A composite tube sheet, an air-cooled heat exchanger tube bundle, and a preparation process

Abstract

The present invention discloses a composite tube sheet, an air cooler tube bundle and a preparation process, relating to the technical field of air coolers. The specific implementation manners thereof include: a composite tube sheet applied to an air cooler tube bundle, comprising: a base plate, a plurality of tube holes arranged side by side on the base plate, a plurality of first grooves and a plurality of welding parts, wherein each tube hole is used for installing the end part of a base tube of the air cooler tube bundle; each first groove is located on a main surface of the base plate and is arranged around a tube hole; each welding part is fixed in the first groove and is used for welding connection with the end part of the base tube. This composite tube sheet can set welding parts in the area of the base plate welded to the base tube, overcome the welding defects easily generated in the current technology, and improve the welding quality.

Description

Technical Field

[0001] The present invention relates to the technical field of air coolers, and particularly to a composite tube sheet, an air cooler tube bundle, and a manufacturing process thereof. Background Art

[0002] An air cooler, also known as an "air-cooled heat exchanger", uses ambient air as a cooling medium, which sweeps across the outside of finned tubes to cool or condense the high-temperature process fluid inside the tubes. This air cooler generally consists of main components such as a tube bundle, a tube box, a fan, a louver, and a framework, and is widely used in industries such as petrochemical, metallurgy, electric power, aerospace, etc.

[0003] An air cooler tube bundle generally consists of finned tubes, a tube sheet, and a tube box. Among them, the base tube of the finned tube passes through the tube holes of the tube sheet and is welded to the tube sheet. For the widely used flat-tube type aluminum finned tubes currently, in order to weld the aluminum finned tubes to the tube sheet, a steel-aluminum composite tube sheet is generally selected.

[0004] Currently, the steel-aluminum composite tube sheet used in air cooler tube bundles is obtained by explosively cladding a whole aluminum plate or aluminum alloy plate to a steel plate, and a steel-aluminum bonding surface is formed between the aluminum plate and the steel plate or between the aluminum alloy plate and the steel plate. However, when the base tube is welded to the steel-aluminum composite tube sheet, due to the influence of the welding high temperature, defects such as cracking and steel-aluminum peeling are likely to occur on the steel-aluminum bonding surface. And the fracture of the bonding surface and the peeling of aluminum and steel can result in poor welding quality of the welded connection between the base tube and the steel-aluminum composite tube sheet. Summary of the Invention

[0005] In view of this, the present invention provides a composite tube sheet, an air cooler tube bundle, and a manufacturing process thereof, which can fix the welding part through the first groove instead of forming a bonding surface between the welding part and the base plate, thereby overcoming the defect of cracking of the steel-aluminum bonding surface and improving the welding quality.

[0006] To achieve the above object, according to one aspect of an embodiment of the present invention, a composite tube sheet is provided, which is applied to an air cooler tube bundle and includes: a base plate, a plurality of tube holes arranged side by side on the base plate, a plurality of first grooves, and a plurality of welding parts, wherein,

[0007] Each of the tube holes is used to install the end of a base tube of the air cooler tube bundle;

[0008] Each of the first grooves is located on a main surface of the base plate and is arranged around one of the tube holes;

[0009] Each of the welding parts is fixed in the first groove and is used for welded connection with the end of the base tube.

[0010] Optionally, the depth of the first groove is 4 - 10 mm.

[0011] Optionally, the included angle between the bottom surface and the side surface of the first groove is 75 to 80 degrees.

[0012] Optionally, at least one sealing groove is provided on the side surface of the first groove;

[0013] A part of the welding portion is filled and extruded into the sealing groove.

[0014] Optionally, the cross-sectional shape of the sealing groove is any one of a triangle, a trapezoid, an arc, a rectangle, and other polygons.

[0015] Optionally, the cross-section of the first groove is a flat-mouth structure.

[0016] Optionally, the size of the first groove is (228 - 248) mm × 38 mm.

[0017] Optionally, the welding portion is made of an aluminum material.

[0018] Optionally, the tube hole has a flat-mouth structure.

