Method for manufacturing a can unit

Abstract

The present application relates to a manufacturing method of a tank unit, the manufacturing method of the tank unit comprising: a pressure resistance inspection process of performing pressure resistance inspection on each high-pressure tank before linking a plurality of high-pressure tanks; and a linking process of linking a gas flow path to the plurality of high-pressure tanks that have passed the pressure resistance inspection.

Description

TECHNICAL FIELD

[0001] The technology disclosed in this specification relates to a manufacturing method of a tank unit in which a plurality of high-pressure tanks are joined. BACKGROUND

[0002] A tank unit in which a plurality of high-pressure tanks are joined is disclosed in Japanese Patent Application Publication No. 2019-033657. The tank unit of Japanese Patent Application Publication No. 2019-033657 is a tank unit filled with hydrogen gas, which is mounted on a fuel cell vehicle. The plurality of high-pressure tanks are joined by a joining member. The joining member functions as a pipe that guides gas of the plurality of high-pressure tanks to the outside. The plurality of high-pressure tanks are housed in a housing.

[0003] A tank unit is also disclosed in Japanese Patent Application Publication No. 2021-124171. The high-pressure tanks are elongated cylindrical, and the plurality of high-pressure tanks are arranged in parallel. The head sides and the tail sides of the plurality of high-pressure tanks are joined by a joining member, respectively.

[0004] A pressure resistance test of a high-pressure tank is disclosed in Japanese Patent Application Publication No. 2014-119292. SUMMARY

[0005] A method of efficiently manufacturing a tank unit in which a plurality of high-pressure tanks are joined is provided.

[0006] The manufacturing method disclosed in this specification includes: a pressure resistance inspection step of inspecting the pressure resistance of each of the plurality of high-pressure tanks before the plurality of high-pressure tanks are joined; and a joining step of joining a gas flow path to the plurality of high-pressure tanks that have passed the pressure resistance inspection. The gas flow path is thinner than a pipe of a water injection device that injects liquid into the high-pressure tank. Therefore, if the pressure resistance inspection is performed by injecting water after the gas flow path is attached to the high-pressure tank, it takes time because of the loss of the gas flow path. By performing the pressure resistance inspection of the high-pressure tank before the gas flow path is assembled, the tank unit can be efficiently manufactured.

[0007] An opening is provided at the head and the tail of each of the high-pressure tanks, and the pressure resistance inspection can be performed by sealing the opening of the tail with a plug and injecting liquid from the opening of the head. In this case, after the plug is removed and the inside of each of the high-pressure tanks is dried, an end cap can be attached to the opening of the tail, and the end caps of the plurality of high-pressure tanks can be inserted into the tail-side joining member to join the plurality of high-pressure tanks.

[0008] Dried air that has entered from the opening of the head passes through the inside of the high-pressure tank and flows out from the opening of the tail. Since the dried air can pass in one direction inside, the inside of the high-pressure tank can be dried quickly.

[0009] The joining step includes joining the heads of the plurality of high-pressure tanks with the head-side joining member, and all of the high-pressure tanks can be included in the smallest rectangular parallelepiped that includes the tail-side joining member and the head-side joining member. The tail-side joining member and the head-side joining member can protect all of the high-pressure tanks.

[0010] Detailed techniques and further improvements disclosed in the present specification will be described in the "DETAILED DESCRIPTION" below. BRIEF DESCRIPTION OF DRAWINGS

[0011] The features, advantages, technical and industrial significance of exemplary embodiments of the present application will be described in the following non-limiting specific embodiments with reference to the attached drawings, wherein like numerals indicate like elements, and wherein:

[0012] Figure 1 is a side view of a fuel cell vehicle on which the tank unit of the embodiment is mounted.

[0013] Figure 2 is a perspective view of the tank unit.

[0014] Figure 3 is an exploded perspective view of the tank unit.

[0015] Figure 4 is a plan view of the tank unit.

[0016] Figure 5 is a sectional view of the tank unit cut along the V-V line of Figure 4

[0017] Figure 6 is a sectional view of the tank unit at the middle of the installation of the high-pressure tank to the lid.

[0018] Figure 7 is a sectional view of the tank unit cut along the VII-VII line of Figure 4

[0019] Figure 8 is an enlarged view as viewed in the arrow VIII direction of Figure 5

[0020] Figure 9 is a plan view of the tank unit.

