US20020133949A1 - Recuperator cell assembly procedure - Google Patents
Recuperator cell assembly procedure Download PDFInfo
- Publication number
- US20020133949A1 US20020133949A1 US09/908,089 US90808901A US2002133949A1 US 20020133949 A1 US20020133949 A1 US 20020133949A1 US 90808901 A US90808901 A US 90808901A US 2002133949 A1 US2002133949 A1 US 2002133949A1
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- United States
- Prior art keywords
- cell
- work
- work station
- pair
- work position
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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- 238000003466 welding Methods 0.000 claims description 50
- 238000004519 manufacturing process Methods 0.000 claims description 18
- 229910000831 Steel Inorganic materials 0.000 claims description 16
- 239000010959 steel Substances 0.000 claims description 16
- 238000012360 testing method Methods 0.000 claims description 10
- 239000000853 adhesive Substances 0.000 claims description 7
- 230000001070 adhesive effect Effects 0.000 claims description 7
- 238000007789 sealing Methods 0.000 claims description 5
- QSHDDOUJBYECFT-UHFFFAOYSA-N mercury Chemical compound [Hg] QSHDDOUJBYECFT-UHFFFAOYSA-N 0.000 claims description 3
- 229910052753 mercury Inorganic materials 0.000 claims description 3
- 125000006850 spacer group Chemical group 0.000 abstract description 8
- 238000010276 construction Methods 0.000 abstract description 7
- 230000000712 assembly Effects 0.000 description 17
- 238000000429 assembly Methods 0.000 description 17
- 239000007789 gas Substances 0.000 description 8
- 239000012530 fluid Substances 0.000 description 6
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 6
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 2
- 238000002485 combustion reaction Methods 0.000 description 2
- 238000001816 cooling Methods 0.000 description 2
- 229910052802 copper Inorganic materials 0.000 description 2
- 239000010949 copper Substances 0.000 description 2
- 239000011800 void material Substances 0.000 description 2
- 230000002950 deficient Effects 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 238000010998 test method Methods 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
- B23P15/26—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass heat exchangers or the like
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P21/00—Machines for assembling a multiplicity of different parts to compose units, with or without preceding or subsequent working of such parts, e.g. with programme control
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
- F28D9/00—Heat-exchange apparatus having stationary plate-like or laminated conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall
- F28D9/0062—Heat-exchange apparatus having stationary plate-like or laminated conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits for one heat-exchange medium being formed by spaced plates with inserted elements
- F28D9/0068—Heat-exchange apparatus having stationary plate-like or laminated conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits for one heat-exchange medium being formed by spaced plates with inserted elements with means for changing flow direction of one heat exchange medium, e.g. using deflecting zones
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/4935—Heat exchanger or boiler making
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/4935—Heat exchanger or boiler making
- Y10T29/49357—Regenerator or recuperator making
Definitions
- This invention relates generally to an recuperator and more particularly to a cell of the recuperator and to a procedure for manufacturing the cell.
- recuperator for a gas turbine engine must be capable of operating at temperatures of between about500 degrees C. and 800 degrees C. and internal pressures of between approximately 140 kPa and 1400 kPa under operating conditions involving repeated starting and stopping cycles.
- Such recuperators include a core which is commonly constructed of a plurality of relatively thin flat sheets having an angled or corrugated spacer fixedly attached therebetween.
- the sheets are joined into cells, sealed and form passages between the sheets.
- These cells are stacked or rolled and form alternate air (recipient) cells and hot exhaust (donor) cells.
- Compressed discharged air from a compressor of the engine passes through the air cell while hot exhaust gas flows through alternate cells.
- the exhaust gas heats the sheets and the spacers, and the compressor discharged air is heated by conduction from the sheets and spacers.
- the need for repeatability of construction of each cell assures that the final recuperator is economically and easily assembled. Examples, of such repeatability required includes length, height, thickness, weld size, weld position, weld splatter and others.
- the present invention is directed to overcoming one or more of the problems as set forth above.
- an automated method of manufacturing a cell is disclosed.
- the cell is adapted for use with a recuperator.
- the method of manufacturing is comprised of the following steps. Actuating a master control system. Actuating a work station control system. Actuating a first work station defining a first work position. Positioning a first donor bar in a first fixture designated as “A”. A second work positioning a second donor bar in a second fixture designated as “B”. A third work position positioning a sheet into the first fixture “A” and the second fixture “B”. Each of the sheets having a recipient side being up. And, attaching the first donor bar and the second donor bar to the sheets forming a pair of cell portions.
- a fourth work position rotating a pair of cell portions and further attaching the sheets and the first donor bars.
- a second work position of the second work station positioning a second recipient bar on the recipient side of the sheet in the second fixture “B′” and attaching the second recipient bar to the sheet.
- a third work position of the second work station positioning a first recipient bar on the recipient side of the sheet in the second fixture “B′”. Positioning a pair of director sheets with the first recipient bar thereon on the recipient side of the sheet in the second fixture “B′” and further attaching the first recipient bar to the sheet.
- a fourth work position of the second work station positioning the cell portion from the first fixture “A′” to the second fixture “B′” with the donor side of the sheet being up and further attaching the cell portion from the first fixture “A′” to the cell portion of the second fixture “B′”.
- a third work station defining a first work position of the third work station. Transferring the cell portion as welded from the second fixture “B′” of the fourth work position of the second work station into a second work position of the third work station and rotating the cell portion into a preestablished position.
- the second work position of the third work station fixedly attaching linearly along a portion of a bottom edge of the sheet and an entire length of the second recipient bar.
- a third work position of the third work station transferring and rotating the cell portion as fixedly attached from the second work position of the third work station to the third work position of the third work station. Forming the cell portion and fixedly attaching a pair of side edges of the sheet to the first recipient bar.
- a fourth work position of the third work station transferring and positioning the cell portion as fixedly attached to the fourth work position of the third work station fixedly attaching a top edge of the sheet and the first recipient bar. And, a fifth work position of the third work station staging the cell portion as fixedly attached. And, actuating a fourth work station defining a first work position of the fourth work station. Transferring the cell portion from the fifth work position of the third work station to a second work position of the fourth work station. The second work position of the fourth work station testing a leakage of the cell portion. The first work position of the fourth work station further transferring the cell portion as tested to a third work position of the fourth work station. Attaching a director sheet to the donor side of the sheet. The first work position of the fourth work station further transferring the cell as completed to a fourth work position of the fourth work station unloading the cell.
- a cell is formed of a plurality of individual components being produced by an automated process and being adapted for use with a recuperator.
- the cell is comprised of a pair of performed sheets defining a donor side and a recipient side.
- a plurality of donor bars are attached to the donor side of the pair of performed sheets.
- a plurality of recipient bars are attached to the recipient side of the pair of performed sheets.
- a donor side director sheet is in contacting relationship with the donor side of at least one of the pair of performed sheets.
- a recipient side director sheet is in contacting relationship with the recipient side of at least one of the pair of performed sheets.
- the pair of performed sheets, the plurality of donor bars and the plurality of recipient bars being fixedly attached one to another forming the cell.
- FIG. 1 is a top view of the assembly apparatus embodying the present invention
- FIG. 2 is a view take through a cell looking at a donor side of a sheet used in making up a recuperator as is embodied in the present invention
- FIG. 3 is a view taken through a cell looking at a recipient side of the sheet use in making up the recuperator as is embodied in the present invention
- FIG. 4 is a sectional view of a cell used in making up a recuperator as is embodied in the present invention
- FIG. 5 is an enlarged view of a portion of the assembly apparatus, a first work station, embodied in the present invention
- FIG. 6 is an enlarged view of a portion of the assembly apparatus, a second work station, embodied in the present invention.
- FIG. 7 is an enlarged view of a portion of the assembly apparatus, a third work station, embodied in the present invention.
- FIG. 8 is an enlarged view of a portion of the assembly apparatus, a fourth work station, embodied in the present invention.
- the assembly process 10 includes a plurality of work stations 12 being interconnected. Each of the plurality of work stations 12 accomplish a plurality of preestablished tasks 14 . Each of the plurality of work stations 12 and the tasks 14 are preestablishly controlled by a master control system 16 of conventional construction. The master control system 16 is divided into a plurality of work station control systems 18 .
- a cell or work piece 20 includes a plurality of components or parts 22 .
- a portion of the plurality of parts 22 includes a pair of performed sheet 24 defining a thickness 25 , a first or donor or gas side 26 , a second or recipient or air side 28 .
- the performed sheet 24 defines a bottom edge 30 , a top edge 32 and a pair of side edges 34 .
- the performed sheet 24 further includes a serpentined portion 36 .
- the sheet 24 could be dimpled or have another configuration rather than being serpentined.
- the sheet 24 has a trapezoidal configuration but could be of other configurations, such as a parallelogram or square or rectangular.
- the serpentined portion 36 has a generally rectangular configuration and is positioned between the top edge 32 and a portion of the bottom edge 30 .
- the serpentined portion 36 could be of other configurations, such as a parallelogram or square or triangle or a trapezoidal.
- the serpentined portion 36 defines an axis 38 .
- the performed sheet 24 further includes a pair of flattened portions 40 .
- each of the pair of flattened portions 40 have a generally triangular configuration.
- the pair of flattened portions 40 could be singular, or of another configuration, such as a square, a rectangle or a parallelogram.
- Each of the pair of flattened portions 40 extends from the serpentined portion 36 to the respective one of the pair of sides 34 and a portion of the top edge 32 and a portion of the bottom edge 30 .
- a portion of the serpentined portion 36 is also flattened along each of the top edge 32 and the bottom edge 30 .
- the flattened portions 40 along each of the top edge 32 and the bottom edge 30 define a preestablished or substantial thickness 42 .
- a plurality of spacer bars 44 are used to form the cell 20 and are positioned upon the performed sheet 24 in a preestablished order and position.
- the plurality of spacer bars 44 are divided into a plurality of donor bars 46 and a plurality of recipient bars 48 .
- a preestablished thickness or substantial thickness “T of D” is defined for each of the plurality of donor bars 46 and a preestablished thickness or substantial thickness “T of R” is defined for each of the plurality of recipient bars 48 .
- the plurality of donor bars 46 define a preestablished thickness, a preestablished width and a preestablished length.
- the plurality of recipient bars 48 have a preestablished thickness, a preestablished width and a preestablished length.
- the preestablished length of individual ones of the plurality of donor bars 46 and the plurality of recipient bars 48 have different lengths.
