Longitudinal Rib Welding Roller Alignment for Finned Tubes

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Solution Overview

Problem

Existing automatic welding machines for longitudinally finned tubes face challenges in achieving high-quality welding due to misalignment of symmetry axes, leading to suboptimal thermal efficiency and heat transfer performance.

Innovation Solution

The automatic welding machine incorporates mechanisms for adjusting the position of the contact welding roller and die components, including eccentric regulators, ball joints, and adjustable nuts, to ensure precise alignment and compensation for wear, allowing for simultaneous welding of eight ribs with improved accuracy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If six welding rollers are located around the circumference with pneumatic cylinders to press trough-shaped profiles, then welding capability is provided, but manufacturing precision deteriorates due to misalignment of symmetry axes

Engineering Contradiction:

Improvewelding capabilityVSAvoidalignment accuracy

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent introduces adjustable mechanisms (eccentric regulators, ball joint assemblies, adjusting lock nuts) that allow dynamic positioning and alignment of welding rollers and clamping units. This enables precise alignment of symmetry axes during operation while maintaining the welding capability provided by the pneumatic cylinder system.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent employs adjustable parameters through eccentric regulators and ball joint assemblies that modify the position and orientation of welding rollers and clamping units. By changing these parameters, the system achieves precise alignment accuracy while maintaining ease of manufacture through the existing pneumatic cylinder configuration.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If the number of clamping units is increased to weld more ribs simultaneously, then productivity increases, but device complexity increases

Engineering Contradiction:

Improvenumber of ribs welded simultaneouslyVSAvoidnumber of clamping units

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent designs clamping units with universal applicability, where each unit can be independently adjusted and positioned to weld multiple ribs. The standardized design of clamping units with integrated adjustment mechanisms allows the same unit type to handle different positioning requirements, reducing overall system complexity while maintaining high productivity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Manufacturing precision

If adjustment mechanisms are added to compensate for wear and improve alignment, then manufacturing precision improves, but device complexity increases

Engineering Contradiction:

Improvealignment accuracyVSAvoidnumber of adjustment mechanisms

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent incorporates self-adjusting features through eccentric regulators and ball joint assemblies that can compensate for wear and maintain alignment accuracy. These mechanisms allow operators to perform simple adjustments without complex procedures or additional sophisticated control systems, improving manufacturing precision while minimizing the increase in device complexity.

Inventive Principle:

Principle #25Self-service

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 solution enhances the quality of longitudinally finned tubes by ensuring precise alignment and uniform wear compensation, resulting in increased heat transfer performance and extended service life of the welding components.

Implementation Method 1

six welding rollers are located around the circumference, with which, due to the operation of pneumatic cylinders, the trough-shaped profiles of the ribs are pressed

Methodology Applied

Scientific EffectPneumatic pressure: Pressure Increase

Implementation Method 2

resistance seam-spot welding

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS20250018495A1Automatic welding machine for forming longitudinal ribs on tubes

Publication Date: 2025.01.16 JOINT- CO MECHANICAL ENG PLANT ZIO-PODOLSK

AI summary

An automatic welding machine comprising clamping units, pushing pneumatic cylinders, a compression drive, and pressing and supplying welding current contact welding rollers. The automatic welding machine also comprises a die positioning of the ribs with respect to the pipe and clamping units, windows for the passage of rollers, and a mechanism for positioning the die. The clamping units have a mechanism for adjusting the position of the longitudinal axis of the compression drive of the roller, consisting of a compression drive guide, two regulators, a compression drive housing, a ball joint assembly, an adjusting lock nut, a fixing screw, and two bronze crackers. A mechanism for adjusting the contact welding roller comprises a roller, bushings, nuts, cheeks, and threaded elements.