CN102215995A - 制造弯曲换热器的改进方法 - Google Patents

制造弯曲换热器的改进方法 Download PDF

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CN102215995A
CN102215995A CN2009801308905A CN200980130890A CN102215995A CN 102215995 A CN102215995 A CN 102215995A CN 2009801308905 A CN2009801308905 A CN 2009801308905A CN 200980130890 A CN200980130890 A CN 200980130890A CN 102215995 A CN102215995 A CN 102215995A
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axle
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D·E·萨木尔森
W·D·赖特
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Delphi Technologies Inc
Delphi Automotive Systems LLC
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D7/00—Bending rods, profiles, or tubes
    • B21D7/02—Bending rods, profiles, or tubes over a stationary forming member; by use of a swinging forming member or abutment
    • B21D7/024—Bending rods, profiles, or tubes over a stationary forming member; by use of a swinging forming member or abutment by a swinging forming member
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
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    • B21D11/10—Bending specially adapted to produce specific articles, e.g. leaf springs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D53/00—Making other particular articles
    • B21D53/02—Making other particular articles heat exchangers or parts thereof, e.g. radiators, condensers fins, headers
    • B21D53/08—Making other particular articles heat exchangers or parts thereof, e.g. radiators, condensers fins, headers of both metal tubes and sheet metal
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    • F28—HEAT EXCHANGE IN GENERAL
    • F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
    • F28D1/00—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
    • F28D1/02—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
    • F28D1/04—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 tubular conduits
    • F28D1/053—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 tubular conduits the conduits being straight
    • F28D1/0535—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 tubular conduits the conduits being straight the conduits having a non-circular cross-section
    • F28D1/05366—Assemblies of conduits connected to common headers, e.g. core type radiators
    • F28D1/05383—Assemblies of conduits connected to common headers, e.g. core type radiators with multiple rows of conduits or with multi-channel conduits
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
    • F28D1/00—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
    • F28D1/02—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
    • F28D2001/0253—Particular components
    • F28D2001/026—Cores
    • F28D2001/0273—Cores having special shape, e.g. curved, annular
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    • F28—HEAT EXCHANGE IN GENERAL
    • F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
    • F28D1/00—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
    • F28D1/02—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
    • F28D2001/0253—Particular components
    • F28D2001/026—Cores
    • F28D2001/028—Cores with empty spaces or with additional elements integrated into the cores
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/4935—Heat exchanger or boiler making

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Abstract

本发明涉及一种改进的弯曲装置，用于在没有设置管道或翅片的钎焊式换热器芯部的窗口处弯曲圆弧式转角。圆柱形心轴和滑动压力模具设计成在窗口区域完全围绕集管，且当弯曲力矩被施加时围绕集管提供一个连续的滚动接触区域或轮廓支承结构。

