Condenser for small car, preparation method and production line

Abstract

The invention relates to a condenser for a small automobile, a preparation method and a production line. The condenser comprises a core body, a first liquid collecting pipe, a second liquid collecting pipe, a first mounting bracket and a second mounting bracket, the core body comprises side plates, a plurality of flat pipes and a plurality of fins, the flat pipes are arranged at intervals one by one, and one fin is arranged between every two adjacent flat pipes; the two ends of the flat pipes are connected with the first liquid collecting pipe and the second liquid collecting pipe respectively, and the first liquid collecting pipe is connected with a liquid inlet pipe assembly and a liquid outlet pipe assembly; the first mounting bracket comprises a first adjusting part and a first clamping part, and the second mounting bracket comprises a second adjusting part and a second clamping part; the first clamping part and the second clamping part are used for clamping an auxiliary accessory, and the first adjusting part and the second adjusting part are used for adjusting the positions of the first clamping part and the second clamping part so as to adapt to the size of the auxiliary accessory. The mounting structure has the effect of reducing the occupied mounting space.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of automobile air conditioning, in particular to a condenser for small cars, a preparation method and a production line. BACKGROUND

[0002] The automobile accessories commonly used in the automobile air conditioning system include a compressor, a condenser and an evaporator, etc., and auxiliary accessories such as a liquid storage tank and an expansion valve are used together to form an air conditioning system to adjust the temperature in the car. With the diversification of public demand, some cars are developing towards miniaturization, and the size of the existing condenser is generally large, and in addition to the auxiliary accessories such as the liquid storage tank and the expansion valve and the connecting pipeline, it needs to occupy a large installation space in the car, and thus is not suitable for use in small cars. SUMMARY

[0003] Therefore, the present application provides a condenser for small cars, a preparation method and a production line, which can reduce the occupied installation space and are suitable for small cars.

[0004] In a first aspect, the present application provides a condenser for small cars, which adopts the following technical solution: A condenser for small cars, comprising a core body, a first liquid collecting pipe, a second liquid collecting pipe, a first mounting bracket and a second mounting bracket; the core body comprises a side plate, a plurality of flat tubes and a plurality of fins, the plurality of flat tubes are arranged one by one at intervals, and one fin is arranged between adjacent two flat tubes; the two ends of the plurality of flat tubes are connected with the first liquid collecting pipe and the second liquid collecting pipe respectively, the first liquid collecting pipe is connected with a liquid inlet pipe assembly and a liquid outlet pipe assembly; the first mounting bracket comprises a first adjusting part and a first clamping part, the second mounting bracket comprises a second adjusting part and a second clamping part; the first clamping part and the second clamping part are used for clamping auxiliary accessories, and the first adjusting part and the second adjusting part are used for adjusting the positions of the first clamping part and the second clamping part to adapt to the size of the auxiliary accessories.

[0005] By adopting the above technical solution, the auxiliary accessories are integrated with the condenser, the occupied installation space is reduced, and the positions of the first clamping part and the second clamping part can be adjusted to facilitate the quick installation of the auxiliary accessories.

[0006] Preferably, the first adjusting part comprises an upper inclined plate, the second adjusting part comprises a lower inclined plate, the first clamping part comprises a circular socket, the circular socket is provided with a notch, the auxiliary accessories enter the circular socket through the notch, and the circular socket is arranged on the upper inclined plate; the second clamping part is the same as the first clamping part and corresponds in position.

[0007] By adopting the above technical solution, the auxiliary accessories are subjected to pulling force in two directions after installation, and the installation stability is increased.

[0008] Preferably, the first adjusting part comprises an arc-shaped plate, the first clamping part comprises a triangular clasp with one end open, the auxiliary accessory is clamped into the triangular clasp through the opening and abuts against the inner wall of the triangular clasp, and the position of the triangular clasp is adjusted by changing the arc of the arc-shaped plate; and the second mounting bracket is the same as the first mounting bracket.

[0009] By adopting the technical scheme, the auxiliary accessory is quickly installed, and the auxiliary accessory is stably installed by clamping the auxiliary accessory through the inner wall of the triangular clasp.

[0010] Preferably, the third mounting bracket is connected with the core body and used for mounting the process pipe to limit the position of the process pipe; and the third clamping part of the third mounting bracket is the same as the first clamping part.

[0011] By adopting the technical scheme, the process pipe is limited and the occupied space is reduced.

[0012] Preferably, the flat pipe comprises a first flat pipe and a second flat pipe, the first flat pipe comprises a slot, and the pipe wall of the second flat pipe is adaptively inserted into the slot to adjust the length of the flat pipe.

[0013] By adopting the technical scheme, the length of the flat pipe can be adjusted according to the size of the installation space in the automobile, so that the occupied volume of the entire condenser is adjusted, and different vehicle models are adapted; and the first flat pipe and the second flat pipe can be mass-produced, thereby improving the production efficiency.

[0014] In a second aspect, the application provides a preparation method of a condenser, which is used for preparing the condenser for small cars according to any one of the preceding aspects, and the steps of the method comprise: The parts of the condenser are manufactured, including but not limited to side plates, flat pipes, fins, a first liquid collecting pipe, a second liquid collecting pipe, a liquid inlet pipe assembly and a liquid outlet pipe assembly; the side plates, the flat pipes and the fins are spliced into a core body and connected with the first liquid collecting pipe and the second liquid collecting pipe respectively to form a condenser main body; the condenser main body is bound and fixed; other parts of the condenser main body, including but not limited to the liquid inlet pipe assembly, the liquid outlet pipe assembly and a partition plate, are welded; the condenser is brazed; the brazed condenser is subjected to air tightness detection; and the condenser with qualified air tightness is installed with corresponding brackets.

