Automatic pipe winding machine for spiral wound heat exchangers

Abstract

The utility model relates to winding pipe type heat exchanger automatic pipe winding machine, winding pipe type heat exchanger automatic pipe winding machine, including base, be equipped with the pipe winding assembly for realizing heat exchanger heat exchange pipe winding on the base, be equipped with the ground rail on the base of pipe winding assembly one side, be equipped with the pipe line assembly that can reciprocatingly move on the ground rail, and the pipe line assembly includes the bottom plate that is adapted to the ground rail, the top one side of bottom plate is equipped with the pipe tension unit for realizing pipe and in the pipe process to the heat exchange pipe is pulled tight, the top other side of bottom plate is equipped with the multi -angle pipe winding guide unit that is adapted to with the pipe tension unit, the pipe winding assembly includes pipe winding shaft, and sets up pipe winding shaft and can realize the fixed seat of supporting and rotating to pipe winding shaft, have the advantage that the production efficiency and product quality are improved obviously.

Description

Technical Field

[0001] This utility model relates to an automatic tube winding machine for spiral tube heat exchangers. Background Technology

[0002] A spiral-wound heat exchanger is a type of heat exchanger in which the heat exchange tubes are alternately wound in a helical shape. Due to the special structure of its heat exchange tubes, the spiral-wound heat exchanger boasts outstanding advantages such as a wide applicable temperature range, resistance to thermal shock, self-elimination of thermal stress, high heat transfer efficiency, and high structural compactness. It offers significant advantages over ordinary shell-and-tube heat exchangers.

[0003] In the manufacturing process of wound tube heat exchangers, bending the steel tubes is one of the key steps. As the core component of wound tube heat exchangers, the quality of the manufacturing process of the heat-conducting tube bundles plays a decisive role in the performance of the heat exchanger. Currently, the winding process of heat-conducting tube bundles is mostly done manually. While this is not a significant disadvantage for small heat-conducting tube bundles, the market demand for wound tube heat exchangers is clearly trending towards larger sizes, with tube bundles reaching several meters in diameter and tens or even hundreds of meters in length. Traditional manual methods can no longer meet these requirements. Traditional manual or semi-automatic bending and winding methods suffer from low efficiency, poor precision, and difficulty in ensuring consistency, failing to meet the high precision and high efficiency demands of modern industry. Therefore, there is an urgent need for automated processes to optimize the manufacturing process. Based on this, this automatic tube winding machine solution has been designed. Utility Model Content

[0004] The purpose of this invention is to provide an automatic winding machine for spiral tube heat exchangers to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, this utility model provides the following technical solution: an automatic tube winding machine for a spiral tube heat exchanger, comprising a base, a tube winding assembly for winding the heat exchanger tubes on the base, a ground rail on one side of the base of the tube winding assembly, a reciprocating tube feeding assembly on the ground rail, the tube feeding assembly including a base plate adapted to the ground rail, a tube feeding and tensioning unit on one side of the top of the base plate for feeding the tubes and tensioning the heat exchanger tubes during the feeding process, and a multi-angle tube winding guide unit adapted to the tube feeding and tensioning unit on the other side of the top of the base plate; the tube winding assembly includes a tube winding shaft and a fixed seat for supporting and rotating the tube winding shaft.

[0006] Preferably, the pipe laying and tensioning unit includes a lifting and rotating support column, a pipe laying material wheel disposed on the lifting and rotating support column, and an intermediate guide fixture adapted to the pipe laying material wheel.

[0007] Preferably, the pipeline feeding wheel is fixed to the lifting and rotating support column by a support mounting plate installed on the lifting and rotating support column. The pipeline feeding wheel includes a wheel base and a detachable cover plate, which are fixed by a fixing knob.

[0008] Preferably, the lifting and rotating support column includes a lead screw, which is driven to move up and down by a first motor. A support mounting plate is installed on the lifting and rotating support column, and a rotating support is provided at the bottom of the lifting and rotating support column. The rotating support is driven by a servo motor and its deflection angle can be adjusted to adapt to different tube winding angles.

