Manufacturing method for exhaust components

Abstract

Reduce energy loss. [Solution] A method for manufacturing an exhaust component to be mounted on a vehicle, comprising arranging an exhaust component having a painted portion, which is a painted portion on a part of its outer surface, such that the painted portion is located on the first side. The manufacturing method further comprises blowing air from the first side toward the exhaust component, which is arranged with the painted portion located on the first side, while simultaneously drawing air in from the second side of the exhaust component, and performing partial heating on the painted portion of the exhaust component that has been subjected to the blowing and drawing. The second side is the opposite side of the first side.

Description

Technical Field

[0001] The present disclosure relates to a method for manufacturing an exhaust component.

Background Art

[0002] As described in Patent Document 1, it is known to apply heat-resistant black paint to a baffle located around the exhaust outlet in a muffler.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, in recent years, reduction of CO2 emissions has been demanded for carbon neutrality, and reduction of energy loss in the manufacturing process of components is desired. One aspect of the present disclosure preferably reduces energy loss.

Means for Solving the Problems

[0005] One aspect of the present disclosure is a method for manufacturing an exhaust component mounted on a vehicle, including arranging an exhaust component having a painted portion, which is a painted part on a part of the outer surface, in a state where the painted portion is located on a first side; blowing air from the first side while sucking air from a second side of the exhaust component toward the exhaust component arranged in a state where the painted portion is located on the first side; and partially heating the painted portion of the exhaust component subjected to blowing and sucking. The second side is the opposite side of the first side.

[0006] According to the above configuration, moisture and organic matter can be removed from the painted area of ​​the exhaust component by blowing air and suction, thereby suppressing damage to the paint film caused by heating. This allows for rapid, localized heating of the painted area, reducing the energy required to heat it. Consequently, energy loss can be reduced.

[0007] In one aspect of this disclosure, the first side may be the upper side and the second side may be the lower side. With the above configuration, moisture and organic matter can be effectively removed from the painted parts of the exhaust components by blowing air and suction.

[0008] In one aspect of this disclosure, partial heating of the painted area may be performed by an infrared heater. According to the above configuration, the painted portion of the exhaust component can be heated effectively and partially. One aspect of the present disclosure may involve blowing and sucking air onto the exhaust component in a primary drying area, and partially heating the exhaust component in a secondary drying area. The method for manufacturing the exhaust component may further include: transporting the exhaust component, which has been blown and sucked air in the primary drying area, to a secondary drying area using a transport device; transporting the exhaust component, which has had its painted portion partially heated, from the secondary drying area to a cooling area using a transport device; and cooling the exhaust component, which has had its painted portion partially heated, in the cooling area.

[0009] The above configuration can reduce the burden on workers when manufacturing exhaust components. In one aspect of this disclosure, the exhaust component may include a muffler. According to the above configuration, energy loss can be reduced in the manufacturing process of exhaust components, including mufflers. [Brief explanation of the drawing]

[0010] [Figure 1] Figure 1A is an explanatory diagram of the exhaust components of the first embodiment. Figure 1B is an explanatory diagram of the partial drying apparatus of the first embodiment viewed from above. [Figure 2]This is an explanatory diagram of the primary drying process of the first embodiment. [Figure 3] This is an explanatory diagram of the secondary drying process of the first embodiment. [Figure 4] This is an explanatory diagram of a partial drying apparatus according to the second embodiment. [Modes for carrying out the invention]

[0011] Embodiments to which this disclosure applies will be described below with reference to the drawings. [1. First Embodiment] [(1) Exhaust parts] In the manufacturing method of the first embodiment, an exhaust component 1 is manufactured which is mounted on a vehicle and forms a passage for guiding exhaust gas from the engine to the outside (see Figure 1A). The exhaust component 1 includes, as an example, a muffler 10, a tailpipe 14, and an exhaust pipe 15.

[0012] The muffler 10 comprises a cylindrical main body portion 11 with a substantially elliptical cross-section, and first and second end plates 12 and 13 that cover the openings at both ends of the main body portion 11. The first end plate 12 is provided with an exhaust inlet to the muffler 10. The downstream opening of the exhaust pipe 15 is connected to this inlet.

