Plate-shaped heat dissipation unit with support weld between reinforcing rib and heat dissipation plate

Abstract

Plate-shaped heat dissipation unit with carrier weld of reinforcing rib and heat dissipation plate, comprising several heat dissipation plates (1), two oil collector tubes (2), several reinforcing ribs (3) and several welds, wherein the heat dissipation plate (1) is composed such that two heat dissipation components with a plate thickness of 1.0-1.2 mm are placed on top of each other and welded at a coupled circumference and at a coupled center, and wherein the heat dissipation plate (1) comprises: two flow openings, one of which is designed to distribute oil from the heat dissipation plate (1) into oil channels after the oil enters, and the other of which is designed to discharge the oil after the oil exits the oil channels, and the oil channels, which are opposite each other and form an oil chamber and are fluidically connected to the flow openings, and wherein the coupled perimeter comprises two long coupled edges and four short coupled edges separated by two flow openings, and wherein a long edge (4) of the heat dissipation plate (1) intersects and overlaps an outer surface of the reinforcing rib (3), and wherein the two long coupled edges of the heat dissipation plate (1) are arranged symmetrically with respect to an axis of the oil collector pipe (2), and wherein the welds comprise a continuous weld between the two flow openings of several heat dissipation plates (1) and outer diameters of two oil collection tubes (2) and a spot weld (6) between an outer edge (5) of the long coupled edges of several heat dissipation plates (1) and several reinforcing ribs (3), wherein the diagonal lines of the heat dissipation unit are equal, and wherein the axis of the oil collection tube (2) is perpendicular to the long edges of several heat dissipation plates (1), and wherein a robust connection between several heat dissipation plates (1) is achieved, characterized by the fact that the long edge (4) of the heat dissipation plate (1) intersects with the outer surface of the reinforcing rib (3), wherein a gap adapted to the carrier weld (7) is provided at a cutting area, the gap being 3 mm, and that a weld seam of welding material is formed between the outer edge (5) of the long coupled edge of the heat dissipation plate (1) and the outer surface of the reinforcing rib (3), and the weld seam has a carrier shape, and that the carrier weld (7) is divided into three zones: a fusion zone consisting of the welding material and the reinforcing rib (3), a fusion zone consisting of the welding material and the heat dissipation plate (1), and a connected carrier zone of weld material molten material between the two, wherein the connected carrier zone of weld material molten material is a metallic molten weld material.

Description

[0001] The present disclosure relates to the processing and manufacture of plate-shaped heat dissipation units for transformers and relates in particular to a plate-shaped heat dissipation unit with a carrier weld seam of reinforcing rib and heat dissipation plate.

[0002] The existing welding process for multiple heat dissipation plates and multiple reinforcing ribs of the plate-shaped heat dissipation unit for transformers involves spot welding the edges of the heat dissipation plates on both sides of the reinforcing ribs. This results in a large number of spot welds. However, the welds create an invisible zone at the intersection of the two components and in their narrow areas, which can lead to welding defects that are difficult to visually inspect. These defects can easily cause coating sagging, poor coverage, film shrinkage, pinholes, an uneven surface, and a lack of richness and luster in the outer paint during subsequent anti-corrosion coating. Over time, corrosion defects such as cracking, peeling, blistering, and rusting may also appear.The aforementioned defects, which are difficult to detect, pose corrosion risks to the plate-shaped heat dissipation unit for transformers and are susceptible to transformer oil leaks. To reduce these defects, the heat dissipation unit must be inverted several times during the welding of the heat dissipation plates to the reinforcing ribs, ensuring no invisible areas are present. The existing spot welding process should then be changed to continuous welding, and multiple heat dissipation plates and reinforcing ribs should be fully welded. Due to the limited space, where the distance between multiple heat dissipation plates is typically 45 mm, it is difficult to adjust the welding gun to the optimal welding position for complete welding. Therefore, this method can only eliminate some of the aforementioned defects; they cannot be completely avoided.

[0003] In summary, due to the available spot welding and continuous welding methods for multiple heat dissipation plates and reinforcing ribs in the area of ​​the plate-shaped heat dissipation unit for transformers, the use of spot welding results in a high weld defect rate. This negatively impacts the quality of corrosion protection in later stages, leading to leaks in the heat dissipation unit and a significant increase in the repair rate later on. Although the use of continuous welding can reduce weld defects, it is both labor-intensive and time-consuming, significantly reducing work efficiency and increasing the cost of welding materials.The welding defects that occur lead to a decrease in the corrosion protection capability of the plate-shaped heat dissipation unit used for transformers and simultaneously shorten the service life of the plate-shaped heat dissipation unit used for transformers.