- the preestablished width of the individual ones of the plurality of donor bars 46 and the plurality of recipient bars 48 have generally the same width.
- the width or thickness of the plurality of donor bars 46 and the plurality of recipient bars 48 could be of various preestablished thicknesses or widths of the same thickness or width without changing the jest of the invention.
- the individual ones of the plurality of donor bars 46 have a thickness being about one-half of the thickness of the plurality of recipient bars 48 .
- a first recipient bar 50 of the plurality of recipient bars 48 has a generally “U” configuration being formed by a base, a pair of legs and having an open end 51 .
- the first recipient bar 50 could be segmented to include the base and the pair of legs.
- a second recipient bar 52 of the plurality of recipient bars 48 has a length being generally equal to that of the length of the serpentined portion 36 along the bottom edge 30 .
- the plurality of donor bars 46 has a first donor bar 54 being generally equal to the length of the bottom edge 32 and a second donor bar 56 being generally equal to the length of the top edge 30 of the performed sheet 24 .
- the donor side director sheets 60 define a plurality of alternating root portions 64 and crest portions 66 .
- the plurality of root portions 64 and the crest portions 66 of the donor side director sheet 60 form an axis 68 which is axially aligned with the axis 38 of the serpentined portion 36 .
- the recipient side director sheets 62 also define a plurality of alternating root portions 70 and crest portions 72 .
- the plurality of root portions 68 and the crest portions 72 of the recipient side director sheets 62 form an axis 74 which is generally parallel to the respective one of the pair of side edges 34 .
- the plurality of work stations 12 include a first work station 78 , as best shown in FIG. 5.
- the first work station 78 includes a four position rotary indexer unit 80 defining a first work position 82 , a second work position 84 , a third work position 86 and a fourth work position 88 .
- the unit 80 is indexable between the various work position 82 , 84 , 86 , 88 .
- a first roll of steel stock 90 is positioned in line with a straightening device 92 .
- a pair of press assemblies 94 cuts the steel stock 90 into individual ones of the plurality of donor bars 46 having the preestablished length.
- the first donor bars 54 are positioned in a first fixture 96 of a pair of two nest fixture assemblies 98 , designated as “A” and “B”, in a conventional manner.
- a second roll of steel stock 100 is positioned in line with a straightening device 102 .
- a pair of press assemblies 104 cuts the steel stock 100 into individual ones of the plurality of donor bars 46 having the preestablished length.
- the second donor bars 56 are positioned in a second fixture 106 of the pair of two nest fixture assemblies 98 , designated as “A” and “B” in a conventional manner.
- Each of the two nest fixture assemblies 98 further include two micarata plates which incorporate electrodes and copper bus bars in a conventional manner.
- the assembly process 10 includes a transportation system 110 , which in this application, has a pallet 112 upon which a predetermined number of performed sheets 24 are located and positioned in a pair of stacks.
- a sheet gauge not shown, is used to qualify each of the performed sheets 24 prior to being positioned on the pallet 112 .
- a sheet lifting assembly, not shown, is positioned under the pallet 112 .
- the performed sheets 24 are placed on a conveyer 114 in a pair of rows in a conventional manner.
- the performed sheets 24 are also placed on the conveyer in a predetermined pattern as will be explained latter.
- the transfer of the performed sheets 24 from the conveyer 114 to the four position rotary indexer unit 80 is accomplished by a rotary part handler 120 that incorporates a tooled arm 122 .
- the performed sheets 24 have the recipient side 28 up.
- the tooled arm 122 is rotatable from a first position 124 , being aligned with the pair of rows of performed sheets 24 on the conveyer 114 , to a second position 126 , being aligned with each of the two nest fixture assemblies, “A” and “B”, at the third work position 86 of the first work station 78 .
- the tooled arm 122 includes a vacuum tool 128 which has been adapted for this application.
- an independent resistance weld assembly 136 or tack welding operation will be used to tack the performed sheet 24 to the first donor bar 54 and to the second donor bar 56 .
- an indexing fixture 140 rotates the portion of the cell 20 .
- a water cooled gripper assembly 142 holds the performed sheet 24 and the first donor bar 54 in a fixed position with the bottom edge 30 of the performed sheet 24 up.
- a pair of seamer units 144 having a pair of weld torches 146 which in this application are of a plasma weld type, form a sealed weld between the first donor bar 54 and the performed sheet 24 generally along the pair of flattened portions 40 having the triangular configuration.
- the first work station 78 produces a pair of cell 20 portions or components 148 in a side by side operation.
- the plurality of work stations 12 include a second work station 150 , as best shown in FIG. 6.
- the second work station 150 includes a four position rotary indexer unit 152 defining a first work position 154 , a second work position 156 , a third work position 158 and a fourth work position 160 .
- the unit 152 is indexable between the various work position 154 , 156 , 158 , 160 .
- the transfer of the cell 20 portion, including the performed sheet 24 and the plurality of donor bars 46 is performed by a rotary part handler 170 that incorporates a pair of tooled arms 172 using a vacuum tool 173 .
- the pair of tooled arms 172 are rotatable from a first position 174 , as shown in phantom, being aligned with each of the pair of two nest fixture assemblies 98 designated as “A” and “B” of the fourth work position 88 of the first work station 78 , to a second position 176 , being aligned with a pair of two nest fixture assembly 178 positioned in the first work position 154 of the second work station 150 .
- a first fixture 180 of the pair of two nest fixture assemblies 178 is designated as “A′” and a second fixture 182 of the pair of two nest fixture assemblies 178 is designated as “B′”.
- Each of the pair of two nest fixture assembly 178 further includes two micarata plates which incorporate electrodes and copper bus bars of conventional construction.
- One of the pair of tooled arms 172 also rotates the cell portion 20 to position the donor side 26 up in the second fixture 182 designated as “B′” whereas the cell portion 20 positioned in the first fixture 180 designated as “—A” is positioned with the recipient side 28 up.
- the pair of tooled arms 172 include the vacuum tool 173 which has been adapted for this application. Other types of tools, such as magnets or suction cups could be uses without changing the jest of the invention.
- a third roll of steel stock 190 is positioned in line with a straightening device 192 .
- a press assembly 194 cuts the steel stock 190 into individual ones of the plurality of recipient bars 48 having the preestablished length.
- the second recipient bar 52 is positioned on the recipient side 28 of the performed sheet 24 along the flattened portion of the bottom edge 30 between the pair of flattened portions 40 in a conventional manner.
- the second recipient bar 52 is only placed in the second fixture 182 designated as “B′” of the pair of two nest fixture assemblies 178 .
- the first fixture 180 of the pair of two nest fixture assemblies remains void of the second recipient bar 52 .
- an independent resistance weld assembly 196 will be used to tack the performed sheet 24 to the second recipient bar 52 .
- the first recipient bar 50 being S formed in the “U” configuration, with the recipient side director sheets 62 attached thereto are loaded into a gravity feed rack assembly 200 .
- the first recipient bar 50 and the recipient side director sheets 62 are passed through a gage 202 to insure proper dimensional control prior to being positioned on the recipient side 28 of the performed sheet 24 .
- the first recipient bar 50 and the recipient side director sheets 62 are positioned within the pair of flattened portions 40 and along the flattened portion of the top edge 32 in a conventional manner.
- the first recipient bar 50 and the recipient side director sheets 62 is only placed in the second fixture 182 of the pair of two nest fixture assemblies 178 designated as “B′”.
- the first fixture 180 of the pair of two nest fixture assemblies remains void of the first recipient bar 50 and the recipient side director sheet 62 .
- an electrode assembly 204 is lowered to the second fixture 182 .
- the electrode assembly 204 incorporates tooling that will justify the legs into the proper position, creating the correct sheet and bar gap.
- Two independent electrodes, not shown, of the electrode assembly 204 are lowered to the first recipient bar 50 and resistant tack welds the first recipient bar 50 to the performed sheet 24 near the open end 51 .
- the cell 20 portion including the performed sheet 24 and the plurality of donor bars 46 which has been positioned in the first fixture 180 of the pair of two nest fixture assemblies 178 designated as “A′” is positioned on top of the cell 20 portion built-up within the second fixture 182 of the pair of two nest fixture assemblies 178 designated as “B′”.
- a vacuum tool 206 is used to pick-up, locate and place the cell 20 portion from “A′” to “B′”.
- a pair of independent electrode assemblies 208 are lowered to resistant tack weld the performed sheet 24 and the plurality of donor bars 46 to the performed sheet 24 , the plurality of donor bars 46 , the plurality of recipient bars 48 and the pair of recipient side director sheets 62 .
- the tack weld takes place near the open end 51 .
- the plurality of work stations 12 include a third work station 220 .
- the third work station 220 includes a first work position or robot unit 222 , a pair of second work positions or first welding positions 224 , a pair of third work positions or second welding positions 226 , a pair of fourth work positions or third welding positions 228 and a fifth work position or staging unit 230 .
- Individual ones of the pair of first welding positions 224 , the pair of second weld positions 226 and the pair of third weld positions 228 are divided into two duplicate sides forming a first or left lane 232 and a second or right lane 234 .
- the robot unit 222 of the third work station 220 picks the tack welded cell 20 portion from the fourth work position 160 of the second work station 150 and positions the cell 20 portion into one of the pair of first weld positions 224 .
- a second one of the cell 20 portion from the fourth work position 160 of the second work station 150 is placed in the other of the pair of first weld positions 224 by the robot unit 222 .
- a third one of the cell 20 portion is placed into the staging unit 230 if the pair of first welding positions 224 are not available.
- the cell 20 portion is placed in the pair of first weld positions 224 .
- a water cooled gripper assembly 236 holds the performed sheet 24 and the first donor bar 54 in a fixed position.
- a rotating mechanism 238 rotates the cell 20 portion to a preestablished position for welding.
- the bottom edge 30 of the performed sheets 24 is positioned up.
- a seam welder 240 which in this application, has a pair of torches 242 .
- Each of the pair of torches 242 sealingly does half of the linear weld along a portion of the bottom edges 30 of the performed sheets 24 and the entire length of the second recipient bar 52 .
- the remainder of the bottom edge 30 not being welded forms one of a recipient fluid inlet 244 or a recipient fluid outlet 246 , as are best shown in FIG. 3.
- a pick and place mechanism 250 will grasp the cell 20 portion from the respective one of the pair of first welding positions 224 and position the cell 20 portion in the second welding positions 226 .