[0019] Optionally, the size of the tube hole is (209.2 - 230) mm × 19 mm;

[0020] Optionally, the gap between the tube hole and the base tube is 0.4 - 0.8 mm.

[0021] In a second aspect, an embodiment of the present invention provides an air-cooled heat exchanger tube bundle, including: base tubes arranged side by side, fins provided on the base tubes, and the composite tube sheet provided in any of the above embodiments, where

[0022] The end of the base tube is installed in the tube hole included in the composite tube sheet and is welded to the welding portion included in the composite tube sheet.

[0023] Optionally, the cross-section of the base tube is a harmonica structure.

[0024] Optionally, the size of the base tube is (208.8 - 229.2) mm × 19 mm.

[0025] Optionally, the wall thickness of the base tube is 0.8 - 1.6 mm.

[0026] Optionally, the inner cavity of the base tube includes a plurality of through holes separated by partitions.

[0027] Optionally, the number of the through holes is 1 - 12.

[0028] In a third aspect, an embodiment of the present invention provides a preparation process for a composite tube sheet, including:

[0029] A second groove is machined in each of a plurality of preset tube hole areas arranged side by side on the substrate;

[0030] The welding filler is embedded in the second groove by forging;

[0031] A tube hole is punched in the second groove in which the welding filler is embedded, and a first groove surrounding one of the tube holes and a welding portion fixed in the first groove are formed. Among them, the tube hole is used to install the base tube of the air cooler tube bundle, and the welding portion is welded to the base tube.

[0032] Optionally, the preparation process of the above composite tube sheet further includes:

[0033] A sealing groove is formed on the side surface of the second groove.

[0034] Optionally, the step of embedding the welding filler in the second groove by forging includes:

[0035] A part of the welding filler is filled and extruded into the sealing groove.

[0036] Optionally, the cross-sectional shape of the sealing groove is any one of a triangle, a trapezoid, an arc, a rectangle, and other polygons.

[0037] Optionally, the depth of the second groove is 4 - 10 mm.

[0038] Optionally, the angle between the bottom surface and the side surface of the second groove is 75 - 80 degrees.

[0039] Optionally, the cross-section of the second groove is a flat-mouth structure.

[0040] Optionally, the size of the second groove is (228 - 248) mm × 38 mm.

[0041] Optionally, the welding filler is made of an aluminum material.

[0042] Optionally, the preparation process of the above composite tube sheet further includes:

[0043] Determine the substrate material and the substrate thickness according to preset calculation conditions;

[0044] Select the substrate raw material according to the substrate material and the substrate thickness;

[0045] The substrate raw material is cut by machining such as blanking, and the burrs, unevenness and chamfers of the cut edge are removed to obtain the substrate.

[0046] Fourthly, an embodiment of the present invention provides a preparation process for an air cooler tube bundle, including: the preparation process for the composite tube sheet described in any one of the above, and

[0047] a process of installing the base tubes included in the air cooler tube bundle on the composite tube sheet.

[0048] The above invention has the following advantages or beneficial effects: Since the first groove is located on one main surface of the base plate and is arranged around a tube hole, and the welding part is fixed in the first groove, that is, the welding part is fixed by the first groove, avoiding the formation of a steel-aluminum bonding surface between the steel plate and the aluminum plate or aluminum alloy plate. At the same time, the first groove fixing the welding part can withstand the welding high temperature, thereby overcoming the defect of cracking of the steel-aluminum bonding surface and improving the welding quality.

[0049] The further effects of the above non-conventional optional manner will be described in conjunction with specific embodiments below. Description of the Drawings

[0050] The drawings are used to better understand the present invention and do not constitute an improper limitation to the present invention. Among them:

[0051] Figure 1 is a schematic diagram of a partial main structure of an air cooler tube bundle according to an embodiment of the present invention;

[0052] Figure 2 is according to an embodiment of the present invention Figure 1 a schematic diagram of an enlarged structure of the marked area A;

[0053] Figure 3 is a cross-sectional schematic diagram of a base tube according to an embodiment of the present invention;

[0054] Figure 4 is a cross-sectional structure schematic diagram of a composite tube sheet according to an embodiment of the present invention;

[0055] Figure 5 is a schematic flow diagram of the structural change of the composite tube sheet during the preparation process of the composite tube sheet according to an embodiment of the present invention;

[0056] Figure 6 is a cross-sectional schematic diagram of the planar structure of a composite tube sheet according to an embodiment of the present invention;

[0057] Figure 7 is a schematic diagram of the main process flow of the preparation process of a composite tube sheet according to an embodiment of the present invention.

