Heat exchanger production line

Abstract

This invention provides a heat exchanger production line that can improve the production efficiency of heat exchangers. [Solution] The present invention relates to a heat exchanger production line including a support frame, a fin transport line, and fin loading / unloading devices, end plate mounting devices, tube insertion devices, and nitrogen filling devices installed at corresponding positions on the fin transport line, wherein the fin loading / unloading device is installed at one end of the fin transport line and includes a loading / unloading support holder, a support base plate, a lifting support plate, and a downline robot, and the fin stack is transferred onto the fin transport line by the fin loading / unloading device, and then sequentially transported along the fin transport line to corresponding work positions for processing, ultimately forming the heat exchanger.

Description

Technical Field

[0001] (Cross - reference to related applications) This application claims the priority of a Chinese patent application filed with the China National Intellectual Property Administration on March 27, 2025, with an application number of 202510378193.2 and a title of "Heat Exchanger Production Line", and all of its contents are incorporated herein by reference.

[0002] This application belongs to the technical field of air conditioner manufacturing, and particularly relates to a heat exchanger production line.

Background Art

[0003] In the air conditioner industry, a heat exchanger refers to an evaporator and a condenser, which play roles in evaporation, heat dissipation, and heat exchange, and are important components of a refrigeration system.

[0004] The manufacturing process of a heat exchanger includes many processes such as copper tube insertion, nitrogen filling, and welding. Workers move the fin stacks stored in the temporary storage area to the corresponding workbenches by a transport vehicle and perform processes such as manual pipe installation, nitrogen filling, and welding. Each time a heat exchanger is processed, workers need to bend down to carry away the fin stacks and lift them up with their arms. During this period, a large amount of ineffective setup and transportation occur, resulting in a significant reduction in production efficiency and high labor intensity.

Summary of the Invention

Problems to be Solved by the Invention

[0005] Some embodiments of this application provide a heat exchanger production line to solve the problems existing in related technologies, such as the excessive dependence on manual labor during the processing of heat exchangers and the movement between different working positions, low degree of mechanization and intelligence, and high labor costs.

Means for Solving the Problems

[0006] Some embodiments of this application submit a heat exchanger production line, and the heat exchanger production line is Support frame and A fin conveying line is installed on the support frame and has at least fin insertion / retraction positions, end plate mounting positions, pipe insertion work positions, and nitrogen filling work positions along the conveying direction, Installed at one end of the fin transport line, An internal storage position is formed in the insert / remove support holder, A support base plate horizontally installed at the storage position of the aforementioned retractable support holder, wherein a plurality of drop pins are vertically installed on the support base plate, and the first end of each drop pin is fixed to the support base plate, A lifting support plate is installed parallel to the above support base plate and configured to reciprocate in a direction perpendicular to the retractable support holder, wherein a plurality of through holes are formed on the lifting support plate, the plurality of drop pins each pass through the plurality of through holes, and the second end of each drop pin protrudes on the side away from the support base plate of the lifting support plate, and each drop pin is configured such that when the plurality of fins fall to the storage position, the second end of the drop pin is inserted into the insertion hole of the corresponding fin, and the plurality of fins connected by each drop pin form a fin stack on the lifting support plate, A fin retraction device including a downline robot configured to move the fin stack to the fin retraction position when the lifting support plate moves the fin stack to a target height, An end plate mounting device includes at least two end plate mounting robots provided corresponding to the end plate mounting positions and installed symmetrically on both sides of the fin transport line, wherein the fin transport line is configured to connect end plate members to both ends of the fin stack when the fin stack is transported from the fin insertion / removal position to the end plate mounting position, A pipe insertion device provided corresponding to the pipe insertion work position, wherein the pipe insertion device includes a pipe insertion robot, and after the attachment of the end plate member is completed, the fin transport line transports the fin stack to the pipe insertion work position, the pipe insertion robot including the pipe insertion robot body and pipe insertion jig inserts the heat exchange pipe member into the fin stack, the pipe insertion jig is connected to the pipe insertion robot body and includes two spaced-apart pipe insertion assemblies, each pipe insertion assembly includes an intermediate connection and at least one pipe gripping chuck installed on the intermediate connection, the pipe insertion device grips the pipe member with the pipe gripping chuck, and the pipe insertion device inserts the pipe member into the fin stack by driving the pipe insertion robot body, The nitrogen filling device is provided in accordance with the nitrogen filling work position and includes a nitrogen filling device, a nitrogen filling docking member, and a nitrogen filling robot, wherein the nitrogen filling robot is configured to grip the nitrogen filling docking member and dock with the pipeline member of the fin stack, and the nitrogen filling device fills the pipeline member with nitrogen via the nitrogen filling docking member. The aforementioned downline robot, The downline robot body and A downline jig installed on the downline robot body, comprising a gripping drive member and a symmetrically installed first downline gripping member and second downline gripping member, wherein the gripping drive member is configured to control the distance between the first downline gripping member and the second downline gripping member, the first downline gripping member includes a first downline gripping claw, the second downline gripping member includes a second downline gripping claw, the first downline gripping claw has a first positioning recess that opens toward the second downline gripping claw, the second downline gripping claw has a second positioning recess that opens toward the first downline gripping claw, and the first downline gripping claw and the front The downline jig includes the following: When the second downline gripping claw grips the fin stack by the action of the gripping drive member, both ends of a positioning pin, which is installed on the fin stack and inserted into the insertion opening of each fin in the fin stack by a positioning pin robot after the fin stack is formed, are inserted into the first positioning recess and the second positioning recess, respectively, and after the positioning pin has passed through the insertion opening of each fin in the fin stack, the first end of the positioning pin is supported on the lifting support plate and the second end is exposed above the fin stack, thereby enabling the first and second ends of the positioning pin to grip the first positioning recess and the second positioning recess, respectively. Each of the end plate mounting robots is End plate robot body, A connecting center beam installed on the end plate robot body, wherein a gripping drive member is installed within the connecting center beam, and a first telescopic end and a second telescopic end are formed at both ends of the gripping drive member, Two end plate jigs are installed at the first and second telescopic ends, respectively, and are configured to move relative to each other by the action of the gripping drive member to grip or release the end plate member, The system includes an extrusion member installed on the connecting center beam and configured to push out an end plate member held by an end plate jig to attach the end plate member to the fin stack, Heat exchanger production line.

[0007] The heat exchanger production line according to the present invention includes a fin transport line, on which at least fin insertion / removal positions, end plate mounting positions, pipe insertion positions, and nitrogen filling positions are provided according to the heat exchanger processing process. The fin stack is transferred onto the fin transport line by a fin insertion / removal device, and then sequentially transported along the fin transport line to the corresponding work positions for processing, ultimately forming the heat exchanger. The coordinated operation of each processing device on the heat exchanger production line can save material transfer steps in the heat exchanger production process and improve the production efficiency of the heat exchanger.

[0008] Furthermore, at the fin insertion / removal position, the processed and molded fins are stacked and placed on the lifting support plate via drop pins and positioning pins. Once the fin stack is complete, the lifting support plate raises the fin stack and positioning pins, which are then grasped by a downline robot and placed on the fin transport line. This maintains the integrity of the fin stack, reduces problems such as fin movement and misalignment within the fin stack, and further enhances the degree of mechanization and intelligence.

[0009] After referring to the drawings and reading about the specific embodiments of this application, other features and advantages of this application will become clearer.

[0010] To more clearly illustrate the embodiments of the present application or the technical solutions of the prior art, the following is a brief introduction of the drawings necessary for describing the embodiments or the prior art. Clearly, the drawings described below are some embodiments of the present application, and those skilled in the art can obtain other drawings based on these without expending any creative effort. [Brief explanation of the drawing]

[0011] [Figure 1] This is a schematic diagram of a heat exchanger production line relating to several embodiments. [Figure 2] These are partial configuration diagrams of fin extension / retraction devices according to several embodiments. [Figure 3]It is a positional diagram in the member storage state of the lifting support plate according to several embodiments. [Figure 4] It is a positional diagram in the member removal state of the lifting support plate according to several embodiments. [Figure 5] It is a configuration diagram of the lifting support plate according to several embodiments. [Figure 6] It is a configuration diagram of the down-line robot according to several embodiments. [Figure 7] It is a configuration diagram of the down-line jig according to several embodiments. [Figure 8] It is another configuration diagram of the down-line gripping member according to the embodiment. [Figure 9] It is an enlarged view of part A of FIG. 8. [Figure 10] It is a partial configuration diagram of the end plate mounting device. [Figure 11] It is a diagram of the conveyance state of the fin stack on the end plate mounting device. [Figure 12] It is a schematic diagram of the position of the jack-up member on the end plate mounting device. [Figure 13] It is a configuration diagram of the end plate mounting robot. [Figure 14] It is a schematic connection diagram of part B of FIG. 13. [Figure 15] It is a diagram of the state where the end plate jig grips the end plate member. [Figure 16] It is a configuration diagram of the heat exchanger. [Figure 17] It is a configuration diagram of the tube insertion robot. [Figure 18] It is a configuration diagram of the tube insertion jig. [Figure 19] It is a configuration diagram of the transfer jig. [Figure 20] It is a configuration diagram of the nitrogen filling device. [Figure 21] It is a configuration diagram of the tube insertion robot. [Figure 22] It is a configuration diagram of the pipeline gripping chuck. [Figure 23] It is FIG. 1 of the connection between the nitrogen filling docking member and the pipeline member. [Figure 24]Figure 23 is a cross-sectional view of CC. [Figure 25] This is the second diagram showing the connection between the nitrogen-filled docking member and the pipeline member. [Figure 26] This is a diagram showing the connections of elastic members. [Figure 27] This is a diagram illustrating the configuration of the heat exchanger painting work position in several embodiments. [Figure 28] This is a schematic diagram showing how the capsule portion is dispersed on the fins. [Figure 29] This is a schematic layout diagram of a fully automated, intelligent, smart maintenance system for air conditioners. [Figure 30] This is a flowchart of a fully automated intelligent production method for air conditioners. [Modes for carrying out the invention]

[0012] The technical solutions of the embodiments of the present application will be described clearly and completely below with reference to the drawings of the embodiments of the present application. Clearly, the embodiments described are some, but not all, embodiments of the present application. All other embodiments that a person skilled in the art can obtain without creative effort based on the embodiments of the present application are within the scope of the protection of the present application.

[0013] In the description of this application, directions or positional relationships indicated by terms such as "center," "top," "bottom," "front," "back," "left," "right," "vertical," "horizontal," "top," "bottom," "inside," and "outside" are based on the directions or positional relationships shown in the drawings, and are intended to facilitate the description of this application and simplify the description. They do not indicate or imply that the device or element has a specific direction or must be configured and operated in a specific direction, and therefore should not be understood as limitations on this application.

[0014] The terms “first” and “second” are used solely for descriptive purposes and should not be understood as implicitly specifying the number of technical features that indicate, imply, or are shown to be of relative importance. Therefore, features limited by “first” and “second” may include one or more such features, explicitly or implicitly. In this description, unless otherwise specified, “multiple” means two or more.

[0015] In this description, unless otherwise explicitly stated and limited, the terms “attachment,” “connection,” and “linking” should be interpreted broadly, for example, as fixed connections, detachable connections, or integrated connections; as mechanical or electrical connections; as direct connections or indirect connections via an intermediate medium; or as connections within two elements. Those skilled in the art will be able to understand the specific meaning of these terms in this application depending on the specific circumstances.

[0016] In this application, unless otherwise specifically defined and limited, the presence of a first feature "above" or "below" a second feature may include direct contact between the first and second features, or it may include contact between the first and second features not in direct contact but through another feature between them. Furthermore, the presence of a first feature "above," "above," or "on the top surface" of a second feature may include the first feature being directly above and diagonally above the second feature, or simply indicating that the horizontal height of the first feature is greater than that of the second feature. The presence of a first feature "below," "below," or "on the bottom surface" of a second feature may include the first feature being directly below and diagonally below the second feature, or simply indicating that the horizontal height of the first feature is lower than that of the second feature.

