Device for manufacturing wound body and method for manufacturing wound body

Abstract

An apparatus for manufacturing a wound body in which a belt-shaped flat plate and a corrugated plate disposed overlapping the flat plate are wound into a roll shape about an axis of a shaft orthogonal to the conveyance direction of the flat plate and the corrugated plate, the apparatus comprising: at least one pair of supports on which the flat plate is placed by conveyance while being separated from each other in the conveyance direction of the flat plate; a winding shaft which is provided at a position between the at least one pair of supports or above the at least one pair of supports in the conveyance direction, supports the flat plate placed on the at least one pair of supports, and winds the flat plate and the corrugated plate together into a roll shape by rotating around the axis of the winding shaft; and a pulling member that pulls the flat plate toward the at least one pair of supports on the upstream side and the downstream side of the winding shaft in the conveyance direction.

Description

Technical Field

[0001] The present invention relates to a wound body manufacturing device and a wound body manufacturing method. Background Art

[0002] For example, there is known a catalytic converter for exhaust gas purification that includes a wound body of a honeycomb body formed by overlapping a flat plate and a corrugated plate and winding it around a winding shaft into a spiral shape. For example, Japanese Patent Publication No. 10-156458 discloses a method for manufacturing a wound body of a honeycomb body, wherein the front end of the flat plate is held by a clamp, the front end of the flat plate is inserted into a slit of a winding shaft, and the winding shaft is rotated, thereby overlapping the flat plate and the corrugated plate and winding it around the winding shaft into a spiral shape.

[0003] The flat plate and corrugated plate used to form the winding body usually have individual differences based on the raw materials, and wrinkles may occur due to the raw materials. Therefore, the flat plate and corrugated plate delivered to the manufacturing device may not be arranged at the predetermined position. When forming the winding body, it is necessary to insert the front end of the flat plate into the slit of the winding shaft, etc. to support the flat plate by the winding shaft. However, when the position of the flat plate deviates from the winding shaft, the winding shaft may fail to support the flat plate. In this case, even if the winding shaft is rotated around its axis, the winding body may not be successfully manufactured. Summary of the invention

[0004] An object of the present invention is to provide a wound body manufacturing apparatus and a wound body manufacturing method that can easily support a flat plate more stably using a winding shaft and manufacture the wound body more stably.

[0005] In order to solve the above-mentioned problems, one embodiment of the present invention is a manufacturing device for winding a strip-shaped flat plate and a corrugated plate overlapped with the flat plate into a roll-shaped winding body around the axis of an axis orthogonal to the conveying direction of the flat plate and the corrugated plate, comprising: at least one pair of supports, the at least one pair of supports being separated in the conveying direction of the flat plate and carrying the flat plate by conveying; a winding shaft, the winding shaft being arranged between the at least one pair of supports or above the at least one pair of supports along the conveying direction, supporting the flat plate carried on the at least one pair of supports, and winding the flat plate and the corrugated plate into a roll together by rotating around its axis; and a pulling member, the pulling member pulling the flat plate toward the at least one pair of supports on the upstream and downstream sides of the winding shaft along the conveying direction. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] Figure 1 The schematic diagram shows the manufacturing process of an exhaust gas purifying catalytic converter including a wound body of a honeycomb body formed by stacking a flat plate and a corrugated plate and winding it in a spiral shape around a winding shaft, and an outer cylinder that maintains the shape of the wound body.

[0007] Figure 2 It is a schematic plan view showing the wound body manufacturing device and the first conveying device according to the first embodiment.

[0008] Figure 3 Yes means Figure 2 The schematic perspective view of the mandrel (winding shaft) of the wound body manufacturing device shown.

[0009] Figure 4 It is a schematic block diagram of the winding body manufacturing apparatus according to the first embodiment.

[0010] Figure 5 It is a schematic diagram showing the manufacturing process of the wound body according to the first embodiment.

[0011] Figure 6 It means next Figure 5 A schematic diagram of the manufacturing process of the winding body.

[0012] Figure 7 It means next Figure 6 A schematic diagram of the manufacturing process of the winding body.

[0013] Figure 8 It means next Figure 7 A schematic diagram of the manufacturing process of the winding body.

[0014] Fig. 9 It means next Figure 8 A schematic diagram of the manufacturing process of the winding body.

[0015] Fig.10 It means next Fig. 9 A schematic diagram of the manufacturing process of the winding body.

[0016] Fig.11 This is a schematic flowchart showing the manufacturing process of the wound body according to the first embodiment.

[0017] Fig. 12A It is a schematic diagram of a moving mechanism of a winding device according to a modified example.

[0018] Fig. 12B is from Fig. 12A Schematic diagram of the moving mechanism viewed in the direction indicated by arrow 12B.

[0019] Fig.13 It is a schematic diagram showing the manufacturing process of the wound body according to the second embodiment.

[0020] Fig.14 It means next Fig.13 A schematic diagram of the manufacturing process of the winding body.

[0021] Fig.15 It means next Fig.14A schematic diagram of the manufacturing process of the winding body. DETAILED DESCRIPTION

[0022] (First embodiment)

[0023] use Figures 1 to 11 The present embodiment describes an apparatus 10 for producing a roll 120 that winds a strip-shaped flat plate 150 and a corrugated plate 140 arranged overlapping the flat plate 150 around an axis (mandrel 16) orthogonal to the conveying direction of the flat plate 150 and the corrugated plate 140.

[0024] First, the wound body 120 will be described. Figure 1 The wound body 120 of the present embodiment shown is used as a member housed in the cylindrical outer cylinder 110 of the exhaust gas purifying catalytic converter 100 . Figure 1 An outline of a manufacturing process of the exhaust gas-purifying catalytic converter 100 is shown.

[0025] When manufacturing the wound body 120 of the exhaust gas purifying catalytic converter 100, first, a flat plate 130 for forming the corrugated plate 140 is prepared. The flat plate 130 for forming the corrugated plate 140 is preferably formed into a metal foil shape by rolling. Then, the metal strip-shaped flat plate 130 is conveyed between a pair of rollers 131 and 132, and the concavo-convex shapes added to the outer circumference of the pair of rollers 131 and 132 are transferred to form the metal strip-shaped corrugated plate 140. That is, the metal strip-shaped flat plate 130 is corrugated to form the metal strip-shaped corrugated plate 140. The corrugated plate 140 is corrugated along the conveying direction.

[0026] Next, a metal belt-shaped flat plate 150 is stacked, for example, on the lower side of the corrugated plate 140 in which the corrugations are formed to form an assembly 160. That is, the corrugated plate 140 is placed on the flat plate 150. The flat plate 150 is preferably formed into a metal foil shape by rolling.

[0027] Then, the control unit 200 of the manufacturing device 10 controls the first conveying device 170 to convey the assembly 160 toward the manufacturing device 10 of the wound body 120. At this time, the assembly 160 is conveyed along the track 170a (see FIG. 17A ) of the first conveying device 170 on the upstream side. Figure 2 ) The moving feed chucks 171, 172 (refer to Figure 1 , Figure 5-Figure 7 ) holds the side of the assembly 160, thereby conveying the assembly 160 toward the manufacturing device 10 of the wound body 120. Then, the manufacturing device 10 of the wound body 120 winds the flat plate 150 of the assembly 160 and the metal corrugated plate 140 together in an overlapping state to form the wound body 120. At this time, in this embodiment, the flat plate 150 is the outer side and the corrugated plate 140 is the inner side.

[0028] Then, the cylindrical outer cylinder 110 is disposed on the outer periphery of the wound body 120 , and the wound body 120 is kept in shape by the outer cylinder 110 .

[0029] The wound body 120 is formed, for example, as a honeycomb having a plurality of through holes for the exhaust gas to pass in the axial direction. A catalyst metal for purifying the exhaust gas is carried on the surface of the honeycomb in contact with the plurality of through holes. The exhaust gas purifying catalytic converter 100 is arranged in front of or inside a muffler in order to decompose, purify and discharge harmful substances contained in the gas exhausted from the engine.

[0030] The assembly 160 used in this embodiment will be described.

[0031] The flat plate 150 and the corrugated plate 140 of the assembly 160 are both formed of metal materials such as magnetic bodies. The flat plate 150 and the corrugated plate 140 can also be formed of metal materials of ferromagnetic bodies, but here, an example of a metal material formed of a soft magnetic body is described. The flat plate 150 and the corrugated plate 140 use a material with low heat capacity and excellent heat resistance, pressure resistance, etc. As an example, the flat plate 150 and the corrugated plate 140 preferably use stainless steel materials and heat-resistant steel. In this embodiment, it is preferred to use martensitic stainless steel, which is a soft magnetic body, and ferritic stainless steel, which is a soft magnetic body. In addition, even austenitic stainless steel can be used as a soft magnetic body for the flat plate 150 and the corrugated plate 140 according to the processing state.

