Honeycomb Body Skin Layer Defect Detection
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Solution Overview
Problem
Conventional methods fail to detect defects in the skin layer of honeycomb structural bodies, leading to unnecessary catalyst consumption and increased manufacturing costs due to leaks, as they cannot identify cracks and holes in the skin layer during the catalyst supporting process.
Innovation Solution
A method involving sealing both ends of the honeycomb structural body, supplying compressed gas through it, and using microphones to detect leaks from the skin layer, allowing for the judgment of defects like holes and cracks based on the magnitude of the detected sounds, enabling reliable detection of defects in the skin layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional detection methods are used to detect defects in honeycomb structural bodies, then defects in the cell walls can be detected, but defects in the skin layer cannot be detected
Solution Approach 1:
The detection method segments the detection process into two distinct phases: first detecting cell wall defects by supplying gas to the cell interior, then detecting skin layer defects by supplying gas to the cell exterior. This segmentation allows each detection phase to target specific defect locations, resolving the contradiction between detecting cell wall defects and skin layer defects.
Solution Approach 2:
The invention inverts the conventional detection approach by reversing the gas supply direction. Instead of only supplying gas from the inlet to detect cell wall defects, the method also supplies gas from the outlet side to detect skin layer defects. This inversion enables detection of previously undetectable defects in the skin layer.
2Productivity
If defects in the skin layer are not detected, then the manufacturing process continues, but catalysts are wasted and manufacturing costs increase
Solution Approach 1:
The detection method performs preliminary detection of skin layer defects before the catalyst supporting process begins. By detecting defects in advance through gas supply and acoustic emission monitoring, the system identifies defective products early, preventing unnecessary catalyst application on defective substrates and avoiding subsequent waste.
Solution Approach 2:
The system implements feedback control by using acoustic sensors to detect gas leakage sounds during the detection phase. When defects are detected through acoustic emission signals, the system provides feedback to stop the manufacturing process, preventing catalyst waste and reducing manufacturing costs.
3Measurement precision
If gas is supplied to detect skin layer defects, then defects can be identified, but the detection system becomes more complex
Solution Approach 1:
The detection system uses the product itself (the honeycomb structural body) as part of the detection mechanism. By supplying gas through the product's own structure and using acoustic sensors to listen for leakage, the system leverages the product's inherent properties for self-detection, avoiding the need for additional complex external testing equipment.
Solution Approach 2:
The invention employs pneumatic principles by supplying compressed gas through the honeycomb structural body and detecting defects through acoustic emissions caused by gas leakage. This pneumatic approach provides a simple yet effective detection mechanism that identifies skin layer defects without requiring complex imaging or scanning systems.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method effectively detects defects in the skin layer, reducing catalyst wastage and manufacturing costs by accurately identifying holes and cracks, thereby improving the quality and efficiency of the honeycomb structural body production process.
Implementation Method 1
detecting sounds of gas leaking from the skin layer of the honeycomb structural body by using one or more microphones arranged at an outer periphery of the skin layer
Data Source
AI summary
In a method of detecting defects generated in a honeycomb structural body, both end sections of the honeycomb structural body is sealed along a flowing direction of exhaust gas. Air is supplied in the flowing direction of the exhaust gas from one end section to the other end section of the honeycomb structural body. Microphones are arranged at outer periphery of the honeycomb structural body and detect sounds of air leaking from a skin layer of the honeycomb structural body. A judgment step judges whether or not defects such as holes having not less than a predetermined diameter and cracks are generated on the basis of a magnitude of the detected sounds of the leaking air.