[0015] Preferably, the step of air tightness detection comprises: injecting nitrogen into the condenser, detecting the leakage of a first area after a first pressure maintaining time, injecting helium into the condenser, detecting the leakage of a second area through pressure difference after a second pressure maintaining time, injecting nitrogen into the condenser and detecting the leakage through pressure difference after at least a third time, the second time is greater than the first time and less than the third time, the third time is not less than 12 hours, and the second area is smaller than the first area.

[0016] By adopting the technical scheme, the condenser is prepared, and the air tightness of the condenser is ensured through three sealing detection procedures.

[0017] In a third aspect, the application provides a production line of the condenser, which is used for producing the condenser for small cars according to any one of the preceding aspects, and comprises: processing equipment for processing various parts of the condenser; assembling equipment for assembling a core body and a liquid collecting pipe to form a main body of the condenser; binding equipment for binding the main body of the condenser; welding equipment for welding other parts except the main body of the condenser; brazing equipment for brazing the condenser; and air tightness detection equipment for detecting the air tightness of the condenser.

[0018] Preferably, the assembling equipment comprises a flat tube placing tool, a flat tube arranging tool, a taking mechanism and a moving mechanism; the flat tube placing tool is used for layer-by-layer placing the flat tubes; the flat tube arranging tool comprises a plurality of installation grooves arranged at intervals; the taking mechanism is used for placing the flat tubes in the flat tube placing tool into the installation grooves one by one; and the moving mechanism is used for moving the flat tube arranging tool so that each installation groove corresponds to the taking mechanism one by one.

[0019] Preferably, the brazing equipment comprises a brazing agent coating device, a welding furnace and a cooling device; the brazing agent coating device comprises a feeding conveying mechanism and a spraying mechanism; the feeding conveying mechanism is used for conveying the condenser to the welding furnace; and the spraying mechanism is used for coating the condenser with the brazing agent; the cooling device comprises a discharging conveying mechanism and an air cooling mechanism; the discharging conveying mechanism is used for moving the brazed condenser out of the brazing equipment; and the air cooling mechanism is used for cooling the brazed condenser.

[0020] By adopting the technical scheme, the condenser is prepared, and the air tightness of the condenser is ensured through three sealing detection procedures.

[0021] Through the condenser for small cars, the preparation method and the production line provided in the application, the size of the condenser and the installation space occupied by the condenser are reduced, so that the condenser is suitable for small cars. BRIEF DESCRIPTION OF DRAWINGS

[0022] Figure 1 is a front view of a condenser provided by an embodiment of the application.

[0023] Figure 2 is a top view of a condenser provided by an embodiment of the application.

[0024] Figure 3 is a side view of a condenser provided by an embodiment of the application.

[0025] Figure 4 is a front view of a first mounting bracket provided by an embodiment of the present application.

[0026] Figure 5 is a front view of a second mounting bracket provided by an embodiment of the present application.

[0027] Figure 6 is a top view of a first mounting bracket provided by some other embodiments.

[0028] Figure 7 is a schematic view of a flat tube provided by some other embodiments.

[0029] Figure 8 is a flowchart of a preparation method of a condenser provided by an embodiment of the present application.

[0030] Figure 9 and Figure 10 is a partial schematic view of an assembling device provided by an embodiment of the present application.

[0031] Figure 11 is a schematic view of a brazing device provided by an embodiment of the present application.

[0032] BRIEF DESCRIPTION OF DRAWINGS 100, condenser; 110, core; 111, flat tube; 1111, first flat tube; 1112, second flat tube; 1113, insertion slot; 112, fin; 113, edge plate; 121, first collecting tube; 122, second collecting tube; 123, partition plate; 131, first mounting bracket; 1311, first fixing plate; 1312, upper inclined plate; 1313, circular bayonet; 1314, connecting plate; 1315, arc-shaped plate; 1316, triangular buckle; 132, second mounting bracket; 1321, second fixing plate; 1322, lower inclined plate; 133, third mounting bracket; 141, liquid inlet pipe assembly; 142, liquid outlet pipe assembly; 151, fixing bracket; 152, lower bracket; 210, flat tube placement tool; 220, flat tube arrangement tool; 221, mounting slot; 230, taking mechanism; 231, downward driving assembly; 232, push plate; 233, guide slot; 240, first extruding mechanism; 241, extruding platform; 242, extruding plate; 243, positioning plate; 250, flat tube positioning mechanism; 251, positioning slot; 300, brazing device; 310, brazing agent applying device; 311, brush wheel; 312, brazing agent tank; 313, conveying pump; 314, spray head; 315, first support frame; 320, welding furnace; 330, cooling device; 331, roller; 332, air cooler; 333, air knife; 334, second support frame. DETAILED DESCRIPTION

[0033] In order to more clearly understand the purpose, technical solutions and advantages of the present application, the present application is described and explained below in conjunction with the accompanying drawings and embodiments. However, it should be understood by those of ordinary skill in the art that the present application can be implemented without these details. In some cases, in order to avoid unnecessary description and make aspects of the present application obscure, well-known methods, procedures, systems, components and / or circuits that have been described at a higher level will not be described in detail. It is obvious to those of ordinary skill in the art that various changes can be made to the embodiments disclosed in the present application, and the general principles defined in the present application can be applied to other embodiments and application scenarios without departing from the principles and scope of the present application. Therefore, the present application is not limited to the embodiments shown, but conforms to the broadest scope claimed by the present application.

[0034] It should be noted that the description of the embodiments is used to help understand the present application, but does not constitute a limitation of the present application. In addition, the technical features involved in each embodiment of the present application described below can be combined with each other as long as they do not conflict with each other.

[0035] In the description of the present application, the meaning of one or more is one or more, the meaning of multiple is two or more, greater than, less than, more than, etc. are understood to exclude the number, above, below, etc. are understood to include the number. If it is described as first, second, it is only used to distinguish technical features for the purpose, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of indicated technical features or implicitly indicating the order of indicated technical features.

