WO2015000802A1

WO2015000802A1 - Production method for a heat exchanger, and tool for producing the heat exchanger

Info

Publication number: WO2015000802A1
Application number: PCT/EP2014/063680
Authority: WO
Inventors: Werner Helms; Roland Hemminger; Rüdiger KÖLBLIN
Original assignee: Behr Gmbh & Co. Kg
Priority date: 2013-07-03
Filing date: 2014-06-27
Publication date: 2015-01-08
Also published as: DE102013212939A1

Abstract

The invention relates to a method for producing a heat exchanger (10) having a tube-fin block (12) comprising tubes (14) and comprising corrugated fins (16) running in corrugated-fin ducts (20) and comprising at least one tube plate (18) to which the tubes (14) and the corrugated-fin ducts (20) are connected. The method is distinguished by the fact that a flaring is provided at the corners (30, 32) of the corrugated-fin ducts (20), such that flared corners (27) are produced. The invention also relates to a tool (34) by means of which corners (30, 32) can be flared, said tool having shaping spikes (38). The invention also relates to a heat exchanger (10) having flared corners (27).

Description

Manufacturing method for a heat exchanger and tool for

Production of the heat exchanger

description

Technical area

The invention relates to a method for producing a heat exchanger according to the preamble of claim 1, a tool for producing a heat exchanger and a heat exchanger according to the preamble of claim 9.

State of the art

In a motor vehicle heat exchangers are used on different mounting parts. A particular embodiment of a heat exchanger is an air charge cooler (LLK) that may be provided in the intake manifold of an engine to reduce the temperature of the combustion air supplied to the engine. The intercooler is typically installed between the compressor, such as the turbocharger or compressor in the intake manifold and the intake valve, and dissipates some of the heat generated by the compression of the air.

The intercooler is made of a finned tube block with a number of tubes, in particular flat tubes and arranged therebetween Corrugated ribs built. The flat tubes are arranged substantially parallel to each other and inserted at both ends in each case in a tubesheet and connected thereto. At least on a tube sheet an air box is arranged. At the air box, the inlet and / or outlet are arranged for air supply. The pipes are usually widened for better installation in order to be fixed in the tubesheet. This installation of the pipes is critical because this can cause damage to the corrugated fins and the pipes.

From DE 2 320 886 an arrangement for reinforcing the connection between pipes and a collecting container for a heat exchanger is known. The tubes have a rectangular cross-section and the ends of the tubes are engaged with flanges of the collection container. In the manufacture of the heat exchanger, the tubes are arranged so that the ends of the tubes protrude beyond the flanges and the two longitudinal sides of each tube can be bent and rolled around the flanges. Here, the ends of the tubes are flared by a special tool.

DE 694 02 786 T2 discloses a heat exchanger having tubes and cooling fins, a pair of header plates and a pair of side plates. In the method of manufacturing the heat exchanger, the tubes arranged in a central part of the header plate are widened in a cone shape to a smaller degree than those tubes arranged adjacent to the side plates. This can prevent the tubes from slipping down during a subsequent soldering step.

It is the object of the present invention to provide a safe method of manufacturing a heat exchanger in which neither pipes nor corrugated fins are damaged. This is achieved with a method for producing a heat exchanger with the features of claim 1, according to which, according to a preferred embodiment of the inventive concept, a bulge is provided at the corners. This results in aufgulpte corners in corrugated channels. The heat exchanger has a finned tube block with tubes and ribs arranged in corrugated rib channels, in particular corrugated ribs (corrugated ribs) and at least one tubesheet to which the tubes and the corrugated rib channels are connected. The tubes are preferably formed as flat tubes. The tubes are inserted during assembly before Auftulpen in the tube sheet. Due to the fact that the bulging takes place at the corners, the corrugated ribs can be selectively deformed in such a way that the ends of the ribs can abut respectively against the wall of the corrugated rib channels. The ends of the corrugated ribs can in this case be applied in particular to the corners of passages of the tubesheet. This can cause a tensile stress on the flat sides of the tubes. As a result, an investment in the tube sheet is positively influenced. In the next method step, a cohesive connection can then be produced, preferably by soldering, and the ribs and the walls can be materially bonded. Significant improvements are achieved at the flow-important points of the heat exchanger in the corrugated channels. There are no visual deformations of the ribs and no folding over of the end curves of the ribs after the assembly of the finned tube block to the tubesheet. A subsequent soldering can be done optically without binding.

In one embodiment of the method for producing a heat exchanger, the bulge takes place in the corners by a forming mandrel. The number of mandrels here corresponds to the number of corners of the corrugated channel and thus twice the number of corrugated rib channels, so that in each case in a corner of a corrugated channel a forming mandrel can realize the bulge. Preferably, two rows of mandrels are provided. Thus, four mandrels each engage in a corrugated rib channel with corrugated ribs. It can a uniform distribution of the forces and thus a tensile stress on the flat sides of the tubes of the corrugated rib channels done. The two rows of mandrels, also referred to as tulip inserts, are preferably driven simultaneously into the tube fin block.