- the cell 20 portion is rotated and the bottom edges 30 and the second recipient bar 52 are placed in a forming fixture 252 .
- the cell 20 portion has the top edges 32 of the performed sheets 24 , the second donor bars 56 and the base portion of second recipient bar 52 facing up.
- the forming fixture 252 is used to hold and form the cell 20 portion into a preestablished configuration.
- the preestablished configuration is that of an involute in this application.
- water cooling is incorporated.
- a pair of welding torches 254 are positioned at the each of the pair of side edges 34 near the open end 51 of the first recipient bar 50 .
- the pair of welding torches 254 sealingly does the welding of the respective pair of side edges 34 of the performed sheets 24 and the respective one of the pair of legs of the first recipient bar 50 .
- the pair of welding torches 254 also weld the top and bottom corners.
- the welding torches 254 are attached to a robot 256 in a conventional manner.
- the pick and place mechanism 250 will, at this time, grasp the cell 20 portion from the respective one of the pair of second welding positions 226 and position the cell 20 portion in the third welding position 228 .
- the cell 20 portion has the top edges 32 of the performed sheets 24 , the second donor bars 56 and the base portion of second recipient bar 52 facing up.
- Each of the third welding positions 228 incorporate a water cooled gripper 260 .
- the third welding positions 228 have a slide system 262 positioned therein of conventional construction. The slide system 262 utilizes a pair of welding torches 264 attached thereto.
- Each of the pair of torches 264 sealingly does half of the linear weld along the top edges 32 of the performed sheets 24 and the base portion of the first recipient bar 50 .
- a pair of cells 20 less the pair of donor side director sheets 60 , are formed after the completion of the third work station 220 .
- the plurality of work stations 12 include a fourth work station 270 .
- the fourth work station 270 includes a first work position or walking beam conveyor assembly 272 communicating with each of a second work positions or leak test position 274 , a third work position or donor side director sheet position 276 and a fourth work positions or unloading position 278 .
- a servo driven pick and place assembly 280 is used to transferring the cell 20 portion which has been completely welded on the outer perimeter from the pair of third welding position 228 of the third work station 220 to the walking beam conveyor assembly 272 .
- the cell 20 portion is indexed into the leak test position 274 .
- a sealing tool assembly 282 is properly positioned on the cell 20 portion and a leak test procedure is performed.
- a vacuum of about 25 inches of mercury is pulled within the cell 20 to qualify the structure and functionality of the cell 20 . If a cell 20 portion fails to qualify the cell 20 portion is removed from further operations at a reject unloading station 284 . After the cell 20 portion has been qualified, it is transferred to the donor side director sheet position 276 .
- a forming tool 286 takes a precut sheet and forms the plurality of alternating root portions 64 and the crest portions 66 .
- the forming tool 286 forms the pair of donor side director sheets 60 at the same time.
- An adhesive system 288 dispenses a thin line of adhesive to the donor side 26 , in the flattened portions 40 , of the performed sheets 24 .
- a pick and place mechanism 290 picks and places the pair of donor side director sheets 60 on the donor side 26 , in the flattened portions 40 , of the performed sheets 24 in a preestablished position.
- the cell 20 is complete. From the donor side director sheet position 276 , the cell 20 is transferred to the unloading position 278 and unloaded therefrom and transferred to a recuperator assembly area in a conventional manner, not shown.
- the cell 20 being manufactured by the automated process or method 10 provides a cell 20 having a preestablished configuration and defining a preestablished thickness “T of C”.
- the automated process or method 10 provides an actual thickness “T of A” being within about plus or minus about “0.6 mm (0.025 inches)” of the preestablished thickness “T of C”. And, with the automated welding processed used, the welding operation fails to increase the actual thickness “T of A”.
- Water cooling is used as necessary to increase life of the grippers, fixtures etc.
- a plasma welding process is used.
- a vacuum process is used for the pick-up and place operation.
- a spool de-coiling system along with a positive feed system is used with the rolls of steel stock.
- other welding processes, transferring processes and pick-up and place processes could be used without changing the essence of the invention.
- the assembly process 10 is used for making a recuperator cell 20 .
- the master control system 16 is activated and the plurality of work station control systems 18 are functionally operationable.
- the assembly process 10 begins with the first roll of steel stock 90 being positioned and passed through the straightening device 92 .
- the steel stock 90 is cut into the preestablished length forming the first donor bar 54 and is placed in the portion of the nest fixture designated as “A”.
- a second first donor bar 54 is also cut and placed in the portion of the nest fixture designated as “B”.
- the indexer unit 80 of the first work station 78 is indexed and moved to the second work position 84 .
- the second roll of steel stock 100 passed through the straightening device 92 .
- the steel stock 90 is cut into the preestablished length forming the second donor bar 56 and is placed in the nest fixture designated as “A′”.
- a second second donor bar 56 is also cut and placed in the nest fixture designated as
- the indexer unit 80 is indexed and moved to the third work position 86 .
- the performed sheets 24 having been communicated to the conveyer 114 are picked up by the vacuum tooling at the first position 124 of the rotary part handler 120 , rotated and are properly positioned in the pair of nest fixtures 98 at the second position 126 .
- the width of the first and second donor bars 54 , 56 is in contacting relationship with the donor side 26 .
- the first and second donor bars 54 , 56 are respectively positioned in the flattened portion of the bottom edge 30 and the top edge 32 .
- the resistance weld assembly 136 is used to tack the individual first and second donor bars 54 , 56 and individual performed sheets 24 in each of the pair of nest fixtures 98 .
- Each of the first and second donor bars 54 , 56 have two points of resistance tack weld, additional points of resistance tack weld could be used.
- the indexer unit 80 is indexed and moved to the fourth work position 88 .
- the water cooled gripper assembly 124 grasps the work piece and the indexing fixture 140 rotates the performed sheets 24 and the tack welded plurality of donor bars 46 into the fixed position with the bottom edge 30 of the performed sheet 24 up.
- the pair of weld torches 146 of each of the seamer units 144 are positioned above the interface of the bottom edge 30 and the first donor bar 54 at the respective one of the flattened portions 40 of each cell 20 portion produced by “A” and “A′”, and “B” and “B′”.
- one of the pair of weld torches 146 is positioned near one of the pair of sides 34 .
- the other one of the pair of weld torches 146 is positioned near the serpentined portion 36 .
- the pair of weld torches are activated by the appropriate one of the plurality of work station control systems 18 and the sealed weld is completed.
- the completed weld extends linearly from the each of the pair of sides 34 to the serpentined portion 36 .
- the length of each weld is about 15 ⁇ 8′′ or about 41.3 mm.
- the pair of tooled arms 172 of the rotary part handler 170 at the first position 174 pick the cell 20 portions from the fourth work position 88 of the first work station 78 . And, the pair of tool arms 172 of the rotary part handler 170 are moved into the second position 176 . Prior to positioning the cell 20 portions, one of the pair of tooled arms 172 is rotated and the cell portion 20 is positioned with the donor side 26 up in the second fixture 182 designated as “B”. The cell portion 20 positioned in the first fixture 180 designated as “A” is positioned with the recipient side 28 up.
- the indexer unit 152 of the second work station 150 is indexed and moved to the second work position 156 .
- the third roll of steel stock 190 is passed through the straightening device 192 .
- the steel stock 190 is cut into the preestablished length forming the second recipient bar 52 and is placed in the nest fixture designated as “B” along the flattened portion of the bottom edge 30 and is interposed the welds completed at the fourth work position 88 of the first work station 78 .
- the resistance well assembly 196 is positioned and tack welds the performed sheet to the second recipient bar 52 .
- the performed sheet and the second recipient bar 52 are resistance tack welded in two places, additional points of resistance tack weld could be used.
- the indexer unit 152 of the second work station 150 is indexed and moved to the third work position 158 .
- the preassemblied first recipient bar 50 having the “U” configuration with the recipient side director sheets 62 attached thereto are passed through the gage 202 assuring uniformity of the final assembly.
- the preassemblied bar 50 and sheet 62 are positioned in the second fixture 178 designated as “B”.
- the preassembly is positioned with the respective sheet 62 and leg in the respective one of the pair of flattened portions 40 and the base in the flattened portion along the top edge 32 .
- the electrode assembly 204 is lowered and the first recipient bar 50 is resistance tack welded to the performed sheet 24 .
- the resistance tack weld is completed in two places, additional points of resistance tack weld could be used. The two places being near the open end 51 of the first recipient bar 50 .
- the indexer unit 152 of the second work station 150 is indexed and moved to the fourth work position 160 .
- the vacuum tool 206 picks the cell 20 portion from the second fixture 182 designated as “A”, and locates and positions the cell 20 portion from “A” on top of the cell 20 portion within the first fixture 180 designated as “B”.
- the pair of electrode assemblies 208 resistance tack weld the performed sheet 24 from “A” to the first recipient bar 50 .
- the resistance tack weld is completed in two places, additional points of resistance tack weld could be used. The two places being near the open end 51 of the first recipient bar 50 .
- the tasks 14 of the second work station 78 are completed.
- the robot unit 222 of the third work station 220 picks the cell 20 portion from the fourth work position 160 of the second work station 150 and one of the plurality of station control systems 18 of the master control system 16 directs the robot unit 222 to place the cell 20 portion into the appropriate one of the pair of first weld positions 224 . If each of the pair of first weld positions 224 is full, the master control system 16 will direct the robot unit 222 to place the cell 20 portion into the staging unit 230 .
- the cell 20 portion is rotated by the rotating mechanism 238 to the preestablished position to be welded.
- the pair of torches 242 of the seam welder 240 are positioned along the bottom edge 30 of the performed sheets 24 and the entire length of the second recipient bar 52 is welded.
- One of the pair of torches 242 is positioned at the end of the second recipient bar 52 and the other one of the pair of torches 242 is positioned at a lineal distance half way along the length of the second recipient bar 52 . As the pair of torches 242 slide and travel linearly along the length of the second recipient bar 52 the entire length of the second recipient bar 52 is sealingly welded. Each of the pair of torches 242 does half of the linear weld and the two welds are blendingly and sealingly connected near the center of the second recipient bar 52 .
- the pick and placer mechanism 250 After being welded along the bottom edges 30 and the second recipient bar 52 , the pick and placer mechanism 250 removes the cell 20 portion from the respective one of the pair of first welding positions 224 .
