Condenser for small cars, method of manufacture and production line

Abstract

The application relates to a condenser for small cars, a preparation method and a production line, which comprise a core body, a first collecting pipe, a second collecting pipe, a first mounting support and a second mounting support; the core body comprises a side plate, a plurality of flat tubes and a plurality of fins, the plurality of flat tubes are arranged at intervals, and one fin is arranged between two adjacent flat tubes; the two ends of the plurality of flat tubes are connected with the first collecting pipe and the second collecting pipe respectively, the first collecting pipe is connected with a liquid inlet pipe assembly and a liquid outlet pipe assembly; the first mounting support comprises a first adjusting part and a first clamping part, the second mounting support 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 so as to adapt to the sizes of the auxiliary accessories. The application has the effect of reducing occupied mounting space.

Description

A condenser for a small car, its manufacturing method and production line Technical Field

[0001] This application relates to the field of automotive air conditioning technology, and in particular to a condenser for small cars, its preparation method, and a production line. Background Technology

[0002] Common automotive air conditioning system components include compressors, condensers, and evaporators, which, along with auxiliary components such as receiver condenser and expansion valves, work together to form the air conditioning system to regulate the temperature inside the car. With the diversification of consumer demand, some cars are becoming smaller. However, existing condensers are generally quite large, and when combined with auxiliary components such as receiver condenser and expansion valve, as well as connecting pipes, they require a significant amount of installation space, making them unsuitable for use in smaller cars. Summary of the Invention

[0003] In view of this, this application provides a condenser for small cars, a manufacturing method and a production line, which can reduce the installation space occupied and is suitable for small cars.

[0004] Firstly, this application provides a condenser for a small car, which adopts the following technical solution:

[0005] A condenser for a small car includes a core, a first liquid collecting pipe, a second liquid collecting pipe, a first mounting bracket, and a second mounting bracket. The core includes a side plate, multiple flat tubes, and multiple fins. The multiple flat tubes are spaced apart, and a fin is disposed between two adjacent flat tubes. The two ends of the multiple flat tubes are respectively connected to the first liquid collecting pipe and the second liquid collecting pipe. The first liquid collecting pipe is connected to an inlet pipe assembly and an outlet pipe assembly. The first mounting bracket includes a first adjusting part and a first snap-fit ​​part, and the second mounting bracket includes a second adjusting part and a second snap-fit ​​part. The first snap-fit ​​part and the second snap-fit ​​part are used to snap-fit ​​auxiliary accessories, and the first adjusting part and the second adjusting part are used to adjust the position of the first snap-fit ​​part and the second snap-fit ​​part to adapt to the size of the auxiliary accessories.

[0006] By adopting the above technical solution, the auxiliary accessories are integrated with the condenser, reducing the installation space required, and the positions of the first and second snap-fit ​​parts can be adjusted to facilitate the quick installation of the auxiliary accessories.

[0007] Preferably, the first adjusting part includes an upper inclined plate, the second adjusting part includes a lower inclined plate, the first locking part includes a circular latch with a notch, the auxiliary accessory enters the circular latch through the notch, and the circular latch is located on the upper inclined plate; the second locking part is the same as the first locking part and the positions correspond to each other.

[0008] By adopting the above technical solution, the auxiliary accessories are subjected to tensile forces in two directions after installation, thereby increasing installation stability.

[0009] Preferably, the first adjustment part includes an arc-shaped plate, and the first snap-fit ​​part includes a triangular buckle with one end open. The auxiliary accessory is snapped into the triangular buckle through the opening and abuts against the inner wall of the triangular buckle. 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.

[0010] By adopting the above technical solution, the auxiliary accessories can be installed quickly, and the auxiliary accessories can be clamped by the inner wall of the triangular buckle to ensure stable installation.

[0011] Preferably, it further includes a third mounting bracket, which is connected to the core and used to mount the process tube to restrict the position of the process tube; the third mounting bracket includes a third snap-fit ​​portion, which is the same as the first snap-fit ​​portion.

[0012] By adopting the above technical solution, the process pipe is restricted, thus reducing the space it occupies.

[0013] Preferably, the flat tube includes a first flat tube and a second flat tube, the first flat tube including a slot, and the wall of the second flat tube being adapted to be inserted into the slot to adjust the length of the flat tube.

[0014] By adopting the above technical solution, the length of the flat tube can be adjusted according to the size of the installation space in the car, thereby adjusting the volume occupied by the entire condenser and making it easier to adapt to different car models; moreover, the first and second flat tubes can be mass-produced, improving production efficiency.

[0015] Secondly, this application provides a method for preparing a condenser, used to prepare a condenser for a small car as described in any of the above claims, the steps of which include:

[0016] Fabricate components for the condenser, including but not limited to side plates, flat tubes, fins, a first liquid collecting pipe, a second liquid collecting pipe, an inlet pipe assembly, and an outlet pipe assembly; assemble the side plates, flat tubes, and fins into a core, and connect them to the first and second liquid collecting pipes respectively to form the condenser body; bind and fix the condenser body; weld other components besides the condenser body, including but not limited to the inlet pipe assembly, the outlet pipe assembly, and partitions; braze the condenser; perform an airtightness test on the brazed condenser; and install the corresponding bracket on the condenser that passes the airtightness test.

[0017] Preferably, the airtightness detection steps include: injecting nitrogen into the condenser, maintaining pressure for a first time, and then detecting leakage in a first area; injecting helium into the condenser, maintaining pressure for a second time, and then detecting leakage in a second area by pressure difference; injecting nitrogen into the condenser, allowing it to stand for at least a third time, and then detecting leakage by pressure difference; wherein 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.

