Helical Tube Bundle Forming Apparatus with Movable Carriage
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Solution Overview
Problem
Existing methods do not provide a means to simultaneously form a plurality of tubes into a helical bundle, which is necessary for enhanced durability and thermal efficiency in heat exchanger applications.
Innovation Solution
An apparatus comprising a pair of bending die assemblies mounted on a movable carriage, with grooved rollers that apply a bending force to elongate members, allowing them to be rotated independently or in unison to establish a helical shape, while a collet holds the tubes in place, enabling the formation of a helical bundle with adjustable pitch and radius.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If existing methods are used to form helical shapes, then a single rod or thin strands can be formed into a helix, but multiple tubes cannot be simultaneously formed into a helical bundle
Solution Approach 1:
The apparatus divides the tube bundle into multiple individual tubes, each processed independently by separate bending die assemblies. Each die assembly contains grooved rollers that engage with individual tubes, allowing simultaneous but independent formation of multiple helical tubes while maintaining control over each tube's positioning and bending
Solution Approach 2:
Multiple bending die assemblies are combined into a single apparatus that processes multiple tubes simultaneously. The die assemblies are mounted on a movable carriage that can be advanced along the tube bundle axis, integrating multiple forming operations into one coordinated system that produces a complete helical tube bundle in a single process
2Reliability
If multiple tubes are formed into a helical bundle, then thermal efficiency and durability are enhanced, but precise control over helical geometry is required
Solution Approach 1:
The apparatus employs movable components including a carriage that can be advanced along the tube bundle and grooved rollers that can be adjusted in position and depth. The lead screw mechanism provides dynamic control over the bending process, allowing precise adjustment of helical parameters such as pitch, radius, and lead angle while maintaining consistent geometry across all tubes in the bundle
Solution Approach 2:
The apparatus allows independent adjustment of multiple geometric parameters including the lead angle of the helix (accounting for elastic recovery), the pitch through carriage spacing and angular orientation, and the helical radius through roller depth adjustment. These parameter changes enable precise control over the final helical geometry to achieve desired thermal efficiency and durability characteristics
3Ease of manufacture
If grooved rollers are used to apply bending force, then tubes can be formed into helical shapes, but the tubes must be held firmly in place during the operation
Solution Approach 1:
A collet serves as an intermediary device that firmly holds the ends of the tubes during the bending operation. The collet provides a stable reference point and constraint system that enables the grooved rollers to apply bending forces effectively without causing tube misalignment or movement, while maintaining relative simplicity in the overall apparatus design
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
Enables the simultaneous formation of multiple tubes into a helical bundle, enhancing durability and thermal efficiency by allowing for precise control over the helical angle, pitch, and radius, addressing the limitations of prior art in forming multiple tubes into a cohesive helical shape.
Implementation Method 1
the lead angle of the helix is established, taking into account the elastic recovery of the tubes
Data Source
AI summary
Apparatus and method for forming a plurality of elongate members into a helical bundle in which a pair of bending die assemblies are mounted on a moveable carriage, the moveable carriage itself being supported by a frame. The bending dies each have a plurality of grooved rollers that engage the sides of the tubes to apply a bending force while allowing the tubes to move longitudinally through the die assemblies. The die assemblies can be rotated independent of each other or in unison by means of stepper motors. A collet, attached to the frame, holds the ends of the tubes during the bending operation.