Heat exchanger manufacturing method and heat exchanger manufacturing apparatus

Abstract

To provide a heat exchanger manufacturing method and a heat exchanger manufacturing device capable of suppressing deterioration in heat exchange efficiency.SOLUTION: A heat exchanger manufacturing method includes a first process of disposing a guide member, a second process of providing a gap inside in a first direction of a plurality of heat exchange parts, and a third process of bending the heat exchanger. The heat exchanger includes a plurality of heat exchange parts disposed aligned in the first direction. The guide member extends in a third direction orthogonal to the first direction and a second direction. In the first process, the guide member is disposed outside in the first direction of the plurality of heat exchange parts in an intermediate part in the second direction of the heat exchanger. In the second process, a gap is provided inside in the first direction of the plurality of heat exchange parts in a second end part in the second direction of the heat exchanger. In the third process, the heat exchanger is bent around the guide member while reducing the gap.SELECTED DRAWING: Figure 6

Description

[Technical field]

[0001] An embodiment of the present invention relates to a method and an apparatus for manufacturing a heat exchanger. [Background technology]

[0002] A heat exchanger having a pair of heat exchange parts arranged side by side in a first direction is used. The heat exchange parts have heat exchange tubes and fins. The heat exchange tubes extend in a second direction and are arranged side by side in a third direction. The fins are attached to the heat exchange tubes and are arranged side by side in the second direction. The heat exchanger may be used by bending the pair of heat exchange parts around the third direction. It is required for the heat exchanger to suppress a decrease in heat exchange efficiency. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2013-127341 A Summary of the Invention [Problem to be solved by the invention]

[0004] An object of the present invention is to provide a method and an apparatus for manufacturing a heat exchanger that can suppress a decrease in heat exchange efficiency. [Means for solving the problem]

[0005] A manufacturing method of a heat exchanger according to an embodiment includes a first step of arranging a guide member, a second step of providing a gap on the inside of a plurality of heat exchange sections in a first direction, and a third step of bending the heat exchanger. The heat exchanger has a plurality of heat exchange sections arranged side by side in the first direction. The relative positions of the plurality of heat exchange sections are fixed at a first end in a second direction perpendicular to the first direction. The guide member extends in a third direction perpendicular to the first and second directions. In the first step, the guide member is arranged outside the plurality of heat exchange sections in the first direction at a middle portion of the heat exchanger in the second direction. In the second step, a gap is provided inside the plurality of heat exchange sections in the first direction at a second end in the second direction of the heat exchanger. In the third step, while reducing the gap, Raise the first end of the heat exchanger. The heat exchanger is bent around the guide member. [Brief description of the drawings]

[0006] [Figure 1] FIG. [Diagram 2] FIG. 2 is a cross-sectional view taken along line II-II in FIG. [Diagram 3] FIG. 4 is a side view of an end support device included in the heat exchanger manufacturing apparatus according to the embodiment. [Figure 4] FIG. 2 is a first explanatory diagram of a method for manufacturing a heat exchanger according to an embodiment. [Diagram 5] FIG. 4 is a second explanatory diagram of the method for manufacturing the heat exchanger according to the embodiment. [Figure 6] FIG. 4 is a third explanatory diagram of the manufacturing method of the heat exchanger according to the embodiment. [Figure 7] FIG. 4 is a fourth explanatory diagram of the manufacturing method of the heat exchanger according to the embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0007] Hereinafter, a method and an apparatus for manufacturing a heat exchanger according to an embodiment will be described with reference to the drawings. FIG. 1 is a plan view of an outdoor unit 1 including a heat exchanger 10. FIG. 1 shows a state in which the top plate of the outdoor unit 1 is removed. In the present application, the X direction, Y direction, and Z direction of the Cartesian coordinate system are defined as follows. The X direction (first direction) is the direction in which the second header 17 of the second heat exchange section 12 and the first header 16 of the first heat exchange section 11 are aligned. The +X direction is the direction from the second header 17 to the first header 16. The Y direction (second direction) is the direction in which the heat exchange tube 20 extends at the connection portion of the heat exchange tube 20 to the second header 17. The -Y direction is the direction from the heat exchange tube 20 to the second header 17 at the connection portion. The Z direction (third direction) is the direction in which the second header 17 extends. The +Z direction is the upward direction of the outdoor unit 1.

[0008] The outdoor unit 1, together with an indoor unit (not shown) having an indoor heat exchanger, constitutes an air conditioner, which is a refrigeration cycle device. The outdoor unit 1 has a casing 2, an equipment unit 4, a fan 6, and a heat exchanger (outdoor heat exchanger) 10. The equipment unit 4, the fan 6, and the heat exchanger 10 are disposed inside the casing 2.