[0018] By adopting the above technical solution, the condenser is prepared, and the airtightness of the condenser is ensured through three sealing test processes.

[0019] Thirdly, this application provides a condenser production line for producing condensers for small cars as described in any of the above claims, comprising: processing equipment for processing various parts for manufacturing condensers; assembly equipment for assembling the core and collecting pipe of the condenser to form a condenser body; binding equipment for binding the condenser body; welding equipment for welding other parts besides the condenser body; brazing equipment for brazing the condenser; and airtightness testing equipment for testing the airtightness of the condenser.

[0020] Preferably, the assembly equipment includes a flat tube placement fixture, a flat tube arrangement fixture, a part-removing mechanism, and a moving mechanism; the flat tube placement fixture is used to place the flat tubes layer by layer, the flat tube arrangement fixture includes multiple spaced mounting slots, the part-removing mechanism is used to place the flat tubes in the flat tube placement fixture one by one into the mounting slots, and the moving mechanism is used to move the flat tube arrangement fixture so that each mounting slot corresponds to the part-removing mechanism.

[0021] Preferably, 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 being used to convey the condenser to the welding furnace, and the spraying mechanism being used to apply flux to the condenser; the cooling device includes a discharging conveying mechanism and an air-cooling mechanism, the discharging conveying mechanism being used to remove the brazed condenser from the brazing equipment, and the air-cooling mechanism being used to dissipate heat and cool the brazed condenser.

[0022] By adopting the above technical solutions, rapid flux application and rapid cooling of the condenser can be achieved, thereby improving the efficiency of brazing and the overall production efficiency of the condenser.

[0023] The condenser for small cars, its manufacturing method, and production line provided in this application reduce the size and installation space occupied by the condenser, making it suitable for small cars. Attached Figure Description

[0024] Figure 1 is a front view schematic diagram of a condenser provided in an embodiment of this application.

[0025] Figure 2 is a top view schematic diagram of a condenser provided in an embodiment of this application.

[0026] Figure 3 is a side view of a condenser provided in an embodiment of this application.

[0027] Figure 4 is a front view schematic diagram of the first mounting bracket provided in an embodiment of this application.

[0028] Figure 5 is a front view schematic diagram of the second mounting bracket provided in an embodiment of this application.

[0029] Figure 6 is a top view of a first mounting bracket provided in some other embodiments.

[0030] Figure 7 is a schematic diagram of a flat tube provided in some other embodiments.

[0031] Figure 8 is a schematic flowchart of the condenser preparation method provided in the embodiment of this application.

[0032] Figures 9 and 10 are partial schematic diagrams of the assembly equipment provided in the embodiments of this application.

[0033] Figure 11 is a schematic diagram of the brazing equipment provided in an embodiment of this application.

[0034] Explanation of reference numerals in the attached drawings: 100, condenser; 110, core; 111, flat tube; 1111, first flat tube; 1112, second flat tube; 1113, slot; 112, fin; 113, side plate; 121, first liquid collecting pipe; 122, second liquid collecting pipe; 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, inlet pipe assembly; 142, outlet pipe assembly; 151, fixing bracket. ; 152, Lower support; 210, Flat tube placement fixture; 220, Flat tube arrangement fixture; 221, Mounting slot; 230, Picking mechanism; 231, Lowering drive assembly; 232, Push plate; 233, Guide slot; 240, First extrusion mechanism; 241, Extrusion platform; 242, Extrusion plate; 243, Positioning plate; 250, Flat tube positioning mechanism; 251, Positioning slot; 300, Brazing equipment; 310, Flux coating device; 311, Brush wheel; 312, Flux tank; 313, Conveying pump; 314, Nozzle; 315, First support frame; 320, Welding furnace; 330, Cooling device; 331, Roller; 332, Air cooler; 333, Air knife; 334, Second support frame. Detailed Implementation

[0035] To better understand the purpose, technical solutions, and advantages of this application, it has been described and illustrated below with reference to the accompanying drawings and embodiments. However, those skilled in the art should understand that this application can be implemented without these details. In some cases, to avoid obscuring various aspects of this application due to unnecessary description, well-known methods, processes, systems, components, and / or circuits already described at a higher level will not be elaborated upon. It will be apparent to those skilled in the art that various modifications can be made to the embodiments disclosed in this application, and the general principles defined in this application can be applied to other embodiments and application scenarios without departing from the principles and scope of this application. Therefore, this application is not limited to the illustrated embodiments, but conforms to the broadest scope consistent with the scope of protection claimed in this application.

[0036] It should be noted that the descriptions of these embodiments are for the purpose of aiding understanding the present invention, but do not constitute a limitation thereof. Furthermore, the technical features involved in the various embodiments of the present invention described below can be combined with each other as long as they do not conflict with each other.

[0037] In the description of this application, "several" means one or more, "more than" means two or more, "greater than," "less than," and "exceeding" are understood to exclude the stated number, while "above," "below," and "within" are understood to include the stated number. The use of "first" and "second" in the description is merely for distinguishing technical features and should not be construed as indicating or implying relative importance, or implicitly indicating the number of indicated technical features, or implicitly indicating the order of the indicated technical features.

[0038] In the description of this application, the terms "one embodiment," "some embodiments," "illustrative embodiment," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any one or more embodiments or examples.

[0039] This application discloses a condenser for a small car.