[0004] CN 1 13 035 516 A relates to a uniform, low-stress cooling fin for a transformer cooler. The cooling fin is formed by welding peripheral and central mounting positions after two individual cooling fins are positioned opposite each other, each individual cooling fin featuring a shunt groove, a converging groove, an oil channel, a circumferential weld, and a central weld. The forming line where the main forming line of the oil channel on the individual cooling fin intersects with the weld is an arcuate curve, and this arcuate curve allows stress concentration areas at all edges, corners, and sharp corners of the heat dissipation element to form an arcuate shape.

[0005] CN 1 07 014 238 A relates to a hot-dip galvanized sheet metal heater comprising an oil inlet pipe, an oil outlet pipe, and a set of radiation plates. The set of radiation plates consists of the front radiation plates and the rear radiation plates. The hot-dip galvanized sheet metal heater is characterized in that several separating strips are arranged at intervals in the lateral direction on the heating plates, the separating strips extending vertically from top to bottom of the heating plates. The positions at which the separating strips are located are punched and fused together on the front and rear radiation plates, and the radiation oil paths between the front and rear radiation plates are separated to form several vertical runners.Front radiant panel zinc coatings are applied to the outer walls of the front radiant panels using a hot-dip galvanizing process; rear radiant panel zinc coatings are applied to the outer walls of the rear radiant panels using a hot-dip galvanizing process; and raceway zinc coatings are applied accordingly to the inner walls of the front and rear radiant panels. The hot-dip galvanized sheet metal radiator is resistant to harsh external environmental conditions, resistant to corrosion from contaminated transformer oil, and offers improved rot resistance, extended service life, reduced maintenance costs, and lower operating costs. Furthermore, the compressive strength of the radiant panels is improved, ensuring effective radiation.

[0006] DE 38 20 848 A1 relates to a method for joining workpieces, in particular sheet metal, using laser radiation, wherein the intensity of the laser radiation for the formation of a laser-induced plasma at the joining point is controlled depending on one or more joining point parameters and the intensity of the laser radiation is increased until the threshold intensity required for plasma formation is reached or slightly exceeded, and then, after the set intensity has been maintained for a predetermined time, is reduced to a value that leads to the extinguishing of the plasma.

[0007] The present disclosure provides a plate-shaped heat dissipation unit with a carrier weld connecting the reinforcing rib and the heat dissipation plate. The objective of this disclosure is to produce a highly efficient and high-quality plate-shaped heat dissipation unit with reduced material consumption and a low repair rate, in which the reinforcing rib and the heat dissipation plate are welded together.

[0008] A plate-shaped heat dissipation unit with a carrier weld between a reinforcing rib and a heat dissipation plate, comprising several heat dissipation plates, two oil collection tubes, several reinforcing ribs, and several welds, wherein the heat dissipation plate is composed such that two heat dissipation components with a plate thickness of 1.0-1.2 mm are placed on top of each other and welded at the coupled perimeter and at the coupled center, and wherein the heat dissipation plate comprises: two flow openings, one of which is designed to distribute oil from the heat dissipation plate into oil channels after the oil enters, and the other of which is designed to discharge the oil after the oil exits the oil channels; oil channels that are opposite each other and form an oil chamber and are fluidically connected to the flow openings, and wherein a coupled perimeter of the heat dissipation plate comprises two long coupled edges and four short coupled edges.which are separated by two flow openings, and wherein the long edge of the heat dissipation plate intersects and overlaps an outer surface of the reinforcing rib, and wherein the two long coupled edges of the heat dissipation plate are arranged symmetrically with respect to an axis of the oil collector pipe, and wherein the welds comprise a continuous weld between the two flow openings of several heat dissipation plates and outer diameters of two oil collector pipes and a spot weld between an outer edge of the long coupled edges of several heat dissipation plates and several reinforcing ribs, and wherein the diagonal lines of the heat dissipation unit are equal, and wherein the axis of the oil collector pipe is perpendicular to the long edges of several heat dissipation plates, and wherein a robust connection between several heat dissipation plates is achieved.

[0009] The long edge of the heat dissipation plate of the plate-shaped heat dissipation unit intersects the outer surface of the reinforcing rib, with a gap at the intersection, adapted to the carrier weld. The gap is 3 mm. A fusion weld is formed between the outer edge of the long coupled edge of the heat dissipation plate and the outer surface of the reinforcing rib, and the weld has a carrier shape. The carrier weld is divided into three zones: a fusion zone of the weld and the reinforcing rib, a fusion zone of the weld and the heat dissipation plate, and a bonded carrier zone of molten weld between the two, the bonded carrier zone of molten weld being a metallic melt of the weld.

