Apparatus for manufacturing metal substrate for exhaust gas purification

Abstract

An apparatus for manufacturing a metal substrate for exhaust gas purification, which is formed by winding a flat plate and a corrugated plate provided on the flat plate, comprises a first winding shaft and a second winding shaft, a rotating mechanism, and a moving mechanism. The first take-up shaft is supported by a cantilever, and has a pair of first facing pieces on a free end side, the first facing pieces defining a first slit and facing each other. The second take-up shaft is supported by a cantilever, and has a pair of second facing pieces that define a second slit and face each other on the free end side. The rotating mechanism arranges the rotating shafts of the first winding shaft and the second winding shaft on the same axis so that the free ends of the first winding shaft and the second winding shaft face each other, and at least the flat plate and / or the corrugated plate are arranged so as to be capable of being inserted through the first slit and the second slit so that the first winding shaft and the second winding shaft synchronously rotate in the same direction. The moving mechanism enables the free ends of the first winding shaft and the second winding shaft to approach or separate from each other while arranging the rotating shafts of the first winding shaft and the second winding shaft on the same axis.

Description

Technical Field

[0001] The present invention relates to a device for manufacturing a metal substrate for exhaust gas purification. Background Art

[0002] For example, Japanese Patent Application Laid-Open No. 6-198198 discloses a manufacturing device for a metal substrate for exhaust gas purification, which is used to wind a honeycomb-shaped metal substrate (honeycomb body) in a state where a corrugated plate is arranged on a flat plate. For example, after the corrugated plate is placed on a flat plate, the flat plate is arranged from the end side in the width direction of the flat plate to a slit along the length direction of a winding shaft (shaft), and the winding shaft is rotated around its axis, thereby forming a substantially cylindrical metal substrate (wound body).

[0003] The inner diameter of the center portion of the metal substrate may be determined by the outer diameter of the winding shaft (mandrel). In addition, it is known that the inner diameter of the center portion of the metal substrate has a moderate influence on the exhaust gas purification performance. For example, when metal substrates having outer diameters of a predetermined size are compared with each other, the smaller the inner diameter of the center portion of the metal substrate, the larger the contact area between the metal catalyst carried on the metal substrate and the exhaust gas can be manufactured by the metal substrate, and it is conceivable that the exhaust gas purification performance becomes good.

[0004] When a metal substrate is manufactured by rotating a winding shaft around its axis, it is assumed that the deflection of the winding shaft at the free end side when stationary and rotating becomes larger than that at the fixed end side due to the rigidity of the winding shaft. Therefore, when an assembly formed by winding a corrugated sheet and a flat sheet together using a winding shaft is used, in order to suppress the deflection at the free end side, a winding shaft with an appropriate outer diameter needs to be used, and there is a limit to reducing the inner diameter of the center portion of the metal substrate. Summary of the invention

[0005] An object of the present invention is to provide a device for manufacturing a metal substrate for exhaust gas purification, which can reduce the inner diameter of the center portion of the metal substrate as much as possible.

[0006] One embodiment of the present invention is a manufacturing device for a metal substrate for exhaust gas purification formed by winding a flat plate and a corrugated plate arranged on the flat plate, which comprises a first winding shaft and a second winding shaft, a rotating mechanism, and a moving mechanism. The first winding shaft is supported by a cantilever, and has a first pair of mutually facing plates defining a first slit on the free end side. The second winding shaft is supported by a cantilever, and has a second pair of mutually facing plates defining a second slit on the free end side. The rotating mechanism arranges the rotating axes of the first winding shaft and the second winding shaft on the same axis so that the free ends of the first winding shaft and the second winding shaft face each other, and at least the flat plate and / or the corrugated plate are arranged to be inserted into the first slit and the second slit, so that the first winding shaft and the second winding shaft rotate synchronously in the same direction. The moving mechanism arranges the rotating axes of the first winding shaft and the second winding shaft on the same axis while bringing the free ends of the first winding shaft and the second winding shaft closer to or away from each other. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] 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.

[0008] Figure 2 It is a schematic plan view showing the wound body manufacturing device and the first conveying device according to the first embodiment.

[0009] Figure 3 This is a schematic diagram showing a state in which the free ends of the mandrels (a pair of winding shafts) are brought close to each other.

[0010] Figure 3A Yes Figure 2 A schematic diagram of a pair of winding shafts whose free ends are separated from each other and a flange holding the pair of winding shafts in a manufacturing device shown by a solid line in the middle.

[0011] Figure 3B It means from Figure 3A A schematic diagram of a pair of winding shafts and a flange of a manufacturing device viewed from the direction indicated by reference numeral 3B in FIG.

[0012] Figure 3C It means to make Figure 3A A schematic diagram showing a state in which free ends of a pair of winding shafts and flanges of the manufacturing device shown are close to each other.

[0013] Figure 3D It means from Figure 3C A schematic diagram of a pair of winding shafts and a flange of a manufacturing device viewed from the direction indicated by reference numeral 3D in FIG.

