Radiator production line for transformer

Abstract

The production line is sequentially provided with an uncoiling station, a feeding station, a forming station, a welding station, an automatic sheet discharging and stacking station, a radiator assembling and welding station and a control system, a plate is rolled at the forming station to form an oil duct groove, the production line is suitable for different radiating single sheets, and mixed production scheduling is facilitated; a lifting and rotating device is arranged between a forming station and a welding station, and the lifting and rotating device lifts and rotates the cooling fins with the precision deviation by 180 degrees to compensate the deviation. The method has the advantages that uncoiling, feeding, forming, welding, automatic unloading and stacking and assembling and welding are integrated, full-process production from raw materials to radiators is achieved, the workload is reduced, and efficiency and quality are improved; the cooling fins are produced through combination of rolling and stamping, limitation of a die on the length of the cooling fins is avoided, mixed production scheduling can be achieved without die replacement, and the production flexibility is enhanced; the lifting rotation structure is used for rotating the heat dissipation single pieces with size deviation and then combining the pieces, deviation compensation is achieved, the rejection rate is reduced, and the production cost is reduced.

Description

Technical Field

[0001] This invention relates to a production line, specifically to a production line for transformer radiators. Background Technology

[0002] Transformers typically generate heat during operation, and excessive heat accumulation can be dangerous. Therefore, it is necessary to cool down transformers in a timely manner to ensure their smooth operation. Currently, the most mature method for cooling transformers is to install a plate-type heat sink on their casing for heat dissipation.

[0003] With the rapid development of the power industry, the requirements for transformer performance are increasing. Not only are higher capacity and efficiency required, but also more stringent standards are set for their heat dissipation performance. This requires transformer radiators to have more efficient heat dissipation capabilities and more reliable quality to meet the heat dissipation needs of transformers of different specifications in different application scenarios.

[0004] The following problems currently exist in the transformer radiator production line: 1. Low production efficiency, large workload, and high labor costs: The radiator production process includes multiple steps such as single-piece molding, sheet assembly, welding into heat sinks, and assembly and welding into radiators. These steps require manual intervention and material handling. In addition, after the heat sinks are produced, they still need to be manually assembled and welded into radiators, resulting in low production efficiency and long production cycles. Moreover, due to the low level of automation, quality control in the production process mainly relies on manual inspection, which is highly dependent on manpower, has low work efficiency, and is labor-intensive. It is also easy to have problems such as missed inspections and false inspections, which affect the consistency and stability of product quality. 2. Poor production line flexibility: The traditional processing method of transformer heat sinks is to use a hydraulic press to press and form them with molds. Most existing heat sink production lines are designed for specific specifications of heat sinks. The equipment configuration and process parameters on the production line are fixed, making it difficult to adapt to the production needs of heat sinks of different specifications. When it is necessary to produce heat sinks of different specifications, it is often necessary to carry out large-scale modification and adjustment of the production line. This not only increases production costs and production preparation time, but also reduces the utilization rate of the production line. In addition, during the production process, due to the diversity of orders, it is often necessary to mix and schedule the production of heat sinks of different specifications. However, due to the lack of a flexible production adjustment mechanism, the existing production line is difficult to achieve the mixed production of heat sinks of different specifications, resulting in low production efficiency. 3. Poor utilization rate of good products with dimensional deviations: During the production of heat sinks, due to differences in raw materials, fluctuations in processing technology, and other factors, some deviations in the size of the heat sinks are inevitable. These deviations may cause the heat sinks to fail to align accurately during assembly, affecting the overall quality and heat dissipation performance of the heat sink. Most existing production lines lack effective deviation detection and compensation mechanisms before assembly, and heat sinks with deviations can only be treated as scrap, resulting in waste of raw materials and increased production costs.

[0005] In view of the above-mentioned problems existing in the radiator production line, it is of great significance to develop a production line that can produce transformer radiators efficiently and with high quality, while reducing workload and production costs. Summary of the Invention

[0006] The technical problem to be solved by the present invention is that the existing heat sink production lines mentioned in the background art have low automation, low production efficiency and unstable quality, high labor costs, and the existing production lines cannot perform mixed production scheduling and have poor utilization of good products with dimensional deviations.

[0007] To address the aforementioned technical problems, a transformer radiator production line is proposed, achieved through the following technical solution: A transformer radiator production line, comprising an uncoiling station, a feeding station, a forming station, a welding station, an automatic unloading and stacking station, a radiator assembly and welding station, and a control system arranged sequentially. The uncoiling station includes a feeding trolley and an uncoiling device. The feeding trolley, used for storing and feeding raw material coils, is connected to the uncoiling device. An uncoiler spindle is installed on the uncoiling device. The feeding trolley transports the coils it stores and installs them onto the uncoiler spindle. The uncoiler spindle can be controlled to rotate and gradually release the coils. The feeding station is connected to the forming station. The feeding station guides the sheet material released from the coils into the forming station for forming, and cleans the sheet material during the guiding process. The forming station rolls the sheet material to form oil channel grooves and punches the two ends of the sheet material to form guide grooves, thus forming a heat dissipation fin. This system is suitable for producing heat sink fins of different lengths and for mixed production scheduling. The forming station and the welding station are connected by a transition conveyor roller conveyor. The transition conveyor roller conveyor transports the formed heat sink fins to the assembly station and then transports the assembled heat sink fins to the welding station for welding into heat sink fins. A lifting and rotating device is installed in the transition conveyor roller conveyor between the forming station and the welding station. Before assembly, the lifting and rotating device can controllably lift heat sink fins with precision deviations and rotate them horizontally by 180° to compensate for the deviations. An automatic unloading and stacking station is located at the end of the welding station. The automatic unloading and stacking station includes a robotic arm and a transfer trolley. The robotic arm automatically picks up the formed heat sink fins and stacks them on the transfer trolley. The transfer trolley transports the stacked heat sink fins to the radiator assembly and welding station for assembly and welding to form the radiator body. A control system is installed in the production line to control the overall operation of the production line.