[0009] Preferably, the intermediate guide fixture is installed at the end of the support mounting plate and includes a housing. A heat exchange tube to be cut is inserted inside the housing. Guide wheels are provided above and below the heat exchange tube to be cut to allow it to pass through. A permanent magnet damper is installed on one side of the guide wheel and is connected to the guide wheel. A rodless cylinder is provided on the upper part of the permanent magnet damper. A pneumatic gripper is provided on one side of the guide wheel. A second motor is provided on the outside of the housing. The main shaft of the second motor is connected to a secondary shaft via a belt. The secondary shaft drives the heat exchange tube to be cut to rotate. A rotary tube cutting mechanism is provided on the outside of the secondary shaft. The rotary tube cutting mechanism includes two symmetrically arranged cutters that are in contact with the heat exchange tube to be cut. The movement of the two cutters is controlled by their respective cylinders.

[0010] Preferably, the multi-angle tube winding guide unit includes a six-axis robotic arm mounted on a base plate. The top of the six-axis robotic arm is provided with a tube winding guide fixture. The tube winding guide fixture includes a flange base, and a tube winding guide fixture housing is provided on the flange base. A tube winding guide vision camera is provided on the top of the tube winding guide fixture housing. The heat exchange tube to be cut passes through the inside of the tube winding guide fixture housing and is installed between the upper guide wheel and the lower guide wheel. A variable pitch linear module is provided on the upper part of the upper guide wheel, and a lifting cylinder is provided on the lower part of the lower guide wheel. A parallel pressure rail is provided on the heat exchange tube to be cut outside the tube winding guide fixture housing to apply pressure to the heat exchange tube to be cut. A pressure plate is provided on the pressure rail, a pressure block is provided on the pressure plate, and a clamping cylinder is provided on the pressure block.

[0011] Preferably, a dynamic torque sensor is provided on one side of the permanent magnet damper.

[0012] Preferably, the guide wheel is provided with a rubber sleeve.

[0013] Preferably, the lifting and rotating support column is equipped with multiple pipeline material rollers.

[0014] Preferably, there is a one-to-one correspondence between the plurality of pipeline feeding wheels and the intermediate guide fixture.

[0015] The advantages of this utility model are as follows:

[0016] (1) The rotary tube cutting mechanism can automatically cut tubes, improve tube cutting efficiency, and improve overall winding efficiency.

[0017] (2) Set up multiple wire feeding rollers to enable multiple heat exchange tubes to be fed and wound at the same time, thereby improving the overall winding efficiency.

[0018] (3) Pneumatic grippers and permanent magnet dampers are used to tension the heat exchange tubes and prevent the heat exchange tubes from springing back after winding.

[0019] In summary, this utility model, through the integration of mechanical design, automated control, sensor technology, and visual recognition system, can achieve precise bending of heat exchange tubes, simultaneous winding of multiple heat exchange tubes, and controllable winding pressure, thus significantly improving production efficiency and product quality. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the overall structure of this utility model.

[0021] Figure 2 This is a schematic diagram of the pipeline assembly structure of this utility model.

[0022] Figure 3 This is a schematic diagram of the structure of the pipeline feeding wheel of this utility model.

[0023] Figure 4 This is an exploded view of the lifting and rotating support column of this utility model.

[0024] Figure 5 This is a schematic diagram of the intermediate guide tool of this utility model.

[0025] Figure 6 This is a partial structural diagram of the intermediate guide tooling of this utility model.

[0026] Figure 7 This is a schematic diagram of the structure of the tube winding guide tool of this utility model. Detailed Implementation

[0027] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present utility model. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments.