- the cell 20 portion is positioned into the second welding position 226 .
- the pick and place mechanism 250 prior to positioning the cell 20 portion into the second welding position 226 rotates the cell 20 portion.
- the bottom edge 30 of the performed sheets 24 is gripped by the forming fixture 252 .
- the forming fixture 252 is actuated by the station control system 18 and the cell 20 portion is formed into the involute configuration.
- the station control system 18 directs the robots 256 to position the respective one of the pair of welding torches 254 to the intersection of the top edge 32 and the respective one of the pair of sides 34 . And, the station control system 18 directs the pair of welding torches 254 to plasma weld each of the pair of sides 34 .
- the welds sealingly connect the ends of the donor bars 46 near the bottom edges 30 of the performed sheets 24 , the pair of sides 34 of the performed sheets 24 , the ends of the donor bars 46 near the top edges 32 of the performed sheets 24 and the pair of legs of the first recipient bar 50 .
- the pick and placer mechanism 250 After being formed and welded along the pair of sides 34 , the pick and placer mechanism 250 removes the cell 20 portion from the respective one of the pair of second welding positions 226 and positions the cell 20 portion into the third welding position 228 .
- the pick and place mechanism 250 positions the cell 20 portion with the top edges 32 of the performed sheets 24 , the second donor bars 56 and the base portion of the first recipient bar 50 facing up.
- the station control system 18 directs the slide system 262 into place. For example, one of the pair of welding torches 264 is positioned at the intersection of the respective one of the pair of sides 34 and the top edge 32 of the performed sheets 24 .
- the other one of the pair of torches 264 is positioned at a lineal distance half way along the length of the top edge 32 of the performed sheets 24 .
- the pair of torches 264 slide and travel linearly along the length of the top edge 32 the entire length of the top edges 32 of the performed sheets 24 , the second donor bars 56 and the base portion of the first recipient bar 50 are sealingly welded.
- Each of the pair of torches 264 does half of the linear weld and the two welds are blendingly and sealingly connected near the center of the second recipient bar 52 .
- the tasks 14 of the third work station 220 are completed.
- the master control system 16 sends a signal to the appropriate one of the plurality of station control systems 18 .
- the station control system 18 directs the servo driven pick and place assembly 280 of the fourth work station 270 to pick the cell 20 portion from the third welding position 228 of the third work station 220 and to place the cell 20 portion onto the walking beam conveyor assembly 272 of the fourth work station 270 .
- the cell 20 portion passes along the walking beam conveyor assembly 272 and is indexed into the leak test position 274 .
- a sealing tool assembly 282 is positioned on the cell 20 portion.
- the sealing tool assembly 282 is sealingly positioned about the recipient fluid inlet 244 and the recipient fluid outlet 246 .
- the walking beam conveyor assembly 272 moves the cell 20 portion to the reject unloading station 284 and the defective cell 20 portion is removed. If the cell 20 portion qualifies the leak test, the walking beam conveyor assembly 272 moves the cell 20 portion from the leak test position 274 to the donor side director sheet position 278 .
- the forming tool 286 takes the precut sheet and forms the plurality of alternating root portions 64 and crest portions 66 .
- the thin line of adhesive is dispenses by the adhesive system 288 to the donor side 26 , in the flattened portions 40 , of the performed sheets 24 .
- the pick and place mechanism 290 picks and places the pair of donor side director sheets 60 onto the donor side 26 , in the flattened portions 40 , of the performed sheets 24 in the preestablished position.
- the assembly process 10 for making the cell 20 is completed.
- the qualified cell 20 is unloaded from the assembly process 10 and is transferred to the recuperator assembly area.
- the assembly process 10 produces an economical and functional process.
- the need for repeatability of construction of each cell 20 assures that the final recuperator is economically and easily assembled. Examples, of such repeatability required includes length, height, thickness, weld size, weld position, weld splatter and others.
- the steps and work stations produce a recuperator cell 20 which insures an effective and repeatable product. For example, the height and thickness insures that the position and location of each cell 20 within the recuperator structure enables the position of individual passages within the cell 20 to be accurate and provide efficient functional operations of the recuperator.
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Abstract
Recuperators include a core which is commonly constructed of a plurality of relatively thin flat sheets having an angled or corrugated spacer fixedly attached therebetween. The sheets are joined into cells, sealed and form passages between the sheets. These cells are stacked or rolled and form alternate air (recipient) cells and hot exhaust (donor) cells. Compressed discharged air from a compressor of the engine passes through the air cell while hot exhaust gas flows through alternate cells. The exhaust gas heats the sheets and the spacers, and the compressor discharged air is heated by conduction from the sheets and spacers. The need for repeatability of construction of each cell assures that the final recuperator is economically and easily assembled. Examples, of such repeatability required includes length, height, thickness, weld size, weld position, weld splatter and others. The recuperator assembly method provides a cell and a recuperator having repeatability of length, height, thickness, weld size, weld position, weld splatter and others.
Description
- This invention relates generally to an recuperator and more particularly to a cell of the recuperator and to a procedure for manufacturing the cell.
- Many gas turbine engines use a heat exchanger or recuperator to increase the operating efficiency of the engine by extracting heat from the exhaust gas and preheating the combustion air. Typically, a recuperator for a gas turbine engine must be capable of operating at temperatures of between about500 degrees C. and 800 degrees C. and internal pressures of between approximately 140 kPa and 1400 kPa under operating conditions involving repeated starting and stopping cycles.
- Such recuperators include a core which is commonly constructed of a plurality of relatively thin flat sheets having an angled or corrugated spacer fixedly attached therebetween. The sheets are joined into cells, sealed and form passages between the sheets. These cells are stacked or rolled and form alternate air (recipient) cells and hot exhaust (donor) cells. Compressed discharged air from a compressor of the engine passes through the air cell while hot exhaust gas flows through alternate cells. The exhaust gas heats the sheets and the spacers, and the compressor discharged air is heated by conduction from the sheets and spacers. The need for repeatability of construction of each cell assures that the final recuperator is economically and easily assembled. Examples, of such repeatability required includes length, height, thickness, weld size, weld position, weld splatter and others.
- An example of such a recuperator is disclosed in U.S. Pat. No. 5,060,721 issued to Charles T. Darragh on Oct. 29, 1991. In such a system, Darragh discloses a heat exchanger having been used to increase the efficiency of the engine by absorbing heat from that exhaust gases and transferring a portion of the exhaust heat to the combustion air. The heat exchanger is built-up from a plurality of performed involute curved cells stacked in a circular array to provide flow passages for the donor fluid and the recipient fluid respectively.
- Thus, to economically and functionally produce such a recuperator, used with gas turbine engines, requires a process which insures an effective and repeatable procedure. For example, to assure the stacking of a fixed number of cell within a preestablished curricular configuration the height and thickness is extremely critical. To further insure the position and location or each cell within the recuperator structure, the position of individual passages within the cell needs to be accurate to insure for efficient functional operation.
- The present invention is directed to overcoming one or more of the problems as set forth above.
- In one aspect of the invention an automated method of manufacturing a cell is disclosed. The cell is adapted for use with a recuperator. The method of manufacturing is comprised of the following steps. Actuating a master control system. Actuating a work station control system. Actuating a first work station defining a first work position. Positioning a first donor bar in a first fixture designated as “A”. A second work positioning a second donor bar in a second fixture designated as “B”. A third work position positioning a sheet into the first fixture “A” and the second fixture “B”. Each of the sheets having a recipient side being up. And, attaching the first donor bar and the second donor bar to the sheets forming a pair of cell portions. And, a fourth work position rotating a pair of cell portions and further attaching the sheets and the first donor bars. Actuating a second work station defining a first work position of the second work station. Transferring and rotating one of the pair of cell portions from the first fixture “A” of the fourth work position of the first work station to a first fixture “A” of the first work position of the second work station and having the donor side of the sheet being up. Transferring the other one of the pair of cell portions from the second fixture “B” of the fourth work position of the first work station to a second fixture “B′” of the first work position of the second work station and having a recipient side of the sheet being up. A second work position of the second work station positioning a second recipient bar on the recipient side of the sheet in the second fixture “B′” and attaching the second recipient bar to the sheet. A third work position of the second work station positioning a first recipient bar on the recipient side of the sheet in the second fixture “B′”. Positioning a pair of director sheets with the first recipient bar thereon on the recipient side of the sheet in the second fixture “B′” and further attaching the first recipient bar to the sheet. And, a fourth work position of the second work station positioning the cell portion from the first fixture “A′” to the second fixture “B′” with the donor side of the sheet being up and further attaching the cell portion from the first fixture “A′” to the cell portion of the second fixture “B′”. Actuating a third work station defining a first work position of the third work station. Transferring the cell portion as welded from the second fixture “B′” of the fourth work position of the second work station into a second work position of the third work station and rotating the cell portion into a preestablished position. The second work position of the third work station fixedly attaching linearly along a portion of a bottom edge of the sheet and an entire length of the second recipient bar. A third work position of the third work station transferring and rotating the cell portion as fixedly attached from the second work position of the third work station to the third work position of the third work station. Forming the cell portion and fixedly attaching a pair of side edges of the sheet to the first recipient bar. A fourth work position of the third work station transferring and positioning the cell portion as fixedly attached to the fourth work position of the third work station fixedly attaching a top edge of the sheet and the first recipient bar. And, a fifth work position of the third work station staging the cell portion as fixedly attached. And, actuating a fourth work station defining a first work position of the fourth work station. Transferring the cell portion from the fifth work position of the third work station to a second work position of the fourth work station. The second work position of the fourth work station testing a leakage of the cell portion. The first work position of the fourth work station further transferring the cell portion as tested to a third work position of the fourth work station. Attaching a director sheet to the donor side of the sheet. The first work position of the fourth work station further transferring the cell as completed to a fourth work position of the fourth work station unloading the cell.
- In another embodiment of the invention, a cell is formed of a plurality of individual components being produced by an automated process and being adapted for use with a recuperator. The cell is comprised of a pair of performed sheets defining a donor side and a recipient side. A plurality of donor bars are attached to the donor side of the pair of performed sheets. A plurality of recipient bars are attached to the recipient side of the pair of performed sheets. A donor side director sheet is in contacting relationship with the donor side of at least one of the pair of performed sheets. A recipient side director sheet is in contacting relationship with the recipient side of at least one of the pair of performed sheets. And, the pair of performed sheets, the plurality of donor bars and the plurality of recipient bars being fixedly attached one to another forming the cell.