[0014] Figure 4 It is a schematic block diagram of the winding body manufacturing apparatus according to the first embodiment.

[0015] Figure 5 It is a schematic diagram showing the manufacturing process of the wound body according to the first embodiment.

[0016] Figure 6 It means next Figure 5 A schematic diagram of the manufacturing process of the winding body.

[0017] Figure 7 It means next Figure 6 A schematic diagram of the manufacturing process of the winding body.

[0018] Figure 8 It means next Figure 7 A schematic diagram of the manufacturing process of the winding body.

[0019] Fig. 9 It means next Figure 8 A schematic diagram of the manufacturing process of the winding body.

[0020] Fig.10 It means next Fig. 9 A schematic diagram of the manufacturing process of the winding body.

[0021] Fig.11 This is a schematic flowchart showing the manufacturing process of the wound body according to the first embodiment.

[0022] Fig. 12A It is a schematic diagram of a moving mechanism of a winding device according to a modified example.

[0023] Fig. 12B is from Fig. 12A Schematic diagram of the moving mechanism viewed in the direction indicated by arrow 12B.

[0024] Fig.13 This is a schematic diagram showing a state in which the free ends of a mandrel (a pair of winding shafts) of the exhaust gas-purifying catalytic converter manufacturing apparatus according to the second embodiment are brought close to each other.

[0025] Fig.13A Yes Figure 2 A schematic diagram of a pair of winding shafts whose free ends are separated from each other and a flange holding the pair of winding shafts in a manufacturing device shown by a solid line in the middle.

[0026] Fig. 13B It means from Fig.13A A schematic diagram of a pair of winding shafts and a flange of a manufacturing device viewed from the direction indicated by reference numeral 13B in FIG. 1 .

[0027] Fig. 13C It means to make Fig.13A A schematic diagram showing a state in which free ends of a pair of winding shafts and flanges of the manufacturing device shown are close to each other.

[0028] Fig.13D It means from Fig. 13C A schematic diagram of a pair of winding shafts and a flange of a manufacturing device viewed from the direction indicated by reference numeral 13D in FIG. 1 .

[0029] Fig.14 This is a schematic diagram showing a state in which a flat plate having a through hole is sandwiched between slits of a mandrel in an exhaust gas-purifying catalytic converter manufacturing apparatus according to a second embodiment. DETAILED DESCRIPTION

[0030] Hereinafter, a mode for carrying out the present invention will be described with reference to the drawings.

[0031] (First embodiment)

[0032] use Figures 1 to 11 A manufacturing apparatus 10 of a first embodiment for winding a strip-shaped flat plate 150 and a corrugated plate 140 arranged overlapping the flat plate 150 into a roll-shaped wound body (metal substrate) 120 around an axis (mandrel 16) orthogonal to the conveying direction of the flat plate 150 and the corrugated plate 140 will be described.

[0033] 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.

[0034] 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.

[0035] 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.

[0036] 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.

[0037] 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 .

[0038] 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.

[0039] The assembly 160 used in this embodiment will be described.

[0040] 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.

[0041] 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 .

[0042] 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.

[0043] 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.

[0044] For example, in order to reduce weight, through holes 150c may be formed at appropriate intervals on the flat plate 150 (see Fig.14 ). 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 these flat plates 150 and the corrugated plates 140, the exhaust gas can flow in the catalytic converter 100 for exhaust gas purification and come into contact with the catalyst metal more, thereby promoting the purification of the exhaust gas.

[0045] 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.

[0046] 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 .

[0047] Figure 3 The schematic diagram shows a state in which free ends of a mandrel 16 (winding shafts 16a and 16b) to be described later are brought close to each other while being brought toward each other. Figure 3A Indicates Figure 2 The solid line in the middle is a schematic diagram of the winding shafts 16a and 16b whose free ends are separated from each other and the flanges 16a1 and 16b1 that hold the winding shafts 16a and 16b. Figure 3B The figure shows that from Figure 3A Schematic diagram of the winding shafts 16a, 16b and flanges 16a1, 16b1 of the manufacturing device 10 as viewed from the direction indicated by the reference numeral 3B in FIG. Figure 3C Indicates Figure 2 The free ends of the manufacturing device 10 shown in the dashed line are close to each other, that is, Figure 3A The schematic diagram of the manufacturing device 10 shown is a state where the free ends of the winding shafts 16a and 16b and the flanges 16a1 and 16b1 are close to each other. Figure 3D Indicates from Figure 3C Schematic diagram of the winding shafts 16a, 16b and flanges 16a1, 16b1 of the manufacturing device 10 as viewed from the direction indicated by the reference numeral 3D in FIG.

[0048] Figure 4 A schematic block diagram showing the manufacturing apparatus 10 of the wound body 120 , the first conveying apparatus 170 , and the second conveying apparatus 180 .

[0049] exist 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 figure is shown. Fig.11 It is a flowchart explaining a series of manufacturing steps of the wound body 120 using the manufacturing apparatus 10 .

[0050] 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 )

[0051] 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.