[0017] The following disclosure provides many different embodiments or examples for realizing different structures of the present application. To simplify the disclosure, the following describes the parts and settings of a particular example. Of course, these are merely illustrative and are not intended to limit the present application. Furthermore, the present application may repeatedly reference reference numbers and / or reference letters in different examples, and this repetition is for the purpose of simplification and clarification and does not itself indicate relationships between the various embodiments and / or settings discussed. Furthermore, the present application provides examples of various particular processes and materials, but those skilled in the art will be able to recognize the application of other processes and / or the use of other materials.

[0018] Referring to Figure 1, several embodiments of the present application provide a heat exchanger production line including a support frame 50, a fin conveying line 40, and a plurality of processing devices installed along the conveying direction of the fin conveying line 40.

[0019] The fin conveying line 40 is installed on the support frame 50, and along the conveying direction of the fin conveying line 40, at least a fin insertion / removal position, an end plate attachment position, a pipe insertion work position, and a nitrogen filling work position are provided.

[0020] The processing device includes a fin insertion / retraction device 400 provided in accordance with the fin insertion / retraction position, an end plate mounting device 500 provided in accordance with the end plate mounting position, a pipe insertion device 600 provided in accordance with the pipe insertion work position, and a nitrogen filling device 700 provided in accordance with the nitrogen filling work position.

[0021] When Figure 9 is combined, specifically, the fin conveying line 40 includes an upstream conveying line 41 and a downstream conveying line 42. The upstream conveying line 41 includes a plurality of rollers 4101 installed at intervals along the conveying direction of the upstream conveying line 41. Each roller 4101 is connected to a motor, which rotates the rollers 4101 to convey the fin stack 60.

[0022] The downstream transport line 42 includes a transport drive member and a transport belt. The transport drive member moves the transport belt to achieve the objective of transporting the fin stack 60 between work positions. When the fin stack 60 is transported to the corresponding machining work position, the transport drive member stops. Once the work corresponding to that machining work position is completed, the transport drive member restarts and continues transporting to the next work position.

[0023] The fin loading / unloading device 400 is installed at the end of the fin transport line 40 and is used to transfer the fin stack 60, which consists of fins processed and formed by an aluminum sheet unwinding machine and a punching machine, onto the fin transport line 40. The fin stack 60 then goes through subsequent processes to form a heat exchanger or evaporator.

[0024] The end plate mounting position and pipe insertion work position are located on the upstream conveyor line 41, and the nitrogen filling work position is located on the downstream conveyor line 42.

[0025] Between the upstream transport line 41 and the downstream transport line 42, an expanding device 43 and a drying device 44 are further installed, and the fin stack 60 is transported by a transfer robot 45 between the upstream transport line 41 and the expanding device 43, between the expanding device 43 and the drying device 44, and between the drying device 44 and the downstream transport line 42.

[0026] Further on the downstream transport line 42, there are pipe bending work positions, welding work positions, and nitrogen filling work positions. The pipe bending work position is located upstream of the nitrogen filling work position, and the welding work position and nitrogen filling work position are located sequentially downstream of the nitrogen filling work position along the transport direction of the downstream transport line 42.

[0027] Since the downstream transport line 42 is controlled on and off by a transport drive member, the arrangement of each work position must satisfy the requirement that each process performs the corresponding machining operation when the transport drive member is stopped, and when the transport drive member starts and transmits the data, the corresponding fin stack 60 is simultaneously transported to the next machining position.

[0028] The following provides a detailed explanation of the related processing devices. Referring to Figures 2 to 4, the fin extension / retraction device 400 includes an extension / retraction support holder 410. The extension / retraction support holder 410 has an overall frame structure, and a storage position is formed inside it. This storage position is a storage space formed within the extension / retraction support holder 410 that can accommodate a fin stack.

[0029] As an example, as shown in Figure 2, the retractable support holder 410 is approximately rectangular in shape. In the following description, the bottom of the retractable support holder 410 refers to the side facing the floor when in use, and the top refers to the side opposite the bottom. The direction from the top to the bottom of the retractable support holder 410 is the height direction.

[0030] The fin extension / retraction device 400 further includes a support base plate 420. The support base plate 420 is mounted horizontally on the extension / retraction support holder 410 and is located at the bottom of the storage position formed within the extension / retraction support holder 410.

[0031] Multiple drop pins 61 are vertically installed on the support base plate 420. The bottom of each drop pin 61 is fixed to the support base plate 420, and the top of the drop pin 61 extends vertically upward, positioned to move the fins into their storage positions after processing and molding.

[0032] Referring to Figure 3, in the operating state, when the fins are positioned within the fin extension / retraction device 400, the length direction of the fins is defined as the first direction, the width direction of the fins as the second direction, and the thickness direction of the fins as the third direction. Along the second direction, the fins in the retracted position form multiple groups of fin stacks 60, and each group of fin stacks 60 includes multiple fins stacked on the drop pins 61 along the third direction. This third direction is also the height direction of the extension / retraction support holder 410.

[0033] The fin extension / retraction device 400 further includes a lifting support plate 430. The lifting support plate 430 is located above the support base plate 420 and is movably connected to the extension / retraction support holder 410, and is reciprocally movable in the height direction of the extension / retraction support holder 410. Exemplarily, the lifting support plate 430 is installed parallel to the support base plate 420. The lifting support plate 430 has a plurality of through holes 432 formed therein, which are configured to allow the plurality of drop pins 61 to pass through.

[0034] To make it clear, the plurality of drop pins correspond to the plurality of through holes. Each of the plurality of drop pins passes through the plurality of through holes, and the top of each drop pin protrudes away from the support base plate of the lifting support plate.

[0035] The lifting support plate 430 is configured to accommodate fins. Each fin has a through-hole (not shown) formed therein, and when a fin is placed on the lifting support plate 430, a drop pin 61 passes through the corresponding through-hole 432 and then connects to the corresponding insertion hole. Each drop pin can pass through multiple stacked fins, and fins passed through one drop pin form one fin stack.

[0036] A drive device 440 is installed on the retraction support holder 410, and drives the lifting support plate 430 to move up and down in the height direction of the retraction support holder 410.

[0037] In some embodiments, the drive device 440 is a cylinder. In other embodiments, the drive device 440 may be a motor.

[0038] As the lifting support plate 430 moves up and down in the height direction of the retraction support holder 410, the fin stack can be moved up and down, the drop pin 61 remains fixed, and the insertion hole and through hole 432 move up and down relative to the drop pin 61.

[0039] After the fin stack 60 is formed in its storage position, positioning pins 62 are further installed on the fin stack 60. After the fin stack is formed, the positioning pins 62 are inserted into the insertion openings of each fin in the fin stack by a positioning pin robot (not shown).

[0040] One end of the positioning pin 62 is supported on the lifting support plate 430, and the other end passes through a pre-prepared insertion hole in each fin within the fin stack 60 and extends upwards from the fin stack 60.

[0041] There are no through holes 432 in the positions where the lifting support plate 430 and the positioning pin 62 correspond. As the lifting support plate 430 moves up and down, the positioning pin 62 also moves, always passing through and holding each fin in the same group of fin stacks 60.

[0042] The heat exchanger production line further includes a downline robot 450. When combined with Figure 6, the downline robot 450 is configured to transfer each group of fin stacks 60 onto the upstream transport line 41. The downline robot 450 includes a downline robot body 451 and a downline jig 452, the downline jig 452 being mounted on the downline robot body 451.

[0043] The downline robot body 451 includes a downline robot base 4511, a downline robot arm 4512, and a downline robot forearm 4513, which are connected in sequence.

[0044] In addition, the downline robot 450 further includes a robot motor and a vision camera. The downline robot base 4511 is bolted to the floor, the robot motor is connected to the downline robot base 4511 (for example, by bolts), the downline robot base 4511, the downline robot arm 4512, and the downline robot forearm 4513 are all connected via sliding joints, and the vision camera is mounted on the downline jig 452 and used to acquire positional information of the fin stack 60.

[0045] Referring to Figures 7 to 9, the downline jig 452 includes a first downline gripping member 4521 and a second downline gripping member 4522, which are symmetrically positioned. The first downline gripping member 4521 and the second downline gripping member 4522 are each equipped with a gripping portion, which is used to grip both ends of the positioning pin 62.

[0046] The downline robot 450 is configured to grasp both ends of the fin stack 60 on the lifting support plate 430 and move it to the target position, that is, to grasp and move the fin stack 60 up to the upstream transport line 41.

[0047] Along the length of each fin, at least one positioning pin 62 is inserted at each end of the fin stack 60, the bottom of the positioning pin 62 is in contact with the lifting support plate 430, the top of the positioning pin 62 extends to the upper end of the fin stack 60, and the first downline gripping member 4521 and the second downline gripping member 4522 are used to grip the upper end and lower end of the positioning pin 62, respectively.

[0048] The first downline gripping claw has a first positioning recess that opens toward the second downline gripping claw, and the second downline gripping claw has a second positioning recess that opens toward the first downline gripping claw. When the first downline gripping claw and the second downline gripping claw grip the fin stack by the action of the gripping drive member, both ends of the positioning pin installed on the fin stack are inserted into the first positioning recess and the second positioning recess, respectively.

[0049] Exemplary, the first downline gripping member 4521 and the second downline gripping member 4522 are each connected to the end of the downline robot forearm 4513 via a gripping drive member, the first downline gripping member 4521 includes two spaced-apart first downline gripping claws, and the second downline gripping member 4522 includes two spaced-apart second downline gripping claws, the first downline gripping claws are used to grip the upper end of the positioning pin 62, and the second downline gripping claws are used to grip the lower end of the positioning pin 62. As can be understood, the number of downline gripping claws may be other values, and the present invention is not limited thereto.

[0050] There may be two gripping drive members, each of which includes one output terminal connected to a first downline gripping claw and a second downline gripping claw, respectively.

[0051] Alternatively, the number of gripping drive members may be one, with two output terminals, the two output terminals located on either side of the gripping drive member and connected to a first downline gripping claw and a second downline gripping claw.

[0052] The first downline gripping claw and the second downline gripping claw are each connected to the gripping drive member via adapter plates 4523. That is, the output end of the gripping drive member is connected to the adapter plate 4523, and the first downline gripping claw and the second downline gripping claw are each connected and fixed to the corresponding side of the adapter plate 4523.

[0053] The first downline gripping claw has a first positioning clamp plate formed perpendicular to the adapter plate 4523, and the first positioning clamp plate has at least one first positioning recess formed toward the second downline gripping claw.

[0054] The second downline gripping claw has a second positioning clamp plate 4524 formed perpendicular to the adapter plate 4523, and the second positioning clamp plate 4524 has at least one second positioning recess 4525 that opens toward the first downline gripping claw.

[0055] When in the gripping state, the upper end of the positioning pin 62 is inserted into the first positioning recess, and the lower end of the positioning pin 62 is inserted into the second positioning recess 4525.

[0056] The first downline gripping claw further includes a first connecting plate, which is positioned perpendicular to the first positioning clamp plate, and the first positioning clamp plate is detachably connected to the adapter plate 4523 via the first connecting plate.

[0057] The second downline gripping claw further includes a second connecting plate 4527, which is positioned perpendicular to the second positioning clamp plate 4524, and the second positioning clamp plate 4524 is detachably connected to the adapter plate 4523 via the second connecting plate 4527.

[0058] The first downline gripping claw and the second downline gripping claw are detachably connected to the adapter plate via a positioning clamp plate. If the positioning clamp plate wears out and affects its operation, it can be easily replaced without replacing the entire robot, saving maintenance costs.

[0059] The first connecting plate and the first positioning clamp plate are formed as a single unit, and the second connecting plate 4527 and the second positioning clamp plate 4524 are formed as a single unit. Reinforcement parts 4528 are installed between the first connecting plate and the first positioning clamp plate, and between the second connecting plate 4527 and the second positioning clamp plate 4524, respectively, to increase the connection strength between the first connecting plate and the first positioning clamp plate, and between the second connecting plate 4527 and the second positioning clamp plate 4524.