- FIG. 1 is a top view of the assembly apparatus embodying the present invention;
- FIG. 2 is a view take through a cell looking at a donor side of a sheet used in making up a recuperator as is embodied in the present invention;
- FIG. 3 is a view taken through a cell looking at a recipient side of the sheet use in making up the recuperator as is embodied in the present invention;
- FIG. 4 is a sectional view of a cell used in making up a recuperator as is embodied in the present invention;
- FIG. 5 is an enlarged view of a portion of the assembly apparatus, a first work station, embodied in the present invention;
- FIG. 6 is an enlarged view of a portion of the assembly apparatus, a second work station, embodied in the present invention;
- FIG. 7 is an enlarged view of a portion of the assembly apparatus, a third work station, embodied in the present invention; and
- FIG. 8 is an enlarged view of a portion of the assembly apparatus, a fourth work station, embodied in the present invention.
- Referring to FIG. 1, an assembly process or an
automated method 10 is shown. Theassembly process 10 includes a plurality ofwork stations 12 being interconnected. Each of the plurality ofwork stations 12 accomplish a plurality ofpreestablished tasks 14. Each of the plurality ofwork stations 12 and thetasks 14 are preestablishly controlled by amaster control system 16 of conventional construction. Themaster control system 16 is divided into a plurality of workstation control systems 18. - Referring to FIGS. 2, 3 and4, a cell or
work piece 20 is shown and includes a plurality of components orparts 22. For example, a portion of the plurality ofparts 22 includes a pair of performedsheet 24 defining athickness 25, a first or donor orgas side 26, a second or recipient orair side 28. The performedsheet 24 defines abottom edge 30, atop edge 32 and a pair of side edges 34. The performedsheet 24 further includes a serpentinedportion 36. As an alternative, thesheet 24 could be dimpled or have another configuration rather than being serpentined. Additionally, thesheet 24 has a trapezoidal configuration but could be of other configurations, such as a parallelogram or square or rectangular. In this application, the serpentinedportion 36 has a generally rectangular configuration and is positioned between thetop edge 32 and a portion of thebottom edge 30. As and alternative the serpentinedportion 36 could be of other configurations, such as a parallelogram or square or triangle or a trapezoidal. The serpentinedportion 36 defines anaxis 38. The performedsheet 24 further includes a pair of flattenedportions 40. In this application, each of the pair of flattenedportions 40 have a generally triangular configuration. However, as an alternative the pair of flattenedportions 40 could be singular, or of another configuration, such as a square, a rectangle or a parallelogram. Each of the pair of flattenedportions 40 extends from the serpentinedportion 36 to the respective one of the pair ofsides 34 and a portion of thetop edge 32 and a portion of thebottom edge 30. In this application, a portion of the serpentinedportion 36 is also flattened along each of thetop edge 32 and thebottom edge 30. The flattenedportions 40 along each of thetop edge 32 and thebottom edge 30 define a preestablished orsubstantial thickness 42. - As further shown in FIGS. 2 and 3, a plurality of spacer bars44 are used to form the
cell 20 and are positioned upon the performedsheet 24 in a preestablished order and position. In this application, the plurality of spacer bars 44 are divided into a plurality of donor bars 46 and a plurality of recipient bars 48. A preestablished thickness or substantial thickness “T of D” is defined for each of the plurality of donor bars 46 and a preestablished thickness or substantial thickness “T of R” is defined for each of the plurality of recipient bars 48. In this application, the plurality of donor bars 46 define a preestablished thickness, a preestablished width and a preestablished length. Furthermore, the plurality of recipient bars 48 have a preestablished thickness, a preestablished width and a preestablished length. The preestablished length of individual ones of the plurality of donor bars 46 and the plurality of recipient bars 48 have different lengths. The preestablished width of the individual ones of the plurality of donor bars 46 and the plurality of recipient bars 48 have generally the same width. However, as an alternative, the width or thickness of the plurality of donor bars 46 and the plurality of recipient bars 48 could be of various preestablished thicknesses or widths of the same thickness or width without changing the jest of the invention. And, the individual ones of the plurality of donor bars 46 have a thickness being about one-half of the thickness of the plurality of recipient bars 48. In this application, afirst recipient bar 50 of the plurality of recipient bars 48 has a generally “U” configuration being formed by a base, a pair of legs and having anopen end 51. As an alternative, thefirst recipient bar 50 could be segmented to include the base and the pair of legs. Asecond recipient bar 52 of the plurality of recipient bars 48 has a length being generally equal to that of the length of the serpentinedportion 36 along thebottom edge 30. The plurality of donor bars 46 has afirst donor bar 54 being generally equal to the length of thebottom edge 32 and asecond donor bar 56 being generally equal to the length of thetop edge 30 of the performedsheet 24. - Also used to construct the
cell 20 is a pair of donorside director sheets 60 and a pair of recipientside director sheets 62. The donorside director sheets 60 define a plurality of alternatingroot portions 64 andcrest portions 66. In this application, the plurality ofroot portions 64 and thecrest portions 66 of the donorside director sheet 60 form anaxis 68 which is axially aligned with theaxis 38 of the serpentinedportion 36. The recipientside director sheets 62 also define a plurality of alternatingroot portions 70 andcrest portions 72. In this application, the plurality ofroot portions 68 and thecrest portions 72 of the recipientside director sheets 62 form anaxis 74 which is generally parallel to the respective one of the pair of side edges 34. - As further shown in FIG. 1, the plurality of
work stations 12 include afirst work station 78, as best shown in FIG. 5. Thefirst work station 78 includes a four positionrotary indexer unit 80 defining afirst work position 82, asecond work position 84, athird work position 86 and afourth work position 88. Theunit 80 is indexable between thevarious work position - In the
first work position 82 of thefirst work station 78, a first roll ofsteel stock 90 is positioned in line with a straighteningdevice 92. A pair ofpress assemblies 94 cuts thesteel stock 90 into individual ones of the plurality of donor bars 46 having the preestablished length. The first donor bars 54 are positioned in afirst fixture 96 of a pair of twonest fixture assemblies 98, designated as “A” and “B”, in a conventional manner. - In the
second work position 84 of thefirst work station 78, a second roll ofsteel stock 100 is positioned in line with astraightening device 102. A pair ofpress assemblies 104 cuts thesteel stock 100 into individual ones of the plurality of donor bars 46 having the preestablished length. The second donor bars 56 are positioned in asecond fixture 106 of the pair of twonest fixture assemblies 98, designated as “A” and “B” in a conventional manner. Each of the twonest fixture assemblies 98 further include two micarata plates which incorporate electrodes and copper bus bars in a conventional manner. - As further shown in FIGS. 1 and 5, the
assembly process 10 includes atransportation system 110, which in this application, has apallet 112 upon which a predetermined number of performedsheets 24 are located and positioned in a pair of stacks. A sheet gauge, not shown, is used to qualify each of the performedsheets 24 prior to being positioned on thepallet 112. A sheet lifting assembly, not shown, is positioned under thepallet 112. The performedsheets 24 are placed on aconveyer 114 in a pair of rows in a conventional manner. The performedsheets 24 are also placed on the conveyer in a predetermined pattern as will be explained latter. - In this application, the transfer of the performed
sheets 24 from theconveyer 114 to the four positionrotary indexer unit 80 is accomplished by arotary part handler 120 that incorporates atooled arm 122. The performedsheets 24 have therecipient side 28 up. Thetooled arm 122 is rotatable from afirst position 124, being aligned with the pair of rows of performedsheets 24 on theconveyer 114, to asecond position 126, being aligned with each of the two nest fixture assemblies, “A” and “B”, at thethird work position 86 of thefirst work station 78. Thetooled arm 122 includes avacuum tool 128 which has been adapted for this application. Other types of tools, such as magnets or suction cups could be uses without changing the jest of the invention. At thethird work position 86 of thefirst work station 78, an independentresistance weld assembly 136 or tack welding operation will be used to tack the performedsheet 24 to thefirst donor bar 54 and to thesecond donor bar 56. - And, at the
fourth work position 88 of thefirst work station 78, anindexing fixture 140 rotates the portion of thecell 20. A water cooledgripper assembly 142 holds the performedsheet 24 and thefirst donor bar 54 in a fixed position with thebottom edge 30 of the performedsheet 24 up. A pair ofseamer units 144 having a pair of weld torches 146, which in this application are of a plasma weld type, form a sealed weld between thefirst donor bar 54 and the performedsheet 24 generally along the pair of flattenedportions 40 having the triangular configuration. Thefirst work station 78 produces a pair ofcell 20 portions orcomponents 148 in a side by side operation. - As further shown in FIG. 1, the plurality of
work stations 12 include asecond work station 150, as best shown in FIG. 6. Thesecond work station 150 includes a four positionrotary indexer unit 152 defining afirst work position 154, asecond work position 156, athird work position 158 and afourth work position 160. Theunit 152 is indexable between thevarious work position - In the
first work position 154 of thesecond work station 150, the transfer of thecell 20 portion, including the performedsheet 24 and the plurality of donor bars 46, is performed by arotary part handler 170 that incorporates a pair of tooled arms 172 using avacuum tool 173. The pair of tooled arms 172 are rotatable from afirst position 174, as shown in phantom, being aligned with each of the pair of twonest fixture assemblies 98 designated as “A” and “B” of thefourth work position 88 of thefirst work station 78, to asecond position 176, being aligned with a pair of twonest fixture assembly 178 positioned in thefirst work position 154 of thesecond work station 150. Afirst fixture 180 of the pair of twonest fixture assemblies 178 is designated as “A′” and asecond fixture 182 of the pair of twonest fixture assemblies 178 is designated as “B′”. Each of the pair of twonest fixture assembly 178 further includes two micarata plates which incorporate electrodes and copper bus bars of conventional construction. One of the pair of tooled arms 172 also rotates thecell portion 20 to position thedonor side 26 up in thesecond fixture 182 designated as “B′” whereas thecell portion 20 positioned in thefirst fixture 180 designated as “—A” is positioned with therecipient side 28 up. The pair of tooled arms 172 include thevacuum tool 173 which has been adapted for this application. Other types of tools, such as magnets or suction cups could be uses without changing the jest of the invention. - In the