Preferably, the mandrel has a conical shape, wherein the mandrel is part of a Tulpstempels. The tulip also has a substantially cylindrical portion, a 90 degree counterbore and a heel. But it can also be provided other stamp shapes, for example, with a tapered shape in stages. Preferably, both rows of mandrels are retracted simultaneously into the finned tube block. Thus, forces are introduced at the same time tulip for all corners of the Rippenrohrbiocks. The object is likewise achieved by a tool for producing a heat exchanger, which has at least one punch holding plate, can be used in the mandrels, wherein the mandrels are arranged in rows on the stamp plate, so that each tulip with the mandrels can be made a bulge at the corners , The arrangement of the mandrels on the punch holder plate depends on the geometry of the respective heat exchanger, in particular on the width of the tubes and / or corrugated rib channels and the distance between the tubes and / or corrugated rib channels with each other. The mandrels may preferably be arranged symmetrically and have a uniform distance from each other.

Preferably, the tool for producing a heat exchanger on two rows of form mandrels. Here, all corners of the heat exchanger can be simultaneously sculpted.

The object is also achieved by a heat exchanger with a finned tube block with tubes and corrugated fins and at least one tubesheet, the tubes are inserted into the tubesheet and the corners of the tubes and / or corrugated rib channels are made up prior to making a cohesive connection. The corrugated channels have aufgetuipte corners. The deformation of the tubes is also recognizable after the cohesive connection. The cohesive connection is preferably a solder joint.

Preferably, the heat exchanger is a charge air cooler (LLK or iLLK). A lag air cooler is disposed in a motor vehicle between a compressor, such as a turbocharger and an intake valve, and serves to cool the air after the compressor.

Further advantageous embodiments are described by the following description of the figures and by the subclaims.

Brief description of the figures of the drawing

The invention will be explained in more detail on the basis of at least one embodiment with reference to the figures of the drawing. Show it:

Fig. 1 is a photograph of a Rippenrohrbiocks

Heat exchanger in plan view;

FIG. 2 is a photograph of damage to a heat exchanger made by a prior art method; FIG.

3a, 3b a photograph of undamaged ribs of a

Heat exchanger, made with an inventive

Method; a photograph ie a stamp of a tool for Ecktulpen; a tool for Ecktulpen; a schematic representation of a top view of the tool for Ecktulpen; a schematic sectional view in the plane BB; a schematic representation of the tool of Figure 6 obliquely from the front. a schematic representation of a stamp plate of the tool of Fig. 6; a representation of the tulip stamp of the tool of Fig. 6.

Figure 1 illustrates a photograph of a heat exchanger 10, in particular a charge air cooler 10 (LLK) of a motor vehicle (not shown) of which only one finned tube block 12 is shown. The intercooler 10 may be a charge air / air cooler, is used in the direct charge air cooling with ambient air. The intercooler 10 may also be charge air / coolant radiator, which may operate with indirect intercooler with a fluid coolant. The charge air cooler 10 generally has tubes 14 and corrugated fins 16 arranged between the tubes 14. The tubes 14 are preferably formed as flat tubes 14 and can be flowed through by the coolant (air or liquid coolant). The tubes 14 and the corrugated fins 16 are arranged on a tube plate 18 and connected thereto. The heat exchanger 10 is preferably in an engine compartment a motor vehicle between a compressor and an inlet valve and cools the charge air. The heat exchanger 10 generally has air inlet nozzle for the hot air and air outlet nozzle for the cooled air (not shown).

FIG. 2 shows a section of a corrugated channel 20 of the heat exchanger 10 in which the method used in the prior art for producing the heat exchanger 10 has led to damage 22 to the corrugated fins 16. The ribs 16 are bent at the ends 26, whereby no proper soldering can take place and whereby the flow through the corrugated channel 20 is disturbed during operation. The damage 22 may have occurred by using a U-punch - as usual in the art - for bulging. Figure 3 shows the section of the heat exchanger 10, in which the bulge of a tube 24 of the corrugated channel 20 was performed with a tool according to the invention. There are no bent rib ends 26 to recognize. A collar 25 of the tube 24 shows recessed corners 27. The rib ends 26 abut against a wall 28 and have been properly soldered. The bulge is done at each corner 30 and 32.

Figure 4a shows the tool 34 for Ecktulpung. The tool 34 has a punch-holding plate 36, in the tulip stamp 39 having a forming mandrel 38 are used. The mandrels 38 inserted into the punch holder plate 36 are shown enlarged in FIG. 4b. The mandrels 38 have a conical shape (conical portion 42) and have a rounded tip 40. Figures 10 and 10a show the tulip punch 39 with the mandrel 38 in a more detailed technical drawing. The tool 34 has a first row 44 of mandrels 38 and a second row 46 of mandrels 38, with twenty-six (26) mandrels 38 per row 44, 46, respectively. The mandrels 38 are also referred to as tulip inserts 38. This corresponds to twice the number of Corrugated rib channels 20 per row 44, 46, wherein each corrugated channel 20 has four corners 30, 32. In the figure 1, these four corners 30, 32 can be seen, in the figures 2 and 3, only the corners 30 and 32 are shown at one end.