[0060] A guide slope 4526 is formed at the end of the second positioning clamp plate 4524, which corresponds to the lower end of the fin stack 60. The guide slope 4526 is used to lift the bottommost fin of the fin stack 60 and guide the lower end of the positioning pin 62 into the second positioning recess 4525 as the second downline gripping claw moves to the bottom of the fin stack 60.

[0061] To facilitate gripping of the second positioning clamp plate 4524, in some embodiments of the present application, an upwardly extending support projection 431 is formed on the lifting support plate 430, and the length of the support projection 431 along the first direction is shorter than the length of the fin.

[0062] Each fin stack 60 is supported on a support projection 431, and the action of the support projection 431 creates a gripping gap between the bottom of each fin stack 60 and the lifting support plate 430, and the second downline gripping member 4522 moves from the gripping gap to the bottom of the fin stack 60 and grips the positioning pin 62.

[0063] In order to avoid interference between the adapter plate 4523 on the second positioning clamp plate 4524 and the support projection 431 during the gripping process, the length of the second connecting plate 4527 is designed to extend beyond the end of the adapter plate 4523 in a direction away from the first connecting plate, so that the adapter plate 4523 is positioned above the support projection 431 during the gripping process of the second positioning clamp plate 4524, thereby avoiding interference.

[0064] Next, we will describe the end plate mounting device 500.

[0065] Referring to Figures 10 and 11, the fin transport line 40 has end plate mounting positions, and the end plate mounting device 500 fits into the end plate mounting positions.

[0066] The end plate mounting device 500 includes an end plate mounting robot 510. The end plate mounting robot 510 is installed symmetrically on both sides of the fin transport line 40 and is used to simultaneously attach end plate members 63 to both ends of the fin stack 60.

[0067] Each end plate mounting robot 510 includes an end plate robot body 511, a connecting center beam 512, a gripping drive member, and two end plate fixtures 513. The connecting center beam 512 is mounted on the end plate robot body, the gripping drive member is mounted on the connecting center beam 512, and the two end plate fixtures 513 are mounted on the gripping drive member. The gripping drive member causes the two end plate fixtures 513 to move relative to or opposite to each other, gripping or releasing the end plate member 63.

[0068] The gripping drive member is positioned along the longitudinal direction of the connecting center beam 512, and a first telescopic end and a second telescopic end are formed on the gripping drive member. Two end plate jigs 513 are installed on the first telescopic end and the second telescopic end, respectively.

[0069] Alternatively, in another embodiment, the gripping drive member corresponds to the end plate jig 513, the two gripping drive members are each symmetrically mounted on the connecting center beam 512, and the end plate jig 513 is mounted on the output end of the gripping drive member.

[0070] The end plate mounting device 500 further includes a lifting stopper member 520. The lifting stopper member 520 is installed on the fin transport line 40, and before the fin stack 60 is transported to the end plate mounting position, the lifting stopper member 520 rises and stops the fin stack 60.

[0071] The lifting stopper member 520 specifically includes a lifting drive member 521 and a stopper portion 522. The lifting drive member 521 is used to be installed below the fin conveying line 40, and the stopper portion 522 is installed at the output end of the lifting drive member 521. By the action of the lifting drive member 521, the stopper portion 522 moves up and down between corresponding adjacent rollers 4101 on the fin conveying line 40, and is used to stop and correct the position of the fin stack 60 at corresponding positions on the fin conveying line 40.

[0072] The stopper section 522 includes two or more stopper blocks 5221 spaced apart along the axial direction of the roller 4101, both of which are connected to the output end of the lifting drive member 521, which simultaneously raises the two stopper blocks 5221 so that they rise above the roller 4101 and stop the forward transport of the fin stack 60 before the fin stack 60 is transported to the end plate mounting position.

[0073] If there is an angle misalignment between the fin stack 60 and the roller 4101, the stopper block 5221 corrects the fin stack 60 so that it is parallel to the axial direction of the roller 4101, making it easier for the end plate robot to attach the end plate member 63.

[0074] A gripping position for the end plate is formed between two end plate jigs 513 of the end plate mounting robot 510, and an extrusion member 514 extending in the direction of the end plate gripping position is installed on the connecting center beam 512. The extrusion member 514 includes an extrusion power member and an extrusion end, the extrusion power member is fixed to the connecting center beam 512, and the extrusion end is fixed to the output end of the extrusion power member. The extrusion member 514 is configured to push out the end plate member 63 gripped by the end plate jig and attach the end plate member 63 to the fin stack.

[0075] A pallet member 4102 is further installed on the fin conveying line 40, and the downline robot positions the fin stack 60 on the pallet member 4102 so that the positioning pins installed in the fin stack are parallel to the width direction of the fin conveying line and also parallel to the pallet member. The fin conveying line conveys the fin stack via the pallet member 4102 along the direction of travel of the conveying line.

[0076] The end plate mounting device 500 further includes a jack-up member 530. The jack-up member 530 is installed upstream of the lifting stopper member 520 and includes a jack-up drive member and a jack-up block, the jack-up drive member is installed below the end plate mounting position and the jack-up block is installed at the output end of the jack-up drive member, and by the action of the jack-up drive member the jack-up block moves up and down between the corresponding rollers 4101 and is used to lift a pallet that has been transported to the jack-up block installation position. In some embodiments, the jack-up drive member is a cylinder.

[0077] If the conveying direction of the fin conveying line 40 is defined as the X direction, the width direction of the fin conveying line 40 as the Y direction, and the height direction of the fin conveying line 40 as the Z direction, and the dimension of the end plate member 63 along the Z direction is defined as the width of the end plate member 63, and the dimension of the fin stack 60 along the Z direction is defined as the width of the fin stack 60, then the width L1 of the end plate member 63 is greater than the width L2 of the fin stack 60, and the thickness L3 of the pallet member 4102 satisfies L3 > (L1 - L2) / 2, so that the end plate member 63 does not interfere with the roller 4101 when it is attached to both ends of the fin stack 60.

[0078] Further upstream of the end plate mounting position, a detection member 550 is installed. The detection member 550 is mounted on the support frame 50 and positioned on one side of the roller 4101. The detection member 550 is configured to detect the position of the pallet member on which the fin stack is placed, and to generate a detection signal when it detects that the pallet member on which the fin stack is placed has reached a predetermined position. The detection member 550 is connected to a controller 70, which communicates with the lifting drive member 521 and the jack-up drive member. The controller 70 receives the detection signal from the detection member 550 and controls the operation of the lifting drive member 521 and the jack-up drive member based on the detection signal.

[0079] The controller 70 controls the entire processing line and is used to control the starting and stopping of the fin conveying line 40, the operation of each robot, and the switching of each device. The operating principle of the controller 70 can be found in related technologies and will not be explained in detail here.

[0080] In other embodiments, the fin conveying line 40 is further equipped with a centering assembly 540, which includes two centering beams 541 symmetrically positioned on the fin conveying line 40, the centering beams 541 located downstream of the end plate mounting position, and a centering passage is formed between the centering beams 541, which is used to center the pallet to an intermediate position on the fin conveying line 40.

[0081] A guide section 542 is installed at one end of each centering beam 541 near the end plate mounting position, and a guide channel is formed between the two guide sections 542 that gradually narrows along the transport direction of the fin stack 60.

[0082] The centering beam 541 is fixed to the support frame 50 via a centering bracket 543, and the height of the centering beam 541 is lower than the positioning pins 62 on the fin stack.

[0083] After the end plate installation is complete, the stopper block 5221 on the lifting stopper member 520 descends, and the fin stack 60 continues to be transported downstream along the fin transport line 40.

[0084] After the end plate members 63 at both ends of the fin stack 60 pass through the guide channels, the fin stack 60 moves toward an intermediate position on the fin transport line 40 due to the action of the guide section 542, improving the positional accuracy of the fin stack 60 during transport and making it easier for the tube insertion robot 610 to operate when inserting subsequent tubes.

[0085] Multiple limit protrusions are provided on opposing sides of the two end plate jigs 513, and a gripping position that restricts the end plate member 63 is formed between the limit protrusions of each end plate jig 513. When gripped, the end of the end plate member 63 is positioned between the limit protrusions, restricting the position of the end plate member 63 and preventing it from falling off the end plate jig 513.

[0086] Referring to Figures 13 to 16, the end plate robot body 511, like the downline robot body 451, includes sequentially connected end plate robot bases, end plate robot arms, and end plate robot forearms.

[0087] In addition, the end plate robot includes a robot motor and a vision camera. The base of the end plate robot is fixed to the floor with bolts, the robot motor is connected to the base of the end plate robot via bolts, and the base of the end plate robot, the end plate robot arm, and the end plate robot forearm are all connected via sliding joints. The vision camera is mounted on the end plate jig 513 and is used to acquire positional information of the fin stack 60 and positioning pins 62. The end plate robot installs the end plate members based on this positional information.

[0088] Through holes corresponding to the fins are also provided on the end plate member 63, and the end plate member 63 is inserted onto the positioning pin 62 through the corresponding through holes. After the insertion of the end plate member 63 is complete, the extrusion power member drives the extrusion end to push the end plate member 63 forward, simultaneously pushing both end plate members 63 toward the center, attaching the end plate member 63 to the predetermined position, eliminating the gaps between the fins, and closely connecting the fins.

[0089] After the end plate members are attached, the fin stack 60 is transported downstream along the fin transport line 40 to reach the pipe insertion work position.

[0090] A pipe insertion device 600 is installed to the side of the pipe insertion work position. The pipe insertion device 600 is configured to grip the pipeline member 64 and insert the pipeline member 64 into the insertion hole in the fin stack 60.

[0091] Referring to Figures 17 and 18, the pipe insertion device 600 includes a pipe insertion robot 610, which includes a pipe insertion robot body 611 and a pipe insertion jig 612, which is connected to the pipe insertion robot body 611 and includes two spaced-apart pipe insertion assemblies, each pipe insertion assembly including an intermediate connection 613 and at least one pipe gripping chuck 614 installed on the intermediate connection 613, the pipe insertion device 600 grips the pipe member 64 with the pipe gripping chuck 614 and inserts the pipe member 64 into the fin stack 60 by driving the pipe insertion robot body 611.

[0092] In addition, the pipe insertion robot 610 also includes a robot motor and a vision camera, the pipe insertion robot base is fixed to the floor (for example with bolts), the robot motor is connected to the pipe insertion robot base (for example with bolts), the pipe insertion robot base, the pipe insertion robot arm, and the pipe insertion robot forearm are all connected via sliding joints, and the vision camera is mounted on the pipe insertion jig 612 and used to acquire positional information of the fin stack 60 and the insertion hole.

[0093] Each conduit gripping chuck 614 includes a gripping chuck drive member 6141 and a gripping chuck end 6142. The gripping chuck drive member 6141 has a first telescopic end and a second telescopic end at both ends, and there are two gripping chuck end 6142, which are installed at the first and second telescopic ends, respectively. Each gripping chuck end 6142 has a gripping chuck recess 6143, and the conduit member 64 is used to grip within the gripping position formed by the two gripping chuck recesses 6143. In some embodiments, the gripping chuck drive member 6141 is a cylinder.

[0094] The conduit member 64 has an overall U-shaped structure, and both ends of the conduit member 64 are simultaneously inserted into the corresponding insertion holes of the fin stack 60. To enhance the gripping stability of the conduit member 64, each conduit insertion jig 612 includes two conduit gripping chucks 614 that are spaced apart, and the conduit gripping chucks 614 on each conduit insertion jig 612 are used to grip and insert one side of the conduit of the conduit member 64.

[0095] At least two pipe insertion devices 600 are installed at intervals along the conveying direction of the fin conveying line 40 to improve the insertion efficiency of the pipe members 64.

