JP4361813B2 - Aligned winding method and winding apparatus for porous flat tubes - Google Patents

Description

  The present invention relates to a method for winding a coated porous flat tube (hereinafter abbreviated as a tube) used for heat exchanger parts for automobiles and the like, and an apparatus used for the winding.

Tubes used for automotive heat exchanger parts usually use aluminum alloy (JIS-A1050) with excellent corrosion resistance as the base material and have a cross-sectional shape after painting as shown in FIG. ing. The tube 2 shown in FIG. 7 is 1.1 mm long and 16.15 mm wide, rounded at the both ends, with a distance of about 0.25 mm from the upper and lower outer circumferences and 0.875 mm from the left and right ends of the tube. The 19 small holes 50 have a cross-sectional shape formed in a row at intervals of about 0.2 mm, and a coating film of about 50 μm is provided on the surface thereof.

This tube is generally manufactured by a method of extrusion by using an aluminum rough wire as a starting material and a method of manufacturing by a hot extrusion by using a billet as a starting material. In either case, the tube is once wound into a coil and sent to the next coating process.
In the coating process, using the equipment shown in FIG. 1 , painting, heating, drying, cooling, and winding are continuously performed, and the tube surface is coated with paint necessary for the subsequent assembly process. A coil is manufactured.

As a coating material used for brazing in an assembling process, the inventors have used a powder of a simple substance of Si or AL-Si based alloy having a brazing effect, or a simple substance of Zn or a powder of AL-Zn based alloy having a sacrificial anode effect. At least one of them, or a mixture of the metal powder and the flux powder or a compound powder of the metal and the flux, and the coating amount is preferably about 5 to 13 g / m ^2. Found that by supplying the paint by the top feed method, applying it by the reverse method, and drying it, the uniformity and adhesion of the coating film is good and sufficient brazing adhesion can be obtained. There was a problem that the coil shape after winding of the tube was uneven and could not be wound in alignment, and the tube was deformed.

  Therefore, as a representative technique for winding such a long tube-shaped object and winding it in an aligned manner without causing irregularities in the coil form after winding, (1) winding torque during winding (2) a method of making the winding tension constant at the time of winding, and (3) a method of changing the tension itself corresponding to the winding diameter of the coil (for example, see Patent Document 1). Yes.

Japanese Patent No. 3336893

However, even with the above-described prior art, the coil shape after winding a completely coated tube could not be wound in an aligned manner without causing irregularities.
First, in the method of keeping the torque constant during the first winding, since the torque control is slow in response, it cannot prevent the occurrence of fine irregularities due to fluctuations in tension. Unevenness may occur in later coil forms.

  Next, in the method of keeping the tension constant during the second winding, the winding force increases and the coil shape becomes uneven as the winding diameter increases. The coil shape could not be wound up without causing irregularities.

  Furthermore, a method for changing the tension itself corresponding to the third winding diameter is, for example, as shown in Patent Document 1, in which the winding height of a metal strip coil is detected by a winding height detection sensor, and the winding height is detected. Accordingly, the axis of the winding shaft (mandrel) is automatically raised and lowered, and the winding height of the metal strip coil detected by this winding height detection sensor reduces the tension when the winding diameter is small, and the winding diameter. The tension is automatically changed so that the tension increases as a result of increasing the thickness. As a result, a thick plate portion having a deformed cross section and a thick central portion with respect to the width direction and a thin strip portion having both ends thin. In the case of winding a tube to be coated by this method, the strain applied to the already wound tube increases as the winding diameter increases. Concavity and convexity occur in the Article is sliding on the coil under the influence of the projections, a problem that can not be wound up has occurred in the alignment.

In view of such a situation, the present invention has been found by repeatedly conducting various studies on a method of winding a coated tube used in an automobile heat exchanger, and winding a long tube-like object into a coil shape. without causing irregularities on the coil shape after winding, by winding the alignment method of manufacturing a deformed though not coated porous flat tube for a heat exchanger for an automobile which can obtain a tube and its production A device is provided.