[0021] Figure 10 is a side view of the tank unit.

[0022] Figure 11 is a view of the tank unit as viewed from the head side.

[0023] Figure 12 is a view of the tank unit as viewed from the tail side.

[0024] Figure 13 is a view showing one example of the posture of the tank unit when dropped.

[0025] Figure 14 is an exploded perspective view of the tank unit of the modified example.

[0026] Figure 15 is a sectional view of the tank unit cut along the VIII-VIII line of Figure 14 ​​​FIG. 1 is a sectional view of the tank unit after cutting along the XV-XV line of FIG. 1.

[0027] Figure 16 FIG. 1 is a sectional view of the tank unit after cutting along the XV-XV line of FIG. 1.

[0028] Figure 17 FIG. 1 is a sectional view of the tank unit after cutting along the XV-XV line of FIG. 1.

[0029] Figure 18 FIG. 1 is a sectional view of the tank unit after cutting along the XV-XV line of FIG. 1.

[0030] Figure 19 FIG. 1 is a sectional view of the tank unit after cutting along the XV-XV line of FIG. 1.

[0031] Figure 20 FIG. 1 is a sectional view of the tank unit after cutting along the XV-XV line of FIG. 1. DETAILED DESCRIPTION

[0032] A tank unit 10 of an embodiment is described with reference to the drawings. The tank unit 10 is mounted on a fuel cell vehicle. The tank unit 10 supplies hydrogen gas to a fuel cell stack of the fuel cell vehicle. Figure 1 FIG. 1 is a sectional view of the tank unit after cutting along the XV-XV line of FIG. 1.

[0033] Figure 2 FIG. 1 is a sectional view of the tank unit after cutting along the XV-XV line of FIG. 1. The tank unit 10 includes a plurality of high-pressure tanks 100 that are connected by a head-side connecting member 200 and a tail-side connecting member 300. In Figure 2 In FIG. 1, only one of the plurality of high-pressure tanks 100 is labeled with reference numeral 100, and the other high-pressure tanks are omitted from the drawing.

[0034] The tank unit 10 is fixed to the lower surface of the floor 4 by bolts 999. A protector 5 is disposed below the tank unit 10. The protector 5 protects the tank unit 10 from stones that are kicked up during travel.

[0035] Figure 3 FIG. 1 is a sectional view of the tank unit after cutting along the XV-XV line of FIG. 1. Figure 4 FIG. 1 is a sectional view of the tank unit after cutting along the XV-XV line of FIG. 1. The direction of the coordinate system is different to the left and right of the straight line L1 in Figure 3

[0036] ​The high-pressure tank 100 is a long cylindrical shape. For the sake of explanation, one end of the high-pressure tank 100 in the axial direction is referred to as "head 100a", and the other end is referred to as "tail 100b". The high-pressure tank 100 has an opening 101 at the head 100a. The tank unit 10 includes a plurality of high-pressure tanks 100, which are arranged in parallel with the plurality of heads 100a aligned and the plurality of tails 100b aligned. The heads 100a of the plurality of high-pressure tanks 100 are connected by a head-side connector 200, and the tails 100b are connected by a tail-side connector 300.

[0037] A metal port 110 is installed at the head 100a. The main body of the high-pressure tank 100 is made of carbon fiber reinforced plastic, and the metal port 110 is made of metal. The metal port 110 is a joint for connecting the high-pressure tank 100 and the head-side connector 200. The metal port 110 is a part of the high-pressure tank 100.

[0038] The head-side connector 200 includes a protector 250 and an intake manifold 210. The intake manifold 210 has a gas flow path 240 and a plurality of caps 211, which are connected to the respective metal ports 110 of the plurality of high-pressure tanks 100. The cap 211 plugs the opening 101 on the head side of the high-pressure tank 100. In addition, the inner side of the plurality of caps 211 communicates with the gas flow path 240. That is, the gas flow path 240 opens at the inner side of each cap 211.

[0039] One end of the gas flow path 240 extends from the intake manifold 210 in the X-direction of the coordinate system in the drawing. The one end of the gas flow path 240 is connected to the main stop valve 290 through a groove 251 provided in the protector 250. If each cap 211 is installed in the opening (metal port 110) of the high-pressure tank 100, the opening 101 of the high-pressure tank 100 communicates with the gas flow path 240. The gas flow path 240 guides the gas of the high-pressure tank 100 to the outside.