[0008] In a preferred embodiment of the technical solution of the present invention, the forming station includes a roll forming device and an end forming device. The roll forming device includes a roll forming roller, which rolls and forms the oil groove in the middle of the heat dissipation fin. The end forming device includes a stamping machine, which stamps the oil grooves at both ends of the heat dissipation fin. The roll forming device facilitates the production line to produce heat dissipation fins of different lengths as needed, realizes the production of heat dissipation fins of different specifications, achieves mixed production scheduling capability, and improves the flexibility of the production line.

[0009] In a preferred embodiment of the present invention, the rolling rollers include a first roller group and a second roller group. Each of the first roller group and the second roller group includes two rollers with shaped protrusions on their surfaces. After being rolled by the first roller group, the sheet material enters the second roller group for further rolling. The distance between the shaped protrusions on the rollers in the second roller group is greater than the distance between the shaped protrusions on the rollers in the first roller group. This arrangement allows the central part of the heat sink to be finally formed through two rolling processes, avoiding a large deformation in a single rolling process, which could lead to damage or cracking of the sheet and affect its service life.

[0010] In a preferred embodiment of the present invention, the lifting and rotating device includes a lifting frame, a lifting rod, a rotating table, and a detection structure. The lifting frame is located below the heat sink conveyed in the transition conveyor roller conveyor. The lifting frame is connected to the rotating table via the lifting rod. The rotating table is mounted on the transition conveyor roller conveyor. The detection structure is mounted on the transition conveyor roller conveyor. The detection structure detects the accuracy of the heat sink conveyed by the transition conveyor roller conveyor and controls the movement of the lifting rod and the rotating table. The lifting frame controls the heat sink with accuracy deviation to rotate horizontally by 180° to compensate for the deviation. The lifting and rotating device facilitates the rotation of the heat sink with dimensional deviations into good products before reassembling them, thereby compensating for the deviation, salvaging good products, and avoiding waste of raw materials and increased production costs.

[0011] In a preferred embodiment of the technical solution of the present invention, the welding station includes an end-deep TIG welding device, a multi-spot welding device, and a long-side seam welding device. The multi-spot welding device spot welds the middle part of the heat sink, the end-deep TIG welding device welds both ends of the heat sink, and the long-side seam welding device welds the two long sides of the heat sink. The multi-spot welding device and the long-side seam welding device preheat the welding area before welding and temper the welding area after welding. This arrangement improves the welding effect of the heat sink at the welding position and ensures the stability of the heat sink after welding.

[0012] In a preferred embodiment of the technical solution of the present invention, the welding station further includes a leveling and finishing device, which includes a leveling roller group and a long straight edge grinding mechanism. The leveling roller group levels the heat sink after welding, and the long straight edge grinding mechanism grinds the long edge of the heat sink after welding. The setting of the long straight edge grinding mechanism facilitates the grinding and deburring of the long edge of the heat sink after welding, thereby improving the smoothness of the long edge of the heat sink.

[0013] In a preferred embodiment of the present invention, three transfer trolleys are provided, which are respectively located at the robotic arm and the radiator assembly and welding station. This arrangement facilitates the transfer of the semi-finished radiator during the assembly process and is convenient to use.

[0014] In a preferred embodiment of the present invention, a comb frame is provided on a transfer trolley near the robotic arm, and limiting teeth are provided on the comb frame to place and separate multiple heat sinks. The distance between two adjacent limiting teeth is 1.9-2.2 times the thickness of the heat sink. This arrangement helps to ensure the heat dissipation effect of a single heat sink under the premise of limited heat sink size.

[0015] In a preferred embodiment of the present invention, the automatic unloading and palletizing station includes a temporary palletizing station, on which a comb frame for palletizing heat sinks is provided. Heat sinks of different specifications produced in mixed batches are placed at the temporary palletizing station. This arrangement facilitates the differentiation of heat sinks produced in mixed batches and is convenient to use.

[0016] In a preferred embodiment of the present invention, the radiator assembly and welding station includes a fin assembly station, an oil collection pipe circumferential weld station, and an oil collection pipe straight seam weld station. The fin assembly station installs oil collection pipes at both ends of the stacked radiator fins and fixes them with spot welding. The oil collection pipe circumferential weld station welds the circumferential seam at the connection between the oil collection pipe and the radiator fins. The oil collection pipe straight seam weld station welds the straight seam at the connection between the oil collection pipe and the radiator fins. The radiator assembly and welding station facilitates the assembly and welding of the stacked radiator fins, ultimately forming the radiator body, achieving automation and reducing manual labor.

[0017] The beneficial effects of this invention compared to the prior art are: The technical solution of this invention integrates an uncoiling station, a feeding station, a forming station, a welding station, an automatic unloading and stacking station, and a radiator assembly and welding station. This realizes the entire production process of radiators, from the uncoiling of raw materials to the production of heat sinks and the assembly of heat sinks, ultimately producing the radiator. This reduces the reliance on manual labor and improves production efficiency and product quality stability. The heat sink is produced by combining rolling and stamping forming processes. The oil guide groove in the middle of the heat sink is formed by rolling, and the oil guide grooves at both ends of the heat sink are formed by stamping. This solves the limitation of mold size on the length of heat sink, realizes the production of heat sinks of multiple specifications, reduces mold costs, and has the ability to mix production without changing molds, thus enhancing production flexibility. In addition, this application also utilizes a lifting and rotating structure to rotate good heat sinks with dimensional deviations 180° horizontally before reassembling them, thereby compensating for the deviations and enabling heat sinks with dimensional deviations to be used normally, reducing the scrap rate and lowering production costs. Attached Figure Description

