Heat Exchanger Convex Head Design for Two-Side Welding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional heat exchangers with non-detachable casings face issues such as non-uniform heat exchange due to limited convex head size, restricted material selection due to one-side welding requirements, and inconvenient maintenance, leading to inefficiencies and increased costs.
Innovation Solution
The design includes convex heads with enlarged openings and annular bodies allowing two-side welding, enabling larger axial dimensions for improved flow and maintenance access, and the use of materials like clad steel and chrome-molybdenum steel, along with additional features like flow guide plates and check rings to enhance heat transfer efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If the convex head caliber is kept small to reduce axial dimension, then the heat exchanger size is reduced, but the heat transfer medium flow becomes non-uniform and dead areas form
Solution Approach 1:
The patent introduces a radial dimension solution by creating an annular passage within the convex head structure. This annular passage allows the heat transfer medium to flow along the cylindrical wall surface, utilizing the radial and circumferential directions to achieve uniform distribution without increasing the axial dimension. The medium enters through the annular passage and is guided to flow uniformly across the heat exchange surface.
2Ease of manufacture
If only one-side welding is performed due to limited space, then the manufacturing process is simplified, but material selection is restricted
Solution Approach 1:
The patent creates additional working space in the radial direction by designing the convex head with an annular passage and sufficient wall thickness. This allows welders to access both sides of the joint, enabling two-side welding procedures. The increased radial space accommodates welding equipment and personnel, making complex materials like clad steel and chrome-molybdenum steel manufacturable.
3Length of stationary object
If the convex head axial dimension is limited, then the heat exchanger is more compact, but auxiliary devices cannot be added to improve heat exchange efficiency
Solution Approach 1:
The patent utilizes the radial and circumferential dimensions of the convex head to create an annular passage that can accommodate auxiliary flow control devices. These devices, such as flow guide plates and distribution rings, are installed within the annular passage structure, allowing them to function without increasing the axial dimension. The auxiliary devices optimize the flow distribution of the heat transfer medium through the annular passage.
4Volume of stationary object
If the convex head has small caliber, then the heat exchanger structure is compact, but dead areas form and pressure drop increases
Solution Approach 1:
The patent incorporates flow guide plates and distribution rings within the annular passage before the medium enters the main heat exchange area. These preliminary flow control elements straighten and distribute the medium flow, eliminating turbulence and dead areas that would otherwise cause increased pressure drop. The flow is pre-conditioned to ensure uniform entry into the heat exchange surface.
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 design improves heat exchange efficiency, reduces pressure drop, and allows for wider material selection, making the heat exchanger more reliable and cost-effective for high-temperature applications by optimizing flow conditions and enabling easier maintenance.
Implementation Method 1
a heat transfer medium passage 3 being formed on one convex head 2
Data Source
AI summary
A heat exchange, which includes a casing having a cylinder; two connectors respectively attached to one end of the cylinder through the small opening; two convex heads respectively connected through the opening end to the large opening of a connector; a core disposed inside the casing; and two heat transfer medium passages. In this way, the space at the ends of the casing of the heat exchanger may be enlarged, thereby providing a space large enough to accommodate the construction personal and better working environment for two-side welding and future maintenance and wider selection range of material of the casing of the heat exchanger; a buffer area is provided for the flow of the heat transfer medium, and the auxiliary like baffles may be mounted inside the convex heads as required to further improve the heat exchange efficiency and reduce the cost.