second work position 156 of thesecond work station 150, a third roll ofsteel stock 190 is positioned in line with astraightening device 192. Apress assembly 194 cuts thesteel stock 190 into individual ones of the plurality of recipient bars 48 having the preestablished length. Thesecond recipient bar 52 is positioned on therecipient side 28 of the performedsheet 24 along the flattened portion of thebottom edge 30 between the pair of flattenedportions 40 in a conventional manner. Thesecond recipient bar 52 is only placed in thesecond fixture 182 designated as “B′” of the pair of twonest fixture assemblies 178. Thefirst fixture 180 of the pair of two nest fixture assemblies remains void of thesecond recipient bar 52. Further at thesecond work position 156 of thesecond work station 150, an independentresistance weld assembly 196 will be used to tack the performedsheet 24 to thesecond recipient bar 52. - In the
third work position 158 of thesecond work station 150, thefirst recipient bar 50, being S formed in the “U” configuration, with the recipientside director sheets 62 attached thereto are loaded into a gravityfeed rack assembly 200. Thefirst recipient bar 50 and the recipientside director sheets 62 are passed through agage 202 to insure proper dimensional control prior to being positioned on therecipient side 28 of the performedsheet 24. Thefirst recipient bar 50 and the recipientside director sheets 62 are positioned within the pair of flattenedportions 40 and along the flattened portion of thetop edge 32 in a conventional manner. Thefirst recipient bar 50 and the recipientside director sheets 62 is only placed in thesecond fixture 182 of the pair of twonest fixture assemblies 178 designated as “B′”. Thefirst fixture 180 of the pair of two nest fixture assemblies remains void of thefirst recipient bar 50 and the recipientside director sheet 62. After being located in thesecond fixture 182 of the pair of two 178 designated as “B′”, anelectrode assembly 204 is lowered to thesecond fixture 182. Theelectrode assembly 204 incorporates tooling that will justify the legs into the proper position, creating the correct sheet and bar gap. Two independent electrodes, not shown, of theelectrode assembly 204 are lowered to thefirst recipient bar 50 and resistant tack welds thefirst recipient bar 50 to the performedsheet 24 near theopen end 51. - In the
fourth work position 160 of thesecond work station 150, thecell 20 portion, including the performedsheet 24 and the plurality of donor bars 46 which has been positioned in thefirst fixture 180 of the pair of twonest fixture assemblies 178 designated as “A′” is positioned on top of thecell 20 portion built-up within thesecond fixture 182 of the pair of twonest fixture assemblies 178 designated as “B′”. Avacuum tool 206 is used to pick-up, locate and place thecell 20 portion from “A′” to “B′”. And, a pair ofindependent electrode assemblies 208 are lowered to resistant tack weld the performedsheet 24 and the plurality of donor bars 46 to the performedsheet 24, the plurality of donor bars 46, the plurality of recipient bars 48 and the pair of recipientside director sheets 62. The tack weld takes place near theopen end 51. - As further shown in FIGS. 1 and 7, the plurality of
work stations 12 include athird work station 220. Thethird work station 220 includes a first work position orrobot unit 222, a pair of second work positions orfirst welding positions 224, a pair of third work positions or second welding positions 226, a pair of fourth work positions orthird welding positions 228 and a fifth work position orstaging unit 230. Individual ones of the pair offirst welding positions 224, the pair of second weld positions 226 and the pair of third weld positions 228 are divided into two duplicate sides forming a first or leftlane 232 and a second orright lane 234. - The
robot unit 222 of thethird work station 220 picks the tack weldedcell 20 portion from thefourth work position 160 of thesecond work station 150 and positions thecell 20 portion into one of the pair of first weld positions 224. A second one of thecell 20 portion from thefourth work position 160 of thesecond work station 150 is placed in the other of the pair of first weld positions 224 by therobot unit 222. And, a third one of thecell 20 portion is placed into thestaging unit 230 if the pair offirst welding positions 224 are not available. Thecell 20 portion is placed in the pair of first weld positions 224. A water cooledgripper assembly 236 holds the performedsheet 24 and thefirst donor bar 54 in a fixed position. Arotating mechanism 238 rotates thecell 20 portion to a preestablished position for welding. In this application, thebottom edge 30 of the performedsheets 24 is positioned up. Aseam welder 240, which in this application, has a pair oftorches 242. Each of the pair oftorches 242 sealingly does half of the linear weld along a portion of thebottom edges 30 of the performedsheets 24 and the entire length of thesecond recipient bar 52. The remainder of thebottom edge 30 not being welded forms one of arecipient fluid inlet 244 or arecipient fluid outlet 246, as are best shown in FIG. 3. - A pick and
place mechanism 250, being of conventional construction, will grasp thecell 20 portion from the respective one of the pair offirst welding positions 224 and position thecell 20 portion in the second welding positions 226. Thecell 20 portion is rotated and thebottom edges 30 and thesecond recipient bar 52 are placed in a formingfixture 252. Thecell 20 portion has thetop edges 32 of the performedsheets 24, the second donor bars 56 and the base portion ofsecond recipient bar 52 facing up. The formingfixture 252 is used to hold and form thecell 20 portion into a preestablished configuration. The preestablished configuration is that of an involute in this application. To increase the life of the formingfixture 252, water cooling is incorporated. With thecell 20 portion formed in the involute configuration and held in position, a pair of welding torches 254 are positioned at the each of the pair of side edges 34 near theopen end 51 of thefirst recipient bar 50. The pair ofwelding torches 254 sealingly does the welding of the respective pair of side edges 34 of the performedsheets 24 and the respective one of the pair of legs of thefirst recipient bar 50. The pair of welding torches 254 also weld the top and bottom corners. The welding torches 254 are attached to arobot 256 in a conventional manner. - The pick and
place mechanism 250 will, at this time, grasp thecell 20 portion from the respective one of the pair ofsecond welding positions 226 and position thecell 20 portion in thethird welding position 228. In the each ofthird welding positions 228, thecell 20 portion has thetop edges 32 of the performedsheets 24, the second donor bars 56 and the base portion ofsecond recipient bar 52 facing up. Each of thethird welding positions 228 incorporate a water cooledgripper 260. Furthermore, thethird welding positions 228 have aslide system 262 positioned therein of conventional construction. Theslide system 262 utilizes a pair of welding torches 264 attached thereto. Each of the pair oftorches 264 sealingly does half of the linear weld along thetop edges 32 of the performedsheets 24 and the base portion of thefirst recipient bar 50. Thus, a pair ofcells 20, less the pair of donorside director sheets 60, are formed after the completion of thethird work station 220. - As further shown in FIG. 1, the plurality of
work stations 12 include afourth work station 270. Thefourth work station 270 includes a first work position or walkingbeam conveyor assembly 272 communicating with each of a second work positions orleak test position 274, a third work position or donor sidedirector sheet position 276 and a fourth work positions or unloadingposition 278. - A servo driven pick and
place assembly 280 is used to transferring thecell 20 portion which has been completely welded on the outer perimeter from the pair ofthird welding position 228 of thethird work station 220 to the walkingbeam conveyor assembly 272. Thecell 20 portion is indexed into theleak test position 274. A sealingtool assembly 282 is properly positioned on thecell 20 portion and a leak test procedure is performed. A vacuum of about 25 inches of mercury is pulled within thecell 20 to qualify the structure and functionality of thecell 20. If acell 20 portion fails to qualify thecell 20 portion is removed from further operations at areject unloading station 284. After thecell 20 portion has been qualified, it is transferred to the donor sidedirector sheet position 276. In the donor sidedirector sheet position 276, a formingtool 286 takes a precut sheet and forms the plurality of alternatingroot portions 64 and thecrest portions 66. The formingtool 286 forms the pair of donorside director sheets 60 at the same time. Thus, the pair of donorside director sheets 60 are formed. Anadhesive system 288 dispenses a thin line of adhesive to thedonor side 26, in the flattenedportions 40, of the performedsheets 24. With the adhesive applied to thedonor side 26 of thesheet 60, a pick andplace mechanism 290, picks and places the pair of donorside director sheets 60 on thedonor side 26, in the flattenedportions 40, of the performedsheets 24 in a preestablished position. Thus, thecell 20 is complete. From the donor sidedirector sheet position 276, thecell 20 is transferred to theunloading position 278 and unloaded therefrom and transferred to a recuperator assembly area in a conventional manner, not shown. - The
cell 20 being manufactured by the automated process ormethod 10 provides acell 20 having a preestablished configuration and defining a preestablished thickness “T of C”. The automated process ormethod 10 provides an actual thickness “T of A” being within about plus or minus about “0.6 mm (0.025 inches)” of the preestablished thickness “T of C”. And, with the automated welding processed used, the welding operation fails to increase the actual thickness “T of A”. - Water cooling is used as necessary to increase life of the grippers, fixtures etc. A plasma welding process is used. And, a vacuum process is used for the pick-up and place operation. Furthermore, a spool de-coiling system along with a positive feed system is used with the rolls of steel stock. As an alternative, other welding processes, transferring processes and pick-up and place processes could be used without changing the essence of the invention.
