KR101077868B1 - Method for manufacturing intercooler system - Google Patents

Abstract

Preparing a heat dissipation fin 110 of a thin plate to drill a plurality of pin holes 112; Stacking the heat dissipation fins 110 at predetermined intervals (2); Inserting (3) the tubes 150 having an elliptical cross section into the heat dissipation fin holes 112 of the stacked heat dissipation fins 110; In order to remove the clearance between the outer surface of the tube 150 and the heat dissipation fin hole 112, by pushing the elliptical expansion means into the tube so that the tubes 150 and the heat dissipation fin hole 112 are completely bound (4). ); Applying an external force to both ends of the tube except for the portion where the tube 150 and the heat dissipation fin 110 are bound, thereby reducing the length of the major axis of the elliptical cross section of the tube (5); Inserting (6) both ends of the tube into a plurality of tubesheet holes (122) formed in the tubesheet (120); Pushing the expansion means having a circular cross section into each tube end portion (c portion) inserted into the tube sheet hole 122, thereby completely binding the tube sheet hole 122 surface and the tube end portion (c portion). (7); Cutting (8) a portion (c 'portion) of the tube end protruding out of the tube sheet 120 (completion of the heat dissipation fin and the tube and the tube sheet); An intercooler comprising a step (9) of assembling the side plates (180a, 180b), the back cover (175), the condensate collector (190), and the channel cover (170) with the combined assembly in step 7. A device manufacturing method is presented.

Description

Method for manufacturing intercooler system

The present invention belongs to the technical field related to a method of manufacturing an intercooler device. More specifically, the method of manufacturing the intercooler device is completed by using a tube having an elliptical cross section and a heat radiation fin corresponding to the shape thereof as a cooling means, but the shape of the tube sheet hole is formed into a garden for productivity. It belongs to the technical field of the manufacturing process of the intercooler device, characterized in that it undergoes a tube deformation and expansion process for coupling.

Conventional marine intercooler is a system for improving the engine power by cooling the intake air of the engine to increase the air density and increase the amount of intake air, heat radiating fins and tubes / coupled to the tube passing through the cooling water to promote heat transfer It is manufactured by combining other components such as a tube sheet and a side plate supporting the heat dissipation fin assembly.

In general, a tube with a coolant is used, because a circular tube having a circular cross section is used, and the air flows around the tube for cooling, and a wake occurs behind the tube and a pressure gradient is severe around the tube. An improved intercooler device has not been developed.

In addition, since the conventional heat sink fins and tubes were not manufactured separately, when the repair due to defects in the heat sink fins and tubes, the intercooler had to be replaced in an assembly state, and the cost of the related expenses was repeated. The method is not presented.

In view of the above problems, through the present invention, to provide a more efficient heat transfer ability, less energy consumption, to propose an innovative intercooler device manufacturing method capable of downsizing the intercooler, and also to lower the heat radiation fin / tube in the intercooler It provides a manufacturing method that can replace the bay.

The problem to be solved in the intercooler device manufacturing method of the present invention is summarized as follows.

First, by using a tube having an elliptical cross-section as a cooling tube, it is possible to promote heat transfer than a conventional round tube, smooth flow of cooling air, as well as stronger strength than the circular cross-section tube in terms of strength and durability It is to present a method for manufacturing an intercooler device.

Second, after assembling the tube and the heat dissipation fins among the elements of the intercooler and expanding them, the independent assembly can be completed to repair and replace the intercooler device. To provide a method of manufacturing an intercooler device.

In addition, it is possible to significantly reduce the repair time, and to significantly reduce the repair cost by replacing the tube / heat sink fins as one of the challenges.

Third, the carbon dioxide emission can be greatly reduced by greatly improving the heat transfer rate, and as the heat transfer rate is improved, the size of the intercooler can be reduced (down sizing), so that the manufacturing cost can be reduced, the space to be occupied, and the convenience in handling such as transportation It is to present a method for manufacturing an intercooler device.

The present invention is intended to propose the following solutions to solve the above problems.