[0036] In the description of the present application, the description of the terms "one embodiment", "some embodiments", "illustrative embodiment", "example", "specific example", or "some examples" means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present application. In the present specification, the illustrative description of the above terms does not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or more embodiments or examples in a combined manner.

[0037] The embodiments of the present application disclose a condenser for a small car.

[0038] As Figure 1As shown, the condenser 100 for small cars comprises a core body 110, a first collecting pipe 121, a second collecting pipe 122, a first mounting bracket 131 and a second mounting bracket 132. The first collecting pipe 121 and the second collecting pipe 122 are respectively located at the left and right sides of the core body 110. The core body 110 comprises two upper and lower side plates 113, and a plurality of flat tubes 111 and a plurality of fins 112 are arranged between the two upper and lower side plates 113. The plurality of flat tubes 111 are arranged in parallel and at intervals, and one fin 112 is arranged between every two adjacent flat tubes 111. The flat tubes 111 or fins 112 located at the top and bottom are connected with the side plates 113. The opposite sides of the first collecting pipe 121 and the second collecting pipe 122 are provided with a plurality of notches arranged in layers. The two ends of each flat tube 111 in the length direction are respectively inserted into the notches of the first collecting pipe 121 and the second collecting pipe 122, so that the inside of each flat tube 111 is in communication with the inside of the first collecting pipe 121 and the second collecting pipe 122. The surface of the core body 110, the first collecting pipe 121 and the second collecting pipe 122 is coated with a brazing layer, so as to realize the brazing connection between the flat tubes 111, the fins 112 and the collecting pipes. The first collecting pipe 121 is provided with a liquid inlet pipe assembly 141 and a liquid outlet pipe assembly 142, which are used to connect with the conveying pipelines of external refrigerant medium. The first collecting pipe 121 and the second collecting pipe 122 are provided with a partition plate 123 inside, which is used to separate flow channels. The two ends of the first collecting pipe 121 and the second collecting pipe 122 are plugged with plugs.

[0039] The first mounting bracket 131 and the second mounting bracket 132 are used to mount liquid storage tanks, expansion valves, capillary tubes or other auxiliary accessories required in the refrigeration system of the automobile air conditioner, so as to integrate the auxiliary accessories with the condenser, reduce the connecting pipelines and reduce the occupied installation space. Specifically, the first mounting bracket 131 comprises a first adjusting part and a first clamping part, and the second mounting bracket 132 comprises a second adjusting part and a second clamping part. The first clamping part and the second clamping part are used to clamp the auxiliary accessories, so as to quickly mount the auxiliary accessories and reduce the space required for the mounting operation. Since the sizes of the auxiliary accessories are different, and there are machining errors in the machining process of the condenser, the first adjusting part and the second adjusting part are arranged to adjust the positions of the first clamping part and the second clamping part, so as to adapt to the sizes of the auxiliary accessories.

[0040] Please refer to Figures 1 to 5The first mounting bracket 131 further comprises a first fixed plate 1311 in the shape of an L-shaped plate, a vertical plate of which is connected to the upper side of the side plate 113 by a bolt, and a horizontal plate extends horizontally away from the core body 110. The first fixed plate 1311 is close to the first liquid collecting pipe 121. The first adjusting part comprises an upper inclined plate 1312, one end of which is connected to the first fixed plate 1311, vertically arranged upwards and then bent, and inclined towards the upper side of the core body 110 and the second liquid collecting pipe 122. The other end of the upper inclined plate 1312 is free. The first clamping part comprises a circular clamping hole 1313 arranged on the upper inclined plate 1312, and a gap is formed on one side of the top of the upper inclined plate 1312. The size of the gap is smaller than the diameter of the circular clamping hole 1313. The auxiliary accessory can enter the circular clamping hole 1313 from the gap, thereby achieving clamping of the auxiliary accessory. A horn-shaped guide hole is further arranged on the outside of the gap to guide the auxiliary accessory to be clamped. The second mounting bracket 132 is close to the bottom of the core body 110, and comprises a second fixed plate 1321 in the shape of a horizontal plate, which is connected to the core body 110 by a bolt and protrudes horizontally away from the core body 110. The second adjusting part comprises a lower inclined plate 1322 in the shape of an inverted L, one end of which is connected to the second fixed plate 1321, and the other end is free. The lower inclined plate 1322 is arranged upwards and then bent downwards. The other end of the lower inclined plate 1322 is free and is arranged to be inclined towards the bottom of the core body 110 and the second liquid collecting pipe 122. The second clamping part is arranged on the lower inclined plate 1322, and the structure and size of the second clamping part are the same as those of the first clamping part and correspond in position.

[0041] The upper inclined plate 1312 and the lower inclined plate 1322 are connected to the fixed plate at one end and free at the other end, thereby achieving adjustability. The upper inclined plate 1312 is inclined upwards, and the lower inclined plate 1322 is inclined downwards, so that the auxiliary accessory is pulled in opposite directions after installation, thereby improving the stability of the installation. In this embodiment, the first mounting bracket 131 and the second mounting bracket 132 are made of thin sheet metal or aluminum plate, further improving the elasticity of the mounting bracket. In this embodiment, the first mounting bracket 131 and the second mounting bracket 132 are installed on the front side of the core body 110, and the installation of the first mounting bracket 131 and the second mounting bracket 132 does not protrude beyond the boundary of the condenser, so that the auxiliary accessory is also located on the front side of the core body 110 after installation and does not protrude beyond the boundary of the condenser. Therefore, the length or height of the condenser is not enlarged, and the overall installation space is reduced.

