Container of exhaust system and manufacturing method thereof

Abstract

To provide a technology of manufacturing a container of an exhaust system for accurately holding an end panel at a predefined three-dimensional posture and position, and fitting the end panel to an opening of a shell.SOLUTION: A container of an exhaust system in which an opening of both ends of a shell is closed by an end panel in which a cylindrical part having a cylindrical shape is formed at a peripheral edge, includes at least one first plane at a part other than a fitting part with the shell of the end panel, the first plane being a plane having a normal line which is parallel with a maximum diameter of the end panel or forms an acute angle of 45 degrees or less with respect to the maximum diameter, and parallel with the first axis, in a vertical projection view of a plane perpendicular to the first axis as a center axis of the shell. In a process of fitting a cylindrical part of the end panel to an opening of both ends of the shell, the end panel is set to holding means which is movable in a direction parallel with the first axis, and the end panel is supported and fixed in a predefined posture by bringing a first contact surface which is a predefined plane formed on the holding means into a plane contact with the first plane.SELECTED DRAWING: Figure 15

Description

Technical Field

[0001] The present invention relates to a container body for an exhaust system and a method for manufacturing the same.

Background Art

[0002] As a container body constituting an exhaust system of an internal combustion engine mounted on a vehicle such as a muffler (silencer) or a catalytic converter, a structure in which openings at both ends of a cylindrical shell formed of a thin metal plate are closed by end plates (also referred to as "outer plates" or "end plates", etc.) is frequently used.

[0003] Conventionally, the lock seam method (also referred to as "curling") in which the edge of the opening of the shell and the edge of the end plate are overlapped and caulked in a state where the openings at both ends of the shell are closed by the end plate has been the mainstream. However, recently, due to the increasing demand for improving airtightness and / or workability, the method of fitting the edge of the opening of the shell and the edge of the end plate and hermetically fixing and fixing them by continuous welding (mainly laser welding) has also been increasing in the opportunity of adoption.

[0004] The manufacturing method of the container body by continuous welding after fitting like the latter is roughly classified into two types. As a first method, for example, as illustrated in FIG. 21, an intermediate product (20) composed of end plates (4, 6), pipes (12, 14) and / or separators (partition walls) (8, 10), etc. is pre-assembled, and after covering the intermediate product with a shell formed by winding a plate material (21) around the end plate and / or the separator, a method of welding and fixing each part can be mentioned (for example, refer to Patent Document 1 (Japanese Patent No. 3934396)).

[0005] As a second method, as illustrated in FIG. 22, an intermediate component (composed of pipes (7, 8) and / or separators (45, 46) etc., without end plates) is press-fitted into a shell (42) formed by winding a plate material, and after press-fitting end plates (43, 44) into the openings at both ends of the shell (fitting the axially bent cylindrical peripheral edge), a method of fixing by continuous welding can be mentioned (for example, refer to Patent Document 2 (Japanese Patent No. 4572828)). Further, as a specific example of an apparatus for press-fitting end plates into the openings at both ends of the shell in this way, for example, the apparatus illustrated in FIG. 23 can be mentioned (for example, refer to Patent Document 3 (Japanese Utility Model Laid-Open No. 1-148239)).

[0006] The specific method of supporting the intermediate component in the process of winding the plate material included in the above-described first method is not disclosed in Patent Document 1. However, until midway through the process, for example, it is possible to support the lower surface of the intermediate component by a jig or the like and perform positioning relatively easily. However, after a certain point, the plate material begins to interfere with the jig. Therefore, after that point, the intermediate component must be supported from both sides. Thus, it is presumed to be extremely difficult to accurately position the intermediate component in a predetermined three-dimensional posture and rotate the intermediate component or the plate material to wind the plate material around the intermediate component.

[0007] Also, in the above-described second method, it is relatively easy to grip (clamp) the shell from the outside by a jig or the like for positioning. However, it is not easy to clamp an end plate, which is a member formed from a single thin metal plate, from one side by a jig and / or an assembly hand etc. and press it into the shell that is being gripped as described above. Moreover, it is extremely difficult to press-fit the end plate into the opening of the shell while accurately maintaining the end plate in a predetermined three-dimensional posture, position, and indexing (positional relationship with the opening of the shell in the rotational direction).

[0008] As a means for solving the above problems, as illustrated in FIG. 24, a bead (9b), which is a depression extending radially on the circumference of a contact groove (9) formed on the outer peripheral portion of an end plate (2), is provided, and a convex portion (11a) protruding from a jig for supporting the end plate is fitted into the bead. A technique has been proposed (see, for example, Patent Document 4 (Japanese Patent Application Laid-Open No. 2008-31851)). Although the main purpose of this technique is to increase the surface rigidity of the end plate without increasing the plate thickness to reduce radiated noise, as a secondary effect, it is said that relative rotation between the jig and the end plate during lock seam processing can be suppressed.

[0009] However, although the above technique can suppress relative rotation between the jig and the end plate, it does not provide a function of accurately gripping the end plate in a predetermined three-dimensional posture, position, and alignment. Furthermore, these days, containers having non-circular cross-sectional shapes such as substantially rectangular and substantially trapezoidal shapes, as well as elliptical and oval shapes, are frequently used. In either of the first method and the second method described above, the importance of accurately gripping the end plate in a predetermined three-dimensional posture, position, and alignment is increasing more and more.

Prior Art Documents

Patent Documents

[0010]

Patent Document 1

Patent Document 2

Patent Document 3

Patent Document 4

Summary of the Invention

Problems to be Solved by the Invention

[0011] As described above, in this technical field, there is a need for a technology that enables fitting an end plate into an opening of a shell while accurately gripping the end plate in a predetermined three-dimensional posture, position, and alignment (hereinafter, these may be collectively referred to simply as "three-dimensional posture" or "posture").

Means for Solving the Problem

[0012] Therefore, as a result of intensive research by the present inventor, a plane intersecting the direction of the maximum diameter of the end plate at a predetermined angle is provided on the end plate, and in the process of fitting the end plate into the opening of the shell, the end plate is supported and fixed in a three-dimensional posture by bringing a predetermined contact surface formed on a jig for gripping the end plate into surface contact with the above plane. It has been found that the above problems can be solved.

[0013] Specifically, the exhaust system container body according to the present invention (hereinafter, may be referred to as "the present invention container body") is an exhaust system container body formed by closing the openings at both ends of a cylindrical shell with end plates. In the present invention container body, a cylindrical portion, which is a portion having a cylindrical shape capable of fitting with the opening of the shell, is provided at the peripheral edge of the end plate, and at least a part of the cylindrical portion is fitted with the opening of the shell to form a fitting portion. Further, a first plane is provided at at least one location in a non-fitting portion, which is a portion other than the fitting portion of the end plate. The first plane is a plane parallel to a first axis, which is the central axis of the shell, and a first normal line, which is a normal line of the first plane, is parallel to a first diameter, which is the maximum diameter of the end plate, in a first projection view, which is a perpendicular projection view onto a plane orthogonal to the first axis, or the acute angle formed with the first diameter is 45 degrees or less.

[0014] By the way, as described at the beginning of this specification, the present invention relates not only to an exhaust system container body but also to a method for manufacturing an exhaust system container body.

[0015] Specifically, the manufacturing method of the container body of the exhaust system according to the present invention (hereinafter may be referred to as "the method of the present invention") is a manufacturing method of the container body of the exhaust system in which the openings at both ends of the cylindrical shell are closed by end plates. A cylindrical portion, which is a portion having a cylindrical shape capable of fitting with the opening of the shell, is formed at the peripheral edge of the end plate, and at least a part of the cylindrical portion is configured to be fitted with the opening of the shell to form a fitting portion. Further, a first plane is provided at at least one location in the non-fitting portion, which is a portion other than the fitting portion of the end plate. The first plane is a plane parallel to the first axis, which is the central axis of the shell, and the first normal line, which is the normal line of the first plane, is parallel to the first diameter, which is the maximum diameter of the end plate, in the first projection view, which is a perpendicular projection view onto a plane orthogonal to the first axis, or the acute angle formed with the first diameter is 45 degrees or less.

[0016] In addition, the method of the present invention includes the first step, the second step, and the third step listed below.

[0017] The first step is a step of setting the shell on the first jig and supporting and fixing the shell in the first posture, which is a predetermined posture. The second step is a step of setting the end plate on the gripping means movable in a direction parallel to the first axis and supporting and fixing the end plate in the second posture, which is a predetermined posture, by bringing the first contact surface, which is a predetermined plane formed on the gripping means, into contact with the first plane. The third step is a step of assembling the container body of the exhaust system by bringing the gripping means closer to the shell in a direction parallel to the first axis and fitting at least a part of the cylindrical portion into the openings at both ends of the shell to form a fitting portion.

Effect of the Invention

[0018] As described above, in the present invention, a first plane, which is a plane intersecting the direction of the first diameter, which is the maximum diameter of the end plate, at a predetermined angle, is provided on the end plate. Thereby, in the step of fitting the end plate to the opening of the shell, the first contact surface, which is a predetermined plane formed on the jig for gripping the end plate, and the first plane of the end plate are brought into surface contact to support and fix the end plate in a predetermined posture. Therefore, according to the present invention, in the manufacture of the container body of the exhaust system, the end plate can be accurately gripped in a predetermined three-dimensional posture and fitted to the opening of the shell.

[0019] Other objects, other features and attendant advantages of the present invention will be readily understood from the description of each embodiment of the present invention described with reference to the following drawings.

Brief Description of the Drawings

[0020]

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DETAILED DESCRIPTION OF THE INVENTION

[0021] 《FIRST EMBODIMENT》 Hereinafter, an exhaust system container body according to a first embodiment of the present invention (hereinafter, may be referred to as "first container body") will be described with reference to the drawings.

[0022] 〈Configuration〉 FIG. 1 is a schematic diagram illustrating a fitting state between a shell and an end plate constituting a first container body. As illustrated in FIG. 1, a first container body 101 is an exhaust system container body in which openings at both ends of a cylindrical shell 110 are closed by end plates 121 and 122. In the first container body 101, a cylindrical portion Pc, which is a portion having a cylindrical shape capable of fitting with an opening of the shell 110, is provided at the peripheral portions of the end plates 121 and 122, and at least a part of the cylindrical portion Pc is fitted with an opening of the shell 110 to form a fitting portion Pf.

[0023] As illustrated in FIG. 1(b), in one end plate 121, only a part of the tip side of the cylindrical portion Pc is fitted with the opening of the shell 110 to form a fitting portion Pf, and in the other end plate 122, the entire cylindrical portion Pc provided at the peripheral portion is fitted with the opening of the shell 110 to form a fitting portion Pf (Pc = Pf). As will be described later, portions other than the fitting portions Pf of the end plates 121 and 122 may be referred to as "non-fitting portions Pnf". Further, when only a part of the cylindrical portion Pc is fitted with the opening of the shell 110 to form a fitting portion Pf as in the end plate 121, the portion of the cylindrical portion Pc that is not fitted with the opening of the shell 110 may be referred to as a "non-fitting cylindrical portion Pcnf". Furthermore, in any case, the portion that is not the cylindrical portion Pc may be referred to as a "general portion Pg".

[0024] In FIG. 1(b), for the purpose of clearly illustrating the configuration of the first container body 101, the end plates 121 and 122 and the shell 110 are depicted as being slightly separated. However, in reality, the end plates 121 and 122 are fitted with the opening of the shell 110 and are in contact with each other. Also, in FIG. 1, the direction parallel to the first diameter, which is the maximum diameter of the end plates 121 and 122, is defined as the x-axis direction, the direction orthogonal to the x-axis direction is defined as the y-axis direction, and the direction parallel to the first axis AX1, which is the central axis of the shell 110, is defined as the z-axis direction. In this specification, the "central axis of the shell" refers to an axis that passes through the center of symmetry and extends in the longitudinal direction of the shell when the cross-sectional shape of the shell is a rotationally symmetric shape such as a circle, an ellipse, or an oblong. On the other hand, when the cross-sectional shape of the shell is not a rotationally symmetric shape, it refers to an axis that passes through the centroid of the cross-sectional shape of the shell and extends in the longitudinal direction of the shell. The positive direction on each coordinate axis is indicated by an arrow in the figure. The same applies to other drawings referred to in the following description.

