 (c). It is possible to cope with the case where the axis is decentered from the axis of the catalyst installation part 1a as in 1b. Next, as shown in FIG. 1 (c), a catalyst 2 such as a monolith is inserted into the catalyst installation portion 1a from the other end in the open state, and spinning is performed so that the other end is reduced in diameter. The catalyst 2 is accommodated and installed in 1a, and the cone 1c and the joint 1b are integrally formed continuously from the catalyst installation part 1a (d). In addition, the joining part 1b in a state where the end face of one end formed earlier is closed is formed by forming a hole in the end face or by joining the joining part 1b.
Is opened by cutting at a predetermined position in the longitudinal direction. Since the catalyst container 1 of the catalytic converter integrally formed in this manner has no connecting portion for connecting a plurality of members by welding or the like as in the related art, the catalyst container 1 is accurately and stable, and performs an air leak test. No need. Also,
In the same process as the molding of the cone part 1c and the joint part 1b at the other end,
By performing spinning processing so as to reduce the outer diameter of the catalyst installation portion 1a while the catalyst 2 is inserted, the inner circumference of the catalyst installation portion 1a and the outer circumference of the catalyst 2 can also be brought into close contact.

Separately, in order to form a catalyst container 1 having a single joint 1b formed at both ends thereof by spinning from a flat work W, as shown in FIG. The work W is formed into a circular shape (a), and the flat work W is formed into a bottomed cylindrical shape having substantially the same diameter as the catalyst installation portion 1a over the entire length of which one end is closed by spinning in the plane direction ( b), the closed end is opened by cutting or the like, and a catalyst 2 such as a monolith is inserted therein (c), and a spinning process is performed so that one end is first reduced in diameter to form a catalyst installation section 1a. Then, the cone portion 1c and the joint portion 1b are continuously formed integrally (d), and then the other end is subjected to spinning so as to reduce the diameter, thereby accommodating and installing the catalyst 2 in the catalyst installation portion 1a. Catalyst installation section The cone portion 1c and the joint portion 1b can be integrally formed continuously from 1a (e). In this case, since both ends of the cylindrically shaped work W are formed to have substantially the same diameter as the catalyst installation part 1a, the axis of the work W is connected to the catalyst as shown in a joint part 1b at both ends in FIG. It is also possible to cope with the case where the axis is inclined at a predetermined angle with respect to the axis of the installation section 1a, or the axis is eccentric from the axis of the catalyst installation section 1a as in the joint section 1b at both ends in FIG. Can be. Also in this case, since there is no joint part by welding or the like as in the conventional technique, and the molding is performed stably with high accuracy, it is not necessary to perform an air leak inspection.

On the other hand, when forming a branch portion 1d provided with a plurality of joint portions 1b, as shown in FIG. 4, a flat work W is formed into a circular shape, and a joint portion 1b is formed at the center portion thereof. A hole 1b 'having a predetermined shape (this shape will be described in detail later) is formed (a), and the flat work W is spinned in a plane direction to form a branch portion having a plurality of holes 1b'. While molding 1d at one end,
The catalyst installation part 1a is formed integrally with the branch part 1d (b). At this time, the hole 1 of the branch portion 1d formed at one end
The spinning b ′ causes the material of the work W to flow and changes into a circular opening 1b ″. The other end is constituted by the peripheral portion of the circular flat work W before the spinning. , The cone portion 1c and the joint portion 1b are open without being formed.
A cylindrical joining portion 1b is formed by, for example, burring the opening 1b "of the branch portion 1d (c), and then a catalyst 2 such as a monolith is placed from the other end in the open state into the catalyst setting portion 1.
The catalyst is accommodated and installed in the catalyst installation section 1a by spinning so as to reduce the diameter of the other end by inserting it into the a (d), and the cone section 1c and the joining section 1b are continuously integrated from the installation section. (E). In this manner, the catalyst converter in which the catalyst container 1 is integrally formed has a branch portion 1d having a plurality of cylindrical joint portions 1b, a cone portion 1c, and a single joint portion 1b at both ends of the catalyst installation portion 1a. Since it is integrally and stably formed with high precision, there is no connection part by welding or the like unlike the prior art, and there is no need to perform an air leak inspection. Also in this case, not only the cone portion 1c and the joint portion 1b but also the branch portion 1d can be formed so as to be deviated and / or eccentric as shown in FIG. This is the same as the case where the part 1b is formed.

Next, an embodiment of a processing device used for manufacturing a catalytic converter having the above-described catalyst container 1 will be described in detail with reference to FIGS.

The processing apparatus of the present invention generally comprises a holding means 10 for holding a work W, a revolution drive means 12 for driving the spinning roller 11 to revolve relatively to the work W, and a spinning roller 11. The workpiece W is moved and spinned in the plane direction of the workpiece W.
A spinning roller moving means 13 for plastically deforming a plate from a flat shape to a hollow shape, a spinning roller attitude adjusting means 14 for adjusting the attitude of the spinning roller 11 in accordance with the shape of a work W plastically deformed from a flat shape to a hollow shape, It has.

On one side (left side in FIG. 5) of the base 20, a spindle 22 having a chuck 21 is rotatably supported by a bearing 23. Spindle 22
A support table 24 is provided above. Support stand 24
A spindle drive motor 25 is supported above. Pulleys 26 and 27 are provided on the end of the spindle 22 and the drive shaft of the spindle drive motor 25, respectively. A belt 28 is wound around the pulleys 26 and 27. Then, as shown in FIG. 1, FIG. 2 or FIG. 4, when the work W is formed from a flat plate shape to a hollow shape,
A mandrel 29 is inserted and carried in the spindle 22 such that it cannot rotate relatively. The mandrel 29 has a joint 1b
It is formed according to the shape and size of the cone portion 1c or the branch portion 1d and the catalyst installation portion 1a. When the spindle drive motor 25 is driven to rotate, the mandrel 29 is driven to rotate together with the spindle 22 via a pulley 26, a belt 28, and a pulley 27 provided on the drive shaft.