- In operation, the
assembly process 10 is used for making arecuperator cell 20. Themaster control system 16 is activated and the plurality of workstation control systems 18 are functionally operationable. Theassembly process 10 begins with the first roll ofsteel stock 90 being positioned and passed through the straighteningdevice 92. Thesteel stock 90 is cut into the preestablished length forming thefirst donor bar 54 and is placed in the portion of the nest fixture designated as “A”. A secondfirst donor bar 54 is also cut and placed in the portion of the nest fixture designated as “B”. - The
indexer unit 80 of thefirst work station 78 is indexed and moved to thesecond work position 84. At thesecond work position 84, the second roll ofsteel stock 100 passed through the straighteningdevice 92. Thesteel stock 90 is cut into the preestablished length forming thesecond donor bar 56 and is placed in the nest fixture designated as “A′”. A secondsecond donor bar 56 is also cut and placed in the nest fixture designated as - The
indexer unit 80 is indexed and moved to thethird work position 86. The performedsheets 24 having been communicated to theconveyer 114 are picked up by the vacuum tooling at thefirst position 124 of therotary part handler 120, rotated and are properly positioned in the pair ofnest fixtures 98 at thesecond position 126. The width of the first and second donor bars 54,56 is in contacting relationship with thedonor side 26. Furthermore, the first and second donor bars 54,56 are respectively positioned in the flattened portion of thebottom edge 30 and thetop edge 32. After the components have been positioned, theresistance weld assembly 136 is used to tack the individual first and second donor bars 54,56 and individual performedsheets 24 in each of the pair ofnest fixtures 98. Each of the first and second donor bars 54,56 have two points of resistance tack weld, additional points of resistance tack weld could be used. - The
indexer unit 80 is indexed and moved to thefourth work position 88. At thefourth work position 88, the water cooledgripper assembly 124 grasps the work piece and theindexing fixture 140 rotates the performedsheets 24 and the tack welded plurality of donor bars 46 into the fixed position with thebottom edge 30 of the performedsheet 24 up. The pair of weld torches 146 of each of theseamer units 144 are positioned above the interface of thebottom edge 30 and thefirst donor bar 54 at the respective one of the flattenedportions 40 of eachcell 20 portion produced by “A” and “A′”, and “B” and “B′”. For example, one of the pair of weld torches 146 is positioned near one of the pair ofsides 34. And, the other one of the pair of weld torches 146 is positioned near the serpentinedportion 36. The pair of weld torches are activated by the appropriate one of the plurality of workstation control systems 18 and the sealed weld is completed. The completed weld extends linearly from the each of the pair ofsides 34 to the serpentinedportion 36. In this application, the length of each weld is about 1⅝″ or about 41.3 mm. Thus, thetasks 14 of thefirst work station 78 are completed. - The pair of tooled arms172 of the
rotary part handler 170 at thefirst position 174 pick thecell 20 portions from thefourth work position 88 of thefirst work station 78. And, the pair of tool arms 172 of therotary part handler 170 are moved into thesecond position 176. Prior to positioning thecell 20 portions, one of the pair of tooled arms 172 is rotated and thecell portion 20 is positioned with thedonor side 26 up in thesecond fixture 182 designated as “B”. Thecell portion 20 positioned in thefirst fixture 180 designated as “A” is positioned with therecipient side 28 up. - The
indexer unit 152 of thesecond work station 150 is indexed and moved to thesecond work position 156. At thesecond work position 156, the third roll ofsteel stock 190 is passed through thestraightening device 192. Thesteel stock 190 is cut into the preestablished length forming thesecond recipient bar 52 and is placed in the nest fixture designated as “B” along the flattened portion of thebottom edge 30 and is interposed the welds completed at thefourth work position 88 of thefirst work station 78. Additionally, theresistance well assembly 196 is positioned and tack welds the performed sheet to thesecond recipient bar 52. The performed sheet and thesecond recipient bar 52 are resistance tack welded in two places, additional points of resistance tack weld could be used. - The
indexer unit 152 of thesecond work station 150 is indexed and moved to thethird work position 158. At thethird work position 158, the preassembliedfirst recipient bar 50 having the “U” configuration with the recipientside director sheets 62 attached thereto are passed through thegage 202 assuring uniformity of the final assembly. Thepreassemblied bar 50 andsheet 62 are positioned in thesecond fixture 178 designated as “B”. The preassembly is positioned with therespective sheet 62 and leg in the respective one of the pair of flattenedportions 40 and the base in the flattened portion along thetop edge 32. Theelectrode assembly 204 is lowered and thefirst recipient bar 50 is resistance tack welded to the performedsheet 24. The resistance tack weld is completed in two places, additional points of resistance tack weld could be used. The two places being near theopen end 51 of thefirst recipient bar 50. - The
indexer unit 152 of thesecond work station 150 is indexed and moved to thefourth work position 160. At thefourth work position 160, thevacuum tool 206 picks thecell 20 portion from thesecond fixture 182 designated as “A”, and locates and positions thecell 20 portion from “A” on top of thecell 20 portion within thefirst fixture 180 designated as “B”. After being positioned, the pair ofelectrode assemblies 208 resistance tack weld the performedsheet 24 from “A” to thefirst recipient bar 50. The resistance tack weld is completed in two places, additional points of resistance tack weld could be used. The two places being near theopen end 51 of thefirst recipient bar 50. Thus, thetasks 14 of thesecond work station 78 are completed. - The
robot unit 222 of thethird work station 220 picks thecell 20 portion from thefourth work position 160 of thesecond work station 150 and one of the plurality ofstation control systems 18 of themaster control system 16 directs therobot unit 222 to place thecell 20 portion into the appropriate one of the pair of first weld positions 224. If each of the pair of first weld positions 224 is full, themaster control system 16 will direct therobot unit 222 to place thecell 20 portion into thestaging unit 230. Thecell 20 portion is rotated by therotating mechanism 238 to the preestablished position to be welded. The pair oftorches 242 of theseam welder 240 are positioned along thebottom edge 30 of the performedsheets 24 and the entire length of thesecond recipient bar 52 is welded. One of the pair oftorches 242 is positioned at the end of thesecond recipient bar 52 and the other one of the pair oftorches 242 is positioned at a lineal distance half way along the length of thesecond recipient bar 52. As the pair oftorches 242 slide and travel linearly along the length of thesecond recipient bar 52 the entire length of thesecond recipient bar 52 is sealingly welded. Each of the pair oftorches 242 does half of the linear weld and the two welds are blendingly and sealingly connected near the center of thesecond recipient bar 52. - After being welded along the
bottom edges 30 and thesecond recipient bar 52, the pick andplacer mechanism 250 removes thecell 20 portion from the respective one of the pair of first welding positions 224. Thecell 20 portion is positioned into thesecond welding position 226. The pick andplace mechanism 250 prior to positioning thecell 20 portion into thesecond welding position 226 rotates thecell 20 portion. And, thebottom edge 30 of the performedsheets 24 is gripped by the formingfixture 252. The formingfixture 252 is actuated by thestation control system 18 and thecell 20 portion is formed into the involute configuration. With the formingfixture 252 actuated, thestation control system 18 directs therobots 256 to position the respective one of the pair of welding torches 254 to the intersection of thetop edge 32 and the respective one of the pair ofsides 34. And, thestation control system 18 directs the pair of welding torches 254 to plasma weld each of the pair ofsides 34. The welds sealingly connect the ends of the donor bars 46 near thebottom edges 30 of the performedsheets 24, the pair ofsides 34 of the performedsheets 24, the ends of the donor bars 46 near thetop edges 32 of the performedsheets 24 and the pair of legs of thefirst recipient bar 50. - After being formed and welded along the pair of
sides 34, the pick andplacer mechanism 250 removes thecell 20 portion from the respective one of the pair ofsecond welding positions 226 and positions thecell 20 portion into thethird welding position 228. The pick andplace mechanism 250 positions thecell 20 portion with thetop edges 32 of the performedsheets 24, the second donor bars 56 and the base portion of thefirst recipient bar 50 facing up. Thestation control system 18 directs theslide system 262 into place. For example, one of the pair of welding torches 264 is positioned at the intersection of the respective one of the pair ofsides 34 and thetop edge 32 of the performedsheets 24. And, the other one of the pair oftorches 264 is positioned at a lineal distance half way along the length of thetop edge 32 of the performedsheets 24. As the pair oftorches 264 slide and travel linearly along the length of thetop edge 32 the entire length of thetop edges 32 of the performedsheets 24, the second donor bars 56 and the base portion of thefirst recipient bar 50 are sealingly welded. Each of the pair oftorches 264 does half of the linear weld and the two welds are blendingly and sealingly connected near the center of thesecond recipient bar 52. Thus, thetasks 14 of thethird work station 220 are completed. - The
master control system 16 sends a signal to the appropriate one of the plurality ofstation control systems 18. Thestation control system 18 directs the servo driven pick andplace assembly 280 of thefourth work station 270 to pick thecell 20 portion from thethird welding position 228 of thethird work station 220 and to place thecell 20 portion onto the walkingbeam conveyor assembly 272 of thefourth work station 270. Thecell 20 portion passes along the walkingbeam conveyor assembly 272 and is indexed into theleak test position 274. With thecell 20 portion nested in theleak test portion 274, a sealingtool assembly 282 is positioned on thecell 20 portion. For example, the sealingtool assembly 282 is sealingly positioned about therecipient fluid inlet 244 and therecipient fluid outlet 246. And, a vacuum of about 25 inches of mercury is pulled within thecell 20 portion. If thecell 20 portion does not qualify the leak test, the walkingbeam conveyor assembly 272 moves thecell 20 portion to thereject unloading station 284 and thedefective cell 20 portion is removed. If thecell 20 portion qualifies the leak test, the walkingbeam conveyor assembly 272 moves thecell 20 portion from theleak test position 274 to the donor sidedirector sheet position 278. At the donor sidedirector sheet position 276, the formingtool 286 takes the precut sheet and forms the plurality of alternatingroot portions 64 andcrest portions 66. The thin line of adhesive is dispenses by theadhesive system 288 to thedonor side 26, in the flattenedportions 40, of the performedsheets 24. The pick andplace mechanism 290 picks and places the pair of donorside director sheets 60 onto thedonor side 26, in the flattenedportions 40, of the performedsheets 24 in the preestablished position. Thus, theassembly process 10 for making thecell 20 is completed. And, thequalified cell 20 is unloaded from theassembly process 10 and is transferred to the recuperator assembly area. - The
assembly process 10 produces an economical and functional process. The need for repeatability of construction of eachcell 20 assures that the final recuperator is economically and easily assembled. Examples, of such repeatability required includes length, height, thickness, weld size, weld position, weld splatter and others. The steps and work stations produce arecuperator cell 20 which insures an effective and repeatable product. For example, the height and thickness insures that the position and location of eachcell 20 within the recuperator structure enables the position of individual passages within thecell 20 to be accurate and provide efficient functional operations of the recuperator. - Other aspects, objects and advantages of this invention can be obtained from a study of the drawings, the disclosure and the appended claims.