[0032] The widths of the corrugated plate 140 and the flat plate 150 of the assembly 160 are formed to be the same or substantially the same. As an example, the widths of the corrugated plate 140 and the flat plate 150 are about 60 mm. The thicknesses of the corrugated plate 140 and the flat plate 150 are, for example, about 50 μm. The front end 150 a of the flat plate 150 of the assembly 160 protrudes in the conveying direction relative to the front end 140 a of the corrugated plate 140. The amount of protrusion of the front end 150 a of the flat plate 150 of the assembly 160 relative to the front end 140 a of the corrugated plate 140 varies depending on the outer diameter (size) of the winding body 120 to be formed, and can be appropriately set. The amount of protrusion of the front end 150 a of the flat plate 150 of the assembly 160 relative to the front end 140 a of the corrugated plate 140 is greater than the distance between the winding shafts 16 a, 16 b and the second magnets 18 c, 18 d. In addition, a region of the flat plate 150 between the front end 140 a of the corrugated plate 140 and the front end 150 a of the flat plate 150 of the assembly 160 is referred to as a front end portion 150 b .

[0033] In addition, as an example, the amount of protrusion of the front end 150a of the flat plate 150 of the assembly 160 relative to the front end 140a of the corrugated plate 140 is preferably about 5 cm or more. The base end (not shown) of the corrugated plate 140 of the assembly 160 may be located at a position downstream of the base end (not shown) of the flat plate 150 in the conveying direction, or may be located at a position upstream. When the wound body 120 is formed, it is preferred that the base end of the corrugated plate 140 of the assembly 160 and the base end of the flat plate 150 are located at positions close to each other in the circumferential direction of the wound body 120.

[0034] One end of the corrugated plate 140 in the width direction is denoted by 141a, and the other end is denoted by 141b. Similarly, one end of the flat plate 150 in the width direction is denoted by 151a, and the other end is denoted by 151b.

[0035] For example, in order to reduce weight, through holes may be formed on the flat plate 150 at appropriate intervals. That is, as long as the flat plate 150 is transported to the manufacturing device 10 as a flat plate, the solidity, that is, the density, may be different at appropriate positions. In addition, through holes may be formed on the corrugated plate 140 at appropriate intervals. When through holes are formed on the corrugated plate 140, it is preferred to form the through holes at the time of the flat plate 130 used for the corrugated plate 140, and then form the corrugated plate 140. The sizes of the through holes of the flat plate 150 and the corrugated plate 140 may be the same or different. When the catalytic converter 100 for exhaust gas purification is used, due to the presence of the through holes of the flat plate 150 and the corrugated plate 140, the exhaust gas can flow in the catalytic converter 100 for exhaust gas purification and contact more with the catalyst metal, thereby promoting the purification of the exhaust gas.

[0036] The first conveying device 170 conveys the assembly 160 in a predetermined conveying direction while holding the side surfaces of the assembly 160 by the feed chucks 171 and 172. The conveying path of the first conveying device 170 is preferably straight.

[0037] Next, use Figures 2 to 11 The manufacturing apparatus 10 of the wound body 120 will be described. Figure 2 A schematic plan view showing the manufacturing device 10 of the wound body 120 and the first conveying device 170 . Figure 3 A schematic perspective view showing a branching portion 17 at the end of a mandrel 16 (winding shafts 16a and 16b) to be described later. Figure 4 A schematic block diagram showing the manufacturing device 10 of the wound body 120, the first conveying device 170, and the second conveying device 180. Figures 5 to 10 In the following, a series of manufacturing steps of the wound body 120 using the manufacturing device 10 are described. Figures 5 to 10 As an observation along Figure 2 The direction of the α-α line in the diagram is shown. Fig.11 It is a flowchart explaining a series of manufacturing steps of the wound body 120 using the manufacturing apparatus 10 .

[0038] The manufacturing apparatus 10 of the wound body 120 of this embodiment and the first conveying device 170 (see FIG. 1 ) that conveys the assembly 160 toward the manufacturing apparatus 10 of the wound body 120 Figure 2 ) is used together. In addition, the manufacturing device 10 of the winding body 120 of this embodiment is used together with the second conveying device 180 (refer to Fig. 9 and Fig.10 )

[0039] The manufacturing device 10 of the winding body 120 includes: a base 12; a support body 14 (rollers 14a-14d), which is supported by the base 12; a core rod 16 (winding shaft (straight shaft) 16a, 16b), which holds the flat plate 150 of the assembly 160 and rotates around its axis; a pulling member 18 (magnets 18a-18d), which pulls the assembly 160 toward the support body 14 on the upstream and downstream sides of the winding shafts 16a, 16b along the conveying direction; and an adjustment member 20, which adjusts the outer diameter of the winding body 120.

[0040] The base 12 is formed in a block shape, for example. In the present embodiment, the base 12 is formed in a substantially rectangular parallelepiped shape. Figure 4 The first action part 210 shown controls the air cylinder 214 so as to be able to move up and down. Specifically, the first action part 210 has a first pump (compressed air supply source) 212 and a first electromagnetic valve 214a of the air cylinder 214. The first pump 212 supplies compressed air to the air cylinder 214 provided on the base 12. The first electromagnetic valve 214a switches the movement direction of the rod of the air cylinder 214 under the control of the control part 200. Therefore, when the first pump 212 and the first electromagnetic valve 214a of the first action part 210 are controlled by the control part 200, the rod of the air cylinder 214 is driven and the base 12 moves up and down. In addition, the first electromagnetic valve 214a is controlled by the control part 200 to adjust the position of the rod of the air cylinder 214 provided on the base 12 and adjust the height of the base 12.

[0041] The base 12 has a guide portion 13 for the assembly 160 at the upstream end portion. The guide portion 13 guides the assembly 160 to the upper surface side of the base 12 so that the assembly 160 is placed on first rollers (support bodies) 14a and 14b described later.

[0042] In addition, the base 12 is provided with a first sensor 220, which detects that the front end 150b of the flat plate 150 of the assembly 160 is placed on the base 12, and detects the rear end of the assembly 160 (the end of the base end of the flat plate 150 and the base end of the corrugated plate 140 that is on the upstream side along the conveying direction). The first sensor 220 is provided, for example, on the first conveying device 170 side of the base 12. The first sensor 220 can use, for example, a photo interrupter (light blocking sensor). In addition, the first sensor 220 can use, for example, a light reflector that detects reflection of LED light or laser. In the case where the first sensor 220 is a photo interrupter, for example, a light source that emits LED light or laser is arranged above the base 12, and the first sensor 220 can output whether the light is blocked by at least one of the flat plate 150 and the corrugated plate 140. When the first sensor 220 is a photo reflector, the first sensor 220 can output whether the light emitted from the LED light source or the laser light source is reflected by at least one of the flat plate 150 and the corrugated plate 140 and received by the light receiving element.

[0043] The support body 14 is supported on the base 12. The support body 14 has a pair of first rollers 14a, 14b on the upstream side and a pair of second rollers 14c, 14d on the downstream side along the conveying direction of the assembly 160. The rotation axes of the pair of first rollers 14a, 14b and the pair of second rollers 14c, 14d are parallel to each other and are orthogonal to the conveying direction of the first conveying device 170. A portion of the pair of first rollers 14a, 14b and the pair of second rollers 14c, 14d that is above the rotation axis protrudes relative to the upper surface of the base 12. An opening for protruding the pair of first rollers 14a, 14b and the pair of second rollers 14c, 14d is formed in the base 12, and a portion of the pair of first rollers 14a, 14b and the pair of second rollers 14c, 14d passes through the opening and protrudes upward relative to the upper surface of the base 12.

[0044] In addition, the pair of first rollers 14a and 14b are separated in a direction that is preferably orthogonal to the conveying direction of the assembly 160. Similarly, the pair of second rollers 14c and 14d are separated in a direction that is preferably orthogonal to the conveying direction of the assembly 160. In addition, the distance between the pair of first rollers 14a and 14b and the distance between the pair of second rollers 14c and 14d are smaller than the width of the flat plate 150 of the assembly 160. Therefore, the assembly 160 conveyed by the first conveying device 170 is placed on the pair of first rollers 14a and 14b, and is placed on the pair of second rollers 14c and 14d.

[0045] Furthermore, the first rollers 14 a and 14 b and the second rollers 14 c and 14 d are used to position the front end portion 150 b of the plate 150 in relation to the mandrel 16 .

[0046] In the present embodiment, the support body 14 , namely the rollers 14 a to 14 d , is supported by the base 12 , and thus moves up and down together with the base 12 .

[0047] The pair of first rollers 14 a and 14 b and the pair of second rollers 14 c and 14 d may be actively rotated by, for example, a motor (not shown) or may be passively rotated by contact with the plate 150 of the assembly 160 .

[0048] The mandrel 16 has a pair of winding shafts 16a and 16b facing each other in an axially aligned state. The axial directions of the winding shafts 16a and 16b are parallel to the pair of first rollers 14a and 14b and the pair of second rollers 14c and 14d. That is, the rotation axes of the pair of winding shafts 16a and 16b are orthogonal to the conveying direction of the first conveying device 170.

