Automatic welding device for heat exchanger
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- SAMSUNG ELECTRONICS CO LTD
- Filing Date
- 2026-01-22
- Publication Date
- 2026-07-30
Smart Images
Figure KR2026001312_30072026_PF_FP_ABST
Abstract
Description
Automatic welding device for heat exchangers
[0001] The various embodiments disclosed in this document relate to an automatic welding device for a heat exchanger.
[0002] A heat exchanger is a device used in a refrigeration cycle. It acts as a condenser or evaporator that exchanges heat between the refrigerant and the outside air.
[0003] The heat exchanger may include a refrigerant tube through which a refrigerant flows and which exchanges heat between the refrigerant and external air, a heat exchange fin that contacts the refrigerant tube to increase the heat dissipation area, a distribution tube (or connecting tube) for supplying refrigerant to the refrigerant tube, and a bending tube coupled to the end of the refrigerant tube to change the direction of refrigerant flow in the refrigerant tube.
[0004] The refrigerant tubes and distribution tubes, or the refrigerant tubes and bending tubes of a heat exchanger, can be joined through a welding process. Generally, this welding process is performed manually by a worker. When the welding process is performed manually, the welding quality may vary depending on the worker's skill level, making it difficult to ensure uniform welding quality.
[0005] The information described above may be provided as related art for the purpose of aiding understanding of the present disclosure. No claim or determination is made as to whether any of the foregoing may be applied as prior art related to the present disclosure.
[0006] An automatic welding device for a heat exchanger according to one embodiment of the present disclosure may include a welding section comprising a welding torch and a manipulator for controlling the position of the welding torch, one or more temperature sensors for detecting the ambient temperature of the heat exchanger or the temperature of a welding area adjacent to the welding section of the heat exchanger, an image sensor for photographing the welding section of the heat exchanger, and a processor for controlling the operation of the welding section. The processor may be configured to determine welding conditions regarding the welding section of the heat exchanger based on the temperature detected by the one or more temperature sensors, operate the welding section according to the welding conditions of the heat exchanger, and adjust the welding conditions during the operation of the welding section based on the current temperature of the welding area of the heat exchanger, the welding conditions, and the welding state of the welding section of the heat exchanger.
[0007] A control method for an automatic welding device for a heat exchanger, according to one embodiment of the present disclosure, comprising a welding part including a welding torch and a manipulator for position control of the welding torch, one or more temperature sensors for detecting the ambient temperature of the heat exchanger or the temperature of a welding part adjacent to the welding part of the heat exchanger, and an image sensor for photographing the welding part of the heat exchanger, may include: an operation of obtaining the ambient temperature of the heat exchanger and the temperature of the welding part adjacent to the heat exchanger through the temperature sensor; an operation of determining welding conditions regarding the welding part of the heat exchanger based on the obtained ambient temperature of the heat exchanger and the temperature of the welding part adjacent to the heat exchanger; an operation of controlling the welding part according to the welding conditions of the heat exchanger; and an operation of adjusting the welding conditions based on the current temperature of the welding part adjacent to the heat exchanger, the welding conditions, and the welding state of the welding part of the heat exchanger during the operation of the welding part.
[0008] However, the problems to be solved in this disclosure are not limited to those mentioned above, and may be determined in various ways without departing from the spirit and scope of this disclosure.
[0009] FIG. 1 is a schematic diagram of an automatic welding device for a heat exchanger according to one embodiment of the present disclosure.
[0010] FIG. 2 is a drawing illustrating the welded portions of the pipes of a heat exchanger according to one embodiment of the present disclosure.
[0011] FIG. 3 is a control block diagram of an automatic welding device according to one embodiment of the present disclosure.
[0012] FIG. 4 is a control flowchart of an automatic welding device according to one embodiment of the present disclosure.
[0013] FIG. 5 is a control flowchart of an automatic welding device according to one embodiment of the present disclosure.
[0014] FIG. 6 is a schematic diagram showing the welding process of a heat exchanger by an automatic welding device according to one embodiment of the present disclosure.
[0015] FIG. 7 is a schematic diagram showing the welding process of a heat exchanger by an automatic welding device according to one embodiment of the present disclosure.
[0016] FIG. 8 is a schematic diagram showing the welding process of a heat exchanger by an automatic welding device according to one embodiment of the present disclosure.
[0017] In the following description, the attached drawings are referenced, and specific examples of implementation are illustrated within the drawings. Additionally, other examples may be used and structural modifications may be made without departing from the scope of the various examples.
[0018] The terms used in this document are used merely to describe specific embodiments and are not intended to limit the technical features of this document. For example, a component expressed in the singular form should be understood as a concept including singular or plural components unless the context clearly indicates only the singular form.
[0019] In this document, each of the following phrases may include any one of the items listed with the corresponding phrase, or any combination thereof: "A or B," "at least one of A and B," "at least one of A or B," "A, B or C," "at least one of A, B and C," and "at least one of A, B, or C." The term "and / or" as used in this document should be understood to encompass any possible combination of one or more of the multiple items listed with the corresponding term. Terms such as "first," "second," "first," or "second" as used in this document may be used simply to distinguish a component from another component and do not limit the components in any other aspect (e.g., importance or order).
[0020] Where it is stated that any (e.g., 1st) component is “coupled,” “connected,” “linked,” “coupled,” “supported,” “connected,” or “contacted” with or without the terms “functionally” or “communicationly,” it includes not only cases where the component is directly coupled, connected, linked, coupled, supported, or contacted with the other component, but also cases where it is indirectly coupled, connected, linked, coupled, supported, or contacted through a third component.