[0028] Please see Figure 1As shown in Figure 7, one embodiment of this utility model provides an automatic tube winding machine for a wound tube heat exchanger, including a base 1. The base 1 is provided with a tube winding assembly for winding the heat exchanger tubes. A ground rail 2 is provided on one side of the base 1 of the tube winding assembly. A reciprocating tube feeding assembly is provided on the ground rail 2. The tube feeding assembly includes a base plate 7 adapted to the ground rail 2. A tube feeding and tensioning unit is provided on one side of the top of the base plate 7 for feeding the tubes and tightening the heat exchanger tubes during the feeding process. A multi-angle tube winding guide unit adapted to the tube feeding and tensioning unit is provided on the other side of the top of the base plate 7. The tube winding assembly includes a tube winding shaft 42 and a fixed seat 3 for supporting and rotating the tube winding shaft 42. The structure of the tube winding shaft 42 and the fixed seat 3 is conventional. The tube winding shaft 42 is driven to rotate by a motor.

[0029] Furthermore, the pipe laying and tensioning unit includes a lifting and rotating support column 5, a pipe laying material wheel 4 disposed on the lifting and rotating support column 5, and an intermediate guide fixture 6 adapted to the pipe laying material wheel 4.

[0030] Furthermore, the cable laying wheel 4 is fixed to the lifting and rotating support column 5 by a support mounting plate 8 installed on the lifting and rotating support column 5. The cable laying wheel 4 includes a wheel base 12 and a detachable cover plate 13, which are fixed by a fixing knob 14. When loading, the detachable cover plate 13 is removed manually, the cable laying material is placed on the base, and then the detachable cover plate 13 is installed to fix the cable laying material. The detachable cover plate 13 is made of lightweight material, which is convenient to operate and safe and reliable.

[0031] Furthermore, the lifting and rotating support column 5 includes a lead screw 15, which is driven to move up and down by a first motor 16. A support mounting plate 8 is installed on the lifting and rotating support column 5, and a rotating support 17 is provided at the bottom of the lifting and rotating support column 5. The rotating support 17 is driven by a servo motor 18 and its deflection angle can be adjusted to adapt to different winding angles. The lifting and rotating support column 5 is the main structure supporting the feed roller 4. Its support mounting plate 8 can install at least two feed rollers 4. The lifting structure is completed by the first motor 16 driving the lead screw 15. At the same time, the base is equipped with a rotating support 17, which can be driven by a servo motor 18 and its deflection angle can be adjusted to adapt to different winding angles.

[0032] Furthermore, the intermediate guide fixture 6 is installed at the end of the support mounting plate 8, including a housing 19. A heat exchange tube 20 to be cut is inserted inside the housing 19. Guide wheels 21 are provided above and below the heat exchange tube 20 to allow it to pass through. A permanent magnet damper 22 is installed on one side of the guide wheel 21, and the permanent magnet damper 22 is connected to the guide wheel 21. A rodless cylinder 23 is provided on the upper part of the permanent magnet damper 22. A pneumatic gripper 24 is provided on one side of the guide wheel 21. The housing 19... A second motor 25 is provided on the outside of the heat exchange tube 20. The main shaft 26 of the second motor 25 is connected to the secondary shaft 28 via a belt 27. The secondary shaft 28 drives the heat exchange tube 20 to be cut to rotate. A rotary tube cutting mechanism is provided on the outside of the secondary shaft 28. The rotary tube cutting mechanism includes two symmetrically arranged cutters 29 that are in contact with the heat exchange tube 20 to be cut. The movement of the two cutters 29 is controlled by their respective cylinders 30. The rotary tube cutting mechanism realizes the automatic cutting of the ultra-long heat exchange tube 20 and improves the cutting efficiency of the heat exchange tube 20.

[0033] The intermediate guide fixture 6 is a mechanism for supporting and guiding the heat exchange tube 20 to be cut. It is equipped with a permanent magnet damper 22, which is connected to the guide wheel 21. It can apply damping friction to the heat exchange tube 20 to be cut, making the winding tighter and preventing loosening. The rotary tube cutting mechanism can cut the heat exchange tube 20 to be cut. The pneumatic gripper 24 is used to clamp the pipeline during the cutting process.