[0025] Also, in the first container body 101 as well, actually, similar to the container body illustrated in FIG. 22 referred to in the description regarding Patent Document 2 described above, through-holes for inserting, for example, an inlet pipe and / or an outlet pipe, etc. and unevenness for enhancing the rigidity of the end plates 121 and 122 are generally provided in the end plates 121 and 122. Further, inside the shell 110, intermediate finished products constituted by, for example, pipes and / or separators (partition walls), etc. may be accommodated. Furthermore, as will be described later, in the first container body 101, a first plane, which is a plane having a predetermined normal line at at least one location in a portion (non-fitting portion Pnf) other than the fitting portion Pf of the end plate, is provided (details will be described later).

[0026] However, in FIG. 1, for the purpose of easily illustrating the fitting state between the shell 110 constituting the first container body 101 and the end plates 121 and 122, the above-described accompanying structures and components as well as the first plane are omitted.

[0027] The first container body 101 is an exhaust system container body provided with a first plane P1 at at least one location in a non-fitting portion Pnf, which is a portion other than the fitting portion Pf of the end plate 121 and / or 122. The first plane P1 is a plane parallel to the first axis AX1, which is the central axis of the shell 110, and the first normal line N1, which is the normal line of the first plane P1, is parallel to the first diameter D1, which is the maximum diameter of the end plate 121 and / or 122, or is a normal line having an acute angle θ1 of 45 degrees or less with the first diameter D1 in the first projection view Vp1, which is a vertical projection view onto a plane orthogonal to the first axis AX1.

[0028] Specific examples of the configurations of various first planes P1 that satisfy the above requirements will be described in detail below with reference to FIG. 2. FIG. 2 is a schematic diagram showing some examples of the configuration of the first plane provided on the end plate constituting the first container body. Note that in the following description, the reference signs shown in FIG. 1 referred to in the previous description may also be used, so please refer to FIG. 1 as needed.

[0029] Also, in the following description, for the purpose of distinguishing the plurality of first planes P1 respectively provided on the end plates 121 and 122, their first normal lines N1, and the first diameter D1 of the end plates 121 and 122, branch numbers from "a" to "h" are attached to their respective symbols for explanation. On the other hand, when the terms "first plane P1", "first normal line N1", and "first diameter D1" are used without such branch numbers, those terms respectively mean the general names of the plurality of first planes and their first normal lines and the first diameters of the two end plates.

[0030] Fig. 2(a) is a schematic plan view when observing the end plate 121 from the outside of the first container body 101 (the positive side on the z-axis shown in Fig. 1) in a direction parallel to the first axis AX1 (black circular mark) which is the central axis of the shell 110. Therefore, Fig. 2(a) corresponds to the above-mentioned "first projection view Vp1 which is a vertical projection view onto a plane orthogonal to the first axis AX1 which is the central axis of the shell 110".

[0031] Fig. 2(b) is a schematic plan view when observing the end plate 122 from the outside of the first container body 101 (the negative side on the z-axis shown in Fig. 1) in a direction parallel to the first axis AX1 (black circular mark). Therefore, Fig. 2(b) also corresponds to the above-mentioned "first projection view Vp1 which is a vertical projection view onto a plane orthogonal to the first axis AX1 which is the central axis of the shell 110", similar to Fig. 2(a).

[0032] Fig. 2(c) is a schematic cross-sectional view of the first container body 101 by a plane including the first axis AX1 and the first diameters D1a and D1b, and Fig. 2(d) is a schematic cross-sectional view of the first container body 101 by a plane including the first axis AX1 and orthogonal to the first diameters D1a and D1b.

[0033] In the end plate 121 illustrated in FIG. 2, first planes P1a and P1b are respectively provided at two positions in a non-fitting portion Pnf (a non-fitting cylindrical portion Pcnf which is a portion of the cylindrical portion Pc other than the fitting portion Pf), which is a portion other than the fitting portion Pf. The first plane P1a is a plane parallel to the first axis AX1, and a first normal line N1a, which is a normal line of the first plane P1a, is parallel to a first diameter D1a which is the maximum diameter of the end plate 121 (that is, the first plane P1a is perpendicular to the direction of the first diameter D1a). Another first plane P1b is also a plane parallel to the first axis AX1, but a first normal line N1b, which is a normal line of the first plane P1b, is not parallel to the first diameter D1a (that is, the first plane P1b is not perpendicular to the direction of the first diameter D1a), and an acute angle θ1 formed by the first normal line N1b and the first diameter D1a is 45 degrees or less.

[0034] On the other hand, in the end plate 122 illustrated in FIG. 2, first planes P1c and P1d are respectively provided at two positions in a non-fitting portion Pnf (a general portion Pg which is a portion other than the cylindrical portion Pc). The first plane P1c is also a plane parallel to the first axis AX1, and a first normal line N1c, which is a normal line of the first plane P1c, is parallel to a first diameter D1b (that is, the first plane P1c is perpendicular to the direction of the first diameter D1b). Another first plane P1d is also, similar to the first plane P1c, a plane parallel to the first axis AX1, and a first normal line N1d, which is a normal line of the first plane P1d, is parallel to the first diameter D1b (that is, the first plane P1d is perpendicular to the direction of the first diameter D1b).

[0035] However, although the first planes P1a to P1c described above are provided at the periphery of the non-fitting portion Pnf (that is, the periphery of the non-fitting cylindrical portion Pcnf or the periphery of the general portion Pg), the first plane P1d is provided in the middle of the general portion Pg (between the periphery of the general portion Pg and the first axis AX1). Thus, the first plane P1 is typically provided at the periphery of the non-fitting portion Pnf, but may be provided at a position other than the periphery of the non-fitting portion Pnf (for example, in the middle of the general portion Pg) as long as the above-described requirements are satisfied.

[0036] Preferably, in the first projection view Vp1, the first normal line N1 and the first diameter D1 are parallel. In other words, in the first projection view Vp1, the direction of the first plane P1 and the direction of the first diameter D1 are orthogonal. More preferably, in the first projection view Vp1, the first plane P1 and the first diameter D1 intersect. As a result, the first plane P1 does not exist only on either the left or right side of the first diameter D1 as in the case where the first plane P1 and the first diameter D1 do not intersect, but the first plane P1 exists across both the left and right sides of the first diameter D1. As a result, in the process of integrating the first container body 101 by fitting the end plates 121 and 122 into the opening of the shell 110 as described later, by bringing the first plane P1 into surface contact with the first contact surface C1 formed on the gripping means, the end plates 121 and 122 can be press-fitted into the opening of the shell 110 while accurately maintaining them in a predetermined three-dimensional posture.

[0037] In addition, in FIG. 2, different types of first planes P1a to P1d are provided on the end plates 121 and 122 for the purpose of exemplifying the configuration of the first plane. However, providing a plurality of first planes P1 on one end plate or combining different types of first planes P1 as illustrated in FIG. 2 is not an essential component in the first container body 101. Therefore, for example, one first plane P1 may be provided on one end plate, a plurality of first planes P1 of the same type may be provided on one end plate, or the same type of first plane P1 may be provided on both end plates.

[0038] Also, although it was described above that the first plane P1 is a plane parallel to the first axis AX1, the first plane P1 does not necessarily have to be strictly parallel to the first axis AX1. For example, for the purpose of facilitating the operation of supporting and fixing the end plates 121 and 122 by the gripping means by bringing the first plane P1 into surface contact with the first contact surface C1 in the process of integrating the first container body 101, the first plane P1 may be slightly inclined so as to approach the first axis AX1 as it moves away from the fitting portion Pf in the direction of the first axis AX1.

[0039] FIG. 3 is a schematic diagram illustrating the process of assembling the first container body 101 by fitting end plates 121 and 122 having the configuration illustrated in FIG. 2 into the openings at both ends of the shell 110. More specifically, FIG. 3 is a schematic side view when observed from a direction (the positive side on the y-axis shown in FIG. 1 etc.) orthogonal to both the first axis AX1 which is the central axis of the shell 110 and the first diameters D1a and D1b which are the maximum diameters of the end plates 121 and 122. FIG. 3(a) shows a state where the shell 110 is supported and fixed in a predetermined posture by a jig (not shown), and the end plates 121 and 122 are supported and fixed in a predetermined posture by bringing the first contact surfaces C1a to C1d formed on the gripping means 131 and 132 into surface contact with the first planes P1a to P1d respectively. FIG. 3(b) shows a state where the first container body 101 is assembled by bringing the gripping means 131 and 132 closer to the shell 110 in a direction parallel to the first axis AX1 (refer to the black arrows) and fitting the end plates 121 and 122 supported and fixed in the predetermined posture into the openings at both ends of the shell 110.

[0040] As illustrated in FIG. 3, in the first container body 101, first planes P1a to P1d which are planes intersecting at a predetermined angle with the directions of the first diameters D1a and D1b which are the maximum diameters of the end plates 121 and 122 are respectively provided on the end plates 121 and 122. Thereby, in the process of fitting the end plates 121 and 122 into the openings of the shell 110, the first contact surfaces C1a to C1d which are predetermined planes formed on the jig (gripping means 131 and 132) for gripping the end plates 121 and 122 can be brought into surface contact with the first planes P1a to P1d of the end plates 121 and 122 to support and fix the end plates 121 and 122 in a predetermined posture. Therefore, in the manufacture of the first container body 101, the end plates 121 and 122 can be accurately gripped at a predetermined three-dimensional posture and position and fitted into the openings of the shell 110.

[0041] Incidentally, when a plurality of first planes P1 are provided, as illustrated in FIG. 3, the plurality of first contact surfaces C1 and the plurality of first planes P1 are in surface contact, so that the end plates 121 and 122 can be accurately held in a predetermined three-dimensional posture and position and fitted into the opening of the shell 110. However, as described above, the first plane P1 is provided at at least one location in the non-fitting portion Pnf of the end plates 121 and 122. When only one first plane P1 is provided, typically, a jig is provided to support the end plates 121 and 122 from the side opposite to the first plane P1 with the first axis AX1 interposed therebetween. The end plates 121 and 122 are supported by the jig and the first plane P1, and the posture of the end plates 121 and 122 is precisely fixed by the first plane P1.

[0042] As described above, FIG. 4 illustrates a case where only one first plane P1 is provided on each individual end plate, and a jig is provided to support the end plates 121 and 122 from the side opposite to the first plane P1 with the first axis AX1 interposed therebetween. The end plates 121 and 122 are supported and fixed in a predetermined posture by the jig and the first plane P1.

[0043] In FIG. 4(a), the shell 110 is supported and fixed in a predetermined posture by a jig (not shown), and the end plates 121 and 122 are fixed in a predetermined posture by bringing the first contact surfaces C1a and C1c formed on the gripping means 131 and 132 into surface contact with the first planes P1a and P1c, respectively. A state is shown in which the end plates 121 and 122 are supported and fixed in a predetermined posture by the first contact surfaces C1a and C1c and the jigs 131g and 132g. FIG. 4(b) shows a state in which the gripping means 131 and 132 are brought closer to the shell 110 in a direction parallel to the first axis AX1 (see the black arrows), and the first container body 101 is assembled by fitting the end plates 121 and 122, which are supported and fixed in a predetermined posture as described above, into the openings at both ends of the shell 110.

[0044] As illustrated in FIG. 4, in the first container body 101, even when only one first plane P1 is provided on each end plate 120, a jig that supports end plates 121 and 122 from the side opposite to the first plane P1 with the first axis AX1 interposed therebetween, and the first plane P1 can support and fix the end plates 121 and 122 in a predetermined posture. However, even when a plurality of first planes P1 are provided, a jig as described above may be provided to support and fix the end plates 121 and 122 in a predetermined posture in the step of fitting the end plates 121 and 122 into the opening of the shell 110.

[0045] In addition, for the purpose of, for example, making the fitting of the end plates 121 and 122 into the opening of the shell 110 smoother, the tip of the cylindrical portion Pc that becomes the fitting portion Pf of the end plates 121 and 122 may be slightly reduced in diameter, and / or the periphery of the opening of the shell 110 that fits with the fitting portion Pf may be slightly increased in diameter. Alternatively, for the purpose of, for example, making the appearance of the end plates 121 and 122 when fitted into the opening of the shell 110 smoother, the tip of the cylindrical portion Pc that becomes the fitting portion Pf of the end plates 121 and 122 may be slightly increased in diameter, and / or the periphery of the opening of the shell 110 that fits with the fitting portion Pf may be slightly reduced in diameter.