[0058] 10 Composite tube sheet 11 Base plate 12 Tube hole

[0059] 13 First groove 131 Bottom surface of the first groove

[0060] 132 Side of the first groove 1321 Sealing groove 14 Welding part

[0061] 15 Second groove 151 Bottom surface of the second groove

[0062] 152 Side of the second groove 16 Welding filler

[0063] 20 Base tube 21 Gap between the tube hole and the base tube

[0064] 30 Fins Detailed implementation manners

[0065] The following describes exemplary embodiments of the present invention with reference to the accompanying drawings. Various details of the embodiments of the present invention are included to facilitate understanding, and they should be considered merely exemplary. Therefore, those skilled in the art should recognize that various changes and modifications can be made to the embodiments described herein without departing from the scope and spirit of the present invention. Similarly, descriptions of well-known functions and structures are omitted in the following description for clarity and conciseness.

[0066] Figure 1 、 Figure 2 and Figures 4 to 6 is a schematic structural diagram of a composite tube sheet according to an embodiment of the present invention. Among them, Figure 1 shows a partial main structure of an air-cooled heat exchanger tube bundle, which gives the relative positional relationship between the composite tube sheet and the base tube of the air-cooled heat exchanger tube bundle, as well as the relative positional relationship between the tube holes, the first grooves, and the welding parts included in the composite tube sheet; Figure 2 shows Figure 1 the enlarged structure of the area A marked; Figure 4 shows the cross-sectional structure of the composite tube sheet; Figure 5 shows the change process of the composite tube sheet structure during the preparation process of the composite tube sheet; Figure 6 shows a schematic cross-sectional view of the planar structure of the composite tube sheet.

[0067] As Figure 1 、 Figure 2 and Figures 4 to 6 shown, the composite tube sheet applied to the air-cooled heat exchanger tube bundle may include: a base plate 11, a plurality of tube holes 12 arranged side by side on the base plate, a plurality of first grooves 13, and a plurality of welding parts 14. Among them, each tube hole 12 is used to install the end of a base tube 20 of the air-cooled heat exchanger tube bundle; each first groove 13 is located on a main surface of the base plate 11 and is arranged around a tube hole 12; each welding part 14 is fixed in the first groove 13 and is used for welded connection with the end of the base tube 20.

[0068] Among them, the base tube of the following air-cooled heat exchanger tube bundle and the base tube in the finned tube both refer to the base tube 20 shown in this drawing.

[0069] In addition, the material used for the welding part 14 is generally the same as or close to the material of the base pipe 20, so that the welding between the welding part 14 and the base pipe 20 can be matched to ensure the firmness of the welded joint. For the case where the base pipe 20 is made of aluminum, which is commonly used at present, the welding part 14 is made of pure aluminum or aluminum alloy. In a preferred embodiment, the welding part 14 is made of aluminum alloy. Selecting aluminum alloy material to prepare the welding part can make the welding part 14 not easily deformed and have good sealing performance, and at the same time have practicality. Among them, the aluminum alloy material used as the welding part 14 can be any one of aluminum-manganese alloy, aluminum-magnesium alloy, aluminum-magnesium-silicon alloy, etc. In a preferred embodiment, the aluminum alloy material used as the welding part 14 can be aluminum-manganese alloy. By selecting aluminum-manganese alloy, the fitting between the welding part and the first groove can be ensured to be relatively firm, so as to further improve the sealing performance of the composite tube sheet. It can be understood that for the case where other materials are selected for the base pipe 20, the material used for the welding part 14 can be adjusted accordingly to meet the welding requirements.

