CN212264809U - Heat exchanger automatic weld intelligence control system - Google Patents
Heat exchanger automatic weld intelligence control system Download PDFInfo
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- CN212264809U CN212264809U CN202020748908.1U CN202020748908U CN212264809U CN 212264809 U CN212264809 U CN 212264809U CN 202020748908 U CN202020748908 U CN 202020748908U CN 212264809 U CN212264809 U CN 212264809U
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Abstract
The utility model relates to the technical field of heat exchangers, in particular to an automatic welding intelligent control system of a heat exchanger, which comprises a controller and a conveyer belt, wherein the conveyer belt is sequentially provided with a clamping station, a welding agent coating station, a welding station, a cooling station and a discharging station along the conveying direction, and the clamping station comprises a clamping device for clamping the heat exchanger and a position sensor for detecting the position of the heat exchanger; the flux coating station comprises a flux storage tank, an auxiliary agent detection device and a flux brush which are sequentially communicated; the welding station comprises a welding flux conveying device, a temperature sensing instrument, a distance measuring instrument, a flame welding gun group and an air source assembly, the air source assembly is correspondingly communicated with the flame welding gun group, and an auxiliary monitoring device and an electromagnetic valve are communicated between the air source assembly and the flame welding gun group.
Description
Technical Field
The utility model relates to a heat exchanger technical field, concretely relates to heat exchanger automatic weld intelligence control system.
Background
The heat exchanger is generally connected by metal pipelines, and in order to ensure that media (such as refrigerant and the like) flowing in the heat exchanger do not leak, the metal pipeline connection needs to be sealed, except for a general fastening tension connection mode (such as a Rockwell ring), the metal pipelines (made of the same or different materials) at the connection part of the heat exchanger are heated or pressurized or used together with the metal pipelines and filled or not, so that the materials of workpieces are combined among atoms to form a permanent connection process. Such as resistance welding, flame welding, fusion welding, etc., are common methods for metal joining in the industry.
Although different methods can be adopted for welding, the quality of a welded part after welding, such as welding strength, welding sealing performance, welding oxidation condition and the like, needs to be ensured through a welding process, because a metal pipeline after welding cannot be restored to a state before welding, and quality problems occur after welding for reworking, so that a large amount of manpower and material resources are consumed, and the quality of secondary welding is more difficult to ensure. The quality of the welded area is therefore only ensured by a strict process control during a single welding operation.
There are many factors that affect the quality of the welded part, such as the material of the metal pipeline, the fit clearance, the choice of welding material, the temperature during welding, the welding time, etc., and as long as one of the factors changes, the quality of the welding department will be affected.
For the welding of a specific heat exchanger, the material, the fit clearance, the selection of welding materials and the like of the welded metal pipeline are determined, and the rest is the welding construction process. Because the temperature, flame and the like generated during welding affect the working strength of people, such as the increase of heat to human fatigue, the stimulation of bright flame to human eyes and the like, which all affect the quality assurance of manual welding. Meanwhile, the supply of the welding flux, the welding temperature, the welding time and the like are all affected by human factors, and the quality inconsistency of the welding part is increased.
SUMMERY OF THE UTILITY MODEL
An object of the utility model is to the not enough among the prior art, and provide a heat exchanger automatic weld intelligence control system, guarantee welding quality, reduce the influence of human factor to welding position quality, improve welded production efficiency simultaneously.
The purpose of the utility model is realized through the following technical scheme: the application provides an automatic welding intelligent control system of a heat exchanger, which comprises a controller and a conveying belt, wherein the conveying belt is sequentially provided with a clamping station, a welding agent coating station, a welding station, a cooling station and a discharging station along the conveying direction; the clamping station comprises a clamping device for clamping the heat exchanger and a position sensor for detecting the position of the heat exchanger, and the clamping device and the position sensor are electrically connected with and controlled by the controller; the flux coating station comprises a flux storage tank, an auxiliary agent detection device and a flux brush which are sequentially communicated, wherein the flux storage tank, the auxiliary agent detection device and the flux brush are all electrically connected with and controlled by the controller; the welding station comprises a welding flux conveying device, a temperature sensing instrument, a distance measuring instrument, a flame welding gun group and an air source assembly, wherein the welding flux conveying device, the temperature sensing instrument, the distance measuring instrument, the flame welding gun group and the air source assembly are positioned above the conveying belt; the cooling station comprises a fan positioned above the conveying belt, and the fan is electrically connected with and controlled by the controller; the unloading station is positioned at the tail end of the conveying belt.
Wherein, the conveyer belt includes the motor of drive conveyer belt operation.
The auxiliary agent detection device comprises an auxiliary agent pressure gauge, an auxiliary agent flow meter, an auxiliary agent electromagnetic valve and a driving pump for conveying the combined welding agent.
The soldering flux storage tank is also provided with a soldering flux liquid level indicator for detecting the liquid level in the soldering flux storage tank, and the soldering flux liquid level indicator is electrically connected with the controller and is controlled by the controller.