[0042] In other embodiments, as Figure 6As shown, the first mounting bracket 131 includes a connecting plate 1314, the first adjusting part includes an arc-shaped plate 1315, and the first clamping part includes a triangular clasp 1316. The arc-shaped plate 1315 is connected with the connecting plate 1314 and the triangular clasp 1316 on both sides, respectively. The connecting plate 1314 is fixedly connected with the core body 110. The arc-shaped plate 1315 can adjust the length by changing the curvature, so as to realize the ductility. One end of the triangular clasp 1316 is open. The auxiliary accessory is clamped into the triangular clasp 1316 through the opening and abuts against the inner wall of the triangular clasp. An arc-shaped guide plate is arranged at the opening, so as to facilitate guiding the auxiliary accessory to be clamped in. The space in the triangular clasp 1316 can be smaller than the part clamped by the auxiliary accessory, so that at least two opposite inner walls of the triangular clasp 1316 can extrude the auxiliary accessory, so as to realize reliable connection. The second mounting bracket 132 can be the same as the first mounting bracket 131.

[0043] Please refer to Figure 3 The mounting bracket assembly provided in the embodiment of the present application further includes a third mounting bracket 133. The third mounting bracket 133 includes a third adjusting part and a third clamping part. The third mounting bracket 133 is connected with the front side of the second liquid collecting pipe 122 through a third fixing plate. One end of the third adjusting part is connected with the third fixing plate. The other end extends forward and inclines toward the first liquid collecting pipe 121. The structure size of the third clamping part can be the same as that of the first clamping part. The third mounting bracket 133 can be used to mount a process pipe such as a conveying pipe of a refrigerant medium, so as to limit the position of the process pipe and avoid shaking of the pipe during driving.

[0044] As shown in Figure 1 and Figure 3 The condenser 100 provided in the embodiment of the present application further includes two fixing brackets 151 and two lower brackets 152. The two fixing brackets 151 are connected with the upper side plate 113 and are used to be fixedly connected with the automobile. The two lower brackets 152 are in an inverted U shape and are connected with the bottom of the first liquid collecting pipe 121 and the second liquid collecting pipe 122, respectively, and are used to support the condenser. The two lower brackets 152 can be connected with the liquid collecting pipes by bolts. The second fixing plate 1321 of the second mounting bracket 132 can be connected with the lower bracket 152. The condenser provided in the embodiment of the present application is used in a small automobile. The length and height are smaller than those of the existing condenser. For example, the condenser can be 80% of the volume of the existing condenser. The weight of the reduced condenser is also lighter. In order to ensure the stability during installation, the condenser is supported by the lower bracket 152 and is fixed by the fixing bracket 151 through bolts, so as to ensure reliable connection of the condenser. The fixing bracket 151 and the lower bracket 152 are made of iron or stainless steel materials and have high strength.

[0045] The flat tube 111 provided in the embodiment of the present application is in the form of a whole tube. The length of the flat tube 111 may be different depending on the vehicle type. Figure 7 As shown, the flat tubes include a first flat tube 1111 and a second flat tube 1112. The first flat tube 1111 includes a first chamber and a slot 1113, while the second flat tube 1112 includes a second chamber. The tube wall of the second flat tube 1112 fits into the slot 1113. The first and second flat tubes 1111 and 1112 are movably connected through the slot 1113, connecting the first and second chambers. By adjusting the insertion depth of the second flat tube 1112 into the first slot 1113, the length of the entire flat tube can be adjusted to accommodate different installation spaces. Because the space reserved for condensers varies across vehicle models, each condenser must be customized for each vehicle model, making mass production impossible. In this embodiment, the flat tubes are separated into a first flat tube 1111 and a second flat tube 1112. These first and second flat tubes 1111, 1112 can be standardized for mass production. During assembly, the first and second flat tubes 1111, 1112 are plugged together, and the length of the flat tubes 111 is flexibly adjusted based on the known vehicle model space. After adjustment, the connection between the first and second flat tubes 1111, 1112, is welded and sealed to secure the connection and prevent leakage. The sealing process can be achieved by applying sealant and / or wrapping with sealing tape. Accordingly, the notches of the first and second manifolds 121, 122 are of different sizes to accommodate the first and second flat tubes 1111, 1112, respectively. The side panels may also include a first side panel and a second side panel, and the same plug-in method may be used to adjust the adaptable size, so that the side panels may also be standardized and mass-produced. Alternatively, after the adjustment of the first flat tube 1111 and the second flat tube 1112 is completed, the length of the side panels may be cut according to the determined length of the flat tube, so that at least the flat tubes may be standardized and mass-produced, thereby improving production efficiency.

[0046] The present invention provides a method for preparing a condenser, the steps of which include: S810: Produce spare parts for the condenser, including but not limited to side plates, flat tubes, fins, first collecting pipe, second collecting pipe, liquid inlet pipe assembly and liquid outlet pipe assembly.

[0047] The components in the condenser include, but are not limited to, flat tubes 111, fins 112, first liquid collecting tubes 121, second liquid collecting tubes 122, liquid inlet pipe assemblies 141, liquid outlet pipe assemblies 142, partitions 123, plugs and corresponding supports, etc. In this embodiment, each component is made of aluminum material, wherein the flat tubes 111 can be cut, bent and welded into hollow square tube shape from aluminum plate, or can be purchased deformed aluminum pipe profiles which are cut according to the required size. The fins 112 can be processed into a wave shape from aluminum sheet; the liquid collecting tubes can be cut according to the required size from aluminum pipe, and a slot is punched on one side along the length direction, and a partition slot is cut on the other side for welding the partition 123.

[0048] S820: Assemble the edge plates, flat tubes and fins into a core, and connect the first liquid collecting tubes and the second liquid collecting tubes respectively to form a condenser main body.

[0049] The core 110 of the condenser includes flat tubes 111, fins 112 and edge plates 113. When assembling, a plurality of flat tubes 111 are arranged horizontally and spaced apart by using an arrangement tool, then the fins 112 are placed in the gap between two flat tubes 111, and the edge plates 113 are placed at both ends of the flat tube 111 arrangement direction. The two ends of the flat tube 111 arrangement direction are extruded so that the edge plates 113, flat tubes 111 and fins 112 are tightly closed and the gap is eliminated. Then the top surface of each flat tube 111 and fin 112 is pressed down so that the top surfaces are flush.