  According to the first aspect of the present invention, in the method of winding a porous flat tube coated on a surface into a coil shape, the tension applied to the porous flat tube is reduced as the winding of the porous flat tube into the coil shape proceeds. The winding device is controlled so that the coil configuration is aligned winding while the tension control is performed and the temperature control is performed so that the temperature of the porous flat tube is 50 ° C. or less during winding into the coil configuration. This is an aligned winding method for a porous flat tube.

  According to a second aspect of the present invention, there is provided the method of aligning and winding porous flat tubes according to the first aspect, wherein the tension control is performed by an electropneumatic conversion control system.

  According to a third aspect of the present invention, the electropneumatic conversion control method is performed by a control device including a dancer roll, a counter balance cylinder, and an electropneumatic regulator. This is an aligned winding method for porous flat tubes.

According to a fourth aspect of the present invention, there is provided a method of controlling a winding device so that the coil form is an aligned winding, comprising: a recoiler comprising a bobbin for winding a porous flat tube, a recoiler moving device, and a control device for the recoiler. Using the take-off device, the recoiler is moved at a predetermined speed so that the porous flat tube reaches the end of the bobbin, and then the porous flat tube arrives, and then the movement of the recoiler is stopped, and then in the opposite direction. when that moved, until the porous flat tube is wound sequences in the bobbin, winding the moving speed faster than the predetermined speed, 1 to thereafter claim and performing the winding is returned to the predetermined velocity It is the aligned winding method of the porous flat tube of Claim 3.

According to a fifth aspect of the present invention, there is provided an unwinding device for supplying a porous flat tube wound in a coil form and a surface of the porous flat tube drawn out from the unwinding device in a coating / aligning winding device for a porous flat tube. A coater machine for applying a coating material thereon, a heating device for fixing the applied coating material to the porous flat tube, a cooling device for cooling the heated porous flat tube to a predetermined temperature, and a cooled porous flat tube A tension control device that performs tension control to reduce the tension applied to the porous flat tube as the winding into the coil form progresses, and temperature control that the porous flat tube temperature during winding is 50 ° C. or less. while a paint-aligned-winding-up device of the porous flat tube, characterized in that the alignment winding control is composed of a winding machine which has been subjected.

A sixth aspect of the present invention is the coating / aligning winding device for a porous flat tube according to the fifth aspect, wherein the tension control is performed by an electropneumatic conversion control system.

The invention according to claim 7 is characterized in that the electropneumatic conversion control system is performed by a control device including a dancer roll, a counter balance cylinder, and an electropneumatic regulator. This is a painting / aligning winding device for porous flat tubes.

According to an eighth aspect of the present invention, there is provided a method of controlling a winding device so that the coil form is an aligned winding. Using the take-off device, the recoiler is moved at a predetermined speed so that the porous flat tube reaches the end of the bobbin, and then the porous flat tube arrives, and then the movement of the recoiler is stopped, and then in the opposite direction 6. When moving, until the porous flat tube is wound around the bobbin in several rows, the winding speed is wound at a speed higher than the predetermined speed, and then wound back at the predetermined speed. A coating / aligning winding device for a porous flat tube according to claim 7.

As described above, according to the aligned winding method and the aligned winding apparatus according to the present invention, the coil shape and pitch after tube winding are stabilized to prevent meandering of the tube in the production line in the next process, A trouble in the manufacturing process can be avoided and a stable operation can be performed, and a remarkable industrial effect can be achieved.