In the intercooler manufacturing method,

Preparing a thin heat dissipation fin 110 and drilling a plurality of heat dissipation fin holes 112;

Stacking the heat dissipation fins 110 at predetermined intervals (2);

Inserting (3) the tubes 150 having an elliptical cross section into the heat dissipation fin holes 112 of the stacked heat dissipation fins 110;

In order to remove the clearance between the outer surface of the tube 150 and the heat dissipation fin hole 112, by pushing the elliptical expansion means into the tube so that the tubes 150 and the heat dissipation fin hole 112 are completely bound (4). );

Applying an external force to both ends of the tube except for the portion where the tube 150 and the heat dissipation fin 110 are bound, thereby reducing the length of the major axis of the elliptical cross section of the tube (5);

Inserting (6) both ends of the tube into a plurality of tubesheet holes (122) formed in the tubesheet (120);

Pushing the expansion means having a circular cross section into each tube end portion (c portion) inserted into the tube sheet hole 122, thereby completely binding the tube sheet hole 122 surface and the tube end portion (c portion). (7);

Cutting (8) a portion (c 'portion) of the tube end protruding out of the tube sheet 120 (completion of the heat dissipation fin and the tube and the tube sheet);

Assembling the side plate (180a, 180b), the back cover 175, the condensate collector 190 and the channel cover 170 with the combined coupling is completed in step 7 (9)

Characterized in that it comprises a.

Other details such as preferred embodiments of the present invention will be described in detail in the following detailed description.

According to the intercooler device manufacturing method of the present invention, the following effects can be obtained.

First, by using a tube having an elliptical cross-section as a cooling tube, it is possible to promote heat transfer than a conventional round tube, smooth flow of cooling air, as well as stronger strength than the circular cross-section tube in terms of strength and durability There is this.

Second, after assembling the tube and the heat dissipation fins among the elements of the intercooler and expanding them, the independent assembly can be completed to repair and replace the intercooler device. Thus, the intercooler repair time can be significantly reduced, and the repair cost can be significantly reduced.

Third, the carbon dioxide emission can be greatly reduced by greatly improving the heat transfer rate, and as the heat transfer rate is improved, the size of the intercooler can be reduced (down sizing), so that the manufacturing cost can be reduced, the space to be occupied, and the convenience in handling such as transportation There is this.

1 is an external perspective view of an intercooler body according to a process of the present invention;
2 is an exploded perspective view of FIG. 1;
Figure 3 is a perspective view of the heat radiation fin / tube block mounted on the tube sheet of the component of Figure 1,
4 is a real photograph of the heat radiation fin / tube in a state of removing the tube sheet of the component of Figure 3,
FIG. 5 is a perspective view illustrating a plurality of heat dissipation fins / tube blocks of FIG. 4;
6 is a close-up photo of the heat radiation fins used in FIG.
FIG. 7 is a perspective view of only the tube sheet separated from the components of FIG. 3; FIG.
8 is a view for explaining a process for joining a tube with a tube,
9 is a view for explaining the process after mounting the tube on the tube sheet,
10 is a view for explaining the appearance of the tube during the process of mounting the tube on the tube sheet;
11 is a view for explaining a process of fully adhering and binding the tube inside the tube seat hole by the expander after inserting the tube in the tube sheet,
12 is a view for explaining the advantages of the oval (oval type) tube used in the present invention.

Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings. However, the scope of the present invention is not limited only to the examples, and all equivalents of the inventions identified in the claims are previously disclosed to belong to the scope of the present invention.

The intercooler device manufacturing method process according to the present invention includes the following steps. However, even if the order of some of the steps of the following several changes in the level of those skilled in the art obviously belong to the scope of the present invention.

That is, a step (1) of preparing a heat dissipation fin 110 of a thin plate to punch a plurality of pin holes 112;

Stacking the heat dissipation fins 110 at predetermined intervals (2);

Inserting (3) tubes 150 having an elliptical cross section into the pinholes 112 of the stacked heat dissipation fins 110;

Pushing an elliptical expansion means into the tube to completely engage the tubes 150 and the pinholes 112 to remove the play between the outer surface of the tube and the pinholes 112;

Applying an external force to both ends of the tube except for the portion where the tube 150 and the heat dissipation fin 110 are bound, thereby reducing the length of the major axis of the elliptical cross section of the tube (5);

Inserting (6) both ends of the tube into a plurality of tubesheet holes (122) formed in the tubesheet (120);

Pushing the expansion means having a circular cross section into each tube end portion (c portion) inserted into the tube sheet hole 122, thereby completely binding the tube sheet hole 122 surface and the tube end portion (c portion). (7);

Cutting (8) a portion (c 'portion) of the tube end protruding out of the tube sheet 120 (completion of the heat dissipation fin and the tube and the tube sheet);

Assembling (9) the side plate (180a, 180b) and the back cover 175, the condensate collector 190 and the channel cover 170 with the combined coupling in step 7

Characterized in that it comprises a.