[0040] The intake manifold 210 is connected to the protector 250 by a bolt 999. The protector 250 is made of high-strength steel, connects the plurality of high-pressure tanks 100, and protects the high-pressure tanks 100.

[0041] The high-pressure tank 100 also has an opening at the tail 100b, and the opening on the tail side is plugged by an end cap 150. The end cap 150 installed on the high-pressure tank 100 protrudes outward from the tail of the high-pressure tank 100. The tail-side connector 300 has a plurality of holes 301, and the end cap 150 of each high-pressure tank 100 is inserted into each hole 301. The plurality of high-pressure tanks 100 are also bundled by the tail-side connector 300. Several high-pressure tanks 100 are fixed to the tail-side connector 300 by the bolt 999 with the aid of the end cap 150. By fixing several high-pressure tanks 100 to the tail-side connector 300, the other high-pressure tanks 100 also do not come off the tail-side connector 300.

[0042] AlongFigure 4 The cross-section of the V-V line is as follows Figure 5 As shown. Figure 5 This illustrates an example of the connection structure between the opening 101 of the high-pressure canister 100 and the cover 211. A metal opening 110 is pressed into the outer periphery of the head 100a of the high-pressure canister 100. Threaded teeth 112 are provided on the outer periphery of the metal opening 110 (i.e., the outer periphery of the head 100a of the high-pressure canister 100), and a threaded groove 212 is provided on the inner circumferential surface of the cover 211. The high-pressure canister 100 (metal opening 110) can be screwed into the cover 211, and the threaded teeth 112 of the metal opening 110 engage with the threaded groove 212 of the cover 211, thus connecting the high-pressure canister 100 and the cover 211.

[0043] A locking groove 402 is provided on the outer periphery of the rear end of the metal opening 110. The locking groove 402 surrounds the outer periphery of the rear end of the metal opening 110. On the other hand, a locking pin 401 is provided on the inner side of the cover 211, which can move forward and backward relative to the metal opening 110. The locking pin 401 is installed on the cover 211 in a way that allows it to move forward and backward relative to the side of the metal opening 110. The locking pin 401 is forced towards the metal opening 110 by a spring 403.

[0044] One side of the locking pin 401 (the side of the opening of the cover 211) is inclined, and the opposite side is perpendicular to the inner surface of the cover 211. Figure 6 The middle indicates that the metal port 110 (the head 100a of the high-pressure can 100) is being gradually screwed into the cover 211. If the high-pressure can 100 is gradually inserted into the cover 211, the locking pin 401 is pushed back by the metal port 110. Figure 6 If the metal port 110 enters the cover 211, and the locking groove 402 and locking pin 401 are opposite each other, then the locking pin 401 is engaged with the locking groove 402 by the spring 403. Figure 5 If the locking pin 401 engages with the locking groove 402, the metal port 110 (high-pressure tank 100) will not detach from the cover 211. The locking pin 401, the locking groove 402, and the spring 403 constitute a locking mechanism 400 that locks the high-pressure tank 100 without detaching it from the cover 211.

[0045] A plug 230 is provided on the inside of the cover 211. The plug 230 is part of the intake manifold 210. The plug 230 enters into the inside of the opening 101 of the high-pressure tank 100. In addition, the gas flow path 240 also passes through the inside of the plug 230. As previously described, the gas flow path 240 is provided on the inside of the cover 211 (plug 230). If the high-pressure tank 100 is connected to the cover 211, the interior of the high-pressure tank 100 is connected to the main check valve 290 via the gas flow path 240.

[0046] Other examples of locking mechanisms are described below. Along... Figure 4 The cross section of line VII-VII is as follows Figure 7indicated. Figure 5 , 6 An example of the locking mechanism 400 is shown in Figure 7 Another example of the locking mechanism (locking mechanism 410) is shown in

[0047] Although not visible in Figure 7 , the same is true in the case of the locking mechanism 410. Figure 5 , Figure 6 Also, a thread 112 is provided on the outer peripheral surface of the metal mouth 110, and a thread groove 212 is provided on the inner peripheral surface of the lid 211. The thread 112 of the high-pressure tank 100 engages with the thread groove 212 of the lid 211, and the high-pressure tank 100 is fixed to the lid 211. A gear 412 is formed at the root of the metal mouth 110 of the high-pressure tank 100. The lid 211 is equipped with a locking pin 411 that advances and retreats with respect to the metal mouth 110, and a spring 413 that applies force to the locking pin 411 toward the metal mouth 110.