Wherein, the gas source subassembly includes oxygen source and the combustible gas source of hydrocarbon.
Wherein, the cooling station still is provided with the cooling station distancer that is used for detecting the heat exchanger distance.
Treat software personnel programming back, the beneficial effects of the utility model: the application provides an automatic welding intelligent control system of a heat exchanger, compared with the prior art, the automatic welding intelligent control system solves the problem of incapability of automatic welding, is particularly suitable for automatic welding of a plurality of parallel pipelines with small pipe diameters, simultaneously realizes intelligent control of the welding temperature of the pipelines through control of welding flame, solves the artificial operation factor of manual welding, ensures the welding quality, and in addition, forms a production line by a plurality of welding procedures (online, flux coating, welding and offline) to realize automation and intelligence, improves the production efficiency, lightens the labor intensity of manual welding, can collect, analyze and calculate and control related equipment through a controller after software personnel are programmed, realizes control integration of all process links, and enables data to be electronized, Networking;
drawings
The present invention is further explained by using the drawings, but the embodiments in the drawings do not constitute any limitation to the present invention, and for those skilled in the art, other drawings can be obtained according to the following drawings without any inventive work.
Fig. 1 is the utility model discloses a heat exchanger automatic weld intelligence control system's schematic structure diagram.
Fig. 2 is a schematic view of the overall structure of the heat exchanger of the present application in embodiment 1.
Fig. 3 is a schematic structural diagram of the inner diameter of the parallel pipeline pipes, the outer diameter of the parallel pipeline pipes, and the pipe spacing in embodiment 1.
Fig. 4 is a schematic view of the parallel tube fin structure in embodiment 1.
FIG. 5 is a schematic diagram of a structure in which a plurality of parallel lines are arranged in parallel in example 1.
FIG. 6 is a schematic diagram of the structure of the embodiment 1 in which multiple parallel pipes are arranged in a staggered manner
Fig. 7 is a schematic view of the overall structure of the heat exchanger according to the present application in embodiment 2.
Fig. 8 is a schematic structural diagram of the inner diameter of the parallel pipeline pipes, the outer diameter of the parallel pipeline pipes, and the pipe spacing in embodiment 2.
FIG. 9 is a schematic diagram of a structure in which a plurality of parallel lines are arranged in parallel according to example 2.
Fig. 10 is a schematic structural view of the embodiment 2 in which a plurality of parallel pipes are arranged in a staggered manner.
Detailed Description
The invention will be further described with reference to the following examples.
Example 1
The utility model discloses a heat exchanger automatic weld intelligence control system's embodiment, as shown in fig. 1, including controller 1 and conveyer belt 5, conveyer belt 5 has set gradually centre gripping station, solder coating station, welding station, cooling station and has rolled off the production line station along direction of delivery. The conveyor belt 5 includes a motor 6 that drives the conveyor belt 5 in operation. The conveying belt 5 and the motor 6 form a movable power source for welding the heat exchanger 4, and the heat exchanger 4 smoothly and horizontally moves on the conveying belt 5 to keep the conveying stability of the heat exchanger 4. Motor 6 is connected with controller 1 electricity, and motor 6's rotational speed is controlled by controller 1 to guarantee that controller 1 can the accurate control conveyer belt 5 transport heat exchanger 4, improve welded quality.
In this embodiment, the clamping station includes a clamping device for clamping the heat exchanger 4 and a position sensor for detecting the position of the heat exchanger 4, and both the clamping device and the position sensor are electrically connected to the controller 1 and controlled by the controller 1. The clamping station mainly automatically clamps the heat exchanger 4 to ensure that the welded pipeline required by the heat exchanger 4 is in a fixed position.
In this embodiment, the flux coating station includes a flux storage tank 3, an auxiliary agent detection device 7 and a flux brush 8 located above the conveyor belt 5, which are sequentially communicated with each other, and the flux storage tank, the auxiliary agent detection device 7 and the flux brush 8 are all electrically connected to the controller 1 and controlled by the controller 1. Specifically, the auxiliary agent detection device 7 includes an auxiliary agent pressure gauge, an auxiliary agent flow meter, an auxiliary agent electromagnetic valve, and a drive pump for conveying the flux. The flux coating station is mainly used for automatically coating the soldering flux on the welding part required by the heat exchanger 4, so that the flux coating amount and the uniformity of the soldering flux at the welding part of the heat exchanger 4 are ensured, and the consistency of the welding quality is improved. It should be noted that the height matching between the soldering flux brush 8 and the heat exchanger 4 is controlled by a motor screw or a cylinder (oil cylinder), a push rod, a travel switch, etc., and such a brush head driving control manner is an existing control manner, which will be obvious to those skilled in the art.
