JP7513911B2 - Heat exchanger manufacturing apparatus and method - Google Patents

Description

This disclosure relates to a heat exchanger manufacturing apparatus and a heat exchanger manufacturing method.

Patent Document 1 discloses a heat exchanger. The heat exchanger described in Patent Document 1 includes a heat exchange section and a header. The heat exchanger includes fins and heat transfer tubes that are inserted into the fins. A header is attached to the protruding portion of the heat transfer tube that protrudes from the fin.

Conventionally, when attaching a header to the protruding portion of a heat transfer tube, the heat exchange unit is positioned so that the protruding portion of the heat transfer tube protrudes horizontally, and the header is positioned so that the header insertion hole extends horizontally and faces the protruding portion horizontally. Then, the header is moved horizontally to insert the protruding portion into the header insertion hole.

JP 2020-201020 A

However, when attaching the header to the protruding part of the heat transfer tube, the header is constantly moved horizontally, which causes frictional force from the header to be applied to the protruding part of the heat transfer tube in the same direction (horizontal direction) from the header from start to finish, and this frictional force can cause problems such as deformation of the heat transfer tube or horizontal misalignment of the heat transfer tube with respect to the fins. To avoid such problems, techniques that rely on the sense of the worker, such as their level of skill, are required.

The objective of this disclosure is to make it easier to attach headers (21, 22, 24) to heat transfer tubes (13).

The first aspect is directed to a manufacturing apparatus for a heat exchanger. The heat exchanger includes a header (21, 22, 24) including an insertion hole (112, 42) and a heat transfer tube (13) installed on a fin (16). The manufacturing apparatus for the heat exchanger includes a mechanism for inserting a protrusion (131) of the heat transfer tube (13) protruding from the fin (16) into the insertion hole (112, 42) of the header (21, 22, 24), and the mechanism inserts the protrusion (131) into the insertion hole (112, 42) while supporting the header (21, 22, 24) so that the extension direction (V) of the insertion hole (112, 42) is along a tilt direction (W), and the tilt direction (W) is a direction tilted with respect to the protruding direction of the protrusion (131).

In the first embodiment, the headers (21, 22, 24) can be easily attached to the heat transfer tube (13).

In the second aspect, the heat transfer tube (13) is a flat tube in the first aspect, the fin (16) includes a fin groove portion (17) into which the flat tube is inserted, and the mechanism inserts the protrusion (131) into the insertion hole (112, 42) from the opening (17a) side of the fin groove portion (17).

In the second embodiment, the headers (21, 22, 24) can be easily attached to the flat tubes.

In the third aspect, in the first or second aspect, when the mechanism inserts the protrusion (131) into the insertion hole (112, 42) of the header (21, 22, 24), the protrusion (131) contacts the inner wall surface (a2, a3) of the insertion hole (112, 42).

In the third aspect, when the protrusion (131) is inserted into the insertion hole (112, 42), the frictional force acting on the heat transfer tube (13) in the protruding direction can be effectively reduced.

In the fourth aspect, which is any one of the first to third aspects, the mechanism inserts the protrusion (131) into the insertion hole (112, 42) from the inclined direction (W) side.

In the fourth aspect, the protrusion (131) can be inserted into the insertion hole (112, 42) with the header (21, 22, 24) tilted so that the extension direction (V) of the insertion hole (112, 42) is aligned with the tilt direction (W).

In the fifth aspect, which is any one of the first to third aspects, the mechanism inserts the protrusion (131) into the insertion hole (112, 42) from a direction perpendicular to the protruding direction of the protrusion (131).

In the fifth aspect, the protrusion (131) can be inserted into the insertion hole (112, 42) with the header (21, 22, 24) tilted so that the extension direction (V) of the insertion hole (112, 42) is aligned with the tilt direction (W).

In the sixth aspect, which is any one of the first to third aspects, the mechanism inserts the protrusion (131) into the insertion hole (112, 42) from the protruding direction side of the protrusion (131).

In the sixth aspect, the protrusion (131) can be inserted into the insertion hole (112, 42) with the header (21, 22, 24) tilted so that the extension direction (V) of the insertion hole (112, 42) is aligned with the tilt direction (W).

In the seventh aspect, in any one of the first to sixth aspects, the mechanism inserts the protrusion (131) into the insertion hole (112, 42) and then rotates the header (21, 22, 24) relative to the protrusion (131).

In the seventh aspect, after inserting the protrusion (131) into the insertion hole (112, 42), the header (21, 22, 24) can be rotated relative to the protrusion (131) to adjust the position of the header (21, 22, 24).

The eighth aspect is any one of the first to seventh aspects, in which the heat transfer tubes (13) are provided in multiple stages, and the mechanism inserts the heat transfer tube (13) located in the stage closest to the inclination direction (W) of the multiple stages into the insertion hole (112, 42) from the protruding portion (131).

In the eighth aspect, the headers (21, 22, 24) can be easily attached to the multiple stages of heat transfer tubes (13).

The ninth aspect is directed to a method for manufacturing a heat exchanger. The heat exchanger includes a header (21, 22, 24) and a heat transfer tube (13) installed on a fin (16). The method for manufacturing a heat exchanger includes an insertion step of inserting a protrusion (131) of the heat transfer tube (13) protruding from the fin (16) into an insertion hole (112, 42) of the header (21, 22, 24), in which the protrusion (131) is inserted into the insertion hole (112, 42) while supporting the header (21, 22, 24 so that the extension direction (V) of the insertion hole (112, 42) is aligned with an inclination direction (W), and the inclination direction (W) is inclined with respect to the protrusion direction of the protrusion (131).