[0018] Figure 1 This is a flowchart of the production line for this application; Figure 2 This is a three-dimensional schematic diagram of the present application; Figure 3 This is a schematic diagram showing the storage of the coil at the uncoiling station. Figure 4 A three-dimensional schematic diagram of the material loading station and the forming station; Figure 5 This is a three-dimensional schematic diagram of the lifting and slewing device after lifting. Figure 6 This is a three-dimensional schematic diagram of the welding station; Figure 7 A three-dimensional schematic diagram of the leveling and finishing equipment; Figure 8 3D schematic diagram of the automatic unloading and palletizing station; Figure 9 This is a three-dimensional schematic diagram of the comb frame in the palletizing station; Figure 10 A schematic diagram of the heat sink assembly and welding station; Figure 11 This is a three-dimensional schematic diagram of the heat sink; Figure 12 A three-dimensional diagram showing the assembled radiator body; Explanation of reference numerals in the attached drawings: 1-Uncoiling station, 11-Feeding trolley, 12-Roll placement rack, 13-Uncoiling machine spindle, 14-Spindle expansion and contraction mechanism, 2-Feeding station, 21-Guiding device, 22-Guiding roller, 23-Guiding wheel, 24-Degreasing device, 25-Degreasing felt, 26-Felt fixing plate, 27-Feeding device, 28-Feeding roller, 29-Reduction gearbox, 3-Forming station, 31-Roll forming equipment, 32-Roll forming roller, 33-First pressure roller group, 34-Second pressure roller group, 35-End forming equipment, 36-Punching machine, 37-Punching die, 38-Transition conveyor roller table, 39-Conveying roller, 310-Mounting frame, 311-Tilting and laminating equipment, 4-Lifting and rotating device, 41-Lifting frame, 42-Lifting rod, 43-Rotating table, 5-Welding station, 51-End depth 52-Multi-spot welding equipment, 53-Long side seam welding equipment, 54-End punching equipment, 56-Leveling and finishing equipment, 57-Leveling roller group, 58-Long straight edge grinding mechanism, 59-Grinding wheel, 510-Drive motor, 6-Automatic unloading and palletizing station, 61-Robotic arm, 62-Electromagnetic adsorption frame, 63-Transfer trolley, 64-Trolley moving frame, 65-Comb frame, 66-Limiting tooth plate, 67-Temporary palletizing station, 7-Radiator assembly and welding station, 71-Pipe assembly station, 72-Oil collection pipe circumferential seam welding station, 73-Oil collection pipe straight seam welding station, 8-Control system, 81-First control cabinet, 82-Second control cabinet, 83-Third control cabinet, 84-Fourth control cabinet, 85-Fifth control cabinet, 9-Radiator body, 91-Heat sink, 92-Oil collection pipe. Detailed Implementation

[0019] The following will refer to the appendices in the embodiments of the present invention. Figure 1-12 The technical solutions in the embodiments of the present invention will be described in detail below. Example

[0020] like Figure 1 and 2 As shown, a transformer radiator production line includes an uncoiling station 1, a feeding station 2, a forming station 3, a welding station 5, an automatic unloading and stacking station 6, and a radiator assembly and welding station 7 arranged in sequence.

[0021] The production line is controlled by a control system 8. The raw material roll is first unwound at the unwinding station 1 and gradually released. The unwound roll is cleaned, degreased, and guided to the forming station 3 via the feeding station 2. The forming station 3 rolls the unwound sheet in the middle and punches the ends to form a heat dissipation sheet with oil channel grooves. The oil channel grooves in the middle of the heat dissipation sheet are formed by rolling. The length of the heat dissipation sheet is not limited. This allows the production of heat dissipation sheets of different specifications (different specifications refer to different lengths) without changing the mold.

[0022] Two heat sinks are flipped and joined together at the flipping and joining device 311 to form a heat sink 91 with a hollow flow channel inside. During this process, for good heat sinks with dimensional deviations (good heat sinks with dimensional deviations refer to heat sinks with complete oil channel grooves that can be used normally after being joined together after the direction is adjusted and do not affect the heat dissipation effect, such as the oil channel grooves shifting as a whole during rolling, and the distance between the oil groove and the two sides being different, such as the oil channel being asymmetrical but not affecting normal use), the lifting and rotating device 4 set between the flipping and joining device 311 and the forming station 3 can rotate one of the heat sinks with dimensional deviations horizontally by 180°, and then flip and join it with another heat sink with the same dimensional deviation through the flipping and joining device 311 to achieve error compensation. In this way, the two heat sinks with dimensional deviations can form a heat sink 91 with normal internal flow channels.

[0023] After being flipped and assembled, the heat sink 91 is moved to the welding station 5 by the transition conveyor roller 38. The multi-spot welding equipment 52 in the welding station 5 welds the assembled heat sink 91 along the length direction (flow channel extension direction) to prevent crossflow between the various flow channels. Then, the long side seam welding equipment 53 in the welding station 5 welds the two long sides of the heat sink 91. The end punching equipment 54 in the welding station 5 punches the two ends of the heat sink 91 to form two inclined shoulders to facilitate the flow of cooling oil. Then, the end deep-melt TIG welding equipment 51 in the welding station 5 welds the two ends of the punched heat sink 91 to complete the fixation of the two heat sink 91 after being assembled.

[0024] After the end welding is completed, the leveling and finishing equipment 56 in welding station 5 levels the heat sink 91 and grinds the long side welding area to ensure the straightness and surface smoothness of the heat sink 91 and prevent residual welding burrs. At this point, the heat sink 91 is completed.

[0025] After welding, the heat sink 91 is transferred to the automatic unloading and stacking station 6. The robotic arm 61 on the automatic unloading and stacking station 6 removes the produced heat sink 91 and stacks it on the transfer trolley 63. After stacking, the heat sink 91 is automatically moved by the transfer trolley 63 to the plate tube assembly station 71 in the radiator assembly and welding station 7. The plate tube assembly station 71 places the oil collection pipe 92 at both ends of the stacked heat sink 91 and then performs spot welding to fix it.

[0026] After the oil collection pipe 92 is spot-welded and fixed, the stack of heat sinks 91 is transferred by another transfer trolley 63 to the oil collection pipe circumferential welding station 72 in the radiator assembly welding station 7. The transfer trolley 63, which was originally used for stacking, returns to the robotic arm 61. The stacks moved to the oil collection pipe circumferential welding station 72 are welded by the oil collection pipe circumferential welding station 72, welding the opening on the oil collection pipe 92 together with the opening on the heat sink 91. This welding process is a circumferential welding, realizing the connection between the oil collection pipe 92 and the internal oil passage of the heat sink 91.

[0027] After the circumferential welding is completed, the transfer trolley 63 moves the stacked circumferentially welded stack to the oil collection pipe straight seam welding station 73 in the radiator assembly welding station 7. The oil collection pipe straight seam welding station 73 welds along the extension direction of the oil collection pipe 92, and welds the oil collection pipe 92 and multiple heat sinks 91 in a straight line at the contact point, which further enhances the stability of the connection between the heat sinks 91 and the oil collection pipe 92.