[0050] The assembled core 110 is extruded and kept stationary, and the first liquid collecting tubes 121 and the second liquid collecting tubes 122 are inserted into the left and right sides of the core 110, so that the two ends of each flat tube 111 are inserted into the slots of the liquid collecting tubes, and the main body of the condenser is completed. The distance between the slots of the liquid collecting tubes is the same as the distance set by the arrangement tool, so it corresponds to the arrangement position of the flat tubes 111 one by one.

[0051] S830: Bundle and fix the condenser main body.

[0052] The condenser main body is clamped by using a clamp and moved to a bundling device. The bundling device uses iron wire to bundle from both ends of the flat tube 111 arrangement direction, so that the edge plates 113 are tightly fixed between the flat tubes 111 and the fins 112, so as to control the gap between the fins 112 and the flat tubes 111 to be not more than the set requirement.

[0053] S840: Weld other components outside the condenser main body, including but not limited to liquid inlet pipe assemblies, liquid outlet pipe assemblies and partitions.

[0054] The liquid inlet pipe assemblies 141, liquid outlet pipe assemblies 142, partitions 123 and plugs are welded with the first liquid collecting tubes 121 and / or the second liquid collecting tubes 122, and the assembly work of the condenser is completed.

[0055] S850: Brazing the condenser.

[0056] The assembled condenser can be pretreated before brazing, which includes removing grease, stains, oxides and other substances on the condenser. Then flux is coated on the surface of the condenser, and then sent into the welding furnace for high-temperature welding. The brazing in the welding furnace can be divided into two stages, the first stage is at a temperature of 200-400℃, which is used to remove water in the flux, and the second stage is at a temperature above 550℃, which is used to melt the flux, so that the flat tube 111 and the collecting tube, the fin 112 and the flat tube 111, the side plate 113 and the flat tube 111 or the fin 112 are welded together. Specifically, before pretreatment, the condenser can also be subjected to flattening treatment and finishing treatment. The flattening treatment can include tapping each surface of the condenser to make each surface flat, and the finishing treatment includes removing burrs and protrusions on the surface of the condenser. After flattening and finishing treatment, the flux coating is uniform and comprehensive.

[0057] S860: Brazed condenser is subjected to air tightness detection.

[0058] Before detection, the welding slag or oil stains on the surface of the condenser can be removed to avoid affecting the detection effect. The steps of air tightness detection specifically include: S861: Inject nitrogen into the condenser, and after the first pressure holding time, detect the leakage of the first area.

[0059] The liquid outlet pipe assembly and other outlets are blocked, and the liquid inlet pipe assembly is used to first inject nitrogen into the condenser, then block the liquid inlet, hold pressure for the first time, and judge whether there is a large area of leakage. If there is a large area of leakage, the condenser is first subjected to repair welding, and then the next step of detection is entered, so as to avoid directly using helium detection, and large area leakage will cause waste of helium. The detection result can be judged by the fluctuation of the pressure gauge or the pressure difference detected by the pressure sensor, or it can be judged by manual. The injected nitrogen pressure can be 3.5Mpa, and the first time can be 2S. Larger gas pressure can make the large area of leakage position have a direct manifestation in a short time.

[0060] S862: Inject helium into the condenser, and after the second pressure holding time, detect the leakage of the second area by pressure difference.

[0061] The liquid inlet pipe assembly is connected to the pressure injection pipeline, the high pressure valve is arranged on the pressure injection pipeline, nitrogen is injected into the condenser through the pressure injection pipeline, the high pressure valve and other outlets are closed, and the pressure is maintained for a second time. Whether there is a small area leakage phenomenon is judged through the pressure fluctuation of the pressure gauge or the pressure difference detected by the pressure sensor. The injected nitrogen pressure can be 0.8 MPa, and the second time can be 8 s. If the pressure difference exceeds the set range, for example, the pressure drop is greater than 5%, it is considered that there is a leakage, and re-welding is needed. After re-welding, helium detection is performed again until the pressure drop is within the set range. The helium leak detection has high sensitivity and can accurately locate the leakage point, which is convenient for rapid repair welding.

[0062] In other embodiments, the condenser can be placed in a sink for immersion. If bubbles are generated in the water, the location of the bubbles is the leakage location, which needs to be repaired. After re-immersion detection, if no bubbles are generated, the water on the condenser is dried, and the next step of detection is performed.

[0063] S863: Inject nitrogen into the condenser and maintain for a third time to detect leakage.

[0064] The liquid inlet pipe assembly is connected to the pressure injection pipeline, the high pressure valve is arranged on the pressure injection pipeline, nitrogen is injected into the condenser through the pressure injection pipeline, the high pressure valve and other outlets are closed, and the pressure is maintained for a second time. Whether there is a small area leakage phenomenon is judged through the pressure fluctuation of the pressure gauge or the pressure difference detected by the pressure sensor. The injected nitrogen pressure can be 0.8 MPa, and the second time can be 8 s. If the pressure difference exceeds the set range, for example, the pressure drop is greater than 5%, it is considered that there is a leakage, and re-welding is needed. After re-welding, helium detection is performed again until the pressure drop is within the set range. The helium leak detection has high sensitivity and can accurately locate the leakage point, which is convenient for rapid repair welding.

[0065] In the embodiments of the present application, the second time is greater than the first time and less than the third time, and the second area is smaller than the first area. The shortest time is used to quickly find large area leakage, the second time is used to find small area leakage, and the third time is used to detect long-term sealing and stability. Through the three sealing detection processes of the condenser, the sealing reliability of the condenser is ensured, and the quality of the product is guaranteed.

[0066] In other embodiments, a nitrogen mass spectrometer can be used to detect the leakage position.

[0067] S870: Install the corresponding support on the condenser with air tightness.