[0013] The second end plate 13 is provided with an exhaust outlet from the muffler 10. A tailpipe 14 is connected to this outlet. Furthermore, the manufacturing method of the first embodiment may produce exhaust components having only a muffler 10, exhaust components having only a muffler 10 and a tailpipe 14, or exhaust components having only an exhaust pipe 15. In addition, the manufacturing method may produce exhaust components including an exhaust purification device (for example, a catalytic converter).

[0014] [(2) Overview of manufacturing methods for exhaust components] In the manufacturing method of the first embodiment, the exhaust component 1 is subjected to a painting process, an arrangement process, a primary drying process, a secondary drying process, and a cooling process in that order.

[0015] <Painting Process> In the painting process, the exhaust component 1 is painted (see FIG. 1A). In the first embodiment, as an example, a part of the outer surface of the exhaust component 1, namely, the tail pipe 14, the second end plate 13 of the muffler 10, and the main body portion 11, are painted black. Of course, the color of the paint is not limited to black, and for example, it may be silver or other colors. Also, the tail pipe 14 and the second end plate 13 may be painted. Regarding the main body portion 11, painting may be performed only on the portion located on the lower side when the exhaust component 1 is mounted on the vehicle.

[0016] [(3) Partial Drying Device] Following the painting process, the placement process, the primary drying process, the secondary drying process, and the cooling process are performed in this order, and through these processes, the paint applied to the exhaust component 1 in the painting process is dried. As a result, the portion painted in the painting process of the exhaust component 1 (in other words, the painted portion) hardens until a B rating is obtained in the pencil hardness test, for example. Also, these processes are automatically performed by the partial drying device 5 (see FIG. 1B). The partial drying device 5 includes a partitioning portion 50, four holding portions 51, and a rotating portion 52. Further, the partial drying device 5 is provided with a blower device 2, a suction device 3, and at least one infrared heater 4 (see FIGS. 2 and 3).

[0017] <Partitioning Portion> The partitioning portion 50 is a frame-shaped part that partitions the placement area 50A, the primary and secondary drying areas 50B and 50C, and the cooling area 50D (see FIG. 1B). In the placement area 50A, the primary drying area 50B, the secondary drying area 50C, and the cooling area 50D, the placement process, the primary drying process, the secondary drying process, and the cooling process are performed, respectively.

[0018] These areas are fan-shaped regions arranged circumferentially around the central axis 52A. More specifically, when viewed from above, these areas are arranged in the order of the placement area 50A, the primary drying area 50B, the secondary drying area 50C, and the cooling area 50D, in a counterclockwise direction to form a full circle. Also, as an example, the central angle of these areas is 90°.

[0019] Also, in these areas, the stop positions of the holding part 51 are defined, and an arrangement area is defined, which is an area that can be occupied by the exhaust part 1 placed on the holding part 51 at the stop position.

[0020] <Holding part> The holding part 51 is a plate-shaped member on which the exhaust part 1 is placed, and is arranged at the stop positions of each area (see Fig. 1B).

[0021] <Rotating part> The rotating part 52 includes a drive part (not shown) and an arm part (not shown) that supports each of the four holding parts 51 (see Fig. 1B).

[0022] During the operation of the partial drying device 5, work cycles arrive periodically. Note that the work cycle may continue for a predetermined time, for example, or each work cycle may be started or ended by an operator's operation.

[0023] When each work cycle ends, the rotating part 52 executes a rotation action. Specifically, in the rotation action, each holding part 51 supported by the arm part is rotated 90° counterclockwise around the rotating part 52 as viewed from above by the drive part. As a result, the holding part 51 at the stop position of each area moves to the stop position of the adjacent area, and then a new work cycle is started.

[0024] <Primary drying area> In the primary drying area 50B, the blower device 2 and the suction device 3 are arranged (see Fig. 2).

[0025] <Blower device> The blower device 2 comprises a blower section 20, a plurality of tubes 21, and a plurality of air outlets 22 (see Figure 2).

[0026] The air blower unit 20 is equipped with a motor and the like for generating airflow, and is positioned, for example, above the rotating unit 52. Multiple tubes 21 extend from the blower unit 20, and each tube 21 is provided with a cylindrical air outlet 22 at its tip. Each air outlet 22 is positioned above the area where the exhaust component 1 is located in the primary drying area 50B, facing downwards, in other words, facing the bottom 32A of the receiving portion 32 of the suction device 3, which will be described later. The air generated by the blower unit 20 is then released through each tube 21 and each air outlet 22, passes through the area where the exhaust component 1 is located, and heads towards the bottom 32A of the suction device 3.

