Forming process of high-frequency welding multi-channel heat dissipation aluminum pipe

Abstract

The invention relates to a forming process of a high-frequency welding multi-channel heat dissipation aluminum pipe, which comprises the following steps of: (1) outputting a pipe aluminum foil along the horizontal direction by a pipe aluminum foil aluminum coil in a vertical uncoiling manner, and outputting a fin aluminum foil along the horizontal direction by a fin aluminum foil aluminum coil in a horizontal uncoiling manner, the pipe aluminum foil and the fin aluminum foil are parallel to each other in the conveying process. (2) the fin aluminum foil is guided in the horizontal direction through centering auxiliary wheels on the two sides and guided in the vertical direction through a guide pressing plate, and the method has the advantages that the aluminum pipe is produced in a composite aluminum strip two-in-one forming high-frequency welding mode, the pipe type can be provided with multiple holes, the pressure and flow in the pipe are dispersed, the corrosion resistance is improved, and the heat dissipation performance is improved; the radiator is simple and efficient to assemble, and product quality is stable. The process for producing the aluminum pipe overcomes the defects caused by other processes for producing the aluminum pipe. The method is suitable for various all-aluminum radiator brazing forming processes.

Description

Technical Field

[0001] The invention relates to a forming process of a high-frequency welded multi-channel heat dissipation aluminum tube, belonging to the field of aluminum tube forming. Background Art

[0002] Traditional radiators and heat exchangers are manufactured using high-frequency welded aluminum foil single-channel flat tubes, aluminum foil folded multi-channel flat tubes, and aluminum ingot extruded multi-channel flat tube assembly processes. High-frequency welded aluminum foil flat tubes are made from aluminum ingots through high-temperature melting, multi-pass hot rolling, and multi-pass cold rolling. They offer excellent material properties, including elongation, corrosion resistance, strength, heat dissipation performance, and cost-effectiveness. However, due to the new technology, the current tube manufacturing industry can only produce high-frequency welded single-channel aluminum tubes. These tubes have poor pressure bearing capacity, low flow resistance, average heat dissipation performance, and a limited number of tube types, making them unsuitable for use in high-pressure radiators (such as high-horsepower engineering machinery radiators, large generator set radiators, air conditioning condensers, air conditioning evaporators, and radiators used in special environments).

[0003] Folded aluminum foil multi-channel flat tubes can overcome some of the drawbacks of high-frequency welded single-channel aluminum flat tubes. However, these tubes are typically formed by overlapping the edges of the folded aluminum foil before being brazed in a furnace. However, microscopic gaps exist at the overlapped joints, which can lead to uneven flux flow during the brazing process, resulting in corrosion and false welds, leading to unstable product quality.

[0004] Aluminum ingot extruded multi-channel flat tubes are directly extruded by heating the aluminum ingot. Due to the uncoordinated control of the extrusion process, heating temperature, extrusion force, and extrusion speed, the extruded aluminum tubes are prone to uneven tube wall thickness, bubbles, and scratches in the semi-heated state. The anti-corrosion layer cannot be added to the tube surface, and the auxiliary heat sinks formed on the inner wall of the tube have a single shape. These defects make the quality of the finished radiator seriously unstable.

[0005] The above aluminum tube products are difficult to solve the existing process technology difficulties of aluminum radiators. Summary of the Invention

[0006] In order to overcome the defects of the prior art, the present invention provides a high-frequency welding multi-channel heat dissipation aluminum tube forming process. The technical solution of the present invention is:

[0007] A high-frequency welded multi-channel heat dissipation aluminum tube forming process comprises the following steps:

[0008] (1) The aluminum foil coil for pipes is unwound vertically to output the aluminum foil for pipes in the horizontal direction, and the aluminum foil coil for fins is unwound horizontally to output the aluminum foil for fins in the horizontal direction. The aluminum foil for pipes and the aluminum foil for fins are parallel to each other during the transportation process;

[0009] (2) The fin aluminum foil is guided in the horizontal direction by the centering auxiliary wheels on both sides and in the vertical direction by the guide pressure plate;

[0010] (3) The aluminum foil fins in step (2) continue to move forward along the conveyor line and are rolled several times by the roller die to achieve the fins of the preset required size;

[0011] (4) The aluminum foil for the tube is guided by the supporting roller and is located below the fins, and runs synchronously with the fins; the aluminum foil for the tube and the rolled fins synchronously pass through the flat guide plate and the positioning roller to continue moving forward;