[0021] Terms such as "include" or "have" are intended to specify the existence of the features, numbers, steps, actions, components, parts, or combinations thereof described in this Document, and do not preclude the existence or addition of one or more other features, numbers, steps, actions, components, parts, or combinations thereof. When a component is said to be located "on" another component, this includes not only cases where the component is in contact with the other component, but also cases where another component exists between the two components.
[0022] As used in this document, the expression "configured to..." may be appropriately substituted depending on the context, for example, with "suitable for...", "capable of...", "designed to...", "modified to...", "made to...", or "capable of...". The term "configured to..." does not necessarily mean only that it is "specially designed" in hardware. Instead, in some situations, the expression "device configured to..." may mean that the device is "capable of..." in conjunction with other devices or components. For example, the phrase "device configured (or set) to perform A, B, and C" may refer to a device dedicated to performing the said operation, or it may refer to a general-purpose device capable of performing various operations, including the said operation.
[0023] Terms such as "upper side," "lower side," and "front-rear direction" used in this document are defined based on the drawings, and the shape and location of each component are not limited by these terms.
[0024] The description in this document is centered on specific embodiments, but this document is not limited to such specific embodiments and should be understood to encompass all various modifications, equivalents, and / or substitutions of the various embodiments described in this document. In relation to the description of the drawings, similar reference numerals may be used for similar or related components.
[0025] FIG. 1 is a schematic diagram of an automatic welding device (100) for a heat exchanger (200) according to one embodiment of the present disclosure.
[0026] FIG. 2 is a drawing showing the welded portions of the pipes of a heat exchanger (200) according to one embodiment of the present disclosure.
[0027] Referring to FIGS. 1 and 2, a heat exchanger (200) according to one embodiment is a device configured to circulate a refrigerant and to exchange heat between the circulating refrigerant and external air. The heat exchanger (200) can be used in various home appliances, such as air conditioners and refrigerators, that require air conditioning, such as heating or cooling of external air.
[0028] According to one embodiment, the heat exchanger (200) may include a heat exchange fin (210), a support plate (220), a refrigerant pipe (230), a bending pipe (240), and a distribution pipe (250).
[0029] According to one embodiment, the heat exchange fin (210) may be attached to the outer surface of the refrigerant pipe (230). The heat exchange fin (210) is attached to the refrigerant pipe (230) and can perform the function of increasing the heat exchange area between the outside air and the refrigerant pipe (230).
[0030] According to one embodiment, the heat exchange fin (210) may be made of aluminum, which has high thermal conductivity.
[0031] According to one embodiment, the heat exchange fin (210) may be positioned on the inner side of the support plate (220) with respect to the support plate (220). The heat exchange fin (210) may be provided in any shape so that the refrigerant pipe (230) can efficiently release or absorb heat. For example, the heat exchange fin (210) may have a plate shape overall.
[0032] According to one embodiment, the heat exchange fins (210) may be provided in multiple units rather than as a single unit. Each of the multiple heat exchange fins (210) may be spaced apart from one another in a direction parallel to the extension direction (or length direction) of the refrigerant pipe (230) (e.g., vertical direction). For example, the multiple heat exchange fins (210) may be stacked with a predetermined spacing in the vertical direction. The spacing between the heat exchange fins (210) may be referred to as the stacking spacing. The narrower the stacking spacing of the heat exchange fins (210), the more heat exchange fins (210) can be stacked relative to the same length. However, if the stacking spacing of the heat exchange fins (210) is excessively narrow, the heat exchange fins (210) may act as a flow resistance for the external air flowing into the heat exchanger (200). Accordingly, the stacking spacing of the heat exchange fins (210) can be appropriately adjusted to minimize air pressure loss.
[0033] According to one embodiment, a support plate (220) may be disposed on one side of a heat exchange fin (210). For example, the support plate (220) may be provided at one end of a plurality of stacked heat exchange fins (210). The support plate (220) can maintain the arrangement of the refrigerant pipe (230) by stably fixing the heat exchange fin (210) and the refrigerant pipe (230).
[0034] According to one embodiment, the refrigerant pipe (230) may provide a refrigerant flow path through which a fluid refrigerant flows. The refrigerant pipe (230) may be provided as a refrigerant tube. A microchannel refrigerant tube may be used as the refrigerant tube. A microchannel refrigerant tube may refer to a tube having a hydraulic diameter of 3 mm or less. Here, the hydraulic diameter is the value obtained by dividing the cross-sectional area of the tube by the circumference of the tube.
[0035] According to one embodiment, the refrigerant pipes (230) may be arranged in a plurality of rows so as to be divided into a portion where the refrigerant enters and a portion where the refrigerant exits. The refrigerant pipes (230) may be arranged parallel to one side of the support plate (220). For example, the refrigerant pipes (230) may be arranged along a first row, which is the portion where the refrigerant enters, so as to be arranged to correspond to one side of the support plate (220). For example, the refrigerant pipes (230) may be arranged parallel to the other side of the support plate (220) opposite to one side of the support plate (220). For example, the refrigerant pipes (230) may be arranged along a second row, which is the portion where the refrigerant exits, so as to be arranged to correspond to the other side of the support plate (220).
[0036] The refrigerant can flow along the refrigerant path formed in the refrigerant pipe (230) and be compressed or expanded to release heat to the surroundings or absorb heat from the surroundings. In order for the refrigerant to be compressed or expanded and efficiently release or absorb heat, a heat exchange fin (210) may be attached to the refrigerant pipe (230).