Description

制造弯曲换热器的改进方法
技术领域
本发明涉及用于弯曲钎焊式铝质换热器的方法及装置。其要求2008年8月8日提交的、美国临时专利申请NO.61/188440的优先权。
背景技术
钎焊式铝质换热器具有间隔设置的上水箱(或集管)、成波纹空气翅片或中心的扁平细长管，在汽车中具有普遍的应用，它们具有相对比较小的表面积和安装面，比如空气冷凝器。众所周知的是，将汽车热交换器弯曲成V或U形，如US4876778所示，但是这种弯曲方法相对简单而且直接，管和翅片(芯部表面)本身被垂直于管道而弯曲，而不是较重的集管本身，它们仍然保持直的状态。
芯部表面的该U或V形弯曲也可以用于静态的空调应用(比如住宅的热泵)，但是这种应用通常需要更加困难的弯曲操作，使得管道保持不弯、直的且垂直，而集管被弯曲成长方形。垂直的管道的排水性能更好，但是集管更重而且更难于弯曲。众所周知一些不同的弯曲装置和方法。一个典型的设备包括：在集管之间与芯部表面配合的实心圆柱形心轴、与外芯部表面和/或集管配合的对置的平夹板，所述平夹板的其中之一保持静置，而其他的被摆动而绕着圆柱形心轴使得芯部弯曲。芯部弯曲成90度的圆弧式转角。另一个问题是集管被弯曲时转角处的管或者翅片的形态。这些管或者翅片可能变弯或者变形，即使在性能上没有降低，也至少呈现一种美学缺陷。翅片还可在弯曲区域从管道拉离，降低了性能。这就限制了可以实现弯曲半径的紧或小的程度。
已公开的日本申请JP2005090806揭露了上述的基本弯曲结构，也披露了一些可以解决弯曲问题的现有手段。最基本的手段就是简单地去除(省去)转角处的管或翅片，然后用最后安装的某些挡板来遮盖住打开的窗口。芯部表面的热交换区域被除去相当数量时就显示了明显的缺陷，除了在转角处为了“填补”缺失的区域而需要增加某些挡板以及避免强气流在最小阻力路径上的干扰。如果弯曲装置或方法不允许有紧的急弯，则这尤其是一个问题，因为更多的管和翅片不得不被除去。任何工艺都没有披露将甚至没有管和翅片的集管弯曲成既紧又易于控制的圆弧式转角弯曲方法及装置。一种典型的弯曲装置在弯曲区域的一侧夹住芯部，将弯曲力施加到另外一侧，也可以穿过芯部区域或集管或者二者，但是没有措施用于有效地控制集管弯曲部分的轮廓和形状。
附图说明
本发明将被进一步的说明，参照如下附图：
图1是在弯曲之前具有芯部窗口的换热器的前视图和顶视图；
图2是图1的截面图；
图3所示为图2的换热器在弯曲之后的截面图；
图4所示为弯曲装置的立体图；
图5所示为同一弯曲装置的立体图，其中弯曲的换热器已就位；
图6所示为图5的截面图；
图7A-D所示为弯曲过程的先后步骤。
具体实施方式
根据本发明的一个优选的实施例，如图1-2所示，基本的、弯曲之前的芯部10被堆叠并钎焊。在图中，仅允许制出一个弯曲，但是可能包括两个或三个弯曲的区域，这些全都被相同的处理。芯部10包括一系列竖直定向的扁平挤压铝管道12，这些管道在互相平行的、上下圆柱形的铝质集管14之间延伸。集管14不必必然具有圆截面，尽管圆截面优选地用于抗压。成波纹的空气翅片或中心部16被焊接在相邻的管道12之间。芯部10是常规的，但是特意去除8或9个管道12用于留出敞开的窗口18，集管14上无槽长度大约为4英寸。这会根据芯部的尺寸而变化。在一个典型的芯部堆垛机器中，敞开的区域必须作出一些调节，从而间隔件用来暂时填充窗口18。在弯曲区域或转角处(最终将成为转角)存在窗口18本质上不是新的，本发明提供了一种新的装置和方法，其更好地利用窗口18以提供紧的、对称的、不变形的弯曲，且相邻管道12具有最小应力。
如图4、5、6所示，用于本发明的方法的改进的弯曲装置设计成仅施加弯曲力到集管14，且具体在弯曲区域对集管14提供附加的有效支承。中心柱20可以绕着其中心轴线旋转，该中心柱带着相同的上下半圆柱形弯曲心轴22，每个半圆柱形弯曲心轴都有以半圆柱形的上下槽边26、28为界的半圆柱形槽24。槽24沿其长度方向为半圆柱形，而其横截面集管14的轮廓相匹配。心轴22还有平直的衬垫夹具30，该衬垫夹具具有平直的槽32，该平直的槽具有与半圆柱形槽24相同的截面，以上下直边缘34、36为界。槽24、32的尺寸设计成可以紧密围绕集管14，上边26、34沿集管14中心线(12点时刻的位置)对齐，但是下边28、36正好可以从芯部10的内表面抽出。心轴22中的下心轴与上心轴是精确镜像对称的，因此术语“上边”、“下边”是可以互相颠倒的，尽管基本的形状是相同的。半圆柱形凸部38从半圆柱形心轴的下边28径向向内延伸，该半圆柱形凸部与上边26同心，并延伸足够的弧长以与位于窗口18内的集管14的那部分平直长度相等。一对压板模具40位于芯部10的相对侧，分别与每个心轴22相对，每个压板模具都有一个半圆柱形直槽42，该半圆柱形直槽在横截面上与心轴直槽32相同，以上边44、下边46为界。上边44也与集管14的中心线对齐，而下边46可从芯部10的外表面抽出。平直凸部48从下边46向内延伸，正好从每个模具40的末端开始，该平直凸部与上边44共面且具有与半圆柱形凸部38的弧长基本上相等的平直长度。一对夹板50分别置于与心轴衬垫夹具30的对面，都有一个横截面与心轴衬垫夹具的直槽32尺寸相等的、半圆柱形直槽52。
上述用于实施本发明的方法的设备的操作通过图7A-D加以说明。芯部10放置成：上下集管14位于在一对相对的夹板50和窗口18前侧的心轴衬垫夹具30之间。每个半圆柱形凸部38的前缘与窗口18的前缘对齐，压板模具40上的平直凸部48的前缘也与窗口18的前缘对齐。凸部38、48的两个前缘的位置用虚线标出，与柱20的转动轴线相交，也可以视为切线，代表了集管14的窗口部分在其被弯曲时持续运动通过的滚动点或区域。然后，上下集管14在一对相对的心轴衬垫夹具30和夹板50之间被紧紧地夹住，而压板模具40被移动至与夹板50相对齐。这使得凸部38、48的前缘在窗口18内进入夹持配合，以使得集管14在窗口18内那一部分的整个外部轮廓(内半部、外半部)紧密包含在环绕的槽24和42内。也就是说，在窗口18内，上边26、44被紧紧地夹在集管14的12点位置处，凸部38、48被紧紧地夹在集管的6点位置处。这在该区域提供了最大可能的对集管14的支承，较所公知的弯曲装置更大。
接下来，如图7A-7D所示，柱20被逆时针旋转，由此沿相同方向摆动心轴22，与心轴衬垫夹具30配合的夹板50沿相同方向以相同的枢轴摆动从而保持夹紧集管14。这用来将集管14的被窗口18环绕的部分拉到切线的右侧，并围绕心轴的半圆柱形槽24将该部分拉入心轴的半圆柱形槽24。同时，压板模具40直地、以足够的速度滑向左侧，以保持平直凸部48与半圆柱形凸部38滚动非滑动的接触，当集管14被弯曲为一个匹配的半径时，半圆柱形凸部38移入窗口18内，同时平直凸部48移出弯曲的窗口18。因此，在整个弯曲的过程中，集管14被移动弯曲的部分一直被槽26、42支承在上部槽边26、44与下部凸部边38、48之间，该上部槽边维持滚动接触，而该下部凸部边也维持滚动接触。在整个弯曲过程中，不断滚动的外部轮廓支承区域被置于虚线标出的切线的中间以维持其轮廓，将轮廓的内半部支承在一个槽中，并将轮廓的外半部支承在另一个槽中(上部和下部，如标出的所示，当然对于下部心轴22来说可以颠倒)。这既使得集管维持圆形轮廓，也能保护管道12与集管14的接合处，这是因为全部的弯曲力只施加于集管14。这也允许弯曲半径收紧。
虽然本发明已经以优选的实施例加以描述，但并不限于所描述的，而是延伸到下面所列出的权利要求里。从根本上讲，也是最简单的，本发明包含了支承在弯曲过程中位于窗口的开放区域的集管部分的整个轮廓，连接旋转的支承心轴内侧的圆柱形心轴，所述内侧具有理想的半径和弯曲时产生的内弧长，一对相对的支承集管部分的另一侧的平直压力模具，其沿着长度方向在它和圆柱形心轴中间以可以维持连续滚动接触的速度以作为弯曲力被应用，尽管被应用，直到弯曲完全完成。通过结合心轴上的平直衬垫夹具和相对的夹板，有一个附加的好处就是在弯曲区域的前部提供了一对夹紧零件。还有利的是，在弯曲的前侧支承更多的集管并通过衬垫夹具提供弯曲力，并用压力模具的附加长度将更多的集管支承在弯曲部的后侧，而非仅仅支承弯曲轮廓。由于插入管道，设在弯曲部前侧和后侧上的附加集管支承件不能支承集管轮廓的整个圆周，但是仍然具有优势。集管轮廓可以是圆形之外的形状，这就意味着不同的支承槽可以有不同的横截面与之匹配(方形或椭圆形)，但是滚动接触凸部给具有相同的基本结构的轮廓提供了全面的支承。