[0068] The first mounting bracket 131, the second mounting bracket 132, the third mounting bracket 133, the lower bracket 152, and the fixing bracket 151 are installed on the condenser to complete the preparation work. After the preparation of the condenser is completed, a dust collector can be used to clean the front and back surfaces of the core to remove dust inside.

[0069] The application further provides a production line for manufacturing the condenser, which comprises processing equipment (not shown in the figure), assembling equipment, bundling equipment (not shown in the figure), welding equipment (not shown in the figure), brazing equipment 300 and air tightness detection equipment (not shown in the figure). The processing equipment includes but is not limited to cutting machines, bending machines, punching machine tools and fin forming machines, etc. The cutting machines are used to cut aluminum materials or other metal materials according to size requirements, such as cutting a circular aluminum pipe to obtain the base material of the collecting pipe or cutting a flat aluminum pipe to obtain the flat pipe 111. The bending machines are used to bend the plates to form the required shapes, such as bending an aluminum plate to form the base material of the flat pipe 111 or bending sheet metal parts to form corresponding supports. The punching machine tools punch the base material, such as punching the collecting pipe to process the notches, and the fin forming machines are used to make the aluminum material into wavy or other shaped fins 112.

[0070] The assembling device comprises a flat tube placing tool 210 for assembling the core 110, a flat tube arranging tool 220, a taking mechanism 230 and a moving mechanism (not shown in the figure). The flat tube placing tool 210 is used to store a plurality of flat tubes 111, which are stacked in layers in the tool. The flat tube arranging tool 220 is provided with a plurality of installation grooves 221 at intervals, and each installation groove 221 is used to place a flat tube 111. The flat tube placing tool 210 is located above the flat tube arranging tool 220 and is arranged obliquely. The taking mechanism 230 is located at the bottom of the flat tube placing tool 210 and above the flat tube arranging tool 220, and is used to push the flat tube 111 at the bottom layer into the installation groove 221 of the flat tube arranging tool 220. The moving mechanism is connected with the flat tube arranging tool 220 and can drive the flat tube arranging tool 220 to move along the arrangement direction of the installation grooves 221. The taking mechanism 230 comprises a downward driving assembly 231, a push plate 232 and a guide groove 233. The downward driving assembly 231 is connected with the push plate 232. The notch at the bottom of the guide groove 233 corresponds to the first installation groove 221 of the flat tube arranging tool 220. The groove wall at the top of the guide groove 233 supports the flat tube 111 at the bottom layer of the flat tube placing tool 210. The volume of the push plate 232 gradually increases from bottom to top. When the downward driving assembly 231 is not started, the push plate 232 does not contact the flat tube 111. When the downward driving assembly 231 is started, the push plate 232 is driven to move downward, and then the push plate 232 contacts the flat tube 111 at the bottom layer and pushes it into the guide groove 233. Under the guidance of the guide groove 233, the flat tube 111 falls into the installation groove 221 of the flat tube arranging tool 220 below. Then the moving mechanism drives the flat tube arranging tool 220 to move, so that the position of the second installation groove 221 corresponds to the position of the notch at the bottom of the guide groove 233. The flat tube 111 in the flat tube placing tool 210 automatically moves downward. The taking mechanism 230 pushes the flat tube 111 at the bottom layer into the second installation groove 221. In this way, all the installation grooves 221 are filled with the flat tubes 111. In this embodiment, the moving mechanism comprises a motor, a screw rod assembly and a sliding rail assembly. The motor is connected with the screw rod of the screw rod assembly. The nut of the screw rod assembly is connected with the flat tube arranging tool 220. The flat tube 111 arranging work is connected with the sliding block of the sliding rail assembly. The motor drives the screw rod to rotate, so that the flat tube arranging tool 220 can move back and forth along the arrangement direction of the installation grooves 221.

[0071] The assembling device further comprises a flat tube positioning mechanism 250, a collecting tube pair inserting mechanism (not shown in the figure), a first extruding mechanism 240 and a second extruding mechanism (not shown in the figure). The first extruding mechanism 240 comprises an extruding platform 241, a positioning plate 243 and an extruding plate 242. The positioning plate 243 and the extruding plate 242 are respectively located at two ends of the extruding platform 241 in the length direction, and the length direction of the extruding platform 241 is consistent with the arrangement direction of the plurality of mounting grooves 221 in the flat tube arrangement tooling 220. The second extruding mechanism is located above the extruding platform 241. The flat tube positioning mechanism 250 is movably arranged at two sides of the extruding platform 241 in the length direction and can be moved to below the extruding platform 241. The flat tube positioning mechanism 250 is provided with a plurality of positioning grooves 251 at intervals. The size of the positioning groove 251 is consistent with the size of the mounting groove 221 on the flat tube arrangement tooling 220. The number of the positioning grooves 251 can be greater than or equal to the number of the mounting grooves 221. The collecting tube pair inserting mechanism is movably arranged at two sides of the extruding platform 241 in the length direction. After the flat tube arrangement tooling 220 is mounted with the flat tubes 111, the flat tube positioning mechanism 250 is moved to two sides of the extruding platform 241. The moving mechanism drives the flat tube arrangement tooling 220 to move to above the flat tube positioning mechanism 250, so that the mounting grooves 221 and the positioning grooves 251 correspond one by one. The end plate at the bottom of the mounting groove 221 of the flat tube arrangement tooling 220 can be removed, so that the flat tubes 111 fall into the extruding platform 241 and fall into the corresponding positioning grooves 251 one by one. The moving mechanism drives the flat tube arrangement tooling 220 to return to below the flat tube placing tooling 210 to perform the second flat tube 111 arrangement work. Before the flat tubes 111 fall into the positioning grooves 251, the edge plates 113 can be placed on the opposite surfaces of the positioning plate 243 and the extruding plate 242. After the flat tubes 111 fall into the positioning grooves 251, the fins 112 are placed between two adjacent flat tubes 111. Then the flat tube positioning mechanism 250 moves away from the two ends of the flat tubes 111 and moves to below the extruding platform 241. The extruding plate 242 is driven by the driving mechanism to extrude the edge plates 113, the flat tubes 111 and the fins 112 to the positioning plate 243, so that the edge plates 113, the flat tubes 111 and the fins 112 abut against each other, the gap is reduced, and the splicing tooling of the condenser core 110 is completed. Then the second extruding mechanism extrudes downward from above, so that the top surfaces of the flat tubes 111 and the fins 112 are flat, and the core 110 is fixed. The collecting tube pair inserting mechanism moves to two sides of the extruding platform 241 and slowly approaches the core 110 until the slot of the collecting tube is inserted with the flat tube 111. Then the collecting tube pair inserting mechanism is removed, the second extruding mechanism is removed, and the assembling work of the condenser main body is completed.