[0049] The fixed ends of the pair of winding shafts 16a and 16b are supported by flanges 16a1 and 16b1, respectively. Figure 3 A to Figure 3 As shown in FIG. 2 , a shaft 17a having a rotation axis coaxial with the rotation axis of the first winding shaft 16a is provided on the flange 16a1. A shaft 17b having a rotation axis coaxial with the rotation axis of the second winding shaft 16b is provided on the flange 16b1. The shaft 17a is supported by the frame of the manufacturing device 10 via a bearing (not shown) provided on the shaft 17a. Similarly, the shaft 17b is supported by the frame of the manufacturing device 10 via a bearing (not shown) provided on the shaft 17b. Furthermore, these shafts 17a and 17b are supported by, for example, Figure 4 The control of the motors (e.g., servo motors) 230a, 230b and the gears (not shown) meshing with the rotating shafts of the motors 230a, 230b is adjusted so as to rotate in the same direction at the same speed and at the same rotation angle. In addition, when the shaft 17a rotates, the flange 16a1 and the first winding shaft 16a rotate in the same direction as the shaft 17a at the same speed and at the same rotation angle. In addition, when the shaft 17b rotates, the flange 16b1 and the second winding shaft 16b rotate in the same direction as the shaft 17b at the same speed and at the same rotation angle.

[0050] The rotation angle of the rotating shaft of the motors 230a and 230b, or the position (rotation angle), speed, and rotation force of the pair of winding shafts 16a and 16b via gears are acquired by encoders 232a and 232b.

[0051] As the motors 230a and 230b, stepper motors may be used instead of servo motors. When stepper motors are used as the motors 230a and 230b, encoders 232a and 232b may not be required. Alternatively, one of the motors 230a and 230b may be used to rotate the two winding shafts 16a and 16b in the same direction at the same speed and by the same rotation angle via gears.

[0052] That is, the motors 230a, 230b cooperate with the control unit 200 to form a rotating mechanism (200, 230a, 230b) that causes the first winding shaft 16a and the second winding shaft 16b to rotate synchronously in the same direction when the rotating axes of the first winding shaft 16a and the second winding shaft 16b are arranged on the same axis.

[0053] like Figure 2 As shown by the solid line, the free ends of the pair of winding shafts 16a and 16b can be withdrawn from above the base 12 and moved to a separated position. Figure 2 As shown by the dotted line, the free ends of the pair of winding shafts 16a and 16b can move to a close position above the base 12. In addition, the free ends of the pair of winding shafts 16a and 16b can not only approach each other above the base 12, but also abut each other.

[0054] The axial movement of the pair of winding shafts 16a and 16b is performed, for example, by the control of the cylinder 244 or the like. Specifically, the second action unit (moving mechanism) 240 has a second pump (compressed air supply source) 242 and a second electromagnetic valve 244a of the cylinder 244. The second pump 242 supplies compressed air to the cylinders 244 respectively provided on the pair of winding shafts 16a and 16b. The second electromagnetic valve 244a switches the movement direction of the rod of the cylinder 244 by the control of the control unit 200. Therefore, when the second pump 242 and the second electromagnetic valve 244a of the second action unit 240 are controlled by the control unit 200, the rod of the cylinder 244 is driven, and the pair of winding shafts 16a and 16b are relatively close to or separated. In addition, the free ends of the pair of winding shafts 16a and 16b can also abut each other to the extent that no load is applied to each other. Therefore, the position of each rod of the pair of winding shafts 16a and 16b relative to the base 12 is adjusted.

[0055] That is, the second pump 242 and the cylinder 244 having the second solenoid valve 244a cooperate with the control unit 200 to form a moving mechanism, which arranges the rotating axis of the first winding shaft 16a and the rotating axis of the second winding shaft 16b on the same axis while moving the free end of the first winding shaft 16a and the free end of the second winding shaft 16b in directions of approaching and moving away.

[0056] Preferred by Figure 4 The second pump (compressed air supply source) 242 of the second operating unit 240 for operating the pair of winding shafts 16a and 16b and the second electromagnetic valve 244a of the cylinder 244 are controlled to drive the cylinder 244 to move the pair of winding shafts 16a and 16b in the axial direction. Figure 2. A disk-shaped flange 16a1 is provided on the winding shaft 16a. In addition, a disk-shaped flange 16b1 is provided on the winding shaft 16b. Therefore, the flanges 16a1, 16b1 approach the side of the base 12 at a predetermined distance or abut against the side of the base 12, thereby defining the maximum approach position of the winding shafts 16a, 16b. At this time, the distance between the flanges 16a1, 16b1 is substantially consistent with the width of the flat plate 150, or is formed to be slightly larger than the width of the flat plate 150, thereby suppressing the meandering of the flat plate 150. In addition, the outer diameter of the flanges 16a1, 16b1 is formed to be smaller than the outer diameter of the wound body 120 of the manufactured exhaust gas purification catalytic converter 100. Therefore, it is possible to prevent the outer peripheral surfaces of the flanges 16a1, 16b1 from interfering with, for example, the adjustment member 20.

[0057] In addition, since the flanges 16a1 and 16b1 rotate together with the pair of winding shafts 16a and 16b, it is preferable that the flanges 16a1 and 16b1 do not substantially come into contact with the side surface of the base 12.

[0058] like Figure 3 As shown, the winding shafts 16a and 16b are preferably formed in the same shape with the same length. The winding shafts 16a and 16b are preferably formed as metal rods with a diameter of about 5 mm, for example, by processing a suitable steel material with high rigidity and high toughness.

[0059] The first winding shaft 16a, which is one of the pair of winding shafts 16a and 16b, is cantilevered on the flange 16a1. The second winding shaft 16b, which is the other of the pair of winding shafts 16a and 16b, is cantilevered on the flange 16b1. The pair of winding shafts 16a and 16b each have a pair of bifurcated portions 17 on the end sides facing each other. The bifurcated portions 17 of the winding shafts 16a and 16b each have a first extension piece 17a, a second extension piece 17b facing the first extension piece 17a, and a slit 17c between the first extension piece 17a and the second extension piece 17b. The front end portion 150b of the flat plate 150 is inserted through the slit 17c. The extension direction of the slit 17c along the axial direction of the winding shafts 16a and 16b is orthogonal to the extension direction of the flat plate 150. The length of the slit 17 c along the axial direction of the winding shafts 16 a and 16 b is preferably formed to be, for example, approximately half the width of the flat plate 150 .

[0060] The directions of the slits 17c of the bifurcated portions 17 of the pair of winding shafts 16a and 16b facing each other are adjusted to be the same. The bifurcated portions 17 of the pair of winding shafts 16a and 16b are arranged in an initial position so that the pair of extension pieces 17a and 17b face each other up and down. At this time, the slits 17c of the bifurcated portions 17 are located in a horizontal position. The distance between the extension pieces 17a and 17b of the bifurcated portions 17 is greater than the thickness of the plate 150. In addition, since the rotation speed and rotation angle of the pair of winding shafts 16a and 16b facing each other are the same, the torsion of the plate 150 can be suppressed.

[0061] In addition, the manufacturing device 10 preferably includes sensors 250a and 250b for detecting whether the slit 17c of the branching portion 17 of each of the pair of winding shafts 16a and 16b is in a horizontal position and whether the front end portion 150b of the plate 150 is inserted through the slit 17c of the branching portion 17 of each of the pair of winding shafts 16a and 16b. The sensor 250a is provided on the flange 16a1, for example, and the sensor 250b is provided on the flange 16b1, for example. These sensors 250a and 250b use, for example, optical sensors, image sensors, etc. If the sensors 250a and 250b are optical sensors, one is a laser oscillator and the other is a photodetector. If the sensors 250a and 250b are image sensors, the control unit 200 can perform image processing on the image acquired by the image sensor and output whether the plate 150 is inserted through the slit 17c of the branching portion 17 of each of the pair of winding shafts 16a and 16b.

[0062] The core rod 16, namely the pair of winding shafts 16a, 16b, flanges 16a1, 16b1, shafts 17a, 17b, and bearings 17a1, 17b1, are preferably separated from the base 12 and the support 14, and also separated from the adjustment member 20 and do not move up and down.

[0063] A pulling member 18 is provided on the base 12, and the pulling member 18 pulls the assembly 160 toward the support body 14 on the upstream side and downstream side of the pair of winding shafts 16a and 16b along the conveying direction. In the present embodiment, the pulling member 18 uses permanent magnets 18a, 18b, 18c, and 18d such as neodymium magnets. A pair of first magnets 18a and 18b are provided on the upstream side of the pair of winding shafts 16a and 16b in the base 12. A pair of second magnets 18c and 18d are provided on the downstream side of the pair of winding shafts 16a and 16b in the base 12. In the present embodiment, the pair of first magnets 18a and 18b are provided adjacent to the upstream side of the pair of first rollers 14a and 14b. Therefore, the pulling position of the flat plate 150 or the assembly 160 in the pulling member 18 is located on the upstream side of the support body 14 (first rollers 14a and 14b) further upstream. The pair of second magnets 18c and 18d are disposed adjacent to the downstream side of the pair of second rollers 14c and 14d. Therefore, the pulling position of the flat plate 150 in the pulling member 18 is located further downstream of the downstream support 14 (second rollers 14c and 14d).

[0064] In the present embodiment, an example in which a pair of first magnets 18a and 18b are provided as the pulling member 18 at the corners on the upstream side relative to the pair of winding shafts 16a and 16b in the base 12 is described, but it is also preferable to provide one first magnet in the center of the width direction along the horizontal direction orthogonal to the conveying direction of the first conveying device 170. In addition, it is also preferable that three or more magnets are provided at the upstream side relative to the pair of winding shafts 16a and 16b in the base 12.

