A simple-to-install condenser, its preparation method and production line

Abstract

This application relates to a simple-to-install condenser, its manufacturing method, and production line, comprising a core, a first liquid collecting pipe, a second liquid collecting pipe, and multiple support assemblies. The core includes two pressing members, multiple flat tubes, and multiple fins. The multiple flat tubes and fins are located between the two pressing members. The multiple flat tubes are spaced apart, with one fin positioned 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 multiple support assemblies are connected to the core, and each support assembly includes a connecting screw for fitting into mounting holes in an automotive vehicle. The connecting screw has multiple screws with different axes to accommodate mounting holes with different axes. This application offers the advantages of simple and quick installation and ease of maintenance.

Description

Technical Field

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

[0002] Air conditioning systems in both new energy vehicles and gasoline-powered vehicles typically consist of components such as compressors, condensers, and evaporators, which work together to regulate the temperature inside the vehicle. After a period of use, lint, dander, and other impurities tend to accumulate on the air conditioning system, clogging the condenser fins and affecting its heat dissipation. Therefore, it is usually necessary to disassemble the condenser for cleaning to remove these impurities. Existing condensers are generally installed inside the vehicle using fixed brackets. After disassembly and cleaning, reinstallation requires first placing the condenser inside the car, then adjusting its position within the limited space to align the mounting holes on the bracket with the installation holes inside the car, and finally tightening the bolts using screwdrivers and wrenches. This process, all within the confined space of the car, is very inconvenient and slows down the installation process. Summary of the Invention

[0003] In view of this, this application provides a simple-to-install condenser, a preparation method and a production line, which can be easily installed in automobiles and improve installation efficiency.

[0004] Firstly, this application provides a simple-to-install condenser, which adopts the following technical solution:

[0005] A simple-to-install condenser includes a core, a first liquid collecting pipe, a second liquid collecting pipe, and multiple support assemblies. The core includes two pressing members, multiple flat tubes, and multiple fins. The multiple flat tubes and multiple fins are located between the two pressing members. The multiple flat tubes are spaced apart, and one 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 multiple support assemblies are connected to the core. Each support assembly includes a connecting screw for fitting into mounting holes in an automobile. The connecting screw has multiple screws with different axes to adapt to mounting holes with different axes.

[0006] By adopting the above technical solution, the connecting screw is connected to the mounting hole in the car, which simplifies the installation. Moreover, the connecting screw has multiple screws with different axes, which can be adapted to mounting holes with different axes, eliminating the need for individual customization according to different mounting holes and enabling mass production.

[0007] Preferably, the bracket assembly includes a connector that is detachably connected to the core, and the sleeve screw includes a first screw and a second screw. The first screw is connected to the connector, the second screw is perpendicular to the first screw, and the first screw or the second screw is connected to an axially parallel mounting hole.

[0008] Preferably, the connecting screw further includes a sleeve, which is threadedly connected to the first screw, and the second screw is connected to the sleeve. The sleeve is used to adjust the angle of the second screw to fit mounting holes of different angles.

[0009] By adopting the above technical solution, the connecting screw can be connected to mounting holes of different directions and angles, thus improving ease of use.

[0010] Preferably, the bracket assembly further includes an adjustment part, which is used to adjust the position of the bracket assembly relative to the core according to the position of the mounting hole in the vehicle, so that the sleeve screw corresponds to the position of the mounting hole.

[0011] Preferably, the pressing element includes a strip groove, the opening of which is away from the core; the adjusting part includes a third screw and a movable block, the third screw and the movable block are rotatably connected, when the movable block is rotated to a first position, it can enter the strip groove through the opening, when the movable block is rotated to a second position, the support assembly and the pressing element can be connected and fixed by a nut and the third screw.

[0012] By adopting the above technical solution, the position of the bracket assembly can be adjusted to correspond to the mounting holes in different positions.

[0013] Preferably, it further includes an inlet hydraulic plate and an outlet hydraulic plate, wherein the inlet hydraulic plate is connected to the first liquid collection pipe and the outlet hydraulic plate is connected to the second liquid collection pipe; the inlet hydraulic plate includes an inlet port and an inlet channel, the inlet port is connected to a refrigerant transport pipe, and the inlet channel is connected to both the inlet port and the first liquid collection pipe; the outlet hydraulic plate includes an outlet port and an outlet channel, the outlet port is connected to a refrigerant transport pipe, and the outlet channel is connected to both the outlet port and the second liquid collection pipe.

[0014] Secondly, this application provides a method for preparing a condenser, used to prepare the simple-installation condenser described in any of the above claims, the steps of which include:

[0015] The process involves manufacturing components for the condenser, including but not limited to edge-pressing parts, flat tubes, fins, a first liquid collecting pipe, a second liquid collecting pipe, an inlet hydraulic plate, and an outlet hydraulic plate; assembling the edge-pressing parts, flat tubes, and fins into a core, and connecting them to the first and second liquid collecting pipes respectively to form the condenser body; binding and fixing the condenser body; welding other components besides the condenser body, including but not limited to the inlet hydraulic plate, outlet hydraulic plate, and partitions; brazing the condenser; performing an airtightness test on the brazed condenser; and installing corresponding supports on condensers that pass the airtightness test.

