Plugged Honeycomb Structure Perforation Method
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Solution Overview
Problem
The existing methods for producing plugged honeycomb structures fail to accurately recognize and plug outermost circumferential cells, leading to untrapped particulate matter and increased production costs due to slurry adherence issues with adjacent cells and the circumferential wall.
Innovation Solution
A method involving image processing to recognize usual cells and calculating positions for outermost circumferential cells from an average cell pitch, with virtual perforation regions divided into squares for precise perforation, ensuring holes are within the cell's open range to prevent slurry leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If image processing is used to recognize cell positions, then usual cells can be accurately identified, but outermost circumferential cells are not recognized due to their cut-off shape and reduced area
Solution Approach 1:
The patent segments the cell recognition process into two distinct methods: image processing for usual cells and geometric calculation for outermost circumferential cells. This segmentation allows each method to be optimized for its specific target, resolving the contradiction between accurate usual cell identification and reliable outermost cell detection.
Solution Approach 2:
The patent creates a virtual model of the honeycomb structure with calculated cell positions based on geometric parameters. This virtual copy serves as a reference to identify outermost circumferential cells that cannot be detected by image processing, complementing the actual image data.
2Manufacturing precision
If perforation processing is performed at calculated outermost circumferential cell positions, then plugging can be achieved, but plugging slurry adheres to adjacent cells and circumferential walls
Solution Approach 1:
The patent applies different processing strategies to different cell types: image processing for usual cells and calculated geometric positioning for outermost circumferential cells. This local quality approach ensures that each cell type receives the most appropriate treatment method for its specific characteristics.
Solution Approach 2:
The patent performs preliminary calculation of outermost circumferential cell positions using geometric parameters before performing perforation processing. This preliminary action allows for precise positioning and prevents slurry adherence issues by ensuring holes are made only within the actual cell boundaries.
3Ease of manufacture
If the outermost circumferential cell is not plugged, then production issues are avoided, but particulate matter passes through untrapped reducing filter performance
Solution Approach 1:
The patent segments the cell population into usual cells and outermost circumferential cells, applying appropriate plugging strategies to each segment. This ensures that outermost cells are properly plugged to maintain filter performance while usual cells follow the standard plugging process.
Solution Approach 2:
The patent uses a calculated virtual model to identify and plug outermost circumferential cells that would otherwise be missed by image processing alone, ensuring complete filter performance without complicating the actual manufacturing process.
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 prevents slurry adherence to adjacent cells and the circumferential wall, reducing production steps and costs by ensuring accurate plugging of outermost circumferential cells, thereby enhancing filter performance.
Implementation Method 1
the image of the end face of the honeycomb structure imaged with a CCD (charge-coupled device) camera or the like is first subjected to binarization processing
Implementation Method 2
perforation processing is performed by laser processing or the like at positions on the above sheet which correspond to the cells to be plugged
Data Source
AI summary
The present invention includes recognizing, as positions of outermost circumferential cells, positions each of which is calculated from an average cell pitch of usual cells and each of which is present on an inner side from a circumference of an end face of a honeycomb structure; disposing, on the basis of the recognition, virtual perforation regions at positions on a sheet which correspond to the outermost circumferential cells to be plugged, each of the virtual perforation regions being divided into a plurality of squares; and performing perforation processing of perforating at least one of a plurality of squares in each of the virtual perforation regions. Positions and a number of squares to be perforated in each of the virtual perforation regions are individually set in accordance with each of the positions of the outermost circumferential cells to be plugged to which each of the virtual perforation regions corresponds.