As will be described later, when a plurality of openings 1b "formed in the branch portion 1d are formed into a cylindrical joining portion 1b by burring (see FIG. 21), a spinning roller is used. 11 is replaced with a burring roller, and a holding jig for holding the work W is replaced with a mandrel 29 so that each opening 1b "appropriately faces the burring roller. In the case where the cone portion 1c and the joint portion 1b are integrally formed from the installation portion 1a by spinning so as to squeeze the end of the hollow workpiece W (see FIG. 13), a burring roller is used. The spinning roller 11 for drawing is replaced with a chuck 21 for appropriately holding the work W so that the spinning roller 11 revolves relatively to the peripheral wall of the hollow work W. Attached to.

On the other side (right side in FIG. 5) of the base 20, a clamper support 30 is provided. On the clamper support 30, the clamper cylinder 31 is provided with the spindle 22 (that is, the mandrel 29). Are supported so as to be located on an extension of the rotation center axis of the rotation axis. At the tip of the piston rod of the clamper cylinder 31, a clamper member 32 is rotatably provided. By disposing a flat work W between the distal end surface of the mandrel 29 and the clamper member 32 and driving the clamper cylinder 31 to extend, the work W is held between the two 29 and 32 so as to be rotatable. The Rukoto. That is, the work holding means 10 in this embodiment includes a mandrel 29 and a clamper cylinder 31 provided to face the mandrel 29. Further, in this embodiment, the spindle motor 25 is rotated to drive the workpiece W held between the tip end surface of the mandrel 29 and the clamper member 32.
, The spinning roller 11 movably supported as described later revolves relatively to the workpiece W. That is, the revolution driving means 12 in the present embodiment includes a spindle drive motor 25
And a spindle 22 rotationally driven thereby, and a mandrel 29 carried inside the spindle 22.

A pair of guide rails 33 are disposed at an intermediate position on the base 20 in parallel with the rotation center axis of the spindle 22. On the guide rails 33, an axial movement support base 34 is provided in the axial direction (see FIG. 5 and the horizontal direction in FIG. 6). A ball screw 35 is provided on the base 20 in parallel with the guide rail 33. A ball screw nut (not shown) screwed to the ball screw 35 is provided on the lower surface of the axial movement support base 34. ) Is provided. An axial drive motor 36 is connected to one end of the ball screw 35. The ball screw 35 is rotated around its axis by rotating and driving the axial drive motor 36 in an arbitrary direction and a rotation amount, and the axial movement support base 34 provided with a ball screw nut (not shown) , Ie, in the plane direction with respect to the flat work W and in the axial direction of the hollow work W.

Further, a pair of guide rails 37 are disposed on the axial movement support table 34 in a direction orthogonal to the rotation axis of the spindle 22, and a radial movement support table 38 is rotated on the guide rail 37. It is slidably supported in a radial direction (vertical direction in FIG. 6 which is a plan view) orthogonal to the axial direction. A ball screw 39 is disposed on the axial movement support base 34 in parallel with the guide rail 37, and a ball screw 39 is provided on the lower surface of the radial movement support base 38.
Is provided with a ball screw nut 40 screwed into the nut.
A radial drive motor 41 is connected to one end of the ball screw 39. The ball screw 39 is rotated around its axis by rotating the radial drive motor 41 in an arbitrary direction and an amount of rotation, and the radial moving support base 38 provided with the ball screw nut 40 is attached to the guide rail 37. Along the axis of rotation of the spindle 22, that is, in the radial direction of the workpiece W.

On the upper surface of the radial movement support table 38, there is provided a spinning roller support table 42 rotatable around a rotation axis set to extend in the vertical direction. A pair of bearing brackets 43 are erected on the upper surface of the spinning roller support base 42, and the rotating shaft of the spinning roller 11 is supported on both ends of the upper end of the bearing bracket 43. A gear 44 is provided below the spinning roller support 42. A spinning roller angle adjustment motor 46 is supported by a support bracket 45 on the upper surface of the radial movement support base 38. A gear 47 meshed with the gear 44 of the spinning roller support 42 is provided on the rotation shaft of the spinning roller angle adjustment motor 46. By rotating the spinning roller angle adjusting motor 46, the gear 4 is rotated.
7, 44, the rotation axis of the spinning roller 11 supported by the bearing bracket 43 of the spinning roller support 42 is adjusted to be inclined at an arbitrary angle with respect to the rotation center axis direction of the spindle 22. .

That is, in this embodiment, the spinning roller moving means 13 comprises an axial moving support base 34 and a radial moving supporting base 38 which are moved by an axial driving motor 36 and a radial driving motor 41, and the like. Further, the spinning roller attitude adjusting means 14 is constituted by a spinning roller support 42 and the like which are rotationally driven by a spinning roller angle adjusting motor 46.

Further, although not shown, the processing apparatus of the present invention is provided with control means for controlling each means 10, 12, 13, 14 and the like. The control means includes a spinning process in a plane direction for forming a flat work W into a hollow shape, a burring process for forming a cylindrical joint portion 1b from an opening 1 ″ of the work W, or a hollow work. The spindle drive motor 25, the axial drive motor 36, and the radial drive according to the contents of each forming process such as spinning for forming the cone portion 1c and the joint portion 1b from the catalyst installation portion 1a by narrowing the end of the shaft. Each component 1 of the processing apparatus such as a motor 41 and a spinning roller angle adjusting motor 46
A molding program including a plurality of servo programs set to control 0, 12, 13, and 14 is stored. The control means includes input means for setting and inputting various processing conditions such as the rotational speed of the spindle 22 and the axial and radial movement speeds of the various forming rollers 11, 11 ', 60. And storage means for storing the respective processing conditions set and input from (not shown). The control contents of this control means will be described in detail in the following manufacturing method.

An embodiment of the method for manufacturing a catalytic converter according to the present invention is described in which a cone 1c and a single joint 1b are provided at both ends of a catalyst installation section 1a by using the processing apparatus constructed as described above. The case of molding will be described with reference to FIGS.