[0012] (5) The aluminum foil for the tube is moved toward the middle through a groove roller die with multiple stages of variable diameter, so that a space for accommodating fins is formed in the middle of the aluminum foil for the tube; the fins are guided by the convex roller die and then placed into the space for accommodating fins, and the aluminum foil for the tube and the fins form an open tube blank with inner fins;

[0013] (6) The open tube blank in step (5) is guided by a ceramic guide block and an insulating spacer connected to the bottom of the ceramic guide block, wherein the ceramic guide block is located at the opening of the open tube blank. When the open tube blank passes through the insulating spacer, the insulating spacer is located between the fin and the tube aluminum foil, so that the fin and the tube aluminum foil are insulated; (7) the open tube blank enters the high-frequency welding induction coil area, and the edge of the open tube blank is heated by electromagnetic induction and then enters the extrusion roller die, and the high-frequency welding of the tube blank is completed by extruding the edges of the open tube blank and adhering them together;

[0014] (8) The high-frequency welding formed tube blank is scraped to remove the welding slag on the outer surface caused by high-frequency welding extrusion;

[0015] (9) The tube blank with the inner fins after the welding slag is removed is continuously rolled and sized to a preset tube shape through several active sizing dies arranged in the vertical direction and passive auxiliary dies arranged in the horizontal direction. The active sizing dies and the passive auxiliary dies are arranged at intervals.

[0016] The aluminum foil of the fin aluminum foil aluminum coil comprises an aluminum foil layer and a brazing layer compounded on both sides of the aluminum foil layer.

[0017] The aluminum foil of the fin aluminum foil coil includes an aluminum foil layer.

[0018] The guide platens include an upper guide platen and a corresponding lower guide platen. A space is formed between the lower guide platen and the upper guide platen for the passage of the finned aluminum foil, which contacts both the upper and lower guide plates. The tube shaping step utilizes an R-angle flexible roll-forming method, adjusting the active sizing die and the passive auxiliary die to accommodate tubes of varying sizes.

[0019] The advantages of the present invention are as follows:

[0020] The composite aluminum strip is formed into an aluminum tube by a two-in-one high-frequency welding method. The tube can have multiple holes in one tube, which can disperse the pressure and flow inside the tube, improve the anti-corrosion performance and heat dissipation performance. Moreover, the assembly of the radiator is simple and efficient, and the product quality is stable. The aluminum tube produced by this process solves the drawbacks brought by other processes for producing aluminum tubes. It is applicable to various brazing forming processes of all-aluminum radiators. Brief Description of the Drawings

[0021] Figure 1 It is a schematic diagram of the operation of the aluminum foil coil for the tube and the fin aluminum foil main body of the present invention.

[0022] Figure 2 It is a schematic diagram of the fin aluminum foil when passing through the centering auxiliary wheel and the guiding pressing plate of the present invention.

[0023] Figure 3 It is Figure 2 the top view of

[0024] Figure 4 It is a schematic diagram of the fin aluminum foil when passing through the roller die of the present invention.

[0025] Figure 5 It is a schematic diagram of the aluminum foil for the tube and the rolled fins passing through the plane guiding plate and the positioning roller synchronously of the present invention.

[0026] Figure 6 It is a schematic diagram of the aluminum foil for the tube passing through the groove roller die and the fin passing through the convex roller die of the present invention.

[0027] Figure 7 It is a schematic diagram of the aluminum foil for the tube moving closer to the middle of the present invention.

[0028] Figure 8 It is a schematic diagram of forming an open tube blank of the present invention.

[0029] Figure 9 It is a schematic diagram of the open tube blank entering the high-frequency welding induction coil area of the present invention.

[0030] Figure 10 It is a schematic diagram of the formed tube blank passing through the scraper of the present invention.

[0031] Figure 11 It is a schematic diagram of the tube blank passing through the active sizing die of the present invention.

[0032] Figure 12 It is a schematic diagram of the tube blank passing through the passive auxiliary die of the present invention.

[0033] Figure 13 It is a schematic diagram of the tube type after forming of the present invention. Specific Embodiments

[0034] The present invention will be further described below in conjunction with specific embodiments, and the advantages and features of the present invention will become clearer as the description progresses. However, these embodiments are merely exemplary and do not constitute any limitation to the scope of the present invention. Those skilled in the art should understand that modifications or substitutions can be made to the details and forms of the technical solutions of the present invention without departing from the spirit and scope of the present invention, but such modifications and substitutions all fall within the protection scope of the present invention.