[0046] <Effect> As described above, the first plane, which is a plane intersecting the direction of the first diameter, which is the maximum diameter of the end plate, at a predetermined angle, is provided on the end plate. Therefore, by bringing the first contact surface, which is a predetermined plane formed on the jig that grips the end plate in the step of fitting the end plate into the opening of the shell, into surface contact with the first plane of the end plate, not only the position of the end plate in the direction of the first normal, which is the normal of the first plane, but also the position (alignment) of the end plate in the rotational direction around the axis parallel to the first axis can be fixed. That is, according to the first container body, in the step of fitting the end plate into the opening of the shell, the end plate can be supported and fixed in a predetermined three-dimensional posture and position. Therefore, in the manufacture of the container body of the exhaust system, the end plate can be accurately gripped in a predetermined three-dimensional posture and fitted into the opening of the shell.

[0047] <Modification Example 1-1> By the way, from the viewpoint of more accurately gripping the end plates in a predetermined three-dimensional posture and position in the manufacture of the container body of the exhaust system, it is desirable that a plurality of first planes P1 are provided on the end plates 121 and 122 and that the plurality of first planes P1 have a predetermined positional relationship.

[0048] Therefore, in the first container body according to Modification 1-1, a plurality of first planes P1 are provided on the end plate 121 and / or 122, and at least a part of the plurality of first planes P1 forms a pair of first planes P1 that are symmetric with respect to a plane having a plane perpendicular to the first diameter D1 as a symmetric plane (hereinafter, may be referred to as the "first symmetric plane Ps1"). It is a container body of the exhaust system. Preferably, the first symmetric plane Ps1 includes the first axis AX1.

[0049] FIG. 5(a) is a schematic plan view when the end plate 121 constituting the first container body 101 according to Modification 1-1 is observed from the front side (the positive side in the z-axis shown in FIG. 1 etc.) in a direction parallel to the first axis AX1 (black circular mark). In the end plate 121 illustrated in FIG. 5(a), four first planes P1e to P1h are provided, and both the pair of the first planes P1e and P1f and the pair of the first planes P1g and P1h are perpendicular to the first diameter D1a and include the first axis AX1. They are in a position relationship that is symmetric with respect to a plane (first symmetric plane Ps1) as a symmetric plane.

[0050] In the first container body according to Modification 1-1 having the above-described configuration, by bringing the first contact surface C1, which is a predetermined plane formed on the jig that grips the end plates 121 and 122, into surface contact with the first planes P1 provided on the end plates 121 and 122, not only the position (alignment) of the end plates 121 and 122 in the rotational direction around the axis parallel to the first axis AX1, but also the positions of the end plates 121 and 122 in the direction of the first normal N1, which is the normal of the first plane P1, can be more reliably fixed. That is, according to the first container body according to Modification 1-1, in the step of fitting the end plates 121 and 122 into the opening of the shell 110, the end plates 121 and 122 can be more reliably supported and fixed in a predetermined three-dimensional posture and position.

[0051] Also, in the example shown in FIG. 5(a), the number of pairs of the first planes P1 satisfying the above requirements on one end plate is two. However, the number of pairs of the first planes P1 satisfying the above requirements on the end plates 121 and 122 constituting the first container body according to the first modification 1-1 is not limited to two, and may be, for example, one, or may be three or more. Further, the end plates 121 and 122 constituting the first container body according to the first modification 1-1 may further include other first planes P1 that do not satisfy the above requirements.

[0052] <First Modification 1-2> By the way, from the viewpoint of more accurately gripping the end plate at a predetermined three-dimensional posture and position in the manufacture of the container body of the exhaust system, it is desirable that a plurality of first planes are provided on the end plate and the plurality of first planes are in a rotationally symmetric positional relationship.

[0053] Therefore, the first container body according to the first modification 1-2 is a container body of the exhaust system in which a plurality of first planes P1 are provided on the end plate 121 and / or 122, and at least a part of the plurality of first planes P1 constitutes a pair of first planes P1 having a rotationally symmetric positional relationship with the first axis AX1 as the axis of symmetry.

[0054] FIG. 5(b) is a schematic plan view when the end plate 122 constituting the first container body 101 according to the first modification 1-2 is observed from the front side (the negative side on the z-axis shown in FIG. 1 etc.) in a direction parallel to the first axis AX1 (black circular mark). Also in the end plate 122 illustrated in FIG. 5(b), four first planes P1e to P1h are provided, similarly to the end plate 121 constituting the first container body according to the first modification 1-1 described above. However, in the end plate 122 illustrated in FIG. 5(b), the positions of the first planes P1g and P1h are interchanged with respect to the positions of the first planes P1g and P1h in the end plate 121 illustrated in FIG. 5(a) across the first diameter D1b, and both the pair of the first planes P1e and P1g and the pair of the first planes P1f and P1h are in a rotationally symmetric positional relationship with the first axis AX1 as the axis of symmetry.

[0055] In the first container body according to Modification 1-2 having the above-described configuration, in the step of fitting end plates 121 and 122 to the opening of the shell 110, not only the positions of the end plates 121 and 122 in the direction of the first normal line N1, which is the normal line of the first plane P1, but also the positions (alignment) of the end plates 121 and 122 in the rotational direction around an axis parallel to the first axis AX1 can be more reliably fixed by bringing the first contact surface C1, which is a predetermined plane formed on the jig for gripping the end plates 121 and 122, into surface contact with the first planes P1 provided on the end plates 121 and 122. That is, according to the first container body according to Modification 1-2, in the step of fitting the end plates 121 and 122 to the opening of the shell 110, the end plates 121 and 122 can be more reliably supported and fixed in a predetermined three-dimensional posture and position.

[0056] In addition, in the example shown in Fig. 5(b), the number of pairs of the first planes P1 that satisfy the above requirements is two in one end plate, but the number of pairs of the first planes P1 that satisfy the above requirements in the end plates 121 and 122 constituting the first container body according to Modification 1-2 is not limited to two, and may be, for example, one, or three or more. Further, the end plates 121 and 122 constituting the first container body according to Modification 1-2 may further include other first planes P1 that do not satisfy the above requirements.

[0057] 《Second Embodiment》 Hereinafter, a container body of an exhaust system (hereinafter, may be referred to as the "second container body") according to the second embodiment of the present invention will be described with reference to the drawings.

[0058] 〈Configuration〉 The second container body is the above-described first container body, which is a container body of an exhaust system in which a second plane P2 is provided at at least one location in the non-fitting portion Pnf of the end plates 121 and / or 122. The second plane P2 is a plane parallel to the first axis AX1 and different from the first plane P1, and the second normal line N2, which is the normal line of the second plane P2, is a normal line that is orthogonal to the first normal line N1 or forms an acute angle θ2 of 45 degrees or more with the first normal line N1 in the first projection view Vp1.

[0059] Regarding specific examples of the configurations of various second planes P2 that satisfy the above requirements, a detailed description will be given below with reference to FIG. 6. FIG. 6 is a schematic diagram showing some examples of the configurations of the second plane P2 provided on the end plates 121 and / or 122 that constitute the second container body. In the following description, the reference numerals shown in FIGS. 1 to 5 referred to in the previous description may also be used, so please refer to FIGS. 1 to 5 as necessary.

[0060] Also, in the following description, for the purpose of distinguishing the plurality of second planes P2 and their second normal vectors N2 respectively provided on the end plates 121 and 122, branch numbers from "a" to "g" are attached to each symbol for explanation. On the other hand, when the terms "second plane P2" and "second normal vector N2" are used without such branch numbers, those terms respectively mean the general terms for the plurality of second planes and their second normal vectors.

[0061] FIG. 6(a) is a schematic plan view when observing the end plate 121 from the outside of the second container body 102 (the positive side on the z-axis shown in FIG. 1 etc.) in a direction parallel to the first axis AX1 (black circular mark). FIG. 6(b) is a schematic plan view when observing the end plate 122 from the outside of the second container body 102 (the negative side on the z-axis shown in FIG. 1 etc.) in a direction parallel to the first axis AX1 (black circular mark). Therefore, FIGS. 6(a) and (b) also correspond to the first projection view Vp1. FIG. 6(c) is a schematic cross-sectional view of the second container body 102 by a plane including the first axis AX1 and the first diameters D1a and D1b, and FIG. 6(d) is a schematic cross-sectional view of the second container body 102 by a plane passing through the second planes P2c, P2d, and P2g and perpendicular to the first diameters D1a and D1b.

[0062] In the end plate 121 illustrated in FIG. 6, in addition to the first planes P1a and P1b illustrated in FIG. 2, second planes P2a to P2d are respectively provided at four locations in the non-fitting portion Pnf (the non-fitting cylindrical portion Pcnf which is not the fitting portion Pf of the cylindrical portion Pc) which is a portion other than the fitting portion Pf. The second normal line N2a which is the normal line of the second plane P2a is orthogonal to the first normal line N1a which is the normal line of the first plane P1a, and the acute angle θ2 formed by the first normal line N1b which is the normal line of the first plane P1b and the second normal line N2a is 45 degrees or more. The same applies to the other three second planes P2b to P2d other than the second plane P2a.

[0063] On the other hand, in the end plate 122 illustrated in FIG. 6, in addition to the first planes P1c and P1d illustrated in FIG. 2, second planes P2e to P2g are respectively provided at three locations in the non-fitting portion Pnf (the general portion Pg which is not a portion of the cylindrical portion Pc). The second normal line N2e which is the normal line of the second plane P2e is orthogonal to both the first normal line N1c which is the normal line of the first plane P1c and the first normal line N1d which is the normal line of the first plane P1d. On the other hand, for the second normal line N2f which is the normal line of the second plane P2f and the second normal line N2g which is the normal line of the second plane P2g, the acute angle θ2 formed by each of them and the first normal lines N1c and N1d is 45 degrees or more.

[0064] However, although the above-described second planes P2a to P2e are provided at the periphery of the non-fitting portion Pnf (that is, the periphery of the non-fitting cylindrical portion Pcnf or the periphery of the general portion Pg), the second planes P2f and P2g are provided in the middle of the general portion Pg (between the periphery of the general portion Pg and the first axis AX1). Thus, the second plane P2 is typically provided at the periphery of the non-fitting portion Pnf, but may be provided at a position other than the periphery of the non-fitting portion Pnf (for example, in the middle of the general portion Pg) as long as the above-described requirements are satisfied.

[0065] Preferably, in the first projection view Vp1, the first normal line N1 and the second normal line N2 are orthogonal. In other words, in the first projection view Vp1, the direction of the first plane P1 and the direction of the second plane P2 are orthogonal. As a result, in the process of integrating the second container body 102 by fitting the end plates 121 and 122 to the opening of the shell 110 as described later, the first plane P1 and the second plane P2 are brought into surface contact with the first contact surface C1 and the second contact surface C2 formed on the gripping means, respectively, so that the end plates 121 and 122 can be press-fitted into the opening of the shell 110 while maintaining a more accurate predetermined three-dimensional posture.

[0066] In addition, in FIG. 6, different types of second planes P2a to P2g are provided on the end plates 121 and 122 for the purpose of exemplifying the configuration of the second plane. However, providing a plurality of second planes P2 on one end plate or combining different types of second planes P2 as illustrated in FIG. 6 is not an essential component in the second container body 102. Therefore, for example, one second plane P2 may be provided on one end plate, a plurality of second planes P2 of the same type may be provided on one end plate, or the same type of second plane P2 may be provided on both end plates, respectively.

[0067] Also, although it was described above that the second plane P2 is a plane parallel to the first axis AX1, similar to the first plane P1 described above, the second plane P2 does not necessarily have to be strictly parallel to the first axis AX1. For example, for the purpose of facilitating the operation of supporting and fixing the end plates 121 and 122 by the gripping means by bringing the second plane P2 into surface contact with the second contact surface C2 in the process of integrating the second container body 102, the second plane P2 may be slightly inclined so as to approach the first axis AX1 as it moves away from the fitting portion Pf in the direction of the first axis AX1.

[0068] FIG. 7 is a schematic diagram illustrating a process of assembling the second container body 102 by fitting end plates 121 and 122 having the configuration illustrated in FIG. 6 into the openings at both ends of the shell 110. More specifically, FIG. 7 is a schematic side view when observed from a direction (the positive side on the x-axis shown in FIG. 1 etc.) orthogonal to the first axis AX1 which is the central axis of the shell 110 and parallel to the first diameters D1a and D1b which are the maximum diameters of the end plates 121 and 122. Incidentally, although the end plates 121 and 122 illustrated in FIG. 6 are provided with not only the second plane P2 but also the first plane P1, for the purpose of easily illustrating the configuration of the second plane P2 etc., the first plane P1 and the first contact surface C1 are omitted in FIG. 7.