[0028] After the straight seam welding is completed, the production of the radiator body 9 is finished. The transfer trolley 63 moves the completed radiator body 9 to the end of the radiator assembly and welding station 7 without affecting the normal operation of the straight seam welding station 73 for oil collection pipe. The material is then manually hoisted and unloaded. In this production process, only loading and unloading require manual operation, while the rest is completed automatically by the production line, reducing the dependence on manual labor, reducing the workload, and realizing the full-process production from raw materials to heat sink 91 to radiator body 9.

[0029] like Figure 2 and 3 As shown, the uncoiling station 1 includes a loading trolley 11 and an uncoiling device. The loading trolley 11 and the uncoiling device are connected by a sliding frame with a slide rail. An uncoiling machine spindle 13 is installed on the uncoiling device. A spindle expansion and contraction mechanism 14 is installed on the spindle 13. A coil is placed on the loading trolley 11. The loading trolley 11 can drive the coil to move along the sliding frame and put the coil onto the spindle expansion and contraction mechanism 14. After the coil is put on, the spindle expansion and contraction mechanism 14 expands under hydraulic action to stably fix the coil.

[0030] The unwinding equipment with an unwinder spindle 13 and a spindle expansion and contraction mechanism 14 is an existing device, commonly used in the field, and can be used directly.

[0031] The loading trolley 11 is a rectangular trolley with a drive motor. The drive motor can drive the loading trolley 11 to move linearly along the slide rail on the sliding frame (this is the prior art). An arc-shaped material roll placement rack 12 is connected to the loading trolley 11 by a hydraulic rod. The material roll is placed on the material roll placement rack 12, and the hydraulic rod can drive the material roll placement rack 12 to rise, thus completing the loading.

[0032] In this embodiment, the maximum load capacity of the preferred material roll placement rack 12 is 5000KG.

[0033] The loading trolley 11 facilitates loading and also allows a roll of material to be pre-stored on the roll placement rack 12. This ensures that after the rolls on the uncoiler spindle 13 are used up, they can be loaded from the roll placement rack 12 in a timely manner, avoiding waiting and making it convenient to use.

[0034] like Figure 2 and 4 As shown, the feeding station 2 includes a guiding device 21, an oil removal device 24, and a feeding device 27. The unrolled sheet metal passes through the guiding device 21, the oil removal device 24, and the feeding device 27 to complete cleaning, oil removal, and feeding.

[0035] The guiding device 21 includes a trapezoidal feeding frame. Two circular rollers, named guide rollers 22, are fixed to the front end of the feeding frame with screws. Guide wheels 23 are fixed between the guide rollers 22 and the degreasing device 24 with screws. The guide wheels 23 can rotate along the connection. V-shaped guide grooves are recessed on the cylindrical surface of the guide wheels 23. There are four guide wheels 23, which are distributed in pairs on the feeding frame. The unfolded board first passes through the guide rollers 22 and is placed in the guide grooves of the two sets of opposing guide wheels 23, so as to guide the board feeding and prevent the board from deviating.

[0036] Definition: In this implementation, the production line is placed on the ground. The direction from the ground to the production line is upward, and the opposite direction is downward. The part of the production line closest to the uncoiling station 1 is the front, and the opposite direction is the rear.

[0037] The main function of the degreasing device 24 is to clean and remove oil from the board. The degreasing device 24 includes degreasing felt 25 and felt fixing plate 26. The felt fixing plate 26 is a rectangular metal plate, and the degreasing felt 25 is a rectangular block made of felt. The degreasing felt 25 is fixed to the felt fixing plate 26 with screws. There are two sets of each of the felt fixing plate 26 and degreasing felt 25. The two sets are distributed vertically and horizontally. The two sets of degreasing felt 25 are in contact. After being guided, the unfolded board passes between the two vertically distributed degreasing felts 25 and is wiped clean and degreased using the degreasing felt 25.

[0038] like Figure 4Regarding the fixing of the felt fixing plate 26, both ends of one felt fixing plate 26 are fixed to the rear end of the feeding rack using "L"-shaped corner brackets. The degreasing felt 25 in this felt fixing plate 26 faces upward. A screw and a circular sliding rod are welded to each end of this felt fixing plate 26. At the same time, a hole for a screw to pass through is opened at each end of the other felt fixing plate 26. The screw passes through this hole, and a sliding sleeve that can cooperate with the sliding rod is also welded to one side of the hole. The sliding sleeve cooperates with the sliding rod, and the upper felt fixing plate 26 can be raised and lowered. After the screw passes through the upper felt fixing plate 26, a spring is wrapped around the exposed screw, and a nut is screwed to the end of the screw. One end of the spring abuts against the nut, and the other end abuts against the upper felt fixing plate 26. By rotating the nut, the pressure of the spring on the felt fixing plate 26 can be adjusted, thereby adjusting the distance between the two degreasing felts 25, which facilitates the cleaning of oil stains on the board.

[0039] The main function of the feeding device 27 is to drive the unfolded sheet material into the forming station 3 for feeding. The feeding device 27 includes two feeding rollers 28 distributed vertically, a reduction gearbox 29, and a base. The base is placed on the ground, and the reduction gearbox 29 is fixed to the base with screws. The reduction gearbox 29 is driven by a motor mounted on the base. The feeding rollers 28 are connected to the gears in the reduction gearbox 29. The rotation of the motor drives the gears in the reduction gearbox 29 to rotate, which in turn drives the feeding rollers 28 to rotate. The sheet material is then cleaned by the degreasing device 24. The material is inserted between two feeding rollers 28. The feeding rollers 28 rotate and drive the sheet material to move towards the forming station 3 to achieve feeding. In order to facilitate the application of sheet materials of different thicknesses, this embodiment preferably makes the distance between the two feeding rollers 28 adjustable. The adjustment method is to connect a hydraulic push rod to the main shaft on the upper feeding roller 28. The position of the feeding roller 28 is adjusted by the push rod, and it is ensured that the reduction gear box 29 can drive the feeding roller 28 to rotate normally after adjustment. Using the feeding roller 28 to drive feeding and adjust the position of the feeding roller 28 is a technology that can be directly used.

