Staged Mat Compression for Exhaust Gas Cleaning Catalysts
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Solution Overview
Problem
Existing methods for compressing mats wrapped around cylindrical catalysts in exhaust gas cleaning devices often result in the formation of convex sections, increasing labor and the risk of mat wedging, especially when dealing with varying catalyst diameters.
Innovation Solution
A method involving pressers divided into an even number, where odd-numbered pressers initially compress the mat, followed by even-numbered pressers to address convexities, ensuring a uniform compression without convex portions, and an apparatus with a primary and secondary drive mechanism to facilitate this process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If all pressers move forward simultaneously to compress the mat, then compression efficiency is improved, but convex sections are formed in the mat
Solution Approach 1:
The pressers are divided into two groups (odd-numbered and even-numbered pressers) that operate in sequence rather than simultaneously. The odd-numbered pressers first compress the mat, then the even-numbered pressers compress the remaining portions, preventing convex section formation while maintaining efficient compression through staged operation.
2Shape
If pressers are positioned close together to avoid gaps, then mat uniformity is improved, but the apparatus complexity increases
Solution Approach 1:
The pressers operate in periodic cycles where odd-numbered pressers advance first, then even-numbered pressers advance. This periodic operation allows pressers to be positioned at regular intervals (reducing apparatus complexity) while still achieving uniform mat compression through the sequential compression cycles.
3Shape
If multiple compression steps are used to eliminate convex sections, then mat uniformity is improved, but labor intensity increases
Solution Approach 1:
The compression system performs self-correction through its sequential operation. When odd-numbered pressers compress the mat, any convex sections that form are automatically compressed in the subsequent cycle by the even-numbered pressers, eliminating the need for separate manual flattening operations and reducing labor intensity.
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 convex section formation and reduces labor, allowing for efficient mat compression and wrapping around catalysts with varying diameters, minimizing the risk of mat wedging and simplifying the apparatus configuration.
Implementation Method 1
primarily compressing the mat by causing only odd-numbered ones of the pressers to move forward
Implementation Method 2
The mat 202 is then compressed until the outside diameter reaches d1
Implementation Method 3
Frictional force is generated between the pipe 203 and the mat 202 and between the catalyst 201 and the mat 202 due to the pressing force
Data Source
AI summary
An apparatus compresses a mat against a cylindrical catalyst to provide an exhaust gas cleaning device having the catalyst and the mat wrapped around the catalyst. The apparatus has a base to which first and second rods are movably mounted, and first and second pressers connected to respective ones of the first and second rods. A first drive mechanism moves the first, but not the second, rods to bring the first pressers into contact with first peripheral surface portions of the mat so that second peripheral surface portions of the mat are formed into respective convex portions. A second drive mechanism moves the second rods to bring the second pressers into contact with the convex portions of the mat to compress the convex portions while the first pressers are maintained in pressure contact with the first peripheral surface portions of the mat.