1 is an external perspective view of an intercooler main body according to a process of the present invention, FIG. 2 is an exploded perspective view of FIG. 1, and FIG. 3 is a perspective view of a heat dissipation fin / tube block mounted on a tube sheet among components of FIG. 1.

The intercooler device of the present invention is for cooling the intake air in an industrial engine, in particular a marine engine, and is a system that effectively discharges heat contained in water that is supplied from above and passes through a tube as shown in FIG. 1.

As shown in FIG. 2, each of the components of FIG. 1 includes a tube (see FIG. 4, 150) and a heat dissipation fin 110 that is integrated by retracting the tube and a pair of tube sheets 120 that accommodate the tube ends. Located in the center of 100).

In addition, the front and rear of the main body is a channel cover 170 and a back cover 175, respectively, the back cover is located, the side plates (180a, 180b) are coupled to both sides of the main body, respectively, the bottom of the main body The condensate collector 190 is located.

The passages through which water flows into and out of the tube are absorbing holes 160 and drains 161, respectively.

Hereinafter, the manufacturing method of the intercooler apparatus main body as shown in FIG. 1 is demonstrated in detail.

4 is a real picture of the heat dissipation fin / tube in the state of removing the tube sheet of the component of Figure 3, Figure 5 is a perspective view showing a plurality of heat dissipation fin / tube block of Figure 4, Figure 6 is a heat dissipation fin used in Figure 4 This is a close-up picture.

First, tubes of elliptical cross section located in the middle of the block shown in FIG. 4 are prepared. These elliptical tubes 150 are fastened to the heat dissipation fin 110 in a state in which the major axis (long axis, the axis having the longest diameter among the two diameters of the ellipse) in the up and down directions in the cross section.

In the present invention, the tube for the intercooler is adopted as the tube having an elliptic cross section for the first time, and exhibits excellent heat transfer characteristics in terms of functional and effective functions as well as a simple change in shape.

In addition, by solving the difficulties in manufacturing, such as the coupling with other components in the point of the elliptic-shaped tube to propose an intercooler device manufacturing method equipped with an elliptical tube that has not yet been tried by other companies.

The heat dissipation fins 110 are stacked in plurality at predetermined intervals (FIG. 4), but have a spacing of about 0.5 to 2.0 mm, but is not necessarily limited thereto.

The heat dissipation fin 110 has a heat dissipation fin hole 112 corresponding to the cross-sectional shape of the tube 150 (see FIG. 6). A protruding portion of about 0.5 to 1.3 mm is formed along the edge of the heat dissipation fin hole 112.

After inserting the tube 150 into the heat radiation fin holes 112 of the stacked heat radiation fins, there is a slight gap between the heat radiation fin holes and the tube. By expanding the tube, the outer circumferential surface of the heat radiation fin holes 112 is completely compressed. A block in which the heat dissipation fin / tube as shown in FIG. 4 is combined is completed.

Expansion operation is performed while the tube 150 is inserted into the heat dissipation fin hole 112 by inserting an egg-shaped ball (not shown) into the end of the tube 150 and applying a high pressure pressure. The inner diameter of the tube is increased by being pushed out through it, so that the space between the outer circumferential surface of the tube is filled on the inner surface of the heat dissipation fin 112 and the combination of the heat dissipation fin and the tube is made.

On the other hand, between the radiating fin holes 112 of Figure 4 are formed projections 114 by the embossing process, which is for the purpose of promoting heat transfer by generating turbulent flow when air flows between the radiating fins Is formed, the projections 114 are formed during the heat radiation fin pressing operation.

The heat dissipation fin hole 122 has a long axis portion (a) and a short axis portion (b), wherein the long axis portion (a) is made somewhat larger than the long axis length of the cross section of the tube 150, the short axis portion (b) of the tube Obviously, you will want to insert the tube into the heat dissipation fin hole 112 only slightly larger than the short axis length of the cross section.

When the tube 150 and the heat dissipation fin 110 are coupled as shown in FIG. 4, the tubes are arranged in a plurality of layers. In FIG. 4, the tubes are formed of three layers, and the number of the layers is arbitrarily adjustable.