Claims (50)
1. An automated method of manufacturing a cell, said cell being adapted for use with a recuperator; said method of manufacturing comprising the steps of:
actuating a master control system;
actuating a work station control system;
actuating a first work station defining a first work position positioning a first donor bar in a first fixture designated as “A”, a second work position positioning a second donor bar in a second fixture designated as “B”, a third work position positioning a sheet into said first fixture “A” and said second fixture “B”, each of said sheets having a recipient side being up and attaching said first donor bar and said second donor bar to said sheets forming a pair of cell portions, and a fourth work position rotating a pair of cell portions and further attaching said sheets and said first donor bars;
actuating a second work station defining a first work position of said second work station transferring and rotating one of said pair of cell portions from said first fixture “A” of said fourth work position of said first work station to a first fixture “A′” of said first work position of said second work station and having said donor side of said sheet being up and transferring said other one of said pair of cell portions from said second fixture “B” of attaching linearly along a portion of a bottom edge of said sheet and an entire length of said second recipient bar, a third work position of said third work station transferring and rotating said cell portion as fixedly attached from said second work position of said third work station to said third work position of said third work station, forming said cell portion and fixedly attaching a pair of side edges of said sheet to said first recipient bar, a fourth work position of said third work station transferring and positioning said cell portion as fixedly attached to said fourth work position of said third work station fixedly attaching a top edge of said sheet and said first recipient bar and a fifth work position of said third work station staging said cell portion as fixedly attached; and
actuating a fourth work station defining a first work position of said fourth work station transferring said cell portion from said fifth work position of said third work station to a second work position of said fourth work station, said second work position of said fourth work station testing a leakage of said cell portion, said first work position of said fourth work station further transferring said cell portion as tested to a third work position of said fourth work station attaching a director sheet to said donor side of said sheet, said first work position of said fourth work station further transferring said cell as completed to a fourth work position of said fourth work station unloading said cell.
2. The automated method of manufacturing the cell of claim 1 wherein said attaching includes a tack welding operation.
3. The automated method of manufacturing the cell of claim 1 wherein said actuating of said third work station of said third work position forming said cell portion includes said cell portion being formed into an involute configuration.
4. The automated method of manufacturing the cell of claim 1 wherein said actuating a fourth work station of said third work position attaching a director sheet to said donor side being gluingly attached.
5. The automated method of manufacturing the cell of claim 1 wherein said sheet having a serpentined portion.
6. The automated method of manufacturing the cell of claim 5 wherein said sheet further having a flattened portion.
5. The automated method of manufacturing the cell of claim 1 wherein said first work position of said first work station positioning said first donor bar in said first fixture designated as “A” including a first roll of steel stock being straightened and cut to a preestablished length.
8. The automated method of manufacturing the cell of claim 1 wherein said second work position of said first work station positioning said second donor bar in said first fixture designated as “B” including a second roll of steel stock being straightened and cut to a preestablished length.
9. The automated method of manufacturing the cell of claim 1 wherein said third work position of said first work station positioning said sheet being positioned by a rotary part handler.
10. The automated method of manufacturing the cell of claim 9 wherein said rotary part handler using a vacuum tool.
11. The automated method of manufacturing the cell of claim 1 wherein said third work position of said first work station attaching said first donor bar and said second donor bar to said sheet being a tack welding operation.
12. The automated method of manufacturing the cell of claim 1 wherein said fourth work position of said first work station further welding said sheet and said first donor bar includes a sealed weld between said first donor bar and said sheet generally along a pair of flattened portions of said sheet.
13. The automated method of manufacturing the cell of claim 1 wherein said first work position of said second work station transferring and rotating being transferred and rotated by a rotary part handler.
14. The automated method of manufacturing the cell of claim 9 wherein said rotary part handler using a vacuum tool.
15. The automated method of claim 1 wherein said second work position of said second work station positioning said second recipient bar including a third roll of steel stock being straightened and cut to a preestablished length.
16. The automated method of claim 1 wherein said second work position of said second work station attaching said second recipient bar being a tack welding operation.
17. The automated method of claim 1 wherein said third work position of said second work station positioning said first recipient bar including said first recipient bar having a recipient side director sheet attached thereto.
18. The automated method of claim 17 wherein said third work position of said second work station positioning said first recipient bar including said first recipient bar having a second recipient side director sheet attached thereto.
19. The automated method of claim 1 wherein said third work position of said second work station positioning said first recipient bar including said sheet having a flattened portion along a top edge and a pair of flattened portions and said first recipient bar being positioned in said flattened portion along said top edge and said pair of flattened portions.
20. The automated method of claim 1 wherein said third work position of said second work station welding said first recipient bar being a tack welding operation.
21. The automated method of claim 20 wherein said third work position of said second work station attaching said first recipient bar and said tack welding operation being near an open end of said first recipient bar.
22. The automated method of claim 1 wherein said fourth work position of said second work station positioning said cell portion from said first fixture “A′” to said second fixture “B′” being positioned by a vacuum tool.
23. The automated method of claim 1 wherein said fourth work position of said second work station attaching said cell portion from said first fixture “A′” to said second fixture “B′” being a tack welding operation.
24. The automated method of claim 1 wherein said first work position of said third work station transferring said cell portion from said second fixture “B′” of said fourth work position of said second work station into said second work position of said third work station being transferred by a robot unit.
25. The automated method of claim 1 wherein said second work position of said third work station includes a pair of second work positions.
26. The automated method of claim 1 wherein said second work position of said third work station fixedly attaching linearly along said portion of said bottom edge of said sheet and said entire length of said second recipient bar being welded by a seam welder having a pair of torches.
27. The automated method of claim 1 wherein said third work position of said third work station includes a pair of third work positions.
28. The automated method of claim 1 wherein said third work position of said third work station forming said cell portion including said cell portion being placed in a forming fixture having said top edge of said sheet, the second donor bar and the base portion of said second recipient bar facing up.
29. The automated method of claim 1 wherein said third work position of said third work station fixedly attaching said pair of side edges including a pair of welding torches each welding a respective one of said pair of side edges.
30. The automated method of claim 29 wherein said welding said pair of side edges including welding a top and bottom corners.
31. The automated method of claim 1 wherein said fourth work position of said third work station includes a pair of fourth work positions.
32. The automated method of claim 1 wherein said fourth work position of said third work station fixedly attaching said top edge of said sheet and said first recipient bar includes a slide system having a pair of welding torches.
33. The automated method of claim 32 wherein each of said pair of welding torches sealingly welds half of a linear weld along said top edge of said sheet and a base portion of said first recipient bar.
34. The automated method of claim 1 wherein said first work position transferring said cell portion from said fifth work position of said third work station to said second work position of said fourth work station includes a servo driven pick and place assembly.
35. The automated method of claim 34 wherein said servo driven pick and place assembly transferring said cell portion onto a walking beam conveyor assembly.
36. The automated method of claim 1 wherein said second work position of said fourth work station testing includes a sealing tool assembly.
37. The automated method of claim 36 wherein said sealing tool assembly includes actuating a vacuum of about 25 inches of mercury through said cell.
38. The automated method of claim 1 wherein said third work position of said fourth work station includes forming a precut sheet defining a plurality of alternating root portion and crest portion making said director sheet.
39. The automated method of claim 38 wherein said forming said precut sheet includes using a forming tool.
40. The automated method of claim 1 wherein said third work position of said fourth work station includes a pair of director sheets being positioned in a pair of flattened portions.
41. The automated method of claim 1 wherein said third work position of said fourth work station includes an adhesive system dispersing a thin line of adhesive to said donor side of said sheet.
42. A cell being formed of a plurality of individual components and being produced by an automated process and being adapted for use with a recuperator, said cell comprising:
a pair of performed sheets defining a donor side and a recipient side;
a plurality of donor bars being attached to said donor side of said pair of performed sheets;
a plurality of recipient bars being attached to said recipient side of said pair of performed sheets;
a donor side director sheet being in contacting relationship with said donor side of at least one of said pair of performed sheets;
a recipient side director sheet being in contacting relationship with said recipient side of at least one of said pair of performed sheets; and
said pair of performed sheets, said plurality of donor bars and said plurality of recipient bars being fixedly attached one to another forming said cell.
43. The cell being produced by the automated process of claim 42 wherein one of said donor side director sheets and said recipient side director sheets being trapped between said pair of performed sheets.
44. The cell being produced by the automated process of claim 43 wherein said recipient side director sheets being trapped between said pair of performed sheets.
45. The cell being produced by the automated process of claim 42 wherein one of said donor side director sheets and said recipient side director sheets being connected to one of said pair of performed sheets.
46. The cell being produced by the automated process of claim 42 wherein said cell having a preestablished configuration defining a preestablished thickness (“T of A”).
47. The cell being produced by the automated process of claim 40 wherein said thickness (“T of A”) being maintained to within plus or minus about “0.6 mm”.
48. The cell being produced by the automated process of claim 46 wherein said pair of performed sheets having a substantial thickness, said plurality of donor bars having a substantial thickness, and said plurality of recipient bars having a substantial thickness being combined to define said preestablished thickness (“T of C”) of said cell.
49. The cell being produced by the automated process of claim 48 wherein said plurality of individual components are fixedly attached by welding operation.
50. The cell being produced by the automated process of claim 49 wherein said welding operation fails to increase the preestablished thickness (“T of C”) of said cell.
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US09/305,430 US6308409B1 (en) | 1999-05-05 | 1999-05-05 | Recuperator cell assembly system |
US09/908,089 US20020133949A1 (en) | 1999-05-05 | 2001-07-18 | Recuperator cell assembly procedure |
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US09/305,430 Division US6308409B1 (en) | 1999-05-05 | 1999-05-05 | Recuperator cell assembly system |
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- 1999-05-05 US US09/305,430 patent/US6308409B1/en not_active Expired - Lifetime
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- 2000-05-02 JP JP2000133565A patent/JP2000343384A/en active Pending
-
2001
- 2001-07-18 US US09/908,089 patent/US20020133949A1/en not_active Abandoned
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Cited By (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6668446B2 (en) * | 2001-10-31 | 2003-12-30 | Solar Turbines Inc | Recuperator duct assembly line |
US20030088982A1 (en) * | 2001-11-09 | 2003-05-15 | Ervin Douglas R. | Method and apparatus for aligning a circular recuperator core |
US6684502B2 (en) * | 2001-11-09 | 2004-02-03 | Solar Turbines Inc | Method and apparatus for aligning a circular recuperator core |
CN104476423A (en) * | 2014-12-04 | 2015-04-01 | 张和庆 | Fiber mesh picking and placing device |
CN108213710A (en) * | 2018-03-29 | 2018-06-29 | 东莞市力星激光科技有限公司 | A kind of automatic laser bonding machine of cover plate of power battery and burst disk |
CN110370020A (en) * | 2019-08-13 | 2019-10-25 | 深圳市思必德科技有限公司 | A kind of Intelligent assembly production line |
Also Published As
Publication number | Publication date |
---|---|
DE10021327A1 (en) | 2000-11-30 |
US6308409B1 (en) | 2001-10-30 |
JP2000343384A (en) | 2000-12-12 |
DE10021327B4 (en) | 2011-01-27 |
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