[0052] 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.

[0053] 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 14a and 14b (support bodies) described later.

[0054] 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.

[0055] 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.

[0056] 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.

[0057] 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 .

[0058] 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 .

[0059] 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 .

[0060] 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.

[0061] The fixed ends of the pair of winding shafts 16a and 16b are supported by flanges 16a1 and 16b1, respectively. FIG. 3A to FIG. 3D As shown, 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 17a1 provided on the shaft 17a, and similarly, the shaft 17b is supported by the frame of the manufacturing device 10 via a bearing 17b1 provided on the shaft 17b. And, these shafts 17a, 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.

[0062] 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.

[0063] 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.

[0064] 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.

[0065] like Figure 2 As shown by the solid line or Figure 3A and Figure 3B As shown in FIG. 1 , the free ends of the pair of winding shafts 16a and 16b can be retracted from above the base 12 and moved to a separated position. Figure 2 As shown in the dashed line or Figure 3C and Figure 3D As shown, the free ends of the pair of winding shafts 16a and 16b can move to a close position above the base 12. 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.

[0066] 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.

[0067] 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.

[0068] Preferred by Figure 4The 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 The solid line position in Figure 3A and Figure 3B ) and the dotted line position (refer to Figure 3C and Figure 3D ) are moved between. A disc-shaped flange 16a1 is provided on the take-up shaft 16a. A disc-shaped flange 16b1 is provided on the take-up 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 take-up 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.

[0069] 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.

[0070] like Figures 3 to 3D As shown, the pair of winding shafts 16a, 16b are preferably formed in the same shape with the same length. The pair of winding shafts 16a, 16b are preferably formed as metal rods with a diameter of about 5 mm, for example, by processing a high-rigidity and high-toughness steel material such as SUS440C and SKD11. In addition, it is preferred that the pair of winding shafts 16a, 16b are formed as follows to have a first pair of facing pieces 22a, 22b and a second pair of facing pieces 24a, 24b, and then, for example, quenched and used.

[0071] One of the pair of winding shafts 16a, 16b (hereinafter referred to as the first winding shaft 16a) is cantilevered on the flange 16a1, and has a first pair of mutually facing pieces 22a, 22b that define the first slit 22 on the free end side. One of the first pair of facing pieces 22a, 22b is set as the 1-1 piece 22a, and the other is set as the 1-2 piece 22b. The free end side of the first winding shaft 16a is divided into two parts, the 1-1 piece 22a and the 1-2 piece 22b. The 1-1 piece 22a and the 1-2 piece 22b are preferably formed symmetrically with respect to the rotation axis of the first winding shaft 16a. The 1-1 sheet 22a and the 1-2 sheet 22b are separated by at least the thickness of the flat plate 150, and the position including the free end of the first winding shaft 16a is formed as a first slit 22 that penetrates in a direction intersecting (orthogonal) with the separation direction of the 1-1 sheet 22a and the 1-2 sheet 22b. In addition, at least the flat plate 150 is arranged in the first slit 22 defined between the 1-1 sheet 22a and the 1-2 sheet 22b.

[0072] In addition, the axial length of the first slit 22 along the first winding shaft 16a is formed to be equal to or slightly larger than half the width of the flat plate 150. That is, the distance between the branching portion of the 1-1 sheet 22a and the 1-2 sheet 22b and the free ends of the 1-1 sheet 22a and the 1-2 sheet 22b is formed to be equal to or slightly larger than half the width of the flat plate 150. Therefore, the axial length of the first slit 22 along the first winding shaft 16a is preferably formed to be, for example, about half the width of the flat plate 150.

[0073] The distance between the 1-1st piece 22a and the 1-2nd piece 22b, i.e., the size of the first slit 22 is preferably the same from the branch portion to the vicinity of the free end. In order to guide the flat plate 150 to be accommodated in the first slit 22 near the free end, the size of the first slit 22 is preferably increased toward the free end side.

[0074] Similarly, the other of the pair of winding shafts 16a, 16b (hereinafter referred to as the second winding shaft 16b) is cantilevered on the flange 16b1, and has a second pair of facing pieces 24a, 24b facing each other that define the second slit 24 on the free end side. One of the second pair of facing pieces 24a, 24b is set as the 2-1 piece 24a, and the other is set as the 2-2 piece 24b. The free end side of the second winding shaft 16b is divided into two parts, the 2-1 piece 24a and the 2-2 piece 24b. The 2-1 piece 24a and the 2-2 piece 24b are preferably formed symmetrically with respect to the rotation axis of the second winding shaft 16b. The 2-1 sheet 24a and the 2-2 sheet 24b are separated by at least the thickness of the flat plate 150, and the position including the free end of the second winding shaft 16b is formed as a second slit 24 that penetrates in a direction intersecting (orthogonal) with the separation direction of the 2-1 sheet 24a and the 2-2 sheet 24b. In addition, at least the flat plate 150 is arranged in the second slit 24 defined between the 2-1 sheet 24a and the 2-2 sheet 24b.