[0096] In addition to inserting the pipe insertion robot 610, it can also remove the positioning pins 62. For example, although not limited to this, after the upstream pipe insertion robot 610 has inserted some of the pipe insertion members 64, the fin stack 60 is transported to the corresponding position of the downstream pipe insertion robot 610, which first removes the positioning pins 62 and then inserts the remaining pipe insertion members.

[0097] When removing the positioning pin 62, the pipe insertion robot forearm of the pipe insertion robot 610 can rotate 90 degrees to push out the positioning pin 62. In this case, a single positioning pin 62 can be removed using only one pipe gripping chuck 614.

[0098] The operation of the forearm of the tube insertion robot can be found in related technologies and is not a design focus of this application, so it will not be described in detail here.

[0099] After the pipe insertion is complete, the fin stack 60 is transported further downstream to the pipe expansion work position, where the pipe expansion device 43 performs the pipe expansion operation on the pipeline member 64.

[0100] After the expansion is complete, the fin stack 60 is transferred from the fin transport line 40 to the drying device 44 by the transfer robot 45, where the drying operation is performed. After drying is complete, the fin stack 60 is transferred to the downstream transport line 42 by the transfer robot 45.

[0101] Referring to Figure 19, the transfer robot 45 includes a transfer robot body and a transfer jig, the transfer jig is installed on the transfer robot body, and the transfer jig includes a transfer center beam 4501, a transfer drive member 4502, and a transfer clamp plate 4503, the transfer center beam 4501 is connected to the transfer robot body, the transfer drive member 4502 is installed on the transfer center beam 4501, the transfer drive member 4502 has a first telescopic end and a second telescopic end formed thereon, there are two transfer clamp plates 4503, each installed on the first telescopic end and the second telescopic end, the transfer clamp plates 4503 move toward each other or away from each other when driven by the transfer drive member 4502 and are used to grip or release the end plate members 63 at both ends of the fin stack 60.

[0102] On the downstream transport line 42, the fin stack 60 is connected to the pipes by a pipe bending device 46. The pipe bending device 46 includes a pipe bending robot, whose structure is similar to that of a pipe insertion robot 610. The pipe bending robot grasps the U-shaped pipe and, using machine vision positioning, inserts the U-shaped pipe into the pipeline member 64 on the fin stack 60.

[0103] One point to note is that if the heat exchanger is an outdoor heat exchanger, it needs to be bent into an L-shape in the final stage. Therefore, during the bending pipe insertion process, a certain height difference will occur between the two fin ends of the bent outdoor heat exchanger. Consequently, it is necessary to tilt the bending pipe at a certain angle when inserting it. In the case of an evaporator, there is no need to bend it, so there is no height difference between the two aluminum sheets that make up the evaporator, and it is not necessary to tilt it when inserting the bending pipe.

[0104] When inserting a bent pipe into the outdoor heat exchanger, the pipe insertion jig 612 of the pipe insertion robot 610 is automatically tilted to a predetermined angle by the pipe insertion robot forearm, and the bent pipe is inserted into the pipeline member 64.

[0105] After the bent pipe is attached to the end of the fin stack 60, the fin stack is transported to the nitrogen filling work position, where the nitrogen filling operation is performed.

[0106] Referring to Figure 20, the nitrogen filling device 700 includes a nitrogen filling apparatus 710, a nitrogen filling docking member 720, and a nitrogen filling robot 730. The nitrogen filling apparatus 710 is connected to an external nitrogen filling pipeline 711, and the nitrogen filling docking member 720 is installed at the end of the nitrogen filling pipeline 711. In some embodiments, a coupling channel is formed within the nitrogen filling docking member 720 that gradually widens away from the nitrogen filling pipeline 711. This coupling channel is configured to act as a guide during the coupling process between the nitrogen filling pipeline 711 and the pipeline member 64.

[0107] Referring to Figure 21, the nitrogen filling robot 730 includes a nitrogen filling robot body 731 and a nitrogen filling jig 732. The nitrogen filling robot 730 is installed to the side of the nitrogen filling work position on the fin conveying line 40, and the nitrogen filling jig 732 is installed on the nitrogen filling robot 730. The nitrogen filling jig 732 is configured to grip the nitrogen filling docking member 720 and connect to the pipeline member 64 on the fin stack 60, thereby filling the pipeline member 64 with nitrogen.

[0108] In some embodiments, the nitrogen filling device 710 is installed inside the nitrogen filling chamber 740, the nitrogen filling chamber 740 is provided with an access port, and the nitrogen filling pipeline 711 extends from the access port to the outside of the nitrogen filling chamber 740.

[0109] The nitrogen filling chamber 740 is supported by legs directly above the nitrogen filling work position, the mounting port is installed in the bottom wall of the nitrogen filling chamber 740, the nitrogen filling pipeline 711 extends from directly below the nitrogen filling chamber 740, and the nitrogen filling docking member 720 is connected to the nitrogen filling pipeline 711.

[0110] Specifically, referring to Figures 23 and 24, in some embodiments of the present application, the nitrogen-filled docking member 720 is detachably connected to the nitrogen-filled pipeline 711, and a connecting end is provided at one end of the nitrogen-filled docking member 720 that connects to the nitrogen-filled pipeline 711, with an internal thread formed on the inner wall of the connecting end, and an external thread formed at the end of the nitrogen-filled pipeline 711, so that the nitrogen-filled pipeline 711 is screw-connected to the connecting end.

[0111] During the nitrogen filling process, the nitrogen filling robot 730 grasps the nitrogen filling pipeline 711 above the nitrogen filling docking member 720, pulls the nitrogen filling pipeline 711 downwards, and moves it onto the pipeline member 64. The pipeline member 64 is then guided into the nitrogen filling pipeline 711 via the nitrogen filling docking member 720 and connected to the nitrogen filling pipeline 711. Subsequently, the nitrogen filling device 710 injects nitrogen gas into the pipeline member 64.

[0112] To ensure that the pipeline member 64 is reliably guided into the nitrogen-filled pipeline 711, the minimum inner diameter dimension within the connecting channel is less than or equal to the inner diameter dimension of the nitrogen-filled pipeline 711.

[0113] Referring to Figure 25, in other embodiments, the nitrogen-filled docking member 720 and the nitrogen-filled pipeline 711 are integrally molded, and the nitrogen-filled docking member 720 as a whole is trumpet-shaped.

[0114] Referring to Figure 26, in another embodiment, an elastic member 750 is designed to be installed between the nitrogen filling pipeline 711 and the nitrogen filling chamber 740 so that the nitrogen filling pipeline 711 automatically returns towards the nitrogen filling chamber after nitrogen filling. One end of the elastic member 750 is fixed to the inner wall of the nitrogen filling chamber 740, and the other end is connected to the nitrogen filling pipeline 711 located inside the nitrogen filling chamber 740. When the nitrogen filling pipeline 711 moves outward and connects to the pipeline member 64, the elastic member 750 is compressed, and after nitrogen filling is complete, when the nitrogen filling robot 730 releases the nitrogen filling pipeline 711, the elastic member 750, due to its own restoring force, raises and returns the nitrogen filling pipeline 711 to its original position.

[0115] In another embodiment, an elastic member 750 is installed between the nitrogen-filling pipeline 711 and the nitrogen-filling chamber 740. One end of the elastic member 750 is fixed to the outside of the mounting opening, and the other end is connected to the nitrogen-filling pipeline 711 located outside the nitrogen-filling chamber 740. When the nitrogen-filling pipeline 711 moves away from the nitrogen-filling chamber and connects to the pipeline member 64, the elastic member 750 is stretched. After nitrogen filling is complete, when the nitrogen-filling robot 730 releases the nitrogen-filling pipeline 711, the elastic member 750, through its own restoring force, raises and returns the nitrogen-filling pipeline 711 to its original position.

[0116] In other embodiments, an elastic conduit section is formed in the nitrogen-filled conduit 711, enabling the nitrogen-filled conduit 711 to expand and contract relative to the connection port.

[0117] The elastic conduit section is at least a part of the nitrogen-filled conduit 711. When nitrogen-filled, the elastic conduit section is stretched, and after nitrogen filling is complete, the elastic conduit section contracts due to its own elastic action, raising and returning the nitrogen-filled docking member 720 to its original position.

[0118] Referring to Figure 22, the nitrogen filling jig 732 includes a gripping drive member and a gripping claw assembly 733 connected to the gripping drive member, the gripping claw assembly 733 including a symmetrically positioned first gripping claw 7331 and a second gripping claw 7332, the first gripping claw 7331 and the second gripping claw 7332 each having a gripping recess 7333, the dimensions of which match the outer diameter of the nitrogen filling pipeline 711, and the nitrogen filling pipeline 711 is used to be gripped between the gripping recesses 7333.

[0119] The specific connection between the gripping drive member and the first gripping claw 7331 and the second gripping claw 7332, and the realization of opening and closing the first gripping claw 7331 and the second gripping claw 7332 can be found in related technologies and will not be explained in detail here.

[0120] Similarly, the nitrogen filling robot body 731 includes the base of the nitrogen filling robot 730, the arm of the nitrogen filling robot 730, and the forearm of the nitrogen filling robot 730, which are sequentially connected.

[0121] In addition, the nitrogen filling robot 730 also includes a robot motor and a vision camera. The base of the nitrogen filling robot 730 is fixed to the floor (for example, with bolts), the robot motor is connected to the base of the nitrogen filling robot 730 (for example, with bolts), the base of the nitrogen filling robot 730, the arm of the nitrogen filling robot 730, and the forearm of the nitrogen filling robot 730 are all connected via sliding joints, and the vision camera is mounted on the nitrogen filling jig 732 and used to acquire positional information of the fin stack 60 and positioning pins 62.

[0122] After nitrogen filling is complete, the fin transport line 40 transports the fin stack 60 forward, performs welding at the welding work position, and then transports it to the helium inspection work position for inspection of the welding condition.

[0123] If the heat exchanger is an outdoor heat exchanger, after the helium test is completed, the fin stack 60 must be bent further by the bending device 49, and finally the heat exchanger is formed.

[0124] The following describes the specific procedure for processing the fin stack 60 to form a heat exchanger.

[0125] First, an unopened aluminum sheet is placed on the opening machine frame of the aluminum sheet opening machine, the ends of the coiled aluminum sheet are inserted between the opening rollers, and then the motor is started to open the aluminum sheet. The opened aluminum sheet is then connected to a press machine.

[0126] Many processes are carried out in a press machine. The first stage is straightening and oiling. After the strip material is straightened by a group of rollers, it enters an oil immersion tank. A pair of roller shafts are provided at the tank outlet to remove dust and excess oil from the surface of the strip material, forming a uniform oil film on the material surface, which facilitates mold lubrication and pressing.

[0127] The second stage is material extraction. The extraction mechanism is designed to be integrated with the host machine, and the rotation of the press spindle is connected to the die via a toothed belt, toothed wheel axle, slide plate, pull rod, oscillating plate, and extraction shaft, causing the material extraction and the spindle press to move in sync. By adjusting the length of the slide plate and pull rod, the pitch of material extraction can be precisely set. The third stage is cutting and counting. Cutting is performed by upper and lower shear blades and a cylinder controlled by a non-contact cam controller 70, and the number of operations is recorded. The final stage is material dropping, where the material is dropped to a designated position.

[0128] The heat exchanger fins are punched out by the press action of a die in a punching machine. The fin lengths range from 500 mm to 1000 mm, the widths from 50 mm to 100 mm, the thicknesses from 0.2 mm to 0.5 mm, and the fin spacing from 8 mm to 12 mm. These dimensions can be determined according to the dimensions of the die.

[0129] The press process of the die-cutting machine is an existing technology and is not the focus of this application's design; therefore, in consideration of the completeness of the technical solution, it will be explained briefly.

[0130] The punching machine ejects the fins 30 and drops them onto the steel drop pins. Then, the positioning pin robot inserts the positioning pins 62.

[0131] The positioning pin robot grasps the positioning pin 62 and inserts it into the corresponding slot for each fin. The positioning pin robot's vision camera takes pictures (RGB-D camera, capable of providing RGB images and depth information), and the obtained pictures are recognized, processed, and positioned by the central processing unit to facilitate the insertion of the positioning pin 62.