[0037] According to one embodiment, the refrigerant pipe (230) may have two open ends. Additionally, the refrigerant pipe (230) may have a bending portion formed at a position opposite to the two open ends and bent to change the flow direction of the refrigerant.
[0038] According to one embodiment, the refrigerant pipe (230) may be positioned such that the end of the refrigerant pipe (230) penetrates the support plate (220). For example, a portion of the refrigerant pipe (230) may be positioned on the inside of the support plate (220) relative to the support plate (220), and another portion of the refrigerant pipe (230) may be positioned on the outside of the support plate (220) relative to the support plate (220).
[0039] In one embodiment, the refrigerant pipe (230) penetrates the support plate (220) and is connected to the bending pipe (240) on the outside of the support plate (220), so that the refrigerant can flow from the refrigerant pipe (230) to another refrigerant pipe (230) adjacent to the refrigerant pipe (230).
[0040] In one embodiment, the refrigerant pipe (230) penetrates the support plate (220) and is connected to the distribution pipe (250) on the outside of the support plate (220), so that refrigerant may flow into the refrigerant pipe (230) or refrigerant that has completed heat exchange may flow out of the refrigerant pipe (230).
[0041] According to one embodiment, the bending pipe (240) may be provided to connect two adjacent refrigerant pipes (230) among a plurality of refrigerant pipes (230).
[0042] An open end of the refrigerant pipe (230) is connected to one of the plurality of distribution pipes (250) so that refrigerant may flow into the refrigerant pipe (230) or refrigerant may flow out of the refrigerant pipe (230).
[0043] The other open end of the refrigerant pipe (230) can be connected to the bending pipe (240). The open ends of two adjacent refrigerant pipes (230) can be connected to each other by the bending pipe (240).
[0044] Accordingly, the refrigerant introduced into the refrigerant pipe (230) flows along the flow path inside the refrigerant pipe (230), is diverted by the bending portion of the refrigerant pipe (230), and the refrigerant can flow into or be discharged into an adjacent refrigerant pipe (50) by the bending pipe (240).
[0045] Additionally, the open one end and the open other end of the refrigerant pipe (230) can be connected to different bending pipes (240) respectively to form a path for the refrigerant to travel.
[0046] According to one embodiment, the distribution pipe (250) may be connected to the refrigerant pipe (230). The refrigerant may be supplied from the distribution pipe (250) to the refrigerant pipe (230), or may flow out from the refrigerant pipe (230) to the distribution pipe (250) after heat exchange is completed.
[0047] According to one embodiment, the connection between the refrigerant pipe (230) and the bending pipe (240) and / or the connection between the refrigerant pipe (230) and the distribution pipe (250) may be performed by welding. For example, solder (or filler metal) for joining may be provided at the connection portion between the refrigerant pipe (230) and the bending pipe (240) and / or the connection portion between the refrigerant pipe (230) and the distribution pipe (250) (or weld portion (P1)). For example, the solder may have a ring shape corresponding to the outer diameter of the bending pipe (240) and / or the distribution pipe (250). The solder may be named a solder ring.
[0048] The solder (e.g., solder ring), refrigerant pipe (230), bending pipe (240), and distribution pipe (250) of the heat exchanger (200) of the disclosed invention may all be provided to include aluminum material.
[0049] The shape of the distribution pipe (250) can be designed differently depending on the installation environment of the heat exchanger (200). Generally, the shape of the distribution pipe (250) can be provided in a complex shape, unlike the bending pipe (240). Therefore, welding to connect the distribution pipe (250) to the refrigerant pipe (230) is difficult to apply an automated process to and is performed manually by a skilled worker.
[0050] An automatic welding device (100) for a heat exchanger (200) according to one embodiment may be a welding device for joining components of the heat exchanger (200) by welding. The automatic welding device (100) may be a robot device that replaces the existing welding method relying on the handwork of a skilled worker, and which senses information regarding the heat exchanger (200) on its own and automatically performs and controls welding based on the sensed information of the heat exchanger (200). For example, the automatic welding device (100) may be used in the welding process of the welding portion (P1) between the refrigerant pipe (230) and the distribution pipe (250), where the application of an automated process is difficult due to the complex structure as described above, thereby promoting the productivity and / or quality improvement of the heat exchanger (200).
[0051] According to one embodiment, the automatic welding device (100) may have the form of a robot arm. Hereinafter, an automatic welding device (100) for a heat exchanger (200) will be described with reference to the drawings from Fig. 3 onwards. At this time, in relation to the distribution pipe (250), the remaining components of the heat exchanger (200) excluding the distribution pipe (250) (e.g., heat exchanger fin (210), support plate (220), refrigerant pipe (230), bending pipe (240)) may be referred to as the heat exchanger body.
[0052] FIG. 3 is a control block diagram of an automatic welding device (100) according to one embodiment of the present disclosure.
[0053] The embodiment of FIG. 3 can be optionally combined with the embodiments of FIG. 1, FIG. 2 and FIG. 4 to FIG. 8.
[0054] Referring to FIG. 3, an automatic welding device (100) according to one embodiment may include a sensor unit (110), a control unit (120), and a welding unit (130).
[0055] According to one embodiment, the sensor unit (110) can obtain information for controlling the automatic welding device (100) through various sensors (111, 113). For example, the sensor unit (110) may be configured to detect the operating state of the automatic welding device (100) and / or the external environment.