In the ninth embodiment, the headers (21, 22, 24) can be easily attached to the heat transfer tube (13).

FIG. 1 is a perspective view of a heat exchanger according to an embodiment. FIG. 2 is a perspective view of the heat exchange unit. FIG. 3 is a perspective view of the header. FIG. 4 is a perspective view of the header. FIG. 5 is a perspective view of the heat exchange unit. FIG. 6 is a side view of a heat exchanger manufacturing apparatus. FIG. 7 is a front view of the heat exchanger manufacturing apparatus. FIG. 8 is a plan view of the heat exchanger manufacturing apparatus. FIG. 9 is a perspective view of a heat exchanger manufacturing apparatus. FIG. 10 is a side view showing a state in which the header is held by the heat exchanger manufacturing apparatus. FIG. 11 is a block diagram showing the configuration of a heat exchanger manufacturing apparatus. FIG. 12 is an end view showing a procedure for attaching a header to a heat exchange section. FIG. 13 is an end view showing a procedure for attaching a header to a heat exchange section. FIG. 14 is an end view showing a procedure for attaching a header to a heat exchange section. 15(a) to 15(c) are perspective views showing a procedure for mounting a header to a heat exchange section. 16(a) to 16(c) are perspective views showing a procedure for mounting multiple header stages to multiple heat exchange sections. 17(a) to 17(c) are end views showing a first modified example of the procedure for mounting a header on a heat exchange section. 18(a) to 18(c) are end views showing a second modified example of the procedure for mounting a header on a heat exchange section. 19(a) and 19(b) are end views showing a third modified example of the procedure for mounting a header on a heat exchange section.

Embodiments of the present disclosure will be described in detail below with reference to the drawings. Note that the present disclosure is not limited to the embodiments shown below, and various modifications are possible without departing from the technical spirit of the present disclosure. Each drawing is intended to conceptually explain the present disclosure, and therefore dimensions, ratios, or numbers may be exaggerated or simplified as necessary for ease of understanding.

An exemplary embodiment is described in detail below with reference to the drawings.

<Configuration of heat exchanger>
Fig. 1 is a perspective view of a heat exchanger (100), and Fig. 2 is a perspective view of a heat exchange section (10).

The heat exchanger (100) is provided, for example, in an indoor unit or an outdoor unit of an air conditioner. The heat exchanger is a device that uses air as a cooling or heating source to condense or evaporate a refrigerant, and is, for example, a component of the refrigerant circuit of a vapor compression type refrigeration device. For example, carbon dioxide refrigerant is used as the refrigerant that circulates through the refrigerant circuit.

As shown in FIG. 1, the heat exchanger (100) has a heat exchange section (10) that exchanges heat between outdoor air and a refrigerant, a refrigerant distributor (20) provided at the other end of the heat exchange section (10) (the right end of the heat exchanger (100) shown in FIG. 1), a header (21), a header (22), and a header (24) provided at one end of the heat exchange section (10) (the left front end of the heat exchanger (100) shown in FIG. 1). In the heat exchanger (100), the refrigerant distributor (20), the header (21), the header (22), the header (24), and the heat exchange section (10) are made of, for example, aluminum or an aluminum alloy, and the respective parts are joined by brazing, for example, furnace brazing.

The heat exchange section (10) has a first heat exchange section (11) constituting the windward side of the heat exchanger (100) and a second heat exchange section (12) constituting the leeward side of the heat exchanger (100), and the heat exchange sections (11) and (12) are arranged in multiple rows (for example, two rows) so as to be adjacent to each other in the passage direction (tube row direction) of outdoor air generated by driving an outdoor fan (not shown). The first heat exchange section (11) has a first main heat exchange section (11a) constituting the upper part of the heat exchanger (100) and a first sub-heat exchange section (11b) constituting the lower part of the heat exchanger (100). The second heat exchange section (12) has a second main heat exchange section (12a) constituting the upper part of the heat exchanger (100) and a second sub-heat exchange section (12b) constituting the lower part of the heat exchanger (100).

As shown in FIG. 2, the heat exchange section (10) is composed of a plurality of heat transfer tubes (13), for example, flat tubes, and a plurality of fins (16), for example, plug fins.

The heat transfer tubes (13) are made of, for example, aluminum or an aluminum alloy, and are flat, multi-hole tubes having a flat surface (14) that serves as a heat transfer surface and a large number of small internal flow paths (15) through which the refrigerant flows. The heat transfer tubes (13) are arranged at intervals with their flat surfaces (14) facing each other. The heat transfer tubes (13) are arranged in multiple rows (for example, two rows) so that they are adjacent to each other in a staggered manner along a direction perpendicular to the flat surfaces (14). One longitudinal end of each heat transfer tube (13) (the left front end of the heat exchange section (10) in FIG. 1) is connected to the header (24), and the other end of each heat transfer tube (13) (the right end of the heat exchange section (10) in FIG. 1) is connected to the header (21) and the header (22).

The fins (16) are made of, for example, aluminum or an aluminum alloy, and are arranged at intervals along the longitudinal direction of the heat transfer tube (13). A plurality of fin grooves (17) are formed in the fins (16). The plurality of fin grooves (17) are aligned along the longitudinal direction of the fins (16). The heat transfer tube (13) is inserted into the fin grooves (17).