[0075] In addition, the axial length of the second slit 24 along the second winding shaft 16b is formed to be equal to or slightly larger than half the width of the flat plate 150. That is, the distance between the branching portion of the 2-1st piece 24a and the 2-2nd piece 24b and the free ends of the 2-1st piece 24a and the 2-2nd piece 24b is formed to be equal to or slightly larger than half the width of the flat plate 150. Therefore, the axial length of the second slit 24 along the second winding shaft 16b is preferably formed to be, for example, about half the width of the flat plate 150.

[0076] The distance between the 2-1st piece 24a and the 2-2nd piece 24b, i.e., the size of the second slit 24 is preferably the same from the branch portion to the vicinity of the free end. In order to guide the flat plate 150 to be accommodated in the second slit 24 near the free end, the size of the second slit 24 is preferably increased toward the free end side.

[0077] Furthermore, the pair of winding shafts 16a and 16b are adjusted to maintain a state in which the free ends of the 1-1 sheet 22a and the 2-1 sheet 24a face each other in the horizontal direction and the extension directions of the 1-1 sheet 22a and the 2-1 sheet 24a are arranged on the same axis. In addition, the pair of winding shafts 16a and 16b are adjusted to maintain a state in which the free ends of the 1-2 sheet 22b and the 2-2 sheet 24b face each other in the horizontal direction and the extension directions of the 1-2 sheet 22b and the 2-2 sheet 24b are arranged on the same axis. Therefore, regardless of the rotational position of the pair of winding shafts 16a and 16b, the direction of the first slit 22 and the direction of the second slit 24 are aligned. Therefore, the front end portion 150b of the flat plate 150 is inserted through the first slit 22 between the first pair of facing sheets 22a and 22b and the second slit 24 between the second pair of facing sheets 24a and 24b.

[0078] In addition, a pair of winding shafts 16a and 16b are provided from Figure 3B The position shown is moved to the position of holding the plate 150, as shown in FIG. Figure 3D As shown, the 1-1 sheet 22a and the 2-1 sheet 24a are arranged on the upper side, and the 1-2 sheet 22b and the 2-2 sheet 24b are arranged on the lower side. At this time, the first slit 22 and the second slit 24 are horizontally located between the 1-1 sheet 22a and the 2-1 sheet 24a on the upper side and the 1-2 sheet 22b and the 2-2 sheet 24b on the lower side. In addition, the rotation of the pair of winding shafts 16a and 16b facing each other is synchronized, and the rotation speed and rotation angle of the pair of winding shafts 16a and 16b are the same, so that the torsion generated in the plate 150 is suppressed.

[0079] In addition, the manufacturing device 10 preferably has sensors 250a and 250b for detecting whether the first slit 22 and the second slit 24 are in the horizontal position and whether the front end 150b of the plate 150 is inserted into the first slit 22 and the second slit 24. 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 into the first slit 22 and the second slit 24.

[0080] 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.

[0081] 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).

[0082] 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.

[0083] 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.

[0084] 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.

[0085] 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.

[0086] 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.

[0087] 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.

[0088] 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.

[0089] 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.

[0090] 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.

[0091] 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.

[0092] 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 deviated from the upper surface of the base 12. In addition, the first slit 22 and the second slit 24 of the pair of winding shafts 16a and 16b are oriented in the horizontal direction. In addition, the center position of the first slit 22 and the second slit 24 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).

[0093] In this state, the assembly 160 is placed on the base 12 along a predetermined conveying direction by the 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 140 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.

[0094] 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 of the front end 150b of the flat plate 150 faces the branching portion of the first slit 22 and the branching portion of the second slit 24 of the pair of winding shafts 16a, 16b, respectively.

[0095] 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.

[0096] 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.

[0097] Here, the first slit 22 and the second slit 24 of the pair of winding shafts 16a and 16b face the horizontal direction. Therefore, the front end 150b of the flat plate 150 of the assembly 160 is inserted into the first slit 22 and the second slit 24 of the pair of winding shafts 16a and 16b. Therefore, the front end 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.

[0098] Then, the sensors 250a and 250b disposed in the frame of the manufacturing device 10 are used to detect whether the front end 150b of the plate 150 is inserted into the first slit 22 and the second slit 24 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 first slit 22 and the second slit 24 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 make the pair of winding shafts 16a and 16b move from the first slit 22 to the second slit 24. Figure 2 When the control unit 200 determines that the front end 150b of the plate 150 is not inserted through the first slit 22 and the second slit 24 based on the signals of the sensors 250a and 250b for multiple times (S3-No), an error is output and the processing is terminated, returning to the initial position.

[0099] 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 through the first slit 22 and the second slit 24 of a 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).

[0100] 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 two pairs of facing pieces 22a, 22b, 24a, and 24b of the pair of winding shafts 16a and 16b are supported in a manner of sandwiching the flat plate 150 placed on the support body 14. Then, the front end portion 150b of the flat plate 150 sandwiches 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 7 The 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. 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.

[0101] 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.

[0102] 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.