[0065] Similarly, in the present embodiment, a pair of second magnets 18c and 18d are provided at the corners of the base 12 on the downstream side relative to the pair of winding shafts 16a and 16b as an example of the pulling member 18, but it is also preferable to provide one second magnet in the center in the width direction. In addition, it is also preferable to provide three or more magnets at the downstream side of the base 12 relative to the pair of winding shafts 16a and 16b.

[0066] The adjustment member 20 for adjusting the outer diameter of the winding body 120 is provided above the base 12 so as to be movable up and down above the winding shafts 16a and 16b. The adjustment member 20 cooperates with the support body 14 provided on the base 12 to adjust the outer diameter of the winding body 120. The adjustment member 20 is preferably adjusted to move at the same speed in the opposite direction to the base 12 with respect to the winding shafts 16a and 16b.

[0067] The third operating unit 260 includes a third pump (compressed air supply source) 262 and a third electromagnetic valve 264a of the air cylinder 264. The third electromagnetic valve 264a switches the operating direction of the rod of the air cylinder 264 provided in the adjusting member 20 under the control of the control unit 200. Figure 4 The third pump (compressed air supply source) 262 of the third action unit 260 shown in the figure and the third electromagnetic valve 264a of the cylinder 264 are controlled to drive the cylinder 264, so that the adjustment member 20 moves up and down. The third pump 262 and the third electromagnetic valve 264a are controlled by the control unit 200 to adjust the position of the rod of the cylinder 264 provided on the adjustment member 20, and the height of the adjustment member 20 is adjusted.

[0068] Furthermore, the adjustment member 20 is provided with a pressure sensor 266. The pressure sensor 266 can detect the contact pressure with the wound body 120. The control unit 200 can adjust the height of the adjustment member 20, that is, the outer diameter of the wound body 120, based on the detection data of the pressure sensor 266.

[0069] The second conveying device 180 on the downstream side is formed so as to sandwich and hold the wound body 120 from the upper side and the lower side, respectively, and convey it to the downstream side, for example.

[0070] like Figure 4 As shown, the first action unit 210, the first sensor 220, the motors 230a, 230b, the encoders 232a, 232b, the second action unit 240, the 2-1 sensor 250a, the 2-2 sensor 250b, the third action unit 260, and the pressure sensor 266 are connected to the control unit 200 by wire or wireless, respectively, and are controlled by the control unit 200. In addition, the control unit 200 is connected to the first conveying device 170 and the second conveying device 180 by wire or wireless, and the first conveying device 170 and the second conveying device 180 can be controlled by the control unit 200.

[0071] The control unit 200 is composed of, for example, a computer, etc., and has a processor (processing circuit) and a storage medium. The processor includes any one of a CPU (Central Processing Unit), an ASIC (Application Specific Integrated Circuit), a microcomputer, an FPGA (Field Programmable Gate Array), and a DSP (Digital Signal Processor). In addition to a main storage device such as a memory, the storage medium may also include a non-temporary auxiliary storage device. As storage media, non-volatile memories that can be written and read at any time, such as HDD (Hard Disk Drive), SSD (Solid State Drive), magnetic disks, optical disks (CD-ROM, CD-R, DVD, etc.), optical disks (MO, etc.), and semiconductor memories, can be listed.

[0072] In the control unit 200, only one processor and a storage medium may be provided, or multiple processors may be provided. In the control unit 200, the processor performs processing by executing a program stored in a storage medium, etc. In addition, the program executed by the processor of the control unit 200 may also be stored in a computer (server) connected to the control unit 200 via a network such as the Internet, or a server in a cloud environment, etc. In this case, the processor downloads the program via the network.

[0073] The following describes a process of manufacturing the wound body 120 using the manufacturing device 10 of the wound body 120. The manufacturing device 10 operates based on a command from the control unit 200. The manufacturing device 10 of the wound body 120 is controlled by the control unit 200 including the above-mentioned cylinders 214, 244, 264, various motors, and the like.

[0074] In the initial position of the manufacturing device 10 of the winding body 120, as Figure 2 As shown by the solid line, the pair of winding shafts 16a and 16b are located at positions that are retracted from the upper surface of the base 12 to the sides that are orthogonal to the conveying direction. Here, the free ends of the pair of winding shafts 16a and 16b are retracted to positions that are offset from the upper surface of the base 12. In addition, the slits 17c of the branching parts 17 of the pair of winding shafts 16a and 16b are oriented in the horizontal direction. In addition, the central position of the slits 17c of the branching parts 17 of the pair of winding shafts 16a and 16b in the vertical direction is substantially consistent with the height of the upper surface of the support body 14 (rollers 14a to 14d).

[0075] In this state, the assembly 160 is placed on the base 12 along a predetermined conveying direction by conveyance of the first conveying device 170 under the control of the control unit 200 (see Figure 5 and Figure 6 ). The flat plate 150 and the corrugated plate 160 of the assembly 160 are conveyed by the feed chucks 171 and 172 in a state where they protrude from the feed chucks 171 and 172 by a predetermined length. The feed chucks 171 and 172 stop at a predetermined position, and the first sensor 220 is used to detect that the front end portion 150b of the flat plate 150 is placed on the base 12 (step S1). When the first sensor 220 detects that the front end portion 150b of the flat plate 150 of the assembly 160 is placed on the base 12 (S1-Yes), the control unit 200 proceeds to the next step (S2). In addition, when the first sensor 220 cannot detect that the front end portion 150b of the flat plate 150 of the assembly 160 is placed on the base 12 (S1-No), the control unit 200 repeatedly performs the operation of detecting the front end portion 150b of the flat plate 150 using the first sensor 220.

[0076] At this time, as described above, the amount of protrusion of the front end 150a of the flat plate 150 of the assembly 160 relative to the front end 140a of the corrugated plate 140 is greater than the distance between the winding shafts 16a, 16b and the second magnets 18c, 18d. Furthermore, when the front end 150a of the flat plate 150 exceeds the position of the first magnets 18a, 18b and is located above the second magnets 18c, 18d, the front end 140a of the corrugated plate 140 does not reach the position of the pair of winding shafts 16a, 16b. The edge portions of the front end portion 150b of the flat plate 150 face the slits 17c of the branching portion 17 of the pair of winding shafts 16a, 16b, respectively.

[0077] In addition, at this time, the assembly 160 is separated upward relative to the base 12 by the support body 14 (rollers 14a-14d). In addition, even if the front end 150a of the flat plate 150 of the assembly 160 is shaped upward, for example, the flat plate 150 of the assembly 160 can be pulled toward the support body 14 by the pulling member 18 (magnets 18a-18d). The flat plate 150 may or may not be in contact with the base 12 by the pulling member 18. At this time, the front end 150b of the flat plate 150 is in a state of being stretched between the first rollers 14a, 14b on the upstream side and the first rollers 14a, 14b on the downstream side.

[0078] Then, the control unit 200 controls the second pump 242 and the second electromagnetic valve 244a of the second operation unit 240 to move the pair of winding shafts 16a and 16b from Figure 2 The solid line position in FIG. 1 is moved to the dotted line position (step S2). That is, the free ends of the pair of winding shafts 16a and 16b are close to or abut against each other.

[0079] Here, the slits 17c of the bifurcated portions 17 of the pair of winding shafts 16a and 16b are oriented in the horizontal direction. Therefore, the front end portion 150b of the flat plate 150 of the assembly 160 is inserted into the slits 17c between the extension pieces 17a and 17b of the bifurcated portions 17 of the pair of winding shafts 16a and 16b. Therefore, the front end portion 150b of the flat plate 150 is restricted from moving in the vertical direction by the pair of winding shafts 16a and 16b from the end in the width direction of the flat plate 150 to the center (near the center) in the width direction.

[0080] Then, for example, sensors 250a and 250b disposed on the extension pieces 17a and 17b are used to detect whether the front end 150b of the plate 150 is inserted into the slit 17c of the branching portion 17 of the pair of winding shafts 16a and 16b (step S3). When the control unit 200 determines that the front end 150b of the plate 150 is not inserted into the slit 17c based on the signals of the sensors 250a and 250b (S3-No), the control unit 200 controls the second pump (compressed air supply source) 242 and the second electromagnetic valve 244a of the second operation unit 240 to move the pair of winding shafts 16a and 16b from the first pump 242 to the second pump 242. Figure 2 When the control unit 200 determines that the front end 150b of the plate 150 is not inserted into the slit 17c based on the signals of the sensors 250a and 250b for multiple times (S3-No), an error is output and the process is terminated, returning to the initial position.

[0081] When the control unit 200 determines based on the signals of the sensors 250a and 250b that the front end portion 150b of the flat plate 150 is inserted into the slit 17c between the respective extension pieces 17a and 17b of the pair of winding shafts 16a and 16b (S3-yes), the control unit 200 controls the third pump 262 and the third solenoid valve 264a of the third action unit 260 to lower the outer diameter adjustment member 20 of the winding body 120 arranged above the pair of winding shafts 16a and 16b to the vicinity of the pair of winding shafts 16a and 16b (step S4).

