CN101600523A - 用于生产扁管的方法、轧机以及包括该扁管的热交换器 - Google Patents
用于生产扁管的方法、轧机以及包括该扁管的热交换器 Download PDFInfo
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B21C37/06—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape of tubes or metal hoses; Combined procedures for making tubes, e.g. for making multi-wall tubes
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B21C37/00—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape
- B21C37/06—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape of tubes or metal hoses; Combined procedures for making tubes, e.g. for making multi-wall tubes
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- B21D13/08—Corrugating sheet metal, rods or profiles; Bending sheet metal, rods or profiles into wave form by combined methods
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- F28D1/03—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid with plate-like or laminated conduits
- F28D1/0391—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid with plate-like or laminated conduits a single plate being bent to form one or more conduits
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Abstract
本发明涉及用于生产扁管的方法、轧机以及包括该扁管的热交换器。一种用于在装备有辊对的轧机上由至少一条连续带状材料(Bb)生产扁管的生产方法,所述扁管包括至少一个壁部(a)和波浪形内部部分(c)。所述内部部分(c)形成有褶皱,所述轧机设置有辊对,所述条经过所述辊沿纵向(LR)前进并成形,内部部分(c)在成形的壁部(a、b)之间形成有褶皱,随后,进行所述扁管的封闭。为了改善生产扁管的方法,形成沿所述条(c)的纵向(LR)延伸并间隔布置的细线(B),并且生产位于所述细线(B)中的褶皱波峰(Wb)和褶皱波谷(Wt)。
Description
技术领域
本发明涉及一种方法,用于在设有辊对(roller pair)的轧机上由至少一个无端(endless)带状材料条来生产扁管(flat tube),该带状材料条具有至少一个壁部并且具有形成有褶皱的内部部分,带沿着纵向延伸经过辊并且成形,形成有褶皱的内部部分被置于成形的壁部之间,此后进行扁管的封闭。本发明还涉及实现该方法的轧机以及具有所生产的扁管的热交换器。
背景技术
上述的方法步骤可以从在先专利申请(参考DE102006029378.9)获得。
生产扁管所需要的是这样的轧机:该轧机例如根据内部部分的期望几何形状或产生内部部分的“无端”条的期望几何形状可以延伸超过10-20m,这需要相当大的投资。上述文件的图16(在本申请中作为图22示出)指出了实质问题。如该图所示,在生产内部部分的褶皱70的过程中,条的宽度相应地减小并且褶皱70的数量增加,这因为需要大量辊对60而影响轧机的安装费用等。