[0048] The locking pin 411, the spring 413, and the gear 412 constitute a ratchet configuration that allows rotation of the high-pressure tank 100 in the direction of the arrow Al, and prohibits rotation in the direction of the arrow A2 (reverse rotation). As Figure 7 indicated, the metal mouth 110 (high-pressure tank 100) having the gear 412 can rotate in the direction of the arrow Al, but rotation in the direction of the arrow A2 (reverse rotation) is prevented by the gear 412, the locking pin 411, and the spring 413. The locking mechanism 410 (configuration of Figure 7 ) that employs the ratchet configuration also locks in such a manner that the high-pressure tank 100 does not come off the lid 211.

[0049] A plan view as viewed along the arrow VIII of Figure 5 is shown in Figure 8 . Figure 8 is an enlarged view of the vicinity of the boundary between the opening rim 211a of the lid 211 and the high-pressure tank 100 (metal mouth 110). A tally-impression 220 is marked at the boundary between the lid 211 (opening rim 211a) and the high-pressure tank 100 (metal mouth 110). The tally-impression 220 is marked after the high-pressure tank 100 is installed in the lid 211. Figure 6 is a view of the high-pressure tank 100 halfway through installation in the lid 211, and the tally-impression 220 has not yet been marked.

[0050] Since the locking mechanism 400 / 410 is provided, the high-pressure tank 100 does not easily come off the lid 211. However, even if the high-pressure tank 100 comes off the lid 211 due to some accident and is again connected, since the tally-impression 220 is broken, it is immediately clear that the high-pressure tank 100 has come off the lid 211. The tally-impression 220 can be a sticker or a stamp.

[0051] As described above, the tank unit 10 includes a plurality of high-pressure tanks 100, a head-side link member 200, and a tail-side link member 300. The high-pressure tanks 100 are long in shape, and are arranged in parallel with the heads 100a aligned and the tails 100b aligned. The head-side link member 200 links the heads 100a of the plurality of high-pressure tanks 100, and the tail-side link member 300 links the tails 100b of the plurality of high-pressure tanks 100.

[0052] In Figure 9 , a plan view of the tank unit 10 is shown again. The dashed-line rectangle B1 is the smallest rectangle that contains the head-side link member 200 and the tail-side link member 300. All of the high-pressure tanks 100 are located inside the dashed-line rectangle B1. Figure 10 A side view of the tank unit 10 is shown. Figure 10 The dashed-line rectangle B2 in Figure 10 and the later-described Figure 11 , 12 omits the illustration of the main stop valve 290.

[0053] Figure 11 is a view of the tank unit 10 as viewed from the head side of the high-pressure tanks 100. As viewed from the head side, all of the high-pressure tanks 100 are located inside the outline of the head-side link member 200. Figure 12 is a view of the tank unit 10 as viewed from the tail side of the high-pressure tanks 100. As viewed from the tail side, all of the high-pressure tanks 100 are located inside the outline of the tail-side link member 300.

[0054] As Figure 9 to Figure 12 shown, the tank unit 10 has the following feature. As viewed from the tank length direction (X direction in the figure) that connects the heads 100a and the tails 100b of the high-pressure tanks 100, all of the high-pressure tanks 100 are arranged inside the outline of the head-side link member 200 and inside the outline of the tail-side link member 300 Figure 11 , Figure 12 ). As viewed from the arrangement direction of the plurality of high-pressure tanks 100 (Y direction in the figure) and from the plan direction (Z direction in the figure) that intersects the tank length direction (X direction) and the arrangement direction (Y direction), all of the high-pressure tanks 100 are arranged inside the outline (dashed-line rectangles B1, B2) that contains the head-side link member 200 and the tail-side link member 300. In other words, one configuration feature of the tank unit 10 can be expressed as follows. All of the high-pressure tanks 100 are located in the smallest cuboid that contains the head-side link member 200 and the tail-side link member 300.