[0082] Then, the control unit 200 controls the motors 230a and 230b, for example, to rotate the pair of winding shafts 16a and 16b simultaneously in the same direction and at the same speed via gears, so that the front end portion 150b including the front end 150a of the flat plate 150 overcomes the magnetic force of the magnets 18c and 18d and separates. Therefore, the branching portion 17 of the pair of winding shafts 16a and 16b supports the flat plate 150 placed on the support body 14 by clamping it. Then, the front end portion 150b of the flat plate 150 clamps the front end 140a of the corrugated plate 140. At this time, the rotation direction of the pair of winding shafts 16a and 16b is from Figure 6 The location shown to Figure 7The direction of rotation is such that the position shown is obtained. Therefore, the direction of rotation of the pair of winding shafts 16a and 16b is the direction in which the front end 150a of the flat plate 150 is separated from the magnets 18c and 18d. At this time, the magnetic force of the magnets 18a and 18b on the upstream side acts on the flat plate 150 and the corrugated plate 140. Therefore, on the base 12 on the upstream side of the pair of winding shafts 16a and 16b, a force that pulls (presses) the assembly 160 against the first rollers 14a and 14b acts by the magnetic force of the magnets 18a and 18b on the upstream side. In this state, the pair of winding shafts 16a and 16b are further rotated to wind up the assembly 160 to produce the wound body 120 (step S5). On the base 12 on the upstream side of the pair of winding shafts 16a and 16b, when the assembly 160 is wound, the assembly 160 is continuously pulled toward the base 12 by the magnetic force of the magnets 18a and 18b.

[0083] Furthermore, when the pair of winding shafts 16a and 16b are rotated to sandwich the front end 140a of the corrugated plate 140 with the front end 150b of the flat plate 150, the feed chucks 171 and 172 may be moved in a predetermined conveying direction in synchronization with the rotation speed of the pair of winding shafts 16a and 16b to press the flat plate 150 and the corrugated plate 140 into the pair of winding shafts 16a and 16b. Thus, the front end 150b of the flat plate 150 can be used to suppress the initial poor winding of the front end 140a of the corrugated plate 140.

[0084] At this time, the magnetic force of the magnets 18a and 18b also acts on the corrugated plate 140 on the flat plate 150. Therefore, the corrugated plate 140 is attracted by the magnets 18a and 18b on the upstream side of the pair of winding shafts 16a and 16b, thereby suppressing the warping of the corrugated plate 140.

[0085] Therefore, on the base 12 on the upstream side of the pair of winding shafts 16a, 16b, the flat plate 150 and the corrugated plate 140 of the assembly 160 can be suppressed from vibrating, for example, up and down, near the rollers 14a, 14b. Therefore, on the upstream side of the base 12, the movement of the assembly 160 when the assembly 160 is wound as the winding body 120 can be stabilized.

[0086] In addition, the free ends of the pair of winding shafts 16a and 16b are close to or abut against each other. Therefore, the front end portion 150b of the flat plate 150 is maintained over the substantially entire width direction. Furthermore, the pair of winding shafts 16a and 16b are continuously maintained from the pair of ends 151a and 151b in the width direction of the flat plate 150 to near the center. Therefore, when winding the flat plate 150 and the corrugated plate 140 placed on the flat plate 150, the flat plate 150 can be wound while suppressing wrinkles. In addition, by using a pair of winding shafts 16a and 16b of the same size, the dimensional stability of one end and the other end of the winding body 120 can be ensured compared to when the winding body 120 is wound using one winding shaft. That is, by using a pair of winding shafts 16a and 16b of the same size, the inner diameter of the center portion of one end of the winding body 120 and the inner diameter of the center portion of the other end can be maintained substantially constant. In addition, the free ends of the pair of winding shafts 16a and 16b are held until the width direction center of the front end portion 150b of the flat plate 150. Therefore, by using the pair of winding shafts 16a and 16b, in addition to the inner diameter of the center portion of one end and the other end of the winding body 120, the inner diameter of the center portion of the region between the one end and the other end can be kept substantially constant.

[0087] In addition, instead of using one winding shaft to wind up the flat plate 150, the two winding shafts 16a and 16b are used to wind up the flat plate 150 in a state where the free ends thereof are brought close to each other. Therefore, the total length of each of the two winding shafts 16a and 16b can be shortened compared to the case where one winding shaft is used. Therefore, when the two winding shafts 16a and 16b of the present embodiment are used, the amount of deflection of the free ends can be reduced compared to the case where one winding shaft is used to wind up the flat plate 150. Therefore, when the two winding shafts 16a and 16b of the present embodiment are used, the outer diameters of the two winding shafts 16a and 16b can be reduced compared to the case where one winding shaft is used. Therefore, when the two winding shafts 16a and 16b of the present embodiment are used, the inner diameter of the center portion of the winding body 120 can be formed as small as possible compared to the case where one winding shaft is used. Therefore, the wound body 120 manufactured by the manufacturing apparatus 10 of the present embodiment can have a large contact area between the metal catalyst carried on the wound body 120 and the exhaust gas, and can improve the exhaust gas purification performance.

[0088] At this time, based on the information obtained by the encoders 232a and 232b of the motors 230a and 230b, the control unit 200 controls the first pump 212 and the first electromagnetic valve 214a of the first operating unit 210 and the second pump 242 and the second electromagnetic valve 244a of the second operating unit 240, so that the base 12 and the adjustment member 20 are retracted in a manner of being separated from the pair of winding shafts 16a and 16b in accordance with the rotation angle of the pair of winding shafts 16a and 16b. At this time, the base 12 is retracted downward relative to the pair of winding shafts 16a and 16b, and the adjustment member 20 is retracted upward relative to the pair of winding shafts 16a and 16b. Therefore, the support body 14 (rollers 14a to 14d) protruding from the base 12 and the adjustment member 20 adjust the outer diameter of the winding body 120.

[0089] The mutually facing surfaces of the pair of flanges 16a1 and 16b1 are formed, for example, as flat surfaces, and are arranged to be separated by a distance greater than the width of the wound body 120 when the wound body 120 is wound. The mutually facing surfaces of the pair of flanges 16a1 and 16b1 are arranged in parallel so that the end of the flat plate 150 can be aligned with the end of the corrugated plate 140. When the wound body 120 is wound, the width direction end 151a of the flat plate 150 is along the surface side of the flange 16a1 facing the flange 16b1, and the width direction end 151b of the flat plate 150 is along the surface side of the flange 16b1 facing the flange 16a1. In addition, when the winding body 120 is wound, the width direction end 141a of the corrugated plate 140 is along the surface side of the flange 16a1 facing the flange 16b1, and the width direction end 141b of the corrugated plate 140 is along the surface side of the flange 16b1 facing the flange 16a1. When the corrugated plate 140 and the flat plate 150 start to be wound, the separation distance of the pair of flanges 16a1 and 16b1 arranged to be separated by a distance larger than the width of the winding body 120 is controlled to be substantially the same as the width of the winding body 120. Here, the separation distance between the width direction end 151a and 141a and the facing surface of the flange 16a1 is set to 0.5 mm, and the separation distance between the width direction end 151b and 141b and the facing surface of the flange 16b1 is set to 0.5 mm. Therefore, the wound body 120 is formed while correcting the overlapping position of the corrugated plate 140 and the flat plate 150 when the corrugated plate 140 and the flat plate 150 are wound. One end face of the wound body 120 is formed in a state where the end 151a of the flat plate 150 is aligned with the end 141a of the corrugated plate 140, and the other end face of the wound body 120 is formed in a state where the end 151b of the flat plate 150 is aligned with the end 141b of the corrugated plate 140. In addition, the separation distance between the facing surfaces of the width direction ends 151a, 141a and the flange 16a1, and the separation distance between the facing surfaces of the width direction ends 151b, 141b and the flange 16b1 are adjusted to about 0 mm to 1.0 mm depending on the presence or absence of holes formed in the corrugated plate 140, the presence or absence of holes formed in the flat plate 150, or the thickness of the foil material. In particular, when the flat plate 150 or the corrugated plate 140 as the foil material is relatively thin, for example, the thickness of the flat plate 150 or the corrugated plate 140 is 30μm to 50μm, when the flat plate 150 or the corrugated plate 140 is conveyed onto the base 12, there may be undesirable situations such as the corner between the front end 150a of the flat plate 150 and the end 151a or the end 151b, the corner between the front end 140a of the corrugated plate 140 and the end 141a or the end 141b of the corrugated plate 140 contacts the flange 16a1 and the flange 16b1, and the flat plate 150 is not inserted into the slit 17c of the pair of winding shafts 16a and 16b, and the front end 150b of the flat plate 150 cannot be used to roll up the front end 140a of the corrugated plate 140.Therefore, when the foil material is thin, it is preferred to separate the facing surfaces of the width direction ends 151a, 141a of the flat plate 150 and the corrugated plate 140 and the flange 16a1, and the facing surfaces of the width direction ends 151b, 141b of the flat plate 150 and the corrugated plate 140 and the flange 16b1, respectively, before rotating a pair of winding shafts 16a, 16b and clamping the front end 140a of the corrugated plate 140 with the front end 150b of the flat plate 150. After the flat plate 150 is inserted into the slit 17c of a pair of winding shafts 16a, 16b and the winding shafts 16a, 16b are rotated 180 degrees, by making the facing surfaces of the width direction ends 151a, 141a of the flat plate 150 and the corrugated plate 140 and the flange 16a1, and the facing surfaces of the width direction ends 151b, 141b of the flat plate 150 and the corrugated plate 140 and the flange 16b1 abut and wind up, it is possible to prevent the foil (flat plate 150 or corrugated plate 140) from breaking, and make the end 151a of the flat plate 150 and the end 141a of the corrugated plate 140 aligned, and make the end 151b of the flat plate 150 and the end 141b of the corrugated plate 140 aligned.