[0040] like Figure 4 As shown, the forming station 3 includes a roll forming equipment 31 and an end forming equipment 35. The roll forming equipment 31 is used to roll form the oil channel groove in the middle of the heat sink, and the end forming equipment 35 is used to form the oil grooves and end structure at both ends of the heat sink.

[0041] The roll forming equipment 31 includes a roll forming roller 32, which includes a first roller group 33 and a second roller group 34. Each roller group consists of two upper and lower rollers. The surface of the lower roller has protrusions for forming oil channel grooves, and the surface of the upper roller has corresponding grooves. The oil channel grooves of the heat dissipation fin are rolled out by the interlocking of the upper and lower rollers.

[0042] To avoid large deformation in a single rolling process, which could lead to breakage or cracking of the sheet and affect its service life, the protrusion distance on the roller above the first pressure roller group 33 is smaller than the protrusion distance on the roller above the second pressure roller group 34. The first pressure roller group 33 and the second pressure roller group 34 roll in sequence, and through two deformations, the oil channel groove that meets the requirements is finally formed.

[0043] The first pressure roller group 33 and the second pressure roller group 34 are both fixed on the base at the feeding station 2. The fixing and driving methods adopt the existing fixing and driving methods, which are commonly used in the production line of variable radiator and are known to those skilled in the art.

[0044] The end forming equipment 35 includes a stamping machine 36, which is an existing piece of equipment. A stamping die 37 is installed on the stamping machine 36. After the heat sink fin is rolled and formed in the middle, it stops below the stamping machine 36. The stamping machine 36 presses down to stamp out the oil channel groove at the end of the heat sink fin. At the same time, it can also cut the continuous plate into individual pieces. There are two sets of structures forming the oil channel groove on the stamping die 37. The two sets are symmetrically distributed, so that the front and rear ends of two heat sink fins can be stamped at the same time during stamping.

[0045] After the heat sink fins are rolled and stamped, a flipping and joining device 311 is placed after the end forming device 35 to facilitate joining. The flipping and joining device 311 is connected to the end forming device 35 via a transition conveyor roller 38. The transition conveyor roller 38 is used to transport the formed heat sink fins. The flipping and joining device 311 is an existing wheel-type flipping and joining device. The flipping and joining device 311 consists of a wheel-type flipping mechanism, a joining mechanism, and a pushing mechanism. A drive chain is installed on one wheel of the wheel-type flipping mechanism. The lower AC geared motor drives the flipping mechanism to rotate 180° through a sprocket. The pushing mechanism and the joining mechanism are arranged in a frame between two wheels, with double-row chain drive and driven by an AC geared motor. After being formed, the heat dissipation sheet is conveyed to the wheel-type flipping mechanism via the transition conveyor roller 38. The transmission chain and the pusher mechanism push the heat dissipation sheet to the assembly mechanism. The heat dissipation sheet is placed on the assembly mechanism, and then the rotating frame rotates 180°. When the second heat dissipation sheet is covered on it by the transmission, the two heat dissipation sheets are joined together to form the heat dissipation sheet 91.

[0046] The main function of the transition conveyor roller 38 is to convey the heat sink 91. The transition conveyor roller 38 includes a mounting frame 310 and conveyor rollers 39. The conveyor rollers 39 are mounted on the mounting frame 310. A gear is fixed at one end of each conveyor roller 39. The mounting frame 310 is also equipped with a drive motor and a chain. The chain connects the drive motor and the gear to drive the conveyor rollers 39 and convey the heat sink 91. This type of transmission device is common in existing technologies and production lines. There are no technical barriers to it, so it will not be described in detail here.

[0047] like Figure 2 , 4 As shown in Figure 5, during roll forming, sometimes due to tilting of the feeding or improper adjustment, some good heat dissipation sheets with dimensional deviations may be produced (for example, the oil channel groove formed on the heat dissipation sheet may have a small positional deviation. This deviation is only a positional deviation, such as the distance of the oil channel groove from the two long sides is not the same. After the two deviated heat dissipation sheets are adjusted in direction, they can be joined together normally, and after joining, they can form normal heat dissipation oil channels, which does not affect subsequent welding). The technical solution of this application is to install a lifting and rotating device 4 on the transition conveyor roller 38 between the flipping and joining equipment 311 and the end forming equipment 35. The lifting and rotating device 4 can lift one of the two deviated heat dissipation sheets from the transition conveyor roller 38 and rotate it horizontally by 180° to compensate for the deviation and avoid material waste.

[0048] The lifting and rotating device 4 includes a lifting frame 41, a lifting rod 42, and a rotating platform 43. The lifting frame 41 is a rectangular metal frame welded from square tubing. The lifting frame 41 is located between two sets of conveyor rollers 39 within the mounting frame 310. To avoid positional interference between the lifting frame 41 and the conveyor rollers 39, the width of the lifting frame 41 is less than the distance between the two sets of opposing conveyor rollers 39. A mounting plate is welded to the middle of the lifting frame 41, and a lifting rod 42 is fixed to the mounting plate. The lifting rod 42 is an electrically telescopic rod. A rectangular mounting plate is mounted on the mounting frame 310 using screws, and a circular rotating platform 43 is fixed to the mounting plate using screws. 43 is a rotating platform driven by a servo motor. The rotating platform is connected to the output shaft of the servo motor. The other end of the lifting rod 42 is fixed to the rotating platform with screws. When not in use, the lifting frame 41 is located below the conveyor roller 39 in the transition conveyor roller table 38, which does not affect the normal conveying of the heat sink. When a heat sink with deviation is encountered and it is located directly above the lifting frame 41, the lifting rod 42 rises first, the lifting frame 41 lifts the problematic heat sink, and then the rotating table 43 drives the lifting frame 41 to rotate horizontally by 180°. After completion, the lifting rod 42 descends and puts the heat sink back onto the conveyor roller 39 to ensure normal conveying.

[0049] To improve safety, arc-shaped guardrails are welded around the 180° rotation range of the heat dissipation fin in the lifting and rotating device 4 to prevent accidental injury during rotation.

