Panel Radiator Lintel Welding for Defect-Free Rib-to-Fin Joints
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Solution Overview
Problem
Existing welding methods for panel type radiators in transformers suffer from high defect rates due to tack welding and continuous welding, leading to corrosion issues, increased repair rates, and reduced efficiency and anti-corrosion quality.
Innovation Solution
A panel type radiator with reinforcing ribs and cooling fins using lintel welding, featuring continuous welding seams and tack welding seams, with a 3 mm gap for lintel-shaped welding seams to eliminate blind zones and improve connection strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If tack welding method is used for cooling fins and reinforcing ribs, then the welding process is simple and fast, but the welding defect rate increases and anti-corrosion quality deteriorates
Solution Approach 1:
The welding process is segmented into two distinct stages: tack welding for rapid positioning and connection, followed by lintel welding for defect-free reinforcement. This segmentation allows the process to benefit from both the speed of tack welding and the quality of continuous welding without requiring multiple repositioning operations.
Solution Approach 2:
Tack welding is performed as a preliminary action to establish initial connections and positioning between cooling fins and reinforcing ribs. This preliminary connection enables the subsequent lintel welding to proceed efficiently without requiring the radiator to be repositioned, thereby maintaining high productivity while ensuring quality.
2Reliability
If continuous welding method is used for cooling fins and reinforcing ribs, then the welding defect rate decreases, but the labor consumption and time consumption increase significantly
Solution Approach 1:
The welding process is divided into two stages: initial tack welding for positioning and connection, followed by lintel welding for defect-free reinforcement. This segmentation eliminates the need for multiple repositioning operations while ensuring high welding quality, thereby maintaining productivity.
Solution Approach 2:
Tack welding serves as a preliminary action that establishes initial connections, enabling the subsequent lintel welding to proceed in a single continuous operation without repositioning. This preliminary positioning reduces the total welding time and labor consumption compared to performing full continuous welding from scratch.
3Productivity
If multiple tack welding points are used, then the connection is established quickly, but the welding blind zones increase and visual inspection becomes difficult
Solution Approach 1:
The welding process is segmented into tack welding for quick connection establishment and lintel welding for creating accessible, defect-free reinforcement. The lintel welding produces continuous, visually inspectable seams that eliminate the hidden defects associated with multiple tack welding points.
Solution Approach 2:
The harmful effect of welding blind zones is extracted and eliminated by performing lintel welding after tack welding. The lintel welding process accesses and reinforces areas that would otherwise remain hidden, making defects visible and inspectable while maintaining the speed benefits of initial tack welding.
4Reliability
If the radiator is turned over multiple times during welding, then the welding blind zones are avoided, but the manufacturing time and complexity increase
Solution Approach 1:
The welding process is divided into two stages performed in a single positioning: tack welding for initial connection and lintel welding for defect-free reinforcement. This segmentation eliminates the need to turn over the radiator multiple times while ensuring comprehensive welding quality through the lintel welding stage.
Solution Approach 2:
Tack welding is performed as a preliminary action in the first positioning, creating initial connections that allow subsequent lintel welding to proceed without repositioning. This preliminary connection enables complete welding quality assurance in a single positioning, reducing manufacturing time and complexity.
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
Reduces welding defect rates, enhances anti-corrosion quality, and extends the service life of the radiator while reducing manufacturing costs and improving efficiency.
Implementation Method 1
Each of the multiple cooling fins is formed by welding two cooling sub-fins oppositely arranged with a sheet thickness of 1.0-1.2 mm at attached positions of peripheral sides and attached positions of middle portions of the two cooling sub-fins
Data Source
AI summary
Provided is a panel type radiator with reinforcing ribs and cooling fins in lintel welding, which includes multiple cooling fins, two oil collecting tubes, multiple reinforcing ribs and multiple welding seams. Each cooling fin is formed by welding two cooling sub-fins oppositely arranged. An edge of a long side of the cooling fin intersects with an outer surface of the reinforcing rib, and a gap suitable for a lintel-shaped weld is provided at an intersection. A welding material droplet weld is formed between an outer edge at an attached position of the long side of the cooling fin and the outer surface of the reinforcing rib, and the shape of the weld is lintel-shaped. The lintel-shaped weld is divided into three regions. The welding material fusion welding connection lintel region is self-fusion welding metal of the welding material.