[0132] After inserting the multiple positioning pins 62, the aluminum sheets constituting the heat exchanger are still movable vertically, but movement in the X-axis direction, movement in the Y-axis direction, rotation around the X-axis, rotation around the Y-axis, and rotation around the Z-axis are restricted by the positioning pins 62. In other words, only movement in the Z-axis direction is not restricted.

[0133] After the positioning pin 62 is inserted, the downline robot 450 starts. The manipulator of the downline robot 450 stops its jig at the designated position and faces the heat exchanger to be gripped. When the downline jig 452 makes contact with the heat exchanger, its movement encounters a certain resistance, and when the resistance reaches a certain value, the gripping drive member stops moving, and at this point the gripping of the heat exchanger is completed. Subsequently, the downline robot arm 4512 moves the downline robot forearm 4513 and places it on the fin conveyor line 40.

[0134] When the end plate member 63 is installed, the end plate robot arm drives the end plate robot forearm and grips the end plate from the rear via the end plate jig 513. Subsequently, a vision camera on the end plate robot takes a picture and recognizes the position of the positioning pin 62 and the insertion hole. Based on the recognized position, the processor controls the movement of the arm and forearm to lift the end plate member 63 to the target height and face the side of the fin stack 60, and insert the end plate member 63 into the fin stack 60 having the positioning pin 62. The end plate jig 513 releases its force, and then the extrusion end slowly pushes out, pushing the end plate member 63 in.

[0135] Regarding the transport of heat exchangers, related technologies grip both sides of the heat exchanger, but maintaining the gripping force during the gripping process is not precise. Therefore, this invention adopts a method of gripping the end plates on both sides of the heat exchanger to better maintain the shape of the heat exchanger.

[0136] The fin transport line 40 transports the fin stack 60 to the next operating position. The fixture used by the pipe insertion robot 610 is the same as that used by the positioning pin robot. First, the robot grasps the pipe member 64 from the rear raw material area. Then, the robot fixture moves close to both sides of the heat exchanger, and the vision camera takes a picture. Following the positioning method and gripping force maintenance method described above, the pipe member 64 is slowly inserted into the heat exchanger. After insertion is complete, the fixture releases its force.

[0137] After the pipe insertion is complete, the pipe insertion robot 610 removes the positioning pin 62 from the heat exchanger. At this time, the inserted pipe member 64 positions and restrains the heat exchanger fins in place of the positioning pin 62. Similarly, it restricts movement in the X-axis direction, movement in the Y-axis direction, rotation around the X-axis, rotation around the Y-axis, and rotation around the Z-axis.

[0138] After the pipe insertion robot 610 removes the positioning pin 62, the pipe insertion robot 610 grasps the pipe member 64 from the raw material area and repeats the above process to insert the pipe member 64 into the insertion hole from which the positioning pin 62 was removed.

[0139] After the pipe insertion is complete, the transfer robot 45 transports the heat exchanger to the pipe expansion work position and performs the pipe expansion operation.

[0140] A tube expander is a specialized device for tightly fixing metal tubes and tube sheets, and is widely used in fields such as air conditioning, heat exchangers, and boilers. Its core principle is to ensure airtightness and connection strength by expanding the tube material mechanically or hydraulically, causing plastic deformation of the tube sheet hole wall, and forming an interference fit. In this application, a hydraulic tube expander is employed, and its operating principle is to inject hydraulic fluid into the tube material, uniformly expanding the tube wall with liquid pressure and making it tightly adhere to the tube sheet hole, and the pressure value can be precisely controlled.

[0141] First, the hydraulic head of the tube expander is inserted into the tube and positioned at the hole in the tube sheet. Then, the hydraulic pump is started, and high-pressure oil is injected into the tube, causing the tube wall to expand uniformly and seal tightly against the hole in the tube sheet. After the tube expansion is complete, the hydraulic tube expander must be depressurized and the hydraulic head removed.

[0142] After the pipe expansion process is complete, the transfer robot 45 moves the fin stack 60 to the drying position and performs the drying process.

[0143] The dryer starts up. The dryer's role is to dry the lubricating oil inside the heat exchanger. If the lubricating oil is not dried before later use, it will evaporate into the air and could cause harm to people.

[0144] First, the dryer's heat exchanger is pre-cleaned. A hot water spray is used to remove large lubricating oil particles adhering to the surface, thereby reducing the burden of the main degreasing process. After that, the main degreasing process is carried out: 1. Spray degreasing: The spray system uniformly covers the workpiece surface with degreasing solution at a pressure of 0.3 to 0.8 MPa for 5 to 15 minutes. 2. Temperature control: The degreasing tank is heated to 50 to 70°C (in the case of alkaline degreasing). 3. Circulation filtration: The degreasing solution is recycled after removing impurities using a filter or centrifuge to extend its service life.

[0145] After degreasing is complete, a multi-stage cleaning is performed. The first stage cleaning uses hot water (60-80°C) to wash away any remaining degreasing agent and prevent crystallization. The second stage cleaning uses room temperature water to further remove any trace residue and ensure a neutral pH value. After that, a drying treatment is performed using hot air drying, quickly drying the parts with hot air at 80-120°C to prevent water residue. A neutral or weakly alkaline degreasing agent is used for the piping members 64 to prevent corrosion.

[0146] After the drying operation is complete, the fin stack 60 is sent out from the end of the dryer along the fin transport line 40, at which point another transport robot 45 completes the downline process of the fin stack 60 according to the process described above.

[0147] The next step is inserting the bent pipe. Here, there is a difference in the process between outdoor and indoor heat exchangers. In the case of outdoor heat exchangers, bending is required in the final stage, so a certain height difference is created in the aluminum sheets that make up the heat exchanger during the bent pipe insertion process. Therefore, the pipe must be tilted at a certain angle when inserting it. In the case of indoor heat exchangers, bending is not required, so no height difference occurs.

[0148] The pipe bending robot is the same as the pipe insertion robot 610, and its positioning method and gripping force maintenance are consistent with the description above. During pipe bending, a height difference exists, so the robot jig is set to a certain inclination angle. This inclination angle is related to the height difference of the heat exchanger.

[0149] After the above operations are completed, the next step is to fill the heat exchanger with nitrogen. The main purpose of filling with nitrogen before welding is to prevent the inner wall of the pipe member 64 from forming an oxide film at high temperatures. The chemical properties of nitrogen are very stable and can block contact between the pipe member 64 and oxygen, thereby preventing the pipe member 64 from undergoing an oxidation reaction and forming oxides during the welding process.

[0150] A vision camera on the nitrogen filling robot 730 takes a picture of the fin stack 60 to identify the location of the pipe member 64 opening that requires nitrogen filling. Then, the nitrogen filling jig 732 is controlled to grasp the nitrogen filling pipe 711 and pull it downward to connect it to the pipe member 64. The nitrogen filling pipe 711 is extendable and retractable, and the nitrogen filling docking member 720 is positioned opposite the opening of the pipe member 64, after which nitrogen filling is performed. After nitrogen filling is complete, the nitrogen filling jig 732 removes the grasped nitrogen filling pipe 711 from the opening of the pipe member 64.

[0151] The heat exchanger is then transported to the welding device 47 by a conveyor belt. In the bending pipe insertion process described above, the bending pipe itself has solder material attached, and the automatic welding device 47 only needs to weld it for 3 to 5 seconds to melt the solder material. This is completed under the control of the control cabinet of the automatic welding device 47, which has a temperature control range of 180° to 250°.

[0152] After welding is complete, the next step is helium testing. Before helium testing, the nitrogen protective gas that was filled in the previous step is first removed, and then helium gas is injected. This process is the same as the nitrogen filling process described above.

[0153] Helium gas is an inert gas and is often used for detection because helium molecules are small and can easily pass through narrow gaps. Helium testing rooms are equipped with helium mass spectrometers that can monitor changes in helium concentration in the surrounding environment, and simultaneously have sensors that can accurately pinpoint leak points.

[0154] After helium testing, the outdoor heat exchanger requires further bending. The bending machine rotates the fin stack 60 by 90 degrees, bending the heat exchanger into an L-shape. With this, the heat exchanger production process is complete.

[0155] After the heat exchanger fabrication is complete, the heat exchanger is attached to the bottom plate of the air conditioner. After the attachment is complete, the surface is painted.

[0156] Referring to Figures 27 and 28, the heat exchanger painting system 10 includes a painting robot 20, the end of which is fitted with a spray head 21, which is configured to paint the fins 30. A first rail 230 is installed on the floor, and the painting robot 20 moves along the first rail 230.

[0157] During painting, the spray head unit 21 is positioned on one side of the heat exchanger and sprays paint from one side to the other. The painting area is controlled by controlling parameters such as the range of motion and width of the spray head unit 21, the spray pressure of the spray head unit 21, and the distance between the spray head unit 21 and the heat exchanger.

[0158] The spray head section 21 is a two-fluid atomizing nozzle with a nozzle diameter of 0.3 mm, ensuring an atomized particle diameter of ≤10 μm and ensuring uniform coating on the surface of the fins 30.

[0159] The painting system further includes a paint tank, which is configured to supply paint to the spray head unit 21. The paint contains a capsule unit 300, and the capsule unit 300 is filled with a repair agent.

[0160] The painting system further includes a visual device 100, which is configured to acquire image information of the heat exchanger.

[0161] The painting system further includes a control system, which communicates with the painting robot 20 and the vision device 100. The control system is configured to analyze image information of the heat exchanger to obtain dimensional data information of the heat exchanger and to control the movement of the spray head unit 21.

[0162] The painting system further includes a magnetic field generator 220, which is configured to radiate a magnetic field onto the heat exchanger.

[0163] The capsule portion 300 is configured to move toward the insertion hole 31 under the influence of a magnetic field, and is further configured to rupture when subjected to an external force, releasing the internal repair agent to repair the paint on the fin 30.

[0164] Specifically, the paint ejected from the spray head 21 has a repair function, the paint is mixed with capsules 300, and the capsules 300 are filled with a repair agent, which contains siloxane and a catalyst.

[0165] The outer diameter of the capsule portion 300 is at the nanoscale, and the particle size of the capsule portion 300 is 5 to 20 μm. Figure 13 shows the structure of the capsule portion 300, where the outer shell of the capsule portion 300 exhibits a spherical core-shell structure, ensuring that it receives force uniformly under magnetic field conditions.

[0166] The capsule 300 is made from triiron tetroxide and silicon dioxide. The capsule 300 uses triiron tetroxide nanoparticles and is coated with silicon dioxide by a sol-gel method to form a core-shell structure. The triiron tetroxide gives the capsule 300 a high magnetic susceptibility, facilitating precise trajectory control by an external magnetic field. The silicon dioxide provides the capsule 300 with chemical inertness and a certain level of mechanical strength, protecting the inner core from environmental corrosion while controlling the burst threshold of the outer shell by adjusting the degree of crosslinking.

[0167] Microfluidic technology is used to seal the repair agent into the lumen of the capsule 300. When a crack occurs in the fin 30 due to corrosion or mechanical load, a high-stress region is formed at the crack tip. When the local stress, tensile stress, and shear stress resulting from crack propagation exceed the mechanical strength threshold of the capsule 300's outer shell, the capsule 300's outer shell ruptures, releasing the repair agent.

[0168] By adjusting the thickness and degree of crosslinking of the capsule 300 outer shell, or by adding a toughening agent, the mechanical strength and sensitivity of the outer shell are balanced, and the capsule 300 is pre-embedded at the root of the fin 30 and in areas prone to stress concentration during painting, thereby improving trigger efficiency.

[0169] The magnetic field generator 220 employs an electromagnetic array device, which generates a gradient magnetic field. The capsule section 300 is driven by magnetic force in the magnetic field and concentrates in the region of high magnetic field strength at the root of the fin 30 (i.e., the location of the insertion hole 31). The equation is as follows: F = ▽(M × B) F is the magnetic force (in N) that moves the capsule, M is the magnetization intensity of capsule 300 (in A / m), and B is the magnetic induction intensity of the gradient magnetic field generated by the electromagnetic array device (in T).