[0103] 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.

[0104] 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.

[0105] 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.

[0106] 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 first slit 22 and the second slit 24 of the pair of winding shafts 16a and 16b, or 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 first slit 22 and the second slit 24 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 (the flat plate 150 or the corrugated plate 140) from breaking, and to make the end 151a of the flat plate 150 and the end 141a of the corrugated plate 140 aligned, and to make the end 151b of the flat plate 150 and the end 141b of the corrugated plate 140 aligned.

[0107] 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.

[0108] 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.

[0109] 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 action unit 210 to stop the descent of the base 12, and controls the third action 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-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. 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 become 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. When the detection value of the pressure sensor 266 deviates from the predetermined pressure range, the control unit 200 operates the third operation unit 260 to move the adjustment member 20 upward, for example, to adjust the detection value detected by the pressure sensor 266 to 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.

[0110] 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 .

[0111] 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 alleviating the winding force of the front end portion 150b of the flat plate 150 relative to the outer peripheral surfaces of the pair of winding shafts 16a and 16b (the outer peripheral surfaces of the 1-1 sheet 22a, the 1-2 sheet 22b, the 2-1 sheet 24a, and the 2-2 sheet 24b). 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 2The 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.

[0112] 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.

[0113] According to the present embodiment, the manufacturing device 10 does not use one winding shaft, but uses the two winding shafts 16a, 16b while aligning the rotation axes and making the free ends face each other. Compared with the case of using one winding shaft, the manufacturing device 10 of the present embodiment can make each winding shaft 16a, 16b shorter and exert appropriate rigidity, and can reduce the outer diameter of each winding shaft 16a, 16b compared with the case of using one winding shaft. Therefore, according to the present embodiment, a manufacturing device 10 of a metal substrate for exhaust gas purification that can reduce the inner diameter of the center part of the winding body 120 as much as possible can be provided. Therefore, a manufacturing device 10 that can form a smaller inner diameter of the center part of the winding body 120 and make the exhaust gas purification performance better when manufacturing the winding body 120 is provided.

[0114] Furthermore, when the wound body 120 is manufactured from the assembly 160 using the manufacturing apparatus 10 , the assembly 160 can be arranged at a predetermined position using the pulling member 18 , so that the flat plate 150 of the assembly 160 can be stably wound.

[0115] 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.

[0116] 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.

[0117] 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.

[0118] In the present embodiment, the pulling member 18 is described as a permanent magnet such as a neodymium magnet. An electromagnet controlled by the control unit 200 may be used instead of a permanent magnet. In addition, the pulling member 18 may also use an adsorption portion that makes the interior negative pressure such as an adsorption pad connected to a vacuum suction device. 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. At this time, the vacuum suction device can be controlled by the control unit 200, and the control unit 200 can also control an electromagnetic valve (not shown) connected to the vacuum suction device.

[0119] 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.

[0120] In addition, as described above, the flat plate 150 has a through hole (opening) 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.

[0121] 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.

[0122] 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.

[0123] 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.

[0124] 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.

[0125] 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.

[0126] 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.

[0127] 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.

[0128] In the present embodiment, an example in which the flat plate 150 is inserted through the first slit 22 and the second slit 24 is described. For example, in addition to the flat plate 150, the front end portion of the corrugated plate 140 may be inserted through the first slit 22 and the second slit 24. In addition, instead of the flat plate 150, the front end portion of the corrugated plate 140 may be inserted through the first slit 22 and the second slit 24. That is, the front end portion of the corrugated plate 140 may protrude in the conveying direction from the front end 150a of the flat plate 150. Therefore, in the first slit 22 and the second slit 24, at least the flat plate 150 and / or the corrugated plate 140 are configured to be able to be inserted through the first slit 22 and the second slit 24. In addition, the front end portion of the corrugated plate 140 may be formed as a flat surface like the front end portion 150b of the flat plate 150, or may be formed as a portion formed into a wave shape.

[0129] (Variation Example)

[0130] 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.

[0131] 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.

[0132] Furthermore, the extending direction of the pair of racks 272 a and 272 b is parallel to the width direction of the flat plate 150 and the corrugated plate 140 .

[0133] 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.

[0134] (Second embodiment)

[0135] use Figures 13 to 13D A second embodiment of a manufacturing apparatus 10 for a wound body (metal substrate) 120 is described. This embodiment is a modification of the first embodiment, and components identical to those described in the first embodiment or components having the same functions are denoted by the same reference numerals, and detailed descriptions thereof are omitted.

[0136] Fig.13 This is a schematic diagram showing the free ends of the mandrel 16 (winding shafts 16a, 16b) being brought close to each other. Fig.13A Indicates Figure 2 The solid line in the middle is a schematic diagram of the take-up shafts 16a and 16b whose free ends are separated from each other and the flanges 16a1 and 16b1 that hold the take-up shafts 16a and 16b. Fig. 13B The figure shows that from Fig.13A Schematic diagram of the winding shafts 16a, 16b and flanges 16a1, 16b1 of the manufacturing device 10 as viewed from the direction indicated by the reference numeral 13B in FIG. Fig. 13C Indicates Fig.13A The schematic diagram of the manufacturing device 10 shown is a state where the free ends of the winding shafts 16a and 16b and the flanges 16a1 and 16b1 are close to each other. Fig.13D Indicates from Fig. 13C Schematic diagram of the winding shafts 16a, 16b and flanges 16a1, 16b1 of the manufacturing device 10 as viewed from the direction indicated by the reference numeral 13D in FIG.