[0010] The plate-shaped heat dissipation unit with a carrier weld between the reinforcing rib and the heat dissipation plate, as proposed in the present disclosure, offers the following advantages. The gap between the heat dissipation plate and the welded reinforcing rib of the plate-shaped heat dissipation unit for a transformer is set to 3 mm, and the weld has a carrier shape. This eliminates the invisible zone created during welding, thus reducing the difficulty of visual inspection. The carrier weld is a single point, creating a robust connection between the heat dissipation plates and reducing the consumption of consumables. The 3 mm gap between the heat dissipation plate and the welded reinforcing rib reduces the weld defect rate, improves the corrosion resistance of the weld, and decreases the subsequent repair rate.Under the premise of improving welding efficiency, ensuring the corrosion protection capability of the product and reducing product manufacturing costs, the service life of plate-shaped heat dissipation units for transformers is extended. Fig. Figure 1 is a schematic section view of the shape of the support weld between the reinforcing rib and the heat dissipation plate, as well as the three zones of the welded support weld; Fig. Figure 2 is a schematic section view of the shape of the carrier weld between the reinforcing rib and the heat dissipation plate; Fig. Figure 3 is a schematic section view of the existing spot welding between the heat dissipation plate and the reinforcing rib; Fig. Figure 4 is an axonometric schematic representation of the plate-shaped heat dissipation unit with carrier weld seam of reinforcing rib and heat dissipation plate; Fig. Figure 5 is a schematic front view of the plate-shaped heat dissipation unit with the carrier weld seam of the reinforcing rib and heat dissipation plate and the position of the welding gun; Fig. Figure 6 is a schematic section view of the enlarged front view of the arc start position of the beam welding between the reinforcing rib and the heat dissipation plate in Fig. 5; Fig. Figure 7 is a schematic section view of the enlarged front view of the arc end position of the beam welding between the reinforcing rib and the heat dissipation plate in Fig. 5; Fig. Figure 8 is a schematic top view of Fig. 5; Fig. Figure 9 is a schematic section view of the enlarged top view of the arc start position of the beam welding between the reinforcing rib and the heat dissipation plate in Fig. 8; Fig. Figure 10 is a schematic section view of the enlarged top view of the arc end position of the beam welding between the reinforcing rib and the heat dissipation plate in Fig. 8; Fig. Figure 11 is a schematic representation of the front view and sectional view of the heat dissipation plate; Fig. Figure 12 is a schematic enlarged section view of the shape of the carrier weld and the three zones of the welded carrier weld when the oil collector pipe of the heat dissipation unit is aligned horizontally to the horizontal plane; Fig. Figure 13 is a schematic right-hand view of Fig. 12; Fig. Figure 14 is a schematic representation of the position of the oil collector pipe of the plate-shaped heat dissipation unit, which is aligned horizontally to the horizontal plane, with the carrier weld seam of the reinforcing rib and heat dissipation plate, and the position of the welding gun; Fig. Figure 15 is a schematic section view of the enlarged front view of the arc start position of the beam welding between the reinforcing rib and the heat dissipation plate in Fig. 14; Fig. Figure 16 is a schematic section view of the enlarged front view of the arc end position of the beam welding between the reinforcing rib and the heat dissipation plate in Fig. 14; Fig. Figure 17 is a schematic right-hand view of Fig. 14; Fig. Figure 18 is a schematic section view of the enlarged front view of the arc start position of the beam welding between the reinforcing rib and the heat dissipation plate in Fig. 17; and Fig. Figure 19 is a schematic section view of the enlarged front view of the arc end position of the beam welding between the reinforcing rib and the heat dissipation plate in Fig. 17.

[0011] In the figures: 1. Heat dissipation plate; 2. Oil collector pipe; 3. Reinforcing rib; 4. Long edge; 5. Outer edge of the long coupled edge; 6. Spot weld; 7. Beam weld; 8. Welding gun.

[0012] The present disclosure is described in detail below with reference to the attached drawings and embodiments.