[0069] In FIG. 7(a), the shell 110 is supported and fixed in a predetermined posture by a jig (not shown), and the second contact surfaces C2a to C2g and the second planes P2a to P2g formed on the gripping means 131 and 132 are respectively in surface contact (while the first contact surfaces C1a to C1d and the first planes P1a to P1d (not shown) formed on the gripping means 131 and 132 are respectively in surface contact), showing a state where the end plates 121 and 122 are supported and fixed in a predetermined posture. FIG. 7(b) shows a state where the second container body 102 is assembled by bringing the gripping means 131 and 132 closer to the shell 110 in a direction parallel to the first axis AX1 (refer to the black arrow) and fitting the end plates 121 and 122 supported and fixed in a predetermined posture as described above into the openings at both ends of the shell 110.

[0070] As illustrated in FIG. 7, in the second container body 102, in addition to the aforementioned first plane P1 (not shown), second planes P2a to P2g which are normal lines intersecting at a predetermined angle with the direction of the first normal line N1 which is the normal line of the first plane P1 provided on the end plates 121 and 122 are respectively provided on the end plates 121 and 122. Thereby, in the process of fitting the end plates 121 and 122 into the openings of the shell 110, the second contact surfaces C2a to C2g which are predetermined planes formed on the gripping means 131 and 132 and the second planes P2a to P2g provided on the end plates 121 and 122 can be brought into surface contact to support and fix the end plates 121 and 122 in a predetermined posture.

[0071] As a result, in the second container body 102, not only is the displacement of the end plates 121 and 122 in the x-axis direction reduced by the surface contact between the first plane P1 and the first contact surface C1, but also the displacement of the end plates 121 and 122 in the y-axis direction can be reduced by the surface contact between the second plane P2 and the second contact surface C2. Therefore, in manufacturing the second container body 102, the end plates 121 and 122 can be accurately held in a predetermined three-dimensional posture and position and then fitted into the opening of the shell 110.

[0072] By the way, when a plurality of second planes P2 are provided, as described above, in addition to the surface contact between the first contact surface C1 and the first plane P1, the plurality of second contact surfaces C2 and the plurality of second planes P2 are in surface contact, so that the end plates 121 and 122 can be more accurately held in a predetermined three-dimensional posture and position and then fitted into the opening of the shell 110. However, as described above, the second plane P2 is provided at at least one location in the non-fitting portion Pnf of the end plates 121 and 122. When only one second plane P2 is provided, typically, a jig for supporting the end plates 121 and 122 from the side opposite to the second plane P2 with the first axis AX1 interposed therebetween is provided, and the end plates 121 and 122 are supported by the jig and the second plane P2, and the postures of the end plates 121 and 122 are strictly fixed by the second plane P2.

[0073] The form in which the end plates 121 and 122 are supported and fixed by the combined use of the jig when only one second plane P2 is provided as described above is basically the same as the form described with reference to FIG. 4 in the description of the first container body 101. Therefore, a detailed description of this form is omitted.

[0074] <Effect> As described above, in the second container body, a second plane having a normal line intersecting the normal line of the first plane at a predetermined angle is provided on the end plate. Therefore, in the step of fitting the end plate to the opening of the shell, in addition to the surface contact between the first contact surface formed on the gripping means and the first plane provided on the end plate, the second contact surface formed on the gripping means and the second plane provided on the end plate can be brought into surface contact. Thereby, not only the position of the end plate in the normal line direction of the first plane but also the position of the end plate in the normal line direction of the second plane can be surely fixed. Further, the position of the end plate in the rotational direction around an axis parallel to the first axis can be more surely fixed.

[0075] That is, according to the second container body, in the step of fitting the end plate to the opening of the shell, the end plate can be more surely supported and fixed in a predetermined three-dimensional posture and position. Therefore, in the manufacture of the container body of the exhaust system, the end plate can be more accurately gripped in a predetermined three-dimensional posture and the end plate can be fitted to the opening of the shell.

[0076] <Examples of Modifications 2-1 and 2-2> By the way, from the viewpoint of more accurately gripping the end plate in a predetermined three-dimensional posture and position in the manufacture of the container body of the exhaust system, it is desirable that a plurality of second planes P2 are provided on the end plate and the plurality of second planes P2 have a predetermined positional relationship.

[0077] Therefore, the second container body according to the modification 2-1 is an exhaust system container body in which a plurality of second planes P2 are provided on the end plate 121 and / or 122, and at least a part of the plurality of second planes P2 includes the first diameter D1 and is in a positional relationship that is plane-symmetric with a plane parallel to the first axis AX1 as a symmetric plane (hereinafter, may be referred to as the "second symmetric plane Ps2"). Preferably, the second symmetric plane Ps2 includes the first axis AX1.

[0078] Furthermore, in the second container body according to Modification 2-2, a plurality of second planes P2 are provided on the end plates 121 and / or 122, and at least a part of the plurality of second planes P2 forms a pair of second planes P2 that are rotationally symmetric about the first axis AX1. It is a container body of the exhaust system.

[0079] In FIG. 6(a) referred to in the description of the second container body 102, the four second planes P2a to P2d provided on the end plate 121 are symmetric with respect to a plane including the first diameter D1a and parallel to the first axis AX1 as a symmetry plane (second symmetry plane Ps2). At the same time, they are also in a rotationally symmetric positional relationship about the first axis AX1. That is, the four second planes P2a to P2d illustrated in FIG. 6(a) satisfy the requirements that the end plates constituting the second container body according to Modification 2-1 and Modification 2-2 should satisfy.

[0080] In the second container body according to Modification 2-1 or Modification 2-2 having the above-described configuration, in the step of fitting the end plates 121 and 122 to the opening of the shell 110, the first contact surface C1 and the second contact surface C2, which are predetermined planes formed on the jig for gripping the end plates 121 and 122, are brought into surface contact with the first plane P1 and the second plane P2 provided on the end plates 121 and 122, respectively. Thus, not only the positions of the end plates 121 and 122 in the directions of the first normal line N1, which is the normal line of the first plane P1, and the second normal line N2, which is the normal line of the second plane P2, but also the positions (alignment) of the end plates 121 and 122 in the rotational direction around an axis parallel to the first axis AX1 can be more reliably fixed. That is, according to the second container body according to Modification 2-1 or Modification 2-2, in the step of fitting the end plates 121 and 122 to the opening of the shell 110, the end plates 121 and 122 can be more reliably supported and fixed in a predetermined three-dimensional posture and position.

[0081] In the example shown in FIG. 6(a), the number of pairs of the second plane P2 that satisfy the above requirements is two in one end plate. However, the number of pairs of the second plane P2 that satisfy the above requirements in the end plates 121 and 122 that constitute the first container body according to the modified example 2-1 or the modified example 2-2 is not limited to two, and may be, for example, one, or may be three or more. Further, the end plates 121 and 122 that constitute the first container body according to the modified example 2-1 or the modified example 2-2 may further include other second planes P2 that do not satisfy the above requirements.

[0082] <<Third Embodiment>> Hereinafter, a container body of an exhaust system according to a third embodiment of the present invention (hereinafter, may be referred to as a "third container body") will be described with reference to the drawings.

[0083] <Configuration> The third container body is the first container body or the second container body described above, and in the end plates 121 and / or 122, a third plane P3, which is a plane having a third normal line N3 that is a normal line parallel to the first axis AX1, is provided at at least one location in the non-fitting portion Pnf. It is a container body of an exhaust system.

[0084] Specific examples of the configurations of various third planes P3 that satisfy the above requirements will be described in detail below with reference to FIG. 8. FIG. 8 is a schematic diagram showing some examples of the configuration of the third plane P3 provided on the end plates 121 and / or 122 that constitute the third container body. In the following description, the reference signs shown in FIGS. 1 to 6 referred to in the previous description may also be used, so please refer to FIGS. 1 to 6 as necessary. Note that FIG. 8 is the same as FIG. 6 referred to in the description of the second container body 102, except that the third plane P3 is provided on the end plates 121 and / or 122 that constitute the third container body. However, in FIG. 8, for the purpose of easily illustrating the configuration of the third plane P3, the display regarding the first normal line N1 and the second normal line N2, which are the normal lines of the first plane P1 and the second plane P2, is omitted.

[0085] In the following description, for the purpose of distinguishing a plurality of third planes P3 and their third normal lines N3 respectively provided on the end plates 121 and 122, the branches from "a" to "e" are attached to their respective symbols for explanation. On the other hand, when the terms "third plane P3" and "third normal line N3" are used without such attached branches, these terms respectively mean the general terms of a plurality of third planes and their third normal lines.

[0086] FIG. 8(a) is a schematic plan view when observing the end plate 121 from the outside of the third container body 103 (the positive side on the z-axis shown in FIG. 1 etc.) in the direction parallel to the first axis AX1 (black circular mark). FIG. 8(b) is a schematic plan view when observing the end plate 122 from the outside of the third container body 103 (the negative side on the z-axis shown in FIG. 1 etc.) in the direction parallel to the first axis AX1 (black circular mark). Therefore, FIGS. 8(a) and (b) also correspond to the first projection view Vp1. FIG. 8(c) is a schematic cross-sectional view of the third container body 103 by a plane including the first axis AX1 and the first diameters D1a and D1b, and FIG. 8(d) is a schematic cross-sectional view of the third container body 103 by a plane passing through the second planes P2c, P2d, and P2g and P3c and P3g and perpendicular to the first diameters D1a and D1b.

[0087] In the end plate 121 illustrated in FIG. 8, in addition to the first planes P1a and P1b and the second planes P2a to P2d illustrated in FIG. 6, a plurality of third planes P3 are provided in the non-fitting portion Pnf which is a portion other than the fitting portion Pf. Specifically, the third plane P3a is provided at one location in the non-fitting cylindrical portion Pcnf which is a portion of the cylindrical portion Pc other than the fitting portion Pf, and the third planes P3b and P3c are respectively provided at two locations in the general portion Pg which is a portion other than the cylindrical portion Pc. The normal lines (not shown) of the third planes P3a to P3c are all parallel to the first axis AX1. In other words, the third planes P3a to P3c are all planes perpendicular to the direction of the first axis AX1.

[0088] On the other hand, in the end plate 122 illustrated in FIG. 8, in addition to the first planes P1c and P1d and the second planes P2e to P2g illustrated in FIG. 6, third planes P3d and P3e are respectively provided at two locations in the non-fitting portion Pnf (the general portion Pg which is not the cylindrical portion Pc). The normal lines (not shown) of the third planes P3d and P3e are also parallel to the first axis AX1. In other words, both the third planes P3d and P3e are planes orthogonal to the direction of the first axis AX1.

[0089] As described above, the location where the third plane P3 is provided in the end plate 121 and / or 122 constituting the third container body 103 may be the periphery of the non-fitting portion Pnf (that is, the periphery of the general portion Pg or the non-fitting cylindrical portion Pcnf), or may be in the middle of the general portion Pg (between the periphery of the general portion Pg and the first axis AX1).

[0090] In FIG. 8, different types of third planes P3a to P3e are provided on the end plates 121 and 122 for the purpose of exemplifying the configuration of the third plane P3. However, providing a plurality of third planes P3 on one end plate or combining different types of third planes P3 as illustrated in FIG. 8 is not an essential configuration requirement in the third container body 103. Therefore, for example, one third plane P3 may be provided on one end plate, a plurality of the same type of third planes P3 may be provided on one end plate, or the same type of third planes P3 may be provided on both end plates respectively.

[0091] Also, although it was described above that the third normal line N3 which is the normal line of the third plane P3 is parallel to the first axis AX1, the third normal line N3 does not necessarily have to be exactly parallel to the first axis AX1. For example, depending on the shape of the intermediate finished product housed inside the third container body 103 and / or the shape of the space around the third container body 103 in the equipment in which the third container body 103 is installed (for example, a vehicle equipped with an internal combustion engine, etc.), the third normal line N3 may be inclined with respect to the first axis AX1.