[0170] The electromagnetic array device adjusts the magnetic field gradient according to the fin gap, ensuring that the capsule portion 300 is deposited only in the corrosive root region of the fin 30. The magnetic field adjustment satisfies the following equation. ▽B=k / d 2 ▽B is the magnetic field gradient (unit T / m), and k is the material-process coefficient (unit Tm). 2 ), where d is the fin gap width, i.e., the minimum distance (in meters) between adjacent fins.

[0171] During the processing of the fins 30, a flange is formed around the insertion hole 31, and the presence of the flange minimizes the distance between two adjacent fins 30 at the insertion hole 31. As a result, the magnetic field strength is maximized at the insertion hole 31, i.e., at the root of the fins 30, so the capsule portion 300 moves toward the insertion hole 31 under the action of the magnetic field and can be deposited near the insertion hole 31.

[0172] The base of the fin 30 is a location where corrosion is likely to occur. After the fin 30 corrodes, cracks appear on the surface. When the local stress, tensile stress, and shear stress caused by the crack propagation exceed the mechanical strength threshold of the capsule 300's outer shell, the capsule 300's outer shell ruptures, releasing a repair agent that further repairs the corroded area of ​​the fin 30.

[0173] In some embodiments of the present invention, the spray head 21 is located on one side of the heat exchanger and moves along a sinusoidal trajectory in the longitudinal direction X of the heat exchanger, as well as in the width direction Y of the heat exchanger. Compared to conventional segment coating methods, this coating path is more efficient.

[0174] In some embodiments of the present application, when the spray head portion 21 moves in the Y direction, the spray head portion 21 reciprocates in the Y direction, and the amplitude of the swing of the spray head portion 21 is directly proportional to the gap between two adjacent fins 30. The equation is as follows:

number

[0175] The lower limit of the oscillation amplitude of the spray head 21 is 0.5 mm, and it is applied to high-density areas where d ≤ 0.8 mm.

[0176] The upper limit of the oscillation amplitude of the spray head 21 is 3.0 mm, and it is applicable to low-density areas where d ≥ 2.5 mm.

[0177] In some embodiments of the present application, when the spray head portion 21 moves in the Y direction, the spray head portion 21 oscillates back and forth in the Y direction, and the oscillation frequency of the spray head portion 21 is directly proportional to the density of the fins 30. The equation is as follows: f = kf * ρ f is the oscillation frequency of the spray head 21 (in Hz), kf is the density-frequency coefficient (in Hz mm / fin 30), and ρ is the fin 30 density, i.e., the number of fins 30 per unit length (in fins 30 / mm). The higher the fin 30 density, the greater the oscillation frequency of the spray head 21, and the higher the paint coating efficiency.

[0178] As the painting pressure increases, the oscillation frequency of the spray head increases synchronously and matches the atomized particle output velocity.

[0179] The fundamental oscillation frequency of the spray head section 21 is 5 Hz, and it is applied to low-density areas with ρ ≤ 10 fins 30 / cm.

[0180] The upper limit of the oscillation frequency of the spray head unit 21 is 20 Hz, and it is applied to high-density areas with ρ ≥ 30 fins 30 / cm.

[0181] In some embodiments of the present invention, the heat exchanger has straight sections and curved sections, and the spray head section 21 performs painting of the straight sections and curved sections separately.

[0182] In other words, in the case of a U-shaped heat exchanger, the spray head unit 21 paints the heat exchanger in sections. For example, it paints the straight sections first, and then the curved sections. When the spray head unit 21 passes through a curved section, it generates an arc-shaped or broken detour path along the outer edge of the curved section, ensuring that the spray head unit 21 and the curved section maintain a predetermined safety distance.

[0183] In some embodiments of the present invention, the movement path of the spray head unit 21 is located within the projection range of the heat exchanger, and as the spray head unit 21 approaches the boundary of the heat exchanger, the movement speed and oscillation amplitude are reduced.

[0184] In other words, the visual device 100 extracts the fin 30 boundary in real time and generates a dynamic no-painting zone. The movement path of the spray head 21 is strictly limited to within the projection range of the fin 30, and a gradient deceleration strategy is adopted in the edge region, reducing the movement speed and amplitude as it approaches the boundary to prevent paint splatter.

[0185] In some embodiments of this application, the heat exchanger coating system 10 further includes a UV curing device 200 configured to cure the heat exchanger after coating. The UV curing device 200 is existing technology and is not described in detail hereof.

[0186] The heat exchanger coating system 10 further includes a coating transport line 240, and a magnetic field generator 220 and a UV curing device 200 are arranged at intervals along the length of the coating transport line 240, with the magnetic field generator 220 generating a magnetic field on the heat exchanger placed on the coating transport line 240.

[0187] In some embodiments of the present application, the painting process of the heat exchanger painting system 10 includes the following:

[0188] The visual device 100 acquires point cloud data of the heat exchanger fins 30 and extracts topology parameters such as the fin inclination angle, spacing, and height.

[0189] A fin 30 spatial topology relationship model is constructed based on a graph neural network (GNN), and fin 30 surface curvature distribution and gap width data are generated.

[0190] Based on the model, the painting path is broken down so that "the spray head unit 21 moves in the longitudinal direction X of the heat exchanger while simultaneously oscillating in the width direction Y of the heat exchanger to sweep the paint." The spray head unit 21 moves in the longitudinal direction X of the heat exchanger along a sinusoidal trajectory, and the amplitude and frequency of the spray head unit 21 are adaptively adjusted according to the gap between the fins 30 to ensure that the paint penetrates to the roots of the fins 30 and does not clog the gaps.

[0191] The PID algorithm adjusts the compressed air pressure in the spray head 21 in real time to adapt to different fin density areas. The pressure is increased in high-density areas and decreased in low-density areas.

[0192] The mass flow meter 110 monitors the paint flow rate in real time, and if the deviation exceeds ±5%, it triggers an alarm, temporarily suspends painting, and the MES system records the anomaly.

[0193] The painting robot 20 plans its path along the first rail 230 and moves along it, and the spray head 21 ejects atomized particles with a 0.3 mm diameter nozzle, uniformly covering the surface of the fins 30.

[0194] After painting is complete, the heat exchanger enters the UV curing unit 200, which uses a 365nm wavelength and 500W / m² UV curing. 2 Irradiate with the output power for 30 seconds to complete the cross-linking and curing of the paint.

[0195] Paint parameters (paint thickness, repair agent content, etc.) are uploaded to the IoT platform via the OPC UA protocol and integrated with the MES system to enable quality tracking throughout the entire lifecycle.

[0196] Referring to Figures 29 to 30, the heat exchangers produced in the heat exchanger production system described above are further used in the fully automated intelligent smart maintenance system for air conditioners.

[0197] The fully automated intelligent smart maintenance system for air conditioners includes a general-purpose heat exchanger production system 101, an indoor unit production system 102, an outdoor unit production system 103, a material storage system 105, a transport system, and a control system (not shown).

[0198] The general-purpose heat exchanger production system 101 is used to produce heat exchangers.

[0199] The general-purpose heat exchanger production system 101 includes an indoor heat exchanger fin production unit, an outdoor heat exchanger fin production unit, and several indoor / outdoor general-purpose heat exchanger production units.

[0200] The indoor heat exchanger fin production unit is used to produce indoor heat exchanger fins.

[0201] The outdoor heat exchanger fin production unit is used to produce outdoor heat exchanger fins.

[0202] Because the specifications for indoor and outdoor heat exchanger fins differ, the fin production unit is divided into an indoor heat exchanger fin production unit and an outdoor heat exchanger fin production unit.

[0203] Fin specifications can include, for example, fin length and fin hole spacing.

[0204] The general-purpose production unit's pipe bending unit includes a first cutting position and a second cutting position, the first being used for cutting outdoor heat exchanger pipes and the second being used for cutting indoor heat exchanger pipes.

[0205] The general-purpose production unit's pipe expansion unit has two operating frequencies: the first frequency is used for the production of outdoor heat exchangers, and the second frequency is used for the production of indoor heat exchangers.

[0206] Several indoor / outdoor heat exchanger general-purpose production units are used to produce unbent outdoor heat exchangers from outdoor heat exchanger fins and heat exchanger materials, and to produce indoor heat exchangers from indoor heat exchanger fins and heat exchanger materials.

[0207] The indoor unit production system 102 is used to produce indoor units from indoor heat exchangers and indoor unit materials. The indoor unit production system includes several indoor unit production units.

[0208] Bending units are used to bend unbent outdoor heat exchangers into outdoor heat exchangers.

[0209] The outdoor unit production system 103 is used to produce outdoor units from outdoor heat exchangers and outdoor unit materials.

[0210] The outdoor unit production system 103 includes several outdoor unit production units.

[0211] The bending unit is located within the outdoor unit production system and is controlled by the outdoor unit production system.

[0212] In some embodiments, the bending unit may be located within the indoor unit production system and be controlled by the indoor unit production system.

[0213] The material storage system 105 is used to store heat exchanger materials, indoor unit materials, and outdoor unit materials.

[0214] The transport system is used to transport heat exchanger materials to the general heat exchanger production system, indoor unit materials to the indoor unit production system, and outdoor unit materials to the outdoor unit production system.

[0215] The control system communicates with the general-purpose heat exchanger production system, indoor unit production system, outdoor unit production system, material storage system, and transport system. The control system is used to unify and control the operating status of all systems and to acquire relevant information for all systems.

[0216] The control system is configured to control the transport system to transport materials, control the indoor heat exchanger fin production unit and general-purpose production unit to produce indoor heat exchangers, control the indoor unit production system to produce indoor units from indoor heat exchangers and indoor unit materials, control the outdoor heat exchanger fin production unit, general-purpose production unit and bending unit to produce outdoor heat exchangers, and control the outdoor unit production system to produce outdoor units from outdoor heat exchangers and outdoor unit materials.

[0217] By producing indoor and outdoor heat exchangers through the general-purpose heat exchanger production system 101, and controlling the general-purpose heat exchanger production system based on the production needs of indoor and outdoor units, the overall spatial layout and layout costs of the production system can be effectively reduced by producing either outdoor or indoor heat exchangers.

[0218] In some embodiments, the general-purpose heat exchanger production system 101, the indoor unit production system 102, and the outdoor unit production system 103 all include sub-control systems, which are used to communicate with the control system and perform data transmission interactions, and which receive detection information for each production unit and are used to control the operating state of each associated production unit.

[0219] Each sub-control system processes data and then uploads it to the control system, reducing the amount of information transmitted and the computational load on the control system.

[0220] In some examples, a general-purpose heat exchanger production system includes a heat exchanger sub-control system, an indoor unit production system includes an indoor unit sub-control system, and an outdoor unit production system includes an outdoor unit sub-control system.

[0221] In some embodiments, the transport system includes a transport sub-control system, which communicates with a control system.

[0222] In some embodiments, the transport system does not have a separate control system, but is managed and controlled by a material management system.

[0223] The transport system includes an overhead crane system, and in some embodiments, the indoor unit production system 102 and the outdoor unit production system 103 are arranged in parallel between the heat exchanger general-purpose production system 101 and the material storage system 105.

[0224] In the example shown in Figure 1, the general-purpose heat exchanger production system, parallel indoor unit production systems and outdoor unit production systems, and a material storage system are arranged in the direction of the production line.

[0225] The indoor unit production system and the outdoor unit production system are installed in parallel downstream of the general-purpose heat exchanger production system, facilitating the transport of heat exchangers to the indoor unit production system and the outdoor unit production system, respectively.

[0226] The rails include a material rail section, a heat exchanger rail section, an indoor unit rail section, an outdoor unit rail section, and rail sections 1 through 6.

[0227] The material rail section is located above the material storage system, the heat exchanger rail section is located above the general heat exchanger production system, the indoor unit rail section is located above the indoor unit production system, and the outdoor unit rail section is located above the outdoor unit production system.