[0056] According to one embodiment, the sensor unit (110) may include one or more temperature sensors (111) and one or more image sensors (113).
[0057] According to one embodiment, the temperature sensor (111) may include a first temperature sensor (111a) for detecting the ambient temperature of the heat exchanger (200) and a second temperature sensor (111b) for detecting the temperature of the heat exchanger (200). The first temperature sensor (111a) may be named an ambient temperature sensor. The second temperature sensor (111b) may be provided to detect the temperature of a welded area (e.g., P2 in FIG. 2) adjacent to a welded part (P1) of the heat exchanger (200). The second temperature sensor (111b) may be named a welded temperature sensor. For example, the temperature sensor (111) may include an infrared laser sensor or a thermal imaging sensor.
[0058] The above-mentioned welding peripheral portion (P2) may be positioned considering the influence of the welding spark from the welding torch (131) to be described later. For example, the welding peripheral portion (P2) may be located below (e.g., the main body of the refrigerant pipe (231)) the flange portion (232) of the refrigerant pipe (230) in which the solder is received, where the influence of the welding spark from the welding torch (131) is minimal.
[0059] According to one embodiment, an image sensor (113) may be provided to acquire an image (or video) regarding the welding process of a heat exchanger (200). For example, an automatic welding device (100) may check the welded portion (P1) of the heat exchanger (200) through the image sensor (113). For example, the automatic welding device (100) may monitor the condition of the solder (e.g., the degree of melting of the solder) during the welding process of the heat exchanger (200) through the image sensor (113). For example, the image sensor (113) may include a vision sensor.
[0060] According to one embodiment, the control unit (120) may be configured to control the overall operation of the automatic welding device (100). The control unit (120) may include a memory (123) for storing or remembering a program and / or data for controlling each component of the automatic welding device (100), and a processor (121) for generating a control signal for controlling each component of the automatic welding device (100) according to the program and / or data stored in the memory (123) and information obtained from each of the other components.
[0061] According to one embodiment, the memory (123) can store various data that can be used to control the operation of each component of the automatic welding device (100). The memory (123) can store, for example, a number of applications used in the automatic welding device (100), data for controlling the operation of the automatic welding device (100), and commands. At least some of the applications stored in the memory (123) can be downloaded from an external server via wired or wireless communication. At least some of the applications stored in the memory (123) may be stored in the memory (123) from the time of shipment for the basic functions of the automatic welding device (100).
[0062] According to one embodiment, data for calculating welding conditions may be stored in the memory (123). For example, the memory (123) may store the rate of temperature rise of the weld surrounding part (P2) according to the gas flow rate, the temperature difference between the weld part (P1) and the weld surrounding part (P2), the overheating prevention temperature, the welding stop temperature, etc. Here, the overheating prevention temperature may be named as the first set temperature, and the welding stop temperature may be named as the second set temperature. The welding stop temperature (e.g., about 590 degrees) may be set to be higher than the overheating prevention temperature (e.g., about 610 degrees).
[0063] According to one embodiment, the processor (121) can obtain information for controlling the automatic welding device (100) from the sensor unit (110).
[0064] According to one embodiment, the processor (121) can generate operation control commands for each component of the automatic welding device (100) based on various information received from the sensor unit (110). For example, the processor (121) can calculate welding conditions based on information obtained from the sensor unit (110) and control the operation of the welding unit (130) based on the calculated welding conditions.
[0065] According to one embodiment, the control unit (120) is disclosed as a single comprehensive configuration that controls all components included in the automatic welding device (100), but the present disclosure is not limited thereto. In one example, the automatic welding device (100) may be configured to include a plurality of control unit configurations that individually control some of the components of the automatic welding device (100). In one example, the automatic welding device (100) may include a separate control unit equipped with a processor and memory for controlling the operation of the welding unit (130). The processor (121) of the control unit (120) may include a plurality of processors, and the memory (123) may include a plurality of memory devices.
[0066] According to one embodiment, the welding section (130) may be configured to substantially perform welding of the heat exchanger (200) based on a control signal from the control section (120). The welding section (130) may include a welding torch (131), a torch position controller (133), and a gas flow control device (135).
[0067] According to one embodiment, the welding torch (131) may be configured to melt solder by burning a gas. The gas may include, for example, oxygen, air, or natural gas.
[0068] According to one embodiment, a torch position controller (133) may be provided to control the position of a welding torch (131). For example, the torch position controller (133) may have the form of a multi-jointed robot arm, and the position of the welding torch (131) provided at the free end of the robot arm may be controlled by manipulating the joints. The torch position controller (133) may be named a manipulator.
[0069] According to one embodiment, a gas flow control device (135) may be provided to control the flow rate of gas supplied to a welding torch (131). For example, the gas flow control device (135) may control the flame intensity (or welding temperature) of the welding torch (131) by controlling the flow rate of gas supplied to the welding torch (131).
[0070] FIG. 4 is a control flowchart of an automatic welding device (100) according to one embodiment of the present disclosure.
[0071] The embodiment of FIG. 4 can be optionally combined with the embodiments of FIG. 1 to 3 and FIG. 5 to 8.
[0072] Referring to FIG. 4, an automatic welding device (100) according to one embodiment can obtain data for calculating welding conditions from a sensor unit (110) in operation 410. For example, the automatic welding device (100) can obtain data regarding the ambient temperature of the heat exchanger (200) and the temperature of the welding area (P2) of the heat exchanger (200) through a temperature sensor (111). For example, the automatic welding device (100) can obtain data regarding the size and / or location of the welding area (P1) and the volume of the solder through an image sensor (113).