[0013] Example 1: With reference to Fig. 4 and Fig. 11 comprises a plate-shaped heat dissipation unit with a carrier weld between a reinforcing rib and a heat dissipation plate, several heat dissipation plates 1, two oil collection tubes 2, several reinforcing ribs 3, and several welds. The heat dissipation plate 1 is assembled by placing two heat dissipation components with a plate thickness of 1.0–1.2 mm on top of each other and welding them together at their coupled circumference and center. The heat dissipation plate 1 includes: two flow openings, one designed to distribute oil from the heat dissipation plate into oil channels after the oil enters the heat dissipation plate, and the other designed to discharge the oil after it exits the oil channels; oil channels, each opposite the other, forming an oil chamber and fluidically connected to the flow openings.The coupled perimeter of the heat dissipation plate comprises: two long coupled edges and four short coupled edges separated by two flow openings. The long edge 4 of the heat dissipation plate 1 intersects and overlaps an outer surface of the reinforcing rib 3, and the two long coupled edges of the heat dissipation plate 1 are arranged symmetrically with respect to an axis of the oil collector pipe 2. The welds of the heat dissipation plate 1 comprise: a continuous weld between the two flow openings of several heat dissipation plates 1 and the outer diameters of two oil collector pipes 2, and a spot weld 6 between an outer edge 5 of the long coupled edges of several heat dissipation plates 1 and several reinforcing ribs 3.The diagonal lines of the heat dissipation unit are equal, and the axis of the oil collector pipe 2 is perpendicular to the long edges of several heat dissipation plates 1, and a robust connection between several heat dissipation plates 1 is achieved.

[0014] With reference to Fig. 1 and Fig. 2 The long edge 4 of the heat dissipation plate 1 of the heat dissipation unit intersects with the outer surface of the reinforcing rib 3, and a gap adapted to the carrier weld 7 is provided at an intersection area, the gap being 1-4 mm, and preferably 3 mm. A fusion weld is formed between the outer edge 5 of the long coupled edges of the heat dissipation plate 1 and the outer surface of the reinforcing rib 3, and the weld has a carrier shape. The carrier weld 7 is divided into three zones: a fusion zone of the weld and the reinforcing rib 3, a fusion zone of the weld and the heat dissipation plate 1, and a bonded carrier zone of molten weld between the two. The bonded carrier zone of molten weld is the metallic melt of the weld. The shape of the reinforcing rib 3 is not limited to the shape shown in the drawing.

[0015] With reference to Fig. 1, 2, 5 to 10, the welding process for the plate-shaped heat dissipation unit with a carrier weld between the reinforcing rib and the heat dissipation plate is as follows: First, the outer surface of the reinforcing rib 3 is placed against the long edge 4 of the heat dissipation plate 1 of the heat dissipation unit, with a 3 mm gap between the two. Second, using a welding gun 8, welding begins at the arc start position of the molten zone between the weld material and the reinforcing rib, then transitions to the bonded carrier zone of molten weld material, forming a carrier weld. Welding then continues to the arc end position of the molten zone between the weld material and the heat dissipation plate, thus completing the carrier welding process between the heat dissipation plate 1 and the reinforcing rib 3.

[0016] The welding process mentioned above for the plate-shaped heat dissipation unit with carrier weld seam of reinforcing rib and heat dissipation plate comprises the following steps: Step 1: Setting the parameters for carrier seam welding: A welding voltage is set to 19V DC, an arc start current is set to 120A, an arc start time is set to 0.5s, a welding current is set to 100A, a welding speed is set to 3mm / s, an arc end current is set to 90A, and an arc end time is set to 0.5s. Step 2: The heat dissipation unit is arranged in a position where the axis of the oil collection pipe 2 is perpendicular to the horizontal plane. Step 3: The outer surface of the reinforcing rib 3 is held against the long edge 4 of the heat dissipation plate 1 of the heat dissipation unit, with a 3 mm gap between the two. This gap is the gap provided at the cutting area of ​​the long edge 4 of the heat dissipation plate 1 and the outer surface of the reinforcing rib 3 and is adapted to the beam weld 7. Step 4: The welding gun 8 is held at the arc start position on one side of the reinforcing rib 3, with the arc start position 3 mm higher than an upper edge of the outer edge 5 of the long coupled edge of the heat dissipation plate 1. Step 5: Welding is performed with a welding gun 8 from the arc start position of the molten zone consisting of the weld material and the reinforcing rib, then transitions into the connected carrier zone of molten weld material and forms a carrier weld seam of molten weld material. Welding then continues to the arc end position of the molten zone consisting of the weld material and the heat dissipation plate, and the carrier welding process between the heat dissipation plate 1 and the reinforcing rib 3 is completed.