However, it is preferable that the tubes disposed on the same layer are positioned directly below the space between the tubes of the upper layer, not directly below each tube of the upper layer, thereby facilitating heat transfer by the air flowing from the top to the bottom.

As described above, in the present invention, the combination of the tube 150 and the heat dissipation fin 110 is first completed, and this process is a technique not conventionally presented.

In the prior art, after the heat dissipation fin 110, the tube 150, and the tube sheet 120 are preassembled (the conventional joint shape is similar to that of FIG. 3), tube expansion is performed to integrate the heat dissipation fin / tube / tube sheet. .

That is, in the past, a tube having a circular cross section was used, and a heat radiation fin hole of a heat radiation fin accommodating the tube was also circular, and the tube sheet hole 122 was also circular, and expansion was performed only after the temporary assembly state with the tube sheet.

However, this conventional method has a big disadvantage. In other words, in order to replace the intercooler body as a whole, the work was possible only at the factory where the intercooler was manufactured.

In the present invention, only the tube 150 and the heat dissipation fin 110 as shown in FIG. 4 can be completed separately, there is an advantage that the heat dissipation fin / tube combination can be easily exchanged even in the main ship (ship) requiring intercooler repair.

Production time is also about 25 days in the prior art, while the present application has been found by the practical application that can be worked in a day.

In addition, since only the tube / heat sink fin assembly according to the present invention needs to be replaced, other components such as the tube sheet 120, the side plates 180a and 180b, and the condensate collector 190 can be reused, thereby reducing costs and recycling resources. This is a very valuable technique.

Referring to the drawings below, the following process will be described.

The next step is to uniformly deform both ends of the tube 150 of the heat dissipation fin / tube combination to insert the tube end into the tube sheet hole 122 of the tube sheet 120 to integrate the heat dissipation fin / tube / tube sheet. It is a step which performs a process to make it make. It demonstrates below.

The tube sheet (FIG. 7, 120) is a portion to be combined with the prepared heat dissipation fin / tube assembly, and holes 122 should be formed as many as the number of tubes.

However, the tube sheet hole 122 is formed in a garden shape instead of an ellipse in view of processability and productivity. This is because the process of forming the hole in the tube sheet in the shape of a garden is much easier than forming the hole in the ellipse shape.

As described above, the tube 150 has an elliptical shape in cross section, and the tube sheet hole 122 is formed in a circular shape instead of an ellipse, so that the end of the tube must be deformed into a garden shape in the tube sheet hole 122 hole. Compression can be integrated without play.

Hereinafter, the process of deforming the end of the tube 150 to be compressed and bonded to the inner surface of the tube sheet hole 122 will be described.

That is, as shown in FIG. 4, the end of the tube 150 having an elliptical cross section is slightly crushed to be as shown in the upper view of FIG. 8.

At this time, by applying a force to a part corresponding to the long axis of the ellipse in the cross section of the tube, it should be deformed to a length similar to that of the short axis and formed into a similar circle close to the circle.

The top view of FIG. 8 schematically shows the result of deforming a portion corresponding to the long axis among the slightly modified tube sections at both ends (in actual operation, the tube section is deformed into an irregularly distorted shape), and FIG. 8 The bottom left drawing is a cross-sectional view of the AA line from the left (tube long axis length W, post-deformation length X).

The portion corresponding to 151 corresponds to the right end of the tube.

8 shows the tube seat hole 122 into which the tube end is to be inserted (diameter Y). The modified tube end length X must be smaller than at least Y to be inserted into the tube sheet hole 122. .

After inserting the tube end into the tube seat hole 122, there is a certain clearance between the outer peripheral surface of the tube and the tube sheet hole, the tube sheet 120 and the tube 150 is not completely compressed, combined state.

Therefore, an expansion tube (not shown) is inserted into the tube 150 to perform an expansion process such that the tube outer circumferential surface is completely pressed onto the inner circumferential surface of the tube sheet hole 122.

This expansion process is shown in FIG. However, for convenience, the end shape of the tube 150 is represented by a circle rather than a crushed shape.

The left side of FIG. 11 shows a scene of expansion and the right side of the expansion process. In the expansion, there is a constant clearance between the tube 150 end and the tube seat hole 122 as described above, and the expansion process fills the gap. This is the process of integrating the tube and tube sheet.

A tool for making such expansion usually uses an expander. An external photograph is shown in FIG. 13, and a detailed description thereof is omitted since it is commonly used. The expansion is completed as much as the portion h of the right picture of Figure 11, by expanding the portion under the h to completely fill the tube sheet hole 122 inside the tube end to complete the expansion process.