[0035] Refer to Figures 1 to 13 , the present invention relates to a forming process for a high-frequency welded multi-channel heat dissipation aluminum tube, comprising the following steps:

[0036] (1) The aluminum foil coil 1 for the tube is output horizontally in a vertical uncoiling manner to output the aluminum foil for the tube, and the aluminum foil coil 2 for the fins is output horizontally in a horizontal uncoiling manner to output the aluminum foil for the fins. The aluminum foil for the tube and the aluminum foil for the fins are parallel to each other during the conveying process;

[0037] (2) The fin aluminum foil 3 is guided in the horizontal direction by the centering auxiliary wheels 4 on both sides and is guided in the vertical direction by the guiding pressing plate;

[0038] (3) The fin aluminum foil 3 in step (2) continuously advances along the conveying line and is roll-pressed several times by the roller die 5 to form fins with preset required dimensions;

[0039] (4) The aluminum foil 1 for the tube is guided by the supporting wheels and is located below the fins and runs synchronously with the fins; the aluminum foil 1 for the tube and the roll-pressed fins advance synchronously through the plane guiding plate and the positioning roller;

[0040] (5) The aluminum foil 1 for the tube moves closer to the middle through the multi-stage variable-diameter groove roller die 9, so that a space for accommodating the fins is formed in the middle of the aluminum foil for the tube; the fins are guided by the convex roller die 8 and are placed into the space for accommodating the fins, and the aluminum foil for the tube and the fins form an open tube blank with internal fins;

[0041] (6) The open tube blank in step (5) is guided by the ceramic guiding block and the insulating spacer sleeve connected to the bottom of the ceramic guiding block. The ceramic guiding block is located at the opening of the open tube blank. When the open tube blank passes through the insulating spacer sleeve, the insulating spacer sleeve is located between the fins and the aluminum foil for the tube, so that the fins and the aluminum foil for the tube are in an insulating state; (7) The open tube blank enters the high-frequency welding induction coil area, and after the edge of the open tube blank is heated by electromagnetic induction, it enters the extrusion roller die, and the edges of the open tube blank are adhered together by extrusion to complete the high-frequency welding of the tube blank;

[0042] (8) The formed tube blank by high-frequency welding is cleared of the external surface welding slag caused by high-frequency welding extrusion through a scraping knife;

[0043] (9) The tube blank with the welding slag and internal fins cleared is continuously roll-calibrated and formed into a preset tube shape through several active sizing dies arranged vertically and passive auxiliary dies arranged horizontally. The active sizing dies and the passive auxiliary dies are arranged at intervals.

[0044] The forming process of this high-frequency welded multi-channel heat dissipation aluminum tube has the following advantages:

[0045] Automation and high efficiency: The entire process flow from aluminum foil uncoiling to final high-frequency welding forming is continuously automated, reducing manual intervention and improving production efficiency.

[0046] Precise dimension control: Through several rollings of the roller dies, the dimensions of the finned aluminum foil can be precisely controlled to ensure that the fins reach the preset required dimensions.

[0047] Synchronous operation: The aluminum foil for the tube and the rolled fins run synchronously, ensuring the correct alignment and combination of the fins and the aluminum foil for the tube, and avoiding misalignment.

[0048] Forming a receiving space: Through the multi-stage variable-diameter grooved roller dies, a space for receiving the fins is formed in the middle of the aluminum foil for the tube, ensuring that the fins can be accurately placed.

[0049] Insulation protection: The use of ceramic guide blocks and insulating sleeves ensures that the fins and the aluminum foil for the tube are in an insulated state, preventing short circuits or poor welding.

[0050] High-frequency welding quality: By heating the edge of the open tube blank through electromagnetic induction and then entering the extrusion roller dies, the quality of high-frequency welding and the sealing of the tube blank are ensured.

[0051] Surface cleaning: Using a scraping knife to remove the external surface welding slag caused by high-frequency welding extrusion ensures the surface quality of the final product.

[0052] Continuous roll-calibration and forming: Through several active sizing dies arranged vertically and passive auxiliary dies arranged horizontally for continuous roll-calibration and forming, the accuracy and consistency of the tube shape are ensured.

[0053] High material utilization rate: Due to the precise control of the entire process flow, the material utilization rate is improved and waste is reduced.