[0017] Example 2: With reference to Fig. 12, Fig. 13, Fig. 14, Fig. 15, Fig. 16, Fig. 17, Fig. 18 to Fig. 19 The welding process for the plate-shaped heat dissipation unit with carrier weld seam of reinforcing rib and heat dissipation plate comprises the following steps: Step 1: Setting the parameters for carrier seam welding: A welding voltage is set to 19V DC, an arc start current is set to 120A, an arc start time is set to 0.5s, a welding current is set to 100A, a welding speed is set to 3mm / s, an arc end current is set to 90A, and an arc end time is set to 0.5s. Step 2: The heat dissipation unit is arranged in a position where the axis of the oil collection pipe 2 is horizontal (parallel) to the horizontal plane. Step 3: The outer surface of the reinforcing rib 3 is held against the long edge 4 of the heat dissipation plate 1 of the heat dissipation unit, with a 3mm gap between the two. Step 4: The welding gun 8 is held at the arc start position on one side of the reinforcing rib 3, with the arc start position perpendicular to an overlapping line on the long coupled edge of the two heat dissipation components of the welded heat dissipation plate 1. Step 5: Welding is performed with a welding gun 8 from the arc start position of the molten zone consisting of the weld material and the reinforcing rib, then transitions into the connected carrier zone of molten weld material and forms a carrier weld seam of molten weld material. Welding then continues to the arc end position of the molten zone consisting of the weld material and the heat dissipation plate, and the carrier welding process between the heat dissipation plate 1 and the reinforcing rib 3 is completed.

[0018] The gap between the heat dissipation plate and the welded reinforcing rib of the plate-shaped heat dissipation unit for a transformer proposed in this embodiment is set to 3 mm, and the weld has a carrier shape. This eliminates any invisible zone created during welding, thus reducing the difficulty of visual inspection. The carrier weld is a single point weld that creates a robust connection between the reinforcing rib and the heat dissipation plate and reduces the consumption of consumables. The 3 mm gap between the heat dissipation plate and the welded reinforcing rib reduces the weld defect rate, improves the corrosion resistance of the weld, and decreases the subsequent repair rate.Under the premise of improving welding efficiency, ensuring the corrosion protection capability of the product and reducing product manufacturing costs, the service life of plate-shaped heat dissipation units for transformers is extended.

Claims

[1] Plate-shaped heat dissipation unit with carrier weld of reinforcing rib and heat dissipation plate, comprising several heat dissipation plates (1), two oil collector tubes (2), several reinforcing ribs (3) and several welds, wherein the heat dissipation plate (1) is composed such that two heat dissipation components with a plate thickness of 1.0-1.2 mm are placed on top of each other and welded at a coupled perimeter and at a coupled center, and wherein the heat dissipation plate (1) comprises: two flow openings, one of which is designed to distribute oil from the heat dissipation plate (1) into oil channels after the oil enters, and the other of which is designed to discharge the oil after the oil exits the oil channels, and the oil channels, which are opposite each other and form an oil chamber and are fluidically connected to the flow openings, and wherein the coupled perimeter comprises two long coupled edges and four short coupled edges separated by two flow openings, and wherein a long edge (4) of the heat dissipation plate (1) intersects and overlaps an outer surface of the reinforcing rib (3), and wherein the two long coupled edges of the heat dissipation plate (1) are arranged symmetrically with respect to an axis of the oil collector pipe (2), and wherein the welds comprise a continuous weld between the two flow openings of several heat dissipation plates (1) and outer diameters of two oil collection tubes (2) and a spot weld (6) between an outer edge (5) of the long coupled edges of several heat dissipation plates (1) and several reinforcing ribs (3), wherein the diagonal lines of the heat dissipation unit are equal, and wherein the axis of the oil collection tube (2) is perpendicular to the long edges of several heat dissipation plates (1), and wherein a robust connection between several heat dissipation plates (1) is achieved, characterized by , that the long edge (4) of the heat dissipation plate (1) intersects with the outer surface of the reinforcing rib (3), wherein a gap adapted to the carrier weld (7) is provided at a cutting area, the gap being 3 mm, and that a weld seam of welding material is formed between the outer edge (5) of the long coupled edge of the heat dissipation plate (1) and the outer surface of the reinforcing rib (3), and the weld seam has a carrier shape, and that the carrier weld (7) is divided into three zones: a fusion zone consisting of the welding material and the reinforcing rib (3), a fusion zone consisting of the welding material and the heat dissipation plate (1), and a connected carrier zone of weld material molten material between the two, wherein the connected carrier zone of weld material molten material is a metallic molten weld material.

Images