First, the cause of unevenness on the coil surface will be described.
First, FIG. 8 (a) schematically shows the relationship between the winding angle α, the tension T and the winding force F, which is a component force of the tension T, immediately after the start of winding, and FIG. 8 (b). Indicate.
When the tube is wound at a constant tension T, the tension component force F received from the tube 2 on which the wound coil 2a is wound is increased as the coil diameter increases as shown in FIG. Therefore, the winding force F is also increased, and the winding force F at the end of winding is greater than that at the start of winding. In other words, F ₁ <F ₂ in FIG. Here, F ₁ indicates the tension component immediately after the start of winding, F ₂ indicates the tension component immediately before the end of winding, α ₁ indicates the winding angle immediately after the start of winding, and α ₂ indicates the winding immediately before the end of winding. Indicates the take angle.
When the winding force F is increased in this way, as shown in FIG. 9, the adhesion between the tubes of the upper layer portion 51 and the lower layer portion 52 of the tube surface wound around the coil increases, and the cross-sectional profile of the tube 2 becomes clear. Appears in a concavo-convex shape.

  Second, when the temperature exceeds 50 ° C., the strength of the tube decreases. When the coil is wound at a temperature of 50 ° C. or higher, the tube deforms due to thermal deformation. It appears clearly in the irregular shape of the coil surface.

Next, regarding the cause of the disturbance in the aligned winding pitch, the winding device is sent at a constant speed in the alignment direction to perform the aligned winding, and the spacing is determined at that speed. Then, the coated tube becomes slippery, and the coated tube is difficult to transfer on the convex portion, and the aligned winding pitch does not follow the specified pitch.
Embodiments of the present invention will be described below with reference to the drawings.

In FIG. 1, the block diagram of the coating apparatus used by this invention is shown.
The tube 2 wound around the unwinding device 1 is pulled out, and while the meandering detection sensor 3 monitors the meandering, it passes through the entrance-side guide roller 4 and the entrance-side dancer roll 5 and is guided to the coater machine 6 to the surface. The material is applied. After the application, the tube 2 measures the thickness of the brazing material coating film with a coating film thickness meter of 7, and then is inserted into the induction heating furnace 8 and fixed. The tube 2 exiting the induction heating furnace 8 passes through the hot air dryer 9 and the air spray cooling device 10 and is cooled to 50 ° C. or less by the air cooling device 11. The tube 2 cooled to 50 ° C. or less passes through the exit guide roller 12 and the bridle roll 13 and is composed of the exit dancer roll 14, the counterbalance cylinder 15, and an electropneumatic regulator not shown in FIG. While being guided to the tension control device 17 and being subjected to tension adjustment, the winding is performed by the winding device 18 that is subjected to the alignment winding control. In addition, in order to maintain the temperature of the tube 2 at 50 ° C. or less, the temperature from the winding device 18 to the exit side dancer roll 14 is covered with a cover 19 and the temperature of the tube 2 is controlled by air conditioning equipment therein. Is maintained below 50 ° C.

FIG. 2 shows the arrangement of the tension control device 17.
In order to increase the tension at the start of winding so that the coil winding force is constant and to decrease the tension at the end of winding, a counter balance cylinder 15 is attached to the outgoing dancer roll 14 and the coil The winding diameter is used as a control signal, and the signal is sent to an electropneumatic conversion regulator 16 that controls the pressure of the counterbalance cylinder 15, and the output of the counterbalance cylinder 15 is increased by increasing the pressure in proportion to the coil diameter. The tension applied to the tube 2 by the outgoing dancer roll 14 is decreased.

FIG. 3 shows an overall view of the winding device 18.
The coil turn unit 20 performs angle control of the recoiler stop angle and speed control of the recoiler moving speed in combination. That is, the recoiler 21 is stopped at the coil turn section 20 and the tube is wound until the bobbin 22 that winds the tube 2 installed on the recoiler 21 rotates by a set angle from the time when the recoiler is stopped. Next, when the rotation angle of the bobbin 22 reaches the set angle, the recoiler 21 is moved at a speed higher than the predetermined moving speed until the tube 2 is wound around the bobbin 22 in several rows . Thereafter, disturbance of the aligned winding pitch is prevented by a control method in which the moving speed is returned to a predetermined speed and winding is performed. Reference numeral 23 denotes a servo motor for moving the recoiler 21, and reference numeral 24 denotes a winding shaft.