[0072] After the condenser body is assembled, it is moved to a binding device by a clamp for binding, the binding device comprising a binding platform, a bottom threading mechanism, a top threading mechanism and a twisting mechanism, the condenser body is placed on the binding platform, the bottom threading mechanism threads the iron wire from below the condenser body, the top threading mechanism receives the iron wire and threads the iron wire from above the condenser body, the twisting mechanism receives the iron wire and twists and screws the iron wire from above and below together, and the binding work is completed.

[0073] The bound and formed condenser body is moved to a welding area, and the inlet pipe assembly 141 and the outlet pipe assembly 142 and other required parts are welded, so that the assembly work of the parts of the condenser is completed. The welding device comprises a welding agent and a polishing machine, etc., the welding machine is used to weld the inlet and outlet pipe assemblies, the partition plate 123 and other parts outside the condenser body; the polishing machine can be used to remove burrs, bumps, oil stains, etc.

[0074] The assembled condenser 100 is moved to the brazing equipment 300 for brazing. The brazing equipment 300 comprises a flux coating device 310, a welding furnace 320, and a cooling device 330. The flux coating device 310 comprises a feeding conveying mechanism and a spraying mechanism. The feeding conveying mechanism comprises a plurality of brush wheels 311 and a first conveying mechanism. The spraying mechanism comprises a flux tank 312, a conveying pump 313, and a spray head 314. The flux tank 312 stores flux. The conveying pump 313 is connected with the flux tank 312 and communicates with the inside of the flux tank 312 through a pipeline. The spray head 314 is connected with the flux tank 312 through a first support frame 315 and connected with the conveying pump 313 through a pipeline. The brush wheels 311 are provided with bearings at both ends. The flux tank 312 is provided with bearing seats. The brush wheels 311 are rotatably connected with the flux tank 312 through the bearings and the bearing seats. Part of the brush wheels 311 is immersed in the flux in the flux tank 312, and the other part protrudes from the flux tank 312. When the condenser 100 needs to be brazed, the condenser 100 is placed on the brush wheels 311 of the feeding conveying mechanism. The brush wheels 311 are rotated by the first conveying mechanism. The condenser 100 moves towards the welding furnace 320. In the moving process, the brush wheels 311 apply flux in the flux tank 312 to the lower surface of the condenser 100. The conveying pump 313 conveys the flux in the flux tank 312 to the spray head 314 to spray the flux on the upper surface of the condenser 100. The application of flux is automatically completed, without manual application, improving efficiency and ensuring the safety of operators. The flux sprayed from the spray head 314 falls back into the flux tank 312 and can be reused. To prevent the sprayed flux from splashing and polluting the environment, a protective cover can be arranged above the flux tank 312. The welding furnace 320 is provided with a low-temperature zone and a high-temperature zone. The temperature of the low-temperature zone is between 200-400℃, which is used to remove the moisture of the flux on the condenser 100. The temperature of the high-temperature zone is above 550℃, which makes the flux melt to complete welding. The welding furnace 320 is provided with a conveying device. The condenser 100 is conveyed to the external cooling device 330 by the conveying device. The conveying device can be formed by a motor-driven roller and a mesh belt transmission, or in the form of a plurality of rollers. The cooling device 330 comprises a discharging conveying mechanism and an air cooling mechanism. The discharging conveying mechanism comprises a plurality of rollers 331 and a second conveying mechanism. The air cooling mechanism comprises an air cooler 332 and an air knife 333. The air knife 333 is connected with the discharging conveying mechanism through a second support frame 334 and connected with the air cooler 332 through a pipeline. After the condenser 100 comes out of the welding furnace 320, the second conveying mechanism drives the rollers 331 to rotate, so that the condenser 100 moves away from the welding furnace 320. The air cooler 332 conveys cold air to the air knife 333, which sprays cold air to the condenser 100 to cool it quickly.In the embodiment of the present application, the first conveying mechanism comprises a belt pulley, a synchronous belt and a rotary motor. One end of each brush wheel 311 is provided with a belt pulley, and the belt pulley is connected with a driving wheel of the rotary motor through the synchronous belt. The rotary motor is started to rotate the brush wheel 311. The second conveying mechanism can be the same as the first conveying mechanism.

[0075] In other embodiments, the first conveying mechanism and the second conveying mechanism can be in the form of two large rollers and a mesh belt transmission. A large roller is driven to rotate by a speed reducer motor, so that the mesh belt moves. The condenser 100 is placed on the mesh belt, and the flux is applied manually during the movement.