The method for manufacturing a catalytic converter according to the present invention generally comprises spinning a flat work W in the plane direction to form a hollow catalyst container 1 having a catalyst installation portion 1a in which a catalyst 2 is installed. And a catalytic converter including the same.

Prior to manufacturing the catalytic converter,
As shown in the perspective views of FIGS. 1 and 2A, the flat work W is formed into a substantially circular shape. Then, as shown in FIG. 8, the processing device is first driven so that the piston rod of the clamper cylinder 31 is retracted, so that the clamper member 32 is separated from the mandrel 29.

The production of the catalytic converter is started (S in FIG. 7).
In 1), the center of the circular plate-shaped work W is arranged between the clamper member 32 and the distal end surface of the mandrel 29, and driven so as to extend the piston rod of the clamper cylinder 31, as shown in FIG. Next, the center of the work W is clamped and held between the clamper member 32 and the distal end surface of the mandrel 29 (S2 in FIG. 7).

Thereafter, a servo program for spinning the work W in the plane direction is selected from a forming program to form the flat work W into a hollow shape through input means (not shown). (S in FIG. 7
3) The processing conditions such as the number of rotations (rotation speed) of the spindle 22 per unit time and the movement (feed) speed of the spinning roller 11 are set and input (S4 in FIG. 7). The control means reads the selected servo program (S5 in FIG. 7), transfers the set and input machining conditions to the servo program (S6 in FIG. 7), and based on the servo program, sets the coordinate data of the spinning roller 11. Is calculated (S7 in FIG. 7). The selection of the forming program (S3 in FIG. 7) and the input of the processing conditions (S4 in FIG. 7) can also be performed before the clamping of the workpiece W (S2 in FIG. 7).
Subsequently, the control means determines whether or not the calculated coordinate values exceed the axial and radial movement limits (stroke limits) of the spinning roller 11 of the processing apparatus (S8 in FIG. 7). When the stroke limit is exceeded (N
In the case of O), an alarm is output (S9 in FIG. 7), the workpiece W is unclamped (S11 in FIG. 7), and the processing apparatus is stopped (S12 in FIG. 7). On the other hand, if the stroke limit has not been exceeded (YES in S8), a servo program is executed (S10 in FIG. 7) as shown in FIGS. After the execution of the program is completed, the workpiece W is unclamped (S11 in FIG. 7), and the processing apparatus is stopped (S12 in FIG. 7).

When performing a servo program for forming a hollow catalyst installation portion 1a continuous with a single joint portion 1b and a cone portion 1c by performing spinning processing in the plane direction of a flat work W, As shown in FIG. 12, the movement trajectory of the spinning roller 11, first, the spinning roller 11 is interposed between the mandrel 29 and the clamper member 32 and is rotated by the spindle drive motor 25. Is arranged at a position corresponding to the outer periphery of the tip forming the joint 1b of the mandrel 29 near its center in the radial direction, and is arranged at a position separated from the plane of the workpiece W in the axial direction (P1). . From this state, while maintaining the position in the radial direction, the work W is moved leftward in FIG.
The spinning roller 11 is moved forward to the front end position P2 of the portion to be the joining portion 1b, and the spinning roller 11 is brought close to and brought into contact with the plane of the rotationally driven work W. Then, position P
3 while moving the spinning roller 11 forward to the left in FIG.
Is moved radially outward from the center toward the periphery. Then, while moving slightly outward from the position P3 to the position P4 in the axial direction while moving backward from the position P3 to the position P4, the intermediate position P of the portion that becomes the joint 1b from the position P4.
5 is moved backward in the axial direction while moving inward in the radial direction, and then moved forward only along the outer shape of the portion to be joined 1b to the boundary position P6 of the portion to be cone 1c only in the axial direction. The workpiece W is moved radially outward and axially from the distal end position P2 of the portion serving as the joint portion 1b to the boundary position P6 of the portion serving as the cone portion 1c, and is slightly moved outward in the axial direction. A series of these steps may be repeated a plurality of times, such as moving backward in the axial direction while moving radially inward to an intermediate position of the portion to be the joint 1b.

Then, the workpiece W is moved forward in the axial direction while moving radially outward of the workpiece W to P7 in accordance with the inclination α1 of the cone portion 1c to be formed from the boundary position P6. The position is returned to a position P8 which is outward in the radial direction with respect to the boundary position P6 with the cone portion 1c and substantially the same in the axial direction. This prevents springback of the workpiece W pressed in the planar direction and prevents the material from flowing back to the joint 1b. After that, it is moved only radially outward from the position of P8 to a position P9 corresponding to the outer shape of the part to be the catalyst installation part 1a, and subsequently, a predetermined length in the axial direction from the boundary between the cone part 1c and the catalyst installation part 1a To the position P11, and then to the position P11 at a predetermined angle α2 in the radially outward and axial directions of the work W, and to the position P12 while slightly moving in the radially outward direction. In the axial direction while moving radially inward to a position P13, which is advanced by a predetermined length in the axial direction from the previous P10.

Next, the above-mentioned P10-P11-P12
Similarly to the series of movement trajectories of -P13, the workpiece W is moved forward in the radial direction and in the axial direction, and is moved backward in the axial direction while slightly moving outward in the radial direction, and is advanced by a predetermined length in the axial direction. Steps P14-P15-P16 ... of retreating in the axial direction while moving radially inward to the position are repeated. In the embodiment shown in FIG. 12, the axial length (pitch b2.b3.b4... Bn) between the positions P10-P13.P13-P16.P16-P19. And the forming angle α1.α2.α3... Toward the position P10-P11.P13-P14.P16-P20... With respect to the plane of the first flat workpiece (that is, the plane perpendicular to the central axis in the radial direction). Are set so as to gradually increase (approach parallel to the rotation center axis of the mandrel). When the pitch bn is set to be large, the plate thickness t of the work W becomes large, and the pitch bn
Is set small, the plate thickness t of the work W becomes thin. Therefore, the setting of the pitch bn can be included as a processing condition for forming the catalyst container 1 into a desired plate thickness.