[0016] The condenser was successfully manufactured using the aforementioned technical solution.

[0017] Preferably, the step of brazing the condenser includes: attaching the condenser to the flux spraying device; starting the delivery pump to spray flux onto the condenser; after the set spraying time is reached, turning off the delivery pump, starting the drive motor, and conveying the condenser to the welding furnace for brazing; after the set welding time is reached, turning off the welding furnace, starting the drive motor, and conveying the condenser to the cooling device; and turning on the air cooler to dissipate heat and cool the condenser through the air knife.

[0018] The condenser was brazed using the above technical solution.

[0019] Thirdly, this application provides a condenser production line for producing the easy-to-install condenser described in any of the above claims, comprising: processing equipment for processing various parts for manufacturing the condenser; assembly equipment for assembling the condenser core and liquid collection pipe to form the 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 condenser's sealing performance.

[0020] Preferably, the brazing equipment includes a flux spraying device, a welding furnace, and a cooling device; the flux spraying device includes a flux tank, a delivery pump, and a nozzle, the delivery pump being connected to the flux tank and the nozzle respectively to deliver the flux in the flux tank to the nozzle, the nozzle being used to spray flux onto the condenser; the welding furnace being used to weld the condenser after flux spraying; the cooling device includes a cold air blower and an air knife, the cold air blower being used to generate cooling gas and deliver it to the air knife, the air knife being used to blow cold air onto the welded condenser for heat dissipation and cooling.

[0021] By adopting the above technical solutions, rapid flux spraying and rapid cooling of the condenser can be achieved, thereby improving the efficiency of brazing and the overall production efficiency of the condenser.

[0022] The condenser, preparation method, and production line provided in this application can be connected to mounting holes in different locations, making installation simple and quick, and facilitating condenser disassembly and maintenance. Attached Figure Description

[0023] Figure 1 This is a front view schematic diagram of a condenser provided in an embodiment of this application.

[0024] Figure 2 This is a top view schematic diagram of a condenser provided in an embodiment of this application.

[0025] Figure 3 This is a front view schematic diagram of the bracket assembly provided in the embodiment of this application.

[0026] Figure 4 This is a top view of the support assembly provided in an embodiment of this application.

[0027] Figure 5 This is a schematic diagram of the adjustment section provided in an embodiment of this application.

[0028] Figure 6 This is a schematic diagram of the adjustment part in the first position provided in an embodiment of this application.

[0029] Figure 7 This is a schematic diagram of the adjustment part in the second position provided in an embodiment of this application.

[0030] Figure 8 This is a schematic diagram of the hydraulic inlet plate provided in an embodiment of this application.

[0031] Figure 9 This is a cross-sectional schematic diagram of the hydraulic inlet plate provided in an embodiment of this application.

[0032] Figure 10 This is a schematic flowchart of the condenser preparation method provided in the embodiments of this application.

[0033] Figure 11 and Figure 12 This is a partial schematic diagram of the assembly equipment provided in the embodiments of this application.

[0034] Figure 13 This is a schematic diagram of the flux spraying device provided in the embodiments of this application.

[0035] Figure 14 This is a schematic diagram of the brazing equipment provided in the embodiments of this application.

[0036] Explanation of reference numerals in the attached drawings: 100, condenser; 110, core; 111, flat tube; 112, fin; 113, edge clamping component; 1131, first side plate; 1132, second side plate; 1133, positioning block; 1134, flange; 1135, strip groove; 121, first liquid collecting pipe; 122, second liquid collecting pipe; 123, partition plate; 130, support assembly; 131, connector; 1311, flat plate; 1312, First side plate; 1313, Second side plate; 1314, First connecting hole; 1315, Observation window; 1316, Second connecting hole; 132, Sleeve screw; 1321, First screw; 1322, Sleeve; 1323, Second screw; 133, Adjustment part; 1331, Third screw; 1332, Movable block; 1333, Fixed shaft; 141, Hydraulic inlet plate; 1411, First pressure plate; 1412 Second pressure plate; 1413 Liquid inlet; 1414 Liquid inlet channel; 142 Hydraulic outlet plate; 210 Flat tube moving fixture; 211 Support plate; 212 Sliding bar; 213 Sliding groove; 214 Rack; 220 Flat tube arranging fixture; 221 Mounting groove; 222 Mounting component; 223 Slide rail; 240 First extrusion mechanism; 241 Extrusion platform; 242 First extrusion plate ; 243, Positioning plate; 250, Flat tube positioning mechanism; 251, Positioning groove; 300, Brazing equipment; 310, Flux spraying device; 311, Flux tank; 312, Spraying rack; 313, Conveying pump; 314, Nozzle; 315, Drive sprocket; 316, Drive motor; 317, Chain; 320, Welding furnace; 330, Cooling device; 331, Air-cooled rack; 332, Air cooler; 333, Air knife. Detailed Implementation

[0037] 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.

[0038] 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.

[0039] 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.

[0040] 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.

[0041] This application discloses a simple-to-install condenser.