[0055] The aforementioned features bring the following advantages. That is, regardless of the orientation of the tank unit 10 upon impact, either the head-side connector 200 or the tail-side connector 300 will be the first to contact the ground. For example, as... Figure 13 As shown, even if the tank unit 10 falls at an angle, the outer corner 300a of the tail-side connector 300 will be the first to contact the ground G. Since the head-side connector 200 or the tail-side connector 300 will be the first to contact the ground when the tank unit 10 falls, the high-pressure tank 100 can be protected.

[0056] Figure 14 An exploded perspective view of tank unit 10a, representing a modified example. Figure 15 Indicates along Figure 14 A cross-sectional view of the XV-XV wire-cut can unit 10a. The can unit 10a includes the can unit 10 of the embodiment and a housing 500 for housing the can unit 10. The can unit 10 is housed in a lower housing 502. The lower housing 502 is sealed by a cover 501. A buffer 503 is disposed between the plurality of high-pressure cans 100 and the inner surface of the lower housing 502. The buffer 503 is a soft sheet material, for example, made of silicone rubber. The housing 500 protects the plurality of high-pressure cans 100, and the buffer 503 protects the plurality of high-pressure cans 100 from vibration.

[0057] (Manufacturing method of tank unit)

[0058] Reference Figure 16 to Figure 20 The manufacturing method of tank unit 10 will be described. The manufacturing method of tank unit 10 includes an inspection process and a connection process. The inspection process is performed before the connection process. In the inspection process, pressure resistance tests are performed on each of the multiple high-pressure tanks 100. In the connection process, the multiple high-pressure tanks that have passed the pressure resistance tests are connected together.

[0059] The inspection procedures are explained. Figure 16 The pressure vessel is shown before the inspection process. Only the left end of the pressure vessel 100 is shown in cross-section. As previously described, the pressure vessel 100 has an opening 101 at the head 100a and an opening 102 at the tail 100b. The tail-side opening 102 is plugged by a plug 151 before the pressure test (see reference). Figure 16 ).

[0060] After the tail-side opening 102 is plugged with plug 151, a water injection device 600 is installed on the head-side opening 101. The water injection device 600 injects water into each high-pressure tank 100 at high pressure. On the other hand, a strain gauge 601 is installed at various points on the surface of each high-pressure tank 100. Figure 17 The diagram shows only one high-pressure tank 100 in cross-section with a strain gauge 601 installed. Strain gauges are also installed in the other high-pressure tanks 100.

[0061] The plurality of strain gauges 601 are electrically connected to the inspection device 602. In the inspection process, each high-pressure tank 100 is filled with water and a prescribed water pressure is applied. The inspection device 602 inspects whether or not the surface strain of the water-filled high-pressure tank 100 is within a prescribed allowable range. In the case where the surface strain exceeds the allowable range, it is determined that the high-pressure tank does not have sufficient pressure resistance and is designated as a pressure resistance inspection failure. The pressure resistance inspection is independently performed for each high-pressure tank 100 before joining.

[0062] If the pressure resistance inspection is completed, the plug 151 is removed from the opening 102 and the water in the high-pressure tank 100 is drained ( Figure 18 ). Next, a blower 605 is connected to the opening 101 on the head side. Dry air is supplied from the blower 605 to each high-pressure tank 100, and the inside of the high-pressure tank 100 is dried ( Figure 19 ). The dry air that has entered from the opening 101 on the head side passes through the inside of the high-pressure tank 100 and flows out from the opening 102 on the tail side. The high-pressure tank 100 has openings on the head side and the tail side. Since the dry air is able to pass in one direction inside, the inside of the high-pressure tank 100 can be dried quickly.

[0063] Next, the joining process is moved to. In the joining process, the high-pressure tanks 100 that have passed the pressure resistance inspection are collected. In the joining process, an end cap 150 is attached to the opening 102 on the tail side ( Figure 20 ). The end cap 150 attached to the high-pressure tank 100 protrudes outward from the tail 100b. A plurality of high-pressure tanks 100 are arranged and the leading end of the end cap 150 is inserted into the tail-side joining member 300. A plurality of bolts 999 are inserted through the tail-side joining member 300 and are fixed to the end cap 150 ( Figure 20 ). The head-side joining member 200 is fixed to the heads 100a of the plurality of high-pressure tanks 100 by the bolts 999. The plurality of high-pressure tanks 100 arranged side by side are joined by the head-side joining member 200 and the tail-side joining member 300.

