Metal Catalyst Support Manufacturing Apparatus
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Solution Overview
Problem
Conventional metal catalyst supports for exhaust gas treatment, particularly in ship SCR systems, face challenges with complex assembly structures, low productivity, and susceptibility to deformation due to external vibrations and temperature changes, as they require separate cutting steps for shape matching and use of bonding methods like brazing or welding.
Innovation Solution
A manufacturing apparatus that aligns and shapes corrugated plates to have coinciding vertexes, eliminating the need for separate cutting steps by using a transfer unit, shaping rollers, and a position aligning unit with sensors and control systems to ensure consistent corrugated plate formation, allowing for direct assembly without bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional joining methods such as brazing, welding, soldering, or diffusion bonding are used to fabricate integrated wave plate/flat plate assemblies, then the structural integrity of the metal support is improved, but productivity decreases and price competitiveness is reduced
Solution Approach 1:
The support structure is divided into separate wave plates and flat plates that are not joined together, eliminating the need for bonding processes. Each plate type can be manufactured independently and then assembled without requiring brazing, welding, soldering, or diffusion bonding, thereby maintaining structural integrity while significantly improving productivity and reducing costs.
2Device complexity
If wave plates and flat plates are alternately stacked without aligning vertexes, then the assembly process is simplified, but the structure becomes susceptible to deformation due to external vibration, shock, or temperature change
Solution Approach 1:
The wave plates are pre-formed with protruding vertexes that are designed to fit into recesses of adjacent plates. This preliminary shaping of the vertexes enables automatic alignment and stable stacking without requiring complex assembly procedures, while simultaneously providing resistance to deformation from external vibrations, shocks, or temperature changes through the interlocking vertex structure.
3Manufacturing precision
If separate cutting steps are used to match the shapes of corrugated plates, then manufacturing precision is improved, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The corrugated plates are pre-formed with identical shapes and standardized vertex configurations during the initial manufacturing process. This preliminary standardization eliminates the need for subsequent cutting or shape-matching operations, as all plates are designed to fit together directly through their standardized geometries, thereby maintaining high manufacturing precision while significantly reducing production time and process complexity.
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 approach minimizes deformation and enhances the manufacturing efficiency by eliminating the need for separate cutting steps, improving the structural integrity and assembly precision of the metal catalyst support, thus reducing production costs and maintaining mechanical properties.
Implementation Method 1
a first shaping roller and a second shaping roller which are rotatably engaged with each other such that first and second corrugated portions are repeatedly formed in plate members which are transferred by the transfer unit
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
Provided is a metal catalyst support comprising a case having a space through which exhaust gas passes; and flat plates and corrugated plates which are alternately stacked in the case and coated with a catalyst. The corrugated plates are formed such that a first corrugated plate and a second corrugated plate are disposed with the flat plate therebetween, the first corrugated plate and the second corrugated plate are disposed such that a first corrugated portion and a second corrugated portion are alternately and repeatedly formed, and the vertex of the first corrugated portion and the vertex of the second corrugated portion face and coincide with each other.