Heat Exchanger Pipe Spigot Radius Transition
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Solution Overview
Problem
The existing pipe connecting structures for heat exchangers, such as charge air coolers, are time-consuming to assemble and prone to leakage due to the brazing process, and they cause turbulence and pressure drops due to abrupt diameter changes in the flow passage.
Innovation Solution
A pipe connecting structure featuring a spigot integrally formed with the header tank and a connection pipe with an enlarged end region to fit over the spigot, secured by brazing or adhesive, ensuring a smooth radius transition for reduced turbulence and enhanced fluid flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If brazing is used to secure the connection pipe to the header tank, then the connection is sealed and secured, but the assembly process becomes time-consuming and prone to leakage
Solution Approach 1:
The connection pipe is pre-assembled onto the spigot with the enlarged end region fitting over the protruding end, allowing the brazing operation to be performed on a pre-positioned assembly rather than during final assembly, reducing overall assembly time while maintaining sealability
Solution Approach 2:
The spigot structure with its protruding end acts as an intermediary component that facilitates the connection between the header tank and connection pipe, providing a standardized interface that simplifies the brazing process and reduces assembly complexity
2Ease of manufacture
If the connection pipe is inserted into the header tank aperture, then the connection is formed, but abrupt diameter change causes turbulence and pressure drop
Solution Approach 1:
The spigot features a protruding end with a curved transition surface that replaces the abrupt diameter change with a gradual curvature, reducing turbulence and pressure drop in the fluid flow path while maintaining the structural connection between header tank and connection pipe
Solution Approach 2:
The spigot structure provides a localized transition zone with modified geometry at the connection point, creating a smooth flow path in the critical transition area while maintaining the overall structural integrity and manufacturing simplicity of the header tank and connection pipe
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 simplifies the assembly process, provides a clear visual indication of correct assembly, and minimizes turbulence and pressure drops, resulting in a reliable and efficient connection for heat exchangers.
Implementation Method 1
The enlarged end region of the connection pipe is secured to the spigot by brazing
Implementation Method 2
the transition between the spigot and the body of the header tank defines a radius of curvature to minimise turbulence and reduce the pressure drop through the connection pipe
Data Source
Figure 1
AI summary
A pipe connecting structure for a header tank of a heat exchanger having a connection opening, the connecting structure comprising a spigot or stub, projecting from the connection opening of the header tank, and a connection pipe securable to the spigot, said spigot having an internal diameter substantially equal to the internal diameter of the connection pipe, an end region of the connection pipe being enlarged to a greater diameter than the remainder of the connection pipe to fit over the spigot.