As shown in FIG. 1, the refrigerant distributor (20) is connected between the liquid refrigerant pipe (31) and the lower part of the header (21). The refrigerant distributor (20) is, for example, a member made of aluminum or an aluminum alloy. The refrigerant distributor (20) is configured to distribute the refrigerant flowing in through the liquid refrigerant pipe (31) and direct it to the lower part of the header (21), or to join the refrigerant flowing in through the lower part of the header (21) and direct it to the liquid refrigerant pipe (31).

As shown in Figs. 1 and 2, the header (21) is provided on the other end (right end) of the first heat exchange section (11) of the heat exchange section (10). The other longitudinal end (right end) of the heat transfer tube (13) (flat tube) constituting the first heat exchange section (11) is connected to the header (21). The header (21) is, for example, an aluminum or aluminum alloy member. A gas refrigerant tube (32) is connected to the upper part of the header (21), and refrigerant can be exchanged between the first main heat exchange section (11a) and the gas refrigerant tube (32). A refrigerant distributor (20) is connected to the lower part of the header (21), and refrigerant can be exchanged between the first sub-heat exchange section (11b) and the refrigerant distributor (20).

The header (22) is provided on the other end (right end) of the second heat exchange section (12) of the heat exchange section (10). The other end (right end) of the heat transfer tube (13) constituting the second heat exchange section (12) is connected to the header (22). The header (22) is a member made of, for example, aluminum or an aluminum alloy. The header (22) enables the exchange of refrigerant between the second main heat exchange section (12a) and the second sub-heat exchange section (12b).

Figure 3 is a perspective view of the headers (21, 22). As shown in Figure 3, the headers (21, 22) include a housing (111). The housing (111) is a hollow member. The headers (21, 22) include a plurality of insertion holes (112). The plurality of insertion holes (112) are formed in the housing (111). The plurality of insertion holes (112) are aligned in a line. The insertion holes (112) communicate between the inside of the housing (111) and the outside of the housing (111).

As shown in FIG. 1, the header (24) is provided at one end (left front end) of the heat exchange section (10). One end (left front end) of the heat transfer tube (13) constituting the heat exchange section (10) is connected to the header (24). The header (24) is, for example, an aluminum or aluminum alloy member. The header (24) has a connection passage for connecting one end (left front end) of the heat transfer tube (13) constituting the first heat exchange section (11) to one end (left front end) of the heat transfer tube (13) constituting the second heat exchange section (12). This allows the one ends (left front ends) of the heat transfer tubes (13) adjacent to each other to communicate with each other. The header (24) enables the exchange of refrigerant between the first heat exchange section (11) and the second heat exchange section (12).

Figure 4 is a perspective view of the header (24). As shown in Figure 4, the header (24) includes a housing (41). The housing (41) is a hollow member. The header (24) includes a plurality of insertion holes (42). The plurality of insertion holes (42) are formed in the housing (41). The plurality of insertion holes (42) are arranged in two rows in a staggered pattern. In this embodiment, the plurality of insertion holes (42) are composed of an insertion hole (42a) provided in the first row and an insertion hole (42b) provided in the second row. The insertion holes (42) communicate between the inside of the housing (41) and the outside of the housing (41).

When the heat exchanger (100) having the above configuration functions as a refrigerant evaporator, as shown by the arrows indicating the flow of refrigerant in FIG. 1, the refrigerant flowing in from the liquid refrigerant pipe (31) is guided to the first sub-heat exchange section (11b) through the refrigerant flow divider (20) and the lower part of the header (21). The refrigerant that has passed through the first sub-heat exchange section (11b) is guided to the second sub-heat exchange section (12b) through the lower part of the header (24). The refrigerant that has passed through the second sub-heat exchange section (12b) is guided to the second main heat exchange section (12a) through the header (22). The refrigerant that has passed through the second main heat exchange section (12a) is guided to the first main heat exchange section (11a) through the upper part of the header (24). The refrigerant that has passed through the first main heat exchange section (11a) flows out to the gas refrigerant pipe (32) through the upper part of the header (21). During this flow of the refrigerant, the refrigerant evaporates due to heat exchange with the outdoor air.

In addition, when the heat exchanger (100) functions as a refrigerant radiator, as shown by the arrows indicating the flow of the refrigerant in FIG. 1, the refrigerant flowing in from the gas refrigerant pipe (32) is guided to the first main heat exchange section (11a) through the upper part of the header (21). The refrigerant that has passed through the first main heat exchange section (11a) is guided to the second main heat exchange section (12a) through the upper part of the header (24). The refrigerant that has passed through the second main heat exchange section (12a) is guided to the second sub-heat exchange section (12b) through the header (22). The refrigerant that has passed through the second sub-heat exchange section (12b) is guided to the first sub-heat exchange section (11b) through the lower part of the header (24). The refrigerant that has passed through the first sub-heat exchange section (11b) flows out into the liquid refrigerant pipe (31) through the lower part of the header (21) and the refrigerant flow divider (20). As the refrigerant flows in this way, it releases heat through heat exchange with the outdoor air.

In this embodiment, the heat exchange section (10) is configured as a two-stage heat exchange section including a first heat exchange section (11) and a second heat exchange section (12), but it may be configured as a single-stage heat exchange section, or may be configured as a three or more stages of heat exchange sections.

<Heat exchange section>
Fig. 5 is a perspective view of a portion of the heat exchange section 10. In Fig. 5, the X-axis direction, the Y-axis direction, and the Z-axis direction are perpendicular to one another.

As shown in FIG. 5, each of the multiple fins (16) is arranged so that the longitudinal direction of the fin (16) is parallel to the X-axis direction. Each of the multiple heat transfer tubes (13) is arranged so that the longitudinal direction of the heat transfer tube (13) is parallel to the Z-axis direction.