Claims (4)

1.一种制造管道—集管式换热器的方法，包括以下步骤：
提供管道—集管式换热器芯部，所述芯部具有上部集管、下部集管和多个基本平行且竖直的扁平管道，所述下部集管与所述上部集管隔开且大致平行于所述上部集管，所述多个管道在所述上部集管和下部集管之间延伸，其中，所述很多管道隔开来限定至少一个敞开的窗口，所述窗口被所述上部集管和下部集管的没有阻碍的部分所界围，从而限定所述芯部的预期弯曲区域；
提供可旋转的半圆柱形心轴，所述半圆柱形心轴限定所需弯曲半径并具有半圆柱形槽，所述半圆柱形槽的尺寸设计成足以在所需弯曲部位支承集管的整个内部轮廓；
提供可滑动的压力模具，所述压力模具与所述心轴相对并具有直槽，所述直槽的尺寸设计成足以在所需弯曲部位支承集管的整个外部轮廓；
在使所述心轴旋转并使所述压力模具沿所述集管的长度滑动的同时，施加弯曲力以使所述集管绕所述半圆柱形心轴弯曲，从而在所述心轴和所述压力模具之间保持滚动接触，以在所述集管弯曲时连续地支承所述集管的基本整个轮廓。
2.如权利要求2所述的方法，其特征在于，还包括以下步骤：通过在弯曲部位的前部将所述集管夹紧在一对夹紧零件之间并在所述心轴旋转时使所述夹紧零件绕所述心轴的枢轴摆动，来施加弯曲力。
3.如权利要求2所述的方法，其特征在于，还包括以下步骤：使所述夹紧零件中的一个夹紧零件一体设置于所述半圆柱形心轴，并同时使所述心轴旋转且使所述一个夹紧零件摆动。
4.如权利要求1所述的方法，其特征在于，还包括以下步骤：为滑动的压力模具提供一个附加长度，以在弯曲部位之后支承所述集管。
CN2009801308905A 2008-08-08 2009-08-06 制造弯曲换热器的改进方法 Pending CN102215995A (zh)

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