[0027] <Suction device> The suction device 3 comprises a suction section 30, a plurality of tubes 31, and a receiving section 32 (see Figure 2).

[0028] The suction unit 30 is a part equipped with a motor or the like for sucking in air, and is located, for example, below the rotating unit 52. Multiple tubes 31 extend from the suction section 30.

[0029] The receiving portion 32 comprises a bottom portion 32A and a side wall portion 32B. The bottom portion 32A is a plate-shaped part located below the area where the exhaust component 1 is positioned, and facing upwards. In other words, the bottom portion 32A is positioned to face the multiple air outlets 22 of the blower 2 across the area where the exhaust component 1 is positioned. The bottom portion 32A is provided with multiple upward-facing openings, to which the ends of each tube 31 are connected.

[0030] The side wall portion 32B protrudes upward from the edge of the bottom portion 32A, sloping outward, and is provided to encircle the bottom portion 32A. For example, when viewed from the side, it has a tapered shape.

[0031] When the suction unit 30 is activated, the air in the area where the exhaust component 1 is located and its surroundings is drawn in, and the air flows toward each opening in the bottom 32A. <Secondary drying area> The secondary drying area 50C is provided with at least one (for example, multiple) infrared heaters 4 (see Figure 3). Each infrared heater 4 has an irradiation unit 40 that emits infrared rays and a reflector 41 provided on the back of the irradiation unit 40 that reflects infrared rays.

[0032] Some of these infrared heaters 4 are located above the area where the exhaust component 1 is to be placed in the secondary drying area 50C, and are positioned facing the area. The remaining infrared heaters 4 are positioned to the side of the area where the exhaust component 1 is to be placed, either flanking the exhaust component 1 or surrounding it, and facing the area.

[0033] [(4) From the placement process to the cooling process] Each step from the placement process to the cooling process is carried out in parallel in areas 50A to 50D of the partial drying apparatus 5 (see Figure 1B). Specifically, in each work cycle, the placement process is carried out by an operator in placement area 50A. In each work cycle, the partial drying apparatus 5 performs a primary drying process on the exhaust component 1 in the primary drying area 50B, a secondary drying process on the exhaust component 1 in the secondary drying area 50C, and a cooling process on the exhaust component 1 in the cooling area 50D. After the cooling process is completed, the exhaust component 1 is removed from the cooling area 50D by an operator.

[0034] Then, when each work cycle is completed, the partial drying apparatus 5 performs a rotation action to move the holding units 51 in each area 50A to 50D to the adjacent area. After that, when the next work cycle starts, the placement process is performed in the placement area 50A, as in the previous work cycle, and the partial drying apparatus 5 performs the corresponding processes in each area 50B to 50D. By repeating this process, the placement process and the cooling process are performed in parallel.

[0035] <Placement process> In the placement process, the worker places the exhaust component 1, which has been painted in the painting process, onto the holding section 51 in the placement area 50A (see Figure 1B). At this time, the exhaust component 1 is placed in the aforementioned placement area in the placement area 50A with the painted portion facing upwards.

[0036] Specifically, for example, if the tailpipe 14, the second end plate 13, and the main body 11 are painted, as in the first embodiment, the exhaust component 1 may be positioned with the tailpipe 14 and the second end plate 13 on the upper side.

[0037] Then, after the exhaust component 1 is placed on the holding unit 51 and the work cycle is completed, the partial drying device 5 performs a rotation action. As a result, the holding unit 51 with the exhaust component 1 placed on it, which is located in the placement area 50A, moves to the primary drying area 50B. Also, the holding unit 51 without the exhaust component 1 placed on it moves from the cooling area 50D to the placement area 50A.

[0038] <Primary drying process> In the primary drying process, the exhaust component 1, which is placed on the holding section 51 in the primary drying area 50B, is blown from above by the blower 2, and air is drawn in from below by the suction 3 (see Figure 2).

[0039] Air is blown from above to prevent the paint adhering to the painted surface of the exhaust component 1 located above from peeling off, while removing moisture and organic matter contained in the painted surface. The removed moisture and organic matter are then sucked up by the suction device 3 through multiple openings in the receiving section 32.