DE19800096A1的图5同样存在许多辊对。该文件还描述了褶皱板的生产。
发明内容
本发明的目的在于提供一种简化扁管生产的方法,还可以相应地降低投资费用。
根据本发明,通过使用具有权利要求1的特征的生产方法实现上述目的。
该生产方法在具有权利要求11的特征的轧机上实现。轧机具有用于对至少一个无端的条进行成形的至少一个部分、用于连接所述条以形成管的部分以及用于管的分离台,并且所述轧机还进一步形成为使得所述轧机具有至少一个辊对,所述辊对可以用于产生沿所述条的纵向延伸的细线。所述轧机还具有至少一个辊对,通过该辊对形成位于带状细线处的褶皱波峰和褶皱波谷。
根据该方法的一个重要方面,形成沿条的纵向延伸并间隔布置的带状细线,随后产生位于带状细线处的褶皱波峰和褶皱波谷。由于带状细线,可以显著便于形成褶皱,因为可以更容易地(即,不费力地)形成褶皱波谷和褶皱波峰。带状细线有效地预先限定了带中应该弯折以产生褶皱波峰和褶皱波谷的地方。带状细线的深度例如可以在条厚度的50%的范围内。
根据另一方面,在形成带状细线之前或之后,在所述带状细线之间相对于其垂直或倾斜延伸的扰流器被在所述条的平面形成和/或从所述条的平面隆起。这提高了在扁管内部部分流动的介质与在外部围绕扁管流动的介质之间的热传递。扰流器可以是公知的从条的平面折起来的锯齿状突起,或者也可以是满足该目的的其他期望形状。但是,术语“扰流器”也应当理解为涵盖了在没有任何材料从条的平面隆起来情况下,在条中仅由位于带状细线之间的孔构成的设计。
另一方面,带状细线沿平行线形成。
优选地,带状细线交替地形成于一个条的上侧和下侧。但是,根据内部插入件的褶皱的几何形状,例如也可以在上侧提供两条带状细线之后在下侧形成两条带状细线。在每种情况下,形成一对的两条带状细线之间的间隔通常小于其到下一对带状细线之间的间隔。
但是,与此相反,所有的带状细线也可以形成于条的一侧。
对于安装费用而言,优选地通过单个辊对来形成所有的带状细线是有利的。
褶皱波峰和褶皱波谷还可以通过这样的辊对形成:条沿其纵向经过所述辊对延伸。褶皱延伸方向相对于条的纵向而言是横向的。扁管的壁部和形成有褶皱的内部部分可以是单个条的组成部分。与此相反,在一种优选实施例中,内部部分由第一个条形成,而壁部可以由第二个条形成或由第二个条和第三个条形成。
在提出的轧机上根据提出的生产方法可以提供的扁管可以从迄今为止尚未公开的德国专利申请DE102006006670.7而内部得知。该内部所知的扁管尤其适于进一步将板厚度降低到0.03-0.15mm的范围内。装备有这种类型的扁管的热交换器满足了需要,尤其是摩托车辆领域的需要。
扁管的两个窄边已经被加固。扁管的条的厚度为0.25mm或更小。这三个条的厚度可以相同。另外,形成壁的条的厚度可以小于0.25mm,例如0.12mm,而第三个条的厚度可以小于0.10mm。
三个条中每一个的厚度也可以在0.03mm-0.15mm的范围中,以提供具有良好热传递性能的高效低成本的热交换器。
内部部分设置有沿扁管的横向延伸的褶皱,并且形成沿扁管的纵向延伸的导管。这种类型的直褶皱极具性价比,并且简单易于实现。褶皱的形成方式使得褶皱侧部大体上垂直于宽边或仅具有较小的倾斜角度。
如果这种类型的扁管安装在冷却剂的冷却器中,则扁管的小径d在大约0.7mm到例如1.5mm的范围中。在中冷器(charge air cooler)中,小径d也可以大于10.0mm。大径D可以通过使用相应较宽的开始带状材料而在很大范围内自由确定。为生产更宽或更窄的扁管,可以调节辊。但是,优选地,代表优选管尺寸的各组辊是可以完全互换的。根据此方法生产的扁管因此还可以允许在相对宽(更深)或相对窄的冷却网的情况下高效低成本地生产热交换器。
附图说明
现在参考附图简要描述本发明的各种示例性实施例。示例性实施例的描述可能进一步突出了关键特征和优点。
图1示出了一种优选的扁管,内部部分插入其中。
图2示出优选的成品扁管的截面。
图3和4示出了轧机的简化细节。