[0054] The aluminum foil of the finned aluminum foil aluminum coil includes an aluminum foil layer and brazing layers compounded on both sides of the aluminum foil layer.

[0055] The aluminum foil of the finned aluminum foil aluminum coil includes an aluminum foil layer.

[0056] The described guiding pressing plate includes an upper guiding pressing plate 31 and a lower guiding pressing plate 32 corresponding to the upper guiding pressing plate 31. A space for the finned aluminum foil 3 to pass through is formed between the lower guiding pressing plates 32 and the upper guiding pressing plate 31, and the finned aluminum foil 3 contacts the upper guiding pressing plate 31 and the lower guiding pressing plate 32.

[0057] In the preset pipe forming step, an R-angle flexible rolling forming method is adopted, and the active sizing die and the passive auxiliary die are adjusted to adapt to different sizes of pipe types.

[0058] The design of the aluminum foil structure of the finned aluminum foil aluminum coil and the guiding pressing plate, and the R-angle flexible rolling forming method adopted in the preset pipe forming step have the following advantages:

[0059] Enhanced brazing performance: The aluminum foil of the finned aluminum foil aluminum coil includes an aluminum foil layer and brazing layers compounded on both sides of the aluminum foil layer. This structure helps to improve the strength and quality of brazing, ensuring a firm connection between the fins and the pipe body.

[0060] Material strength and corrosion resistance: The aluminum foil layer provides good mechanical strength and corrosion resistance, and the compounded brazing layer helps to form a good bond during the welding process.

[0061] Precise guiding control: The design of the guiding pressing plate, including the upper guiding pressing plate and the lower guiding pressing plate, ensures precise guiding of the finned aluminum foil during transportation, avoiding deviation and deformation.

[0062] Optimization of the contact area: The contact design of the finned aluminum foil with the upper guiding pressing plate and the lower guiding pressing plate helps to reduce wear and extend the service life of the equipment.

[0063] Flexible pipe type adaptability: By adopting the R-angle flexible rolling forming method and adjusting the active sizing die and the passive auxiliary die, different sizes of pipe types can be adapted, increasing the flexibility and applicability of the process.

[0064] Reduction of stress concentration: The R-angle flexible rolling forming method helps to reduce stress concentration during the pipe forming process, improving the structural integrity and durability of the pipe body.

[0065] Improvement of production efficiency: This structure and process design help to improve production efficiency, reduce adjustment time and equipment downtime.

[0066] The working principle of the forming process of the high-frequency welded multi-channel heat dissipation aluminum pipe of this application is specifically as follows:

[0067] Material preparation and uncoiling:

[0068] The aluminum foil aluminum coil for the pipe is output horizontally in a vertical uncoiling manner to obtain the aluminum foil for the pipe.

[0069] The finned aluminum foil coil outputs the finned aluminum foil horizontally through a horizontal uncoiling method.

[0070] The aluminum foil for tubes and the finned aluminum foil remain parallel to each other during the conveying process.

[0071] Guiding and rolling of the finned aluminum foil:

[0072] The finned aluminum foil is guided horizontally by the centering auxiliary wheels on both sides.

[0073] Vertically, the finned aluminum foil is guided through the gap formed by the upper guiding pressing plate and the lower guiding pressing plate to ensure the precise conveyance of the finned aluminum foil.

[0074] The finned aluminum foil continues to move forward along the conveying line and is rolled several times by the roller die to reach the preset required size.

[0075] Synchronous operation and guiding:

[0076] The aluminum foil for tubes is guided by the supporting wheels, located below the fins, and runs synchronously with the fins.

[0077] The aluminum foil for tubes and the rolled fins pass through the plane guiding plate and the positioning roller wheels synchronously and continue to move forward.

[0078] Forming an open tube blank with internal fins:

[0079] The aluminum foil for tubes moves closer to the middle through the grooved roller die with multi-stage variable diameters, forming a space for accommodating the fins.

[0080] The fins are guided by the convex roller die and then placed into the space for accommodating the fins, forming an open tube blank with internal fins.

[0081] Insulating guiding and high-frequency welding:

[0082] The open tube blank is guided through the ceramic guiding blocks and the insulating sleeves to ensure insulation between the fins and the aluminum foil for tubes.

[0083] The open tube blank enters the high-frequency welding induction coil area, is heated by electromagnetic induction at the edge of the open tube blank, and then enters the extrusion roller die to complete high-frequency welding.