[0070] It should be noted that the composite tube sheet generally has two main surfaces, and the tube holes 12 penetrate through these two main surfaces. One main surface of the composite tube sheet is close to the finned tubes of the air cooler tube bundle, and the other main surface of the composite tube sheet is far from the finned tubes of the air cooler tube bundle and forms a welded joint with the end of the base pipe in the finned tubes. Generally speaking, the end of the base pipe 20 passes through the tube hole from one main surface of the composite tube sheet to the other main surface of the composite tube sheet. Then, the main surface of the base plate 11 where each first groove 13 is located refers to the main surface that is far from the finned tubes of the air cooler tube bundle and forms a welded joint with the end of the base pipe in the finned tubes.

[0071] In the embodiment of the present invention, the depth of the first groove 13 is any value within the range of 4 to 10 mm, so that the welding part 14 fixed in the first groove can meet the requirements of different types of welding, ensure the sealing performance between the composite tube sheet and the finned tubes, and avoid waste of the material used for the welding part. For example, for the welding type of tungsten inert gas welding (TIG welding), the depth of the first groove can be 4 mm; for another example, for the welding type of melt inert gas welding (MIG welding), the depth of the first groove can be 10 mm, etc. It should be noted that the depth of the first groove 13 refers to the vertical distance from the bottom surface 131 of the first groove to the main surface of the composite tube sheet that is far from the finned tubes. As Figure 4 shown, the bottom surface 131 of the first groove 13 refers to a surface that is parallel or approximately parallel to the main surface of the composite tube sheet and encloses the first groove.

[0072] It should be noted that in the embodiments of the present invention, if the angle between the bottom surface 131 and the side surface 132 of the first groove 13 is less than 75 degrees, not only does it increase the manufacturing difficulty of the first groove, but also it is very difficult for the welding part 14 to fill the first groove 13, resulting in unqualified sealing of the composite tube sheet. If the angle between the bottom surface 131 and the side surface 132 of the first groove 13 is greater than 80 degrees, the tension force on the side surface of the first groove is small, which will cause the side surface 132 to turn outwards near the main surface area of the composite tube sheet, thus affecting the fixation of the welding part 14. Therefore, in the embodiments of the present invention, the angle α between the bottom surface 131 and the side surface 132 of the first groove 13 is any value within the range of 75 to 80 degrees. Among them, as Figure 4 shown, the side surface 132 of the first groove 13 refers to another surface that is located between the main surface of the composite tube sheet far from the finned tube and the bottom surface 131 of the first groove 13 and encloses the first groove. The side surface 132 of the first groove 13 intersects with the main surface of the composite tube sheet far from the finned tube and the bottom surface 131 of the first groove 13 respectively. Through experimental tests, it is shown that by controlling the angle between the bottom surface 131 and the side surface 132 of the first groove 13 within the range of 75 to 80 degrees, the welding part can be inlaid in the first groove to achieve sealing, and at the same time, the first groove can effectively fix and connect the welding part, and improve the yield rate of the composite tube sheet.

[0073] In the embodiments of the present invention, as Figure 4 and Figure 5 shown, at least one sealing groove 1321 is provided on the side surface 132 of the first groove 13; a part of the welding part 14 is filled and extruded into the sealing groove 1321. Through the setting of the sealing groove 1321, the sealing performance of the composite tube sheet can be further improved. Among them, the cross-sectional shape of the sealing groove 1321 is any one of a triangle, a trapezoid, an arc, a rectangle, and other polygons. Through the cross-sectional shape of the sealing groove 1321, the bonding force between the welding part and the sealing groove 1321 can be effectively improved, thereby better improving the sealing performance of the composite tube sheet.

[0074] In the embodiments of the present invention, as Figure 1 and Figure 6 shown, the cross-section of the first groove 13 is a flat-mouth structure, and this flat-mouth structure can better meet the use requirements of the base tube with a common cross-section of a harmonica structure at present. In addition, while meeting the welding requirements of the base tube with a cross-section of a harmonica structure, the amount of material used for making the welding part can also be well controlled.