图5-9示出了在该方法的过程中一个条上所发生的成形阶段,这些图沿着相对于条的纵向LR而言的横向。
图10-16示出具有不同扰流器的带有褶皱的条。
图17和18示出具有不同褶皱的条。
图19示出另一优选的扁管的生产工艺。
图20示出又一优选的扁管的生产工艺。
图21示意性示出轧机。
图22示出来自目前还没有公开的专利申请的现有技术。
具体实施方式
根据图1和2的优选实施例中的扁管的条a和b是相同的设计,但是它们的纵向边缘4沿横向彼此相反地布置。也就是说,条a和b的一个纵向边缘4设置有台阶10,该台阶10与小弧线11邻接,小弧线11形成下文中的窄边1;而另一纵向边缘仅设置有大弧线12(没有台阶),大弧线12形成下文中的另一窄边1,并且在各种情况下适于在下文的扁管中保持另外一个条a或b的小弧线11。在图1中,在没有完全生产出大弧线12的状态下示出条a或b。术语“弧线”并不仅仅意味着表示半圆。术语“弧线”还表示可以满足该目的的合适几何形状。
连接褶皱波峰Wb和褶皱波谷Wt的褶皱侧部被布置成仅仅稍微倾斜。内部部分c的两个纵向边缘如图2成形,使得其在内部抵靠扁管的窄边1并从而加固两个窄边1。在根据图2的示例性实施例中,每个窄边1的厚度因此对应于三个条a、b、c的厚度和。三个条a、b、c可以具有相同的厚度。三个条a、b、c中每一个的厚度尺寸可以在0.03mm-0.15mm的范围中。形成壁的条a、b优选地具有大约0.10mm-0.25mm之间的厚度尺寸,第三个条c的厚度尺寸大约在0.03-0.10mm之间。虽然这种板厚度较小,但扁管的两个窄边1也具有相当好的稳定度。
内部部分c的褶皱沿扁管的横向延伸,并且形成沿扁管的纵向延伸的管7。管7形成为不连续或开口的流动管7。管7的水力直径可以通过褶皱的相应设计来确定。如果扁管的小径d可以是大约0.8mm并且褶皱的数量较大,则所述水力直径比较小。
条a、b、c中的至少一些具有合适的焊料涂层,因为通过焊接方法(未示出)连接扁管的条a、b、c以及热交换器的整个冷却网。在示例性实施例中,扁管的条a、b、c由铝板材形成,该铝板材以无端的带状材料形式提供。
从引用的申请号为DE102006006670.7的在先申请中可以获得进一步细节,该申请的整个内容应当认为在此处已经示出和描述,以避免进一步的解释。
如图21中的示例性实施例所示并如上所述,使用三个板材金属带Bb(线圈)和三个条a、b、c。一个板材金属带Bb用来生产一个壁部a,另一个板材金属带用来生产第二个壁部b,第三个最宽的板材金属带Bb(图21中的中心)用来生产内部部分c。被解开缠绕的板材金属带Bb起初在允许带状材料有一定缓冲的滚动装置上前进。在图21中可以看出用作此目的的带状环。生产扁管从内部部分c的生产或成形开始。置于轧机开端附近的是至少一个辊对W1,其可以用于在仍为平面的条c中沿其纵向LR形成带状细线B,如图3或4中更详细示出。所述线B通过辊对W1而压制(emboss)。在该示例性实施例中,辊对W1具有的宽度使得全部带状细线B可以使用一个辊对W1产生。在本示例性实施例中,尤其在图5、6或7中还示出,带状细线B交替地形成在条c的上侧和下侧。该处设置有间隔开的单条线B。但是,线B也可以成对布置(见图18:B1、B2)。还可以在条c的一侧形成所有的带状细线B。这里,图5沿图4中的线V-V示出离开辊对W1后的条c。图6沿图4的线VI-VI示出离开下一个辊对W2后的条c,通过使用辊对W2,在带状细线B之间形成扰流器(turbulator)T。
图10-16示出布置在带状细线B之间的不同扰流器T。该扰流器T可以是从条c的平面折起来的凸出部分21或者切口20。扰流器T形成于仍为平面的带中,其中,应当指出,褶皱是在其后形成的。
返回到图21,从该图还可以看出,辊对W1和W2是轧机的第一成形部分U1的一部分。当条c离开辊对W2时,开始形成褶皱波峰Wb和褶皱波谷Wt,这是在下一个辊对W3的帮助下实现的,如图7和图8所示。如图7和8所示,褶皱波峰Wb或褶皱波谷Wt形成于每个带状细线B中。图9示出基本上半成品状态的内部部分c,但是,根据针对期望应用所设置的实体褶皱几何形状,其也可以是成品状态。在此图中,已经形成了褶皱波峰Wb和褶皱波谷Wt。