[0092] FIG. 9 is a schematic diagram illustrating the process of assembling the third container body 103 by fitting end plates 121 and 122 having the configuration illustrated in FIG. 8 into the openings at both ends of the shell 110. More specifically, FIG. 9 is a schematic side view when observed from a direction (the positive side on the y-axis shown in FIG. 1 etc.) orthogonal to both the first axis AX1 which is the central axis of the shell 110 and the first diameters D1a and D1b which are the maximum diameters of the end plates 121 and 122. Incidentally, although the end plates 121 and 122 illustrated in FIG. 9 are provided with not only the third plane P3 but also the first plane P1 and the second plane P2, for the purpose of easily illustrating the configuration of the third plane P3 etc., the second plane P2 and the second contact surface C2 are omitted in FIG. 9.

[0093] In FIG. 9(a), the shell 110 is supported and fixed in a predetermined posture by a jig (not shown), and the second contact surfaces C2a to C2g formed on the gripping means 131 and 132 (while bringing the second contact surfaces C2a to C2g and the second planes P2a to P2g into surface contact respectively) and the second contact surfaces C2a to C2g and the second planes P2a to P2g are brought into surface contact respectively, showing a state where the end plates 121 and 122 are supported and fixed in a predetermined posture. FIG. 9(b) shows a state where the third container body 103 is assembled by bringing the gripping means 131 and 132 closer to the shell 110 in a direction parallel to the first axis AX1 (refer to the black arrow) and fitting the end plates 121 and 122 supported and fixed in a predetermined posture as described above into the openings at both ends of the shell 110.

[0094] As illustrated in FIG. 9, in the third container body 103, in addition to the first plane P1 (not shown) and the second plane P2 described above, a third plane P3 which is a plane having a third normal line N3 which is a normal line parallel to the first axis AX1 is provided. Thereby, in the process of fitting the end plates 121 and 122 into the openings of the shell 110, the third contact surfaces C3a to C3e which are predetermined planes formed on the gripping means 131 and 132 and the second planes P3a to P3e provided on the end plates 121 and 122 can be brought into surface contact to support and fix the end plates 121 and 122 in a predetermined posture.

[0095] As a result, in the third container body 103, not only is the displacement of the end plates 121 and 122 in the x-axis direction reduced by the surface contact between the first plane P1 and the first contact surface C1, and the displacement of the end plates 121 and 122 in the y-axis direction reduced by the surface contact between the second plane P2 and the second contact surface C2, but also the displacement of the end plates 121 and 122 in the z-axis direction can be reduced by the surface contact between the third plane P3 and the third contact surface C3. Therefore, in manufacturing the third container body 103, the end plates 121 and 122 can be accurately gripped at a predetermined three-dimensional posture and position and then fitted into the opening of the shell 110.

[0096] <Effect> As described above, in the third container body, a third plane P3 having a normal parallel to the first axis is provided on the end plate. Therefore, in the step of fitting the end plate into the opening of the shell, in addition to the surface contact between the first contact surface formed on the gripping means and the first plane provided on the end plate, and the surface contact between the second contact surface formed on the gripping means and the second plane provided on the end plate, the third contact surface formed on the gripping means and the third plane provided on the end plate can be brought into surface contact. Thereby, not only the position of the end plate in the normal direction of the first plane and the normal direction of the second plane, but also the position of the end plate in the normal direction of the third plane can be surely fixed. Further, the position of the end plate in the rotational direction around an axis parallel to the first axis can be fixed more surely.

[0097] That is, according to the third container body, in the step of fitting the end plate into the opening of the shell, the end plate can be more surely supported and fixed at a predetermined three-dimensional posture and position. Therefore, in manufacturing the container body of the exhaust system, the end plate can be more accurately gripped at a predetermined three-dimensional posture and then fitted into the opening of the shell.

[0098] <<Fourth Embodiment>> As described at the beginning of this specification, the present invention relates not only to the container body of the exhaust system described above, but also to a method for manufacturing the container body of the exhaust system. Hereinafter, with reference to the drawings, a method for manufacturing a container body of an exhaust system according to a fourth embodiment of the present invention (hereinafter, may be referred to as "the first method") will be described. In the following description, the reference numerals shown in FIGS. 1 to 5 referred to in the previous description may also be used, so please refer to FIGS. 1 to 5 as necessary.

[0099] <Configuration> The first method is a method for manufacturing a container body of an exhaust system in which openings at both ends of a cylindrical shell 110 are closed by end plates 121 and 122. Specifically, the first method is a method for manufacturing the container body (the first container body) 101 of the exhaust system according to the first embodiment of the present invention described above. Therefore, the end plates 121 and / or 122, which are constituent members of the first container body 101 manufactured by the first method, satisfy the following requirements A to C.

[0100] Requirement A: A cylindrical portion Pc, which is a portion having a cylindrical shape capable of fitting with the opening of the shell 110, is formed at the peripheral edge portions of the end plates 121 and 122. Requirement B: At least a part of the cylindrical portion Pc is configured to be fitted with the opening of the shell 110 to form a fitting portion Pf. Requirement C: In a first projection view Vp1, which is a perpendicular projection view onto a plane perpendicular to the first axis AX1, which is the central axis of the shell 110, a first normal line N1, which is a normal line parallel to the first diameter D1, which is the maximum diameter of the end plates 121 and / or 122, or forms an acute angle of 45 degrees or less with the first diameter D1, and a first plane P1, which is a plane parallel to the first axis AX1, is provided at least at one location in a non-fitting portion Pnf, which is a portion of the end plates 121 and / or 122 other than the fitting portion Pf.

[0101] Since the above requirements A to C have already been described in detail in the description of the first container body 101, the description here is omitted.

[0102] FIG. 10 is a flowchart illustrating the flow of each step included in the first method. FIG. 11 is a schematic diagram illustrating the process of manufacturing the first container body 101 by fitting end plates 121 and 122 to the openings at both ends of the cylindrical shell 110 in processing equipment driven by, for example, a press machine or the like.

[0103] As illustrated in FIG. 10, the first method includes the first step, the second step, and the third step listed below.

[0104] First step (step S10): Set the shell on the first jig and support and fix the shell in a first posture which is a predetermined posture. Second step (step S20): Set the end plate on the gripping means movable in a direction parallel to the first axis, and support and fix the end plate in a second posture which is a predetermined posture by bringing the first contact surface which is a predetermined plane formed on the gripping means into surface contact with the first plane. Third step (step S30): Bring the gripping means closer to the shell in a direction parallel to the first axis, and integrate the container body of the exhaust system by fitting at least a part of the cylindrical portion into the openings at both ends of the shell to form a fitting portion.

[0105] Details of each step included in the first method will be described below with reference to FIGS. 10 and 11. First, in the first step executed as step S10 of the above-described flowchart, set the shell 110 on the first jig 141 and support and fix the shell 110 in a first posture which is a predetermined posture. Next, in the second step executed as step S20, set the end plates 121 and 122 (the end plate 122 is not shown because it is behind the gripping means 132) on the gripping means 131 and 132 movable in a direction parallel to the first axis AX1 which is the central axis of the shell 110, and support and fix the end plates 121 and 122 in a second posture which is a predetermined posture by bringing the first contact surface C1 which is a predetermined plane formed on the gripping means 131 and 132 into surface contact with the first plane P1.

[0106] As described with reference to FIG. 3 in the description of the first container body 101, in the first container body 101, first planes P1a to P1d, which are planes intersecting the directions of the first diameters D1a and D1b, which are the maximum diameters of the end plates 121 and 122, at a predetermined angle, are provided on the end plates 121 and 122, respectively. Thereby, in the second step, the first contact surfaces C1a to C1d, which are predetermined planes formed on the gripping means 131 and 132, and the first planes P1a to P1d of the end plates 121 and 122 are brought into surface contact to support and fix the end plates 121 and 122 in a predetermined posture.

[0107] FIG. 11(a) is a schematic perspective view illustrating the states of the shell 110, the end plates 121 and 122, the first jig 141 provided in the processing equipment, and the gripping means 131 and 132 when the execution of the first step and the second step is completed as described above. Note that the execution order of the first step and the second step is not limited to the above example. Therefore, after the second step is executed first to support and fix the end plates 121 and 122 in a second posture, which is a predetermined posture, the first step may be executed to set the shell 110 on the first jig 141 and support and fix the shell 110 in a first posture, which is a predetermined posture.

[0108] In the example shown in FIG. 11, as illustrated in (b), after the first step and the second step are executed as described above, the shell pressing jig 142 is lowered (see the white arrow), and the vicinity of the openings at both ends of the shell 110 is clamped between the first jig 141 and the shell pressing jig 142 to more firmly support and fix the shell 110 in the first posture. FIG. 12 is a schematic perspective view illustrating the state of the vicinity of the opening of the shell 110 clamped between the first jig 141 and the shell pressing jig 142 in this manner.

[0109] Next, in the third step executed as step S30, the gripping means 131 and 132 are brought closer to the shell 110 in a direction parallel to the first axis AX1 of the shell 110 (see the black arrow), and at least a part of the cylindrical portions Pc of the end plates 121 and 122 is fitted into the openings at both ends of the shell 110 to form a fitting portion Pf, thereby assembling the first container body 101. As described above, in the second step, the first contact surfaces C1a to C1d, which are predetermined planes formed on the gripping means 131 and 132, and the first planes P1a to P1d of the end plates 121 and 122 are in surface contact, and the end plates 121 and 122 are supported and fixed in a predetermined posture. Therefore, in the third step, the end plates 121 and 122 can be accurately gripped at a predetermined three-dimensional posture and position, and the end plates 121 and 122 can be fitted into the openings of the shell 110.

[0110] <Effect> As described above, the end plate, which is a constituent member of the first container body manufactured by the first method, is provided with a first plane that is a plane intersecting at a predetermined angle with the direction of the first diameter, which is the maximum diameter of the end plate. Therefore, by bringing the first contact surface, which is a predetermined plane formed on the gripping means, which is a jig for gripping the end plate in the step of fitting the end plate into the opening of the shell, into surface contact with the first plane of the end plate, not only the position of the end plate in the direction of the first normal line, which is the normal line of the first plane, but also the position (alignment) of the end plate in the rotational direction around an axis parallel to the first axis can be fixed. That is, according to the first method, in the step of fitting the end plate into the opening of the shell, the end plate can be supported and fixed at a predetermined three-dimensional posture and position, so that the end plate can be accurately gripped at a predetermined three-dimensional posture and the end plate can be fitted into the opening of the shell.

[0111] <Modification Example 4-1> By the way, as described in the description of the first container body 101 according to Modification Example 1-1, from the viewpoint of more accurately gripping the end plate at a predetermined three-dimensional posture and position in the manufacture of the container body of the exhaust system, it is desirable that a plurality of first planes P1 are provided on the end plates 121 and 122 and that the plurality of first planes P1 have a predetermined positional relationship.

[0112] Therefore, a plurality of first planes P1 are provided on the end plates 121 and / or 122 which are constituent members of the first container body 101 according to the first method of Modification Example 4-1, and a pair of first planes P1 are in a positional relationship that is plane-symmetrical with a plane orthogonal to the first diameter D1 as a symmetry plane (first symmetry plane Ps1). Preferably, the first symmetry plane Ps1 includes the first axis AX1.

[0113] Since the end plates 121 and 122 satisfying the above requirements have already been described with reference to FIG. 5(a) in the description of the first container body 101 according to Modification Example 1-1, the description here is omitted.

[0114] In the first method according to Modification Example 4-1 using the end plates 121 and / or 122 having the above configuration, in the step of fitting the end plates 121 and 122 to the opening of the shell 110, by bringing the first contact surface C1, which is a predetermined plane formed on the jig for gripping the end plates 121 and 122, into surface contact with the first plane P1 provided on the end plates 121 and 122, not only the position (alignment) of the end plates 121 and 122 in the rotational direction around an axis parallel to the first axis AX1 but also the position of the end plates 121 and 122 in the direction of the first normal N1, which is the normal of the first plane P1, can be more reliably fixed. Therefore, according to the first method according to Modification Example 4-1, in the step of fitting the end plates 121 and 122 to the opening of the shell 110, the end plates 121 and 122 can be more reliably supported and fixed in a predetermined three-dimensional posture and position.

[0115] <Modification Example 4-2> By the way, as described in the description of the first container body 101 according to Modification Example 1-2, from the viewpoint of more accurately gripping the end plate at a predetermined three-dimensional posture and position in the manufacture of the container body of the exhaust system, it is desirable that a plurality of first planes are provided on the end plate and the plurality of first planes are in a rotationally symmetric positional relationship.

[0116] Therefore, a plurality of first planes P1 are provided on the end plates 121 and / or 122, which are constituent members of the first container body 101 according to the first method of Modification 4-2, and a pair of first planes in which at least a part of the plurality of first planes has a rotational symmetry with the first axis as the axis of symmetry is formed.