[0075] In the embodiments of the present invention, in order to enable the composite tube sheet to be applied to the base tube with a harmonica structure, as Figure 1 、 Figure 3 and Figure 6As shown, the tube hole 12 has a flat-mouth structure. Among them, the size of the tube hole 12 is (209.2 - 230) mm × 19 mm; among them, the width of the tube hole is 19 mm, and the length of the tube hole is 209.2 - 230 mm. As Figure 6 shown, the width of the tube hole refers to the distance W1 between the two long sides of the tube hole with a flat-mouth structure, and the length of the tube hole refers to the distance L1 between the upper and lower ends of the tube hole with a flat-mouth structure.

[0076] In the embodiment of the present invention, in order to meet the welding requirements between the welding part and the base tube and avoid waste of materials used for the welding part, the size of the first groove 13 is (228 - 248) mm × 38 mm. Among them, the size of the first groove 13 means that when the first groove 13 has a flat-mouth structure, the width of the flat-mouth structure is 38 mm, and the length is 228 - 248 mm. As Figure 6 shown, the width of the flat-mouth structure of the first groove 13 refers to the distance W2 between the two long sides of the flat-mouth structure formed by the sides of the first groove 13 on the main surface of the composite tube sheet; the length of the flat-mouth structure of the first groove 13 refers to the distance L2 between the upper and lower ends of the flat-mouth structure formed by the sides of the first groove 13 on the main surface of the composite tube sheet.

[0077] By selecting the above-mentioned size of the first groove, the welding requirements can be met, and at the same time, waste of welding materials can be reduced. More preferably, the size of the first groove 13 is adapted to the angle between the bottom surface 131 and the side surface 132 of the first groove 13, which is between 75° and 80°, so as to accurately control the amount of welding materials used and further reduce the waste of materials.

[0078] In addition, in order to enable the tube hole to match the base tube and at the same time reduce the manufacturing difficulty of the tube hole and the technical difficulty of installing the base tube in the tube hole, the gap 21 between the tube hole 12 and the base tube 20 in the embodiment of the present invention can be 0.4 - 0.8 mm. The gap between the tube hole 12 and the base tube 20 refers to the gap between the inner wall of the tube hole and the outer wall of the base tube.

[0079] In the composite tube sheet provided in the above-mentioned embodiments, since the first groove is located on one main surface of the base plate and is arranged around a tube hole, and the welding part is fixed in the first groove, that is, the welding part is fixed by the first groove, avoiding the formation of a steel-aluminum bonding surface between the steel plate and the aluminum plate or aluminum alloy plate. At the same time, the first groove fixing the welding part can withstand the welding high temperature, thereby overcoming the defect of cracking of the steel-aluminum bonding surface and improving the welding quality.

[0080] In addition, due to the improvement of the welding quality, the probability of generating waste steel-aluminum composite plates is greatly reduced, effectively avoiding waste of materials.

[0081] The embodiment of the present invention provides an air-cooled heat exchanger tube bundleFigure 1 and Figure 2 shows a partial structural front view of an air-cooled condenser tube bundle. As can be seen from Figure 1 it, the air-cooled condenser tube bundle may include: base tubes 20 arranged side by side, fins 30 provided on the base tubes 20, and the composite tube sheet 10 provided in the above embodiment. Among them,

[0082] the end of the base tube 20 is installed in the tube hole 12 included in the composite tube sheet 10 and is welded and connected to the welding part 14 included in the composite tube sheet 10.

[0083] Since the composite tube sheet used in the above air-cooled condenser tube bundle overcomes the defect of cracking of the steel-aluminum joint surface and improves the welding quality, the quality and service performance of the air-cooled condenser tube bundle are improved.

[0084] It should be noted that the air-cooled condenser tube bundle further includes a tube box (not shown in the figure), and its function is the same as that of the tube box in the existing air-cooled condenser tube bundle manufacturing technology, and will not be elaborated here.