[0042] Please refer to Figure 1 and Figure 2The easy-to-install condenser 100 includes a core 110, a first liquid collecting pipe 121, a second liquid collecting pipe 122, and multiple support assemblies. 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 two upper and lower pressing members 113. Multiple flat tubes 111 and multiple fins 112 are arranged between the upper and lower pressing members 113. The multiple 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 pressing members 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 sprayed onto 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 connected to an inlet hydraulic plate 141, and the second liquid collecting pipe is connected to an outlet hydraulic plate 142. The inlet and outlet hydraulic plates 141 and 142 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 can be sealed with plugs.

[0043] The bracket assembly 130 is used to connect with mounting holes provided in the vehicle to fix the condenser 100 inside the vehicle. The bracket assembly 130 includes a sleeve screw 132, which is used to connect with the mounting holes in the vehicle. The sleeve screw 132 has multiple axes and can be adapted to mounting holes with different axes to connect with mounting holes in different directions. Since the interior space of different vehicles is different, the orientation of the mounting holes is also different. These differences in position make the installation of the condenser 100 extremely inconvenient, requiring adjustments for different positions and orientations or customization of different mounting brackets according to different positions. Therefore, this embodiment of the application provides a sleeve screw 132 with multiple axes, so that the sleeve screw 132 can be flexibly adapted to different mounting holes. The sleeve screw can be mass-produced, reducing costs.

[0044] This embodiment of the application takes four bracket assemblies 130 as an example. The four bracket assemblies 130 are located at the left and right ends and the top and bottom ends of the core 110, and the four bracket assemblies 130 are arranged symmetrically in pairs. During installation, the connecting screws 132 of the two upper bracket assemblies 130 can be inserted into the corresponding mounting holes first, and then the connecting screws 132 of the two lower bracket assemblies 130 can be inserted into the corresponding mounting holes. The screws 132 can be locked with nuts respectively to complete the installation, achieving simple installation.

[0045] Please refer to Figure 2 The pressing element 113 includes two parallel first side plates 1131 and a second side plate 1132 perpendicular to the first side plates 1131. The second side plate 1132 is connected to the uppermost or lowermost fin 112 or flat tube 111. One side of the two first side plates 1131 is connected to the second side plate 1132, and the other side extends away from the core 110. The support assembly 130 includes a connector 131 and a sleeve screw 132. The connector 131 includes a flat plate 1311 and two opposing first side plates 1312. The two first side plates 1312 are perpendicular to the flat plate 1311. The connector 131 is fastened to the pressing element 113 through the two first side plates 1312, so that the two first side plates 1131 are located between the two first side plates 1312. The two first side plates 1312 are provided with first connecting holes 1314. The plate 131 has a corresponding through hole. The bolt passes through the first connecting hole 1314 and the through hole of the pressing member 113 to connect and fix the bracket assembly 130 to the pressing member 113. In order to facilitate observation of whether the bolt is smoothly inserted into the first connecting hole 1314 and the through hole on the other side, the plate 1311 also has an observation window 1315. The observation window 1315 is located above the first connecting hole 1314 so as to observe the position of the first connecting hole 1314 and the corresponding through hole, so that the bolt can be smoothly inserted. When the bracket assembly 130 is fastened to the edge clamping member 113, the two first side plates 1131 of the edge clamping member 113 are easily squeezed and deformed. Therefore, in this embodiment, a second side plate 1313 is provided at one end of the flat plate 1311. The second side plate 1313 is perpendicular to the flat plate 1311 and perpendicular to the first side plate 1312. The second side plate 1313 and the first side plate 1312 are located on the same side of the flat plate 1311. When the connector 131 is connected to the edge clamping member 113, the second side plate 1313 is located between the two first side plates 1131 to provide support and prevent the two first side plates 1131 from deforming. In this embodiment, the second side plate 1313 is formed by bending one end of the flat plate 1311, which also improves the strength of the flat plate 1311.

[0046] In this embodiment, after the connector 131 and the pressing member 113 are connected, they need to be fixed by bolts through the first connecting hole 1314 and the through hole. However, during connection, it cannot be guaranteed that the positions of the first connecting hole 1314 and the through hole are completely aligned, and usually, the position needs to be moved for adjustment, which affects the overall installation efficiency. Therefore, in this embodiment, according to the appropriate distance between the first connecting hole 1314 and the through hole, a positioning block 1133 is provided on the pressing member 113. The positioning block 1133 is located between the two first side plates 1131. When the connector 131 is fastened, it is first positioned by contacting the positioning block 1133 through the second side plate 1313 before being fastened, so that the positions of the first connecting hole 1314 and the through hole are directly aligned without adjustment, thus improving the overall installation efficiency.

[0047] Please refer to Figure 3 The connecting screw 132 includes a first screw 1321, a sleeve 1322, and a second screw 1323. The first screw 1321 is connected to the flat plate 1311 and extends away from the core 110. The first screw 1321 is close to the liquid collecting pipe. The sleeve 1322 is provided with an internal thread that matches the first screw 1321 and is detachably connected to the first screw 1321 through the internal thread. One end of the sleeve 1322 is connected to the second screw 1323. The second screw 1323 and the sleeve 1322 are T-shaped. After the sleeve 1322 is connected to the first screw 1321, the second screw 1323 is perpendicular to the first screw 1321.