FIG. 9 illustrates a partial cross-sectional view of the tube sheet 120, the tube 150, and the heat dissipation fin 110 in a state in which the expansion process is completed, and FIG. 10 illustrates only the tube in FIG. 9.

Outside the tube sheet hole 122, there is a part where the tube end is slightly protruded, and this part 151 is a part which is cut and removed.

The tube end portion (c) of FIG. 10 is a portion to be inserted into the tubesheet hole 122, d is a transition portion, and e is an original tube elliptic cross section by a portion corresponding to the tubesheet thickness (C) of FIG. It is wealth. The c portion of the tube 150 has a circular cross section by an expansion process.

After completing all of these processes, the tube / heat sink fin / tube sheet assembly is completed.

Subsequently, when the side plates 180a and 180b, the back cover 175, the condensate collector 190, and the channel cover 170 shown in FIG. 4 are further combined, the intercooler main body 100 as shown in FIG. 1 is completed. will be.

On the other hand, Figure 12 is a flow field analysis and pressure distribution analysis simulation results performed by applying an oval (oval type) tube shape, which is a tube used in the intercooler manufacturing method of the present invention.

Referring to FIG. 12, when a circular tube (left side) and an elliptical tube (right side) are used, a pressure drop result of air flow is shown. In the case of a circular case, a wake occurs behind the circular part. This indicates that the pressure difference is severe before and after the circle.

In terms of overall pressure reduction, it is shown that the elliptical tube (right) is better. Furthermore, the drag due to the air flow flowing between the plurality of tubes installed is also better when the elliptical tube is installed.

In addition, elliptical tubes are more capable of withstanding external forces than conventional round tubes. According to the experiment of the applicant, when the external force was applied to the outer circumferential 90 degree angle range with a pressure of 3.8 bar from the outside of the tube, the deflection amount was 13.22 mm in the tube of the circular cross section, but the elliptical tube was about 8.85 mm in the same condition. It was confirmed that it is excellent in the aspect.

100: the intercooler body
110: heat radiation fin
112: heat dissipation pin hole
120: tube sheet
122: tube seat hole
150: Tube
160: suction port
161: drain
170: channel cover
175: back cover
180a, 180b: Side plate
190: condensate water collector
W: Length of the long axis

Claims (4)

In the intercooler manufacturing method,
Preparing a thin heat dissipation fin 110 and drilling a plurality of elliptical heat dissipation fin holes 112 (step 1);
Stacking the heat dissipation fins 110 at predetermined intervals (step 2);
Inserting tubes 150 having an elliptical cross section into the elliptical radiation fin holes 112 of the stacked radiation fins 110 (step 3);
In order to remove the clearance between the outer surface of the tube 150 and the heat dissipation fin hole 112, by pushing the elliptical expansion means into the tube so that the tubes 150 and the heat dissipation fin hole 112 are completely bound (4). step);
Applying an external force to both ends of the tube of step 4 to reduce the length of the major axis of the elliptic cross-section of the tube to form a pseudo-circle (step 5);
Inserting both ends of the tube into a plurality of tube sheet holes 122 formed in the tube sheet 120 (step 6);
Pushing the expansion means having a circular cross section into each tube end portion (c portion) inserted into the tube sheet hole 122, thereby completely binding the tube sheet hole 122 surface and the tube end portion (c portion). (Step 7);
Cutting a portion (c 'portion) of the tube end protruding out of the tube sheet 120 (step 8) (completion of the heat radiation fin and the tube and the tube sheet);
Assembling the side plate (180a, 180b) and the back cover 175, the condensate collector 190 and the channel cover 170 with the combined coupling in step 7 (step 9)
Including,

In step 5, the tubes are arranged in a plurality of layers, and the tubes of the same layer are arranged at predetermined intervals, and the tubes disposed in the upper and lower layers of a specific layer are disposed in the space between the tubes of the specific layer, thereby providing cooling. To ensure a smooth air flow

In the step 5, the external force is applied so that the length X of the tube end is smaller than the diameter Y of the tube sheet hole 122,

The tube sheet hole 122 formed in the tube sheet prepared in the step 6 is formed in a garden shape, characterized in that the tube of the fifth step is inserted into the garden-shaped tube sheet hole 122,
Intercooler device manufacturing method.
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