[0085] In the embodiment of the present invention, as Figure 3 shown, the cross-section of the base tube 20 included in the air-cooled condenser tube bundle is a harmonica-shaped structure, which can effectively optimize the heat conduction of the fluid in the base tube.

[0086] In the embodiment of the present invention, the size of the base tube 20 is (208.8 - 229.2) mm × 19 mm. Among them, "(208.8 - 229.2) mm" is the distance between the two ends of the harmonica-shaped structure. As Figure 3 shown, L3 is the distance between the two ends of the harmonica-shaped structure; "19 mm" is the distance between the two long sides of the harmonica-shaped structure. As Figure 3 shown, W3 is the distance between the two long sides of the harmonica-shaped structure; whether it is the distance between the two ends of the harmonica-shaped structure or the distance between the two long sides of the harmonica-shaped structure, the outer side wall of the base tube 20 is used for measurement.

[0087] In the embodiment of the present invention, the wall thickness of the base tube 20 is 0.8 - 1.6 mm. It can meet the heat exchange requirements of the air-cooled condenser tube bundle and at the same time meet the welding requirements between the base tube 20 and the welding part 14.

[0088] In the embodiment of the present invention, the inner cavity of the base tube 20 includes a plurality of through holes separated by partitions. The number of through holes is generally any value from 1 to 12, which can effectively improve the heat exchange efficiency of the air-cooled condenser tube bundle.

[0089] As Figure 5 and Figure 7 shown, the embodiment of the present invention provides a preparation process for a composite tube sheet. Among them, Figure 7 the shown preparation process for the composite tube sheet may include the following steps:

[0090] Step S701: Process a second groove 15 in each of a plurality of preset tube hole regions arranged side by side on the substrate 11;

[0091] As Figure 5 shown, this second groove 15 is not a through groove and can carry the welding filler 16.

[0092] In addition, as Figure 5 shown, a sealing groove can also be opened on the side surface of the second groove 15. This sealing groove is the sealing groove 1321 on the side surface of the first groove 13 mentioned in the foregoing embodiment. Among them, the cross-sectional shape of this sealing groove can be any one of a triangle, a trapezoid, an arc, a rectangle, and other polygons.

[0093] In addition, in order to obtain the first groove 13 with a depth of 4 - 10 mm in the composite tube sheet, the depth of the second groove 15 can be controlled to be the same as that of the first groove 13 in this step to simplify the preparation process of the composite tube sheet.

[0094] In addition, in order to control the included angle between the bottom surface 131 and the side surface 132 of the first groove 13 in the composite tube sheet to be 75 - 80 degrees. It can be achieved by controlling the included angle β between the bottom surface 151 and the side surface 152 of the second groove 15 as Figure 5 shown to be 75 - 80 degrees. Through this process, it is easier to fabricate the included angle between the bottom surface 131 and the side surface 132 of the first groove 13, so as to further simplify the preparation process of the composite tube sheet.

[0095] In addition, in order to obtain the first groove 13 with a flat-mouth structure and the dimensions of the first groove mentioned in the foregoing embodiment, the cross-section of the second groove 15 can also be controlled to be a flat-mouth structure in this step. In addition, the size of the second groove 15 is (228 - 248) mm × 38 mm. The size of this second groove refers to the size of the flat-mouth structure formed by the side surface of the second groove on the main surface of the composite tube sheet.

[0096] Step S702: Embed the welding filler 16 into the second groove 15 by forging;

[0097] In this step, if the second groove 15 is provided with a sealing groove, a part of the welding filler can also be extruded into the sealing groove by forging in this step to fill the sealing groove 1321, thereby effectively improving the sealing performance of the prepared composite tube sheet.

[0098] It should be noted that, as Figure 5 shown, the cross-sectional shape of the welding filler 16 is similar to that of the second groove 15, so that the welding filler 16 is easier to be embedded in the second groove, thus making the preparation process of the composite tube sheet simple and easy to implement.

[0099] The filler 16 for welding can be made of aluminum material.