[0048] In this embodiment, when installing the condenser 100, the first screw 1321 or the second screw 1323 can be selected to be sleeved with the mounting hole according to the direction of the mounting hole, and then locked in place with a nut. When the axis of the mounting hole is parallel to the axis of the first screw 1321, the first screw 1321 is selected to be sleeved with the mounting hole, and the sleeve 1322 and the second screw 1323 can be removed. When the axis of the mounting hole is parallel to the second screw 1323, the sleeve 1322 can be connected to the first screw 1321, and then the second screw 1323 is sleeved with the mounting hole, finally fixed with a nut. Alternatively, the second screw 1323 can be rotated 360° by adjusting the depth of the connection between the sleeve 1322 and the first screw 1321, allowing it to adapt to mounting holes of different angles.

[0049] In some other embodiments, the connecting screw 132 includes only a first screw 1321 and a second screw 1323. The first screw 1321 and the second screw 1323 are fixedly connected and are in a cross shape. During installation, the screw parallel to the mounting hole is rotated to form a connecting sleeve according to the axis of the mounting hole.

[0050] In other embodiments, the connecting screw 132 may include three screws, wherein the first screw is vertically arranged, the second screw is fixedly connected to the first screw in a cross shape, and the third screw is fixedly connected to the second screw in a T shape.

[0051] Since the mounting holes for connecting the condenser 100 are pre-set inside the vehicle, after the condenser body is connected to the bracket assembly 130, it is then placed inside the vehicle and fitted into the mounting holes. However, operational errors may occur during the setting of the mounting holes, resulting in deviations in the distance between the two mounting holes, affecting the installation of the condenser 100. In this case, the position of the bracket assembly 130 needs to be readjusted. The adjustment process includes removing bolts, removing the bracket assembly 130, re-drilling or enlarging the first connecting hole 1314, reinstalling the bracket assembly 130, and retightening the bolts. The entire adjustment process is cumbersome and cannot achieve simple installation. Therefore, the bracket assembly 130 provided in this embodiment also includes an adjustment part 133, such as... Figures 5 to 7 As shown, the adjusting part 133 includes a third screw 1331 and a movable block 1332. The third screw 1331 and the movable block 1332 are rotatably connected. Specifically, one end of the third screw 1331 has a movable hole, and one surface of the movable block 1332 is provided with a fixed shaft 1333. The fixed shaft 1333 is located inside the movable hole, and the diameter of the movable hole is larger than the diameter of the fixed shaft 1333, so that the movable block 1332 can be flipped relative to the third screw 1331. The other side of the two first side plates 1131 of the pressing member 113 has a flange 1134 protruding towards the center of the pressing member 113. A strip groove 1135 is formed inside the pressing member 113, and a slot is formed between the two flanges 1134. The distance between the two flanges 1134 is greater than the sum of the thicknesses of the movable block 1332 and the screw. When the bracket assembly 130 is connected to the core 110, the movable block 1332 is flipped to the first position. In the first position, the movable block 1332 is parallel to the third screw 1331. The movable block 1332 is placed into the strip groove 1135 through the slot. Then the movable block 1332 flips to the second position. In the second position, the movable block 1332 is perpendicular to the third screw 1331. The plate 1311 has a second connecting hole 1316. The connector 131 passes through the second connecting hole 1316 and the third screw 1331 and is fastened to the pressing edge 113. Then it is connected to the third screw 1331 through the nut, so that the movable block 1332 and the plate 1311 press the two flanges 1134 tightly to fix the bracket assembly 130. There is no need to use the first connecting hole 1314 and the through hole. When installing the condenser 100 onto the vehicle, if the position of the first screw 1321 or the second screw 1323 does not correspond to the mounting hole, first loosen the nut on the third screw 1331. This increases the distance between the movable block 1332 and the plate 1311, allowing the bracket assembly 130 to move along the slot 1135 until it corresponds to the mounting hole. Then, fit the first screw 1321 or the second screw 1323 into the mounting hole. After fitting, tighten the nut on the third screw 1331 to fix the position of the bracket assembly 130. Finally, lock the nut to the first screw 1321 or the second screw 1323 to secure the condenser 100. Thus, the distance between the two bracket assemblies 130 on the same side can be adjusted via the adjustment part 133 to accommodate different mounting hole positions.

[0052] In other embodiments, the adjusting part may be a nut pre-embedded in a strip groove, the pre-embedded nut sliding freely in the strip groove, and the bolt passing through the second connecting hole to connect with the pre-embedded nut during connection.

[0053] In this embodiment, the bracket assembly 130 can be connected to mounting holes in different directions via the connecting screw 132, and can be connected to mounting holes in different positions via the adjusting part 133 of the bracket assembly 130. This enables simple and quick installation of the condenser 100 on different vehicles, and also facilitates subsequent disassembly and maintenance of the condenser 100, greatly improving installation efficiency.