[0117] Since the end plates 121 and 122 that satisfy the above requirements have already been described with reference to FIG. 5(b) in the description of the first container body 101 according to Modification 1-2, the description here is omitted.

[0118] In the first method according to Modification 4-2 using the end plates 121 and / or 122 having the above configuration, in the step of fitting the end plates 121 and 122 to the opening of the shell 110, the first contact surface C1, which is a predetermined plane formed on the jig for gripping the end plates 121 and 122, is brought into surface contact with the first plane P1 provided on the end plates 121 and 122, so that not only the positions of the end plates 121 and 122 in the direction of the first normal line N1, which is the normal line of the first plane P1, but also the positions (alignment) of the end plates 121 and 122 in the rotational direction around the axis parallel to the first axis AX1 can be more reliably fixed. Therefore, according to the first method according to Modification 4-2, in the step of fitting the end plates 121 and 122 to the opening of the shell 110, the end plates 121 and 122 can be more reliably supported and fixed in a predetermined three-dimensional posture and position.

[0119] <<Fifth Embodiment>> Hereinafter, a method for manufacturing a container body of an exhaust system according to the fifth embodiment of the present invention (hereinafter, may be referred to as the "second method") will be described.

[0120] <Configuration> The second method is the first method described above and is a method for manufacturing a container body (second container body) of an exhaust system according to the second embodiment of the present invention described above. Therefore, the end plate, which is a constituent member of the second container body manufactured by the second method, satisfies the requirement D described below.

[0121] Requirement D: A second plane P2 is provided at at least one location in the non-fitting portion Pnf of the end plates 121 and / or 122. The second plane P2 is a plane different from the first plane P1 and parallel to the first axis AX1. The second normal N2, which is the normal to the second plane P2, is perpendicular to the first normal N1 in the first projection view Vp1 or is a normal such that the acute angle θ2 formed with the first normal N1 is 45 degrees or more.

[0122] Regarding the end plates 121 and 122 that satisfy the above Requirement D, since they have already been described with reference to FIGS. 6 and 7 in the description of the second container body 102, the description here is omitted.

[0123] In the second method, in the above-described second step, in addition to the surface contact between the first contact surface C1 and the first plane P1, the second contact surface C2, which is a predetermined plane different from the first contact surface C1 formed on the gripping means 131 and / or 132, and the second plane P2 are brought into surface contact to support and fix the end plates 121 and / or 122 in the second posture.

[0124] <Effect> As described above, the end plate, which is a component of the second container body manufactured by the second method, is provided with a second plane having a normal that intersects the normal of the first plane at a predetermined angle. Therefore, in the step of fitting the end plate to the opening of the shell, in addition to the surface contact between the first contact surface formed on the gripping means and the first plane provided on the end plate, the second contact surface formed on the gripping means and the second plane provided on the end plate can be brought into surface contact. As a result, not only the position of the end plate in the normal direction of the first plane but also the position of the end plate in the normal direction of the second plane can be surely fixed. Furthermore, the position of the end plate in the rotational direction around an axis parallel to the first axis AX1 can be more surely fixed.

[0125] That is, according to the second method, in the step of fitting the end plate to the opening of the shell, the end plate can be more surely supported and fixed in a predetermined three-dimensional posture and position. Therefore, in the manufacture of the container body of the exhaust system, the end plate can be more accurately gripped in a predetermined three-dimensional posture and then fitted to the opening of the shell.

[0126] <Examples of Modification 5-1 and Example of Modification 5-2> Incidentally, as described in the description of the second container body 102 according to the first modification example 2-1 and the second modification example 2-2, from the viewpoint of more accurately gripping the end plate in a predetermined three-dimensional posture and position in the manufacture of the container body of the exhaust system, it is desirable that a plurality of second planes P2 are provided on the end plate and that the plurality of second planes P2 have a predetermined positional relationship.

[0127] Therefore, a plurality of second planes P2 are provided on the end plate 121 and / or 122 which are constituent members of the second container body 102 manufactured by the second method according to the first modification example 5-1, and at least a part of the plurality of second planes P2 includes the first diameter D1 and forms a pair of second planes P2 having a plane symmetry with a plane parallel to the first axis AX1 as a symmetry plane (second symmetry plane Ps2). Preferably, the second symmetry plane Ps2 includes the first axis AX1.

[0128] Furthermore, a plurality of second planes P2 are provided on the end plate 121 and / or 122 which are constituent members of the second container body 102 manufactured by the second method according to the second modification example 5-2, and at least a part of the plurality of second planes P2 forms a pair of second planes P2 having a rotational symmetry with the first axis AX1 as a symmetry axis.

[0129] Since the end plates 121 and 122 satisfying the above requirements have already been described with reference to FIG. 6(a) in the description of the second container body 102 according to the first modification example 2-1 and the second modification example 2-2, the description here is omitted.

[0130] In the second method according to Modification 5-1 and Modification 5-2 using the end plates 121 and / or 122 having the above-described configuration, in the step of fitting the end plates 121 and 122 into the opening of the shell 110, the first contact surface C1 and the second contact surface C2, which are predetermined planes formed on the jig for gripping the end plates 121 and 122, are brought into surface contact with the first plane P1 and the second plane P2 provided on the end plates 121 and 122, respectively. By doing so, not only the positions of the end plates 121 and 122 in the directions of the first normal line N1, which is the normal line of the first plane P1, and the second normal line N2, which is the normal line of the second plane P2, but also the positions (alignment) of the end plates 121 and 122 in the rotational direction around an axis parallel to the first axis AX1 can be more reliably fixed. Therefore, according to the second method according to Modification 5-1 or Modification 5-2, in the step of fitting the end plates 121 and 122 into the opening of the shell 110, the end plates 121 and 122 can be more reliably supported and fixed in a predetermined three-dimensional posture and position.

[0131] <<Sixth Embodiment>> Hereinafter, a method for manufacturing a container body of an exhaust system according to the sixth embodiment of the present invention (hereinafter, may be referred to as the "third method") will be described.

[0132] <Configuration> The third method is the above-described first method or second method, and is a method for manufacturing the container body (third container body) of the exhaust system according to the third embodiment of the present invention described above. Therefore, the end plates, which are constituent members of the third container body manufactured by the third method, satisfy the following requirement E.

[0133] Requirement E: At least one location in the non-fitting portion Pnf of the end plates 121 and / or 122 is provided with a third plane P3, which is a plane having a third normal line N3 that is a normal line parallel to the first axis AX1.

[0134] Since the end plates 121 and 122 that satisfy the above requirement E have already been described with reference to FIGS. 8 and 9 in the description of the third container body 103, the description here is omitted.

[0135] In the third method corresponding to the first method described above, in the second step described above, in addition to the surface contact between the first contact surface C1 and the first plane P1, a third contact surface C3, which is a predetermined plane different from the first contact surface C1 formed on the gripping means 131 and 132, and the third plane P3 are brought into surface contact, thereby supporting and fixing the end plates 121 and 122 in the second posture.

[0136] On the other hand, in the third method corresponding to the second method described above, in the second step described above, in addition to the surface contact between the first contact surface C1 and the first plane P1 and the surface contact between the second contact surface C2 and the second plane P2, a third contact surface C3, which is a predetermined plane different from the first contact surface C1 and the second contact surface C2 formed on the gripping means 131 and 132, and the third plane P3 are brought into surface contact, thereby supporting and fixing the end plates 121 and 122 in the second posture.

[0137] <Effect> As described above, on the end plate, which is a component of the third container body manufactured by the third method, a third plane having a normal parallel to the first axis is provided. Therefore, in the step of fitting the end plate to the opening of the shell, in addition to the surface contact between the first contact surface formed on the gripping means and the first plane provided on the end plate or the surface contact between the first contact surface and the second contact surface formed on the gripping means and the first plane and the second plane provided on the end plate, the third contact surface formed on the gripping means and the third plane provided on the end plate can be further brought into surface contact. Thereby, not only the position of the end plate in the normal direction of the first plane or the normal directions of the first plane and the second plane, but also the position of the end plate in the normal direction of the third plane can be surely fixed. Further, the position of the end plate in the rotational direction around an axis parallel to the first axis can be fixed more surely.

[0138] That is, according to the third method, in the step of fitting the end plate to the opening of the shell, the end plate can be more surely supported and fixed in a predetermined three-dimensional posture and position. Therefore, in the manufacture of the container body of the exhaust system, the end plate can be more accurately gripped in a predetermined three-dimensional posture and the end plate can be fitted to the opening of the shell.

[0139] <<Seventh Embodiment>> Hereinafter, a method for manufacturing a container body of an exhaust system according to the seventh embodiment of the present invention (hereinafter, may be referred to as the "fourth method") will be described.

[0140] <Configuration> FIG. 13 is a flowchart illustrating the flow of each step included in the fourth method. Note that the flowchart illustrated in FIG. 13 is the same as the flowchart illustrating the flow of each step included in the first method illustrated in FIG. 10, except that after the third step executed in step S30, steps S40 and S50 for respectively executing the fourth step and the fifth step listed below are added.

[0141] That is, as illustrated in FIG. 13, the fourth method is any one of the first method to the third method described above, and in addition to the first step to the third step described above, further includes the fourth step and the fifth step listed below, and is a method for manufacturing a container body of an exhaust system.

[0142] Fourth step (step S40): After the third step, by using at least any one of the first plane, the second plane, and the third plane as a reference plane, the container body of the exhaust system is supported and fixed in a third posture which is a predetermined posture. Fifth step (step S50): After the fourth step, secondary processing is performed on the container body of the exhaust system supported and fixed in the third posture.

[0143] The fourth and fifth processes may be executed in the processing equipment in which the first to third processes described above have been executed, or may be executed in separate processing equipment different from the processing equipment in which the first to third processes described above have been executed. Further, the above "third posture" is not particularly limited as long as it is a posture suitable for performing secondary processing on the container body of the exhaust system. When the fourth and fifth processes are executed in the processing equipment in which the first to third processes described above have been executed, typically, the third posture is the posture of the container body of the exhaust system at the time of integration by the execution of the first to third processes described above. On the other hand, when the fourth and fifth processes are executed in separate processing equipment different from the processing equipment in which the first to third processes described above have been executed, the third posture may be the same as the posture of the container body of the exhaust system at the time of integration by the execution of the first to third processes described above, or may be a posture different from that posture.

[0144] In addition, the specific content of the above "secondary processing" is not particularly limited. Specific examples of secondary processing may be, for example, welding (such as laser welding or MIG welding, etc.) between the end plates fitted to the openings at both ends of the shell and the shell, or, as will be described later, the assembly of further components to the container body of the exhaust system integrated by the execution of the first to third processes described above.

[0145] FIG. 14 is a schematic diagram comparing the procedure according to the prior art and the procedure according to the fourth method when performing secondary processing on the integrated container body of the exhaust system. More specifically, FIG. 14(a) is a schematic diagram illustrating the procedure when performing secondary processing of assembling an exhaust pipe assembly, an exhaust pipe, etc. on a muffler as a container body of the exhaust system according to the prior art, which is integrated by the lock seam method (curling) according to the method according to the prior art. On the other hand, FIG. 14(b) is a schematic diagram illustrating the procedure when performing secondary processing of assembling an exhaust pipe assembly, an exhaust pipe, etc. on a muffler as a container body of the exhaust system according to the manufacturing method (fourth method) of the container body of the exhaust system according to the seventh embodiment of the present invention.

[0146] In the method according to the prior art illustrated in Fig. 14(a), since a reference is determined using individual jigs for positioning the work one-dimensionally (uniaxially) for each individual process, a changeover of jigs occurs for each individual process. Specifically, first, in Process A, an exhaust pipe is welded to the flange with jig A as a reference, and further, a first support member (such as a support rod and / or a support bracket) is welded to the exhaust pipe to assemble an exhaust pipe assembly (ASSY). In the next Process B, the muffler is supported with a jig B different from jig A, and the outlet pipe is inserted into and welded to the muffler. Further, in the next Process C, the muffler is supported with another jig C as a reference, and a second support member is welded to the muffler. Finally, in Process D, the muffler is supported with yet another jig D as a reference, and the ASSY is inserted into and welded to the muffler.