When the workpiece W is formed into a substantially hollow shape, the spinning roller 11 is moved from the position P38 to the position P39 only radially outward, and thereafter, behind the tip of the joint 1b (rightward in FIG. 12). P40) in the axial direction only to P40, and in accordance with the shape of the catalyst container 1 to be molded, the tip P41 of the joint 1b-the boundary P4 between the joint 1b and the cone 1c.
2-The boundary P43 between the cone portion 1c and the installation portion 1a is moved to the end P44 of the work W, and finish forming is performed. In addition,
When moving to the above-described positions, the spinning roller 11
Is adjusted by driving the spinning roller angle adjusting motor 46 so that the workpiece W is brought into contact with the workpiece W at an optimum inclination angle for spinning the workpiece W in the planar direction. More specifically, at the beginning of performing the spinning process on the flat work W, the flat surface (a plane perpendicular to the rotation center axis of the rotationally driven mandrel 29) is 15 to 45 degrees, preferably 30 degrees. It is adjusted so that it is inclined at an angle of about degrees.

Thus, the work W having a flat plate shape
Is formed by spinning in the plane direction, so that the joining portion 1b at one end (at this stage, the end face is closed as shown in FIG. 1B), the cone portion 1c, and the catalyst installation portion 1a is in a state of being continuously formed into a hollow shape. Thereafter, as shown in FIG. 13, the mandrel 29 is removed from the spindle 22 in the processing device,
Instead, a chuck 21 'capable of properly holding a hollow workpiece W is attached to the spindle 22, and the workpiece W is attached to the workpiece W from its opening as shown in FIG. Of the catalyst 2 is inserted into the installation portion 1a. As shown in FIG. 13A, the chuck 21 ′ includes a pair of work holding members 50 formed in half according to the outer shape of the work W, and a diameter of at least one of the work holding members 50. And a cylinder 51 that is driven to open and close by moving in the direction. In the embodiment shown in FIG. 13, the case where the spinning roller 11 ′ is replaced with a cantilever type is shown. However, as shown in FIG. 5 and FIG. It is also possible to carry out drawing by a spinning roller 11 having a double-supporting shape whose angle can be adjusted for spinning. In FIG. 13, the clamper support 30, the clamper cylinder 31, and the clamper member 32 are not shown. The end face of the joint 1b formed at the tip of the work W having the joint 1b and the cone 1c formed at both ends (the center of the work when it is flat) is shown in FIG. As described above, the hole is opened or the joint portion 1b is opened by being cut at a predetermined position.
The opening of the end face can be performed before the drawing process for forming the cone portion 1c and the joint portion 1b at the opposite end.

In this embodiment, the work W is rotated, and the spinning roller 11 ′ is rotated with respect to the work W.
Although the case where the drawing process is performed by relatively revolving by moving in the axial direction and the radial direction has been described, the present invention is not limited to this embodiment,
The work W may be fixed, and the spinning roller 11 ′ may revolve along the outer peripheral wall of the work W. Then, the revolving shaft of the spinning roller 11 'and the central axis of the workpiece W are deflected at a predetermined angle or decentered by a predetermined amount, thereby allowing one side as shown in (b) or (c) of FIG. The end cone 1c and the joint 1b can be formed so as to be deviated or decentered. Further, as shown in FIG. 2, when spinning the flat work W in the plane direction thereof, the joint 1
b and the cone portion 1c without forming the catalyst installation portion 1
When formed into a cylindrical shape having substantially the same diameter as a, the joint portion 1b and the cone portion 1c at both ends are formed concentrically as shown in FIG. The cone 1c and the joint 1b at one end are decentered or eccentric as shown in c), or the cone 1c at both ends and the joint 1c as shown in FIG. 3 (d) or (e). The portion 1b may be formed so as to be deviated or eccentric.

Next, another embodiment of the present invention will be described with reference to FIG.
This will be described with reference to FIG. In this embodiment, as shown in FIG. 4, a catalytic converter in which a branch portion 1d having a plurality of cylindrical joining portions 1b is provided on one side of a catalyst container 1 is manufactured. Note that the same or corresponding parts as those of the above-described embodiment are denoted by the same reference numerals, and description thereof is omitted.

Branch 1d having a plurality of cylindrical joints 1b
Prior to forming the work W, as shown in FIG. 4A, the flat work W is formed into a circular shape, and is formed at a portion that becomes a branch portion 1d after substantially the center of the work W. A hole 1b 'having a predetermined shape is formed. The shape of the hole 1b 'will be described later in detail. Further, in the processing apparatus, as shown in FIGS. 14 and 15, the shape of the tip of the mandrel 29 is formed so as to correspond to the shape of the branch portion 1d. In this embodiment, the case where the spinning roller 11 is in a cantilever state is shown.

The processing device is first driven so that the piston rod of the clamper cylinder 31 is retracted as shown in FIG. 14A, and the clamper member 32 is separated from the mandrel 29. ing.

As shown in FIG. 7, when starting the production of the catalytic converter (S1), the center of the circular flat work W is placed between the clamper member 32 and the tip end surface of the mandrel 29, and the clamper The piston rod of the cylinder 31 is driven so as to extend, and the center of the work W is clamped and held between the clamper member 32 and the distal end surface of the mandrel 29 as shown in FIG. S
2).

Thereafter, through a not-shown input means, the work W is spin-formed in the plane direction from the forming program in order to form the work W from a flat plate into a hollow shape having a branch portion 1d. A servo program is selected (S3 in FIG. 7), and processing conditions are set and input (S4 in FIG. 7). The control means reads the selected servo program (S5 in FIG. 7), transfers the set and input machining conditions to the servo program (S6 in FIG. 7), and based on the servo program, sets the coordinate data of the spinning roller 11. (S7 in FIG. 7), it is determined whether the stroke limit is exceeded (S8 in FIG. 7). If the stroke limit is exceeded (in the case of NO), an alarm is output (S9 in FIG. 7). The workpiece is unclamped (S11 in FIG. 7), and the processing device is stopped (S1 in FIG. 7).
2). On the other hand, if the stroke limit has not been exceeded (YES in S8), the servo program is executed as shown in (c) of FIG. 14 and (d) to (f) of FIG. Is executed (S10 in FIG. 7),
After the execution of the servo program is completed, the workpiece W is unclamped (S11 in FIG. 7), and the processing apparatus is stopped (S12 in FIG. 7). When the servo program is executed, the spinning roller 11 is tilted and adjusted to a predetermined angle as in the above-described embodiment.