[0073] According to one embodiment, the automatic welding device (100) can calculate welding conditions for controlling the operation of the welding part (130) based on data obtained from the sensor unit (110) in operation 420. For example, the automatic welding device (100) can calculate the expected welding time (or operating time of the welding torch (131)) and / or the flame intensity of the welding torch (131) (or the gas flow rate supplied to the welding torch (131)) using data obtained from the sensor unit (110) regarding the ambient temperature of the heat exchanger (200), the temperature of the welding peripheral part (P2) of the heat exchanger (200), the size and / or location of the welding part (P1), and the volume of the solder.
[0074] According to one embodiment, the automatic welding device (100) can perform feedback control of the weld part (130) based on the calculated welding conditions in operation 430. The feedback control may mean a control operation of the automatic welding device (100) to adjust the existing welding conditions based on the current temperature of the welding surrounding part (P2) of the heat exchanger (200), welding conditions, and the welding state of the welding part (P1) of the heat exchanger (200) during the operation of the weld part (130).
[0075] FIG. 5 is a control flowchart of an automatic welding device (100) according to one embodiment of the present disclosure.
[0076] The embodiment of FIG. 5 can be optionally combined with the embodiments of FIG. 1 to 4 and the embodiments of FIG. 6 to 8.
[0077] Referring to FIG. 5, an automatic welding device (100) according to one embodiment can acquire an image of a welded portion (P1) of a heat exchanger (200) through an image sensor (113) in operation 501. For example, the automatic welding device (100) can acquire information regarding the size, location, and number of welded portions (P1) based on the image acquired through the image sensor (113).
[0078] According to one embodiment, the automatic welding device (100) can select a welding path based on an image obtained from an image sensor (113) in operation 502. For example, the automatic welding device (100) can select a movement path of the welding part (130) based on the position of each welding part (P1) when a plurality of welding parts (P1) are provided.
[0079] According to one embodiment, the automatic welding device (100) can measure the ambient temperature of the heat exchanger (200) and / or the current temperature of the welding area (P2) of the heat exchanger (200) through a temperature sensor (111) in operation 503.
[0080] According to one embodiment, the automatic welding device (100) can calculate the welding conditions of the welding portion (P1) of the heat exchanger (200) based on an image obtained from the image sensor (113) and / or a temperature obtained from the temperature sensor (111) in operation 504. For example, if the welding portion (P1) of the heat exchanger (200) is provided in multiple numbers, the welding conditions may be calculated differently for each welding portion (P1). The welding conditions may include an expected welding time (or operating time of the welding torch (131)) and / or the flame intensity of the welding torch (131) (or the gas flow rate supplied to the welding torch (131).
[0081] According to one embodiment, the automatic welding device (100) can control the operation of the weld part (130) to correspond to the welding conditions calculated in operation 505. For example, the automatic welding device (100) can heat the weld part (P1) with a corresponding flame intensity during the welding time corresponding to the calculated welding conditions.
[0082] According to one embodiment, the automatic welding device (100) can monitor the temperature of the weld surrounding part (P2) in real time through the temperature sensor (111) during welding of the weld part (P1) in operation 506.
[0083] According to one embodiment, the automatic welding device (100) can calculate the temperature rise rate of the weld surrounding part (P2) based on the temperature of the weld surrounding part (P2) monitored through the temperature sensor (111) during welding of the weld part (P1) in operation 507, and determine whether the calculated temperature rise rate of the weld surrounding part (P2) is appropriate. For example, the automatic welding device (100) can determine the appropriateness of the temperature rise rate of the weld surrounding part (P2) by determining whether it is possible to reach the target temperature of the weld surrounding part (P2) (e.g., overheating prevention temperature) when welding is performed up to the expected welding time based on the measured temperature rise rate of the weld surrounding part (P2). Specifically, when the automatic welding device (100) proceeds with welding until the expected welding time based on the measured temperature rise rate of the welding surrounding part (P2), if it is determined that the temperature of the welding surrounding part (P2) to be targeted (e.g., overheating prevention temperature) can be reached when the expected welding time is reached, it can determine that the temperature rise rate of the welding surrounding part (P2) is appropriate, and if not, it can determine that the temperature rise rate of the welding surrounding part (P2) is not appropriate.
[0084] According to one embodiment, the automatic welding device (100) can adjust the flow rate of gas supplied to the welding torch (131) through the gas flow control device (135) when the temperature rise rate of the welding surrounding part (P2) is not appropriate in operation 508. For example, if the temperature rise rate of the welding surrounding part (P2) is excessive (e.g., when welding is performed up to the expected welding time based on the measured temperature rise rate of the welding surrounding part (P2), the temperature of the welding surrounding part (P2) at the expected welding time exceeds the target temperature (e.g., overheating prevention temperature)), the flow rate of gas supplied to the welding torch (131) can be reduced. For example, if the rate of temperature rise of the weld surrounding area (P2) is too low (e.g., when welding is performed up to the expected welding time based on the measured rate of temperature rise of the weld surrounding area (P2), the target temperature of the weld surrounding area (P2) (e.g., overheating prevention temperature) is not reached by the expected welding time), the flow rate of the gas supplied to the welding torch (131) can be increased.
