Heat Exchanger Plate Rolling With Synchronized Profiled Rolls
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Solution Overview
Problem
Existing methods for manufacturing plate parts for heat exchangers by the rolling method face challenges in achieving accurate profile patterns due to misalignment and bending of rolls, leading to inconsistent heat exchange properties.
Innovation Solution
The method involves synchronizing two rolls with a common synchronization gear and disk pack or gear couplings to ensure they rotate at the same rate, minimizing backlash and maintaining accurate profile patterns across the entire surface area, allowing for the formation of multiple plate parts during one revolution and enabling precise control over the rolling process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If separate driving mechanisms with gearing are used for the rolls, then the rolls can be driven independently, but the rotation speed synchronization between rolls deteriorates due to force variations during rolling
Solution Approach 1:
The patent merges the driving mechanisms of the two rolls into a single common driving mechanism. This ensures that both rolls rotate at the same speed without synchronization issues, eliminating the problem of speed mismatch that occurs with separate driving mechanisms while maintaining independent controllability through the shared drive system.
2Force
If heavy plane tools are used for pressing, then sufficient forming force is achieved, but the manufacturing cost increases
Solution Approach 1:
The patent replaces the traditional mechanical pressing system with heavy plane tools with a rolling system. The rolling process achieves the necessary forming force through the mechanical advantage of rolling contact and the design of the rolling mill, eliminating the need for extremely heavy pressing tools while reducing manufacturing costs.
3Duration of action of stationary object
If rolls bend during operation, then continuous rolling is possible, but the profile pattern height becomes inconsistent across the plate surface
Solution Approach 1:
The patent employs dynamically adjustable roll support structures that can compensate for roll bending during operation. The system includes adjustable bearings and support mechanisms that maintain proper roll geometry throughout the rolling process, ensuring consistent profile pattern height across the entire plate surface while enabling continuous operation.
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 approach ensures geometrically accurate profile patterns, reduces manufacturing costs, and improves the quality of plate parts by minimizing the bending of rolls and maintaining synchronized rotation, resulting in consistent heat exchange properties.
Implementation Method 1
the rolls are synchronized to rotate at substantially same rate by controlling the rotation of them in relation to each other with a common synchronization gear
Implementation Method 2
which gear is coupled to the rolls by means of shafts with disk pack or gear couplings so that the backlash is less than 0.1 mm
Implementation Method 3
a sheet material in the form of continuous sheeting is worked between two rolls with opposite surface patterns to form profiled plate part blanks into the sheet material
Data Source
Figure 1
Figure 2~3
AI summary
The present invention relates to a method and a device for manufacturing plate part blanks for a heat exchanger. A sheet material (2) in the form of continuous sheeting is5 worked between two rolls (5, 6) with opposite surface patterns (7, 7', 8) to form profiled plate part blanks (3, 3',3'') into the sheet material (2) so that the rolls (5, 6) are synchronized to rotate at substantially same rate by controlling the rotation of them in relation to each other10 with common synchronization gear (9), which gear is coupled to the rolls (5, 6) by means of shafts (10, 11) with disk pack or gear couplings.