[0084] Surface cleaning and sizing forming:

[0085] The high-frequency welded formed tube blank is cleared of the external welding slag by the scraping knife to ensure the surface quality.

[0086] The tube blank after removing the welding slag is continuously roll-pressed and sized into the preset tube shape through several active sizing dies and passive auxiliary dies.

[0087] R-angle flexible rolling forming:

[0088] In the preset tube forming step, the R-angle flexible rolling forming method is adopted, and the active sizing die and the passive auxiliary die are adjusted to adapt to different sizes of tube types.

[0089] Through the above steps and principles, the present invention realizes the efficient and precise forming of high-frequency welded multi-channel heat dissipation aluminum tubes, ensuring product quality and production efficiency.

[0090] The above is only a preferred specific embodiment of the present invention, but the protection scope of the present invention is not limited thereto. Any person skilled in the art within the technical scope disclosed by the present invention, according to the technical solution and inventive concept of the present invention, making equivalent substitutions or changes should be covered within the protection scope of the present invention.

Claims

1. A forming process for a high-frequency welded multi-channel heat-dissipating aluminum tube, characterized in that, The following steps are involved: (1) The aluminum foil coil for pipes is unwound vertically to output the aluminum foil for pipes in the horizontal direction, and the aluminum foil coil for fins is unwound horizontally to output the aluminum foil for fins in the horizontal direction. The aluminum foil for pipes and the aluminum foil for fins are parallel to each other during the transportation process; (2) The fin aluminum foil is guided in the horizontal direction by the centering auxiliary wheels on both sides and in the vertical direction by the guide pressure plate; (3) The aluminum foil fins in step (2) continue to move forward along the conveyor line and are rolled several times by the roller die to achieve the fins of the preset required size; (4) The aluminum foil for the tube is guided by the supporting roller and is located below the fins, and runs synchronously with the fins; the aluminum foil for the tube and the rolled fins synchronously pass through the flat guide plate and the positioning roller to continue moving forward; (5) The aluminum foil for the tube is moved toward the middle through a groove roller die with multiple stages of variable diameter, so that a space for accommodating fins is formed in the middle of the aluminum foil for the tube; the fins are guided by the convex roller die and then placed into the space for accommodating fins, and the aluminum foil for the tube and the fins form an open tube blank with inner fins; (6) The open tube blank in step (5) is guided by a ceramic guide block and an insulating spacer connected to the bottom of the ceramic guide block, wherein the ceramic guide block is located at the opening of the open tube blank. When the open tube blank passes through the insulating spacer, the insulating spacer is located between the fin and the tube aluminum foil, so that the fin and the tube aluminum foil are insulated; (7) The open tube billet enters the high-frequency welding induction coil area, and after the edge of the open tube billet is heated by electromagnetic induction, it enters the extrusion roller die, and the edges of the open tube billet are extruded and bonded together to complete the high-frequency welding of the tube billet; (8) The high-frequency welding formed tube blank is scraped to remove the welding slag on the outer surface caused by high-frequency welding extrusion; (9) The tube blank with the inner fins after the welding slag is removed is continuously rolled and sized to a preset tube shape through several active sizing dies arranged in the vertical direction and passive auxiliary dies arranged in the horizontal direction. The active sizing dies and the passive auxiliary dies are arranged at intervals.

2. The forming process of a high-frequency welded multi-channel heat dissipation aluminum tube according to claim 1, characterized in that, The aluminum foil of the fin aluminum foil aluminum coil comprises an aluminum foil layer and a brazing layer compounded on both sides of the aluminum foil layer.

3. The forming process of a high-frequency welded multi-channel heat dissipation aluminum tube according to claim 1, characterized in that, The aluminum foil of the fin aluminum foil coil includes an aluminum foil layer.

4. The forming process of a high-frequency welded multi-channel heat dissipation aluminum tube according to claim 1 or 2, characterized in that, The guide plate includes an upper guide plate and a lower guide plate corresponding to the upper guide plate. A space for the fin aluminum foil to pass through is formed between the lower guide plate and the upper guide plate. The fin aluminum foil is in contact with the upper guide plate and the lower guide plate.

5. The forming process of a high-frequency welded multi-channel heat dissipation aluminum tube according to claim 1, characterized in that In the step of presetting the tube shape, an R-angle flexible rolling forming method is adopted, and the active sizing die and the passive auxiliary die are adjusted to adapt to tube shapes of different sizes.

Images