[0054] Please refer to Figure 8 and Figure 9 This is a schematic diagram of the hydraulic inlet plate provided in an embodiment of this application. The hydraulic inlet plate 141 includes a first pressure plate 1411 and a second pressure plate 1412, which are perpendicular to each other. The first pressure plate 1411 and the second pressure plate 1412 are pressed onto the circumferential surface of the first liquid collecting pipe 121. The second pressure plate 1412 includes an arc-shaped portion that is fitted and welded to the circumferential surface of the first liquid collecting pipe 121. The first pressure plate 1411 has a liquid inlet 1413 for connecting to an external cold medium conveying pipeline. The second pressure plate 1412 has a liquid inlet channel 1414 that communicates with both the liquid inlet 1413 and the interior of the first liquid collecting pipe 121. The hydraulic inlet plate 141 is integrally formed. The hydraulic outlet plate 142 has the same structural dimensions as the hydraulic inlet plate 141, and the liquid outlet of the hydraulic outlet plate 142 communicates with the interior of the second liquid collecting pipe 122 through the liquid outlet channel.

[0055] On the other hand, please refer to Figure 10 This application provides a method for preparing a condenser, the steps of which include:

[0056] S101: Manufacturing components for condensers, including but not limited to edge-pressed parts, flat tubes, fins, first liquid collecting pipe, second liquid collecting pipe, inlet hydraulic plate, and outlet hydraulic plate.

[0057] 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, inlet hydraulic plate 141, outlet hydraulic plate 142, baffle plate 123, plug and support assembly 130, etc. In this embodiment, each component can be 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 slots cut on the other side for welding baffle plate 123.

[0058] S102: Assemble the pressing parts, flat tubes and fins into a core, and connect it to the first liquid collecting pipe and the second liquid collecting pipe respectively to form the main body of the condenser.

[0059] The condenser core 110 includes flat tubes 111, fins 112, and pressing elements 113. During assembly, multiple flat tubes 111 are arranged horizontally at intervals using an arrangement tool. Then, fins 112 are placed in the gap between two flat tubes 111. The pressing elements 113 are then 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 pressing elements 113, flat tubes 111, and fins 112 close together, eliminating gaps. Finally, the top surfaces of each flat tube 111 and fin 112 are pressed down to make the top surfaces flush.

[0060] 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.

[0061] S103: Bind and fix the condenser body.

[0062] 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 pressing part 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.

[0063] S104: Weld other components besides the condenser body, including but not limited to the inlet hydraulic plate, outlet hydraulic plate, and partition.

[0064] The inlet hydraulic plate 141, outlet hydraulic plate 142, partition plate 123, and 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.

[0065] S105: Brazing the condenser.

[0066] Before brazing, the assembled condenser can be pre-treated, 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 welding. Specifically, before pre-treatment, the condenser can be leveled and trimmed. Leveling can involve patting each surface flat to make it smooth, and trimming involves removing burrs and protrusions. This leveling and trimming process facilitates even and comprehensive flux application.

[0067] Specifically, the steps for brazing the condenser include:

[0068] S1051: Connect the condenser to the flux spraying device;

[0069] S1052: Start the transfer pump to spray flux onto the condenser;

[0070] S1053: After the set spraying time is reached, turn off the delivery pump, start the drive motor, and deliver the condenser to the welding furnace for brazing.

[0071] S1054: After the set welding time is reached, the welding furnace is turned off, the drive motor is started, and the condenser is transported to the cooling device;

[0072] S1055: Turn on the air cooler to dissipate heat and cool the condenser through the air blades.

[0073] The brazing process in the furnace can be divided into two stages. In the first stage, the furnace temperature is 200~400℃, which is used to remove moisture from the flux. In the second stage, the furnace temperature is above 550℃, which is used to melt the flux so that the flat tube 111 is welded to the liquid collecting tube, the fin 112 is welded to the flat tube 111, and the pressing part 113 is welded to the flat tube 111 or the fin 112.

[0074] S106: Perform an airtightness test on the brazed condenser.

[0075] 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:

[0076] S1061: Inject nitrogen into the condenser, maintain pressure for a certain period of time, and then check for leakage in the first area.

[0077] Seal the liquid outlet and other outlets. First, inject nitrogen into the condenser through the liquid inlet, 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.

[0078] S1062: Inject helium into the condenser, maintain pressure for a second time, and then detect leakage in the second area using the pressure difference.

[0079] Seal the outlet and other outlets. Inject helium through the inlet and then seal the inlet again. Place the chamber in a helium leak detection vacuum chamber and maintain pressure for a second time. Analyze the pressure fluctuations on the pressure gauge or the pressure difference detected by the pressure sensor 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, a pressure drop greater than 5%, a leak is considered to exist, requiring re-welding. After re-welding, helium is injected again for testing until the pressure drop is within the set range. Helium leak detection offers high sensitivity and can accurately locate the leak point, facilitating rapid re-welding.

[0080] 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.

[0081] S1063: Inject nitrogen into the condenser and let it stand for at least three hours. Detect any leaks by checking the pressure difference.