[0040] As shown in Figure 1, the condenser 100 for a small car includes a core 110, a first liquid collecting pipe 121, a second liquid collecting pipe 122, a first mounting bracket 131, and a second mounting bracket 132. The first liquid collecting pipe 121 and the second liquid collecting pipe 122 are located on the left and right sides of the core 110, respectively. The core 110 includes upper and lower side plates 113. A plurality of flat tubes 111 and a plurality of fins 112 are arranged between the upper and lower side plates 113. The plurality of flat tubes 111 are arranged in parallel and spaced apart. A fin 112 is arranged between two adjacent flat tubes 111. The flat tubes 111 or fins 112 located at the top and bottom are connected to the side plates 113. Multiple slots are arranged in a layered pattern on the opposite sides of the first and second liquid collecting pipes 121 and 122. Each flat tube 111 has its two ends inserted into the slots of the first and second liquid collecting pipes 121 and 122 respectively, thus communicating with the interior of each flat tube 111. A flux layer is applied to the surfaces of the core 110 and the first and second liquid collecting pipes 121 and 122 to allow for brazing connections between the flat tubes 111 and the fins 112, and between the flat tubes 111 and the collecting pipes. The first liquid collecting pipe 121 is equipped with an inlet pipe assembly 141 and an outlet pipe assembly 142, which are used to connect to external cooling medium delivery pipes. A partition 123 is provided inside the first and second liquid collecting pipes 121 and 122 to separate the flow channels. Both ends of the first and second liquid collecting pipes 121 and 122 are sealed with plugs.

[0041] The first mounting bracket 131 and the second mounting bracket 132 are used to mount liquid receivers, expansion valves, capillary tubes, or other auxiliary accessories required in the automotive air conditioning refrigeration system. This allows the auxiliary accessories to be integrated with the condenser, reducing the number of connecting pipes and minimizing the installation space required. Specifically, the first mounting bracket 131 includes a first adjusting part and a first snap-fit ​​part, and the second mounting bracket 132 includes a second adjusting part and a second snap-fit ​​part. The first and second snap-fit ​​parts are used to snap-fit ​​with the auxiliary accessories, enabling quick installation and reducing the space required for installation operations. Since the auxiliary accessories vary in size and there may be processing errors during the condenser manufacturing process, the first and second adjusting parts are provided to adjust the positions of the first and second snap-fit ​​parts to accommodate the dimensions of the auxiliary accessories.

[0042] Please refer to Figures 1 to 5. The first mounting bracket 131 also includes a first fixing plate 1311. The first fixing plate 1311 is L-shaped, with its vertical plate connected to the upper side plate 113 by bolts, and its horizontal plate extending laterally away from the core 110. The first fixing plate 1311 is close to the first liquid collection pipe 121. The first adjustment part includes an upper inclined plate 1312. One end of the upper inclined plate 1312 is connected to the first fixing plate 1311. It is set vertically upward and then bent, tilting towards the upper part of the core 110 and the second liquid collection pipe 122. The other end of the upper inclined plate 1312 is free. The first snap-fit ​​part includes a circular snap-fit ​​1313 provided on the upper inclined plate 1312. The circular snap-fit ​​1313 has a notch on one side facing the top of the upper inclined plate 1312. The size of the notch is smaller than the diameter of the circular snap-fit ​​1313. Auxiliary accessories can enter the circular snap-fit ​​1313 through the notch, thereby realizing the snap-fit ​​of the auxiliary accessories. A flared guide port is also provided on the outside of the notch to guide the auxiliary accessories to snap in. The second mounting bracket 132 is located near the bottom of the core 110. It includes a horizontal second fixing plate 1321, which is connected to the core 110 by bolts and extends laterally away from the core 110. The second adjustment part includes a lower inclined plate 1322, which is inverted L-shaped. One end of the lower inclined plate 1322 is connected to the second fixing plate 1321, is inclined upward and then bent downward. The other end of the lower inclined plate 1322 is free and is inclined towards the bottom of the core 110 and the direction of the second liquid collection tube 122. The second snap-fit ​​part is provided on the lower inclined plate 1322. The structural dimensions of the second snap-fit ​​part are the same as those of the first snap-fit ​​part and their positions correspond.

[0043] By setting the upper inclined plate 1312 and the lower inclined plate 1322 to be connected to the fixed plate at only one end, while the rest are free, their adjustability is achieved. A bending section is provided, allowing for extension or contraction, facilitating automatic adjustment of the distance and relative position between the two mounting brackets according to the dimensions of the auxiliary accessories. The upper inclined plate 1312 slopes upwards, and the lower inclined plate 1322 slopes downwards, so that after the auxiliary accessories are installed, they are subjected to pulls in two opposite directions, improving installation stability. 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 brackets. In this embodiment, the first mounting bracket 131 and the second support frame 334 are installed on the front side of the core 110, and the first mounting bracket 131 and the second mounting bracket 132 are positioned so that they do not protrude beyond the boundary of the condenser. This ensures that after the auxiliary accessories are installed, they are also located on the front side of the core 110, not protruding beyond the condenser boundary, thus not increasing the length or height of the condenser and reducing the overall installation space.

[0044] In other embodiments, as shown in FIG6, the first mounting bracket 131 includes a connecting plate 1314, a first adjusting part includes an arc-shaped plate 1315, and a first snap-fit ​​part includes a triangular buckle 1316. The arc-shaped plate 1315 is connected to the connecting plate 1314 and the triangular buckle 1316 on both sides respectively. The connecting plate 1314 is fixedly connected to the core 110. The arc-shaped plate 1315 can adjust its length by changing its curvature, achieving extensibility. One end of the triangular buckle 1316 is open, and auxiliary accessories are inserted into the triangular buckle 1316 through the opening and abut against the inner wall of the triangular buckle. An arc-shaped guide plate is provided at the opening to facilitate the insertion of the auxiliary accessories. The space inside the triangular buckle 1316 can be smaller than the part where the auxiliary accessories are inserted, so that at least two opposing inner walls of the triangular buckle 1316 can compress the auxiliary accessories, achieving a reliable connection. The second mounting bracket 132 can be the same as the first mounting bracket 131.