[0040] Then, when the work cycle is complete, the partial drying device 5 performs a rotation action. As a result, the holding unit 51 on which the exhaust component 1, which has undergone the primary drying process in the primary drying area 50B, is placed moves to the secondary drying area 50C. Also, the holding unit 51 on which the exhaust component 1 is placed, which is located in the placement area 50A, moves to the primary drying area 50B.

[0041] <Secondary drying process> In the secondary drying process, the painted portion of the exhaust component 1, which is placed on the holding portion 51 in the secondary drying area 50C, is partially heated by multiple infrared heaters 4 (see Figure 3). Each infrared heater 4 is positioned to face the painted portion of the exhaust component 1, which is the tailpipe 14, the second end plate 13, and the main body 11, and heats these parts. The temperature of the infrared heaters 4 is preferably higher than the air temperature in the primary drying process. Since moisture and organic matter contained in the painted portion have been removed in the primary drying process, the painted portion is heated efficiently. Note that partial heating of the painted portion may be performed by a heating device other than the infrared heaters 4. Alternatively, infrared and non-infrared heating devices may be used in combination.

[0042] Then, when the work cycle is complete, the partial drying device 5 performs a rotation action. As a result, the holding unit 51 on which the exhaust component 1, which has undergone the secondary drying process in the secondary drying area 50C, is placed moves to the cooling area 50D. Also, the holding unit 51 on which the exhaust component 1 is placed, which is located in the primary drying area 50B, moves to the secondary drying area 50C.

[0043] <Cooling process> In the cooling process, the exhaust component 1, which is placed on the holding unit 51 in the cooling area 50D, is cooled (see Figure 1B). That is, the partial drying apparatus 5 has a cooling unit (not shown), which automatically cools the exhaust component 1 that was heated in the secondary drying process. As an example, cooling may also be performed by blowing air from the cooling unit toward the exhaust component 1.

[0044] Furthermore, the partial drying device 5 stops cooling the exhaust component 1 before the work cycle is completed, and once the cooling stops, the worker removes the exhaust component 1 from the holding section 51 in the cooling area 50D.

[0045] Then, when the work cycle is complete, the partial drying device 5 performs a rotation action. As a result, the holding unit 51 that does not have the exhaust component 1 on it, located in the cooling area 50D, moves to the placement area 50A. Also, the holding unit 51 that has the exhaust component 1 on it, located in the secondary drying area 50C, moves to the cooling area 50D.

[0046] [2. Second Embodiment] The method for manufacturing the exhaust component 1 in the second embodiment differs from that of the first embodiment in the configuration of the partial drying apparatus 6 used in the manufacturing method (see Figure 4). Specifically, the partial drying apparatus 6 in the second embodiment includes a blower 2, a suction device 3, at least one infrared heater 4, and a cooling unit, similar to those in the first embodiment. Furthermore, the partial drying apparatus 6 has a single work area 60, where the process from placement to cooling is carried out.

[0047] In the second embodiment, the painting process is performed in the same manner as in the first embodiment. In the subsequent placement process, the exhaust component 1 is placed in the placement area of ​​the work area 60 in the same manner as in the first embodiment. Then, the partial drying apparatus 6 performs a primary drying process followed by a cooling process on the exhaust component 1 placed in the work area 60, in the same manner as in the first embodiment.

[0048] In the primary drying process, the blower 2 and suction device 3 are arranged in the work area 60 of the partial drying apparatus 6, in the same manner as in the first embodiment. The primary drying process is then carried out in the same manner as in the first embodiment.

[0049] Furthermore, in the secondary drying process, at least one infrared heater 4 is placed in the work area 60 of the partial drying apparatus 6, in the same manner as in the first embodiment. The secondary drying process is then carried out in the same manner as in the first embodiment.

[0050] Furthermore, in the cooling process, a cooling unit is arranged in the work area 60 of the partial drying apparatus 6 in the same manner as in the first embodiment. The cooling process is then carried out in the same manner as in the first embodiment. Once the cooling of exhaust component 1 in the cooling process is complete, the worker removes exhaust component 1 from the work area 60. Subsequently, the placement process and cooling process are repeated in the work area 60.