[0034] Furthermore, the multi-angle tube winding guide unit includes a six-axis robotic arm 9 mounted on a base plate 7. The top of the six-axis robotic arm 9 is provided with a tube winding guide fixture 10. The tube winding guide fixture 10 includes a flange base 31, on which a tube winding guide fixture housing 32 is provided. A tube winding guide vision camera is provided at the top of the tube winding guide fixture housing 32. The heat exchange tube 20 to be cut passes through the inside of the tube winding guide fixture housing 32 and is installed between an upper guide wheel 33 and a lower guide wheel 34. A variable-pitch linear module 35 is provided at the upper part of the upper guide wheel 33, and a lifting cylinder 36 is provided at the lower part of the lower guide wheel 34. A cutting tool is provided on the heat exchange tube 20 to be cut outside the tube winding guide fixture housing 32. The heat exchange tube 20 is pressurized by parallel pressure rails 37, pressure plates 38 and pressure blocks 39, and pressing cylinders 40. The upper guide wheel 33, lower guide wheel 34 and lifting cylinder 36 can maintain the positional accuracy of the winding tube, clamp the tube for winding guidance, and ensure the accuracy of the winding position. The variable pitch linear module 35 can adjust the linear spacing to adjust the winding spacing of the heat exchange tube 20 to be cut. The pressing cylinder 40 and the pressing mechanism composed of pressure rails 37, pressure plates 38 and pressure blocks 39 can ensure that the heat exchange tube 20 to be cut has pre-pressure during winding to prevent the heat exchange tube 20 to be cut from being misaligned. The six-axis robotic arm 9 can adjust the winding tube guide fixture 10 at multiple angles.

[0035] Furthermore, a dynamic torque sensor 41 is provided on one side of the permanent magnet damper 22; the dynamic torque sensor 41 is used to monitor the torque generated by the guide wheel 21 in real time. If the torque is abnormal due to wear of the sheath, improper placement of the steel pipe or other reasons, the winding machine will be shut down through an alarm interlock and the abnormality will be manually checked and handled.

[0036] Furthermore, the guide wheel 21 is provided with a rubber sleeve; the rubber sleeve is used to protect the pipeline and increase friction.

[0037] Furthermore, multiple tube feeding rollers 4 are provided on the lifting and rotating support column 5; this enables the simultaneous winding of multiple heat exchange tubes, thereby improving the overall winding efficiency of the heat exchange tubes and reducing processing costs.

[0038] Furthermore, there is a one-to-one correspondence between the multiple pipeline feeding rollers 4 and the intermediate guide fixture 6.

[0039] Furthermore, a dynamic torque sensor 41 is provided on one side of the permanent magnet damper 22; it is used to monitor the torque generated by the guide wheel 21 in real time. If the torque is abnormal due to wear of the sheath, improper placement of the steel pipe or other reasons, the winding machine will be shut down through an alarm interlock and the abnormality will be manually checked and handled.

[0040] Furthermore, the guide wheel 21 is provided with a rubber sleeve to protect the pipeline and increase friction.

[0041] Furthermore, a winding guide vision camera is provided on the top of the winding guide tool housing 32.

[0042] This invention also includes an electrical control system, which uses a PLC with a touchscreen to control the entire system. The start / stop control of the winding shaft is integrated into this control system, enabling automatic control of the winding action, feeding angle, and feeding position. A formula-based production method is adopted, where winding-related parameters are pre-set in the formula system. During production, the appropriate formula is selected based on the model. The formula system supports common functions such as adding, deleting, and modifying formulas to meet the needs of customized production. The system uses a modern bus control method to control the robot, vision system, and winding shaft, ensuring system stability and real-time performance. The system works in conjunction with safety components to provide safety linkage in emergency situations, ensuring production safety.