[0228] The first rail section 8061 connects the material rail section and the heat exchanger rail section 802, and the first rail section 8061 is located between the indoor unit rail section 803 and the outdoor unit rail section 804.

[0229] The second rail section 8052 connects the heat exchanger rail section 802 and the indoor unit rail section 803.

[0230] The third rail section 8053 connects the first rail section 8061 and the indoor unit rail section 803.

[0231] The fourth rail section 8054 connects the indoor unit rail section 803 and the material rail section.

[0232] The fifth rail section 8055 connects the first rail section 8061 and the outdoor unit rail section 804.

[0233] The sixth rail section 8056 connects the outdoor unit rail section 804 and the material rail section.

[0234] The overhead crane is configured as follows: It travels to the material rail section, grasps a material box containing heat exchanger material, reaches the heat exchanger rail section 802 via the first rail section 8061, releases the heat exchanger material to the heat exchanger general production system 101, then reaches the fourth rail section 8054 via the second rail section 8052 and the indoor unit rail section 803. It travels to the material rail section, grasps a material box containing indoor unit material, reaches the indoor unit rail section 803 via the first rail section 8061 and the third rail section 8053, releases the indoor unit material to the indoor unit production system 102, then reaches the fourth rail section 8054. It travels to the material rail section, grasps a material box containing outdoor unit material, reaches the outdoor unit rail section 804 via the first rail section 8061 and the fifth rail section 8055, releases the outdoor unit material to the outdoor unit production system 103, then reaches the sixth rail section 8056.

[0235] In some embodiments, the rails include an overhead crane standby rail section 806, located between the fourth rail section and the material rail section, and between the sixth rail section and the material rail section.

[0236] The fourth rail section 8054 and the sixth rail section 8056 may or may not be connected.

[0237] The overhead crane is configured to reach the overhead crane standby rail section 806 after material transport is complete and to wait in the overhead crane standby rail section 806.

[0238] In some embodiments, the material storage system includes a material management system used to manage material information, and the material management system communicates with a control system and uploads the material information to the control system.

[0239] In the example shown in Figure 29, the fully automated intelligent smart maintenance system for air conditioners further includes a packaging system 104, which is used to receive the indoor and outdoor units and package them. An overhead crane system is used to transport the packaging materials to the packaging system.

[0240] The packaging materials are divided into indoor unit packaging materials and outdoor unit packaging materials, and both are transported to the packaging system simultaneously or separately. A ground transport device is used to transport the indoor and outdoor units to the packaging system.

[0241] The control system determines whether an indoor or outdoor unit is arriving at the packaging system based on the production status of the outdoor and indoor unit production systems, and transmits the relevant information to the packaging system. If an indoor unit is arriving at the packaging system, the packaging system loads the indoor unit packaging materials and packages the indoor unit. If an outdoor unit is arriving at the packaging system, the packaging system loads the outdoor unit packaging materials and packages the outdoor unit.

[0242] In some embodiments, the packaging materials are stored in a material storage system 105.

[0243] In some embodiments, the packaging system is located below the sixth rail section 8056 of the conveying system, and the material rail section and the sixth rail section 8056 are connected by a seventh rail section 8057.

[0244] The overhead crane is configured to travel to the material rail section, grasp the material boxes containing the packaging materials, release the packaging materials into the packaging system when it reaches above the packaging system in the sixth rail section 8056 via the seventh rail section 8057, and then proceed to the overhead crane standby rail section.

[0245] In some embodiments, the packaging system 104 is located downstream of the outdoor unit production system 103, and the material storage system 105 is located downstream of the indoor unit production system 102.

[0246] The seventh rail section 8057 of the conveying system is located between the outdoor unit production system 103 and the packaging system 104.

[0247] This layout method allows for a more rational structural layout of the entire production system, smoother material transport, and improved production efficiency.

[0248] The fully automated intelligent production system further includes a finished machine storage system, which is used to store finished machines that have been packaged in the packaging system.

[0249] In some embodiments, the finished machine storage system and the material storage system are two independent systems.

[0250] The finished machine storage system includes a finished machine receiving information acquisition unit and a finished machine management system.

[0251] The completed machine receiving information acquisition unit is used to acquire completed machine receiving information and transmit it to the completed machine management system.

[0252] The completed machine management system is used to manage information about completed machines. The completed machine management system communicates with the control system and uploads the completed machine information to the control system.

[0253] In some embodiments, the ground transport device is used to transport the completed machine, which has been packaged in the packaging system, to the completed machine storage system.

[0254] In some embodiments, the ground transport device is an AGV (Automated Guided Vehicle).

[0255] In some embodiments, the completed machines that have been packaged are also stored in the material storage system, the material management system manages the information about the completed machines, and uploads the information about the completed machines to the control system.

[0256] In some embodiments, the material storage system for storing the finished machine forms a warehouse.

[0257] The layout methods of the warehouse, general-purpose heat exchanger production system, indoor unit production system, outdoor unit production system, and packaging system form one final assembly production line. An overhead crane conveyor system is installed around the production line. Between systems, a floor transfer device is used, and inside the systems, a roller conveyor line is used.

[0258] The floor transfer device receives the control information of the control system and is used to transfer according to the control information.

[0259] The floor transfer device is used to transfer the indoor heat exchanger to the indoor unit production system, transfer the outdoor heat exchanger to the outdoor unit production system, transfer the outdoor unit and the indoor unit to the packaging system, and transfer the finished product completed by the packaging system to the finished product storage system.

[0260] In some embodiments, the floor transfer device is versatile, and the transfer between any two systems can be performed by the floor transfer device.

[0261] In some embodiments, the floor transfer device is only responsible for the transfer between two systems, including the first floor transfer device between the general-purpose heat exchanger production system and the indoor unit production system, the second floor transfer device between the general-purpose heat exchanger production system and the outdoor unit production system, the third floor transfer device between the indoor unit production system and the packaging system, the fourth floor transfer device between the outdoor unit production system and the packaging system, and the fifth floor transfer device between the packaging system and the finished product storage system.

[0262] In some embodiments, the production unit includes a production unit status detection module.

[0263] The production unit status detection module is used to detect the operating status information of the production unit device.

[0264] The control system determines or predicts device failures based on the operating status information. When a device failure is determined or predicted, a warning message is issued and notified to the maintenance personnel for maintenance to ensure that the device operation is normal.

[0265] In some embodiments, the sub-control system determines or predicts a device failure based on the operation state information. When a device failure is determined or predicted, it notifies the control system, and the control system issues a warning message to notify the maintenance personnel to perform maintenance to ensure that the device operation is normal.

[0266] In some embodiments, the production unit state detection module includes sensors such as temperature, pressure, vibration, humidity, airtightness, and piezoresistance.

[0267] In some embodiments, the production unit includes a unit lighting device, which is in a constantly turned-off state, saving a large amount of energy and significantly reducing the energy consumption of the production system.

[0268] The unit lighting device is located on each production unit and illuminates the corresponding production unit when the unit lighting device is turned on.

[0269] When the control system determines or predicts a production unit device failure, it is configured to turn on the unit lighting device corresponding to the production unit to facilitate maintenance by the maintenance personnel.

[0270] Some embodiments of the present application provide a fully automatic intelligent production method for air conditioners, including the following steps.

[0271] Obtain air conditioner demand information.

[0272] Determine the production process based on the air conditioner demand information.

[0273] The system controls the operating states of the heat exchanger general-purpose production system, indoor unit production system, and outdoor unit production system based on the production process. When producing outdoor units in the production process, it controls the outdoor heat exchanger fin production unit, general-purpose production unit, and bending unit to produce outdoor heat exchangers, and controls the outdoor unit production system to produce outdoor units. When producing indoor units in the production process, it controls the indoor heat exchanger fin production unit and general-purpose production unit to produce indoor heat exchangers, and controls the indoor unit production system to produce indoor units.

[0274] The control method described above allows for the dynamic determination of the production process based on demand information for air conditioners, enabling the production line to adapt to a wider range of production scenarios, reducing idle time for each production unit, and improving the efficiency and resource utilization of the production system.

[0275] In some embodiments, the required number of indoor and outdoor units for the air conditioner models to be produced is determined based on air conditioner demand information, and the number of indoor heat exchangers to be continuously produced, n, is determined. The production process is as follows.

[0276] The general-purpose heat exchanger production system is controlled to first produce one outdoor heat exchanger for the outdoor unit production system, and then produce n indoor heat exchangers for the indoor unit production system.

[0277] When the number of indoor units reaches the required number of indoor units but the number of outdoor units does not, the production process is changed, and the general-purpose heat exchanger production system is controlled to produce outdoor heat exchangers for the outdoor unit production system.

[0278] When the number of outdoor units reaches the required number of outdoor units but the number of indoor units does not, the production process is changed, and the general-purpose heat exchanger production system is controlled to produce indoor unit heat exchangers for the indoor unit production system. n is a natural number.

[0279] The control method described above effectively reduces the increase in energy consumption due to no-load operation of the production line, facilitates receiving and shipping goods, and improves management efficiency.

[0280] In some embodiments, the method for determining the number n of indoor heat exchangers to be continuously produced is to define the number n of indoor heat exchangers to be continuously produced as the number n of indoor units included in one air conditioning system.

[0281] In some embodiments, the method for determining the number n of indoor heat exchangers to be produced in continuous production is: Based on the model of air conditioner to be produced, the production time t3 for the indoor unit and the production time t4 for the outdoor unit are determined. The production time t4 for the outdoor unit is then divided by the production time t3 for the indoor unit, and the result is converted to an integer to determine n.

[0282] In some embodiments, when the production process produces an outdoor heat exchanger, the outdoor heat exchanger fin production unit is controlled to produce the outdoor heat exchanger fins, the pipe bending unit of the general-purpose production unit cuts the pipe at a first cutting position, the operating frequency of the pipe expanding unit of the general-purpose production unit is set to a first frequency, and the bending unit bends the unbent outdoor heat exchanger.

[0283] When the production process produces indoor heat exchangers, the indoor heat exchanger fin production unit is controlled to produce the indoor heat exchanger fins, the pipe bending unit of the general-purpose production unit cuts the pipe at the second cutting position, the operating frequency of the pipe expanding unit of the general-purpose production unit is set to the second frequency, and the bending unit does not operate. The length of the pipe cut at the first cutting position is the length of the outdoor heat exchanger pipe, the length of the pipe cut at the second cutting position is the length of the indoor heat exchanger pipe, and the second frequency is less than or equal to the first frequency.

[0284] Referring to Figure 30, the fully automated intelligent production method for air conditioners includes the following steps.

[0285] S1: Obtain air conditioner demand information.

[0286] S2: Determine the production process based on the air conditioner demand information.

[0287] The production process includes the production process of the heat exchanger general production system. In some embodiments, after producing one outdoor heat exchanger, n indoor heat exchangers are produced, and after producing one outdoor heat exchanger, producing n indoor heat exchangers is sequentially circulated. When the number of indoor units or the number of outdoor units reaches the required number, the production process is changed.

[0288] When the number of indoor units reaches the required number of indoor units and the number of outdoor units has not reached the required number of outdoor units, change the production process, control the heat exchanger general production system to produce the outdoor heat exchanger for the outdoor unit production system, and stop when the number of outdoor units reaches the required number.

[0289] When the number of outdoor units reaches the required number of outdoor units and the number of indoor units has not reached the required number of indoor units, change the production process, control the heat exchanger general production system to produce the indoor unit heat exchanger for the indoor unit production system, and stop when the number of indoor units reaches the required number.

[0290] S3: The conveying system conveys the materials.

[0291] If it is determined that an outdoor unit is to be produced based on the production process, proceed to step S5; otherwise, proceed to step S9.

[0292] S5: Sequentially input materials according to the outdoor heat exchanger production process and produce the outdoor heat exchanger.

[0293] S6: The AGV transfers the outdoor heat exchanger to the outdoor unit production system, and sequentially inputs materials according to the outdoor unit production process to produce the outdoor unit.

