Method for producing a series of at least a first and second heat exchangers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Custom-built brazed-plate heat exchangers are costly and have long manufacturing lead times due to the need for tailored raw materials, while standardized units either exceed or fall short of requirements, leading to inefficiencies in air separation units.
Innovation Solution
A method for producing heat exchangers with adaptable fluid distribution tanks that can be configured after matrix unit production, allowing for variable assignment of passages to fluids, enabling mass production and reducing lead times by using standardized matrix units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If custom-built heat exchangers are manufactured to meet specific demands, then adaptability to client requirements is improved, but manufacturing cost and lead time increase
Solution Approach 1:
The heat exchanger is divided into two independent parts: a standardized matrix unit (stack of sheets and corrugated fins) that can be mass-produced, and customizable fluid distribution tanks that are configured separately according to client requirements. This segmentation allows the matrix unit to be manufactured in advance while the tanks are adapted to specific needs, reducing overall lead time while maintaining adaptability.
Solution Approach 2:
The matrix unit is manufactured in advance as a standardized component before the final configuration step. By preparing the core heat exchange structure beforehand and only adding the customizable fluid distribution tanks later, the system enables mass production of the standardized portion while accommodating custom requirements in the final assembly stage.
2Manufacturing precision
If custom-built heat exchangers are manufactured with tailored raw materials, then manufacturing precision is improved, but manufacturing cost increases
Solution Approach 1:
The system separates the standardized matrix unit from the customizable fluid distribution tanks. The matrix unit uses standardized raw materials for cost-effective mass production, while the fluid distribution tanks are specifically configured to achieve precise fluid distribution according to client requirements, minimizing the need for customized raw materials across the entire system.
Solution Approach 2:
The standardized matrix unit serves as a universal base component that can be used across multiple configurations. By making the matrix unit interchangeable and standardized, the system reduces manufacturing costs through economies of scale while the fluid distribution tanks provide the necessary customization for precise fluid distribution in different applications.
3Productivity
If standardized matrix units are used, then productivity is improved, but adaptability to specific demands deteriorates
Solution Approach 1:
The heat exchanger is segmented into a standardized matrix unit for mass production and customizable fluid distribution tanks for adaptability. The matrix unit maintains fixed dimensions and structure for efficient manufacturing, while the fluid distribution tanks are configured separately to assign fluids to specific passages according to client requirements, enabling both mass production and customization.
Solution Approach 2:
The system allows dynamic configuration of the fluid distribution tanks after the standardized matrix unit is manufactured. The tanks can be adapted to different client requirements by configuring which openings are capped and how fluids are assigned to passages, providing flexibility without requiring customization of the entire heat exchanger structure.
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 allows for flexible configuration of heat exchangers to meet specific demands, reducing costs and manufacturing time while maintaining energy efficiency and compatibility with existing installations.
Implementation Method 1
a heat exchange matrix unit which comprises a successive stack of separator sheets and of corrugated fins delimiting a plurality of passages suited to allowing at least a first fluid, a second fluid and a third fluid to flow through the matrix unit, so that the third fluid can heat or be heated by the first and second fluids
Data Source
AI summary
In a method for producing a series of at least a first and a second plate-fin heat exchangers, several elongate fluid distribution tanks are installed on the matrix unit, each tank capping just some of the openings assigned to the first fluid and to the second fluid, each tank having its axis in the direction of stacking and each being connected to a pipe so that the number of openings assigned to the first fluid differs from the number of openings assigned to the first fluid, and for preference, the number of openings assigned to the second fluid differs from the number of openings assigned to the second fluid for the at least first and second exchangers of the series.