The multiple fins (16) are aligned along the Z-axis direction, and the multiple heat transfer tubes (13) are aligned along the X-axis direction. Each of the multiple heat transfer tubes (13) is positioned so as to cross the multiple fins (16) in the Z-axis direction. Each of the multiple heat transfer tubes (13) is inserted into the fin groove portion (17) of the fin (16) that it crosses.

The fin groove portion (17) is a void located inside a portion of the fin (16) that is recessed toward the other side (Y2) in the Y-axis direction. The fin groove portion (17) includes an opening (17a). The opening (17a) connects the inside and outside of the fin groove portion (17) and is located on one side (Y1) in the Y-axis direction of the fin groove portion (17). The other side (Y2) in the Y-axis direction of the fin groove portion (17) is closed and forms the bottom of the fin groove portion (17). The fin (16) is inserted into the fin groove portion (17) through the opening (17a).

Each of the heat transfer tubes (13) includes a protrusion (131). The protrusion (131) is a portion of the heat transfer tube (13) that is inserted into the insertion hole (112) (see FIG. 3) of the header (21). In this embodiment, the protrusion (131) is a portion that protrudes toward one side (Z1) in the Z axis direction from the fin (16, 16a) that is located closest to one side (Z1) in the Z axis direction.

<Heat exchanger manufacturing equipment>
The manufacturing apparatus (200) for the heat exchanger (100) will be described with reference to Figures 6 to 11. The manufacturing apparatus (200) for the heat exchanger (100) is a device for mounting the headers (21, 22, 24) on the heat exchange section (10).

As shown in Figures 6 to 9, the heat exchanger manufacturing apparatus (200) includes a first unit (201), a second unit (202), a third unit (203), and a fourth unit (204).

The second table (202) is supported on the first table (201) so as to be movable along the Y-axis direction (up and down direction). The first table (201) has a shape that extends along the Y-axis direction. The second table (202) is installed on the other side (Z2) of the first table (201) in the Z-axis direction so as to be movable along the Y-axis direction.

The third table (203) is supported on the second table (202) so as to be movable along the Z-axis direction (front-rear direction). The second table (202) has a shape that is bent into a substantially L-shape when viewed from the X-axis direction. The second table (202) has a plate surface parallel to the X-axis direction and the Z-axis direction, and the third table (203) is installed on the plate surface of the second table (202) so as to be movable along the Z-axis direction.

A first rotating shaft (205) and a pair of second rotating shafts (206) are rotatably installed on the third table (203). The first rotating shaft (205) has a shaft core (205a) extending along the X-axis direction (left-right direction) and rotates around the X-axis around the shaft core (205a). A first driving source (207) is connected to the first rotating shaft (205) and applies power to rotate the first rotating shaft (205) relative to the first rotating shaft (205). The first driving source (207) includes, for example, a motor.

Each of the pair of second rotating shafts (206) has an axis (206a) extending along the X-axis direction (left-right direction) and rotates around the axis (206a). The pair of second rotating shafts (206) are disposed at a distance from each other along the X-axis direction. The pair of second rotating shafts (206) are disposed on the other side (Z2) in the Z-axis direction relative to the first rotating shaft (205).

A belt (208) is wound around the first rotating shaft (205) and the pair of second rotating shafts (206). The first rotating shaft (205) rotates around the shaft core (205a) due to the power of the first drive source (207), causing the belt (208) to rotate, and the pair of second rotating shafts (206) rotate around the shaft core (206a) in conjunction with the rotation of the belt (208).

As shown in Figures 9 and 10, the third table (203) has a plate surface parallel to the X-axis and Z-axis, and the fourth table (204) is arranged on one side (Z1) in the Z-axis direction of the plate surface of the third table (203). A pair of second rotating shafts (206) are fixed to the fourth table (204). One of the pair of second rotating shafts (206) is fixed to one side in the X-axis direction of the fourth table (204), and the other of the pair of second rotating shafts (206) is fixed to the other side in the X-axis direction of the fourth table (204). The fourth table (204) rotates together with the pair of second rotating shafts (206).

The fourth table (204) is provided with an insertion table (209). The insertion table (209) has a recess (209a) that is recessed to match the shape of the header (21). The header (21) is inserted into the recess (209a) so that the opening (b1) of the recess (209a) and the opening (a1) of the header (21) face in the same direction (the other side (Z2) in the Z-axis direction).

With the header (21) inserted in the recess (209a), the first drive source (207) can rotate the first rotating shaft (205) to rotate the second rotating shaft (206), the fourth table (204), and the insertion table (209) together with the first rotating shaft (205). As a result, the header (21) can be rotated in the recess (209a) of the insertion table (209) to tilt the header (21), for example, as shown in FIG. 15(a).

The fourth table (204) is provided with a header support member (210) for preventing the header (21) from coming out of the recess (209a) of the insertion table (209) when the header (21) is tilted, for example, as shown in FIG. 15(a). The header support member (210) includes a cylinder (211) and a pressing member (212). The cylinder (211) includes a base (211a) and a piston (211b). The base (211a) is fixed to the insertion table (209). The piston (211b) is supported by the base (211a) so as to be movable along a predetermined direction (G). The predetermined direction (G) is a direction extending from the opening (b1) of the recess (209a) along the bottom (b2). The pressing member (212) is fixed to the piston (211b) and moves together with the piston (211b) in a predetermined direction (G).