[0043] Working Principle: During operation, the operator does not use this developed equipment when winding the first tube of each layer. Instead, the operator uses a handheld device to wind the first tube. Simultaneously, the light guidance system provides light indication or guidance at the first bending or welding point. During manual tube winding and unwinding, the operator manually controls the force and spacing to ensure that the equipment requirements are met. This developed equipment starts winding from the second tube of each layer. During winding, the operator bends the tube and inserts the end plate, while the equipment completes the winding of the straight section. This developed equipment can simultaneously wind two heat-conducting tubes. To facilitate end insertion and bending, the two heat-conducting tubes need to be staggered by one lead when winding simultaneously, with a maximum lead allowance of 1 meter. This also provides sufficient space for welding. During winding, the operator needs to communicate with the equipment in real time to ensure stable operation and to stop and start the equipment at the welding position.

[0044] When using this equipment, the parameters of the electrical control system are set in advance, the ground rail 2 and robot 9 are positioned, and the first heat-conducting tube of each layer is wound manually for positioning. Then, the equipment is started, and the heat exchange tube 20 to be cut is placed on the material wheel base 12. The direction and angle are adjusted by lifting and rotating support column 5. Then, the intermediate guide fixture 6 and the multi-angle winding tube guide unit guide the winding position so that the heat exchange tube 20 to be cut can be wound on the winding shaft.

[0045] This invention employs a six-axis robotic arm with an extended seventh axis ground rail, equipped with a light-guided system to guide and indicate the winding position, ensuring high-precision and flexible control of the feeding position and angle of the heat-conducting tube. This achieves automatic and precise feeding and winding of the tube. The robot's front end is equipped with a heat-conducting tube guide fixture to prevent excessive bending or deformation during feeding. The guide fixture is equipped with a clamping mechanism to ensure sufficient clamping force during winding. The feeding mechanism is integrated into the robot platform, facilitating easy loading and unloading, featuring a simple structure and freely adjustable direction. This design modifies existing tube winding equipment to meet automated winding functions. The control system uses a PLC combined with a touchscreen for centralized control of the entire system. By collecting data such as the winding equipment's rotation speed, the tension force is dynamically adjusted, and production is achieved through formula settings to meet product diversity requirements.

[0046] The equipment is compatible with wound-tube heat exchangers with a length not exceeding 30 meters and a diameter not exceeding 4.5 meters; the heat exchange tube diameter ranges from Φ10mm to Φ25mm, the heat exchange tube wall thickness ranges from 0.8mm to 2.0mm, and the heat exchange tube material is stainless steel.

[0047] The optical guidance system is a type of optical projection system used for positioning. Its function is to provide a reference after the operator bends the pipe, which can guide the operator to perform welding positioning or pipe bending positioning. This guidance system needs to project a light beam on the outermost layer of the pipe, within a range of approximately ±20CM of the operator's positioning range. The photoelectric guidance system is purchased directly from the market, and the model is BSRG-03.

[0048] It will be apparent to those skilled in the art that this invention is not limited to the details of the exemplary embodiments described above, and that it can be implemented in other specific forms without departing from the spirit or essential characteristics of this invention. Therefore, the embodiments should be considered illustrative and non-limiting in all respects, and the scope of this invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within this invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. An automatic tube winding machine for wound tube heat exchangers, comprising a base (1), characterized in that: The base (1) is provided with a winding assembly for winding the heat exchanger tubes. A ground rail (2) is provided on one side of the base (1) of the winding assembly. A reciprocating tube laying assembly is provided on the ground rail (2). The tube laying assembly includes a base plate (7) adapted to the ground rail (2). A tube laying tensioning unit is provided on one side of the top of the base plate (7) for laying tubes and tightening the heat exchanger tubes during the laying process. A multi-angle winding guide unit adapted to the tube laying tensioning unit is provided on the other side of the top of the base plate (7). The winding assembly includes a winding shaft (42) and a fixed seat (3) for setting the winding shaft (42) and enabling the winding shaft (42) to be supported and rotated.

2. The automatic tube winding machine for spiral tube heat exchangers according to claim 1, characterized in that: The pipe laying and tensioning unit includes a lifting and rotating support column (5), a pipe laying material wheel (4) set on the lifting and rotating support column (5), and an intermediate guide fixture (6) adapted to the pipe laying material wheel (4).