[0147] As described above, in the method according to the prior art, since a reference is set individually in all four processes, a changeover of jigs occurs in all processes, making the assembly process complicated. Further, since the reference changes with each changeover, it is not possible to support the finished product with accurate position and posture. In addition, since the errors in the position and posture of the finished product are superimposed for each process, it is very difficult to ensure the position and alignment of each finished product with high accuracy for the entire assembled finished product.

[0148] On the other hand, in the fourth method illustrated in Fig. 14(b), at least any one of the first plane, the second plane, and the third plane that contributed to accurately supporting and fixing the end plate in a predetermined three-dimensional (triaxial) posture and position in the step of fitting the end plate to the opening of the shell is used as a reference plane as described above. Specifically, at least any one of the first plane, the second plane, and the third plane used in the assembly of the muffler as the container body of the exhaust system is used as a reference plane, and the muffler is clamped by the jigs X and Y, and the muffler is supported in a three-dimensional (triaxial) correct posture and high positional accuracy. After that, without changing the reference plane and maintaining this state, in step X, the pipe is welded to the muffler, the support member is welded to the pipe, in the next step Y, the ASSY is welded to the muffler, and in the last step Z, the support member is welded to the ASSY.

[0149] As described above, in the fourth method, since all three steps can be executed while the reference plane is shared and the muffler is clamped by the jigs X and Y, no changeover occurs in all steps. Therefore, the assembly process becomes simple, economical, and efficient. Furthermore, since no changeover occurs, the assembled product can be supported with accurate positional accuracy and posture on a certain reference plane. In addition, the errors in the position and posture of the assembled product do not overlap for each step, and the positional accuracy and alignment of each assembled product can be ensured with high accuracy for the entire completed product after all the assembled products are assembled.

[0150] In addition, which of the first plane, the second plane, and the third plane is provided on the end plate constituting the container body of the exhaust system attached to the fourth step and the fifth step included in the fourth method differs depending on which of the first container body to the third container body the container body corresponds to as described above. Therefore, which of the first plane, the second plane, and the third plane is used as a reference plane in the fourth step and the fifth step included in the fourth method needs to be changed according to whether the container body of the exhaust system attached to the step is manufactured by any of the first method to the third method as described above.

[0151] In the fourth method of performing secondary processing on the first container body integrated by the above-described first method, in the fourth step, by using the first plane as a reference plane, the container body of the exhaust system is supported and fixed in the third posture which is a predetermined posture. Further, in the fourth method of performing secondary processing on the first container body integrated by the above-described second method, in the fourth step, by using at least one of the first plane and the second plane as a reference plane, the container body of the exhaust system is supported and fixed in the third posture which is a predetermined posture.

[0152] Furthermore, in the fourth method of performing secondary processing on the first container body integrated by the third method corresponding to the above-described first method, in the fourth step, by using at least one of the first plane and the third plane as a reference plane, the container body of the exhaust system is supported and fixed in the third posture which is a predetermined posture. In addition, in the fourth method of performing secondary processing on the first container body integrated by the third method corresponding to the above-described second method, in the fourth step, by using at least one of the first plane, the second plane, and the third plane as a reference plane, the container body of the exhaust system is supported and fixed in the third posture which is a predetermined posture.

[0153] <Effect> As described above, in the fourth method, after the above-described third step, by using at least one of the first plane, the second plane, and the third plane as a reference plane, while the container body of the exhaust system is supported and fixed in the third posture which is a predetermined posture, secondary processing can be performed on the container body of the exhaust system supported and fixed in the third posture. Therefore, there is no need for a changeover such as replacing the jig for supporting and fixing the container body of the exhaust system and / or the component to be further assembled for each process as in the method according to the above-described prior art. As a result, the assembly process becomes simple, economical, and efficient. Furthermore, since there is no changeover, the component can be supported with accurate position and posture on a certain reference plane. In addition, the errors in the position and posture of the component do not accumulate for each process, and the position and alignment of each component can be ensured with high accuracy for the entire finished product in which all components are assembled.

Example

[0154] Examples of the container body of the exhaust system (the container body of the present invention) and its manufacturing method (the method of the present invention) according to the present invention described above will be described below with reference to the drawings. However, the examples described below are merely illustrative and do not limit the scope of the present invention. In the following description, reference numerals shown in the drawings referred to in the description of various embodiments of the present invention described above may also be used, so please refer to these drawings as necessary.

[0155] FIG. 15 is a schematic perspective view illustrating the configuration of an end plate constituting the container body of the exhaust system according to Embodiment 1 of the present invention (hereinafter may be referred to as the "container body of the first embodiment"). FIG. 16 is a schematic (a) front view, (b) top view, (c) right side view, (d) left side view, and (e) bottom view of the end plate 123 illustrated in FIG. 15. FIG. 17 is a schematic cross-sectional view of the end plate 123 taken along (a) plane A-A, (b) plane B-B, (c) plane C-C, and (d) plane D-D shown in FIG. 16.

[0156] As illustrated in FIGS. 15 to 17, in the end plate 123 constituting the container body of the first embodiment, a cylindrical portion Pc, which is a portion having a cylindrical shape capable of fitting with an opening of a shell (not shown), is provided at the peripheral edge of the end plate 123. Further, the first plane P1, the second plane P2, and the third plane P3 described above are respectively provided on a non-fitting cylindrical portion Pcnf, which is a portion corresponding to a portion other than the fitting portion Pf that fits with the opening of the shell in the cylindrical portion Pc of the end plate 123.

[0157] More specifically, in the end plate 123, in a first projection view which is a perpendicular projection view onto a plane orthogonal to a first axis AX1 (not shown) which is the central axis of the shell, two planes P1a and P1b which are orthogonal to a first diameter D1 which is the maximum diameter of the end plate 123 (i.e., having a first normal line N1 parallel to the first diameter D1) and parallel to the first axis AX1 are respectively provided at two positions which are rotationally symmetric about the first axis AX1 in a non-fitting cylindrical portion Pcnf which is a portion other than a fitting portion Pf in a cylindrical portion Pc of the end plate 123.

[0158] Furthermore, in the end plate 123, four planes P2a to P2d which are different from the first planes P1a and P1b, having a second normal line N2 which is a normal line orthogonal to the first normal line N1 (i.e., orthogonal to the first diameter D1) in the first projection view Vp1 and parallel to the first axis AX1, are respectively provided at four positions which are rotationally symmetric about the first axis AX1 in the non-fitting cylindrical portion Pcnf.

[0159] In addition, in the end plate 123, a third plane P3a which is a plane having a third normal line N3 which is a normal line parallel to the first axis AX1 (i.e., orthogonal to the direction of the first axis AX1) is provided at one position in the non-fitting cylindrical portion Pcnf. Thus, all of the first plane P1, the second plane P2, and the third plane P3 are provided in the end plate 123 constituting the container body of the first embodiment. That is, the container body of the first embodiment corresponds to the third container body described above.

[0160] The end plate 123 having the above-described configuration and an end plate 124 fitted to an opening on the side opposite to the end plate 123 of the shell are gripped by gripping means 131 and 132 provided in processing equipment as exemplified in FIG. 11 referred to in the description regarding the first method above, and a shell (not shown) is sandwiched between a first jig 141 provided in the above-described processing equipment and a shell pressing jig 142.

[0161] FIG. 18 is a schematic (a) front view, (b) top view, (c) right side view, (d) left side view, and (e) bottom view of a state in which the end plate 123 is gripped by the gripping means 131 provided in the processing equipment as illustrated in FIG. 11. Since FIG. 18 corresponds to a view in which the gripping means 131 is added to the end plate 123 illustrated in FIG. 16, the reference numerals for the end plate 123 are omitted, and the gripping means 131 indicates reference numerals only for the claw portions K1 to K7. Further, in the front view shown in FIG. 18(a), the gripping means 131 is omitted, and instead, a first jig 141 for clamping the shell 110 and a shell pressing jig 142 are depicted. In the state illustrated in FIG. 18, by bringing the first contact surface C1, the second contact surface C2, and the third contact surface C3 formed on the claw portions K1 to K7 into surface contact with the first plane P1, the second plane P2, and the third plane P3, respectively, the end plates 123 and 124 can be accurately supported and fixed in the second posture.

[0162] FIG. 19 is a schematic exploded perspective view illustrating a state in which a separate end plate 124 (for example, an end plate fitted to an opening on the opposite side of the opening fitted to the end plate 123 of the shell) provided with the first plane P1 to the third plane P3 in the same manner as the end plate 123 is supported and fixed by the claw portions K1 to K7 provided in the gripping means 132 constituting the processing equipment. In FIG. 19, the gripping means 132 is omitted for the purpose of easily illustrating the positional relationship between the claw portions K1 to K7 and the end plate 124.

[0163] The first contact surface C1 to the third contact surface C3 are respectively formed on the claw portions K1 to K7, and by bringing the first plane P1 to the third plane P3 provided on the end plate 124 into surface contact with the first contact surface C1 to the third contact surface C3, respectively, the end plate 124 can be accurately supported and fixed in a predetermined three-dimensional posture and position. The same applies to the other end plate 123.

[0164] After that, as illustrated in Fig. 11(c), the gripping means 131 and 132 are brought closer to the shell 110 in a direction parallel to the first axis AX1 of the shell 110, and at least a part of the cylindrical portions Pc of the end plates 123 and 124 is fitted into the openings at both ends of the shell 110 to form a fitting portion Pf, thereby assembling the container body 201 of the first embodiment.

[0165] As described above, in the container body of the first embodiment, the first plane P1 provided on the end plates 123 and 124 and the first contact surface C1 to the third contact surface C3 formed on the claw portions K1 to K7 of the gripping means 131 and 132 provided in the processing equipment are brought into surface contact with the third plane P3, respectively, so that the end plates 123 and 124 can be accurately supported and fixed in a predetermined three-dimensional posture and position. Therefore, according to the container body of the first embodiment, the end plate 124 can be accurately gripped in a predetermined three-dimensional posture and fitted into the opening of the shell 110.

Embodiment

[0166] In the descriptions of the various embodiments and Example 1 of the present invention described above, the case where the cross-sectional shapes of the shell and the end plate are elliptical has been taken as an example. However, the shapes and sizes of the spaces around the container body in the equipment where the container body of the exhaust system is installed (for example, a vehicle equipped with an internal combustion engine, etc.) are various, and recently there is a tendency to become even narrower. Against this background, the cross-sectional shapes of the shell and the end plate are diversified, such as rotationally symmetric shapes such as circular, elliptical, and oblong shapes, and non-rotationally symmetric shapes such as irregular cross-sections, as described above.

[0167] Therefore, in the present embodiment, some of the end plates having various cross-sectional shapes are exemplified. Fig. 20 is a schematic front view of four types of end plates having various cross-sectional shapes.

[0168] The end plate 125 illustrated in Fig. 20(a) has a circular cross-section, and two first planes P1a and P1b, two second planes P2a and P2b, and four third planes P3a to P3d are provided on the end plate 125.

[0169] Incidentally, as described above, the shape and size of the space around the container body in the facility where the container body of the exhaust system is installed vary, and recently there has been a tendency to become even narrower. Against this background, the cross-sectional shape of the container body tends to be flattened, and accordingly, the cross-sectional shape of the end plate also tends to be flattened. From this point of view, it can be said that the end plates 121 to 124 provided in the container body of the exhaust system according to various embodiments and Example 1 of the present invention have an elliptical cross-section and are more preferable than the end plate 125 illustrated in FIG. 20(a) having a circular cross-section.

[0170] However, from the viewpoint of reducing the pressure loss (fluid resistance) of the exhaust flowing inside the container body, even if the cross-sectional shape is flat, it is preferable to make the cross-sectional area of the container body as large as possible. Therefore, the cross-section of the end plate 126 illustrated in FIG. 20(b) has a shape intermediate between an ellipse and a rounded rectangle. More specifically, the contour of the cross-section of the end plate 126, as shown in FIG. 20(b), includes a portion (first portion) having a small radius of curvature Rs and intersecting the major axis, a portion (second portion) having a large radius of curvature Rb and intersecting the minor axis, and a portion (third portion) having a medium-sized radius of curvature Rm and connecting the first portion and the second portion. By approaching the cross-sectional shape from an ellipse to a rounded rectangle in this way, the area of the portion corresponding to the corner is added to the cross-sectional area, so that the pressure loss (fluid resistance) of the exhaust flowing inside the container body can be reduced.

[0171] Note that the end plate 126 is provided with one first plane P1a, four second planes P2a to P2d, and four third planes P3a to P3d.