[0045] Referring to Figure 3, the mounting bracket assembly provided in this embodiment further includes a third mounting bracket 133. The third mounting bracket 133 includes a third adjusting portion and a third snap-fit ​​portion. The third mounting bracket 133 is connected to the front side of the second liquid collecting pipe 122 via a third fixing plate. One end of the third adjusting portion is connected to the third fixing plate, and the other end extends forward and is inclined towards the first liquid collecting pipe 121. The structural dimensions of the third snap-fit ​​portion can be the same as those of the first snap-fit ​​portion. The third mounting bracket 133 can be used to install process pipes such as refrigerant delivery pipes to limit the position of the process pipes, prevent the pipes from shaking during operation, and reduce the space occupied by the pipes.

[0046] As shown in Figures 1 and 3, the condenser 100 provided in this embodiment further includes two fixed supports 151 and two lower supports 152. The two fixed supports 151 are connected to the upper side plate 113 for fixed connection with the vehicle. The two lower supports 152 are inverted U-shaped and are respectively connected to the bottom of the first liquid collection pipe 121 and the second liquid collection pipe 122 to support the condenser. The two lower supports 152 can be connected to the liquid collection pipes by bolts. The second fixing plate 1321 of the second mounting bracket 132 can be connected to the lower supports 152. The condenser provided in this embodiment is used in small cars. Its length and height are smaller than existing condensers, for example, it can be 80% of the volume of existing condensers. The reduced condenser is also lighter. To ensure stability during installation, the condenser is supported by the lower supports 152 and fixed by bolts using the fixed supports 151 to ensure reliable connection of the condenser. The fixed supports 151 and the lower supports 152 are made of iron or stainless steel, which has high strength.

[0047] The flat tube 111 provided in this embodiment is a single, continuous tube, and its length varies depending on the vehicle model. In other embodiments, as shown in Figure 7, the flat tube includes a first flat tube 1111 and a second flat tube 1112. The first flat tube 1111 includes a first chamber and a slot 1113, and the second flat tube 1112 includes a second chamber. The wall of the second flat tube 1112 is adapted to the slot 1113. The first flat tube 1111 and the second flat tube 1112 are movably connected through the slot 1113, and the first chamber and the second chamber are connected. By adjusting the depth of the second flat tube 1112 inserted into the first slot 1113, the length of the entire flat tube can be adjusted to adapt to different installation spaces. Because the space dimensions reserved for condenser installation vary across different vehicle models, each condenser requires customized production based on its specific model, making mass production impossible. In this embodiment, the flat tube is divided into a first flat tube 1111 and a second flat tube 1112. The first flat tube 1111 and the second flat tube 1112 can be mass-produced in a standardized manner. During assembly, the first flat tube 1111 and the second flat tube 1112 are inserted together. The length of the flat tube 111 is flexibly adjusted according to the known space available for each vehicle model. After adjustment, welding and sealing are performed at the connection between the first flat tube 1111 and the second flat tube 1112 to ensure fixation and prevent leakage. The sealing treatment can involve applying sealant and / or wrapping sealing tape. Correspondingly, the slots of the first liquid collecting pipe 121 and the second liquid collecting pipe 122 have different opening sizes to accommodate insertion into the first flat tube 1111 and the second flat tube 1112, respectively. The side plate can also include a first side plate and a second side plate, which use the same plug-in method to adjust the size of the fitting. Thus, the side plate can also be mass-produced in a standardized manner. Alternatively, after the first flat tube 1111 and the second flat tube 1112 are adjusted, the length of the side plate can be cut according to the determined length of the flat tube. Thus, at least the flat tube can be mass-produced in a standardized manner, improving production efficiency.

[0048] This application provides a method for preparing a condenser, the steps of which include:

[0049] S810: Manufacturing components for condensers, including but not limited to side plates, flat tubes, fins, first liquid collecting pipe, second liquid collecting pipe, inlet pipe assembly, and outlet pipe assembly.

[0050] The components in the condenser include, but are not limited to, flat tube 111, fins 112, first liquid collecting pipe 121, second liquid collecting pipe 122, liquid inlet pipe assembly 141, liquid outlet pipe assembly 142, baffle plate 123, plugs, and corresponding supports. In this embodiment, all components are made of aluminum. The flat tube 111 can be made by cutting, bending, and welding aluminum sheet into a hollow square tube, or it can be a purchased deformed aluminum tube profile cut to the required size. The fins 112 can be made of aluminum sheet processed into a wavy shape; the liquid collecting pipe can be made of aluminum tube cut to the required size, with slots punched on one side at intervals along the length direction, and baffle plate slots cut on the other side for welding the baffle plate 123.

[0051] S820: The side plate, flat tube and fins are assembled into a core, and connected to the first liquid collection pipe and the second liquid collection pipe respectively to form the main body of the condenser.

[0052] The condenser core 110 includes flat tubes 111, fins 112, and side plates 113. During assembly, multiple flat tubes 111 are arranged horizontally at intervals using an arrangement tool. Then, fins 112 are placed in the gaps between two flat tubes 111. Next, side plates 113 are placed at both ends of the flat tubes 111 in the arrangement direction, and the two ends of the flat tubes 111 in the arrangement direction are squeezed to make the side plates 113, flat tubes 111, and fins 112 close together, eliminating gaps. Then, the top surfaces of each flat tube 111 and fin 112 are pressed down to make the top surfaces flush.