[0090] The control unit 200 determines whether the winding of the roll 120 is completed (step S6 ). When the control unit 200 determines that the winding of the roll 120 is not completed ( S6 -No), the control unit 200 causes the roll 120 to continue winding.

[0091] For example, when the first sensor 220 provided on the base 12 detects the rear end of the assembly 160 (the end of the base end of the flat plate 150 and the base end of the corrugated plate 140 on the upstream side in the conveying direction), the control unit 200 determines that the winding of the winding body 120 is completed. Alternatively, the control unit 200 determines that the winding of the winding body 120 is completed when the rotation amount (rotation angle) of the motors 230a and 230b of the pair of winding shafts 16a and 16b obtained by the encoders 232a and 232b exceeds a predetermined amount.

[0092] Then, when the control unit 200 determines that the winding of the winding body 120 has been completed (S6-Yes), it controls the motors 230a and 230b to stop the rotation of the pair of winding shafts 16a and 16b. At this time, the control unit 200 controls the first operating unit 210 to stop the descent of the base 12, and controls the third operating unit 260 to stop the ascent of the adjustment member 20. Therefore, the shape of the winding body 120 is maintained in the upper and lower parts by the support body 14 (rollers 14a to 14d) and the adjustment member 20, and the outer diameter of the winding body 120 is maintained by overcoming the elastic force of the winding body 120.

[0093] In addition, the outer diameter of the winding body 120 is maintained by the adjustment member 20, but in order to suppress the load on the pair of winding shafts 16a and 16b that serve as the central axis of the winding body 120 as much as possible, the pressure sensor 266 of the adjustment member 20 detects the reaction force based on the elastic deformation of the winding body 120. If the detection value of the pressure sensor 266 is within the predetermined pressure range, the control unit 200 can ignore the influence of the load on the pair of winding shafts 16a and 16b. In the case where the detection value of the pressure sensor 266 deviates from the predetermined pressure range, the control unit 200 operates the third action unit 260 to move the adjustment member 20, for example, upward, and adjust the detection value detected by the pressure sensor 266 to be within the predetermined range. Therefore, it is possible to suppress the unintentional application of a load exceeding the predetermined value to the pair of winding shafts 16a and 16b.

[0094] Then, the control unit 200 controls, for example, the second conveying device 180 disposed on the downstream side of the conveying direction relative to the manufacturing device 10 to clamp (hold) the wound body 120 using the holding members 181 and 182 of the second conveying device 180 (step S7). Figure 2 As shown in FIG. 1 , a groove 12a is formed on the upper surface of the base 12 with a suitable length from the base end toward the front end. Fig. 9 As shown, the holding member 182 is prevented from interfering with the base 12 .

[0095] Afterwards, the control unit 200 controls the motors 230a and 230b to slightly return the rotation angle of the pair of winding shafts 16a and 16b, thereby easing the winding force of the front end portion 150b of the flat plate 150 relative to the outer peripheral surface of the pair of winding shafts 16a and 16b. At this time, the winding body 120 is supported by the adjustment member 20 and is clamped by the holding members 181 and 182 of the second conveying device 180 to maintain the outer diameter. Therefore, the change in the surface area of ​​the inner diameter of the center portion of the winding body 120 is negligible. In this state, the control unit 200 controls the second action unit 240 to move the pair of winding shafts 16a and 16b from Figure 2 The dotted line position shown in the figure retreats to the solid line position (step S8). Next, the control unit 200 controls the third action unit 260 to make the adjustment member 20 retreat upward (step S9). At this time, as needed, the control unit 200 controls the first action unit 210 to make the base 12 and the support body 14 retreat downward. In addition, the action of reversing the rotation of the pair of winding shafts 16a and 16b to ease the winding force of the winding body 120 on the pair of winding shafts 16a and 16b can also be repeated several times, such as reversing the pair of winding shafts 16a and 16b and then rotating forward again.

[0096] Then, the control unit 200 conveys the wound body 120 held by the gripping members 181 and 182 of the second conveying device 180 to the downstream side (step S10), and makes the base 12 and the support body 14 become, for example, Figure 5 The positional relationship shown is in the ascending manner.

[0097] According to the present embodiment, when the wound body 120 is manufactured from the assembly 160 by the manufacturing apparatus 10 , the assembly 160 can be arranged at a predetermined position by the pulling member 18 , so that the flat plate 150 of the assembly 160 can be stably wound.

[0098] When the front end 150a of the flat plate 150 is conveyed toward the base end of the base 12, the front end 150a of the flat plate 150 is placed on a pair of first rollers 14a, 14b and a pair of second rollers 14c, 14d in sequence, for example, after passing through the magnets 18a, 18b on the upstream side. The pair of first rollers 14a, 14b and the pair of second rollers 14c, 14d protrude relative to the upper surface of the base 12, respectively. Therefore, the flat plate 150 is easily warped upward. In this embodiment, due to the presence of the magnets 18a, 18b on the upstream side, the flat plate 150 is pulled toward the base 12 and the pair of first rollers 14a, 14b, that is, the flat plate 150 is forced toward the pair of first rollers 14a, 14b. In other words, the flat plate 150 is forced by the magnets 18a, 18b in a manner of pressing the pair of first rollers 14a, 14b. That is, the front end 150 a of the plate 150 moves from the upstream side toward the downstream side of the base 12 without being separated from the upper surface of the base 12 as much as possible.

[0099] Furthermore, due to the presence of the magnets 18c and 18d on the downstream side, the flat plate 150 conveyed in the conveying direction is pulled toward the pair of second rollers 14c and 14d and the base 12, that is, the flat plate 150 is urged toward the pair of second rollers 14c and 14d. In other words, the flat plate 150 is urged by the magnets 18c and 18d to press the pair of second rollers 14c and 14d.

[0100] Therefore, the magnets 18c and 18d cooperate with the magnets 18a and 18b to apply force to the plate 150 toward the pair of first rollers 14a and 14b and the pair of second rollers 14c and 14d. The plate 150 is applied with force by the magnets 18a to 18d in a manner of pressing the pair of first rollers 14a and 14b and the pair of second rollers 14c and 14d. That is, when the front end 150a of the plate 150 is conveyed in the conveying direction, the front end 150a of the plate 150 moves from the upstream side of the base 12 toward the downstream side without being as far away from the upper surface of the base 12, the first rollers 14a and 14b, and the second rollers 14c and 14d as possible. Therefore, for example, the plate 150 is prevented from floating between the pair of first rollers 14a and 14b and the pair of second rollers 14c and 14d. The first magnets 18 a and 18 b and the second magnets 18 c and 18 d can cause the plate 150 to be in a state of being stretched between the first rollers 14 a and 14 b and the second rollers 14 c and 14 d .

[0101] In addition, the force of the magnets 18a and 18b also acts on the corrugated plate 140 on the flat plate 150. Therefore, the corrugated plate 140 follows the flat plate 150 and is transported in the transport direction, and the corrugated plate 140 is prevented from being separated from the flat plate 150.

[0102] In this embodiment, the pair of winding shafts 16a and 16b are moved from Figure 2 When the retreat position shown by the solid line is moved to the holding position shown by the dotted line, the position of the flat plate 150 can be arranged at a stable position. Therefore, the flat plate 150 can be more reliably held by the pair of winding shafts 16a and 16b. Therefore, the failure of manufacturing the winding body 120 caused by the holding error of the pair of winding shafts 16a and 16b can be suppressed.

[0103] In addition, when the pair of winding shafts 16a and 16b are rotated to manufacture the wound body 120, the flat plate 150 and the corrugated plate 140 are continuously pulled toward the upstream end of the base 12 by the first magnets 18a and 18b. Therefore, the assembly 160, i.e., the flat plate 150 and the corrugated plate 140, can suppress the magnitude of the vertical vibration, and the wound body 120 can be stably wound.

[0104] Therefore, the manufacturing device 10 of this embodiment, which winds a strip-shaped flat plate 150 and a corrugated plate 140 overlapping with the flat plate 150 into a roll-shaped winding body 120 around the axis of an axis orthogonal to the conveying direction of the flat plate 150 and the corrugated plate 140, comprises: at least one pair of support bodies 14, which are separated in the conveying direction of the flat plate 150 and carry the flat plate 150 by conveying; winding shafts 16a, 16b, which are arranged between the at least one pair of support bodies 14 or above the at least one pair of support bodies 14 along the conveying direction, support the flat plate 150 carried on the at least one pair of support bodies 14 (in a clamping manner), and roll the flat plate 150 and the corrugated plate 140 together into a roll by rotating around its axis; and a pulling member 18, which pulls the flat plate 150 toward the at least one pair of support bodies 14 on the upstream and downstream sides of the winding shafts 16a, 16b along the conveying direction. In other words, the pulling member 18 has a magnet that urges the flat plate 150 toward at least one pair of supports 14 on the upstream and downstream sides of the take-up shafts 16a and 16b along the conveying direction, and urges the corrugated plate 140 toward the flat plate 150 on the upstream side of the take-up shafts 16a and 16b relative to the flat plate 150 along the conveying direction.