When performing a servo program for forming a hollow installation portion 1a continuous with a branch portion 1d having a plurality of joining portions 1b by performing spinning processing in the plane direction of a flat work W, FIG. Spinning roller 1 at 16
First, the spinning roller 1
1 in the axial direction from the position P1 toward the position corresponding to the outer periphery of the tip of the mandrel 29 in the radial direction of the work W being rotated by the spindle drive motor 25 in FIG.
Is moved forward to the left, and after contacting the surface of the work W at the position P2, the inclination α1 of the branch portion 1d to be formed is changed.
, The workpiece W is moved forward in the axial direction while being moved radially outward of the work W to P3.

As a result, as shown in FIG. 14C, the work W is plastically deformed into a truncated cone shape at an angle corresponding to the inclination of the branch portion 1d. At this time, the branch 1
As shown in FIG. 17, the hole 1b 'of the work W drilled in advance in the part to be d is filled with the material in the rotation direction of the work W by the rotation of the work W with respect to the spinning roller 11 when performing the spinning process. As a result, an opening 1b ″ having a deformed shape is formed. As shown in FIG. 18, it is assumed that a circular hole 1b ′ having a diameter d is formed in the work W in advance. As the material of the work W flows in the radial direction along with the movement of the spinning roller 11 from P2 to P3 in the radial direction outward as shown in FIG.
Although d1 does not substantially change from the initial diameter d when drilled (d1 ≒ d), the radius r1 from the center of the hole 1b 'to the center of the work W and the work W from the center of the hole 1b'
Is larger than the initial radius d / 2 when both are drilled (r1> d / 2, r2> d / 2), and the radius of the workpiece W from the center of the hole 1b ' Radius r1 toward the center
The radius r2 from the center of the hole 1b 'to the outside in the radial direction of the work W is larger than that of the hole 1b' (r
2> r1).

Therefore, in the present invention, as shown in FIG. 19, the flow of the material of these works W is anticipated, and the shape of the hole 1b 'formed in the work W is set as follows. . That is, assuming that the diameter of the opening 1b "after the spinning is D3, the circumferential diameter D is relatively small.
2 is set to substantially the same size as the final diameter D3 to be formed (D2 ≒ D3), and the radial diameter D1 that changes so as to be relatively large is larger than the final diameter D3 to be formed. It is set to be small (D3> D1) and smaller than the diameter D2 in the circumferential direction (D2> D1).
By setting in this manner, the hole 1b ', which is formed in advance in the work W and serves as the joint portion 1b, is changed into a substantially circular opening 1b "by spinning.

Further, when the spinning roller 11 is moved from P2 to P3 in FIG. 16 to plastically deform the flat work W into a truncated cone shape at an angle α1 corresponding to the inclination of the branch portion 1d, FIG. As shown in (a) and (b), the radially outer edge of the hole 1b 'previously drilled in the work W tends to jump up. Then, as shown in FIG. 20 (c), after plastically deforming into a truncated conical shape at an angle corresponding to the inclination α1 of the branch portion 1d, in order to remove the bouncing of the radially outer edge of the hole 1b ′, Further, the spinning roller 11 is moved back toward the inner side in the radial direction. However, here, from P3 to P2
When the material is moved back along the same path, the material flows from the branch portion 1d toward the end face and is deformed so as to protrude and protrude (see the symbol M in FIG. 20C). Therefore, in the present invention, the spinning roller 11 is simply removed from the branch portion 1d in order to remove the jump of the edge on the radially outer side of the hole 1b 'and to prevent the deformation M from protruding from the branch portion 1d toward the end face. Instead of reciprocating along the same path according to the inclination α1, FIG. 16 and FIG.
As shown in (d) of FIG. 0, it is returned from P3 to P4, which is a position axially rearward of P2 (rightward in FIG. 16, above (d) in FIG. 20), near the end face of the branch portion 1d. The spinning roller 11 is moved so as to be separated from the work W.

Thereafter, as shown in FIG. 16, the spinning roller 11 returned to the position P4 is moved only radially outward to a position P5 corresponding to the outer shape of the portion to be the installation portion 1a. From the boundary between 1c and the installation portion 1a, the workpiece W is moved forward only to the predetermined length in the axial direction to P6 only in the axial direction, and then is advanced toward the position P7 at the predetermined angle α2 in the radially outward direction and in the axial direction of the work W. It is moved axially backward while moving slightly radially outward to P8, and axially retracted while moving radially inward to a position P9, which has advanced a predetermined length in the axial direction from the previous P6. Move. Next, the above-mentioned P6-P7-P8-P
9, the workpiece W is moved forward in the radial direction and in the axial direction of the workpiece W, and is moved backward in the axial direction while slightly moving outward in the radial direction, and is advanced by a predetermined length in the axial direction. Steps P10-P11-P12 ... of retreating in the axial direction while moving inward in the radial direction are regularly repeated. Note that, in the embodiment shown in FIG. 16, as in the embodiment shown in FIG.
The axial length (pitch b2.b3.b4... Bn) between -P12.P12-P15... Is set to be substantially uniform, and the plane of the first flat workpiece W (that is, with respect to the center axis). P6-P7.P9 with respect to the plane perpendicular to the radial direction
-P10.P15-P16 ... forming angle α1. Α2.
.alpha.3 are set so as to gradually increase (to approach parallel to the rotation center axis). When the pitch bn is set to be large, the plate thickness t of the work W becomes large, and when the pitch bn is set to be small, the plate thickness t of the work W becomes small, similarly to the above-described embodiment. is there.