The servo motor controls the moving speed and position of the recoiler that winds the tube. FIG. 4 shows a flowchart of the control method.
A pulse signal from the servomotor is input to the coil turn point to cause the control unit to recognize it, and a command to stop the rotation of the servo motor at that turn point is output to the servo motor. After that, the pulse signal of the vector inverter motor that rotates the recoiler is input to the control unit. When the rotation angle of the vector inverter motor reaches the set angle, the servo motor speed is increased to start the servo motor and move the recoiler. . This is a method of controlling by a program that the tube is wound up in several rows and then returned to the original rotational speed again.

Example 1
21 hole aluminum alloy extruded porous flat tube manufactured by hot extrusion molding of aluminum alloy (flat tube size: width 16.15 mm, thickness 1.1 mm, hole size: about 0.6 mm, hole interval about 0.2 mm ) Was used for the co-test material.
The coating apparatus according to this co試材in FIG. 1, after coating a brazing material on the polarization plane of both sides of the tube, subjected to drying at 140 ° C., cooled to 47 ° C. by cooling, winding speed 80m Winded up at / min .
As for the winding state, for the aligned winding, the interval between the extruded porous flat tubes is set to a target of 19.15 mm, and the aligned winding as shown in FIG. 5 is performed, and 1,000 m, 5,000 m, 10,000 m, 15, The lines were once stopped at 000 m, 20,000 m, and 23,000 m, and the intervals were measured. The results are shown in Table 1.

  As is apparent from Table 1, all the intervals were within ± 1 mm of the target numerical value.

  Regarding the coil shape, after winding 23,000 m, a straight gauge was applied to the coil surface as shown in FIG. 6, and the gap A between the straight gauge and the coil surface was measured with the gap gauge. Was within 1 mm.

In addition, the coating material used is potassium trifluoride zinc 3-methoxy-3-methyl-1-butyl 66.6%, water 13.6%, acrylic resin 12.7%, 3-methoxy-1-butanol 5 A mixture of 9.9%, N, N-dimethylaminoethanol 0.7% and 2- (isopropylamino) ethanol 0.5% was used.

( Comparative Example 1 )
As a comparative example, Table 2 shows the results of measuring the coil shape when a coated tube is wound at a constant tension by the method shown in FIG.
Concavities and convexities of 3 to 4 mm were generated on the coil surface, and the aligned winding pitch was greatly disturbed to a maximum of 7 mm.

(Comparative Example 2)
As a second comparative example, Table 3 shows the results of measuring the coil shape when a coated tube is wound with a constant torque by the method shown in FIG.
The coil surface had irregularities of 2 to 3 mm, and the aligned winding pitch was greatly disturbed at a maximum of 5 mm.

(Comparative Example 3)
As a third comparative example, the cooling degree of the cooling device in the method of Example 1 was weakened, and the coil shape when the material was wound at a temperature of 60 ° C. was measured by the method shown in FIG. Table 4 shows the results.
As is apparent from Table 4, irregularities of 7 mm were generated on the coil surface, and the aligned winding pitch was greatly disturbed to a maximum of 5 mm.

(Comparative Example 4)
As a fourth comparative example, the results of measuring the coil shape in the method of Example 1 in the case of winding into a coil shape without controlling the turn part by the method shown in FIG. Shown in
Concavities and convexities of 3 to 4 mm were generated on the coil surface, and the aligned winding pitch was greatly disturbed at a maximum of 9 mm.

It is a block diagram of the coating and winding apparatus which concerns on this invention. It is a block diagram of a tension control device. It is a block diagram of a winding device. It is a flowchart which shows the control system of aligned winding control. It is sectional drawing which shows the alignment winding used in the Example. It is explanatory drawing which shows the measuring location method of a coil surface shape. It is sectional drawing which shows an example of a porous flat tube. (A) It is a schematic diagram which shows the relationship between the winding angle immediately after winding start, tension | tensile_strength, and winding force. (B) It is a schematic diagram which shows the relationship between the winding angle immediately before completion | finish of winding, tension | tensile_strength, and winding force. It is a fragmentary figure which shows the overlap of the porous flat tube in a winding coil.