3. The automatic tube winding machine for spiral tube heat exchangers according to claim 2, characterized in that: The pipeline feeding wheel (4) is fixed on the lifting and rotating support column (5) by a support mounting plate (8) installed on the lifting and rotating support column (5). The pipeline feeding wheel (4) includes a wheel base (12) and a detachable cover plate (13). The wheel base (12) and the detachable cover plate (13) are fixed by a fixing knob (14).

4. The automatic tube winding machine for a wound tube heat exchanger according to claim 2, characterized in that: The lifting and rotating support column (5) includes a lead screw (15), which is driven to move up and down by a first motor (16). A support mounting plate (8) is installed on the lifting and rotating support column (5). A rotating support (17) is provided at the bottom of the lifting and rotating support column (5). The rotating support (17) is driven by a servo motor (18) and its deflection angle can be adjusted to adapt to different tube winding angles.

5. The automatic tube winding machine for a wound tube heat exchanger according to claim 2, characterized in that: The intermediate guide fixture (6) is installed at the end of the support mounting plate (8) and includes a housing (19). A heat exchange tube (20) to be cut is inserted inside the housing (19). Guide wheels (21) are provided above and below the heat exchange tube (20) to allow it to pass through. A permanent magnet damper (22) is installed on the lateral side of the guide wheel (21). The permanent magnet damper (22) is connected to the guide wheel (21). A rodless cylinder (23) is provided on the upper part of the permanent magnet damper (22). A rodless cylinder (23) is provided on the longitudinal side of the guide wheel (21). There is a pneumatic gripper (24), and a second motor (25) is provided on the outside of the housing (19). The main shaft (26) of the second motor (25) is connected to the secondary shaft (28) via a belt (27). The secondary shaft (28) drives the heat exchange tube (20) to be cut to rotate. A rotary tube cutting mechanism is provided on the outside of the secondary shaft (28). The rotary tube cutting mechanism includes two symmetrically arranged cutters (29) that are in contact with the heat exchange tube (20) to be cut. The movement of the two cutters (29) is controlled by their respective cylinders (30).

6. The automatic tube winding machine for a wound tube heat exchanger according to claim 1, characterized in that: The multi-angle tube winding guide unit includes a six-axis robotic arm (9) mounted on a base plate (7). The top of the six-axis robotic arm (9) is provided with a tube winding guide fixture (10). The tube winding guide fixture (10) includes a flange base (31). A tube winding guide fixture housing (32) is provided on the flange base (31). A tube winding guide vision camera is provided on the top of the tube winding guide fixture housing (32). The heat exchange tube (20) to be cut passes through the inside of the tube winding guide fixture housing (32). The heat exchange tube (20) to be cut is mounted on the upper guide. Between the guide wheel (33) and the lower guide wheel (34), the upper part of the upper guide wheel (33) is provided with a variable pitch linear module (35), and the lower part of the lower guide wheel (34) is provided with a lifting cylinder (36). The heat exchange tube (20) to be cut outside the casing (32) of the tube guide tooling is provided with a parallel pressure rail (37) to apply pressure to the heat exchange tube (20) to be cut. The pressure rail (37) is provided with a pressure plate (38), the pressure plate (38) is provided with a pressure block (39), and the pressure block (39) is provided with a clamping cylinder (40).

7. The automatic tube winding machine for a wound tube heat exchanger according to claim 5, characterized in that: A dynamic torque sensor (41) is provided on one side of the permanent magnet damper (22).

8. The automatic tube winding machine for a wound tube heat exchanger according to claim 5, characterized in that: The guide wheel (21) is provided with a rubber sleeve.

9. The automatic tube winding machine for a wound tube heat exchanger according to claim 2, characterized in that: Multiple pipeline material rollers (4) are installed on the lifting and rotating support column (5).

10. The automatic tube winding machine for a wound tube heat exchanger according to claim 2, characterized in that: The multiple pipeline feeding rollers (4) and the intermediate guide fixture (6) are in a one-to-one correspondence.

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