When the work W is formed into a substantially hollow shape, the spinning roller 11 is moved from the position P34 to the position P35 only radially outward, and thereafter, behind the tip of the joining portion 1b (rightward in FIG. 16). The work W to be formed is moved only in the axial direction up to P36), and the work W is pressed against the mandrel 29 by the spinning roller 11.
The boundary P37 between the tip surface and the branch portion 1d-the boundary P38 between the branch portion 1d and the installation portion 1a-the end portion P39 of the workpiece W according to the shape
To finish molding. Adjustment to move the spinning roller 11 to the workpiece W at an optimum inclination angle for spinning the workpiece W in the plane direction when moving to each position is the same as in the above-described embodiment. is there. Thus, the work W having a flat shape
By the spinning process in the plane direction, a branch portion 1d having a plurality of circular openings 1b ", which is later formed into a cylindrical joint portion 1b, is formed on one end side.

Thereafter, as shown in FIG. 21, a burring roller 6 is provided in the processing apparatus in place of the spinning roller 11.
0, and the mandrel 29 is removed from the spindle 22 so that the hollow work W is appropriately moved so that one of the openings 1b "formed in the branch portion 1d faces the burring roller 60. 21 is attached to the spindle 22. The holding jig 61 is formed into a half-split shape according to the outer shape of the work W as shown in FIG. , A pair of work holding members 62,
62 and a cylinder 6 driven to open and close by moving at least one of the work holding members 62 in the radial direction.
And 3. In the work W, the center of the circular opening 1b "formed in the branch portion 1d coincides with the rotation center axis of the spindle 22, and the periphery of the opening 1b" is positioned on a plane orthogonal to the rotation center axis of the spindle 22. As
It is held by the holding jig 61. In the embodiment shown in FIG. 21, the drive 25 of the spindle drive motor causes the circular opening 1b "formed in the branch portion 1d to rotate about the rotation center axis of the spindle 22, and the burring roller 60 opens the work W 1b ". In FIG. 21, similarly to FIG. 13, the clamper support 30, the clamper cylinder 31 and the clamper member 32
Is abbreviated.

FIGS. 22 and 23 show a case in which a cylindrical joint 1b is formed by burring so as to project outward of the work W. FIG. 24 shows, in order, a case where a cylindrical joint 1b is formed so as to project toward the inside of the work W by burring. 22 to 24, the burring roller 60 is rotated so as to revolve with respect to the opening 1b "of the work W, and the revolving diameter of the burring roller 60 can be arbitrarily changed. In the case shown.

When the cylindrical joining portion 1b is formed so as to protrude toward the outside of the work W by the burring process, the burring roller 60 is opened by the burring roller 60 as shown in FIG. 22. When the burring process is started, the position shown in FIG.
First, as shown in (b) of FIG.
22 is aligned with the opening 1b "of the work W so as not to come into contact with the periphery thereof, and then, as shown in FIG.
b ”. The orbital diameter of the burring roller 60 at this time is changed so as to contact the opening 1b ″ of the work W and slightly expand it. Then, Figure 2
As shown in FIG. 3 (d), the opening 1b "formed in the work W is plastically deformed so as to protrude outward. Then, the revolving diameter of the burring roller 60 relative to the opening 1b" is determined. The opening 1b "of the work W is subjected to burring by repeating the movement such as enlargement and removal, and a cylindrical joint projecting outward from the branch 1d as shown in FIG. 1b will be formed.

Then, by rotating the spindle 22 or the like, as shown in FIG. 23 (f), the workpiece W is formed so that the opening 1b ″ where the cylindrical joining portion 1b is not yet formed faces the burring roller. 26 is changed and held, and a plurality of cylindrical joints 1b having a shape as shown in FIG. 26 are formed by repeatedly performing the same burring process as forming the cylindrical joint 1b first. The work W formed in 1d is formed.

On the other hand, as shown in FIG. 24, when forming a cylindrical joint portion 1b inside the branch portion 1d of the work W,
As shown in FIG. 24A, the burring roller 60 is moved so as to be inserted into the opening 1b "of the work W while revolving so as to be in contact with the peripheral edge of the opening 1b" so as to be enlarged. Then, as shown in FIG. 24B, the opening 1b "of the work W is plastically deformed so as to protrude inward. Then, the orbital diameter of the opening 1b" of the burring roller 60 is increased with respect to the opening 1b ". By repeating the movement of insertion, the opening 1b "of the work W is subjected to burring, and as shown in FIG. 24 (c), a cylindrical joint projecting inward from the branch 1d. 1b will be formed.

Here, as shown in FIG. 25 (a), if the opening 1b "of the work W is scratched or cracked, the joining portion 1b projecting in a cylindrical shape when burring is performed. 25B, a further enlarged crack is formed, and even when the burring roller 60 has a flaw or dirt, a flaw or the like is generated in the opening 1b ". Easier to do. Therefore, when forming the cylindrical joint portion 1b, it is desirable to remove the scratches generated in the opening 1b ″ of the work W and the scratches and dirt attached to the burring roller 60.

As shown in FIG. 26 (a), when the revolving speed of the burring roller 60 is set to be large (fast), the projecting height and the thickness of the cylindrical joint portion 1b are relatively small. A thin cylindrical joint 1b with a low protrusion height is formed,
On the other hand, when the revolving speed is set to be small (slow), a cylindrical joint 1b having a relatively large thickness t and a high protruding height is formed. Therefore, by adjusting the revolving speed of the burring roller 60 among the processing conditions set in S4 of FIG. 7, the cylindrical joint 1b can be formed to have a desired protrusion height and wall thickness t.
Can be molded into

Thus, the work W having a flat plate shape
Is formed into a hollow shape by spinning in the plane direction, and a branch portion 1d having a plurality of cylindrical joints 1b at one end thereof is continuously formed integrally with the catalyst installation portion 1a. . Thereafter, as shown in FIG. 13, the holding jig 61 is removed from the spindle 22 in the processing device,
Instead, a chuck 21 'capable of appropriately holding the hollow workpiece W is attached to the spindle 22, and the workpiece W is provided on the opposite side of the branch portion 1d as shown in FIG. A catalyst 2 such as a monolith is inserted into the installation portion 1a from the opening of the mounting portion 1a. Then, as shown in FIG. 13, the catalyst 2 is accommodated and installed in the installation part 1a by performing spinning processing so as to reduce the diameter of the open end opposite to the branch part 1d, and continuously from the installation part 1a. As a result, a catalytic converter including the catalyst container 1 in which the branch portion 1d having a plurality of cylindrical joint portions 1b, the cone portion 1c, and the joint portion 1b are integrally formed is manufactured.