[0053] The assembled core 110 is held in place by compression. The first and second liquid collecting pipes 121 and 122 are then 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 pipes, thus completing the main body of the condenser. The spacing between the slots of the liquid collecting pipes is the same as the spacing of the arrangement fixture, thus corresponding one-to-one with the arrangement position of the flat tubes 111.

[0054] S830: The condenser body is bound and secured.

[0055] The condenser body is clamped and moved to the binding device using a clamp. The binding device uses iron wire to bind the flat tubes 111 from both ends in the arrangement direction, so that the side plate 113 is fastened to the flat tubes 111 and the fins 112, so as to control the gap between the fins 112 and the flat tubes 111 to not exceed the set requirements.

[0056] S840: Weld other components besides the condenser body, including but not limited to the inlet pipe assembly, outlet pipe assembly, and baffle.

[0057] The inlet pipe assembly 141, the outlet pipe assembly 142, the baffle 123, and the plug are welded to the first liquid collection pipe 121 and / or the second liquid collection pipe 122 to complete the assembly of the condenser.

[0058] S850: Brazing the condenser.

[0059] Before brazing, the assembled condenser can be pretreated, including removing grease, dirt, oxides, and other substances. Then, flux is applied to the surface of the condenser before it is placed in a brazing furnace for high-temperature brazing. The brazing process in the furnace can be divided into two stages: the first stage, at a furnace temperature of 200-400℃, removes moisture from the flux; the second stage, at a temperature above 550℃, melts the flux, allowing the flat tube 111 to be welded to the liquid collector, the fin 112 to the flat tube 111, and the side plate 113 to the flat tube 111 or fin 112, etc. Specifically, before pretreatment, the condenser can also undergo leveling and finishing treatments. Leveling includes flattening each surface of the condenser to make it smooth, and finishing includes removing burrs and protrusions from the condenser surface. These leveling and finishing treatments facilitate even and comprehensive flux coating.

[0060] S860: Perform an airtightness test on the brazed condenser.

[0061] Before testing, remove welding slag or oil stains from the condenser surface to avoid affecting the test results. The specific steps for airtightness testing include:

[0062] S861: Inject nitrogen into the condenser, maintain pressure for a certain period of time, and then check for leakage in the first area.

[0063] After sealing the outlet pipe assembly and other outlets, inject nitrogen into the condenser through the inlet pipe assembly and then seal the inlet. Maintain pressure immediately to determine if there is a large-scale leak. If a large-scale leak is found, repair the condenser by welding before proceeding to the next step of testing. Avoid directly using helium for testing, as large-scale leaks would waste helium. Test results can be determined by pressure gauge fluctuations or pressure differentials detected by pressure sensors, or by manual assessment. The injected nitrogen pressure can be 3.5 MPa, and the initial pressure can be 2 seconds. Higher pressure allows for direct detection of large-scale leaks within a short time.

[0064] S862: Inject helium into the condenser, maintain pressure for a second time, and then detect leakage in the second area using the pressure difference.

[0065] The outlet pipe assembly and other outlets are sealed. Helium is injected through the inlet pipe assembly and then sealed. The chamber is placed in a helium leak detection vacuum chamber and pressurized for a second time. The pressure fluctuations on the pressure gauge or the pressure difference detected by the pressure sensor are used to determine if there is a small-area leak. The injected helium pressure can be 0.8 MPa, and the second time can be 8 seconds. If the pressure difference exceeds the set range, for example, if the pressure drop is greater than 5%, a leak is considered to exist, and re-welding is required. After re-welding, helium is injected again for testing until the pressure drop is within the set range. Helium leak detection has high sensitivity and can accurately locate the leak point, facilitating rapid re-welding.

[0066] In other implementations, the condenser can be immersed in a water tank. If bubbles are generated in the water, the location of the bubbles indicates a leak, which needs to be repaired by welding. After that, the condenser is immersed and tested again. Once no bubbles are generated, the water on the condenser is dried before proceeding to the next step of testing.

[0067] S863: Inject nitrogen into the condenser and let it stand for at least three hours. Detect any leaks by checking the pressure difference.

[0068] Connect the inlet pipe assembly to the injection pipeline, which is equipped with a high-pressure valve. Inject nitrogen into the condenser through the injection pipeline, close the high-pressure valve and other outlets, and allow it to stand for three hours. If the pressure drop is within the set range, the condenser is considered a qualified product and is packaged and stored. If the pressure drop exceeds the set range, the condenser is considered unqualified and is scrapped. The injected nitrogen pressure can be 0.3~0.4 MPa, and the third time should be no less than 12 hours. Perform a pressure test on the condenser again using nitrogen to ensure its sealing performance, structural strength, and long-term stability.

[0069] In this embodiment, 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. Large-area leaks are detected quickly in the shortest time, then small leaks are detected in the second time, and finally, long-term sealing and stability are tested through a longer third time. By performing a three-stage sealing test process on the condenser, the sealing reliability of the condenser is ensured, and the quality of the product is guaranteed.

[0070] In other implementations, the location of the leak can be detected using a nitrogen mass spectrometer.

[0071] S870: Install the appropriate bracket for condensers that meet the airtightness requirements.

[0072] 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 then installed with the condenser to complete the preparation process. After the condenser is prepared, a vacuum cleaner can be used to vacuum the front and back of the core to remove internal dust and debris.