[0137] The pair of winding shafts 16a and 16b of the present embodiment are preferably formed in the same shape. The pair of winding shafts 16a and 16b are preferably formed as metal rods having a diameter of, for example, about 4 mm, by processing steel materials such as SUS440C and SKD11. In addition, the pair of winding shafts 16a and 16b are preferably used after the first slit 22 and the second slit 24 are formed, for example, by quenching.

[0138] In this embodiment, the 1-1 piece 22a and the 1-2 piece 22b of the 1st winding shaft 16a described in the first embodiment are preferably formed asymmetrically. Later, the 1-1 piece 22a is used as the first short piece 22a, and the 1-2 piece 22b is used as the first long piece 22b longer than the first short piece 22a.

[0139] The length from the branch portion to the free end of the first short piece 22 a is shorter than half the width of the flat plate 150 , and the length from the branch portion to the free end of the first long piece 22 b is longer than half the width of the flat plate 150 .

[0140] The first slit 22 is formed between the first short piece 22a and the first long piece 22b, which is at least larger than the thickness of the flat plate 150. Therefore, the axial length of the first slit 22 along the first winding shaft 16a is defined as the length from the branch portion to the free end of the first short piece 22a. In addition, the distance between the first short piece 22a and the first long piece 22b, that is, the size of the first slit 22 is preferably the same from the branch portion to the vicinity of the free end of the first short piece 22a. In order to guide the flat plate 150 in the first slit 22 near the free end of the first short piece 22a, the size of the first slit 22 is preferably increased toward the free end side. In addition, the free end of the first long piece 22b is preferably enlarged toward the free end of the first long piece 22b in order to guide the flat plate 150 to be accommodated in the first slit 22 at a position closer to the free end of the first short piece 22a than the free end of the first long piece 22b.

[0141] Therefore, at least the flat plate 150 is arranged in the first slit 22 defined between the first short piece 22 a and the first long piece 22 b .

[0142] Similarly, the 2-1st piece 24a and the 2-2nd piece 24b of the second winding shaft 16b described in the first embodiment are preferably formed asymmetrically. Hereinafter, the 2-1st piece 24a is regarded as the second long piece 24a, and the 2-2nd piece 24b is regarded as the second short piece 24b shorter than the second long piece 24a.

[0143] The length from the branch portion to the free end of the second long piece 24 a is formed to be longer than half the width of the flat plate 150 , and the length from the branch portion to the free end of the second short piece 24 b is formed to be shorter than half the width of the flat plate 150 .

[0144] The second long piece 24a and the second short piece 24b are separated by at least the thickness of the flat plate 150 to form the second slit 24. Therefore, the axial length of the second slit 24 along the second winding shaft 16b is defined as the length from the branch portion to the free end of the second short piece 24b.

[0145] In addition, the distance between the second long piece 24a and the second short piece 24b, that is, the size of the second slit 24 is preferably the same from the branch portion to the vicinity of the free end of the second short piece 24b. In order to guide the flat plate 150 in the second slit 24 near the free end of the second short piece 24b, the size of the second slit 24 is preferably increased toward the free end side. In addition, for the free end of the second long piece 24a, in order to guide the flat plate 150 in the second slit 24 at a position closer to the free end side of the second long piece 24a than the free end of the second short piece 24b, the size of the second slit 24 is preferably increased toward the free end side of the second long piece 24a.

[0146] Therefore, at least the flat plate 150 is arranged in the second slit 24 defined between the second long piece 24 a and the second short piece 24 b .

[0147] Furthermore, the pair of winding shafts 16a and 16b are adjusted to maintain the state in which the free ends of the first short piece 22a and the second long piece 24a face each other in the horizontal direction and the extending directions of the first short piece 22a and the second long piece 24a are arranged on the same axis. In addition, the pair of winding shafts 16a and 16b are adjusted to maintain the state in which the free ends of the first long piece 22b and the second short piece 24b face each other in the horizontal direction and the extending directions of the first long piece 22b and the second short piece 24b are arranged on the same axis. Therefore, the direction of the first slit 22 is aligned with the direction of the second slit 24. Therefore, the flat plate 150 is inserted through the first slit 22 between the first pair of facing pieces 22a and 22b and the second slit 24 between the second pair of facing pieces 24a and 24b.

[0148] In the initial position of the pair of winding shafts 16a and 16b, for example, the first short piece 22a and the second long piece 24a are arranged on the upper side, and the first long piece 22b and the second short piece 24b are arranged on the lower side. At this time, the first slit 22 and the second slit 24 are located in a horizontal position.