1 Unwinding device 2 Perforated flat tube (tube)
2a perforated flattened pipe coil 3 meandering detection sensor 4 inlet side guide roller 5 entry side dancer roll 6 coater machine 7 coating thickness meter 8 induction furnace 9 a hot air dryer 10 air spray cooling system 11 Air cooler 12 exit-side dancer roll 13 Bridle roll 14 Outgoing dancer roll 14a Control signal input (Recoiler rotation correction)
15 Counterbalance cylinder 16 Pneumatic regulator 16a Control signal input (coil diameter)
17 Tension control device 18 Winding device 19 Cover 20 Coil turn portion 21 Recoiler 22 Bobbin 23 Servo motor 24 Winding shaft 50 Small hole 51 Upper layer portion 52 Lower layer portion

Claims (8)

In the method of winding a porous flat tube with a coated surface into a coil configuration, the tension applied to the porous flat tube and the coil configuration are reduced as the winding of the porous flat tube into the coil configuration progresses. Alignment winding of a porous flat tube that is wound into a coil shape by controlling the winding device so that the coil shape is aligned winding while controlling the temperature so that the temperature of the porous flat tube is 50 ° C. or less at the time of winding Method. 2. The method according to claim 1, wherein the tension control is performed by an electropneumatic conversion control system. The method of aligning and winding porous flat tubes according to claim 1 or 2, wherein the electropneumatic conversion control system is performed by a control device including a dancer roll, a counterbalance cylinder, and an electropneumatic regulator. . A method for controlling a winding device so that the coil form is aligned winding uses a winding device comprising a recoiler comprising a bobbin for winding a porous flat tube, a moving device of the recoiler, and a control device thereof. After moving the recoiler at a predetermined speed so that the tube reaches the end of the bobbin and arriving at the porous flat tube, when the movement of the recoiler is stopped and then moved in the opposite direction, the porous flat tube is until wound sequences in the bobbin, perforated flat tube of the moving speed the predetermined speed faster and wound, then claims 1 to 3, wherein: performing the winding is returned to a predetermined speed Aligned winding method. In a coating / aligning winding device for a porous flat tube, an unwinding machine for supplying a porous flat tube wound in a coil form, and a coater machine for applying a paint onto the surface of the porous flat tube drawn out from the unwinding machine A heating device for fixing the applied paint to the porous flat tube, a cooling device for cooling the heated porous flat tube to a predetermined temperature, and the progress of winding the cooled porous flat tube into a coil form Along with the tension control device that controls the tension to reduce the tension applied to the porous flat tube, and the alignment winding control is performed while controlling the temperature at which the porous flat tube temperature during winding is 50 ° C. or less. A winding and painting apparatus for a porous flat tube characterized by comprising a winding machine. 6. The perforated flat tube coating / aligning winding apparatus according to claim 5, wherein the tension control is performed by an electropneumatic conversion control system. The said electropneumatic conversion control system is performed by the control apparatus comprised from a dancer roll, a counter balance cylinder, and an electropneumatic regulator, The coating and alignment winding of the porous flat tube of Claim 5 and Claim 6 characterized by the above-mentioned. Take-off device. A method for controlling a winding device so that the coil form is aligned winding uses a winding device comprising a recoiler comprising a bobbin for winding a porous flat tube, a moving device of the recoiler, and a control device thereof. After moving the recoiler at a predetermined speed so that the tube reaches the end of the bobbin and arriving at the porous flat tube, when the movement of the recoiler is stopped and then moved in the opposite direction, the porous flat tube is The porous flat tube according to any one of claims 5 to 7, wherein winding is performed by making the moving speed faster than the predetermined speed until the bobbin is wound in several rows, and then returning to the predetermined speed. Painting and alignment winding device.

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