The catalytic converter manufactured according to the present invention can be used not only for the exhaust pipe of a combustion engine such as an internal combustion engine, but also for
In order to remove harmful gas contained in the fuel gas containing air in advance, it can also be connected to an intake pipe.

[0093]

According to the first aspect of the present invention, the installation portion for installing the catalyst from the plate material is integrally formed by spinning, so that the quality is stable with a small number of steps and the air leak inspection is required. No tactile converter can be provided.

According to the second aspect of the present invention, the installation portion for installing the catalyst from the plate material is formed integrally by spinning in the plane direction of the plate material, so that the quality can be stabilized accurately with a small number of steps and the air leak can be performed. A catalytic converter that does not require inspection can be provided.

According to a third aspect of the present invention, in the first or second aspect of the present invention, the plate is preliminarily provided with a hole having a predetermined shape, and the joint is formed by spinning the plate in the plane direction. By forming a circular opening, a mounting portion for installing a catalyst by spinning is integrally formed from a plate material in which holes of a predetermined shape are formed in advance, and a predetermined portion formed in the plate material in advance. It is possible to provide a catalytic converter in which a circular opening forming a joint is formed from a hole having a shape.

According to a fourth aspect of the present invention, in the first or second aspect of the present invention, a plurality of holes having a predetermined shape are formed in advance in the plate material, and the plurality of holes are formed by spinning the plate material. Provided is a catalyst converter in which a branch portion having a plurality of openings is integrally formed together with an installation portion for installing a catalyst from a plate material by spinning processing by forming a branch portion having an opening of the same. can do.

According to a fifth aspect of the present invention, in the third or fourth aspect of the present invention, the cylindrical joint is formed in the opening by burring, so that the cylindrical joint is formed from the opening by the burring. It is possible to provide a catalytic converter whose part is integrally formed.

According to the sixth aspect of the present invention, the plate material is spinned in the plane direction and the installation portion is integrally formed, so that the quality is stabilized with a small number of steps and the air leak inspection is required. The present invention can provide a method for manufacturing a catalytic converter.

According to a seventh aspect of the present invention, in the sixth aspect of the present invention, a hole having a predetermined shape is formed in the plate in advance so as to form a circular opening when the plate is spinned in the plane direction. In addition, it is possible to provide a method of manufacturing a catalytic converter in which a circular opening forming a joint is integrally formed when an installation portion is formed by spinning a plate material in a plane direction thereof.

According to the invention of claim 8, in the invention of claim 6, a plurality of holes having a predetermined shape are previously formed in the plate, and the plate is provided with a plurality of openings by spinning in the plane direction thereof. By forming the branched portion, it is possible to provide a method for manufacturing a catalytic converter in which a branched portion having a plurality of openings is integrally formed.

According to the ninth aspect of the present invention, in the invention according to the seventh or eighth aspect, a burring process is performed on the opening to form a cylindrical joint, whereby the cylindrical joint is integrally formed. A method for manufacturing a catalytic converter can be provided.

According to the tenth aspect, the sixth to ninth aspects are described.
In the invention according to any one of the above, further, by forming the reduced diameter portion of the end portion by spinning, the reduced diameter portion of the end portion is integrally formed with the installation portion and the joint portion for installing the catalyst from the plate material by the spinning process. It is possible to provide a method for manufacturing a catalytic converter molded into a shape.

According to the eleventh aspect of the present invention, there is provided a spinning roller which relatively revolves with respect to a flat work and performs spinning processing in a plane direction to plastically deform the work from a flat shape to a hollow shape. And a spinning roller attitude adjusting means for adjusting the attitude of the spinning roller according to the shape of the work plastically deformed from the flat shape to the hollow shape so that the work is appropriately plastically deformed from a flat plate shape to an integrated hollow shape. And a processing device capable of performing the above.

According to a twelfth aspect of the present invention, in the eleventh aspect of the present invention, the holding means for holding the work can be replaced according to the shape of the work to be plastically deformed, so that the work can be properly replaced. A processing device capable of holding and plastically deforming can be provided.

According to a thirteenth aspect of the present invention, in the eleventh or twelfth aspect of the present invention, the plate-shaped work is formed with a hole of a predetermined shape in advance, and the work near the hole of the work caused by the spinning is bouncing. By providing the control means for controlling the movement of the spinning roller so as to remove the spin, it is possible to provide a processing apparatus capable of removing the splash generated near the hole by the spinning.

According to a fourteenth aspect, in the thirteenth aspect, a circular opening formed from a pre-drilled hole is formed by spinning a flat work. Burring means for forming a cylindrical joint by spinning a flat work to form a circular opening formed from a pre-drilled hole into the cylindrical joint. And a processing apparatus capable of performing such processing.

[Brief description of the drawings]

FIG. 1 is an explanatory view showing one embodiment of a manufacturing process of a catalytic converter provided with a joint portion and a cone portion at both ends of the present invention.

FIG. 2 is an explanatory view showing another embodiment of a manufacturing process of a catalytic converter having a joint portion and a cone portion provided at both ends of the present invention.

FIG. 3 is an explanatory view showing types of shapes of a catalyst container formed according to the present invention.

FIG. 4 is an explanatory view showing one embodiment of a manufacturing process of a catalytic converter provided with a branch portion having a plurality of joints of the present invention.

FIG. 5 is a front view showing the processing apparatus of the present invention.

FIG. 6 is a plan view of FIG. 5;

FIG. 7 is a flowchart illustrating a method for manufacturing a catalytic converter according to the present invention.

FIG. 8 is a plan view showing a state before a work of the processing apparatus is set.

FIG. 9 is a plan view showing a state where a work of the processing apparatus is set.