[0085] According to one embodiment, the automatic welding device (100) can determine whether the temperature of the welding surrounding part (P2) has reached the work stoppage temperature through the temperature sensor (111) during welding of the welding part (P1) in operation 509.
[0086] According to one embodiment, the automatic welding device (100) can determine the welding status of the welding part (P1) through the image sensor (113) in operation 510. For example, the automatic welding device (100) can determine whether the solder in the welding part (P1) has completely melted based on the image of the welding part (P1) obtained through the image sensor (113).
[0087] According to one embodiment, the automatic welding device (100) can perform feedback control to adjust the welding conditions based on the welding conditions calculated in operation 511.
[0088] For example, the automatic welding device (100) can increase the expected welding time and perform welding with the flame intensity of the existing welding torch (131) up to the increased expected welding time when the temperature of the welding area (P2) is below the overheating prevention temperature while the welding of the welding area (P1) is not completed and the current welding progress time has reached the expected welding time.
[0089] For example, the automatic welding device (100) can reduce the flame intensity of the welding torch (131) by reducing the flow rate of the gas supplied to the welding torch (131) when the welding of the welding part (P1) is not completed, the temperature of the welding surrounding part (P2) reaches the overheating prevention temperature, and the current welding progress time is within the expected welding time.
[0090] For example, the automatic welding device (100) can increase the expected welding time and decrease the flame intensity of the welding torch (131) by reducing the flow rate of the gas supplied to the welding torch (131) when the welding of the welding part (P1) is not completed, the temperature of the welding surrounding part (P2) reaches the overheating prevention temperature, and the current welding progress time reaches the expected welding time.
[0091] For example, the automatic welding device (100) may stop the operation of the welding torch (131) when the temperature of the welding area (P2) exceeds the overheating prevention temperature while the welding state of the welding part (P1) is not completed. At this time, the operator may visually inspect the condition of the welding part (P1) and decide whether to re-weld the welding part (P1) and / or manually weld it.
[0092] In this way, the automatic welding device (100) can stably protect the base material (e.g., heat exchanger body) by stably performing the welding process through feedback control based on monitoring of the temperature surrounding part (P2) within the calculated welding conditions.
[0093] According to one embodiment, the automatic welding device (100) can move the position of the welding torch (131) to its original position (or initial position) via the torch position controller (133) in operation 512. For example, the automatic welding device (100) can move the welding torch (131) away from the welding part (P1) when it is determined via the image sensor (113) that the welding of the welding part (P1) is completed. For example, the automatic welding device (100) can move the welding torch (131) away from the welding part (P1) when it is determined via the temperature sensor (111) that the temperature of the welding surrounding part (P2) has reached the welding stop temperature. At this time, when the temperature of the weld area (P2) reaches the welding stop temperature and the welding torch (131) is separated from the weld area (P1), the operator can check the condition of the weld area (P1) and determine whether to re-weld the weld area (P1) and / or manually weld it.
[0094] FIG. 6 is a schematic diagram showing the welding process of a heat exchanger (200) by an automatic welding device (100) according to one embodiment of the present disclosure.
[0095] FIG. 7 is a schematic diagram showing the welding process of a heat exchanger (200) by an automatic welding device (100) according to one embodiment of the present disclosure.
[0096] FIG. 8 is a schematic diagram showing the welding process of a heat exchanger (200) by an automatic welding device (100) according to one embodiment of the present disclosure.
[0097] The embodiments of FIGS. 6 to 8 can be optionally combined with the embodiments of FIGS. 1 to 5.
[0098] Referring to FIGS. 6 to 8, according to one embodiment, a plurality of automatic welding devices (100) may be arranged along a transport device (300, 300a) (e.g., a conveyor belt) for transporting a heat exchanger body (200a, 200b, 200c) and a heat exchanger (200) for welding a distribution pipe (e.g., the distribution pipe (250) of FIG. 2).
[0099] According to one embodiment, a plurality of automatic welding devices (100) may be arranged to be positioned differently along a transport device (300, 300a) in consideration of the position of the welded portion (P1) of the distribution pipe (250) within the heat exchanger (200).
[0100] According to one embodiment, a plurality of automatic welding devices (100) can be positioned differently along a transport device (300, 300a) by monitoring the temperature of the welding surrounding part (P2) of the distribution pipe (250) and taking into account the effect of residual heat generated during the welding process of each welding part (P1).
[0101] For example, as shown in FIG. 6, when the welded portion (P1) of the distribution pipe (250) is formed only on one side of the heat exchanger (200), a plurality of automatic welding devices (100) may be spaced apart from each other along the transport device (300) so as to face one side of the heat exchanger (200).
[0102] For example, as shown in FIG. 7, when the welded portion (P1) of the distribution pipe (250) is formed alternately on both sides of the heat exchanger (200), a plurality of automatic welding devices (100) may be arranged alternately on both sides of the transport device (300) and spaced apart from each other along the direction of movement of the transport device (300).
[0103] For example, as shown in FIG. 8, when a welded portion (P1) of a distribution pipe (250) is arbitrarily formed in a heat exchanger (200), a plurality of automatic welding devices (100) may be spaced apart from each other along the outer circumference of the transport device (300) in the direction of movement of the transport device (300).