[0050] Regarding the identification of dimensional deviation heat sinks, this embodiment preferably adopts a visual recognition method. By installing an identification camera on the transition conveyor roller 38 near the end forming equipment 35, the identification camera is connected to the control system 8. When a dimensional deviation is detected, a signal is sent to the control system 8 to remind manual intervention. At the same time, the control system 8 controls the lifting and rotating device 4 to lift and rotate.

[0051] In addition, multiple infrared sensors are installed on the mounting frame 310 on which the lifting and rotating device 4 is installed. The infrared sensors are connected to the control system 8. By blocking the infrared sensors with a heat sink, the control system determines whether the heat sink with accuracy problems has moved directly above the lifting frame 41. When it is directly above the lifting frame 41, the transition conveyor roller 38 stops moving, and the control system 8 controls the lifting frame 41 to rise and lift the heat sink.

[0052] like Figure 2 and 6 As shown, welding station 5 includes end-to-end deep-melt TIG welding equipment 51, multi-spot welding equipment 52, long-side seam welding equipment 53, and end-to-end punching equipment 54. Multi-spot welding equipment 52 performs multi-point reinforcement welding on the oil groove of the heat sink 91 after assembly. Long-side seam welding equipment 53 welds the long sides of both sides of the heat sink 91 after assembly. End-to-end punching equipment 54 punches the two ends of the heat sink 91 to form inclined shoulders to facilitate the guidance of coolant. End-to-end deep-melt TIG welding equipment 51 welds the punched ends.

[0053] The multi-spot welding equipment 52 includes a welding system, a gantry frame, a pressurizing system, a control box, a programmable controller, and a transition conveyor roller 38. The gantry frame spans above the transition conveyor roller 38, which is connected to the flipping and laminating equipment 311. The laminating heat sink 91 is conveyed to the bottom of the gantry frame via the transition conveyor roller 38. The welding system, pressurizing system, control box, and programmable controller are mounted on the gantry frame.

[0054] When the heat sink 91 passes under the gantry frame, the pressurization system drives the welding system to move down under the control of the control box. In the welding system, the welding head reinforces the oil groove in the heat sink 91 by welding.

[0055] The multi-spot welding equipment 52 uses existing welding equipment, the difference being that the welding in this application uses a medium-frequency inverter AC welding power supply, and utilizes a programmable controller to program the welding specifications and a three-stage welding heating process. The welding heating process is preheating first, then welding, and finally tempering. In this embodiment, the preferred tempering temperature is between 600℃ and 650℃, and the preheating temperature is between 100℃ and 150℃.

[0056] The long-side seam welding equipment 53 includes a welding system, a pressurization system, a control box, a welding wheel dressing mechanism, a rotating support, a frame, a base, an electrical control system, and a transition conveyor roller 38. The frame is mounted on the base, the welding wheel dressing mechanism is mounted on the frame, the welding system is mounted on the rotating support, and the rotating support is mounted on the welding wheel dressing mechanism. The heat sink 91 after multi-point welding is slowly conveyed to the welding system via the transition conveyor roller 38. The welding system is located on both sides of the transition conveyor roller 38. The welding wheel dressing mechanism adjusts the seam welding wheel in the welding system to contact the heat sink 91 and welds the long side of the heat sink 91 that it passes through.

[0057] The long-side seam welding equipment 53 is an existing equipment. The difference is that the welding in this application adopts a medium-frequency inverter AC welding power supply, and uses a programmable controller to program the welding specifications and a three-stage welding heating process. The welding heating process is preheating first, then welding, and finally tempering. In this embodiment, the preferred tempering temperature is between 600℃ and 650℃, and the preheating temperature is between 100℃ and 150℃.

[0058] The end punching equipment 54 includes a punching device with a punching die, which is an existing device. The punching die of the end punching equipment 54 punches out an inclined shoulder on each side of both ends of the heat sink 91. In this embodiment, the inclined angle is preferably 15°. This allows the inclined shoulder to guide the cooling oil into the cooling channel. The punching die has two sets of punching blades, which are symmetrically distributed along the direction of production line movement, making it convenient to punch both ends of the heat sink 91 with a single punching machine.

[0059] In this embodiment, the end-cutting equipment 54 preferably adopts a reciprocating cutting method for cutting the heat sink 91. That is, when one end of the heat sink 91 moves to the end-cutting equipment 54, this end is cut first. Then, the transition conveyor roller 38 drives the heat sink 91 to continue moving until one end passes the end-cutting equipment 54. Then, the heat sink 91 is driven back along the production line direction to cut the other end.

[0060] The end-to-end deep-melt TIG welding equipment 51 is an existing device, mainly used to weld the punched ends to form a complete heat sink 91. The heat sink 91 is produced with openings at both ends for cooling oil to enter and exit.

[0061] In this application, the transfer of heat sinks 91 between various workstations, welding equipment, and stamping and cutting equipment is carried out using transition conveyor rollers 38.

[0062] like Figure 2 and 7As shown, in order to improve the quality of the heat sink 91, a leveling and finishing device 56 is installed on the transition conveyor roller 38 between the end deep-melt TIG welding equipment 51 and the automatic unloading and stacking station 6. The leveling and finishing device 56 includes a leveling roller group 57 and a long straight edge grinding mechanism 58. The leveling roller group 57 consists of multiple sets of leveling rollers with adjustable distance. After welding, the heat sink 91 passes through the leveling roller group 57 and is leveled by the leveling roller group 57.

[0063] The long straight edge grinding mechanism 58 includes a grinding wheel 59 and a drive motor 510. The drive motor 510 is mounted on the mounting frame 310 of the transition conveyor roller 38. The grinding wheel 59 is fixed to the side of the mounting frame 310 where the conveyor roller 39 is mounted using a connecting pin. The grinding wheel 59 is a cylindrical grinding column. When the heat sink 91 passes by, the long side of the heat sink 91 contacts the cylindrical surface of the grinding wheel 59. The lower end of the grinding wheel 59 is mounted with a pulley using a pin. The pulley is connected to the drive motor 510 using a belt. The drive motor 510 drives the grinding wheel 59 to rotate and grind the side of the heat sink 91.