FIG. 10 is a plan view showing a state in which a workpiece of the processing apparatus is being spinned in a plane direction thereof.

FIG. 11 is a plan view showing a state in which spinning processing on a work of the processing apparatus is completed.

FIG. 12 is an explanatory view showing an embodiment of a movement locus of a spinning roller for spinning a flat work into a hollow shape having a single joint portion and a cone portion by spinning the work in the surface direction. is there.

FIG. 13 is a front view of a processing apparatus for explaining a case in which spinning is performed so as to squeeze the opposite end of a hollow workpiece.

FIG. 14 is an explanatory view showing a step in forming a branch portion.

FIG. 15 is an explanatory diagram showing a step that follows the step in FIG. 14;

FIG. 16 is an explanatory view showing an embodiment of a movement locus of a spinning roller for spinning a flat work into a hollow shape having a branch by spinning the work in the surface direction.

FIG. 17 is an explanatory diagram showing a state in which a material flows in a rotation direction of a work by performing spinning processing to form an opening having a deformed shape.

FIG. 18 is an illustration showing a state in which, assuming that a circular hole has been formed in the work in advance, by spinning, the material flows in the radial direction of the work and an opening having a deformed shape is formed. FIG.

FIG. 19 is an explanatory view showing a state in which a hole having a predetermined shape is previously formed in a work and spinning is performed, whereby a material flows in a radial direction of the work and a circular opening is formed. is there.

FIG. 20 shows an embodiment of a state in which the periphery of a hole is bounced when a flat work is spun in the plane direction thereof and the movement locus of the spinning roller of the present invention for preventing the bounce. FIG.

FIG. 21 is a front view of a processing apparatus for describing a case where burring is performed on an opening formed at a branch portion of a work.

FIG. 22 is an explanatory view sequentially showing steps in a case where a cylindrical joint is formed so as to project toward the outside of the work by burring.

FIG. 23 is an explanatory view showing a step that follows the step in FIG. 22;

FIG. 24 is an explanatory diagram sequentially showing steps in a case where a cylindrical joint is formed so as to project toward the inside of the work by burring.

FIG. 25 is an explanatory view showing a state in which a further enlarged crack is formed in a joint formed by performing burring when a crack or the like is formed in an opening of a work.

FIG. 26 is a partial cross-sectional view showing a work in which a branch portion having a plurality of cylindrical joints on one end side is formed according to the present invention;
It is a side view and a plan view.

FIG. 27 is an explanatory view showing an example of a process for manufacturing a conventional catalytic converter provided with a joint portion and a cone portion at both ends.

FIG. 28 is an explanatory view showing another example of a process for manufacturing a conventional catalytic converter provided with a joint portion and a cone portion at both ends.

FIG. 29 is an explanatory view showing an example of a process for manufacturing a conventional catalytic converter provided with a branch portion having a plurality of junctions.

[Description of sign]

 DESCRIPTION OF SYMBOLS 1 Catalyst container 1a Catalyst installation part 1b Joint part 1b 'hole 1b "opening 1c Cone part 1d Branch part 2 Catalyst 10 Work holding means 11 Spinning roller 12 Revolution driving means 13 Spinning roller moving means 14 Spinning roller attitude adjusting means 21, 21' Chuck 61 Holding jig

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification code FI Theme coat ゛ (Reference) B21D 22/16 B21D 22/16 G F01N 3/28 301W F01N 3/28 301 A61L 9/00 C // A61L 9/00 B01D 53/36 B F term (reference) 3G091 AB01 BA39 4C080 AA07 BB01 CC01 HH05 JJ03 KK08 LL02 QQ11 4D048 AA21 AB03 CA01 CA08 CC01 EA08 4G069 AA20 CA03 CA10 DA06 EE10

Claims (14)

[Claims] 1. A catalytic converter, wherein an installation portion for installing a catalyst from a plate material is formed by spinning. 2. A catalytic converter, wherein an installation portion for installing a catalyst from a plate material is formed by spinning a plate material in a planar direction. 3. The plate material is provided with holes of a predetermined shape in advance, and a circular opening forming a joint is formed by spinning in a plane direction of the plate material. 3. The catalytic converter according to 2. 4. The plate member is provided with a plurality of holes having a predetermined shape in advance, and a branch portion having a plurality of openings forming a joint is formed by spinning the plate member. Item 3. The catalytic converter according to Item 1 or 2. 5. A cylindrical joint formed by burring from an opening.
A catalytic converter according to item 1. 6. A method for manufacturing a catalytic converter having an installation part on which a catalyst is installed, wherein the installation part is formed by spinning a plate material in a plane direction thereof. 7. A method for manufacturing a catalytic converter according to claim 6, wherein a hole having a predetermined shape is formed in the plate material so as to form a circular opening when the plate material is spinned in the plane direction. . 8. A plurality of holes of a predetermined shape are previously formed in a plate material,
The method for manufacturing a catalytic converter according to claim 6, wherein the plate material is spinned in a plane direction thereof to form a branch portion having a plurality of openings. 9. The method for manufacturing a catalytic converter according to claim 7, wherein a burring process is performed on the opening to form a cylindrical joint. 10. The method for producing a catalytic converter according to claim 6, wherein the reduced diameter portion at the end is formed by spinning. 11. A spinning roller that relatively revolves with respect to a plate-shaped work and spins in a plane direction to plastically deform the work from a plate shape to a hollow shape, and a plastic deformation from the plate shape to a hollow shape. A spinning roller attitude adjusting means for adjusting the attitude of the spinning roller in accordance with the shape of the work to be processed. 12. The processing apparatus according to claim 11, wherein the holding means for holding the work is replaceable according to the shape of the work to be plastically deformed. 13. A flat work in which a hole having a predetermined shape is formed in advance, and a control means for controlling the movement of the spinning roller so as to remove splashes near the hole of the work caused by spinning. The processing apparatus according to claim 11, wherein: 14. A burring means for burring a circular opening formed from a pre-drilled hole by spinning a flat work to form a cylindrical joint. Claim 1.
4. The processing device according to 3.