[0051] In each of these processes, the blower 2, the suction device 3, at least one infrared heater 4, and the cooling unit may be automatically positioned in the work area 60 by the partial drying device 6 at the start of each process, or they may be positioned manually.

[0052] Of course, multiple partial drying devices 6 may be provided, and the arrangement process and cooling process may be carried out in each partial drying device 6 so that the exhaust components 1 are manufactured in parallel in these partial drying devices 6.

[0053] [3. Effects] (1) According to the above embodiment, moisture and organic matter can be removed from the painted portion of the exhaust component 1 in the primary drying process. Therefore, even if the painted portion is rapidly heated, it is possible to suppress the paint from boiling, damaging the paint film, or igniting. As a result, it becomes possible to rapidly heat the painted portion in a partial area, and the energy and time required for drying can be reduced compared to, for example, when drying the painted portion using a hot air heater in a paint drying oven. Consequently, energy loss can be reduced, as can CO2 emissions and the manufacturing cost of the exhaust component 1. Furthermore, the cost of equipment for drying and the space required for the equipment can be reduced, as well as the risk of fire.

[0054] Furthermore, the exhaust component 1 is positioned so that the painted portion is on the upper side. By blowing air from above the painted portion while simultaneously drawing air in from below the exhaust component, moisture and organic matter can be effectively removed from the painted portion. This allows the painted portion to dry efficiently.

[0055] (2) In the secondary drying process, an infrared heater 4 is used to dry the painted area. This allows for even and localized heating of the painted area on the exhaust component 1. Furthermore, black paint is applied to the painted area. In other words, the black painted area easily absorbs the heat from the infrared heater 4, allowing the painted area to dry well in the secondary drying process.

[0056] (3) In the first embodiment, the partial drying apparatus 5 is provided with four areas 50A to 50D corresponding to the arrangement process, primary drying process, secondary drying process, and cooling process, and each process is carried out in the corresponding area. When the work cycle is completed, the rotating part 52 (in other words, the conveying device) of the partial drying apparatus 5 moves the exhaust components 1 located in each area to the area corresponding to the next process. This reduces the burden on the worker.

[0057] Furthermore, since the painted portion of the exhaust component 1 includes the tailpipe 14 and the portion of the muffler 10 where the tailpipe 14 is installed, when the exhaust component 1 is mounted on the vehicle, the appearance, especially from the rear of the vehicle, can be improved.

[0058] [4. Other Embodiments] (1) In the first and second embodiments, the paint on the exhaust component 1 is dried using partial drying devices 5 and 6. However, drying may be performed automatically using a device different from the partial drying devices 5 and 6, in the same manner as in the first and second embodiments, or drying may be performed in the same manner as in the first and second embodiments without using the partial drying devices.

[0059] (2) The partial drying apparatus of the first embodiment may have three areas: a primary drying area, a secondary drying area, and a cooling area. That is, each step from the placement step to the cooling step may be carried out in parallel in these three areas. When viewed from above, these areas may be arranged in a counterclockwise direction in the order of primary drying area, secondary drying area, and cooling area. The central angle of these regions may be 120° as an example.

[0060] Specifically, in each work cycle, the placement process and the primary drying process may be performed sequentially in the primary drying area. That is, in each work cycle, after the worker places the exhaust component 1 on the holding unit in the primary drying area, the partial drying device may dry the exhaust component 1 using the blower 2 and the suction device 3. In addition, in each work cycle, the partial drying device may perform a secondary drying process on the exhaust component 1 in the secondary drying area and a cooling process on the exhaust component 1 in the cooling area, in the same manner as in the first embodiment.

[0061] Then, when each work cycle is completed, the partial drying apparatus similarly performs a rotational action to move the holding section of each area to the adjacent area. Subsequently, when the next work cycle begins, the corresponding process may be performed in each area, as in the previous work cycle.

[0062] (3) In the first and second embodiments, the exhaust component 1 is positioned in the placement step with the painted portion on the upper side. However, the exhaust component 1 may be positioned with the painted portion on a first side different from the upper side. The first side may be, for example, the side or the lower side. In the primary drying step, air is blown from the blower 2 located on the first side of the exhaust component 1 toward the exhaust component 1, and air may be drawn in by the suction device 3 located on the second side of the exhaust component 1. The second side is the opposite side of the first side.