[0064] Multiple grinding wheels 59 and drive motors 510 are provided and divided into two groups. The two groups are symmetrically installed on the mounting bracket 310 to grind the long side of the heat sink 91.

[0065] The main function of the leveling roller group 57 is for leveling. This type of equipment is widely used in industrial production and will not be elaborated here.

[0066] like Figure 2 , 8 As shown in Figure 9, the automatic unloading and palletizing station 6 includes a robotic arm 61 and a transfer trolley 63. The robotic arm 61 is placed on the ground and is used to remove the polished heat sink 91 from the transition conveyor roller 38 and palletize it on the transfer trolley 63. A comb frame 65 is installed on the transfer trolley 63. The removed heat sink 91 is palletized on the comb frame 65. After palletizing, it is transferred by the transfer trolley 63 to the radiator assembly and welding station 7 for welding to form the radiator body 9.

[0067] To facilitate the removal of the heat sink 91 by the robotic arm 61, an electromagnetic adsorption frame 62 is installed at the end of the robotic arm 61. An electromagnet is installed on the electromagnetic adsorption frame 62 to attract the heat sink 91, making it easy to pick up and put down.

[0068] The transfer trolley 63 is an existing RGV stacking flatcar. To facilitate the movement of the transfer trolley 63, a trolley moving frame 64 is laid on the ground. The transfer trolley 63 moves along the trolley moving frame 64. The fin assembly station 71, the oil collection pipe circumferential weld station 72, and the oil collection pipe straight weld station 73 in the radiator assembly and welding station 7 are arranged in sequence along the extension direction of the trolley moving frame 64. After the transfer trolley 63 transfers and stacks the heat sink 91, it is assembled and welded at the radiator assembly and welding station 7.

[0069] Three transfer trolleys 63 are mounted on the trolley moving frame 64. A comb frame 65 is installed on the transfer trolley 63 near the robotic arm 61 using screws. This comb frame 65 is specifically used for mounting the heat sink 91. The comb frame 65 is a rectangular frame, and multiple limiting teeth 66 are welded onto the comb frame 65. The limiting teeth 66 are rectangular teeth, and two sets of limiting teeth 66 are symmetrically arranged on the comb frame 65. There is a gap between each set of limiting teeth 66. The heat sink 91 is placed between two limiting teeth 66. In this embodiment, the gap between the two limiting teeth 66 is preferably 1.9-2.2 times the thickness of the heat sink 91. In this embodiment, it is preferably 2 times. The thickness of the heat sink 91 is the gap between two heat sink fins. This arrangement allows the heat sink 91 that makes up the heat sink body 9 to be air-cooled during heat dissipation, improving the heat exchange efficiency.

[0070] For the placement of heat sinks 91 in mixed production, there is a temporary palletizing station 67 on the other side of the robotic arm 61. A comb frame 65 is placed at the temporary palletizing station 67. The heat sinks 91 in mixed production are placed using the comb frame 65, and the heat sinks 91 stacked at the temporary palletizing station 67 are assembled and welded manually.

[0071] like Figure 2 , 10 As shown in Figures 11 and 12, the radiator assembly welding station 7 includes a plate tube assembly station 71, an oil collection pipe circumferential weld station 72, and an oil collection pipe straight seam weld station 73. The plate tube assembly station 71, the oil collection pipe circumferential weld station 72, and the oil collection pipe straight seam weld station 73 are all existing devices that can be used directly. The plate tube assembly station 71 can assemble the pre-produced oil collection pipe 92 with the stacked radiator 91 and perform preliminary spot welding to fix them. After fixing, it is transported by a transfer trolley 63 to the oil collection pipe circumferential weld station 72. The oil collection pipe circumferential weld station 72 performs circumferential welding on the radiator 91 and the oil collection pipe 92, fixing the openings at both ends of the radiator 91 to an oil collection pipe 92 respectively, so as to facilitate the unified entry and exit of cooling oil.

[0072] After the circumferential welding is completed, it is transferred by another transfer trolley 63 to the oil collection pipe straight seam welding station 73, where straight seam welding is performed. The purpose of straight seam welding is to weld the straight edge of the opening of the heat sink 91 to the oil collection pipe 92, and at the same time, to weld the oil collection pipe 92 to multiple heat sinks 91 in a straight line at the contact point, which further enhances the stability of the connection between the heat sink 91 and the oil collection pipe 92.

[0073] After the straight seam welding is completed, the production of the radiator body 9 is completed. The transfer trolley 63 moves the completed radiator body 9 to the end of the radiator assembly and welding station 7 without affecting the normal operation of the straight seam welding station 73 for oil collection pipe. The material is then manually hoisted and unloaded. In the normal production process of this application's production line, only the loading and unloading of the heat sink 91, which has been mixed and scheduled, requires manual operation. The rest is completed automatically by the production line, which reduces the dependence on manual labor, reduces the workload, and realizes the full-process production from raw materials to heat sink 91 to radiator body 9.

[0074] The control system 8 comprises five control units: a first control cabinet 81, a second control cabinet 82, a third control cabinet 83, a fourth control cabinet 84, and a fifth control cabinet 85. Each control unit is equipped with a separate PLC cabinet and an operation box, which is existing technology. It can independently control 1-2 workstations and the transition conveyor rollers 38 between them. The control units exchange signals and data via data lines to achieve integrated control of the entire line. The control system 8 has a fully integrated control mechanism, enabling both line-of-line production and independent operation. In automatic operation, when one piece of equipment is shut down, its upstream equipment should stop operating, while subsequent equipment continues to run. However, if the welding equipment is welding radiator fins, it will continue welding until completion and then stop. Simultaneously, the entire line has a mixed production function (automatic switching between long and short pieces), enabling a production control mode based on groups for gooseneck radiators, allowing for the combined production of long and short pieces.

[0075] Regarding the workstations controlled by the five control units respectively: First control cabinet 81: Used for integrated control of uncoiling station 1, feeding station 2, forming station 3 and transition conveyor roller 38; Second control cabinet 82: used to control the flipping and laminating equipment 311 and the multi-spot welding equipment 52; Third control cabinet 83: Used to control long-side seam welding equipment 53; Fourth control cabinet 84: used to control the end punching equipment 54 and the end deep penetration TIG welding equipment 51; Fifth control cabinet 85: Used to control the leveling and finishing equipment 56 and the automatic unloading and palletizing station 6.