In this embodiment, the soldering station includes a solder delivery device 9 located above the conveyor belt 5, a temperature sensor 10 for detecting the soldering temperature, a distance meter for detecting the soldering distance, a flame torch assembly 11, and a gas source assembly, which in this embodiment includes an oxygen source 13 and a hydrocarbon combustible gas source 14. The gas source assembly is correspondingly communicated with the flame welding gun group 11, an auxiliary monitoring device and an electromagnetic valve are communicated between the gas source assembly and the flame welding gun group, and the solder conveying device 9, the temperature sensing instrument 10, the distance measuring instrument, the auxiliary monitoring device and the electromagnetic valve are all electrically connected with the controller 1 and controlled by the controller 1. It should be noted that the flame welding gun set 11 includes a plurality of flame welding guns, and mainly completes the flame preheating of the welding pipeline, the supplying of the solder for heating, fusion welding and the heating for forming the capillary phenomenon of welding, the detection of the temperature of the welding pipeline for preheating, and the control of the pressure gauge and the flow meter in the process of delivering the oxygen source 13 and the hydrocarbon combustible gas source 14 by the controller 1, so as to enable the welding flame to preheat the welding pipeline to the proper temperature. It should be noted that the matching of the distance size between the flame welding gun set 11 and the heat exchanger 4 is controlled by a motor screw rod or a cylinder (oil cylinder), a push rod, a travel switch and the like. The control of the operation of the torch assembly 11 is conventional and will be apparent to those skilled in the art.
In this embodiment, the cooling station includes a fan 12 located above the conveyor belt 5, and the fan 12 is electrically connected to the controller 1 and controlled by the controller 1. The cooling station mainly adopts forced air blowing to the welding part of the heat exchanger 4 to cool the surface of the welding part of the heat exchanger 4. Wherein, the cooling station still is provided with the cooling station distancer that is used for detecting 4 distances of heat exchanger. The distancer can guarantee that scaling powder brush 8 can evenly paint the scaling powder to heat exchanger 4 welding area. Similarly, the matching of the height of the fan 12 and the heat exchanger 4 is controlled by a motor screw rod or a cylinder (oil cylinder), a push rod, a travel switch and the like. The off-line station is positioned at the tail end of the conveyer belt 5, the clamping of the heat exchanger 4 is released, so that the heat exchanger 4 is welded off-line and enters the next procedure.
In this embodiment, the soldering flux storage tank 3 is further provided with a soldering flux liquid level indicator 2 for detecting the liquid level in the soldering flux storage tank 3, and the soldering flux liquid level indicator 2 is electrically connected with the controller 1 and controlled by the controller 1. Like this, the memory space of scaling powder passes through scaling powder liquid level indicator 2 in scaling powder storage tank 3 and detects to receive controller 1 early warning and instruction, when preventing that the scaling powder surplus is not enough and carry out welding operation again, influence welding quality.
In order to further improve the automation degree of the control system, the controller 1 is also electrically connected with a wireless communication module, and the parameters of the controller 1 can be adjusted and read through wireless transmission, so that the information is networked and digitalized.
After the software personnel programs, the automatic welding intelligent control system of the heat exchanger of the embodiment solves the problem of incapability of automatic welding, is particularly suitable for automatic welding of a plurality of parallel pipelines with small pipe diameters, simultaneously realizes intelligent control of the welding temperature of the pipelines by controlling welding flame, solves the artificial operation factor of manual welding, thereby ensuring the welding quality, and in addition, forms a production line by a plurality of welding procedures (online, flux coating, welding and offline) to realize automation and intelligence, improves the production efficiency, lightens the labor intensity of manual welding, can also collect, analyze and operate various parameters (rhythm, flow, pressure, liquid level and the like) of the welding process through the controller 1 and control integration of all process links after the software personnel programs, and the data is electronized and networked. The controller 1 can remotely transmit the equipment parameters, the running state, the production data and the like through a network through a wireless network or a wired network, thereby realizing remote monitoring and management of the equipment.