With the header (21) inserted in the recess (209a), the cylinder (211) adjusts the amount of movement of the piston (211b) in a predetermined direction (G) to position the pressing member (212) so that the pressing member (212) faces the header (21) from the outside of the opening (b1) of the recess (209a). As a result, as shown in Figure 9, the header (21) is pressed from the outside of the recess (209a) by the pressing member (212). Therefore, even when the header (21) is tilted as shown in Figure 15(a), the header (21) is prevented from coming out of the recess (209a) of the insertion table (209), and the header (21) is maintained in the state of being inserted in the recess (209a). The pressing member (212) holds down the portions of the header (21) that are located between adjacent insertion holes (112), thereby avoiding blocking of the insertion holes (112) of the header (21).

As shown in FIG. 11, the heat exchanger manufacturing apparatus (200) includes a second driving source (213), a third driving source (214), a memory unit (215), and a control unit (216). The second driving source (213) moves the second table (202) along the Y-axis direction. The second driving source (213) includes, for example, a Robo Cylinder. The third driving source (214) moves the third table (203) along the Z-axis direction. The third driving source (214) includes, for example, a Robo Cylinder. The memory unit (215) includes a main memory device (e.g., a semiconductor memory) such as a ROM (Read Only Memory) and a RAM (Random Access Memory), and may further include an auxiliary memory device (e.g., a hard disk drive). The main memory device and/or the auxiliary memory device store various computer programs executed by the control unit (216). The control unit (216) includes a processor such as a central processing unit (CPU) and a micro processing unit (MPU). The control unit (216) executes a computer program stored in the memory unit (215) to control various components (such as the first driving source (207), the second driving source (213), and the third driving source (214)) of the heat exchanger manufacturing apparatus (200). The above-mentioned members (insertion table (209) and header support member (210)) that support the header (21), the first drive source (207) that rotates the header (21) around the X-axis, the second drive source (213) that moves the header (21) along the Y-axis, the third drive source (214) that moves the header (21) along the Z-axis, and the control unit (216) that controls the first drive source (207) to the third drive source (214) are an example of the mechanism of the present invention. As with the header (21), the control unit (216) can rotate the headers (22, 24) around the X-axis by the first drive source (207), move them along the Y-axis by the second drive source (213), and move them along the Z-axis by the third drive source (214) while they are supported by the insertion table (209) and the header support member (210).

<First example of procedure for attaching a header to a heat exchanger>
A first example of a procedure for mounting the header (21) on the heat exchange section (10) by the heat exchanger manufacturing apparatus (200) will be described.

As shown in Figures 3 and 5, the multiple insertion holes (112) of the header (21) correspond to the multiple protrusions (131), respectively. The header (21) is attached to the heat exchange section (10) by inserting the corresponding protrusions (131) into the multiple insertion holes (112).

The procedure for inserting the protrusion (131a) into the insertion hole (112a) will be described. The insertion hole (112a) refers to one of the multiple insertion holes (112) in the header (21). The protrusion (131a) refers to the protrusion (131) among the multiple protrusions (131) that corresponds to the insertion hole (112a).

In addition, in Figures 15(a) to 16(c), the rectangular prisms representing the fins (16) are a simplified illustration of the state in which multiple fins (16) are arranged side by side.

As shown in Figures 12 and 15(a), the heat exchange unit (10) is arranged so that the opening (17a) of the fin groove portion (17) faces upward and the protruding direction of the protrusion (131a) is parallel to the horizontal direction. In other words, the heat exchange unit (10) is arranged so that one side (Y1) in the Y-axis direction is the upward direction and one side (Z1) in the Z-axis direction is the protruding direction of the protrusion (131a). The protrusion (131a) is fixed in position using a fin holder (not shown) or the like so that it is prevented from being displaced by pressure from the header (21) when inserted into the insertion hole (112) of the header (21).

As shown in Figures 12, 13, 15(a) and 15(b), the control unit (216) then controls the second driving source (213) and the third driving source (214) to place the header (21) on the inclined direction (W) side with respect to the protrusion (131a) and insert the protrusion (131a) into the insertion hole (112a) from the inclined direction (W). The inclined direction (W) is a direction inclined with respect to the protrusion direction (Z1) of the protrusion (131a) and is a direction in which the inclination angle (θ) with respect to the protrusion direction (Z1) is an acute angle. In this embodiment, the inclined direction (W) is a direction inclined toward one side (Y1) (upward) in the Y-axis direction with respect to the protrusion direction (Z1).

In this embodiment, the fin (16) is positioned so that the opening (17a) of the fin groove portion (17) faces upward. This results in a state in which, when the protrusion (131a) is inserted into the insertion hole (112a) from the inclination direction (W) side (upward side), the protrusion (131a) is inserted into the insertion hole (112a) from the opening (17a) side of the fin groove portion (17).

The control unit (216) controls the first drive source (207) to adjust the rotation angle of the header (21) so that the direction (V) of the insertion hole (112a) extends along the inclination direction (W) from a state in which the header (21) is positioned on the inclination direction (W) side of the protrusion (131a), and then controls the second drive source (213) and the third drive source (214) to move the header (21) along the inclination direction (W), thereby bringing the header (21) close to the protrusion (131a). As a result, the protrusion (131a) is inserted into the insertion hole (112a) through the opening (a1) of the insertion hole (112a).

The direction (V) in which the insertion hole (112a) extends indicates the direction from the opening (a1) of the insertion hole (112a) toward the bottom side of the insertion hole (112a). In addition, in this embodiment, the movement of the header (21) along the inclination direction (W) indicates that the header (21) moves in the opposite direction to the inclination direction (W).