[0076] The air tightness detection equipment comprises a water tank or a helium leak detection system, and a nitrogen detection system. The water tank is used for soaking the condenser. The helium leak detection system is used for generating helium and injecting the helium into the condenser. The helium leak detection system comprises a helium leak detection vacuum box, which is used for placing the condenser in the vacuum box to perform pressure maintaining detection, so as to avoid helium leakage into the environment. The helium leak detection system comprises a pressure gauge or a pressure sensor. The nitrogen detection system is used for injecting nitrogen into the condenser to perform pressure maintaining detection. The nitrogen detection system comprises a large-leak detection hose and a quick connector, which is connected with a transition connector used for detecting the condenser. The nitrogen detection system further comprises an indicator light. Different colors of the indicator light represent the qualified condition of the large-area leakage detection of the condenser. Generally, the detection personnel can intuitively obtain the detection result. After the large-area leakage detection is qualified, the condenser can enter the next process of helium leak detection, so as to avoid helium leakage and waste.

[0077] It should be understood that, although each step in the flowchart of the accompanying drawings is shown in sequence according to the arrow, these steps are not necessarily executed in the order indicated by the arrow. Unless otherwise specified herein, the execution of these steps is not strictly limited in sequence, and they can be executed in other orders.

[0078] The above are preferred embodiments of the present application, and do not limit the protection scope of the present application. Therefore, equivalent changes made on the basis of the structure, shape and principle of the present application should be covered within the protection scope of the present application.

Claims

1. A condenser for a small car, characterized in that: include: a core body, a first manifold, a second manifold, a first mounting bracket, and a second mounting bracket; The core includes side plates, a plurality of flat tubes, and a plurality of fins. The plurality of flat tubes are spaced apart one by one, with one fin disposed between two adjacent flat tubes. Both ends of the plurality of flat tubes are connected to the first liquid collecting pipe and the second liquid collecting pipe, respectively. The first liquid collecting pipe is connected to a liquid inlet pipe assembly and a liquid outlet pipe assembly. The first mounting bracket includes a first adjusting portion and a first clamping portion, and the second mounting bracket includes a second adjusting portion and a second clamping portion; the first clamping portion and the second clamping portion are used to clamp the auxiliary accessories, and the first adjusting portion and the second adjusting portion are used to adjust the positions of the first clamping portion and the second clamping portion to adapt to the size of the auxiliary accessories.

2. The condenser for a small car according to claim 1, characterized in that: The first adjustment part includes an upper inclined plate, the second adjustment part includes a lower inclined plate, the first clamping part includes a circular bayonet, the circular bayonet is provided with a notch, the auxiliary accessories enter the circular bayonet through the notch, and the circular bayonet is provided on the upper inclined plate; the second clamping part is the same as the first clamping part and the position corresponds.

3. The condenser for a small car according to claim 1, characterized in that: The first adjusting portion includes an arc-shaped plate, the first clamping portion includes a triangular buckle with an opening at one end, the auxiliary accessory is inserted through the opening and abuts against the inner wall of the triangular buckle, and the position of the triangular buckle is adjusted by changing the curvature of the arc-shaped plate; the second mounting bracket is the same as the first mounting bracket.

4. The condenser for a small car according to claim 1, characterized in that: It also includes a third mounting bracket, which is connected to the core body and is used to install the process pipe to limit the position of the process pipe; the third mounting bracket includes a third clamping portion, and the third clamping portion is the same as the first clamping portion.

5. The condenser for a small car according to claim 1, characterized in that: The flat tubes include a first flat tube and a second flat tube. The first flat tube includes a slot. The tube wall of the second flat tube is adapted to be plugged into the slot to adjust the length of the flat tubes.

6. A method for preparing a condenser for a small car according to any one of claims 1 to 5, comprising: Manufacturing spare parts for condensers, including but not limited to side plates, flat tubes, fins, first manifold, second manifold, liquid inlet pipe assembly and liquid outlet pipe assembly; Assemble the side plates, flat tubes and fins into a core body, and connect them to the first and second liquid collecting pipes respectively to form the condenser body; Binding and fixing the condenser body; Welding other parts other than the condenser body, including but not limited to the liquid inlet pipe assembly, the liquid outlet pipe assembly and the partition; Brazing of the condenser; Conduct air tightness test on the condenser after brazing; Install the corresponding bracket for the condenser that meets the air tightness requirements.

7. The method for preparing a condenser according to claim 6, wherein: The steps of the air tightness detection include: Inject nitrogen into the condenser, maintain pressure for a first period of time, and then detect leakage in the first area; Inject helium into the condenser, maintain the pressure for a second time, and then detect leakage in the second area by pressure difference; Inject nitrogen into the condenser, let it sit for at least a third time, and check for leaks by pressure differential; The second time is greater than the first time and less than the third time, the third time is not less than 12 hours, and the second area is smaller than the first area.

8. A condenser production line for producing the condenser for a small car according to any one of claims 1 to 5, comprising: Processing equipment used to process and manufacture various spare parts for condensers; Assembly equipment for assembling the condenser core and header to form the condenser body; a bundling device for bundling the condenser body; Welding equipment, used for welding other parts other than the condenser body; Brazing equipment for brazing condensers; Air tightness testing equipment is used to test the sealing of condensers.

9. The condenser production line according to claim 8, characterized in that: The assembly equipment includes a flat tube placement tool, a flat tube arrangement tool, a picking mechanism and a moving mechanism; the flat tube placement tool is used to place the flat tubes layer by layer, the flat tube arrangement tool includes a plurality of installation slots arranged at intervals, the picking mechanism is used to place the flat tubes in the flat tube placement tool one by one in the installation slots, and the moving mechanism is used to move the flat tube arrangement tool so that each installation slot corresponds to the picking mechanism one by one.

10. The condenser production line according to claim 9, characterized in that: The brazing equipment includes a flux coating device, a welding furnace and a cooling device; the flux coating device includes a feeding conveying mechanism and a spraying mechanism, the feeding conveying mechanism is used to convey the condenser to the welding furnace, and the spraying mechanism is used to coat the condenser with flux; the cooling device includes a discharging conveying mechanism and an air cooling mechanism, the discharging conveying mechanism is used to move the brazed condenser out of the brazing equipment, and the air cooling mechanism is used to dissipate heat and cool the condenser after brazing.

Images