The embodiment provides a welding process, which comprises the following steps that A, a conveying belt 5 is started, a heat exchanger 4 to be welded is placed on the conveying belt 5, the heat exchanger 4 is transferred to a clamping station along the conveying direction of the conveying belt 5, and the step B is carried out; step B, after the controller 1 controls the conveyer belt 5 to convey the heat exchanger 4 to a clamping station, the controller 1 controls the clamping device to clamp and fix the heat exchanger 4 to be welded, meanwhile, the position sensor monitors the heat exchanger 4 in the clamping station and feeds back whether clamping is carried out or not to the controller 1, if clamping is successful, the step C is carried out, and if clamping is failed, the step B is repeated; step C, the controller 1 controls the conveyer belt 5 to convey the heat exchanger 4 to a soldering flux coating station, the auxiliary agent detection device 7 feeds back pressure and flow information between the current soldering flux storage tank 3 and the soldering flux brush 8 to the controller 1, the controller 1 controls the soldering flux brush 8 to coat the soldering flux on the heat exchanger 4 according to the pressure and flow information, and the step D is carried out after the coating is finished; step D, the controller 1 controls the conveyer belt 5 to convey the heat exchanger 4 to a welding station, the temperature sensing instrument 10 monitors the surface temperature of a welding area and feeds the surface temperature back to the controller 1, the distance measuring instrument monitors the height between the flame welding gun group 11 and the heat exchanger 4 in the welding area and feeds the height back to the controller 1, the controller 1 controls the flame welding gun group 11 to weld according to the information fed back by the temperature sensing instrument 10 and the distance measuring instrument, in the welding process, the controller 1 can also adjust the air source supply quantity of the air source assembly according to the pressure and flow information fed back by an auxiliary monitoring device between the air source assembly and the flame welding gun group 11, and the step E is carried out after the welding is finished; step E, the controller 1 controls the conveyer belt 5 to convey the heat exchanger 4 to a cooling station, the cooling station distance meter detects the height of the welding area of the heat exchanger 4 and feeds the height back to the controller 1, the controller 1 adjusts the air output of the fan 12 according to the information fed back by the cooling station distance meter, and the step F is carried out after cooling is finished; f, performing a step; the controller 1 controls the conveyer belt 5 to convey the heat exchanger 4 to a station on the lower line for receiving materials to obtain the heat exchanger 4, and finally, the heat exchange amount of the heat exchanger 4 is actually measured and whether the heat exchange amount reaches the standard is judged.
In the step B, a position sensor for detecting whether the heat exchanger 4 is clamped or not is arranged on the conveying belt 5, when the conveying belt 5 is in a neutral position of the heat exchanger 4, a signal is transmitted to the controller 1, and after the controller 1 receives the signal, the flame welding gun group 11 is extinguished, and the conveying and control (including a pressure gauge and a flow meter) of the soldering flux does not convey the soldering flux to the soldering flux brush 8 any more. When the heat exchanger 4 is arranged on the conveying belt 5, the controller 1 sends out an instruction, and after electronic ignition, the flame welding gun group 11 ignites flame and the soldering flux is conveyed and controlled (comprising a pressure gauge and a flowmeter) to convey the soldering flux to the soldering flux brush 8.
In the step C, the soldering flux liquid level indicator 2 can detect the storage amount of the soldering flux in the soldering flux storage tank 3, if the soldering flux in the soldering flux storage tank 3 is insufficient, the soldering flux liquid level indicator 2 generates an early warning signal to the controller 1, and the controller 1 sends out an alarm according to the early warning signal.
In this embodiment, the controller 1 can preset welding parameters for the specification and model of the heat exchanger 4, such as the beat of the conveyer belt 5, the flow and pressure of the oxygen source 13 and the hydrocarbon combustible gas source 14, and after inputting the technical information of a certain heat exchanger 4, the servo adjustment of the beat of the conveyer belt 5, the height of the flame welding gun set 11, the height of the scaling powder brush 8, the height of the fan 12 and the like can be realized, and the intelligent equipment can be quickly adjusted to meet the preset requirements of the specification of the variety of the heat exchanger 4.
In this embodiment, the controller 1 can count the number of specifications and models of the welded heat exchanger 4, and modify the preset welding parameters in combination with feedback of leak detection data of the sealing performance of the heat exchanger 4 in a subsequent process, so as to further improve the quality.
In step F, aiming at the small-channel parallel pipeline heat exchanger with fins, the actual heat exchange quantity of the prepared heat exchanger 4 is Q1Presetting heat exchanger 4 as Q, if Q1Greater than or equal to Q, the heat exchanger 4 meets the standard, if Q1Less than Q, the heat exchanger 4 does not comply with the standard, wherein,
referring to fig. 2 to 6, aThe finned small-channel parallel pipeline heat exchanger comprises an inlet pipe 21, a parallel pipeline 22 and an outlet pipe 23, wherein the parallel pipeline 22 is respectively communicated with the inlet pipe 21 and the outlet pipe 23, fins 44 are arranged on the parallel pipeline 22, the parallel pipeline 22 is arranged in at least one row, and when the outer diameter d of the parallel pipeline 22 is larger than the outer diameter d of the parallel pipeline 22oThe value range of (d) is more than 1mmoWhen the diameter is less than or equal to 3.95mm, the heat exchange quantity of the heat exchanger and the structure of the heat exchanger accord with the following formula:
wherein Q is heat exchange quantity and the unit is W; c0The value of the error coefficient is 0.8-1.2; c1The value is constant and is between 0.023 and 0.027; c2Is a constant and takes a value of 1.2-1.4; lambda is the coefficient of thermal conductivity of the medium outside the pipe, and the unit is W/(m.k); rho is the density of the medium outside the pipe, and the unit is kg/m 3; mu is dynamic viscosity of medium outside the pipe, and the unit is Pa.s; c. CpThe constant pressure specific heat capacity of the medium outside the pipe is expressed in J/(kg.K); s is the flow rate of medium circulating outside the pipe, and the unit is m 3/S; delta t is the heat exchange temperature difference and has the unit of K; m is the number of the heat exchanger tube rows; ζ is the tube spacing factor; h is the height of the heat exchanger and the unit is m; doThe unit is m for the outer diameter of the parallel pipeline; b is the thickness of the heat exchanger, and the unit is m; is a fin factor; eta is a tube bank factor; psi is the tube layer factor and the tube spacing between adjacent parallel tubes 22 is btThe tube spacing factor ζ ═ bt/do(ii) a The spacing between adjacent fins 44 is bfFin factor bf/do(ii) a The distance between the centers of the corresponding pipelines between two adjacent rows of parallel pipelines 22 is t, and the pipeline row factor eta is t/do(ii) a The pipe layer factor psi is the number of layers set according to the reasonable state of the distribution of the medium in the pipe in the parallel pipeline. Psi is an integer greater than 0 and the parallel conduit 22 is divided into at least one layer. Preferably, as shown in fig. 2, the parallel conduit 22 is provided with at least one stratification means 25, the parallel conduit 22 being divided into at least two layers. When there is only one parallel line, it is understood that the center of the corresponding line between the two adjacent parallel lines 22 is the center of the corresponding lineIs infinite. Preferably, each row of parallel lines 22 is provided with at least one tube, which is a particular case of the present application when each row of parallel lines 22 is provided with only one tube, such as by using serpentine tubes in a "parallel" relationship in a serpentine manner, increasing the overall length of the tubes, and more preferably, each row of parallel lines 22 is provided with at least two tubes, such as a serpentine heat exchanger or a straight heat exchanger using two or more "parallel" tubes per row. Preferably, the parallel pipe external diameter doThe value range of (d) is more than 0.46mmoLess than or equal to 6.6mm, more preferably, the external diameter d of the parallel pipelineoThe value range of (d) is more than 1mmoLess than or equal to 5mm, most preferably, the outside diameter d of the parallel pipesoThe value range of (d) is more than 1mmoLess than or equal to 3.95 mm. Because the parallel pipeline is designed by adopting a small pipe diameter, compared with the conventional pipe diameter, the pipe wall does not need to bear larger pressure of a medium in the pipe, so the requirements on the thickness and the mechanical strength of the pipe wall are reduced, and according to a heat exchange quantity formula Q ═ A · Δ t, wherein Q is the heat exchange quantity, A is the heat exchange area, A is the heat exchange coefficient, Δ t is the heat transfer temperature difference, and the reciprocal of the heat exchange coefficient alpha, namely 1/A is the heat exchanger thermal resistance R, the heat exchanger thermal resistance R comprises three contents: riHeat exchanger in-tube thermal resistance; rwThermal resistance of the heat exchanger pipe wall; roHeat exchanger tube external thermal resistance, i.e. a 1/(R)i+Rw+RO) The thermal resistance R outside the heat exchanger tube is reduced by adjusting the tube spacing factor, the fin factor, the tube row factor and the likeoThe value of (d); by adjusting the diameter of the pipe, the thermal resistance R in the heat exchanger pipe is reducediThe value of alpha is reduced, so that the heat exchange coefficient alpha is influenced, and the heat exchange efficiency of the product is further improved; compared with the diameter of the micro-pipe, the production process difficulty of the parallel pipeline with the small inner diameter is correspondingly reduced, and the production efficiency and the yield are improved. Preferably, C0The value of (a) is between 0.9 and 1.1.
Referring to fig. 4, 5 and 6, the parallel tubes 22 are arranged in at least two rows. Preferably, the parallel lines 22 may be arranged in parallel or staggered. Preferably, the distance t between the corresponding tube centers between two adjacent rows of parallel tubes 22 refers to the distance between the tube centers of the tubes corresponding to each row in sequence. Because the density of the medium passing through the cross section of the pipeline is different when the medium in the pipeline is in a gas phase state, a vapor-liquid coexisting state and a liquid phase state, and the space required by the gas phase state is far larger than that required by the liquid phase state in the required theoretical space, the parallel pipeline needs to be layered (whether the layering is reasonable or not is mainly determined by the property of the medium and the distribution state of the medium) according to the property of the medium and the distribution state of the medium in the parallel pipeline. Generally, when the heat exchanger is used as a condenser, the number of parallel pipelines at the position where the refrigerant flows into the heat exchanger is far greater than that of parallel pipelines at the position where the refrigerant flows out of the heat exchanger; when the heat exchanger is used as an evaporator, the number of parallel pipelines at the position where the refrigerant flows out of the heat exchanger is far larger than that of parallel pipelines at the position where the refrigerant flows in the heat exchanger, so that the uniform distribution of the refrigerant in the heat exchanger can be ensured. Meanwhile, after the parallel pipelines are divided into a plurality of equal parts, the flow rate of the medium is greatly increased compared with that of the parallel pipelines. The flow velocity of the medium (refrigerant) in the pipe is increased, and the heat transfer effect of the medium and the inner wall of the pipe is also positively influenced.