[0082] When injecting nitrogen, first seal the inlet and outlet with rubber plugs. Then, insert a charging needle through the rubber plug at either the inlet or outlet and press the start switch to begin nitrogen charging. After charging, remove the pillow and allow it to stand for a third time. If the pressure drop is within the set range, the condenser is considered a qualified product and can be packaged and stored. If the pressure drop exceeds the set range, the condenser is considered unqualified and must be 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.

[0083] 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.

[0084] In other implementations, the location of the leak can be detected using a nitrogen mass spectrometer.

[0085] S107: Condenser mounting bracket assembly with qualified airtightness.

[0086] The four support components were then installed with the condenser to complete the preparation process.

[0087] This application embodiment also provides a condenser manufacturing production line, including processing equipment, assembly equipment, binding equipment, welding equipment, brazing equipment 300, and airtightness testing equipment. 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, such as 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, such as 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, such as stamping the liquid collecting tube to process grooves. The fin forming machine is used to form aluminum materials into wavy or other shaped fins 112.

[0088] The assembly equipment includes a flat tube moving fixture 210 and a flat tube arranging fixture 220 for assembling the core 110. The flat tube moving fixture 210 and the flat tube arranging fixture 220 are slidably connected. The flat tube arranging fixture 210 includes two symmetrically arranged mounting parts 222 and a sealing plate (not shown in the figure). The sealing plate is connected to one end of the two mounting parts, making the two mounting parts connected as one unit. Each mounting part 222 is provided with multiple mounting slots 221 at intervals. Every two symmetrical mounting slots 221 are used to place one flat tube 111. The bottom of the mounting slot 221 is open. The mounting part 222 is provided with a slide rail 223 of equal length along its length. The slide rail 223 is located below the mounting slot 221 and does not protrude from the mounting slot 221. The flat tube moving fixture includes a support plate 210. The support plate 210 is provided with two sliding bars 212 of equal length along its length. The sliding bars 212 are provided with sliding grooves 213. The two sliding grooves 213 are located at the bottom of the support plate 210 and are symmetrically arranged. The dimensions of the sliding groove 213 are adapted to the dimensions of the slide rail 223. The flat tube moving fixture 210 and the flat tube arranging fixture 220 are slidably connected through the sliding groove 213 and the slide rail 223. After connection, the support plate 210 is located at the bottom of the mounting groove 221 and closes the bottom of the mounting groove 221 to support the flat tube 111 in the mounting groove 221 so that it will not fall off the bottom of the mounting groove 221. When the support plate 210 slides away, the bottom of the mounting groove 221 is opened and the flat tube 111 in the mounting groove 221 will fall off the bottom of the groove. In the arrangement state, the support plate 210 slides to contact the sealing plate and is limited by the sealing plate. At this time, the bottom of all the mounting slots 221 are closed. After the flat tubes 111 are processed, the workers can directly place them into the mounting slots 221 one by one for arrangement. After the arrangement is completed, the flat tube moving fixture 210 and the flat tube arranging fixture 220 move together to the flat tube positioning mechanism 250. Then, the support plate 210 is moved to open the bottom of each mounting slot 221 one by one, and the flat tubes 111 fall one by one from the bottom of the slot to the flat tube positioning mechanism 250 for the next assembly fixture. Specifically, racks 214 are provided on both sides of the support plate 210 in the length direction. Both mounting parts 222 are connected to a rotary motor (not shown in the figure). The output shaft of the motor is connected to a gear (not shown in the figure), and the gear meshes with the rack 214. The two rotary motors are started synchronously by electrical control, and the rack 214 is moved by the gear to realize the sliding of the support plate 210.

[0089] The assembly equipment also includes a flat tube positioning mechanism 250, a liquid collecting 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 a first extrusion plate 242, with the positioning plate 243 and the first extrusion plate 242 located at opposite ends of the length of the extrusion platform 241. The second extrusion mechanism includes a second extrusion plate and is located above the extrusion platform 241. The flat tube positioning mechanism 250 is movably disposed on both sides of the length of the extrusion platform 241 and can be moved away from 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 the same as 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 collecting tube insertion mechanism is movably disposed on both sides of the length of the extrusion platform 241. After the flat tube 111 is installed in the flat tube arranging fixture 220, it is placed together with the flat tube moving fixture 210 on the flat tube positioning mechanism 250, so that the positions of the mounting groove 221 and the positioning groove 251 correspond one by one. Then, the support plate 210 is controlled to slide, so that the flat tubes 111 in the mounting groove 221 fall one by one onto the extrusion platform 241 and fall one by one into the corresponding positioning groove 251. After all the flat tubes 111 have fallen into the positioning groove 251, the flat tube arranging fixture 220 and the flat tube moving fixture 210 are removed. Before the flat tube 111 falls into the positioning groove 251, a pressing element 113 can be placed on the opposite side of the positioning plate 243 and the first 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 away from the extrusion platform 241. Under the drive of the driving mechanism, the first extrusion plate 242 presses the pressing element 113, the flat tube 111, and the fin 112 towards the positioning plate 243, so that the pressing element 113... 3. 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 and downwards, making the top surfaces of the flat tube 111 and fin 112 flat through the second extrusion plate, and fixing 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, the second extrusion mechanism is removed, and the assembly of the condenser body is completed.