[0100] Step S703: Punch a tube hole 12 in the second groove 15 inlaid with the filler 16 for welding, and form a first groove 13 arranged around one tube hole 12 and a welding part 14 fixed in the first groove 13. The tube hole 12 is used to install the base tube 20 of the air cooler tube bundle, and the welding part 14 is welded to the base tube 20.

[0101] In the embodiment of the present invention, the preparation process of the above composite tube sheet may further include: determining the substrate material and substrate thickness according to preset calculation conditions; selecting a substrate raw material according to the substrate material and substrate thickness; blanking the substrate raw material by machining such as punching, and removing burrs, flattening and chamfering the edges of the blanking to obtain a substrate. The preset calculation conditions may be parameters such as the pressure borne by the air cooler tube bundle, the fluid volume borne, and the pressure that different specifications of steel plates can withstand.

[0102] Compared with the existing explosion composite process, the composite tube sheet preparation process provided by the embodiment of the present invention does not require a special closed site, wastes less welding filler material, has a simple process, low cost, and can overcome the defects in welding of the existing technology.

[0103] The embodiment of the present invention also provides a preparation process for an air cooler tube bundle, which may include: the preparation process of the composite tube sheet provided by the above embodiment, and the process of installing the base tube included in the air cooler tube bundle on the composite tube sheet.

[0104] In order to clearly illustrate the preparation processes of the composite tube sheet and the air cooler tube bundle, the following will be described with two specific embodiments.

[0105] Embodiment 1

[0106] Substrate preparation: Select a material of Q235B and a thickness of 18 mm according to the design calculation conditions, and use a punching and shearing method for blanking. Remove burrs, flatten and chamfer the four edges.

[0107] Second groove preparation: Arrange one row side by side at each preset tube hole position of the tube sheet, with a depth of 4 mm, a flat mouth shape, and dimensions of 238×38 mm. Use a numerical control drilling and milling cutting process to control the angle between the bottom surface and the side surface of the second groove to be 75 degrees, and open a sealing groove with a triangular cross-section on the side surface of the second groove.

[0108] Filler preparation for welding: The material is aluminum alloy 3003. First, use a mold to punch and process a sheet with a thickness of 4.98 mm into a filler for welding, and the outer shape corresponds to the second groove.

[0109] Welding part and tube hole preparation: Place the welding filler obtained in the previous step in the second groove, and deform it by forging to inlay it in the second groove. The welding filler also fills and squeezes into the sealing groove at the same time. After forging, the surface of the welding filler is basically flush with the main surface of the substrate. Then, punch out the tube hole by mechanical blanking, and form a welding part around the tube hole. The blanking surface is selected on the composite side, and the clearance between the tube hole and the base tube is controlled to be 0.4 mm.

[0110] Base tube installation and welding: Install the end of the base tube into the tube hole, and weld the welding part of the composite tube sheet and the end of the base tube together. In this step, the cross-sectional shape of the base tube is similar to a harmonica shape, the size of the base tube is (219±0.2)×19 mm, the wall thickness of the base tube is 1.5 mm, and the inner cavity of the base tube is composed of several through holes, and the number of through holes is 2.

[0111] Example 2

[0112] Substrate preparation: Select the material Q345R with a thickness of 26 mm according to the design calculation conditions, cut it by laser, and remove burrs, flatten and chamfer the four edges.

[0113] Second groove preparation: The preparation process is the same as that provided in Example 1, but the depth is controlled to be 5 mm, the size is 248×38 mm, the included angle between the bottom surface and the side surface of the second groove is controlled to be 77 degrees, and a sealing groove with a trapezoidal cross-section is opened on the side surface of the second groove.

[0114] Welding filler preparation: The material is aluminum alloy 3003. First, use a mold to punch a 6.27 mm thick plate into a welding filler, and the shape corresponds to the second groove.

[0115] Welding part and tube hole preparation: Place the welding filler obtained in the previous step in the second groove, and deform it by forging to inlay it in the second groove. The welding filler also fills and squeezes into the sealing groove at the same time. After forging, the surface of the welding filler is basically flush with the main surface of the substrate. Then, punch out the tube hole by mechanical blanking, and form a welding part around the tube hole. The blanking surface is selected on the composite side, and the clearance between the tube hole and the base tube is controlled to be 0.6 mm.