[0105] According to this embodiment, a manufacturing device 10 for the winding body 120 and a manufacturing method for the winding body 120 can be provided, which can easily insert the front end portion 150b of the flat plate 150 into the slit 17c of the winding shafts 16a and 16b, that is, can easily utilize the winding shafts 16a and 16b to more stably support the flat plate 150 and more stably manufacture the winding body 120.

[0106] In the present embodiment, an example in which the first magnets 18a and 18b of the pulling member 18 are provided on the base 12 is described. The first magnets 18a and 18b may be arranged on the upstream side of the base 12.

[0107] In the present embodiment, an example in which a pair of winding shafts 16a and 16b are provided as the core rod 16 is described. Alternatively, only one winding shaft 16a may be used as the core rod 16. In this case, the axial length of the slit 17c of the branching portion 17 of the winding shaft 16a is preferably formed to be substantially the same as or longer than the width of the flat plate 150.

[0108] On the other hand, in the present embodiment, an example is described in which the manufacturing device 10 does not use one winding shaft, but uses the two winding shafts 16a and 16b while aligning the rotation axes and facing each other. Compared with the case of using one winding shaft, the manufacturing device 10 of the present embodiment can form each winding shaft 16a and 16b shorter and exert appropriate rigidity, and can reduce the outer diameter of each winding shaft 16a and 16b compared with the case of using one winding shaft. Therefore, according to the present embodiment, a manufacturing device 10 for a metal substrate for purifying exhaust gas that can reduce the inner diameter of the center portion of the winding body 120 as much as possible can be provided. Therefore, a manufacturing device 10 is provided that can easily make the inner diameter of the center portion of the winding body 120 smaller and make the exhaust gas purification performance better when the winding body 120 is manufactured using a pair of winding shafts 16a and 16b.

[0109] In the present embodiment, the pulling member 18 is described as a permanent magnet such as a neodymium magnet. The pulling member 18 may also use an adsorption portion such as an adsorption pad connected to a vacuum suction device to make the inside of the member negative pressure. In this case, the adsorption portion can be used to pull the flat plate 150 toward the base 12, the first rollers 14a, 14b, and the second rollers 14c, 14d. The vacuum suction device at this time may be controlled by the control unit 200, or the control unit 200 may control an electromagnetic valve (not shown) connected to the vacuum suction device.

[0110] The attraction force of the suction unit is applied to the flat plate 150, but is not usually applied to the corrugated plate 140. However, by stably applying the attraction force to the flat plate 150, the flat plate 150 can be stably conveyed toward the manufacturing device 10 of the wound body 120, and thus the corrugated plate 140 on the flat plate 150 can be stably conveyed on the flat plate 150. Therefore, even when the suction unit is used as the pulling member 18, the wound body 120 can be stably manufactured. In this case, the flat plate 150 and the corrugated plate 140 of the assembly 160 can use appropriate raw materials such as stainless steel such as martensitic stainless steel, ferritic stainless steel, and austenitic stainless steel, regardless of whether they are soft magnetic bodies.

[0111] In addition, as described above, the flat plate 150 has openings as appropriate. Therefore, the suction force can act not only on the flat plate 150 but also on the corrugated plate 140 depending on the location.

[0112] The magnets 18a and 18b may be disposed on the upstream side of the take-up shafts 16a and 16b in the pulling member 18 described in the present embodiment, and an attraction portion other than the magnet may be disposed on the upstream side of the take-up shafts 16a and 16b.

[0113] In the present embodiment, an example in which four rollers 14a to 14d are used as the support body 14 is described. As the support body 14, for example, a spherical body may be used instead of the rollers 14a to 14d.

[0114] In the present embodiment, an example in which the manufacturing apparatus 10 uses the base 12 is described. However, the base 12 is not necessarily required as long as the support body 14 and the pulling member 18 can relatively maintain the above-mentioned positions.

[0115] In the present embodiment, an example is described in which an assembly 160 formed by stacking a metal flat plate 150 on the lower side of a corrugated metal plate 140 forming corrugations is conveyed toward the manufacturing device 10 of the wound body 120. Alternatively, the assembly 160 formed by stacking a metal flat plate 150 on the upper side of a corrugated metal plate 140 forming corrugations may be conveyed toward the manufacturing device 10 of the wound body 120 to form the wound body 120. In this case, the rotation direction of the pair of winding shafts 16a and 16b is the opposite direction to the assembly 160 formed by stacking the corrugated plate 140 on the upper side of the flat plate 150. When the magnets 18a to 18d are used as the pulling member 18, the force of the pulling member 18 acts on the flat plate 150 on the upper side in addition to the corrugated plate 140 on the lower side.

[0116] Therefore, when the assembly 160 in which the corrugated plate 140 is arranged at the lower side and the flat plate 150 is arranged at the upper side is used and the pair of winding shafts 16a and 16b are rotated to manufacture the wound body 120, the first magnets 18a and 18b are used to continuously pull the corrugated plate 140 at the lower side and the flat plate 150 at the upper side toward the upstream end of the base 12. Therefore, the assembly 160, i.e., the flat plate 150 and the corrugated plate 140, can suppress the magnitude of the vertical vibration, and the wound body 120 can be stably wound.

[0117] Therefore, regardless of whether the corrugated plate 140 and the flat plate 150 of the assembly 160 are stacked in the up-down direction, the wound body 120 is formed using the manufacturing apparatus 10 of the wound body 120 of the present embodiment.

[0118] In this embodiment, the pressure sensor 266 is provided in the adjustment member 20, and the third operation unit 260 is operated based on the output value of the pressure sensor 266 to suppress the load on the pair of winding shafts 16a and 16b. For example, a strain gauge may be installed on the pair of winding shafts 16a and 16b to measure the strain in real time, and the third operation unit 260 may be operated based on the measured value to suppress the load on the pair of winding shafts 16a and 16b. That is, there may be various means for suppressing the load on the pair of winding shafts 16a and 16b when manufacturing the winding body 120.

[0119] In the present embodiment, an example in which the flat plate 150 is inserted into the slit 17c is described. For example, in addition to the flat plate 150, the front end portion of the corrugated plate 140 may be inserted into the slit 17c. In addition, the front end portion of the corrugated plate 140 may be inserted into the slit 17c instead of the flat plate 150. That is, the front end portion of the corrugated plate 140 may protrude in the conveying direction more than the front end 150a of the flat plate 150. Therefore, in the slit 17c, at least the flat plate 150 and / or the corrugated plate 140 are configured to be able to be inserted into the slit 17c. In addition, the front end portion of the corrugated plate 140 may be formed as a plane like the front end portion 150b of the flat plate 150, or may be formed as a portion formed into a wave shape.

[0120] (Variation Example)

[0121] In the first embodiment described above, as a moving mechanism, the second operating unit (moving mechanism) 240 having the second pump 242 and the cylinder 244 is controlled by the control unit 200 to relatively move the pair of winding shafts 16a and 16b closer or farther away from each other. Fig. 12A and Fig. 12B As shown, the manufacturing device 10 may also include a pair of racks 272a, 272b, a pinion 274 meshing between the pair of racks 272a, 272b, and a motor 276 as a moving mechanism. The pair of racks 272a, 272b, the pinion 274, and the motor 276 are, for example, disposed at a position that does not interfere with the up-and-down movement of the base 12 and the up-and-down movement of the adjustment member 20. The pair of racks 272a, 272b, the pinion 274, and the motor 276 are preferably disposed on the lower side of the base 12. The motor 276 may also be configured to rotate the pinion 274 by a desired angle by a stepping motor or the like.

[0122] Furthermore, the flange 16a1 can be supported so as to be rotatable around the axis of the first winding shaft 16a by using a supporting member 278a of a rack 272a provided on one of the pair of racks 272a, 272b, and the flange 16b1 can be supported so as to be rotatable around the axis of the second winding shaft 16b by using a supporting member 278b of a rack 272b provided on the other of the pair of racks 272a, 272b.

[0123] Furthermore, the extending direction of the pair of racks 272 a and 272 b is a direction parallel to the width direction of the flat plate 150 and the corrugated plate 140 .

[0124] For example, when the motor 276 is rotated by the control unit 200, the pair of racks 272a and 272b are moved in conjunction with the rotation of the pinion 274, and the support members 278a and 278b and the flanges 16a1 and 16b1 are brought closer or separated. In other words, the free ends of the winding shafts 16a and 16b are brought closer or separated. The moving mechanism can also be formed in this way.

[0125] (Second embodiment)

[0126] In the first embodiment, an example of using a permanent magnet or an adsorption portion as the pulling member 18 has been described. Figures 13 to 15 As shown in FIG. 1 , an example using electromagnets 19a and 19b as the pulling member 18 will be described. In addition, this embodiment is a modified example of the first embodiment, and the same reference numerals are given to the same components as those described in the first embodiment, and detailed descriptions thereof will be omitted. Figure 4 As shown, the electromagnets 19 a and 19 b are connected to the control unit 200 , and the control unit 200 can control the on / off of the current flowing through the electromagnets 19 a and 19 b .