Further, the parallel pipe 22 is made of a metal material. The parallel pipelines are made of metal materials, so that the thermal resistance R of the walls of the parallel pipelines can be effectively reducedwThe numerical value of (2) plays a positive role in improving the heat exchange efficiency of the heat exchanger. Preferably, the parallel pipeline 22 is made of aluminum, which has absolute advantages in material cost and processing difficulty compared to the parallel pipeline made of copper and other materials in the prior art. When the parallel pipelines of the heat exchanger are made of metal materials, RwIs much smaller than RiAnd RoTherefore, the heat exchange coefficient α is, in an ideal state, represented by the following formula:
by the theorem of extreme values, when ai＝aoWhen a isi*aoObtain the maximum value, ai+aoTo obtain the minimum value and thus the maximum value of alpha, which is also the aim of the heat exchanger industry to pursue the heat exchange efficiency, therefore, when designing the heat exchanger, it is preferable to make a as much as possibleiAnd aoThe heat exchange performance outside the pipe and the heat exchange performance inside the pipe of the parallel pipeline are matched to achieve the maximum heat exchange effect of the heat exchanger.
Referring to FIG. 2, the wall thickness (d) of the parallel piping 22 is showno-di) The value range of/2 is 0 < do-di) A/2 is less than or equal to 0.4mm, wherein diIs the parallel pipeline inner diameter. Preferably, the wall thickness (d) of the parallel pipeline 22 is taken into consideration in combination with strength, thermal resistance, production cost, and the likeo-di) The value range of the/2 is less than or equal to 0.2mm (d)o-di) The/2 is less than or equal to 0.4 mm. The inner diameter d of the parallel pipeline is very thiniThe numerical range of (A) also falls substantially within the numerical range of 1mm to 3.95 mm.
Referring to FIGS. 2 and 4, the spacing b between adjacent fins 44fThe value range of (b) is more than or equal to 1mmfLess than or equal to 4 mm. Preferably, the spacing b between adjacent fins 44fThe value range of (b) is more than or equal to 2mmfLess than or equal to 4 mm. This kind of structural design cuts heat exchanger main part windward side into very little polylith passageway, has enlarged heat exchange area after fin and the parallel pipeline tight fit on the one hand, and on the other hand is on the microstructure, and there is the cutting action in the flowing medium of existence of fin outside the tubes of the heat exchanger, reaches the purpose of accurate distribution for the heat exchange aggravation between the flowing medium of outside of tubes and the parallel pipeline, can form "little channel effect", can obviously produce positive influence to the heat exchange effect outside the parallel pipeline of heat exchanger outside the tubes.
Referring to fig. 4, the fins 44 are arranged perpendicular to the extending direction of the parallel tubes 22.
Example 2
Referring to fig. 7 to 10, a second embodiment of the automatic welding intelligent control system for a heat exchanger in the present application is the same as that in embodiment 1, and features not explained in this embodiment adopt the explanations in embodiment 1, and are not described again here. This example differs from example 1 in that: the finned-free small-channel parallel pipeline heat exchanger prepared in the embodiment and the calculation method are shown in fig. 7 to 10The small-channel parallel pipeline heat exchanger comprises an inlet pipe 31, a parallel pipeline 32 and an outlet pipe 33, wherein the parallel pipeline 32 is respectively communicated with the inlet pipe 31 and the outlet pipe 33, the parallel pipeline 32 is arranged in at least one row, and when the outer diameter d of the parallel pipeline 32 is larger than the outer diameter d of the parallel pipelineoThe value range of (d) is more than 1mmoWhen the diameter is less than or equal to 3.95mm, the heat exchange quantity of the heat exchanger and the structure of the heat exchanger accord with the following formula:
wherein Q is heat exchange quantity and the unit is W; c0The value of the error coefficient is 0.8-1.2; c1The value is constant and is between 0.023 and 0.027; c2Is a constant and takes a value of 1.2-1.4; lambda is the coefficient of thermal conductivity of the medium outside the pipe, and the unit is W/(m.k); rho is the density of the medium outside the pipe, and the unit is kg/m 3; mu is dynamic viscosity of medium outside the pipe, and the unit is Pa.s; c. CpIs the constant pressure specific heat capacity of the medium outside the pipe, the unit is J/(kg.Ki), S is the flow rate of the medium circulating outside the pipe, the unit is m3/S, delta t is the heat exchange temperature difference, the unit is K, m is the number of the heat exchanger pipe rows, zeta is the pipe spacing factor, h is the height of the heat exchanger, d isoThe unit is m for the outer diameter of the parallel pipeline; eta is a tube bank factor; psi is the tube layer factor and the tube spacing between adjacent parallel tubes 32 is btThe tube spacing factor ζ ═ bt/do(ii) a The distance between the outer walls of the corresponding