In this embodiment, the header (21) is moved along the inclination direction (W) until the corner (131b) of the protrusion (131a) contacts the first inner wall surface (a2) of the insertion hole (112a).

As shown in Figures 13, 14, 15(b) and 15(c), when the protrusion (131a) comes into contact with the first inner wall surface (a2) of the insertion hole (112a), the control unit (216) controls the first drive source (207) to rotate the header (21) relative to the protrusion (131a). In this case, the header (21) is rotated until the extension direction (V) of the insertion hole (112a) becomes parallel to the protrusion direction (horizontal direction in this embodiment) of the protrusion (131a). That is, the header (21) is rotated so that the inclination angle (θ) of the inclination direction (W) relative to the protrusion direction (Z1) becomes 0 degrees. As a result, most of the protrusion (131a) is inserted into the insertion hole (112a), and the header (21) is attached to the protrusion (131a).

The header (22) is attached to the heat exchange section (10) in the same manner as the header (21).

<Second example of procedure for attaching a header to a heat exchanger>
A second example of the procedure for mounting the header (24) on the heat exchange section (10) will be described.

As shown in FIG. 4 and FIG. 16(a) to FIG. 16(c), the control unit (216) controls the second driving source (213) and the third driving source (214) to move the header (24) from a direction inclined with respect to the protruding direction of the protruding portion (131), thereby inserting the first-stage protruding portion (131, 131c) of the multiple protruding portions (131) into each of the first-stage multiple insertion holes (42, 42a) of the header (24), and then controls the first driving source (207) to rotate the header (21) to insert the second-stage protruding portion (131, 131d) of the multiple protruding portions (131) into each of the second-stage multiple insertion holes (42, 42b) of the header (24). As a result, the header (21) is attached to the heat exchange unit (10).

＜Effects＞
As described above, the protrusions (131) are inserted into the insertion holes (112, 42) while the header (21) is supported such that the extension direction (V) of the insertion holes (112, 42) is aligned with the inclination direction (W). As a result, the header (21) is inserted in a tilted state relative to the protrusions (131) of the heat transfer tube (13). Therefore, the protrusions (131) of the heat transfer tube (13) slide through the insertion holes (112, 42) of the headers (21, 22, 24), thereby reducing the horizontal frictional force from the headers (21, 22, 24) acting on the protrusions (131) of the heat transfer tube (13). This makes it possible to suppress the occurrence of defects such as deformation of the heat transfer tube (13) and horizontal positional displacement of the heat transfer tube (13) relative to the fins (16) caused by the frictional force. As a result, the headers (21, 22, 24) can be easily attached to the heat transfer tube (13). Moreover, the protrusion (131) is inserted into the insertion hole (112, 42) from a tilt direction (W) that is tilted with respect to the protruding direction of the protrusion (131). As a result, when the protrusion (131) is inserted into the insertion hole (112, 42), the protrusion (131) can be inserted into the insertion hole (112, 42) from an oblique angle, thereby effectively reducing the friction force acting on the heat transfer tube (13) in the protruding direction.

In addition, the protrusion (131) is inserted into the insertion hole (112, 42) from the opening (17a) side of the fin groove portion (17). As a result, when the header (21, 22, 24) is moved from the inclination direction (W) side to insert the protrusion (131) into the insertion hole (112, 42) of the header (21, 22, 24), the header (21, 22, 24) can be moved in the direction (downward) in which the heat transfer tube (13) is pushed into the fin groove portion (17). As a result, the header (21, 22, 24) can press the heat transfer tube (13) toward the back side of the fin groove portion (17), so that the heat transfer tube (13) can be prevented from coming off the opening (17a) of the fin groove portion (17).

In addition, when the protrusion (131) is inserted into the insertion hole (112, 42) of the header (21, 22, 24), the corner (131b) of the protrusion (131) is brought into contact with the first inner wall surface (a2) of the insertion hole (112a) (see FIG. 13). This effectively reduces the distance that the header (21, 22, 24) moves in the horizontal direction (the protruding direction of the protrusion (131)) when the protrusion (131) is inserted into the insertion hole (112, 42). As a result, the friction force in the protruding direction (horizontal direction) can be effectively reduced.

In addition, the headers (21, 22, 24) are moved along the inclination direction (W) to insert the protrusions (131) into the insertion holes (112, 42), and then the headers (21, 22, 24) are rotated relative to the protrusions (131). In this way, by inserting the protrusions (131) into the insertion holes (112, 42) and then rotating the headers (21, 22, 24) relative to the protrusions (131), the orientation of the headers (21, 22, 24) can be adjusted to the orientation when they are attached to the heat exchange unit (10).

The operation of attaching the headers (21, 22, 24) to the heat exchange section (10) is performed by the heat exchanger manufacturing apparatus (200), but may also be performed manually by an operator.

Although the embodiments and modifications have been described above, it will be understood that various modifications of form and details are possible without departing from the spirit and scope of the claims (for example, (1) to (6) below). Furthermore, the above embodiments, modifications, and other embodiments may be combined or substituted as appropriate as long as the functionality of the subject matter of this disclosure is not impaired.

