Liquid Dispenser Manifold Welding for Pipe Dimension Precision
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Solution Overview
Problem
The precision of distribution pipes in liquid cooling systems for servers is diminished due to varying manufacturing temperatures, necessitating repeated processing and high manufacturing costs.
Innovation Solution
A method for manufacturing a liquid dispenser involves machining a flow tube to form a manifold with precise dispensing holes and fixing parts, using CNC, waterjet, or cold drawing, followed by TIG or laser welding of adapters, and precise cleaning processes to maintain precision without the need for expensive vacuum brazing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manufacturing methods are used for distribution pipes, then manufacturing flexibility is maintained, but manufacturing precision deteriorates due to varying temperatures requiring repeated processing
Solution Approach 1:
The distribution pipe is divided into multiple pipe sections, each with designated clamping positions. By segmenting the pipe into manageable sections and clamping them at specific positions during welding, the patent maintains precision while enabling efficient batch production. The segmentation allows each section to be processed and welded independently without affecting the entire pipe system.
Solution Approach 2:
Clamping positions are pre-designed and pre-marked on the pipe sections before manufacturing begins. This preliminary action ensures that when welding occurs, the pipes are already positioned correctly to maintain precision dimensions. The pre-planned clamping positions prevent the need for repeated processing by ensuring proper positioning from the start.
2Manufacturing precision
If traditional welding positions are used, then manufacturing simplicity is maintained, but manufacturing precision deteriorates due to heat affecting dimensional accuracy
Solution Approach 1:
The patent designates specific local regions on the pipe as clamping positions, which are strategically located away from the welding zones. This local quality approach ensures that the clamping areas have different properties (suitable for secure positioning) than the welding areas. By localizing the clamping function to specific positions, the heat from welding does not affect the dimensional accuracy of the clamped sections.
Solution Approach 2:
The clamping position acts as an intermediary element between the pipe section and the welding process. It provides a stable reference point that maintains dimensional accuracy while allowing the welding process to occur separately. The intermediary clamping position mediates between the need for precision and the heat-generating welding process, ensuring accuracy is maintained despite welding complexity.
3Manufacturing precision
If precise processing is performed repeatedly to maintain precision, then manufacturing precision is maintained, but manufacturing cost increases
Solution Approach 1:
The patent performs preliminary precision processing at designated clamping positions before welding occurs. By preparing the clamping positions and ensuring precise dimensions in advance, the need for repeated processing after welding is eliminated. This preliminary action locks in the precision requirements early in the process, preventing costly rework later.
Solution Approach 2:
The patent changes the processing parameters by focusing precision work on specific clamping positions rather than uniformly processing the entire pipe. This targeted approach to parameter changes (position-specific precision processing) reduces the overall amount of precise processing required while maintaining necessary dimensional accuracy, thereby reducing manufacturing costs.
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 method ensures high precision and reduces manufacturing costs by eliminating the need for repetitive processing and expensive equipment, improving production efficiency and maintaining structural integrity.
Implementation Method 1
welding an inlet adapter and an outlet adapter at opposite ends of the manifold, respectively
Implementation Method 2
the inlet adaptor and the outlet adaptor are welded at the opposite ends of the manifold by tungsten inert gas (ITG) welding or laser welding
Implementation Method 3
the inlet adaptor and the outlet adaptor are welded at the opposite ends of the manifold by tungsten inert gas (ITG) welding or laser welding
Data Source
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AI summary
A method for manufacturing a liquid dispenser includes machining a flow tube to form a manifold that includes a plurality of liquid dispensing holes and a plurality of fixing parts, performing precision processing on the liquid dispensing holes and the fixing parts to adjust dimensions thereof, performing a first cleaning process on the manifold, clamping the manifold in a jig at a clamping position of the manifold, welding a liquid inlet adapter and a liquid outlet adapter at opposite ends of the manifold, respectively, and performing a second cleaning process on the liquid dispenser, wherein the second cleaning process is simpler than the first cleaning process.