[0009] The casing 2 is in the shape of a rectangular parallelepiped box. For example, the casing 2 is short in the X direction and long in the Y direction. A ventilation hole (not shown) is formed on the surface of the casing 2 in the X direction. The equipment unit 4 is disposed, for example, in the -Y direction inside the casing 2. The equipment unit 4 includes a compressor 5 as well as a four-way valve, an expansion valve, and the like (none of which are shown). The fan 6 is disposed inside the casing 2, for example, at the center in the Y direction. The fan 6 introduces air into the casing 2 through ventilation holes in the casing 2.

[0010] The heat exchanger 10 is disposed inside the casing 2 from the center toward the +Y direction. When viewed from the Z direction, the heat exchanger 10 has an L-shaped bent shape. The heat exchanger 10 has a pair of heat exchange sections 11, 12. The pair of heat exchange sections 11, 12 is a first heat exchange section 11 and a second heat exchange section 12. The first heat exchange section 11 is disposed inside the bent heat exchanger 10. The second heat exchange section 12 is disposed outside the bent heat exchanger 10.

[0011] The heat exchanger 10 has a common header 15, a first header 16, and a second header 17. The common header 15 is disposed at a first end A of the heat exchanger 10. The first header 16 and the second header 17 are disposed at a second end B of the heat exchanger 10. The first header 16 is disposed at an end in the -Y direction of the first heat exchange section 11. The second header 17 is disposed at an end in the -Y direction of the second heat exchange section 12. A refrigerant space (not shown) through which a refrigerant flows is formed inside the common header 15, the first header 16, and the second header 17.

[0012] Fig. 2 is a cross-sectional view taken along line II-II in Fig. 1. The pair of heat exchange units 11, 12 has heat exchange tubes 20 and fins 25. The heat exchange tubes 20 and the fins 25 are made of a material having high thermal conductivity and low specific gravity, such as aluminum or an aluminum alloy.

[0013] The heat exchange tube 20 has a flat tubular shape. The cross section of the heat exchange tube 20 perpendicular to the extension direction has an elliptical shape. A refrigerant flow path 22 is formed inside the heat exchange tube 20. The refrigerant flow path 22 is formed over the entire length of the heat exchange tube 20. A plurality of refrigerant flow paths 22 are arranged side by side in the longitudinal direction of the cross section of the heat exchange tube 20. A plurality of heat exchange tubes 20 are arranged side by side in the Z direction. One end of the heat exchange tube 20 opens into the refrigerant space inside the common header 15. The other end of the heat exchange tube 20 opens into the refrigerant space inside the first header 16 and the second header 17.

[0014] The fins 25 are rectangular flat plates extending in the Z direction. A plurality of notches 27 are formed on the long sides of the fins 25. The plurality of notches 27 are formed on the inner side of the bent heat exchanger 10. A plurality of heat exchange tubes 20 are arranged in the plurality of notches 27. The fins 25 extend from the heat exchange tubes 20 to the outer side of the bent heat exchanger 10. The plurality of fins 25 are arranged side by side in the extension direction of the heat exchange tubes 20.

[0015] The heat exchanger 10 of the outdoor unit 1 functions as a condenser during cooling operation and as an evaporator during heating operation. During either cooling operation or heating operation, the refrigerant flows through the heat exchanger 10 as follows. The refrigerant flows into the heat exchanger 10 from the first header 16. The refrigerant flows through the heat exchange tubes 20 of the first heat exchange section 11 and flows into the common header 15. The refrigerant turns around at the common header 15 and flows through the heat exchange tubes 20 of the second heat exchange section 12. The refrigerant flows out of the heat exchanger 10 from the second header 17. During the other of cooling operation and heating operation, the refrigerant flows through the heat exchanger 10 in the opposite manner to the above.

[0016] The wind introduced into the casing 2 by the fan 6 flows between the fins 25 of the heat exchanger 10. Heat exchange is carried out between the wind introduced into the casing 2 and the refrigerant flowing through the heat exchange tubes 20.

[0017] The manufacturing apparatus 40 for the heat exchanger 10 will be described. Fig. 4 is a first explanatory diagram of the manufacturing method of the heat exchanger 10. As shown in Fig. 4, the manufacturing apparatus 40 bends the heat exchanger 10 formed parallel to the YZ plane into an L shape. Below, the manufacturing apparatus 40 in a state before bending the heat exchanger 10 will be described.

