Heat Exchanger Bond Structure for Easier Tube Support Assembly
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Solution Overview
Problem
The existing manufacturing methods for heat exchangers in fluidized bed boilers are cumbersome and difficult to produce, particularly due to the need for mechanical support of heat transfer tubes that must withstand high pressures and temperatures, and require complex assembly and welding processes.
Innovation Solution
A mechanical support system, comprising primary and secondary bond parts cut from a plate, which are adapted to fit around heat transfer tubes, providing a simple and efficient method for supporting heat transfer tubes without the need for extensive assembly or welding, allowing for easier manufacturing and improved mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If heat transfer tubes are supported by walls with apertures, then mechanical support is provided, but manufacturing complexity increases and assembly becomes difficult
Solution Approach 1:
The support structure is divided into separate bond parts that can be independently manufactured and then assembled around the heat transfer tubes. This segmentation allows each bond part to be produced using simple plate cutting rather than complex wall apertures, reducing manufacturing difficulty while maintaining mechanical support functionality.
Solution Approach 2:
Bond parts serve as intermediary elements between the heat transfer tubes and the supporting structure. These bond parts are cut from plates and positioned around the tubes to provide mechanical support, eliminating the need for complex wall apertures and simplifying both manufacturing and assembly processes.
2Strength
If heat transfer tubes are assembled from multiple pieces, then mechanical support is achieved, but welding complexity increases due to high pressure and temperature requirements
Solution Approach 1:
Multiple bond parts are merged together around the heat transfer tubes to form a unified support structure. This merging approach provides mechanical support without requiring the heat transfer tubes themselves to be assembled from multiple welded pieces, thereby reducing welding complexity while maintaining structural integrity under high pressure and temperature conditions.
3Adaptability or versatility
If heat transfer tubes are bent at locations, then flexibility is improved, but mechanical stability decreases requiring additional support
Solution Approach 1:
Bond parts are pre-positioned around the heat transfer tubes at strategic locations before final assembly. This preliminary action provides mechanical support at the bent sections where flexibility is needed, preventing excessive movement and maintaining stability while allowing the tubes to maintain their bent configurations for adaptability.
Data Source
AI summary
A heat exchanger having a first heat transfer tube with a first primary straight part and a first secondary straight part is provided. The heat exchanger includes a first primary bond part and a first secondary bond part. The first primary bond part is welded to the first secondary bond part to form a first primary bond that bonds the first primary straight part and the first secondary straight part of the first heat transfer tube. The first primary bond limits a first primary aperture and a first secondary aperture formed by the holes of the bond parts, wherein the straight parts of the first heat transfer tube extend through the first primary bond via the apertures.