5 shows an experimental paver 48 with the built-in tools 34 with mandrels 38. It is an indirect intercooler with 80 mm width and the punch holder plate 36 with inserted mandrels 38. In the manufacturing process, the two rows drive 44, 46 with mandrels 38 simultaneously in the Finned tube block 12.

FIG. 6 shows a technical drawing of an experimental paver 48 with a tool 34. Two rows 44 and 46 are shown with built-in mandrels 38. The test paver 48 is preferably made of a stainless steel, preferably a 55 CrVMo steel.

FIG. 7 shows the test paver 48 in the section plane B-B. The stamp plate 36 is mounted. FIG. 8 shows the test paver 48 of FIGS. 6 and 7 in a view obliquely from the front.

Figure 9 shows the Stempelhaltepiatte 36 with recesses 50, can be added to the mandrels 38. FIG. 9a shows a top view of the stamp plate obliquely from above. FIG. 9b shows a vertical plan view. Figure 9c shows a sectional view in the plane AA. The punch holder plate 36 is preferably made of X1 55CrVMo 121 steel. FIG. 10 shows, in a technical drawing, the tulip stamp 39 with the shaped dome 38. The tulip stamp 39 has a section 52 of essentially cylindrical shape (cylindrical section 52), at one end of which a 90 ° countersink 54 and a step following the countersinking 56 is arranged. The other end of the tulip die 39 passes through phases 58 and 60 into a conical shape, the conical section 42, which forms the forming mandrel 38. The heel 56 may serve to support the tulip punch 39 in the tool 34. The method according to the invention for producing the heat exchanger 10 comprises the steps:

- Providing the components of the heat exchanger 10, in particular a finned tube block 12 with corrugated fins 16 and tubes 14 and a tube plate 18;

- arranging the parts to each other;

- Inserting the channels 20 in which corrugated fins 16 (corrugated channels 20) are arranged in the tube sheet 18 and / or insertion of arranged between the corrugated fins 20 tubes 14 in the tube sheet 18;

- Auftulpen at the corners 30, 32 of the respective corrugated fins 20 channels by means of the tool 34 by form dome 38 are respectively introduced to the corners 30, 32 of the corrugated fins 20 - in this case arise recessed corners 27;

- Establishing a cohesive connection between the tubes 14, the corrugated fins 20 and the corrugated fins 16 respectively to the

Connecting points to the tube sheet 18; Preferably, the application of a soldering process for producing the integral connection is provided;

- Final assembly of the other missing components of the heat exchanger 10, in particular assembly of inlet and

Outlet.

Claims

claims

1 . Method for producing a heat exchanger (10) with a tube fin block (12) comprising tubes (14), and corrugated fins (16) extending in corrugated channels (20) and at least one tube plate (18), with which the tubes (14) and the corrugated channels ( 20), characterized in that a bulge at the corners (30, 32) of the corrugated rib channels (20) is provided, so that bulged corners (27) arise,

2. A method for producing a heat exchanger (10) according to claim

1, characterized in that the bulge in the corners (30, 32} by means of a forming mandrel (38).

3. A method for producing a heat exchanger (10) according to any one of claims 1 or 2, characterized in that a further method step for producing a cohesive connection is provided.

4. A method for producing a heat exchanger (10) according to any one of the preceding claims, characterized in that the Auftulpung means of a first row (44) mandrels (38) and at least a second row (46) of mandrels (38) by means of the flared corners (27) are realized,

5. A method for producing a heat exchanger (10) according to any one of the preceding claims, characterized in that the first row (44) and the second row (46) of the forming mandrels (38) are retracted simultaneously in the corrugated rib channels (20).

6. Tool (34) for producing a heat exchanger (10) according to a method according to claims 1 to 5, in particular for the bulge of corrugated channels (20) comprising a punch holder plate (36), in the form of mandrels (38) are used, characterized in that the shaping mandrels (36) are arranged in such a way that, when using the tool (34) for tuliping with the mandrels (38), a bulge can be produced at the corners (30, 32) of the respective corrugated rib channels (20).

7. Tool (34) for producing a heat exchanger (10) according to any one of the preceding claims, in particular claim 6, characterized in that the forming mandrel (38) has a conical portion (42).

8. Tool (34) for producing a heat exchanger (10) according to claim 6 and / or 7, characterized in that two rows (44, 46) of mandrels (38) are provided.

9. heat exchanger (10) with a finned tube block (12) with tubes (14) and corrugated fins (16) and at least one tube plate (18), wherein the corners (30, 32) are recessed corners (27).

10. Heat exchanger according to claim 9, characterized in that the heat exchanger (10) is a charge air cooler.