[0018] The manufacturing apparatus 40 includes a table 45 , a first clamper 41 , a second clamper 42 , a guide member 43 , a control unit 49 , and an end support device 30 . The +X surface of table 45 is parallel to the YZ surface. Heat exchanger 10 is placed on the +X surface of table 45. Table 45 supports heat exchanger 10 from the center of heat exchanger 10 in the Y direction toward the -Y direction.

[0019] The -X surface of the first clamper 41 and the +X surface of the second clamper 42 are parallel to the YZ surface. The heat exchanger 10 is disposed on the +X surface of the second clamper 42. The second clamper 42 supports the heat exchanger 10 from the center of the heat exchanger 10 in the Y direction toward the +Y direction. The first clamper 41 and the second clamper 42 gently sandwich the heat exchanger 10 in the X direction. Relative movement in the Y direction is permitted between the first clamper 41 and the second clamper 42 and the heat exchanger 10.

[0020] The guide member 43 has a cylindrical or columnar shape extending in the Z direction. A central axis C of the guide member 43 is parallel to the Z direction. The guide member 43 is disposed in the +X direction (outside in the X direction) of the pair of heat exchange units 11, 12. The guide member 43 is disposed in the middle of the heat exchanger 10 in the Y direction. The guide member 43 and the first clamper 41 are connected to each other.

[0021] The guide member 43 is rotatable around the central axis C. The first clamper 41 and the second clamper 42 rotate in the same phase as the guide member 43. A drive mechanism (not shown) rotates the guide member 43, the first clamper 41 and the second clamper 42. As the second clamper 42 rotates, the drive mechanism moves the second clamper 42 parallel to the heat exchanger 10. As a result, the second clamper 42 continuously supports the first end A of the heat exchanger 10 from the center thereof. The control unit 49 controls the operation of the drive mechanism.

[0022] 3 is an enlarged view of the end support device 30. The end support device 30 has a base member 31 and a tongue member 34. The base member 31 has a base plate 32 and a support column 33.

[0023] The base plate 32 is parallel to the YZ plane. As shown in FIG. 4, the base plate 32 is accommodated in a table 45. The +X surface of the base plate 32 and the +X surface of the table 45 are included in the same plane. A pillow member 37 is attached to the +X surface of the base plate 32. The pillow member 37 supports the second header 17 of the second heat exchange section 12 in the X direction. This reduces the contact pressure between the fins 25 of the second heat exchange section 12 and the base plate 32. The pillow member 37 is movable (freely movable) in the Y direction. This allows the second end B of the second heat exchange section 12 to move freely in the Y direction. 3, the support pillar 33 extends in the +X direction from the base plate 32. The support pillar 33 movably supports the tongue member .

[0024] The tongue member 34 is parallel to the YZ plane. The tongue member 34 can be moved in the X direction by a moving mechanism (not shown). The moving mechanism is, for example, a rack-and-pinion mechanism. The control unit 49 controls the operation of the moving mechanism. The tongue member 34 is movable (freely movable) in the Y direction. As shown in FIG. 4, the tongue member 34 supports the first header 16 of the first heat exchange unit 11 in the X direction. A pressing member 36 and an engaging member 35 are attached to the +X surface of the tongue member. The engaging member 35 is disposed in the +Y direction of the first header 16. The pressing member 36 is disposed in the -Y direction of the first header 16. When the first header 16 moves in the Y direction, the first header 16 presses the engaging member 35 or the pressing member 36, and the tongue member 34 moves in the Y direction. This allows the second end B of the first heat exchange unit 11 to move freely in the Y direction.

[0025] A method for manufacturing the heat exchanger 10 will now be described. Fig. 4 is a first explanatory diagram of a manufacturing method of the heat exchanger 10. Fig. 5 is a second explanatory diagram, Fig. 6 is a third explanatory diagram, and Fig. 7 is a fourth explanatory diagram. In this manufacturing method, the heat exchanger 10 formed parallel to the YZ plane is bent into an L shape by a manufacturing apparatus 40.

[0026] As shown in FIG. 4, a pair of heat exchange sections 11, 12 of the heat exchanger 10 are formed parallel to the YZ plane. The pair of heat exchange sections 11, 12 are arranged side by side in the X direction. The first heat exchange section 11 is arranged in the +X direction, and the second heat exchange section 12 is arranged in the -X direction. The length of the first heat exchange section 11 in the Y direction is shorter than the length of the second heat exchange section 12 in the Y direction. The first header 16 is arranged in the +Y direction of the second header 17. At the first end A in the +Y direction, the relative positions of the pair of heat exchange sections 11, 12 are fixed by a common header 15.