[0116] Base tube installation and welding: Install the end of the base tube into the tube hole, and weld the welding part of the composite tube sheet and the end of the base tube together. In this step, the cross-sectional shape of the base tube is similar to a harmonica shape, the size of the base tube is (229±0.2)×19 mm, the wall thickness of the base tube is 1.6 mm, and the inner cavity of the base tube is composed of several through holes, and the number of through holes is 4.

[0117] The above specific embodiments do not constitute a limitation to the protection scope of the present invention. Those skilled in the art should understand that various modifications, combinations, sub-combinations and substitutions can occur depending on design requirements and other factors. Any modifications, equivalent substitutions and improvements made within the spirit and principle of the present invention shall be included within the protection scope of the present invention.

Claims

1. A composite tube sheet, characterized in that, Applied to the tube bundle of an air cooler, including: a base plate (11), a plurality of tube holes (12) arranged side by side on the base plate, a plurality of first grooves (13), and a plurality of welding parts (14), wherein, Each of the tube holes (12) is used to install the end of a base tube (20) of the air cooler tube bundle; Each of the first grooves (13) is located on one main surface of the base plate (11) and is arranged around one of the tube holes (12); Each of the welding parts (14) is fixed in the first groove (13) and is used for welding connection with the end of the base tube (20). The welding part (14) is formed by punching the welding filler embedded in the second groove by forging, and the welding part (14) is formed before the base tube (20) is installed in the tube hole (12). The second groove (15) is not a through groove.

2. The composite tube sheet according to claim 1, wherein, The depth of the first groove (13) is 4 - 10 mm.

3. The composite tube sheet according to claim 1, wherein, The included angle between the bottom surface (131) and the side surface (132) of the first groove (13) is 75 - 80 degrees.

4. The composite tube sheet according to claim 1, wherein, At least one sealing groove (1321) is provided on the side surface (132) of the first groove (13); A part of the welding part (14) is filled and extruded into the sealing groove (1321).

5. The composite tube sheet according to claim 1, wherein, The cross-section of the first groove (13) is a flat-mouth structure.

6. The composite tube sheet according to claim 1, wherein, The tube hole (12) is a flat-mouth structure; And / or, The size of the tube hole (12) is (209.2 - 230) mm × 19 mm; And / or, The gap (21) between the tube hole (12) and the base tube (20) is 0.4 - 0.8 mm.

7. An air-cooled heat exchanger tube bundle, characterized in that, Including: Base tubes (20) arranged side by side, fins (30) provided on the base tubes (20), and the composite tube sheet (10) according to any one of claims 1 to 6, wherein, The end of the base tube (20) is installed in the tube hole (12) included in the composite tube sheet (10) and is welded to the welding part (14) included in the composite tube sheet (10).

8. A preparation process of a composite tube sheet, characterized in that, Including: Processing a second groove (15) in each of a plurality of preset tube hole areas arranged side by side on the base plate (11), and the second groove (15) is not a through groove; Embedding the welding filler (16) in the second groove (15) by forging; A tube hole (12) is punched out in a second groove (15) inlaid with the filler for welding (16), and a first groove (13) arranged around one tube hole (12) and a welding part (14) fixed in the first groove (13) are formed. Among them, the tube hole (12) is used for installing a base tube (20) of an air cooler tube bundle, the welding part (14) is welded to the base tube (20), and the welding part (14) is formed before the base tube (20) is installed in the tube hole (12).

9. The preparation process according to claim 8, characterized in that, Further comprising: A sealing groove (1321) is opened on the side surface of the second groove (15); The filler for welding (16) is inlaid in the second groove (15) by forging, including: A part of the filler for welding (16) is filled and extruded into the sealing groove (1321).

10. A preparation process for an air cooler tube bundle, characterized in that, Comprising: The preparation process of the composite tube sheet according to claim 8 or 9, and The process of installing the base tube (20) included in the air cooler tube bundle on the composite tube sheet.

Images