Double-Pipe Heat Exchanger Corrugation for Faster Low-Cost Forming
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Solution Overview
Problem
The existing method for manufacturing double-pipe heat exchangers with grooves formed by rolling is expensive and time-consuming, requiring continuous processing.
Innovation Solution
A method involving an inner pipe inserted between a cored bar and a metal movable claw to form corrugated portions by radial inward pressing, using an inexpensive apparatus to increase the heat transfer area efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If grooves are formed by rolling using a grooving tool, then the heat transfer area is increased and heat exchange efficiency is improved, but the manufacturing apparatus becomes expensive and the manufacturing process takes a long time
Solution Approach 1:
The invention changes the manufacturing method from rolling to press forming. Specifically, it uses a press forming apparatus with a punch that has a corrugated surface to directly form corrugated portions on the inner pipe by pressing. This parameter change in the forming method reduces manufacturing time while maintaining the heat exchange efficiency improvement.
Solution Approach 2:
The invention replaces the expensive rolling manufacturing apparatus with a simpler, less expensive press forming apparatus. The press forming method uses a punch with a corrugated surface that can be easily manufactured and replaced, making the overall manufacturing system more cost-effective while achieving the same functional result.
2Area of stationary object
If grooves are formed by rolling, then the heat transfer area is increased, but the manufacturing process must be continuous and takes a long time
Solution Approach 1:
The invention changes the continuous rolling process into a discrete press forming process. The punch with corrugated surface presses the inner pipe to form corrugated portions at specific locations, eliminating the need for continuous rolling. This reduces the manufacturing duration while still achieving the required heat transfer area through the formed corrugated portions.
3Manufacturing precision
If expensive extrusion techniques are used to form corrugated portions, then the heat transfer area is increased, but the manufacturing cost increases
Solution Approach 1:
The invention replaces expensive extrusion techniques with a simpler press forming method using a punch with a corrugated surface. The punch can be manufactured at lower cost and replaced if needed, making the overall process more economical while still achieving the required heat transfer area through the formed corrugated portions on the inner pipe.
Solution Approach 2:
The invention substitutes the complex extrusion mechanical system with a simpler press forming system. Instead of using extrusion equipment to force material through a die, the invention uses a press apparatus to directly form the corrugated portions by pressing the inner pipe with a corrugated punch, reducing manufacturing cost while maintaining the heat transfer enhancement.
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
The method allows for the formation of corrugated portions that enhance heat exchange efficiency in a short time using a cost-effective manufacturing process, with the inner pipe being easily fixed to the outer pipe without the need for expensive extrusion techniques.
Implementation Method 1
a corrugated portion formation step of forming the corrugated portion in a predetermined range of the inner pipe in the axial direction by pressing the inner pipe radially inward by the metal movable claw and plastically deforming the inner pipe
Data Source
AI summary
A method includes: an inner pipe insertion step of inserting an inner pipe to between a cored bar and a metal movable claw; a designated section corrugated portion formation step of forming a corrugated portion in a first designated section by pressing the first designated section of the inner pipe radially inward by the metal movable claw and plastically deforming the first designated section; a movable claw moving step of moving the metal movable claw outward in the radial direction of the inner pipe; and an inner pipe moving step of moving a second designated section that is the next designated section to between the cored bar and the metal movable claw.