[0172] The end plates 121 to 124 provided in the container body of the exhaust system according to various embodiments and Example 1 of the present invention having an elliptical cross-section, as well as the end plate 125 having a circular cross-section illustrated in FIGS. 20(a) and 20(b) and the end plate 126 having an intermediate shape between an ellipse and a rounded rectangle all have a rotationally symmetric cross-sectional shape. However, as described above, the end plates constituting the container body of the exhaust system according to the present invention may have a non-rotationally symmetric cross-sectional shape.

[0173] The cross-section of the end plate 127 illustrated in FIG. 20(c) is symmetric (line-symmetric with the x-axis as the axis of symmetry) in the left-right direction (y-axis direction), but has an asymmetric shape in the up-down direction (x-axis direction). Even in the container body of the exhaust system having such a cross-sectional shape, the present invention can be applied to accurately grip the end plate in a predetermined three-dimensional posture and position and fit the end plate into the opening of the shell. Incidentally, the end plate 127 is provided with two first planes P1a and P1b, two second planes P2a and P2b, and three third planes P3a to P3c.

[0174] Furthermore, the cross-section of the end plate 128 illustrated in FIG. 20(d) has an asymmetric shape both in the left-right direction (y-axis direction) and in the up-down direction (x-axis direction). Even in the container body of the exhaust system having such a cross-sectional shape, the present invention can be applied to accurately grip the end plate in a predetermined three-dimensional posture and position and fit the end plate into the opening of the shell. Incidentally, the end plate 128 is provided with two first planes P1a and P1b, four second planes P2a to P2d, and four third planes P3a to P3d.

[0175] As described above, in this embodiment, while referring to FIG. 20, end plates having various cross-sectional shapes have been exemplified. According to the present invention, however, even in the container body of the exhaust system having such a cross-sectional shape, the end plate can be accurately gripped in a predetermined three-dimensional posture and position and fitted into the opening of the shell.

[0176] As described above, for the purpose of explaining the present invention, several embodiments and modifications having specific configurations have been described with reference to the accompanying drawings at times. However, the scope of the present invention should not be construed as being limited to these exemplary embodiments and modifications, and it goes without saying that appropriate modifications can be made within the scope of the matters described in the claims and the specification.

Explanation of Reference Numerals

[0177] 101, 102, 103… Container bodies of the exhaust system 110… Shell AX1… First axis (central axis of the shell) 121, 122, 123, 124, 125, 126, 127, 128… End plates Pf… Fitting portion Pnf… Non-fitting portion Pc… Cylindrical portion Pcnf… Non-fitting cylindrical portion Pg… General portion Vp1… First projection view D1, D1a, D1b… First diameter (maximum diameter of the end plate in the first projection view Vp1) P1, P1a, P1b, P1c, P1d, P1e, P1f, P1g, P1h… First plane N1, N1a, N1b, N1c, N1d… First normal P2, P2a, P2b, P2c, P2d, P2e, P2f, P2g… Second plane N2, N2a, N2b, N2c, N2d, N2e, N2f, N2g… Second normal 131, 132… Gripping means 131g, 132g… Jigs C1, C1a, C1b, C1c, C1d… First contact surface C2, C2a, C2b, C2c, C2d, C2e, C2f, C2g… Second contact surface K1, K2, K3, K4, K5, K6, K7… Claw portions 141… First jig 142… Shell pressing jig

Claims

1. A container body for an exhaust system, wherein openings at both ends of a cylindrical shell are closed by end plates, a cylindrical portion, which is a portion having a cylindrical shape capable of fitting with the opening of the shell, is provided at a peripheral edge portion of the end plate, at least a part of the cylindrical portion is fitted with the opening of the shell to form a fitting portion, in a first projection view, which is a perpendicular projection view onto a plane orthogonal to a first axis that is a central axis of the shell, a first normal line, which is a normal line parallel to a first diameter that is a maximum diameter of the end plate or forms an acute angle of 45 degrees or less with the first diameter, and a first plane, which is a plane parallel to the first axis, are provided at at least one location in a non-fitting portion, which is a portion of the end plate other than the fitting portion, A container body for an exhaust system.

2. The container body for an exhaust system according to Claim 1, a plurality of the first planes are provided on the end plate, at least a part of the plurality of the first planes, a pair of the first planes having a plane-symmetrical positional relationship with a plane orthogonal to the first diameter as a plane of symmetry, and / or a pair of the first planes having a rotationally symmetrical positional relationship with the first axis as a symmetry axis, constitute. A container body for an exhaust system.

3. The container body for an exhaust system according to Claim 1 or Claim 2, in the end plate, a second plane, which is a plane different from the first plane, having a second normal line, which is a normal line orthogonal to the first normal line or forms an acute angle of 45 degrees or more with the first normal line, and parallel to the first axis, is provided at at least one location in the non-fitting portion, A container body for an exhaust system.

4. The container body for an exhaust system according to Claim 3, a plurality of the second planes are provided on the end plate, at least a part of the plurality of the second planes, a pair of the second planes having a plane-symmetrical positional relationship with a plane including the first diameter and parallel to the first axis as a plane of symmetry, and / or a pair of the second planes having a rotationally symmetrical positional relationship with the first axis as a symmetry axis, constitute. A container body for an exhaust system.

5. The container body for an exhaust system according to Claim 1 or Claim 2, in the end plate, a third plane, which is a plane having a third normal line, which is a normal line parallel to the first axis, is provided at at least one location in the non-fitting portion, A container body for an exhaust system.

6. The container body for an exhaust system according to Claim 3, In the end plate, at least one location in the non-fitting portion is provided with a third plane which is a plane having a third normal line that is a normal line parallel to the first axis. A container body of an exhaust system.

7. The container body of an exhaust system according to claim 4, In the end plate, at least one location in the non-fitting portion is provided with a third plane which is a plane having a third normal line that is a normal line parallel to the first axis. A container body of an exhaust system.

8. A method for manufacturing a container body of an exhaust system that closes openings at both ends of a cylindrical shell with end plates, A cylindrical portion which is a portion having a cylindrical shape capable of fitting with the opening of the shell is formed at a peripheral edge portion of the end plate, At least a part of the cylindrical portion is configured to be fitted with the opening of the shell to form a fitting portion, In a first projection view which is an orthographic projection view onto a plane perpendicular to the first axis which is the central axis of the shell, a first plane which is a plane having a first normal line that is a normal line parallel to the first diameter or forms an acute angle of 45 degrees or less with the first diameter and is parallel to the first axis is provided at least at one location in a non-fitting portion which is a portion other than the fitting portion of the end plate, A first step of setting the shell in a first jig and supporting and fixing the shell in a first posture which is a predetermined posture, A second step of setting the end plate in a gripping means movable in a direction parallel to the first axis and bringing a first contact surface which is a predetermined plane formed in the gripping means into surface contact with the first plane to support and fix the end plate in a second posture which is a predetermined posture, A third step of bringing the gripping means closer to the shell in a direction parallel to the first axis and fitting at least a part of the cylindrical portion into the openings at both ends of the shell to form the fitting portion, thereby assembling the container body of the exhaust system, Including, A method for manufacturing a container body of an exhaust system.

9. The method for manufacturing a container body of an exhaust system according to claim 8, A plurality of the first planes are provided on the end plate, At least a part of the plurality of the first planes, Pairs of the first planes having a plane-symmetrical positional relationship with a plane perpendicular to the first diameter as a symmetry plane, and / or Pairs of the first planes having a rotationally-symmetrical positional relationship with the first axis as a symmetry axis, Constitute, A method for manufacturing a container body of an exhaust system.

10. The method for manufacturing a container body of an exhaust system according to claim 8 or claim 9, In the end plate, a second plane, which has a second normal line that is orthogonal to the first normal line or forms an acute angle of 45 degrees or more with the first normal line in the first projection view and is parallel to the first axis and is different from the first plane, is provided at at least one location in the non-fitting portion. In the second step, in addition to the surface contact between the first contact surface and the first plane, the end plate is supported and fixed in the second posture by bringing a second contact surface, which is a predetermined plane different from the first contact surface formed on the gripping means, into surface contact with the second plane. A method for manufacturing a container body of an exhaust system.

11. A method for manufacturing a container body of an exhaust system according to claim 10, wherein a plurality of the second planes are provided on the end plate, and at least a part of the plurality of the second planes is a pair of second planes having a plane-symmetrical positional relationship with a plane including the first diameter and having the plane parallel to the first axis as a symmetry plane, and / or is a pair of second planes having a rotationally symmetrical positional relationship with the first axis as a symmetry axis, constituting. A method for manufacturing a container body of an exhaust system.

12. A method for manufacturing a container body of an exhaust system according to claim 8 or claim 9, wherein in the end plate, a third plane, which is a plane having a third normal line that is parallel to the first axis, is provided at at least one location in the non-fitting portion, and in the second step, in addition to the surface contact between the first contact surface and the first plane, the end plate is supported and fixed in the second posture by bringing a third contact surface, which is a predetermined plane different from the first contact surface formed on the gripping means, into surface contact with the third plane. A method for manufacturing a container body of an exhaust system.

13. A method for manufacturing a container body of an exhaust system according to claim 10, wherein in the end plate, a third plane, which is a plane having a third normal line that is parallel to the first axis, is provided at at least one location in the non-fitting portion, and in the second step, in addition to the surface contact between the first contact surface and the first plane and the surface contact between the second contact surface and the second plane, the end plate is supported and fixed in the second posture by bringing a third contact surface, which is a predetermined plane different from the first contact surface and the second contact surface formed on the gripping means, into surface contact with the third plane. A method for manufacturing a container body of an exhaust system.

14. A method for manufacturing a container body of an exhaust system according to claim 11, In the end plate, at least one position in the non-fitting portion is provided with a third plane which is a plane having a third normal line that is a normal line parallel to the first axis. In the second step, in addition to the surface contact between the first contact surface and the first plane and the surface contact between the second contact surface and the second plane, the end plate is supported and fixed in the second posture by bringing a third contact surface, which is a predetermined plane different from the first contact surface and the second contact surface formed on the gripping means, into surface contact with the third plane. A method for manufacturing a container body of an exhaust system.

15. A method for manufacturing a container body of an exhaust system according to claim 8 or claim 9, a fourth step of supporting and fixing the container body of the exhaust system in a third posture, which is a predetermined posture, by using the first plane as a reference plane after the third step; a fifth step of performing secondary processing on the container body of the exhaust system supported and fixed in the third posture after the fourth step; further comprising A method for manufacturing a container body of an exhaust system.

16. A method for manufacturing a container body of an exhaust system according to claim 10, a fourth step of supporting and fixing the container body of the exhaust system in a third posture, which is a predetermined posture, by using at least one of the first plane and the second plane as a reference plane after the third step; a fifth step of performing secondary processing on the container body of the exhaust system supported and fixed in the third posture after the fourth step; further comprising A method for manufacturing a container body of an exhaust system.

17. A method for manufacturing a container body of an exhaust system according to claim 11, a fourth step of supporting and fixing the container body of the exhaust system in a third posture, which is a predetermined posture, by using at least one of the first plane and the second plane as a reference plane after the third step; a fifth step of performing secondary processing on the container body of the exhaust system supported and fixed in the third posture after the fourth step; further comprising A method for manufacturing a container body of an exhaust system.

18. A method for manufacturing a container body of an exhaust system according to claim 12, a fourth step of supporting and fixing the container body of the exhaust system in a third posture, which is a predetermined posture, by using at least one of the first plane and the third plane as a reference plane after the third step; a fifth step of performing secondary processing on the container body of the exhaust system supported and fixed in the third posture after the fourth step; further comprising A method for manufacturing a container body of an exhaust system.

19. A method for manufacturing a container body of an exhaust system according to claim 13, wherein: after the third step, a fourth step of supporting and fixing the container body of the exhaust system in a third posture, which is a predetermined posture, by using at least one of the first plane, the second plane, and the third plane as a reference plane; after the fourth step, a fifth step of performing secondary processing on the container body of the exhaust system supported and fixed in the third posture; further comprising: a method for manufacturing a container body of an exhaust system.

20. A method for manufacturing a container body of an exhaust system according to claim 14, wherein: after the third step, a fourth step of supporting and fixing the container body of the exhaust system in a third posture, which is a predetermined posture, by using at least one of the first plane, the second plane, and the third plane as a reference plane; after the fourth step, a fifth step of performing secondary processing on the container body of the exhaust system supported and fixed in the third posture; further comprising: a method for manufacturing a container body of an exhaust system.

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