[0104] An automatic welding device (100) for a heat exchanger (200) according to one embodiment of the present disclosure may include a welding part (130) comprising a welding torch (131) and a manipulator (133) for controlling the position of the welding torch (131), one or more temperature sensors (111) for detecting the ambient temperature of the heat exchanger (200) or the temperature of a welding area (P2) adjacent to a welding part (P1) of the heat exchanger (200), an image sensor (113) for photographing the welding part (P1) of the heat exchanger (200), and a processor (121) for controlling the operation of the welding part (130). The processor (121) may be configured to determine welding conditions for a welding portion (P1) of the heat exchanger (200) based on a temperature detected by one or more temperature sensors (111), operate the welding portion (130) according to the welding conditions of the heat exchanger (200), and adjust the welding conditions based on the current temperature of the welding surrounding portion (P2) of the heat exchanger (200), the welding conditions, and the welding state of the welding portion (P1) of the heat exchanger (200) during the operation of the welding portion (130).
[0105] According to one embodiment, the welding conditions may include a gas flow rate supplied to the welding torch (131) and an expected welding time according to the gas flow rate.
[0106] According to one embodiment, the processor (121) may be configured to increase the expected welding time if the temperature of the welding peripheral part (P2) is below a first set temperature, the welding progress time reaches the expected welding time, and the welding state of the welding part (P1) is incomplete.
[0107] According to one embodiment, the processor (121) may be configured to reduce the gas flow rate supplied to the welding torch (131) when the temperature of the welding peripheral part (P2) is above the first set temperature, the welding progress time is within the expected welding time, and the welding state of the welding part (P1) is incomplete.
[0108] According to one embodiment, the processor (121) may be configured to reduce the gas flow rate supplied to the welding torch (131) and increase the expected welding time when the temperature of the welding peripheral part (P2) is above the first set temperature, the welding progress time reaches the expected welding time, and the welding state of the welding part (P1) is incomplete.
[0109] According to one embodiment, the processor (121) may be configured to stop the operation of the welding part (130) and separate the welding torch (131) from the heat exchanger (200) when the temperature of the welding surrounding part (P2) is above a second set temperature.
[0110] According to one embodiment, the second set temperature may be greater than the first set temperature.
[0111] According to one embodiment, the processor (121) may be configured to obtain size information of the weld portion (P1) and volume information of the solder in the weld portion (P1) of the heat exchanger (200) from the image sensor (113), and to determine the welding conditions in consideration of the information.
[0112] According to one embodiment, the automatic welding device (100) may further include a memory (123) configured to store information regarding the operation of the welding part (130). The information may include the temperature rise rate of the welding peripheral part (P2) of the heat exchanger (200) according to the gas flow rate supplied to the welding torch (131).
[0113] According to one embodiment, the processor (121) may be configured to calculate the current temperature rise rate of the weld surrounding part (P2) of the heat exchanger (200) during the operation of the weld part (130), compare the calculated current temperature rise rate of the weld surrounding part (P2) of the heat exchanger (200) with the temperature rise rate of the weld surrounding part (P2) of the heat exchanger (200) stored in the memory (123), and adjust the gas flow rate supplied to the weld torch (131) based on the comparison value.
[0114] A control method for an automatic welding device (100) for a heat exchanger (200), comprising a welding part (130) including a welding torch (131) and a manipulator (133) for position control of the welding torch (131) according to one embodiment of the present disclosure, one or more temperature sensors (111) for detecting the ambient temperature of the heat exchanger (200) or the temperature of a welding peripheral part (P2) adjacent to a welding part (P1) of the heat exchanger (200), and an image sensor (113) for photographing the welding part (P1) of the heat exchanger (200), comprises: an operation of obtaining the ambient temperature of the heat exchanger (200) and the temperature of the welding peripheral part (P2) of the heat exchanger (200) through the temperature sensor (111); and, based on the obtained ambient temperature of the heat exchanger (200) and the temperature of the welding peripheral part (P2) of the heat exchanger (200), a welding of the heat exchanger (200). The method may include an operation to determine welding conditions regarding a part (P1), an operation to control the weld part (130) according to the welding conditions of the heat exchanger (200), and an operation to adjust the welding conditions based on the current temperature of the weld surrounding part (P2) of the heat exchanger (200), the welding conditions, and the welding state of the weld part (P1) of the heat exchanger (200) during the operation of the weld part (130).
[0115] According to one embodiment, the control method of the automatic welding device (100) may include an operation to increase the expected welding time when the temperature of the welding peripheral part (P2) is below a first set temperature, the welding progress time reaches the expected welding time, and the welding state of the welding part (P2) is incomplete.
[0116] According to one embodiment, the control method of the automatic welding device (100) may include an operation to reduce the gas flow rate supplied to the welding torch (131) when the temperature of the welding peripheral part (P2) is above the first set temperature, the welding progress time is within the expected welding time, and the welding state of the welding part (P1) is incomplete.
[0117] According to one embodiment, the control method of the automatic welding device (100) may include reducing the gas flow rate supplied to the welding torch (131) and increasing the expected welding time when the temperature of the welding peripheral part (P2) is above the first set temperature, the welding progress time reaches the expected welding time, and the welding state of the welding part (P1) is incomplete.
[0118] According to one embodiment, the control method of the automatic welding device (100) may include stopping the operation of the welding part (130) and separating the welding torch (131) from the heat exchanger (200) when the temperature of the welding peripheral part (P2) is above a second set temperature.