[0149] Furthermore, the pair of winding shafts 16a and 16b facing each other rotate synchronously, and the pair of winding shafts 16a and 16b have the same rotation speed and rotation angle.

[0150] like Fig.13As shown in the figure, the length from the branch portion to the free end of the first short piece 22a of the first winding shaft 16a is less than half the width of the flat plate 150 and is relatively short, so the rigidity is relatively high. Therefore, it can be understood that even if the outer diameter of the first winding shaft 16a of this embodiment is thinner than the outer diameter of the first winding shaft 16a described in the first embodiment, the deflection of the free end of the first short piece 22a is smaller than the deflection of the free end of the first short piece 22a described in the first embodiment. In addition, the first short piece 22a and the first long piece 22b facing the first short piece 22a cooperate to hold the end 151a side of one side of the flat plate 150 along the width direction.

[0151] Similarly, the length from the branch portion to the free end of the second short piece 24b of the second winding shaft 16b is less than half the width of the flat plate 150 and is relatively short, so the rigidity is relatively high. Therefore, it can be understood that even if the outer diameter of the second winding shaft 16b of this embodiment is thinner than the outer diameter of the second winding shaft 16b described in the first embodiment, the deflection of the free end of the second short piece 24b is smaller than the deflection of the free end of the second short piece 24b described in the first embodiment. In addition, the second short piece 24b and the second long piece 24a facing the second short piece 24b cooperate to hold the other end 151b side of the flat plate 150 along the width direction.

[0152] The approximate centers of the widthwise ends 151a and 151b of the plate 150 are held by the first long piece 22b of the first winding shaft 16a and the second long piece 24a of the second winding shaft 16b which are longer than half the width of the plate 150, respectively.

[0153] Therefore, when the free end of the first winding shaft 16a and the free end of the second winding shaft 16b are brought close to or in contact with each other, the free end of the first short piece 22a and the free end of the second long piece 24a are offset from the center in the width direction of the flat plate 150 to the first width direction end 151a side. In addition, the free end of the first long piece 22b and the free end of the second short piece 24b are offset from the center in the width direction of the flat plate 150 to the second width direction end 151b side on the side opposite to the first width direction end 151a side. The protruding length of the first long piece 22b relative to the first short piece 22a along the axial direction of the first winding shaft 16a and the protruding length of the second long piece 24a relative to the second short piece 24b along the axial direction of the second winding shaft 16b are equidistant.

[0154] At this time, the front end 150b of the flat plate 150 is held by the first winding shaft 16a and the second winding shaft 16b over the entire width direction. The pair of winding shafts 16a and 16b are held continuously from the pair of ends 151a and 151b in the width direction of the flat plate 150 to the vicinity of the center. Therefore, when the manufacturing device 10 rotates the pair of winding shafts 16a and 16b in the same direction and at the same speed around the axis to wind up the flat plate 150 and the corrugated plate 140 placed on the flat plate 150, it is possible to wind up while suppressing wrinkles in the flat plate 150. 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 of one end of the winding body 120 and the inner diameter of the center of the other end can be kept substantially constant. In addition, the pair of winding shafts 16a and 16b uses the first long piece 22b and the second long piece 24a to hold the front end 150b of the flat plate 150 in the width direction. Therefore, by using the pair of winding shafts 16a and 16b, in addition to the inner diameter of the center of one end and the other end of the winding body 120, the inner diameter of the center of the region between the one end and the other end can be kept substantially constant.

[0155] 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 in the horizontal direction. 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 winding body 120 is manufactured using the two winding shafts 16a and 16b of the present embodiment, the inner diameter of the center portion of the winding body 120 can be formed as small as possible compared to the case where the winding body 120 is manufactured using one winding shaft. 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.

[0156] In addition, Fig.141 is a schematic diagram showing a state in which a flat plate 150 having through holes 150c is sandwiched between the slits 22 and 24 of the mandrel 16 of the manufacturing apparatus 10 for exhaust gas purification catalytic converter according to the present embodiment. That is, through holes 150c of appropriate sizes are formed at appropriate intervals on the flat plate 150. Further through holes may be formed on the corrugated plate 140 in the same manner as the through holes 150c, but their illustration is omitted.

[0157] For example, Fig.14 As shown, the through hole 150c of the flat plate 150 may be provided just below the opposing position of the first short piece 22a and the second long piece 24a, and the through hole 150c of the flat plate 150 may be provided just above the opposing position of the first-second piece 22b and the second short piece 24b. In this case, the front end 150b of the flat plate 150 is also held by the first winding shaft 16a and the second winding shaft 16b over the entire width direction. The pair of winding shafts 16a and 16b are continuously held from the pair of ends 151a and 151b in the width direction of the flat plate 150 to the vicinity of the center. Therefore, when the manufacturing device 10 rotates the pair of winding shafts 16a and 16b in the same direction at the same speed around the axis thereof to wind up 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.

