Folded Heat Exchanger Core Opening for Controlled V-Shape Unfolding
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Solution Overview
Problem
Heat exchanger cores with folded microchannel tubes face challenges in predictable and safe unfolding to a V-shape configuration due to high force requirements and potential damage during manual opening, leading to unpredictable dimensions and increased risk of damage.
Innovation Solution
A device with hinged frames, spring-loaded clamps, and a spindle drive system powered by an electric motor is used to pivot and open the heat exchanger core from a U-shape to a V-shape, featuring a trough for intermediate section curvature and adjustable stops to control the opening angle and prevent damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If folded heat exchanger cores are manually opened from U-shape to V-shape, then the core can be assembled and installed, but the force required exceeds permissible manual forces and causes unpredictable dimensions and potential damage
Solution Approach 1:
A mechanical device with hinged frames acts as an intermediary between the operator and the folded heat exchanger core. The device includes clamps that securely hold the manifolds and a linkage system that gradually opens the core from U-shape to V-shape configuration, distributing the opening force throughout the structure rather than requiring concentrated manual force on the tubes.
Solution Approach 2:
The opening device uses hinged frames that pivot dynamically during the opening process. The frames transition from a closed position (holding the core in folded state) to an open position (allowing V-shape configuration), enabling controlled, progressive opening that adapts to the core's structural requirements throughout the operation.
2Manufacturing precision
If folded heat exchanger cores are opened to achieve specific V-shape configuration, then proper assembly and installation are enabled, but the force required to reach specific shape exceeds permissible forces and risks tube damage
Solution Approach 1:
The clamps are positioned and adjusted before the opening operation begins, securing the manifolds in their correct initial positions. This preliminary setup ensures that as the hinged frames open, the core follows the intended path to the precise V-shape configuration without deviation or risk of tube damage from improper positioning.
Solution Approach 2:
The device structure is designed to distribute and cushion the forces applied during opening. The hinged frames and linkage system provide mechanical advantage and controlled force distribution, preventing concentrated stress on the tubes that could cause damage while achieving the required V-shape precision.
3Volume of moving object
If heat exchanger cores are folded for transport to save space, then packing density increases, but the opening process requires excessive force greater than permissible manual forces
Solution Approach 1:
The manual mechanical opening operation is replaced with an automated or assisted mechanical system. The hinged frames with linkage mechanism provide the necessary mechanical advantage to open the tightly folded core, substituting operator physical effort with a mechanical system designed to handle the high forces required.
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 device ensures safe and repeatable unfolding of heat exchanger cores to a V-shape configuration, reducing manual force requirements and preventing damage, while maintaining the integrity of the microchannels and tubes, thereby improving ergonomics and consistency in the final product dimensions.
Implementation Method 1
The clamps may be spring-loaded to urge the manifolds toward the trough
Implementation Method 2
a spindle drive with a screw rotated by an electric motor
Implementation Method 3
two hinged frames pivotable about a hinge location
Data Source
AI summary
A device is configured for opening a heat exchanger core from a U-shape to a V-shape. Such heat exchanger core has a plurality of parallel flat tubes, each having two ends; and two manifolds. Each of the flat tubes has two straight sections adjacent to the manifolds and an intermediate bent section. The device has two hinged frames, a respective clamp arrangement on each of the hinged frames for holding the two manifolds, and a trough shaped support for the intermediate portion. For opening the U-shaped heat exchanger core, the heat exchanger core is inserted into the device, and the two manifolds are secured with the clamp arrangements. The clamp arrangements are separated from one another by pivoting apart the two hinged frames, on which the clamps are mounted. Simultaneously, the intermediate bent section is pushed toward the trough adapted to provide a desired curvature to the intermediate section.