[0127] The electromagnets 19a and 19b as the pulling member 18 of this embodiment may be arranged at the position described in the first embodiment, for example, they may be provided on the support body 14. In this embodiment, an example in which the electromagnets 19a and 19b are provided on the support body 14 will be described. Figures 13 to 15 In the embodiment, the electromagnet 19a is provided on the roller 14b, but it is preferable that the roller 14a described in the first embodiment (see Figure 2 ) is also provided with an electromagnet 19a. Similarly, an electromagnet 19b is provided on roller 14d, but preferably on roller 14c (refer to Figure 2 ) is also provided with an electromagnet 19b.

[0128] The control unit 200 can switch on / off the generation of magnetic force of the electromagnets 19a and 19b. When current flows through the electromagnets 19a and 19b as the pulling member 18 of this embodiment, the electromagnets 19a and 19b generate magnetic force and function as magnets. When the current stops, the electromagnets 19a and 19b lose their function as magnets.

[0129] In addition, the first electromagnets 19a and 19b are preferably provided on the first rollers 14a and 14b via insulating materials such as rubber materials, and the second electromagnets 19a and 19b are preferably provided on the second rollers 14c and 14d via insulating materials such as rubber materials. For example, when the first rollers 14a and 14b and the second rollers 14c and 14d are formed of metal materials, it is possible to prevent the current from flowing to the assembly 160 via the first rollers 14a and 14b and the second rollers 14c and 14d.

[0130] For example, the first electromagnet 19a provided on the first rollers 14a and 14b of the present embodiment and the second electromagnet 19b provided on the second rollers 14c and 14d can be switched on / off independently. Therefore, the pulling position of the flat plate 150 or the assembly 160 in the pulling member 18 is located on the support body 14 (first rollers 14a and 14b) on the upstream side of the support body 14. In addition, the pulling position of the flat plate 150 in the pulling member 18 is located on the support body 14 (second rollers 14c and 14d) on the downstream side of the support body 14.

[0131] For example, Fig.13 and Fig.14 As shown, when the front end portion 150b of the flat plate 150 of the assembly 160 is placed on the base 12, the first rollers 14a, 14b, and the second rollers 14c, 14d, the control unit 200 allows current to flow through the electromagnets 19a, 19b to pull the front end portion 150b of the flat plate 150 of the assembly 160 onto the first rollers 14a, 14b, and the second rollers 14c, 14d.

[0132] And, if Fig.14 As shown, the control unit 200 maintains the state in which the current flows through the electromagnets 19a and 19b until the front end portion 150b of the plate 150 is gripped by the pair of winding shafts 16a and 16b.

[0133] After the pair of winding shafts 16a and 16b have finished gripping the front end 150b of the plate 150, the control unit 200 stops the current flowing to the second electromagnet 19b while maintaining the state in which the current flows to the first electromagnet 19a. In this state, the control unit 200 controls the motor 230 to rotate the pair of winding shafts 16a and 16b, and the front end 150b of the plate 150 can be easily withdrawn from the second electromagnets 19a and 19b. Fig.15 At this time, the control unit 200 also maintains the state of flowing current through the first electromagnet 19a, so the plate 150 is maintained in contact with the first rollers 14a and 14b.

[0134] Thereafter, the control unit 200 continues to flow the current through the first electromagnet 19 a before the wound body 120 is manufactured, and stops the flow of the current through the first electromagnet 19 a after the wound body 120 is manufactured.

[0135] like Fig.14 and Fig.15As shown in FIG. 1 , when the control unit 200 controls the motor 230 to fold back the front end 150b of the flat plate 150 of the assembly 160 clamped by the pair of winding shafts 16a and 16b to change the direction of the front end 150a of the flat plate 150, the control unit 200 stops the current to the electromagnet 19b on the front end side of the flat plate 150. Therefore, compared with the state in which the control unit 200 allows the current to flow through the electromagnet 19b, the pair of winding shafts 16a and 16b can fold back the front end 150b of the flat plate 150 of the assembly 160 clamped by the pair of winding shafts 16a and 16b with a relatively light force.

[0136] Furthermore, the control unit 200 adjusts the magnitude of the current flowing through the electromagnets 19 a and 19 b , thereby adjusting the pulling force on the assembly 160 .

[0137] Therefore, the manufacturing device 10 of this embodiment, which winds a strip-shaped flat plate 150 and a corrugated plate 140 overlapping with the flat plate 150 into a roll-shaped winding body 120 around the axis of an axis orthogonal to the conveying direction of the flat plate 150 and the corrugated plate 140, comprises: at least one pair of support bodies 14, which are separated in the conveying direction of the flat plate 150 and carry the flat plate 150 by conveying; winding shafts 16a, 16b, which are arranged between the at least one pair of support bodies 14 or above the at least one pair of support bodies 14 along the conveying direction, support the flat plate 150 carried on the at least one pair of support bodies 14 (in a clamping manner), and roll the flat plate 150 and the corrugated plate 140 together into a roll by rotating around their axes; and a pulling member 18, which pulls the flat plate 150 toward the at least one pair of support bodies 14 on the upstream and downstream sides of the winding shafts 16a, 16b along the conveying direction. In other words, the pulling member 18 has an electromagnet that urges the flat plate 150 toward at least one pair of supports 14 on the upstream and downstream sides of the take-up shafts 16a and 16b along the conveying direction, and urges the corrugated plate 140 toward the flat plate 150 on the upstream side of the take-up shafts 16a and 16b relative to the flat plate 150 along the conveying direction.

[0138] According to this embodiment, a manufacturing device 10 for the winding body 120 and a manufacturing method for the winding body 120 can be provided, which can easily insert the front end portion 150b of the flat plate 150 into the slit 17c of the winding shafts 16a and 16b, that is, can easily utilize the winding shafts 16a and 16b to more stably support the flat plate 150 and more stably manufacture the winding body 120.

[0139] In addition, the present invention is not limited to the above-mentioned embodiments, and various modifications can be made in the implementation stage without departing from the scope of the main purpose. In addition, each embodiment can also be implemented in appropriate combination, in which case the effect of the combination can be obtained. Moreover, various inventions are included in the above-mentioned embodiments, and various inventions can be extracted by combining selected from a plurality of disclosed constituent elements. For example, in the case where the problem can be solved and the effect can be obtained even if several constituent elements are deleted from all the constituent elements shown in the embodiments, the structure in which the constituent elements are deleted can be extracted as an invention.

Claims

1. A wound body manufacturing device, the wound body manufacturing device winding a strip-shaped flat plate and a corrugated plate arranged overlapping with the flat plate into a roll shape around an axis perpendicular to the conveying direction of the flat plate and the corrugated plate, wherein: The wound body manufacturing device comprises: at least one pair of supports, the at least one pair of supports being separated in a conveying direction of the flat plate and carrying the flat plate by conveying; a winding shaft, which is disposed between the at least one pair of supports or above the at least one pair of supports along the conveying direction, supports the flat plate placed on the at least one pair of supports, and rotates about its axis to wind up the flat plate and the corrugated plate together into a roll; and A pulling member pulls the flat plate toward the at least one pair of supports at an upstream side and a downstream side of the take-up shaft along the conveying direction.

2. The wound body manufacturing device according to claim 1, wherein: The pulling position of the flat plate in the pulling member is located on the upstream side of the at least one pair of supports.

3. The wound body manufacturing device according to claim 1, wherein: The pulling member is provided on the at least one pair of supporting bodies.

4. The wound body manufacturing device according to claim 1, wherein: The pulling member is a magnet that pulls the flat plate and the corrugated plate toward the at least one pair of support bodies.

5. A wound body manufacturing device, the wound body manufacturing device winding a flat plate formed into a magnetic strip and a corrugated plate formed into a magnetic body and arranged to overlap the flat plate into a roll, wherein: The wound body manufacturing device comprises: at least one pair of supports, the at least one pair of supports being separated in a conveying direction of the flat plate and carrying the flat plate by conveying; a winding shaft, which is disposed between the at least one pair of supports or above the at least one pair of supports along the conveying direction, supports the flat plate placed on the at least one pair of supports, and rotates about its axis to wind up the flat plate and the corrugated plate together into a roll; and A magnet urges the flat plate toward the at least one pair of supports at the upstream and downstream sides of the take-up shaft along the conveying direction, and urges the corrugated plate toward the flat plate at the upstream side of the take-up shaft relative to the flat plate along the conveying direction.

6. A method for producing a wound body, the method comprising winding a strip-shaped flat plate and a corrugated plate arranged to overlap the flat plate into a roll, wherein: The method for manufacturing the wound body comprises the following steps: The flat plate is placed on at least one pair of supports separated along a conveying direction of the flat plate by conveying; pulling the flat plate toward the at least one pair of supports at the upstream and downstream sides of the take-up shaft along the conveying direction; as well as The flat plate is supported by a winding shaft on the at least one pair of support bodies, and the flat plate and the corrugated plate are wound together into a roll shape by rotating around the axis thereof.

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