pipelines between two adjacent rows of parallel pipelines 32 is t, and the pipeline row factor eta is t/do(ii) a The pipe layer factor psi is the number of layers set according to the reasonable state of the distribution of the medium in the pipe in the parallel pipeline. Psi is an integer greater than 0 and the parallel conduit 32 is divided into at least one layer. Preferably, as shown in fig. 7, the parallel conduit 32 is provided with at least one layering device 35, the parallel conduit 32 being divided into at least two layers. When there is only one row of parallel pipelines, it can be understood that the distance t between the outer walls of the corresponding pipelines between two adjacent rows of parallel pipelines 32 is infinite. Preferably, each row of parallel lines 32 is provided with at least one tube, which is a special case of the present application when each row of parallel lines 32 is provided with only one tube, for example by means of a serpentine tubeIn a serpentine manner to form a "parallel" relationship, increasing the overall length of the tubes, and more preferably, each row of parallel tubes 32 is provided with at least two tubes, such as a coiled heat exchanger or a straight heat exchanger employing two or more "parallel" tubes per row. Preferably, the parallel pipe external diameter doThe value range of (d) is more than 0.46mmoLess than or equal to 6.6mm, more preferably, the external diameter d of the parallel pipelineoThe value range of (d) is more than 1mmoLess than or equal to 5mm, most preferably, the outside diameter d of the parallel pipesoThe value range of (d) is more than 1mmoLess than or equal to 3.95 mm. Because the parallel pipeline is designed by adopting a small pipe diameter, compared with the conventional pipe diameter, the pipe wall does not need to bear larger pressure of a medium in the pipe, so the requirements on the thickness and the mechanical strength of the pipe wall are reduced, and according to a heat exchange quantity formula Q ═ A · Δ t, wherein Q is the heat exchange quantity, A is the heat exchange area, A is the heat exchange coefficient, Δ t is the heat transfer temperature difference, and the reciprocal of the heat exchange coefficient alpha, namely 1/A is the heat exchanger thermal resistance R, the heat exchanger thermal resistance R comprises three contents: riHeat exchanger in-tube thermal resistance; rwThermal resistance of the heat exchanger pipe wall; roHeat exchanger tube external thermal resistance, i.e. a 1/(R)i+Rw+RO) The thermal resistance R outside the heat exchanger tube is reduced by adjusting the tube spacing factor, the tube array factor and the likeoThe value of (d); by adjusting the diameter of the pipe, the thermal resistance R in the heat exchanger pipe is reducediThe value of alpha is reduced, so that the heat exchange coefficient alpha is influenced, and the heat exchange efficiency of the product is further improved; compared with the diameter of the micro-pipe, the production process difficulty of the parallel pipeline with the small inner diameter is correspondingly reduced, and the production efficiency and the yield are improved. Preferably, C0The value of (a) is between 0.9 and 1.1.
Referring to fig. 9 and 10, the parallel tubes 32 are arranged in at least two rows. Preferably, the parallel lines 32 may be arranged in a side-by-side or staggered arrangement. Preferably, the distance t between the outer walls of the corresponding tubes between two adjacent rows of parallel tubes 32 refers to the distance between the outer walls of the tubes of each row of parallel tubes that correspond sequentially. Because the density of the medium passing through the cross section of the pipeline is different when the medium in the pipeline is in a gas phase state, a vapor-liquid coexisting state and a liquid phase state, and the space required by the gas phase state is far larger than that required by the liquid phase state in the required theoretical space, the parallel pipeline needs to be layered (whether the layering is reasonable or not is mainly determined by the property of the medium and the distribution state of the medium) according to the property of the medium and the distribution state of the medium in the parallel pipeline. Generally, when the heat exchanger is used as a condenser, the number of parallel pipelines at the position where the refrigerant flows into the heat exchanger is far greater than that of parallel pipelines at the position where the refrigerant flows out of the heat exchanger; when the heat exchanger is used as an evaporator, the number of parallel pipelines at the position where the refrigerant flows out of the heat exchanger is far larger than that of parallel pipelines at the position where the refrigerant flows in the heat exchanger, so that the uniform distribution of the refrigerant in the heat exchanger can be ensured. Meanwhile, after the parallel pipelines are divided into a plurality of equal parts, the flow rate of the medium is greatly increased compared with that of the parallel pipelines. The flow velocity of the medium (refrigerant) in the pipe is increased, and the heat transfer effect of the medium and the inner wall of the pipe is also positively influenced.