[0064] The head-side joining member 200 includes a protection member 250 and an intake manifold 210. The intake manifold 210 has a cover 211 that plugs the opening 101 on the head side of the high-pressure tank 100 and a gas flow path 240 that guides the gas of the high-pressure tank 100 to the outside. The gas flow path 240 is thinner than the tube of the water filling device 600 that puts liquid into the high-pressure tank 100. Therefore, if the water is filled after the gas flow path 240 is attached to the high-pressure tank 100 and the pressure resistance inspection is performed, it takes time because of the loss of the gas flow path 240. By performing the pressure resistance inspection of the high-pressure tank 100 before the gas flow path 240 is assembled, the tank unit can be efficiently manufactured.

[0065] Several features of the manufacturing method of the tank unit 10 are listed below. The head 100a of each high-pressure tank 100 is provided with an opening 101, and the tail 100b is provided with an opening 102. The opening 102 of the tail 100b is sealed with a plug 151, and a pressure resistance test is performed by injecting a liquid from the opening 101 of the head 100a. After the plug 151 is removed and the inside of each high-pressure tank is dried, an end cap 150 is attached to the opening 102 of the tail 100b. The inside of the high-pressure tank 100 can be quickly dried by delivering air from the opening 101 of the head side and discharging air from the opening 102 of the tail side. The manufacturing method of the embodiment can also efficiently manufacture the tank unit 10 in this regard.

[0066] The plurality of end caps 150 attached to the plurality of high-pressure tanks 100 are inserted into the tail-side link member 300 to link the plurality of high-pressure tanks 100. The linking process includes linking the heads of the plurality of high-pressure tanks 100 using the head-side link member 200. All of the high-pressure tanks 100 are included in the smallest rectangular parallelepiped that includes the head-side link member 200 and the tail-side link member 300. The head-side link member 200 and the tail-side link member 300 protect the plurality of high-pressure tanks 100.

[0067] Points to be noted in relation to the technology described in the embodiment are described. The number of high-pressure tanks included in one tank unit can be several as long as it is two or more.

[0068] The head-side link member can also be equipped with a gas flow path that guides the gas of the plurality of high-pressure tanks outward. By providing the head-side link member with a gas flow path, physical linking of the plurality of high-pressure tanks and linking of the flow path can be performed simultaneously.

[0069] The tail of each high-pressure tank can also be provided with an opening, the opening can be plugged by an end cap that extends outside the high-pressure tank, and the tail-side link member can be inserted into the end cap of each high-pressure tank. The tail-side link member can be easily attached to the plurality of high-pressure tanks.

[0070] The specific examples of the present application are described in detail above, but these are merely examples and do not limit the scope of the technical solution. The technology described in the scope of the technical solution includes technology obtained by various modifications and changes to the specific examples exemplified above. The technical elements described in the specification or the drawings exhibit technical usefulness alone or in various combinations, and are not limited to the combinations described in the technical solution at the time of filing. In addition, the technology exemplified in the specification or the drawings can achieve multiple purposes simultaneously, and achieving one of the purposes itself has technical usefulness.

Claims

1. A method for manufacturing a tank unit, characterized in that, include: The inspection process involves performing a pressure resistance test on each of the multiple high-pressure tanks before connecting them. and In the connection process, the gas flow paths of the multiple high-pressure tanks that have passed the pressure resistance test are connected. Each of the aforementioned high-pressure tanks has openings at its head and tail. The pressure test is performed by sealing the opening of the tail with a plug and injecting liquid through the opening of the head. After removing the plugs and drying the inside of each of the high-pressure tanks, install end caps on the openings at the tail. The end caps of the multiple high-pressure tanks are inserted into the tail-side connector to connect the multiple high-pressure tanks.

2. The method for manufacturing a tank unit according to claim 1, characterized in that, The connection process includes connecting the heads of the plurality of high-pressure tanks using head-side connectors. The entire high-pressure tank is contained within the smallest cuboid including the tail-side connector and the head-side connector.

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