[0158] 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 a single 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 and the inner diameter of the center portion of the other end of the winding body 120 can be kept substantially constant. In addition, the pair of winding shafts 16a and 16b uses the first long piece 22b and the second long piece 24a to hold the front end 150b of the flat plate 150 in the width direction. Therefore, by using a 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 also be kept substantially constant. In addition, as described above, when the wound body 120 is manufactured using the two winding shafts 16a and 16b of the present embodiment, the inner diameter of the central portion of the wound body 120 can be formed as small as possible compared to the case where the wound body 120 is manufactured using one winding shaft. Therefore, the wound body 120 manufactured by the manufacturing device 10 of the present embodiment has the through hole 150c in the flat plate 150, so that the contact area between the metal catalyst carried on the wound body 120 and the exhaust gas can be made larger than the case where the flat plate 150 does not have the through hole 150c, and the exhaust gas purification performance can be improved.

[0159] Thus, in this embodiment, unlike the manufacturing device 10 of the first embodiment, the mating parts of the mandrel 16 (the position where the first short piece 22a and the first piece 22b are close to or abut against each other and face each other, and the position where the second long piece 24a and the second short piece 24b are close to or abut against each other and face each other) are set at two locations offset from the center in the width direction of the flat plate 150. Therefore, when the flat plate 150 is rolled up using the mandrel 16, the pulling force applied to the flat plate 150 from the mating parts of the mandrel 16 can be dispersed and reduced, and the generation of wrinkles on the flat plate 150 can be suppressed.

[0160] Compared with the region where the through hole 150c is present in the flat plate 150, the central portion of the flat plate 150 has no through hole 150c, and therefore has a relatively high strength. It is assumed that the reaction force on the mandrel 16 during the winding of the winding body 120 is higher than that in the region where the through hole 150c is formed. The manufacturing device 10 of this embodiment prevents the mating portion of the mandrel 16 from contacting the central portion of the flat plate 150 in the width direction where the through hole 150c is not present. That is, the position of the mating portion of the mandrel 16 is offset relative to the central portion of the flat plate 150 where the mandrel 16 is assumed to receive the largest load when the flat plate 150 is wound. Therefore, when the flat plate 150 is wound using the mandrel 16, the deformation of the mandrel 16, especially the first long piece 22b and the second long piece 24a, can be reduced, and wrinkles on the flat plate 150 can be suppressed.

[0161] In addition, the length of the first long piece 22b protruding from the first short piece 22a and the length of the second long piece 24a protruding from the second short piece 24b are appropriately set. For example, the length of the first long piece 22b protruding from the first short piece 22a and the length of the second long piece 24a protruding from the second short piece 24b may be the same or different. Such lengths may be changed, for example, depending on the position of the through hole 150c provided in the flat plate 150.

[0162] 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 manufacturing device for a metal substrate for exhaust gas purification, wherein the metal substrate for exhaust gas purification is formed by winding a flat plate and a corrugated plate arranged on the flat plate, wherein: The manufacturing device of the metal substrate for exhaust gas purification comprises: a first winding shaft, the first winding shaft being cantilever-supported and having a first pair of mutually facing pieces defining a first slit on a free end side; a second winding shaft, the second winding shaft being cantilever-supported and having a second pair of mutually facing pieces defining a second slit on a free end side; a rotating mechanism, wherein the rotating axis of the first winding shaft and the rotating axis of the second winding shaft are arranged coaxially, the free ends of the first winding shaft and the free ends of the second winding shaft are arranged to face each other, at least the flat plate and / or the corrugated plate are arranged to be inserted into the first slit and the second slit, and the first winding shaft and the second winding shaft are synchronously rotated in the same direction; and A moving mechanism moves the free end of the first winding shaft and the free end of the second winding shaft in a direction of approaching or separating them while arranging the rotating axis of the first winding shaft and the rotating axis of the second winding shaft on the same axis.

2. The manufacturing device of the metal substrate for exhaust gas purification according to claim 1, wherein: The first pair of facing pieces of the first take-up shaft comprises: a first short piece extending from a fixed end side of the first take-up shaft toward the free end of the second take-up shaft; and a first long piece, the first long piece extending from the fixed end side of the first winding shaft toward the free end of the second winding shaft and being longer than the first short piece, The second pair of facing pieces of the second take-up shaft comprises: a second long piece extending from a fixed end side of the second take-up shaft toward the free end of the first take-up shaft; and a second short piece, the second short piece extending from the fixed end side of the second winding shaft toward the free end side of the first winding shaft and being shorter than the second long piece, The first short film and the second long film face each other along the rotation axis of the first winding shaft and the rotation axis of the second winding shaft. The first long film and the second short film are arranged to face each other along the rotation axis of the first winding shaft and the rotation axis of the second winding shaft.

3. The manufacturing device of the metal substrate for exhaust gas purification according to claim 2, wherein: A protruding length of the first long sheet relative to the first short sheet along the axial direction of the first winding axis is equidistant from a protruding length of the second long sheet relative to the second short sheet along the axial direction of the second winding axis.

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