Further, the parallel pipe 32 is made of a metal material. The parallel pipelines are made of metal materials, so that the thermal resistance R of the walls of the parallel pipelines can be effectively reducedwThe numerical value of (2) plays a positive role in improving the heat exchange efficiency of the heat exchanger. Preferably, the parallel pipelines 32 are made of aluminum, and compared with parallel pipelines made of copper and other materials in the prior art, the parallel pipelines have absolute advantages in material cost and processing difficulty. When the parallel pipelines of the heat exchanger are made of metal materials, RwIs much smaller than RiAnd RoTherefore, the heat exchange coefficient α is, in an ideal state, represented by the following formula:
by the theorem of extreme values, when ai＝aoWhen a isi*aoObtain the maximum value, ai+aoTo obtain the minimum value and thus the maximum value of alpha, which is also the aim of the heat exchanger industry to pursue the heat exchange efficiency, therefore, when designing the heat exchanger, it is preferable to make a as much as possibleiAnd aoThe heat exchange performance outside the pipe and the heat exchange performance inside the pipe of the parallel pipeline are matched to achieve the maximum heat exchange effect of the heat exchanger.
See fig. 8The wall thickness (d) of the parallel pipeline 32o-di) The value range of/2 is 0 < do-di) A/2 is less than or equal to 0.4mm, wherein diIs the parallel pipeline inner diameter. Preferably, the wall thickness (d) of the parallel piping 32 is taken into consideration in combination with strength, thermal resistance, production cost, and the likeo-di) The value range of the/2 is less than or equal to 0.2mm (d)o-di) The/2 is less than or equal to 0.4 mm. The inner diameter d of the parallel pipeline is very thiniThe numerical range of (A) also falls substantially within the numerical range of 1mm to 3.95 mm.
It should be finally noted that the above embodiments are only intended to illustrate the technical solutions of the present invention, and not to limit the scope of the present invention, and although the present invention has been described in detail with reference to the preferred embodiments, it should be understood by those skilled in the art that the technical solutions of the present invention can be modified or replaced with equivalents without departing from the spirit and scope of the technical solutions of the present invention.
Claims (6)
1. The utility model provides a heat exchanger automatic weld intelligence control system which characterized in that: the welding device comprises a controller and a conveying belt, wherein the conveying belt is sequentially provided with a clamping station, a welding agent coating station, a welding station, a cooling station and a discharging station along the conveying direction;
the clamping station comprises a clamping device for clamping the heat exchanger and a position sensor for detecting the position of the heat exchanger, and the clamping device and the position sensor are both electrically connected with and controlled by the controller;
the flux coating station comprises a flux storage tank, an auxiliary agent detection device and a flux brush which are sequentially communicated, wherein the flux storage tank, the auxiliary agent detection device and the flux brush are all electrically connected with and controlled by the controller;
the welding station comprises a welding flux conveying device, a temperature sensor, a distance meter, a flame welding gun group and an air source assembly, wherein the welding flux conveying device, the temperature sensor, the distance meter, the flame welding gun group and the air source assembly are positioned above the conveying belt, the distance meter, the flame welding gun group and the air source assembly are used for detecting the welding distance, the air source assembly and the flame welding gun group are correspondingly communicated, an auxiliary monitoring device and an electromagnetic valve are communicated and arranged between the air source assembly and the flame welding gun group, and the welding flux conveying device, the temperature sensor, the distance meter, the auxiliary;
the cooling station comprises a fan positioned above the conveying belt, and the fan is electrically connected with the controller and controlled by the controller;
the off-line station is located at the tail end of the conveying belt.
2. The automatic welding intelligent control system of the heat exchanger according to claim 1, characterized in that: the conveying belt comprises a motor for driving the conveying belt to operate.
3. The automatic welding intelligent control system of the heat exchanger according to claim 1, characterized in that: the auxiliary agent detection device comprises an auxiliary agent pressure gauge, an auxiliary agent flowmeter, an auxiliary agent electromagnetic valve and a driving pump for conveying the combined welding agent.
4. The automatic welding intelligent control system of the heat exchanger according to any one of claims 1 to 3, characterized in that: the soldering flux storage tank is further provided with a soldering flux liquid level indicator for detecting the liquid level in the soldering flux storage tank, and the soldering flux liquid level indicator is electrically connected with the controller and is controlled by the controller.
5. The automatic welding intelligent control system of the heat exchanger according to any one of claims 1 to 3, characterized in that: the gas source assembly comprises an oxygen source and a hydrocarbon combustible gas source.
6. The automatic welding intelligent control system of the heat exchanger according to any one of claims 1 to 3, characterized in that: the cooling station is also provided with a cooling station distance meter for detecting the distance between the heat exchangers.
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| CN111531246A (en) * | 2020-05-08 | 2020-08-14 | 浙江易斐科技有限公司 | Automatic welding intelligent control system and welding process for heat exchanger |
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| CN111531246A (en) * | 2020-05-08 | 2020-08-14 | 浙江易斐科技有限公司 | Automatic welding intelligent control system and welding process for heat exchanger |
| CN111531246B (en) * | 2020-05-08 | 2024-03-29 | 浙江易斐科技有限公司 | Automatic welding intelligent control system and welding process for heat exchanger |
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