[0076] The radiator assembly and welding station 7 has its own control system.

[0077] Advantages of the technical solution in this application: 1. It reduced the amount of manual labor required, improved production efficiency and product quality stability, and realized the entire production process from raw materials to heat sink 91 to heat sink body 9. 2. It has mixed production function (automatic switching between long and short fins), and can realize a production control mode based on groups for heat sinks of different lengths, such as gooseneck heat sinks, and can carry out combined production of long and short fins. 3. The lifting and rotating device 4 can be used to rotate good heat sinks with dimensional deviations 180° horizontally before reassembling them, thus compensating for the deviations. This allows heat sinks with dimensional deviations to be used normally, reducing the scrap rate and lowering production costs.

[0078] The above embodiments are merely illustrative of the technical concept of the present invention and should not be construed as limiting the scope of protection of the present invention. Any modifications made to the technical solutions based on the technical concept proposed in this invention shall fall within the scope of protection of this invention.

Claims

1. A production line for radiators for transformers, characterized in that: The production line is sequentially arranged with an unwinding station, a feeding station, a forming station, a welding station, an automatic fin stacking station, a radiator assembling and welding station and a control system; The unwinding station comprises a feeding trolley and an unwinding device, the feeding trolley for storing and feeding raw material coils is connected with the unwinding device, a main shaft of the unwinding device is provided, the feeding trolley transporting the stored coils is installed on the main shaft, and the main shaft is controlled to rotate to gradually release the coils; The feeding station is connected with the forming station, the feeding station guides the plate material released from the coils into the forming station for forming, and cleans the plate material during the guiding; The forming station rolls and presses the plate material to form oil channel grooves, and punches the both ends of the plate material to form flow guide grooves to form radiator single pieces, which are suitable for production of radiator single pieces of different lengths and mixed production and arrangement; The forming station is connected with the welding station through a transition conveying roller, the transition conveying roller conveys the formed radiator single pieces to the welding station to weld and form the radiator fins; A lifting and rotating device is arranged in the transition conveying roller between the forming station and the welding station, the lifting and rotating device controllably lifts the radiator single pieces with precision deviation before the pieces are combined, and horizontally rotates the pieces by 180° to compensate the deviation; The automatic fin stacking station is arranged at the end of the welding station, the automatic fin stacking station comprises a mechanical arm and a transfer trolley, the mechanical arm automatically takes the formed radiator fins and stacks the fins on the transfer trolley, and the transfer trolley conveys the stacked fins to the radiator assembling and welding station for assembling and welding to form a radiator main body; The control system is arranged in the production line, and the control system controls the operation of the whole production line.

2. The heat sink production line for transformers according to claim 1, characterized in that: The forming station comprises a rolling forming device and an end forming device, the rolling forming device comprises a rolling roller, the rolling roller rolls and forms the middle oil groove of the radiator single piece, and the end forming device comprises a punch, the punch punches the oil groove at both ends of the radiator single piece.

3. The heat sink production line for transformers according to claim 2, characterized in that: The rolling roller comprises a first roller group and a second roller group, each of the first roller group and the second roller group comprises two rollers with forming protrusions on surfaces, the plate material is rolled after the first roller group and then enters the second roller group for continuous rolling, and the distance between the forming protrusions on the rollers in the second roller group is greater than the distance between the forming protrusions on the rollers in the first roller group.

4. The heat sink production line for transformers according to claim 1, characterized in that: The lifting and rotating device comprises a lifting frame, a lifting rod, a rotating table and a detection structure, the lifting frame is located below the radiator single pieces conveyed in the transition conveying roller, the lifting frame is connected with the rotating table through the lifting rod, the rotating table is arranged on the transition conveying roller, the detection structure is arranged on the transition conveying roller, the detection structure detects the precision of the radiator single pieces conveyed on the transition conveying roller, and controls the movement of the lifting rod and the rotating table, the lifting frame is used to control the horizontally rotating of the radiator single pieces with precision deviation by 180° to compensate the deviation.

5. The heat sink production line for transformers according to claim 1, characterized in that: The welding station comprises an end deep melting TIG welding device, a multi-point welding device and a long edge seam welding device, the multi-point welding device spot-welds the middle of the radiator fin, the end deep melting TIG welding device welds both ends of the radiator fin, and the long edge seam welding device welds the two long edges of the radiator fin, the multi-point welding device and the long edge seam welding device preheat the welding positions before welding, and the welding positions are tempered after welding.

6. The heat sink production line for transformers according to claim 1, characterized in that: The welding station further comprises a flattening and finishing device, which comprises a flattening roller group and a long straight edge polishing mechanism, the flattening roller group flattens the heat dissipation fins after welding, and the long straight edge polishing mechanism polishes the long edges of the heat dissipation fins after welding.

7. The heat sink production line for transformers according to claim 1, characterized in that: Three transfer trolleys are arranged, and the three transfer trolleys are arranged at the mechanical arm and the radiator assembly and welding station respectively.

8. The heat sink production line for transformers according to claim 7, characterized in that: The transfer trolley near the mechanical arm is provided with a comb rack, and the comb rack is provided with limiting teeth for placing and spacing a plurality of heat dissipation fins, and the spacing between two adjacent limiting teeth is 1.9-2.2 times the thickness of the heat dissipation fins.

9. The heat sink production line for transformers according to claim 1, characterized in that: The automatic fin unloading and stacking station comprises a temporary stacking station, and the temporary stacking station is provided with a comb rack for stacking heat dissipation fins.

10. The heat sink production line for transformers according to claim 1, characterized in that: The radiator assembly and welding station comprises a fin tube assembly station, an oil collecting pipe ring seam welding station and an oil collecting pipe straight seam welding station, the fin tube assembly station installs the oil collecting pipe at both ends of the stacked heat dissipation fins and performs spot welding fixation, the oil collecting pipe ring seam welding station welds the ring seam at the connection between the oil collecting pipe and the heat dissipation fins, and the oil collecting pipe straight seam welding station welds the straight seam at the connection between the oil collecting pipe and the heat dissipation fins.

Images