[0090] 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.

[0091] The bundled condenser body is transferred to the welding area, where the inlet hydraulic plate 141, outlet hydraulic plate 142, and other necessary components are welded, thus completing 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 hydraulic plates and partition plates 123; the polishing machine is used to remove burrs, bumps, oil stains, etc.

[0092] The assembled condenser 100 is transferred to the brazing equipment 300 for brazing. The brazing equipment 300 includes a flux spraying device 310, a welding furnace 320, and a cooling device 330. The flux spraying device 310 includes a flux tank 311, a spraying frame 312, a delivery pump 313, and nozzles 314. The flux tank 311 contains flux. The delivery pump 313 is connected to the flux tank 311 and communicates with the inside of the flux tank 311 through a pipe. The nozzles 314 are connected to the spraying frame 312 and are connected to the delivery pump 313 through a pipe. Multiple drive motors 316 and multiple drive sprockets 315 are mounted on the spray frame 312. Each drive sprocket 315 is meshed with a chain 317. The condenser 100 is hooked to the chain 317 via a hook-up fixture. Multiple condensers 100 can be hooked on the spray frame 312, allowing for simultaneous application of flux to multiple condensers 100, thus improving efficiency. This application uses two drive motors and two drive sprockets, with four condensers hooked at a time for each application, as an example. When the condenser 100 needs brazing, the delivery pump 313 is started, and the nozzle 314 sprays flux onto the condenser 100. Once the set spraying time is reached, the delivery pump 313 is turned off, stopping the spraying. The spraying time can be set according to the required coating thickness. The nozzle 314 can be an atomizing nozzle to improve the uniformity of the spraying.

[0093] The existing method of applying flux to condensers involves placing the condenser flat on a platform and manually applying flux to each surface with a brush. After coating one surface, the condenser needs to be flipped over for coating the next. This process is inefficient and poses health and safety hazards to operators. Furthermore, uneven surfaces on the condenser can lead to uneven coating, and flipping the condenser can scratch the coated surface, easily removing the flux. Therefore, this embodiment uses a flux spraying device 310 to automatically complete the flux spraying process, eliminating the need for manual spraying, improving efficiency, and ensuring operator safety. The condenser 100 is mounted to avoid uneven spraying caused by uneven surfaces. Both surfaces are sprayed simultaneously, eliminating the need for flipping. The flux sprayed from the nozzle 314 falls back into the flux tank 311 for reuse, saving costs. To prevent the sprayed flux from splashing and polluting the environment, a protective cover can be installed outside the spraying frame 312.

[0094] The welding furnace 320 is equipped with a low-temperature zone and a high-temperature zone. The temperature in the low-temperature zone is between 200 and 400°C, used to remove moisture from the flux on the condenser 100. The temperature in the high-temperature zone is above 550°C, which melts the flux and completes the welding. The cooling device 330 includes an air-cooling frame 331, a cooler 332, and an air knife 333. The air knife 333 is connected to the air-cooling frame 331 and to the cooler 332 through a pipe. The cooler 332 generates cooling gas and delivers it to the air knife 333. The air knife 333 blows cool air onto the welded condenser 100 to dissipate heat and lower its temperature. Multiple driven sprockets (not shown in the figure) are also installed on the air-cooled frame 331. The multiple driven sprockets correspond one-to-one with multiple driving sprockets 315. The chain 317 passes through the inside of the welding furnace 320 and connects to the driven sprockets. After the flux spraying process of the condenser 100 is completed, the drive motor 316 is turned on to make the driving sprocket 315 rotate. The chain 317 drives the condenser 100 to move towards the welding furnace 320 and enter the welding furnace 320 for the welding process. After the set welding time is reached, the drive motor 316 is turned on again to make the condenser 100 move towards the cooling device 330 for rapid heat dissipation and cooling.

[0095] The chain in this embodiment is made of high-temperature resistant stainless steel or alloy material to ensure normal rotation in the welding furnace. By using a motor-driven sprocket, the condenser can be moved through each process in the brazing equipment. The structure is simple, the control is convenient, and the brazing efficiency is improved.

[0096] 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. The helium leak detection system includes a helium leak detection vacuum chamber, used to place the condenser inside for pressure testing to prevent helium leakage into the environment. The helium leak detection 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, quick connectors, and an inflation needle. The quick connector connects to the transition connector used during condenser testing for the first large-area leak detection. The inflation needle pierces the rubber plug at the inlet or outlet for the third detection. The nitrogen leak detection system also includes indicator lights, with different colors representing the pass / fail status of the large-area leak detection. Generally, testing personnel can visually obtain the test results. Only condensers that pass the large-area leak detection can proceed to the next step of the helium leak detection process to avoid helium leakage and waste.

[0097] 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.