在轧机的上述第一成形部分U1中,也开始成形扁管的或条a和b的壁部的边缘4,虽然在图21中没有示出该成形的细节,但是根据图1中从上往下的第三插图可以理解。该插图示出当条a、b、c在连接部分V中时(即,当它们已经离开第一成形部分U1时)大致存在的情形,连接部分在图21中使用标号V表示。在条a、b、c彼此连接后,扁管在第二成形部分U2中封闭(图21),使得管的几何形状最终呈现为例如图2中所示的形状。各个管然后被修剪(切割成期望长度),为此目的,轧机具有分离部分A。如果条a、b、c在对应点处预先被穿孔或设置有预设的断点,则方便分离或提高了分离质量,为此目的,轧机装备有穿孔台P1、P2和P3。在该结合部分V中,确保单个条a、b、c中的预设断点在完全成形的管中位于完全相同的水平。预设断点同样可以是带状细线,但是与上述的带状细线B相反,相对于纵向LR而言是横向的(未示出)。
已经被切割成预定长度的扁管和褶皱翅片放置在一起,以形成热交换器的冷却网。冷却网或整个热交换器在焊炉中被焊接。这里,褶皱翅片被焊接到扁管,而扁管被焊接到它们的内部插入件(未示出)。已经证明,带状细线B在此焊接工艺中具有有利效果。
图17示出具有圆角的褶皱波峰Wb和褶皱波谷Wt的褶皱内部部分,而图18示出褶皱波峰和褶皱波谷为大致平的设计的内部部分c。两种褶皱都可以根据本生产方法而通过轧机提供。在根据图18的示例性实施例中,还可以为每个褶皱波峰Wb和褶皱波谷Wt提供两条带状细线B1和B2,在此情况下,然后在两条带状细线B1和B2中形成一条弯折线,本方案也可以包括此构造。
图19示出扁管的生产,其中仅提供了单一的条a用于形成扁管的壁。与上述示例性实施例相比,该条a被成形得更密集。这里,形成沿条a的纵向延伸的交叠30,然后在交叠30处形成弯折,此弯折形成扁管的窄边1。在此扁管中,第二个条c形成内部部分,后者按照上述进行生产。在图19中,上面三个插图示出条a的中间成形阶段。第四插图示出两个成形的条a和c的连接,而下面的插图示出成品扁管。该扁管也具有两个加固的窄边1。因此该扁管可以形成有非常小的壁厚。
两个加固窄边也适用于图20中所示的示例性实施例,图20以示意图的方式示出从单个条生产扁管的中间阶段。对条的两个部分进行成形,以形成壁部a,条的另一个部分构成形成有褶皱的内部部分c。褶皱都具有相同的褶皱高度(即使示意图给出了不同的印象),因为壁部a在此扁管中应该布置成彼此平行。在轧机上,工艺从由上述另一个部分生产带褶皱的内部部分c开始,其中,首先如上所述,压制出带状细线B,接着生产褶皱。接下来形成属于壁部a的交叠30。在图20的上方插图中可以看出现在所到达的状态。接着进行最后的管封闭,如虚线箭头所示。
Claims (16)
1.一种生产方法,用于在轧机上由至少一个无端的带状材料(Bb)条生产扁管,所述带状材料条具有至少一个壁部(a)并具有内部部分(c),所述内部部分(c)形成有褶皱,所述轧机设有辊对,所述条沿纵向(LR)延伸经过所述辊并被成形,形成有褶皱的所述内部部分(c)被置于成形的壁部(a、b)之间,随后,进行所述扁管的封闭;
其特征在于:形成沿所述条(c)的纵向(LR)延伸并间隔布置的细线(B),并生产位于所述细线(B)处的褶皱波峰(Wb)和褶皱波谷(Wt)。
2.如权利要求1所述的生产方法,其特征在于:所述内部部分(c)和所述壁部(a)是单个条的组成部分。
3.如权利要求1所述的生产方法,其特征在于:所述内部部分(c)由第一个条形成,而所述壁部(a)由第二个条形成。
4.如权利要求1所述的生产方法,其特征在于:所述内部部分(c)由第一个条形成,而所述壁部(a)由第二个条和第三个条(b)形成。
5.如权利要求1所述的生产方法,其特征在于:在形成所述细线(B)之前或之后,在所述细线(B)之间延伸的扰流器(T)被从所述条(c)的平面形成和/或隆起。
6.如上述权利要求中任一项所述的生产方法,其特征在于:所述细线(B)沿平行线形成。
7.如上述权利要求中任一项所述的生产方法,其特征在于:所述细线(B)交替地形成于所述条的上侧和下侧。
8.如权利要求1-6中任一项所述的生产方法,其特征在于:所述细线(B)全部形成于所述条(c)的一侧。
