Cryogenic Tank Heat Exchanger Welded Inserts
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Solution Overview
Problem
The challenge is to produce pressure vessels with integrated heat exchangers for cryogenically stored media, such as hydrogen, in a cost-effective and time-efficient manner while maintaining high quality and gas-tightness, especially for large-scale production.
Innovation Solution
A pressure vessel design featuring a cylindrical jacket with rolled ends and centrally positioned inserts, where the tank heat exchanger is attached to these inserts and welded independently, allowing for separate production and assembly of the heat exchanger components, including flow and return pipes with heat exchange fins, which can be seamlessly drawn from light metal materials for reliable gas-tight connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the heat exchanger is integrated into the pressure vessel during manufacturing, then the structural integrity and gas-tightness are improved, but the production time and manufacturing complexity increase
Solution Approach 1:
The pressure vessel is divided into separate components: the cylindrical jacket with openings and the heat exchanger assembly with inserts. The heat exchanger is manufactured independently and then integrated into the pressure vessel through welding, allowing parallel manufacturing processes that reduce overall production time while maintaining structural integrity through proper welding procedures
2Productivity
If the heat exchanger is manufactured separately and then integrated, then the production time and costs are reduced, but the manufacturing precision and assembly complexity increase
Solution Approach 1:
The heat exchanger and inserts are manufactured and prepared in advance as separate components with precise dimensions and welding surfaces. This preliminary manufacturing allows for quality control and precision work to be done on individual components before final assembly, reducing the complexity of achieving precision during integrated manufacturing
Solution Approach 2:
The inserts serve as intermediary components that facilitate the connection between the heat exchanger pipes and the pressure vessel jacket. These inserts provide standardized welding surfaces and alignment features that simplify the assembly process and ensure manufacturing precision during integration
3Ease of manufacture
If the heat exchanger is attached to inserts and welded independently, then the production costs are reduced, but the device complexity increases
Solution Approach 1:
The heat exchanger system is segmented into multiple independent components (flow pipe, return pipe, inserts) that can be manufactured using standard processes and then assembled. This segmentation allows each component to be optimized for its specific function and manufactured cost-effectively, with the overall assembly complexity managed through standardized connection interfaces
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly reduces production time and costs by allowing independent assembly and welding of the heat exchanger components, ensuring high-quality, gas-tight connections and efficient heat exchange during filling, while maintaining the integrity of the pressure vessel.
Implementation Method 1
a tank heat exchanger (14) which is attached to these inserts (6, 7) and welded independently
Implementation Method 2
the cryogenic medium further through the filling pipe (19) and from there via a second outlet opening (30) in the filling pipe (19) flows into the pressure vessel (1)
Implementation Method 3
the tank heat exchanger (14) which is attached to these inserts (6, 7) and welded independently
Implementation Method 4
it is advantageous if the pipes of the tank heat exchanger are provided with heat exchange fins at least in sections on the outside
Data Source
Figure 1~2
Figure 3~5
AI summary
The invention relates to a pressure vessel comprising a heat exchanger for a cryogenically stored medium, especially for use in a motor vehicle, especially for use as a pressure tank for hydrogen. Said pressure vessel consists of a cylindrical jacket and rounded-off end faces which are rolled onto the ends of the jacket and which have centrally arranged openings closed by welded-in inserts, at least one first insert having filling and removal devices. The invention is characterized in that the inserts form bearings on which at least one in-tank heat exchanger is mounted.