[0073] This application embodiment also provides a condenser manufacturing production line, including processing equipment (not shown in the figure), assembly equipment, binding equipment (not shown in the figure), welding equipment (not shown in the figure), brazing equipment 300, and airtightness testing equipment (not shown in the figure). The processing equipment includes, but is not limited to, cutting machines, bending machines, stamping machines, and fin forming machines. The cutting machine is used to cut aluminum or other metal materials according to size requirements, for example, cutting circular aluminum tubes to obtain a liquid collecting tube substrate or flat aluminum tubes to obtain a flat tube 111; the bending machine is used to bend sheet metal to form the required shape, for example, bending aluminum plates to form the flat tube 111 substrate, or bending sheet metal parts to form corresponding supports; the stamping machine stamps the substrate, for example, stamping the liquid collecting tube to process grooves; and the fin forming machine is used to form aluminum materials into wavy or other shaped fins 112.

[0074] The assembly equipment includes a flat tube placement fixture 210 for assembling the core 110, a flat tube arrangement fixture 220, a part-removing mechanism 230, and a moving mechanism (not shown in the figure). The flat tube placement fixture 210 stores multiple flat tubes 111, which are stacked layer by layer within the fixture. The flat tube arrangement fixture 220 has multiple mounting slots 221 spaced apart, each slot 221 for placing one flat tube 111. The flat tube placement fixture 210 is located above and inclined to the flat tube arrangement fixture 220. The part-removing mechanism 230 is located at the bottom of the flat tube placement fixture 210 and above the flat tube arrangement fixture 220, and is used to push the bottommost flat tube 111 into the mounting slot 221 of the flat tube arrangement fixture 220. The moving mechanism is connected to the flat tube arrangement fixture 220 and can drive the flat tube arrangement fixture 220 to move along the arrangement direction of the mounting slots 221. The picking mechanism 230 includes a downward drive assembly 231, a push plate 232, and a guide groove 233. The downward drive assembly 231 is connected to the push plate 232. The groove at the bottom of the guide groove 233 corresponds to the first mounting groove 221 of the flat tube arrangement fixture 220. The groove wall at the top of the guide groove 233 supports the bottom flat tube 111 of the flat tube placement fixture 210. The volume of the push plate 232 gradually increases from bottom to top. When the downward drive assembly 231 is not activated, the push plate 232 does not contact the flat tube 111. When the downward drive assembly 231 is activated, it drives the push plate 232 to move downward, and then the push plate 232 contacts the bottom flat tube 111 and pushes it into the guide groove 233. Guided by the guide groove 233, it slides into the mounting groove 221 of the flat tube arranging fixture 220 below. Then the moving mechanism drives the flat tube arranging fixture 220 to move, so that the position of the second mounting groove 221 corresponds to the position of the bottom of the guide groove 233. The flat tube 111 in the flat tube placement fixture 210 automatically moves down, and the picking mechanism 230 pushes the flat tube 111 located at the bottom into the second mounting groove 221. This process continues until all mounting grooves 221 are filled with flat tubes 111. In this embodiment, the moving mechanism includes a motor, a lead screw assembly, and a slide rail assembly. The motor is connected to the lead screw of the lead screw assembly, and the nut of the lead screw assembly is connected to the flat tube arranging fixture 220. The flat tube 111 arranging mechanism is connected to the slider of the slide rail assembly. The motor drives the lead screw to rotate, so that the flat tube arranging fixture 220 can move back and forth along the arranging direction of the mounting groove 221.

[0075] The assembly equipment also includes a flat tube positioning mechanism 250, a liquid collection tube insertion mechanism (not shown in the figure), a first extrusion mechanism 240, and a second extrusion mechanism (not shown in the figure). The first extrusion mechanism 240 includes an extrusion platform 241, a positioning plate 243, and an extrusion plate 242. The positioning plate 243 and the extrusion plate 242 are located at both ends of the length direction of the extrusion platform 241, and the length direction of the extrusion platform 241 is consistent with the arrangement direction of the multiple mounting slots 221 in the flat tube arrangement fixture 220. The second extrusion mechanism is located above the extrusion platform 241. The flat tube positioning mechanism 250 is movably arranged on both sides of the length direction of the extrusion platform 241 and can be moved to the bottom of the extrusion platform 241. The flat tube positioning mechanism 250 is provided with multiple positioning slots 251 at intervals. The size of the positioning slots 251 is consistent with the size of the mounting slots 221 on the flat tube arrangement fixture 220. The number of positioning slots 251 can be greater than or equal to the number of mounting slots 221. The liquid collection tube insertion mechanism is movably arranged on both sides of the length direction of the extrusion platform 241. After the flat tube 111 is installed in the flat tube arranging fixture 220, the flat tube positioning mechanism 250 moves to both sides of the extrusion platform 241. The moving mechanism drives the flat tube arranging fixture 220 to move above the flat tube positioning mechanism 250, so that the positions of the mounting groove 221 and the positioning groove 251 correspond one by one. The sealing plate at the bottom of the mounting groove 221 of the flat tube arranging fixture 220 can be removed, so that the flat tube 111 falls into the extrusion platform 241 and falls into the corresponding positioning groove 251 one by one. The moving mechanism drives the flat tube arranging fixture 220 back to the bottom of the flat tube placement fixture 210 to perform the second flat tube 111 arranging operation. Before the flat tube 111 falls into the positioning groove 251, a side plate 113 can be placed on the opposite side of the positioning plate 243 and the extrusion plate 242. After the flat tube 111 falls into the positioning groove 251, a fin 112 is placed between two adjacent flat tubes 111. Then, the flat tube positioning mechanism 250 moves away from both ends of the flat tube 111 and moves downwards towards the extrusion platform 241. Driven by the driving mechanism, the extrusion plate 242 extrudes the side plate 113, the flat tube 111, and the fin 112 towards the positioning plate 243, causing the side plate 113 to... 13. The flat tube 111 and fin 112 are brought close together to reduce the gap, completing the splicing fixture of the condenser core 110. Then, the second extrusion mechanism extrudes from above to make the top surfaces of the flat tube 111 and fin 112 flat and fix the core 110 in place. The liquid collecting tube insertion mechanism moves to both sides of the extrusion platform 241 and slowly approaches the core 110 until the groove of the liquid collecting tube is inserted into the flat tube 111. Then, the liquid collecting tube insertion mechanism is removed and the second extrusion mechanism is removed, completing the assembly of the condenser body.