[0098] 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 of the type which is simple to install, characterized in that The application relates to a heat exchange core for a vehicle air conditioner, which comprises a core body, a first collecting pipe, a second collecting pipe and a plurality of support assemblies; the core body comprises two pressing edges, a plurality of flat tubes and a plurality of fins, the plurality of flat tubes and the plurality of fins are arranged between the two pressing edges, 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 plurality of support assemblies are connected with the core body, the support assembly comprises a sleeving screw rod, the sleeving screw rod is used for sleeving connection with a mounting hole in the vehicle, and the sleeving screw rod has a plurality of different axial screw rods to adapt to mounting holes with different axial directions; the support assembly further comprises an adjusting part and a connecting piece; the adjusting part is used for adjusting the position of the support assembly relative to the core body according to the position of the mounting hole in the vehicle, so that the sleeving screw rod is corresponded with the position of the mounting hole; the pressing edge comprises a strip-shaped groove, and the groove opening of the strip-shaped groove is away from the core body; the adjusting part comprises a third screw rod and a movable block, the third screw rod is rotatably connected with the movable block, the movable block enters the strip-shaped groove through the groove opening when the movable block is rotated to a first position, and the support assembly is connected and fixed with the pressing edge through a nut and the third screw rod when the movable block is rotated to a second position; the pressing edge comprises two parallel first edge plates, the two first edge plates are provided with turned edges which are protruded towards the center of the pressing edge, the strip-shaped groove is formed in the pressing edge, the groove opening is formed between the two turned edges, and the distance between the two turned edges is greater than the sum of the thickness of the movable block and the third screw rod; the movable block is parallel to the third screw rod in the first position, and the movable block is perpendicular to the third screw rod in the second position; the connecting piece comprises a flat plate, the flat plate is provided with a second connecting hole, the connecting piece is buckled on the pressing edge after passing through the third screw rod through the second connecting hole, and the connecting piece is connected with the third screw rod through a nut, so that the movable block and the flat plate tightly press the two turned edges. The connecting piece is detachably connected with the core body, the sleeving screw rod comprises a first screw rod and a second screw rod, the first screw rod is connected with the connecting piece, and the second screw rod is perpendicular to the first screw rod. The sleeving screw rod further comprises a sleeve, the sleeve is threadedly connected with the first screw rod, the second screw rod is connected with the sleeve, and the sleeve is used for adjusting the angle of the second screw rod to adapt to mounting holes with different angles. The application further relates to an inlet liquid pressing plate and an outlet liquid pressing plate, the inlet liquid pressing plate is connected with the first collecting pipe, the outlet liquid pressing plate is connected with the second collecting pipe, the inlet liquid pressing plate comprises an inlet liquid port and an inlet liquid channel, the inlet liquid port is connected with a refrigerant medium conveying pipeline, and the inlet liquid channel is communicated with the inlet liquid port and the first collecting pipe respectively; the outlet liquid pressing plate comprises an outlet liquid port and an outlet liquid channel, the outlet liquid port is connected with the refrigerant medium conveying pipeline, and the outlet liquid channel is communicated with the outlet liquid port and the second collecting pipe respectively. ​ ​ 2. The simple installation type condenser according to claim 1, wherein ​ 3. The simple installation type condenser according to claim 2, wherein ​ 4. The simple installation type condenser according to claim 1, wherein ​ 5. A method of manufacturing a condenser for manufacturing the condenser of claim 4, the steps of which include: The parts of the condenser are made, including the edge pressing part, flat tube, fin, first collecting tube, second collecting tube, liquid inlet pressing plate and liquid outlet pressing plate; the edge pressing part, flat tube and fin are spliced into a core body and connected with the first collecting tube and the second collecting tube to form a condenser main body; the condenser main body is bound and fixed; other parts, including the liquid inlet pressing plate and the liquid outlet pressing plate, are welded outside the condenser main body. The condenser is brazed; the brazed condenser is subjected to air tightness detection; and the condenser with qualified air tightness is installed with a plurality of support assemblies.

6. The method of claim 5, wherein the condenser is prepared by The brazing of the condenser includes: hanging the condenser on a flux spraying device; starting a conveying pump to spray flux on the condenser; after reaching a set spraying time, the conveying pump is turned off, a driving motor is started, and the condenser is conveyed to a welding furnace for brazing; after reaching a set welding time, the welding furnace is turned off, the driving motor is started, and the condenser is conveyed to a cooling device; a cooling fan is turned on to cool the condenser by air knives.

7. A production line for the production of the condenser of claim 4, comprising: Processing equipment for processing various parts of the condenser; Assembly equipment for splicing the core body and the collecting tube to form the condenser main body; binding equipment for binding the condenser main body; welding equipment for welding other parts, including the liquid inlet pressing plate and the liquid outlet pressing plate, outside the condenser main body; brazing equipment for brazing the condenser; air tightness detection equipment for detecting the air tightness of the condenser.

8. The line for the production of condensers according to claim 7, characterized in that, The brazing equipment includes a flux spraying device, a welding furnace and a cooling device; the flux spraying device includes a flux tank, a conveying pump and a nozzle, the conveying pump is connected with the flux tank and the nozzle to convey the flux in the flux tank to the nozzle, the nozzle is used for spraying flux on the condenser; the welding furnace is used for welding the condenser after spraying flux; the cooling device includes a cooling fan and air knives, the cooling fan is used for generating cooling gas and conveying it to the air knives, and the air knives are used for blowing cold air on the welded condenser to cool it.

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