[0027] The heat exchanger 10 is disposed on the +X surface of the second clamper 42, the table 45, and the base plate 32. The common header 15 is supported by the second clamper 42. The second header 17 of the second heat exchange section 12 is supported by the pillow member 37 of the base plate 32. The fins 25 of the second heat exchange section 12 lightly contact the +X surface of the second clamper 42, the table 45, and the base plate 32.

[0028] In the middle of the heat exchanger 10 in the Y direction, a guide member 43 and a first clamper 41 extending in the Z direction are arranged in the +X direction (outside in the X direction) of the pair of heat exchange sections 11, 12 (first step). The guide member 43 and the first clamper 41 lightly contact the heat exchange tubes 20 and the fins 25 of the first heat exchange section 11.

[0029] The tongue member 34 is inserted inside the pair of heat exchange units 11, 12 in the X direction. The first header 16 of the first heat exchange unit 11 is supported by the tongue member 34. The first header 16 is disposed between the engagement member 35 and the pressing member 36. The distance between the tongue member 34 and the base plate 32 in the X direction is S1.

[0030] 5, at the second end B in the -Y direction of the heat exchanger 10, a gap G is provided inside the pair of heat exchange parts 11, 12 in the X direction (second step). The control unit 49 moves the tongue member 34 in the +X direction to form the gap G. The distance in the X direction between the tongue member 34 and the base plate 32 is S2 (>S1).

[0031] As shown in FIG. 6, the control unit 49 bends the heat exchanger 10 (third step). The control unit 49 rotates the guide member 43, the first clamper 41, and the second clamper 42 around the central axis C. The second clamper 42 raises the +Y direction portion of the heat exchanger 10. The heat exchanger 10 bends around the guide member 43 along the outer periphery of the guide member. Since the tongue member 34 is movable in the Y direction, the movement of the second end B of the first heat exchanger 11 in the Y direction is not restricted. The first heat exchanger 11 located inside the bending heat exchanger 10 is allowed to expand in the -Y direction. Since the pillow member 37 is movable in the Y direction, the movement of the second end B of the second heat exchanger 12 in the Y direction is not restricted. The second heat exchanger 12 located outside the bending heat exchanger 10 is allowed to contract in the +Y direction.

[0032] When the heat exchanger 10 bends, a pressing force acts between the pair of heat exchange sections 11, 12 around the guide member 43. This pressing force may deform the fins 25 of the first heat exchange section 11. The gap G provided inside the pair of heat exchange sections 11, 12 reduces the pressing force acting between the pair of heat exchange sections 11, 12. This suppresses deformation of the fins 25 of the first heat exchange section 11.

[0033] The control unit 49 bends the heat exchanger 10 while reducing the gap G. The control unit 49 moves the tongue member 34 in the -X direction, thereby reducing the gap G. The distance in the X direction between the tongue member 34 and the base plate 32 while the heat exchanger 10 is being bent is defined as S3. S2>S3>S1 holds. The angle (rise angle) between the heat exchanger 10 before bending and the heat exchanger 10 while being bent is defined as θ (°). The following formula 1 holds. θ / 90=1-(S3-S1) / (S2-S1)...(1)

[0034] As shown in Fig. 7, the control unit 49 raises the heat exchanger 10 up to θ = 90°. The control unit 49 reduces the gap G until the distance S4 in the X direction between the tongue member 34 and the base plate 32 becomes S1. The gap G becomes a minimum and the heat exchanger 10 takes on a predetermined shape. This completes the bending of the heat exchanger 10.

[0035] As described above in detail, the manufacturing method of the heat exchanger 10 of the embodiment includes a first step of arranging the guide member 43, a second step of providing a gap G on the inner side of the pair of heat exchange parts 11, 12 in the X direction, and a third step of bending the heat exchanger 10. The heat exchanger 10 has a pair of heat exchange parts 11, 12 arranged side by side in the X direction. The relative positions of the pair of heat exchange parts 11, 12 are fixed at a first end A in the Y direction perpendicular to the X direction. In the first step, a guide member 43 extending in the Z direction is arranged on the outer side of the pair of heat exchange parts 11, 12 in the X direction at a middle part of the heat exchanger 10 in the Y direction. In the second step, a gap G is provided on the inner side of the pair of heat exchange parts 11, 12 in the X direction at a second end part of the heat exchanger 10 in the Y direction. In the third step, the heat exchanger 10 is bent around the guide member 43 while reducing the gap G.