[0076] After the condenser body is assembled, it is transferred to the binding equipment by a clamp for binding. The binding equipment includes a binding platform, a bottom wire threading mechanism, a top wire threading mechanism, and a twisting mechanism. The condenser body is placed on the binding platform. The bottom wire threading mechanism passes the wire through the bottom of the condenser body. The top wire threading mechanism takes the wire and passes it through the top of the condenser body. The twisting mechanism takes the wire and twists and screws the top and bottom wires together to complete the binding work.

[0077] The bundled condenser body is transferred to the welding area, where the inlet pipe assembly 141 and the outlet pipe assembly 142, along with other necessary components, are welded to complete the assembly of the condenser parts. The welding equipment includes welding flux and a polishing machine. The welding machine is used to weld components other than the condenser body, such as the inlet and outlet pipe assemblies and the baffle plate 123; the polishing machine is used to remove burrs, bumps, oil stains, etc.

[0078] The assembled condenser 100 is then transferred to the brazing equipment 300 for brazing. The brazing equipment 300 includes a flux coating device 310, a welding furnace 320, and a cooling device 330. The flux coating device 310 includes a feeding and conveying mechanism and a spraying mechanism. The feeding and conveying mechanism includes multiple brush wheels 311 and a first conveying mechanism. The spraying mechanism includes a flux tank 312, a delivery pump 313, and a nozzle 314. The flux tank 312 contains flux. The delivery pump 313 is connected to the flux tank 312 and communicates with the inside of the flux tank 312 through a pipe. The nozzle 314 is connected to the flux tank 312 through a first support frame 315 and is connected to the delivery pump 313 through a pipe. Bearings are provided at both ends of the brush wheels 311. The flux tank 312 is equipped with bearing seats. The multiple brush wheels 311 are rotatably connected to the flux tank 312 through bearings and bearing seats. Part of the multiple brush wheels 311 are located in the flux tank 312 and immersed in the flux, while the other part protrudes from the flux tank 312. When the condenser 100 needs brazing, it is placed on multiple brush wheels 311 of the feeding conveyor mechanism. The brush wheels 311 are rotated by the first conveying mechanism, and the condenser 100 moves towards the welding furnace 320. During the movement, the brush wheels 311 apply the flux in the flux tank 312 to the lower surface of the condenser 100. The delivery pump 313 delivers the flux in the flux tank 312 to the nozzle 314, which sprays the flux onto the upper surface of the condenser 100, automatically completing the flux application work without manual application, improving efficiency and ensuring the safety of operators. The flux sprayed from the nozzle 314 falls back into the flux tank 312 for reuse. To prevent the sprayed flux from splashing and polluting the environment, a protective cover can be erected above the flux tank 312. The welding furnace 320 is equipped with a low-temperature zone and a high-temperature zone. The temperature of the low-temperature zone is between 200 and 400°C, which is used to remove moisture from the flux on the condenser 100. The temperature of the high-temperature zone is above 550°C, which melts the flux and completes the welding. The welding furnace 320 is equipped with a conveying device, which transports the condenser 100 to the external cooling device 330. The conveying device can be a combination of motor-driven rollers and mesh belt drive, or it can be a form of multiple roller conveyors. The cooling device 330 includes a discharge conveying mechanism and an air-cooling mechanism. The discharge conveying mechanism includes multiple rollers 331 and a second conveying mechanism. The air-cooling mechanism includes a cold air blower 332 and an air knife 333. The air knife 333 is connected to the discharge conveying mechanism through a second support frame 334 and to the cold air blower 332 through a pipe. After the condenser 100 comes out of the welding furnace 320, the second conveying mechanism drives the multiple rollers 331 to rotate, causing the condenser 100 to move away from the welding furnace 320. The cold air blower 332 delivers cold air to the air knife 333, and the air knife 333 sprays cold air onto the condenser 100, making it cool quickly.In this embodiment of the application, the first conveying mechanism includes a pulley, a timing belt and a rotary motor. Each brush wheel 311 has a pulley installed at one end and is connected to the drive wheel of the rotary motor through the timing belt. The rotary motor starts to make the brush wheel 311 rotate. The second conveying mechanism can be the same as the first conveying mechanism.

[0079] In other embodiments, the first and second conveying mechanisms can be in the form of two large rollers and a mesh belt drive. The large rollers are driven to rotate by a geared motor, which moves the mesh belt. The condenser 100 is placed on the mesh belt, and flux is applied manually during the movement.

[0080] The airtightness testing equipment includes a water tank or helium leak detection system and a nitrogen leak detection system. The water tank is used to immerse the condenser. The helium leak detection system generates helium and injects it into the condenser. This system includes a helium leak detection vacuum chamber for pressure testing, preventing helium leakage into the environment. The system includes a pressure gauge or pressure sensor. The nitrogen leak detection system injects nitrogen into the condenser for pressure testing. It includes a large-area leak detection hose and quick-connect fittings, which connect to the adapter used during condenser testing. The nitrogen leak detection system also includes indicator lights; different colored lights indicate whether the large-area leak detection of the condenser is satisfactory, allowing inspectors to visually obtain the results. Only condensers that pass the large-area leak detection can proceed to the next step of the helium leak detection process, avoiding helium leakage and waste.