[0294] S7: The AGV transfers the outdoor unit to the packaging system, and sequentially inputs the outdoor unit packaging materials according to the packaging process to perform the packaging.

[0295] S8: The AGV transfers the packed outdoor unit to the finished unit storage system.

[0296] Proceed to Step S4.

[0297] S9: Materials are sequentially fed in according to the indoor heat exchanger production process to produce indoor heat exchangers.

[0298] S10: The AGV transfers the indoor heat exchanger to the indoor unit production system, and the system sequentially feeds materials according to the indoor unit production process to produce the indoor unit.

[0299] S11: The AGV transfers the indoor unit to the packaging system and sequentially loads the indoor unit packaging materials according to the packaging process to complete the packaging.

[0300] S12: The AGV transfers the packed indoor unit to the finished unit storage system.

[0301] Proceed to Step S4.

[0302] To the extent possible, the various embodiments and features described and illustrated in the specification can be applied individually, and these individual embodiments can be the subject matter of a divisional application.

[0303] In the description of the embodiments above, specific features, structures, materials, or properties can be combined in an appropriate manner in any one or more embodiments or examples.

[0304] The above are specific embodiments of the present application, but the scope of protection of this application is not limited thereto. Any modification or substitution that a person skilled in the art could easily conceive within the technical scope disclosed herein should be included in the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of protection of the claims.

Claims

1. This is a heat exchanger production line, Support frame and A fin conveying line is installed on the support frame and has at least fin insertion / retraction positions, end plate mounting positions, pipe insertion work positions, and nitrogen filling work positions along the conveying direction, Installed at one end of the fin transport line, An internal storage position is formed in the insert / remove support holder, A support base plate horizontally installed at the storage position of the aforementioned retractable support holder, wherein a plurality of drop pins are vertically installed on the support base plate, and the first end of each drop pin is fixed to the support base plate, A lifting support plate is installed parallel to the above support base plate and configured to reciprocate in a direction perpendicular to the retractable support holder, wherein a plurality of through holes are formed on the lifting support plate, the plurality of drop pins each pass through the plurality of through holes, and the second end of each drop pin protrudes on the side away from the support base plate of the lifting support plate, and fins are arranged on the surface of the lifting support plate, A fin retraction device including a downline robot configured to move the fin stack to the fin retraction position when the lifting support plate moves the fin stack to a target height, An end plate mounting device includes at least two end plate mounting robots provided corresponding to the end plate mounting positions and installed symmetrically on both sides of the fin transport line, configured to connect end plate members to both ends of the fin stack when the fin transport line transports the fin stack from the fin insertion / removal position to the end plate mounting position, A pipe insertion device provided corresponding to the pipe insertion work position, wherein the pipe insertion device includes a pipe insertion robot, and after the attachment of the end plate member is completed, the fin transport line transports the fin stack to the pipe insertion work position, the pipe insertion robot including the pipe insertion robot body and pipe insertion jig inserts the pipe member into the fin stack, the pipe insertion jig is connected to the pipe insertion robot body and includes two pipe insertion assemblies installed at intervals, each pipe insertion assembly includes an intermediate connection and at least one pipe gripping chuck installed on the intermediate connection, the pipe insertion device grips the pipe member with the pipe gripping chuck, and the pipe insertion device inserts the pipe member into the fin stack by driving the pipe insertion robot body, The nitrogen filling device is provided in accordance with the nitrogen filling work position and includes a nitrogen filling apparatus, a nitrogen filling docking member, and a nitrogen filling robot, wherein the nitrogen filling robot is configured to grip the nitrogen filling docking member and dock with the pipeline member of the fin stack, and the nitrogen filling apparatus includes a nitrogen filling device that fills the pipeline member with nitrogen via the nitrogen filling docking member. The aforementioned downline robot, The downline robot body and A downline jig installed on the downline robot body, comprising a gripping drive member and a symmetrically installed first downline gripping member and second downline gripping member, wherein the gripping drive member is configured to control the distance between the first downline gripping member and the second downline gripping member, the first downline gripping member includes a first downline gripping claw, the second downline gripping member includes a second downline gripping claw, the first downline gripping claw has a first positioning recess that opens toward the second downline gripping claw, the second downline gripping claw has a second positioning recess that opens toward the first downline gripping claw, and the first downline gripping claw and the front The downline jig includes the following: When the second downline gripping claw grips the fin stack by the action of the gripping drive member, both ends of a positioning pin, which is installed on the fin stack and inserted into the insertion opening of each fin in the fin stack by a positioning pin robot after the fin stack is formed, are inserted into the first positioning recess and the second positioning recess, respectively, and after the positioning pin has passed through the insertion opening of each fin in the fin stack, the first end of the positioning pin is supported on the lifting support plate and the second end is exposed above the fin stack, thereby enabling the first and second ends of the positioning pin to grip the first positioning recess and the second positioning recess, respectively. Each of the end plate mounting robots is End plate robot body, A connecting center beam installed on the end plate robot body, wherein a gripping drive member is installed within the connecting center beam, and a first telescopic end and a second telescopic end are formed at both ends of the gripping drive member, Two end plate jigs are installed at the first and second telescopic ends, respectively, and are configured to move relative to each other by the action of the gripping drive member to grip or release the end plate member, The extrusion member, which is installed on the connecting center beam and is configured to push out an end plate member held by an end plate jig to attach the end plate member to the fin stack, Each drop pin is configured such that when multiple fins fall into their storage position, the second end of the drop pin is inserted into the corresponding fin's insertion hole, and the multiple fins connected by each drop pin form a fin stack. Heat exchanger production line.

2. The heat exchanger production line according to claim 1, wherein an upward-extending support projection is formed on the lifting support plate, and the support projection supports each of the fin stacks, thereby forming a gripping gap between the bottom of the fin stack and the lifting support plate.

3. The heat exchanger production line according to claim 2, wherein the first downline gripping claw and the second downline gripping claw are each connected to the gripping drive member via an adapter plate, the first downline gripping claw has a first positioning clamp plate perpendicular to the adapter plate, the first positioning clamp plate has at least one first positioning recess opening toward the second downline gripping claw, the second downline gripping claw has a second positioning clamp plate perpendicular to the adapter plate, and the second positioning clamp plate has at least one second positioning recess opening toward the first downline gripping claw.

4. A guide slope is formed at the end of the second positioning clamp plate, and the guide slope is configured to guide the first end of the positioning pin into the second positioning recess as the second downline gripping claw moves into the gripping gap, as described in claim 3.

5. The first downline gripping claw further includes a first connecting plate, the first connecting plate is positioned perpendicular to the first positioning clamp plate, and the first positioning clamp plate is detachably connected to the adapter plate via the first connecting plate. The heat exchanger production line according to claim 3, wherein the second downline gripping claw further includes a second connecting plate, the second connecting plate is positioned perpendicular to the second positioning clamp plate, and the second positioning clamp plate is detachably connected to the adapter plate via the second connecting plate.

6. The heat exchanger production line according to claim 5, wherein the second connecting plate extends beyond the end of the adapter plate in a direction away from the first connecting plate.

7. The heat exchanger production line according to claim 1, wherein the fin conveying line includes a plurality of rollers installed at intervals along a first direction, a pallet member is installed on the fin conveying line, the downline robot places the fin stack on the pallet member, positioning pins installed in the fin stack are parallel to the width direction of the fin conveying line and to the pallet member, and the fin conveying line conveys the fin stack via the pallet member along the direction of travel of the fin conveying line.

8. The heat exchanger production line according to claim 7, wherein the end plate mounting device further includes a lifting stopper member, the end plate mounting robot is installed symmetrically on both sides of the fin conveying line, the lifting stopper member includes a lifting drive member and a stopper portion, the lifting drive member is installed below the end plate mounting position, the stopper portion is connected to the output end of the lifting drive member, and the stopper portion is configured to move up and down between adjacent rollers by the action of the lifting drive member.

9. The heat exchanger production line according to claim 8, wherein the stopper portion includes at least two stopper blocks installed at intervals along the axial direction of the roller, and when the pallet member is transported to the end plate mounting position, the lifting drive member raises the stopper portion above the roller to stop the pallet member.

10. The end plate mounting device further includes a jack-up member, the jack-up member comprising a jack-up drive member located upstream of the lifting stopper member and installed below the fin conveying line, and a jack-up block connected to the output end of the jack-up drive member, the jack-up block moving up and down between adjacent rollers by the action of the jack-up drive member, lifting the pallet member straightened by the stopper block to a target height, thereby facilitating the end plate mounting robot to attach the end plate member to both ends of the fin stack, according to claim 9.

11. The heat exchanger production line according to claim 1, wherein each of the pipeline gripping chucks includes a gripping chuck drive member and a gripping chuck end, the gripping chuck drive member has a first telescopic end and a second telescopic end, there are two gripping chuck ends, each of which is installed on the first telescopic end and the second telescopic end, a gripping chuck recess is formed in each of the gripping chuck ends, and the pipeline member is gripped within the gripping position formed by the two gripping chuck recesses.

12. The heat exchanger production line according to claim 1, wherein the nitrogen filling device is installed in a nitrogen filling chamber, the nitrogen filling chamber is installed at the nitrogen filling work position, the nitrogen filling chamber is provided with a mounting port, the nitrogen filling pipeline extends from the mounting port to the outside of the nitrogen filling chamber, and the nitrogen filling docking member is connected to the nitrogen filling pipeline.

13. An elastic member is installed between the nitrogen-filled pipeline and the nitrogen-filled chamber, one end of the elastic member is fixed to the side wall of the nitrogen-filled chamber, and the other end is connected to the nitrogen-filled pipeline located inside the nitrogen-filled chamber, and when the nitrogen-filled pipeline moves outward from the nitrogen-filled chamber and connects to the pipeline member, the elastic member undergoes elastic deformation, and after nitrogen filling is completed, when the nitrogen-filling robot releases the nitrogen-filled pipeline, the elastic restoring force causes the nitrogen-filled pipeline to return to its original position, as described in claim 12.

14. The heat exchanger production line according to claim 12, wherein an elastic conduit section is formed in the nitrogen-filled conduit.

15. The heat exchanger production line according to claim 1, wherein the nitrogen filling robot includes a nitrogen filling robot body and a nitrogen filling jig installed on the nitrogen filling robot body, the nitrogen filling jig includes a gripping drive member and a gripping claw assembly connected to the gripping drive member, the gripping claw assembly includes a first gripping claw and a second gripping claw installed symmetrically, the first gripping claw and the second gripping claw each have a gripping recess formed therein, and the gripping recess is configured to grip a nitrogen filling pipeline.

16. The heat exchanger production line according to claim 15, wherein the nitrogen-filled docking member has a bonding channel that gradually expands away from the nitrogen-filled pipeline, and the bonding channel is in communication with the nitrogen-filled pipeline.

17. The fin conveying line includes an upstream conveying line and a downstream conveying line, the upstream conveying line includes a plurality of rollers installed at intervals along the conveying direction of the upstream conveying line, the downstream conveying line includes a conveying drive member and a conveying belt, the end plate mounting position and the pipe insertion work position are located on the upstream conveying line, and the nitrogen filling work position is located on the downstream conveying line. The heat exchanger production line according to claim 1, wherein a tube expansion device and a drying device are further installed between the upstream transport line and the downstream transport line, and the fin stack is transported by a transfer robot between the upstream transport line and the tube expansion device, between the tube expansion device and the drying device, and between the drying device and the downstream transport line.

18. The heat exchanger production line according to claim 17, wherein the transfer robot includes a transfer robot body and a transfer jig, the transfer jig is installed on the transfer robot body, the transfer jig includes a transfer center beam, a transfer drive member and a transfer clamp plate, the transfer center beam is connected to the transfer robot body, the transfer drive member is installed on the transfer center beam, the transfer drive member has a first telescopic end and a second telescopic end, there are two transfer clamp plates, each installed on the first telescopic end and the second telescopic end, and the transfer clamp plate is used to grip the end plate members at both ends of the fin stack.

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