[0063] (4) Multiple functions of one component in the above embodiment may be realized by multiple components, or one function of one component may be realized by multiple components. Also, multiple functions of multiple components may be realized by one component, or one function realized by multiple components may be realized by one component. Furthermore, some of the configurations of the above embodiment may be omitted. Also, at least some of the configurations of the above embodiment may be added to or replaced with the configurations of other above embodiments.

[0064] [5. The technical concept disclosed herein] [Item 1] A method for manufacturing exhaust components installed in a vehicle, The exhaust component having a painted portion, which is a painted part on a part of its outer surface, is positioned such that the painted portion is located on the first side. With the painted portion positioned on the first side, air is blown from the first side toward the exhaust component, while air is drawn in from the second side of the exhaust component. The painted portion of the exhaust component, which has been subjected to the aforementioned blowing and suction, is partially heated. Equipped with, The second side is the opposite side of the first side. Manufacturing method for exhaust components.

[0065] [Item 2] A method for manufacturing exhaust components as described in item 1, The first side is the upper side, and the second side is the lower side. Manufacturing method for exhaust components.

[0066] [Item 3] A method for manufacturing exhaust components as described in item 1 or item 2, The partial heating of the painted area is performed by an infrared heater. Manufacturing method for exhaust components.

[0067] [Item 4] A method for manufacturing exhaust components as described in any one of items 1 to 3, The blowing and suction to the exhaust component are performed in the primary drying area. The partial heating of the exhaust component is performed in a secondary drying area. The conveying device conveys the exhaust components, which have undergone blowing and suction in the primary drying area, to the secondary drying area. The transport device transports the exhaust component, which has undergone the partial heating of the painted portion, from the secondary drying area to the cooling area. The cooling area is used to cool the exhaust component in which the painted portion has been partially heated, A method for manufacturing exhaust components that further enhances the functionality.

[0068] [Item 5] A method for manufacturing exhaust components as described in any one of items 1 to 4, The aforementioned exhaust components include the muffler. Manufacturing method for exhaust components. [Explanation of symbols]

[0069] 1...Exhaust parts, 10...Muffler, 11...Main body, 12...First end plate, 13...Second end plate, 14...Tailpipe, 15...Exhaust pipe, 2...Blower, 20...Blower section, 21...Tube, 22...Air outlet, 3...Suction device, 30...Suction section, 31...Tube, 32...Receiving section, 32A...Bottom section, 32B...Side wall section, 4...Infrared heater, 40...Irradiation section, 41...Reflector, 5...Partial drying device, 50...Compartment section, 50A...Placement area, 50B...Primary drying area, 50C...Secondary drying area, 50D...Cooling area, 51...Holding section, 52...Rotating section, 6...Partial drying device, 60...Work area.

Claims

1. A method for manufacturing exhaust components installed in a vehicle, The exhaust component having a painted portion, which is a painted part on a part of its outer surface, is positioned such that the painted portion is located on the first side. With the painted portion positioned on the first side, air is blown from the first side toward the exhaust component, while air is drawn in from the second side of the exhaust component. The painted portion of the exhaust component, which has been subjected to the aforementioned blowing and suction, is partially heated. Equipped with, The second side is the opposite side of the first side. Manufacturing method for exhaust components.

2. A method for manufacturing an exhaust component according to claim 1, The first side is the upper side, and the second side is the lower side. Manufacturing method for exhaust components.

3. A method for manufacturing an exhaust component according to claim 1 or claim 2, The partial heating of the painted area is performed by an infrared heater. Manufacturing method for exhaust components.

4. A method for manufacturing an exhaust component according to claim 1 or claim 2, The blowing and suction to the exhaust component are performed in the primary drying area. The partial heating of the exhaust component is performed in a secondary drying area. The conveying device conveys the exhaust components, which have undergone blowing and suction in the primary drying area, to the secondary drying area. The transport device transports the exhaust component, which has undergone the partial heating of the painted portion, from the secondary drying area to the cooling area. The cooling area is used to cool the exhaust component in which the painted portion has been partially heated, A method for manufacturing exhaust components that further enhances the functionality.

5. A method for manufacturing an exhaust component according to claim 1 or claim 2, The aforementioned exhaust components include the muffler. Manufacturing method for exhaust components.

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