[0081] It should be understood that although the steps in the flowcharts in the accompanying drawings are shown sequentially as indicated by the arrows, these steps are not necessarily performed in the order indicated by the arrows. Unless otherwise expressly stated herein, there is no strict order in which these steps are performed, and they may be performed in other orders.

[0082] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A condenser for a small car, characterized in that, include: The system comprises a core, a first liquid collecting tube, a second liquid collecting tube, a first mounting bracket, and a second mounting bracket. The core includes a side plate, multiple flat tubes, and multiple fins. The flat tubes are spaced apart, with one fin between each adjacent flat tube. The two ends of the flat tubes are connected to the first and second liquid collecting tubes, respectively. The first liquid collecting tube is connected to an inlet pipe assembly and an outlet pipe assembly. The first mounting bracket includes a first adjusting part and a first snap-fit ​​part, and the second mounting bracket includes a second adjusting part and a second snap-fit ​​part. The first and second snap-fit ​​parts are used to snap-fit ​​auxiliary accessories, and the first and second adjusting parts are used to adjust their positions to accommodate the auxiliary accessories. The dimensions of the auxiliary accessory; the first adjusting part includes an upper inclined plate, the second adjusting part includes a lower inclined plate, the first locking part includes a circular latch with a notch, the auxiliary accessory enters the circular latch through the notch, the circular latch is located on the upper inclined plate; the second locking part is the same as the first locking part and corresponds in position, the auxiliary accessory is located on the front side of the core after installation; or the first adjusting part includes an arc plate, the first locking part includes a triangular buckle with one end open, the auxiliary accessory is inserted through the opening and abuts against the inner wall of the triangular buckle, the position of the triangular buckle is adjusted by changing the curvature of the arc plate; the second mounting bracket is the same as the first mounting bracket.

2. 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 and is used to mount the process tube to restrict the position of the process tube; the third mounting bracket includes a third snap-fit ​​portion, which is the same as the first snap-fit ​​portion.

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

4. A method for preparing a condenser, used to prepare the condenser for a small car as described in any one of claims 1-3, comprising the steps of: Manufacture the components for the condenser, including side plates, flat tubes, fins, first liquid collecting tube, second liquid collecting tube, inlet pipe assembly, and outlet pipe assembly; The side plate, flat tube and fins are assembled into a core, and connected to the first liquid collection pipe and the second liquid collection pipe respectively to form the condenser body; the condenser body is bound and fixed; other parts other than the condenser body are welded, including the liquid inlet pipe assembly, the liquid outlet pipe assembly and the partition plate. Brazing the condenser; Perform an airtightness test on the brazed condenser; Install appropriate brackets on condensers that meet airtightness requirements; The steps for the airtightness test include: injecting nitrogen into the condenser, maintaining the pressure for a first time, and then testing for leakage in the first area. The injected nitrogen pressure is 3.5 MPa. Helium is injected into the condenser and held at pressure for a second time. Leakage is then detected in the second area by differential pressure. The injected helium pressure is 0.8 MPa. Nitrogen is injected into the condenser and left to stand for at least a third time. Leakage is then detected by differential pressure. The injected nitrogen pressure is 0.3~0.4 MPa. The second time is longer than the first time and shorter than the third time, and the third time is no less than 12 hours. The second area is smaller than the first area.

5. A condenser production line for producing condensers for small automobiles as described in any one of claims 1-3, comprising: Processing equipment used to process and manufacture various parts for condensers; Assembly equipment is used to assemble the core and collecting pipe of a condenser to form the main body of the condenser; binding equipment is used to bind the main body of the condenser; welding equipment is used to weld other parts besides the main body of the condenser; brazing equipment is used to braze the condenser; airtightness testing equipment is used to test the airtightness of the condenser; the assembly equipment includes a flat tube placement fixture, a flat tube arrangement fixture, a part-removing mechanism, and a moving mechanism; the flat tube placement fixture is used to place the flat tubes layer by layer, the flat tube arrangement fixture includes multiple spaced mounting slots, the part-removing mechanism is used to place the flat tubes in the flat tube placement fixture one by one into the mounting slots, and the moving mechanism is used to move the flat tube arrangement fixture so that each mounting slot corresponds to the part-removing mechanism; the part-removing mechanism includes a downward drive component, a push plate, and a guide groove. The downward drive component is connected to the push plate. When the downward drive component is activated, it drives the push plate to move downward, the push plate contacts the bottom flat tube and pushes it into the guide groove, where it slides down into the mounting slot of the flat tube arrangement fixture below.

6. The condenser production line according to claim 5, 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 apply flux to the condenser. The cooling device includes a discharging conveying mechanism and an air-cooling mechanism. The discharging conveying mechanism is used to remove the brazed condenser from the brazing equipment, and the air-cooling mechanism is used to dissipate heat and cool the brazed condenser. The feeding conveying mechanism includes multiple brush wheels, and the spraying mechanism includes a flux tank, a delivery pump, and a nozzle. The delivery pump is connected to the inside of the flux tank through a pipe, and the nozzle is connected to the delivery pump through a pipe. Parts of the multiple brush wheels are located in the flux tank and immersed in the flux, while other parts protrude from the flux tank. As the condenser moves towards the welding furnace, the brush wheels apply the flux from the flux tank to the lower surface of the condenser, and the delivery pump delivers the flux from the flux tank to the nozzle, spraying the flux onto the upper surface of the condenser. The flux sprayed from the nozzle falls back into the flux tank.

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