<First Modification>
(1) As shown in Figs. 12 to 14, in this embodiment, when the protrusion (131a) is inserted into the insertion hole (112a) from the inclined direction (W), the protrusion (131a) comes into contact with the first inner wall surface (a2) of the insertion hole (112) and then the header (21, 22) is rotated with respect to the protrusion (131a). However, the present invention is not limited to this. A first modified example of the procedure for mounting the header (21, 22) to the heat exchange unit (10) will be described. As shown in Figs. 17(a) and 17(b), when the protrusion (131a) is inserted into the insertion hole (112a) from the inclined direction (W), the header (21, 22) may be rotated with respect to the protrusion (131a) in a state where the protrusion (131a) is not in contact with the inner wall surface of the insertion hole (112a) after the protrusion (131a) is inserted into the insertion hole (112a). That is, when the protrusion (131a) is inserted into the insertion hole (112a) from the inclined direction (W), the headers (21, 22) may be rotated with respect to the protrusion (131a) before the protrusion (131a) comes into contact with the first inner wall surface (a2) of the insertion hole (112a). As shown in Figures 17(b) and 17(c), after the headers (21, 22) are rotated, the headers (21, 22) are moved to the other side (Z2) in the Z-axis direction, whereby the headers (21, 22) are attached to the heat exchange unit (10). In addition, with regard to the header (24), the protrusion (131) may be inserted into the insertion hole (42) of the header (24) from a direction inclined relative to the protruding direction of the protrusion (131) and the header (24) may be rotated when the protrusion (131) comes into contact with the first inner wall surface (a2) of the insertion hole (42), or the header (24) may be rotated with the protrusion (131) not in contact with the inner wall surface of the insertion hole (42).

(2) In this embodiment, the heat transfer tube (13) is a flat tube. However, the present invention is not limited to this. The heat transfer tube (13) may be a circular tube that is installed so as to pass through the fins (16).

(3) In FIG. 5 and FIG. 12 to FIG. 16(c), one of the multiple protrusions (131) may be structured to be connected to another protrusion (131).

(4) As shown in FIG. 5 and FIG. 12 to FIG. 16(c), in this embodiment, the protrusion (131) is inserted into the insertion hole (112, 42) of the header (21, 22, 24) from one side (Y1) (upward side) of the Y axis with respect to the protruding direction of the protrusion (131). However, the present invention is not limited to this. The protrusion (131) may be inserted into the insertion hole (112, 42) of the header (21, 22, 24) from the other side (Y2) (downward side) of the Y axis with respect to the protruding direction of the protrusion (131).

(5) In the heat exchange section (10), the heat transfer tube (13) (flat tube) may be arranged between a pair of fins (16), with one side of the heat transfer tube (13) inserted into the fin groove portion (17) of one fin (16) and the other side of the heat transfer tube (13) inserted into the fin groove portion (17) of the other fin (16) (double insertion micro).

(6) As shown in FIG. 12, in this embodiment, while the headers (21, 22, 24) are supported in an inclined position, the headers (21, 22, 24) are moved in the opposite direction of the inclination direction (W) (toward the lower left in FIG. 12) to insert the protrusions (131) into the insertion holes (112, 42). The inclined position is a position in which the headers (21, 22, 24) are inclined so that the extension direction (V) of the insertion holes (112, 42) is along the inclination direction (W). When the headers (21, 22, 24) are in an inclined position, the headers (21, 22, 24) are positioned so that the openings (a1) of the insertion holes (112, 42) of the headers (21, 22, 24) face the opposite direction of the inclination direction (W). However, the present invention is not limited to this.

<Second Modification>
A second modified example of the procedure for mounting the headers (21, 22, 24) to the heat exchanger (10) will be described. In the second modified example, the protrusions (131) are inserted into the insertion holes (112, 42) from a direction side perpendicular to the protruding direction of the protrusions (131) (one side (Y1) in the Y-axis direction). As shown in FIG. 18(a) , the headers (21, 22, 24) are arranged on the one side (Y1) in the Y-axis direction (upward in FIG. 18(a) ) of the protrusions (131). Then, while the headers (21, 22, 24) are supported in an inclined position, the headers (21, 22, 24) may be moved to the other side (Y2) in the Y-axis direction (downward in FIG. 18(a) ) to insert the protrusions (131) into the insertion holes (112, 42). Moving the headers (21, 22, 24) to the other side (Y2) in the Y-axis direction means, in other words, moving the headers (21, 22, 24) along a direction perpendicular to the protruding direction of the protrusion (131). When the headers (21, 22, 24) are moved to the other side (Y2) in the Y-axis direction (downward) and the protrusion (131) is inserted into the insertion hole (112, 42), the protrusion (131) comes into contact with the second inner wall surface (a3) of the insertion hole (112, 42). The second inner wall surface (a3) is the wall surface on the opening (a1) side of the insertion hole (112, 42). As shown in Figures 18(a) to 18(c), when the protrusion (131) comes into contact with the second inner wall surface (a3) of the insertion hole (112, 42), the header (21, 22, 24) is rotated relative to the protrusion (131) and the header (21, 22, 24) is moved to the other side (Z2) in the Z-axis direction, thereby attaching the header (21, 22, 24) to the heat exchange section (10).