Claims
1. In an automatic welding device (100) for a heat exchanger (200), A welding part (130) comprising a welding torch (131) and a manipulator (133) for controlling the position of the welding torch (131); One or more temperature sensors (111) for detecting the ambient temperature of the heat exchanger (200) or the temperature of the welded area (P2) adjacent to the welded part (P1) of the heat exchanger (200); An image sensor (113) for capturing the welded portion (P1) of the heat exchanger (200); and It includes a processor (121) for controlling the operation of the above-mentioned welding part (130), and The above processor (121) is, Based on the temperature detected by the above one or more temperature sensors (111), welding conditions for the welded portion (P1) of the heat exchanger (200) are determined, and The welded part (130) is operated according to the welding conditions of the heat exchanger (200), and An automatic welding device configured to adjust the welding conditions based on the current temperature of the welding surrounding part (P2) of the heat exchanger (200), the welding conditions, and the welding state of the welding part (P1) of the heat exchanger (200) during the operation of the welding part (130).
2. In Paragraph 1, The above welding conditions include a gas flow rate supplied to the welding torch (131) and an expected welding time according to the gas flow rate, in an automatic welding device.
3. In Paragraph 2, The above processor (121) is, If the temperature of the weld surrounding part (P2) is below the first set temperature, the welding progress time reaches the expected welding time, and the welding state of the weld part (P1) is incomplete, An automatic welding device configured to increase the above-mentioned expected welding time.
4. In Paragraph 2 or 3, The above processor (121) is, If the temperature of the weld surrounding part (P2) is above the first set temperature, the welding progress time is within the expected welding time, and the welding state of the weld part (P1) is incomplete, An automatic welding device configured to reduce the gas flow rate supplied to the welding torch (131).
5. In any one of paragraphs 2 through 4, The above processor (121) is, If the temperature of the weld surrounding part (P2) is above the first set temperature, the welding progress time reaches the expected welding time, and the welding state of the weld part (P1) is incomplete, Reduces the gas flow rate supplied to the welding torch (131), and An automatic welding device configured to increase the above-mentioned expected welding time.
6. In any one of paragraphs 3 through 5, The above processor (121) is, An automatic welding device configured to stop the operation of the welding part (130) and separate the welding torch (131) from the heat exchanger (200) when the temperature of the welding surrounding part (P2) is above the second set temperature.
7. In Paragraph 6, An automatic welding device in which the second set temperature is greater than the first set temperature.
8. In any one of paragraphs 1 through 7, The above processor (121) is, Size information of the welded portion (P1) and volume information of the solder in the welded portion (P1) of the heat exchanger (200) are obtained from the image sensor (113), and An automatic welding device configured to determine the welding conditions in consideration of the above information.
9. In any one of paragraphs 1 through 8, It further includes a memory (123) configured to store information regarding the operation of the above-mentioned weldment (130), and The above information is an automatic welding device including the temperature rise rate of the welding peripheral part (P2) of the heat exchanger (200) according to the gas flow rate supplied to the welding torch (131).
10. In Paragraph 9, The above processor (121) is, During the operation of the above-mentioned weld (130), the current temperature rise rate of the weld surrounding part (P2) of the heat exchanger (200) is calculated, and The current temperature rise rate of the welded area (P2) of the heat exchanger (200) calculated above is compared with the temperature rise rate of the welded area (P2) of the heat exchanger (200) stored in the memory (123), and An automatic welding device configured to adjust the gas flow rate supplied to the welding torch (131) based on the above comparison value.
11. A method for controlling an automatic welding device (100) for a heat exchanger (200), comprising a welding part (130) including a welding torch (131) and a manipulator (133) for position control of the welding torch (131), one or more temperature sensors (111) for detecting the ambient temperature of the heat exchanger (200) or the temperature of a welding peripheral part (P2) adjacent to the welding part (P1) of the heat exchanger (200), and an image sensor (113) for photographing the welding part (P1) of the heat exchanger (200). The operation of obtaining the ambient temperature of the heat exchanger (200) and the temperature of the welded area (P2) of the heat exchanger (200) through the temperature sensor (111); An operation to determine welding conditions for a welding portion (P1) of a heat exchanger (200) based on the ambient temperature of the heat exchanger (200) obtained above and the temperature of a welding peripheral portion (P2) of the heat exchanger (200); An operation to control the weld portion (130) according to the welding conditions of the heat exchanger (200); and A control method for an automatic welding device, comprising, during the operation of the welding part (130), an operation of adjusting the welding conditions based on the current temperature of the welding surrounding part (P2) of the heat exchanger (200), the welding conditions, and the welding state of the welding part (P1) of the heat exchanger (200).
12. In Paragraph 11, A control method for an automatic welding device, comprising the operation of increasing the expected welding time when the temperature of the welding surrounding part (P2) is below a first set temperature, the welding progress time reaches the expected welding time, and the welding state of the welding part (P2) is incomplete.
13. In Paragraph 11 or 12, A control method for an automatic welding device, comprising reducing the gas flow rate supplied to the welding torch (131) when the temperature of the welding surrounding part (P2) is above the first set temperature, the welding progress time is within the expected welding time, and the welding state of the welding part (P1) is incomplete.
14. In any one of paragraphs 11 through 13, A control method for an automatic welding device, comprising the operation of reducing the gas flow rate supplied to the welding torch (131) and increasing the expected welding time when the temperature of the welding surrounding part (P2) is above the first set temperature, the welding progress time reaches the expected welding time, and the welding state of the welding part (P1) is incomplete.
15. In any one of paragraphs 11 through 14, A control method for an automatic welding device, comprising the operation of stopping the operation of the welding part (130) and separating the welding torch (131) from the heat exchanger (200) when the temperature of the welding surrounding part (P2) is above the second set temperature.