9.如上述权利要求中任一项所述的生产方法,其特征在于:所有所述细线(B)优选地通过单个辊对(W1)形成。
10.如上述权利要求中任一项所述的生产方法,其特征在于:所述褶皱波峰(Wb)和所述褶皱波谷(Wt)通过这样的辊对形成:所述条通过所述辊对沿其纵向前进。
11.一种轧机,用于根据上述方法权利要求中的至少一项而执行由至少一条无端的带状材料生产管(1)的方法,所述轧机具有用于成形所述条的至少一个部分(U)、用于连接所述条以形成管(1)的部分(V)、以及用于管(1)的分离台(A),并且所述轧机具有至少一个辊对(W1),所述至少一个辊对能够用于产生沿所述条(c)的纵向延伸的细线(B)。
13.如权利要求12所述的轧机,其特征在于:所述穿孔台(P)的数量优选为对应于所述条的数量。
14.如权利要求11所述的轧机,其特征在于:所述轧机具有用于在所述一个条(c)上形成扰流器(T)或孔的至少一个辊对(W2)。
15.如权利要求11所述的轧机,其特征在于设置有至少一个辊对(W3),通过所述辊对(W3)形成位于所述细线(B)处的褶皱波峰(Wb)和褶皱波谷(Wt)。
16.一种热交换器,尤其是用于机动车辆的热交换器,具有由扁管和褶皱翅片构成的冷却网,其特征在于:所述扁管根据上述权利要求中至少一项而形成或生产。
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-
2007
- 2007-02-01 DE DE102007004993A patent/DE102007004993A1/de not_active Withdrawn
-
2008
- 2008-01-16 EP EP10008153A patent/EP2251115A1/de not_active Withdrawn
- 2008-01-16 CN CN200880003890.4A patent/CN101600523A/zh active Pending
- 2008-01-16 WO PCT/EP2008/000288 patent/WO2008092563A1/de active Application Filing
- 2008-01-16 EP EP08701132A patent/EP2117742B1/de not_active Expired - Fee Related
- 2008-01-16 BR BRPI0806839-9A2A patent/BRPI0806839A2/pt not_active IP Right Cessation
- 2008-01-16 DE DE502008001525T patent/DE502008001525D1/de active Active
-
2009
- 2009-08-03 US US12/534,654 patent/US8561451B2/en not_active Expired - Fee Related
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Also Published As
Publication number | Publication date |
---|---|
EP2117742B1 (de) | 2010-10-13 |
DE502008001525D1 (de) | 2010-11-25 |
US20100024508A1 (en) | 2010-02-04 |
EP2251115A1 (de) | 2010-11-17 |
WO2008092563A1 (de) | 2008-08-07 |
BRPI0806839A2 (pt) | 2014-12-23 |
EP2117742A1 (de) | 2009-11-18 |
DE102007004993A1 (de) | 2008-08-07 |
US8561451B2 (en) | 2013-10-22 |
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Application publication date: 20091209 |