<Third Modification>
A third modified example of the procedure for mounting the headers (21, 22, 24) to the heat exchange section (10) will be described. In the third modified example, the protrusion (131) is inserted into the insertion hole (112, 42) from the protruding direction side (one side (Z1) in the Z-axis direction) of the protrusion (131). As shown in FIG. 19(a) , the headers (21, 22, 24) are arranged on one side (Y1) in the Z-axis direction (rightward in FIG. 19(a) ) of the protrusion (131). Then, while the headers (21, 22, 24) are supported in an inclined posture, the headers (21, 22, 24) may be moved to the other side (Y2) in the Z-axis direction (leftward in FIG. 19(a) ) to insert the protrusion (131) into the insertion hole (112, 42). Moving the headers (21, 22, 24) toward the other side in the Z-axis direction means, in other words, moving the headers (21, 22, 24) along the protruding direction of the protrusion (131). When the headers (21, 22, 24) are moved toward the other side (Y2) in the Z-axis direction (leftward) and the protrusion (131) is inserted into the insertion hole (112, 42), the protrusion (131) comes into contact with a first inner wall surface (a2) of the insertion hole (112, 42). The first inner wall surface (a2) is the bottom wall surface of the insertion hole (112, 42). As shown in Figures 19(a) and 19(b), when the protrusion (131) contacts the first inner wall surface (a2) of the insertion hole (112, 42), the header (21, 22, 24) is rotated relative to the protrusion (131) such that the header (21, 22, 24) is attached to the heat exchange section (10). In the first to third variants described above, when attaching the headers (21, 22, 24) to the heat transfer tube (13), the attachment operation of the headers (21, 22, 24) includes a rotation operation of the headers (21, 22, 24) (an operation in which the headers (21, 22, 24) are rotated so that the inclination angle (θ) of the inclination direction (W) relative to the protruding direction (Z1) becomes 0 degrees after the protrusion (131) is inserted into the insertion hole (112, 42)). This prevents horizontal frictional force from being applied to the heat transfer tube (13) throughout the entire operation, thereby reducing the horizontal frictional force acting on the heat transfer tube (13). In the first modified example (see FIG. 17(b)), the second modified example (see FIG. 18(b)), and the third modified example (see FIG. 19(b)), when the header (21, 22, 24) is rotated with respect to the protrusion (131) after the protrusion (131) is inserted into the insertion hole (112, 42), the header (21, 22, 24) is rotated until the extending direction (V) of the insertion hole (112, 42) becomes parallel to the protruding direction of the protrusion (131). In the second and third modified examples, as in the first modified example, the protrusion (131) may be inserted into the insertion hole (112, 42) of the header (21, 22, 24) and the header (24) may be rotated in a state in which the protrusion (131) is not in contact with the inner wall surface of the insertion hole (42).

As described above, the present disclosure is useful for a heat exchanger manufacturing apparatus and a heat exchanger manufacturing method.

13 Heat transfer tube
16 Finn
17 Fin groove
17a Fin groove opening
21, 22, 24 Header
42, 112 Header insertion hole
131 Heat transfer tube protrusion
a2 Inner wall surface of insertion hole
W Tilt direction

Claims (8)

An apparatus for manufacturing a heat exchanger, the apparatus comprising: a header (21, 22, 24) including an insertion hole (112, 42); and a heat transfer tube (13) installed on a fin (16),
a mechanism for inserting a protrusion (131) of the heat transfer tube (13) protruding from the fin (16) into an insertion hole (112, 42) of the header (21, 22, 24),
the mechanism supports the header (21, 22, 24) such that the extension direction (V) of the insertion hole (112, 42) is aligned with the inclination direction (W), and inserts the protrusion (131) into the insertion hole (112, 42);
the inclination direction (W) is a direction inclined with respect to the protruding direction of the protrusion (131),
The heat transfer tube (13) is a flat tube,
The fin (16) includes a fin groove portion (17) into which the flat tube is inserted,
The mechanism is a heat exchanger manufacturing apparatus in which the header (21, 22, 24) is moved while fixing the position of the flat tube so that the protruding direction of the protrusion (131a) is parallel to the horizontal direction, thereby inserting the protrusion (131) into the insertion hole (112, 42) from the opening (17a) side of the fin groove portion (17) . In claim 1,
The mechanism brings the protrusion (131) into contact with an inner wall surface (a2, a3) of the insertion hole (112, 42) when inserting the protrusion (131) into the insertion hole (112, 42) of the header (21, 22, 24). In claim 1 or 2 ,
The mechanism inserts the protrusion (131) into the insertion hole (112, 42) from the inclination direction (W) side. In claim 1 or 2 ,
The mechanism inserts the protrusion (131) into the insertion hole (112, 42) from a direction perpendicular to a protruding direction of the protrusion (131). In claim 1 or 2 ,
The mechanism inserts the protrusion (131) into the insertion hole (112, 42) from a protruding direction side of the protrusion (131). In any one of claims 1 to 5 ,
The mechanism inserts the protrusion (131) into the insertion hole (112, 42) and then rotates the header (21, 22, 24) relative to the protrusion (131). In any one of claims 1 to 6 ,
The heat transfer tube (13) is provided in a plurality of stages,
The mechanism inserts the heat transfer tube (13) located in the stage among the plurality of stages closest to the inclination direction (W) into the insertion hole (112, 42) from the protrusion (131). A method for manufacturing a heat exchanger including a header (21, 22, 24) and a heat transfer tube (13) installed on a fin (16), comprising the steps of:
an insertion step of inserting a protrusion (131) of the heat transfer tube (13), which protrudes from the fin (16), into an insertion hole (112, 42) of the header (21, 22, 24);
In the inserting step, the protrusion (131) is inserted into the insertion hole (112, 42) while the header (21, 22, 24) is supported so that the extension direction (V) of the insertion hole (112, 42) is aligned with the inclination direction (W);
the inclination direction (W) is a direction inclined with respect to the protruding direction of the protrusion (131),
The heat transfer tube (13) is a flat tube,
The fin (16) includes a fin groove portion (17) into which the flat tube is inserted,
In the insertion process, the header (21, 22, 24) is moved while fixing the position of the flat tube so that the protruding direction of the protruding portion (131a) is parallel to the horizontal direction, thereby inserting the protruding portion (131) into the insertion hole (112, 42) from the opening (17a) side of the fin groove portion (17) .