[0036] When the heat exchanger 10 is bent, a pressing force acts between the pair of heat exchange sections 11, 12 around the guide member 43. By providing a gap G inside the pair of heat exchange sections 11, 12, this pressing force is reduced. Deformation of the fins 25 of the first heat exchange section 11 is suppressed. Air flows between the fins 25, promoting heat exchange between the air and the refrigerant. Therefore, a decrease in heat exchange efficiency can be suppressed. By bending the heat exchanger 10 while reducing the gap G, the heat exchanger 10 of a predetermined shape is completed.

[0037] In the third step, the movement of the second end B of the heat exchanger 10 in the Y direction is not restricted. This allows the pair of heat exchange sections 11, 12 to expand and contract due to bending of the heat exchanger 10. This suppresses deformation of the fins 25 of the pair of heat exchange sections 11, 12. This makes it possible to suppress a decrease in heat exchange efficiency.

[0038] The manufacturing apparatus for the heat exchanger 10 of the embodiment has a base member 31 and a tongue member 34. The tongue member 34 is supported by the base member 31, and can be inserted inside the pair of heat exchange parts 11, 12 in the X direction at a second end B in the Y direction of the heat exchanger 10. The tongue member 34 is movable in the X direction relative to the base member 31.

[0039] By moving the tongue member 34 in the X direction, a gap G is provided on the inner side in the X direction of the pair of heat exchange sections 11, 12. Deformation of the fins 25 of the first heat exchange section 11 is suppressed, and a decrease in heat exchange efficiency can be suppressed. By bending the heat exchanger 10 while reducing the gap G, the heat exchanger 10 having a predetermined shape is completed.

[0040] The tongue member 34 is freely movable in the Y direction. This allows the expansion of the first heat exchange section 11 located inside the bent heat exchanger 10. This suppresses the deformation of the fins 25 of the first heat exchange section 11, and thus suppresses the decrease in heat exchange efficiency.

[0041] The heat exchanger 10 of the embodiment has, as the multiple heat exchange sections, a pair of heat exchange sections 11 and 12. The heat exchanger 10 may have three or more heat exchange sections.

[0042] According to at least one of the embodiments described above, the gap G is provided on the inner side in the X direction of the pair of heat exchange parts 11, 12, and the heat exchanger 10 is bent while reducing the gap G. This makes it possible to suppress deformation of the fins 25 and suppress a decrease in heat exchange efficiency.

[0043] Although some embodiments of the present invention have been described, these embodiments are presented as examples and are not intended to limit the scope of the invention. These embodiments can be implemented in various other forms, and various omissions, substitutions, and modifications can be made without departing from the spirit of the invention. These embodiments and their modifications are included in the scope of the invention and its equivalents described in the claims, as well as in the scope and spirit of the invention. [Explanation of symbols]

[0044] A...first end, B...second end, G...gap, X...first direction, Y...second direction, Z...third direction, 10...heat exchanger, 11...first heat exchange section (heat exchange section), 12...second heat exchange section (heat exchange section), 31...base member, 34...tongue member, 40...manufacturing apparatus, 43...guide member.

Claims

1. A method for manufacturing a heat exchanger having a plurality of heat exchange units arranged side by side in a first direction, the plurality of heat exchange units being fixed in relative positions at first ends in a second direction perpendicular to the first direction, the method comprising: a first step of arranging a guide member extending in a third direction perpendicular to the first direction and the second direction on an outer side of the plurality of heat exchange sections in the first direction at an intermediate portion of the heat exchanger in the second direction; a second step of providing gaps on inner sides of the plurality of heat exchange sections in the first direction at a second end portion of the heat exchanger in the second direction; and a third step of bending the heat exchanger around the guide member by raising a portion of the heat exchanger on the first end side while reducing the gap. A method for manufacturing a heat exchanger.

2. In the step of bending the heat exchanger, movement of the second end of the heat exchanger in the second direction is not restricted. A method for manufacturing the heat exchanger according to claim 1.

3. A manufacturing apparatus for a heat exchanger, comprising: a plurality of heat exchange units arranged side by side in a first direction; and a relative position of the plurality of heat exchange units is fixed at a first end in a second direction perpendicular to the first direction, the manufacturing apparatus comprising: A base member; a tongue member supported by the base member and insertable into an inner side of the plurality of heat exchange sections in the first direction at a second end of the heat exchanger in the second direction; a guide member disposed on an outer side of the plurality of heat exchange units in the first direction at an intermediate portion of the heat exchanger in the second direction and extending in a third direction perpendicular to the first direction and the second direction; a clamper that is rotatable in the same phase as the guide member while supporting the first end side of the heat exchanger, The tongue member is movable in the first direction relative to the base member. Heat exchanger manufacturing equipment.

4. The tongue member is freely movable in the second direction. An apparatus for manufacturing a heat exchanger according to claim 3.

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