Return Tube Brazing Ring Assembly Using Pipe Shrinking and Expanding
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Solution Overview
Problem
The existing methods for assembling heat exchangers face challenges in stably coupling a brazing ring onto a U-shaped return tube during the brazing process, which is crucial for forming a continuous refrigerant passage, as the brazing ring often escapes due to mismatched diameters between the return tube and the brazing ring.
Innovation Solution
A method involving a pipe shrinking process on the straight portion of the return tube to reduce its diameter, followed by the insertion and coupling of a brazing ring, and then a pipe expanding process to securely fix the ring, utilizing a return tube assembly device with transfer modules and a pressing module to ensure precise pre-assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a brazing ring is directly coupled on a return tube without pre-processing, then the assembly process is simple, but the brazing ring escapes due to diameter mismatch
Solution Approach 1:
The patent applies preliminary action by performing pipe shrinking on the return tube before coupling the brazing ring. This pre-processing step reduces the tube diameter to match the brazing ring inner diameter, ensuring stable coupling. The pipe expanding process is then performed after coupling to restore the original diameter, achieving both reliable assembly and maintained tube dimensions.
2Reliability
If pipe shrinking process is performed on the return tube, then the brazing ring coupling stability is improved, but the assembly process complexity increases
Solution Approach 1:
The patent replaces complex mechanical assembly operations with automated pipe shrinking and expanding processes. By using controlled thermal or mechanical shrinking/expanding mechanisms, the system achieves precise diameter adjustment and stable brazing ring coupling without requiring complex manual manipulation or multiple assembly steps.
3Manufacturing precision
If pipe shrinking and expanding processes are performed, then the assembly precision is improved, but the manufacturing time increases
Solution Approach 1:
The patent implements continuous useful action by performing pipe shrinking, brazing ring coupling, and pipe expanding in a continuous sequence without interruption. The processes are integrated into a single automated workflow where each step immediately follows the previous one, minimizing idle time and maintaining continuous productive action throughout the assembly 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 method achieves stable and precise assembly of the brazing ring on the return tube, ensuring a secure coupling with the straight tube during the brazing process, thereby enhancing the assembly quality and reliability of the heat exchanger.
Implementation Method 1
performing a pipe shrinking process on a straight portion that constitutes the two sides of the supplied return tube
Implementation Method 2
performing a pipe expanding process after inserting the brazing ring
Data Source
AI summary
A method for assembling a brazing ring on a return tube constituting a refrigerant passage of a heat exchanger according to an embodiment of the present disclosure includes performing a pipe shrinking process on a straight portion of the return tube, coupling the brazing ring on the return tube through a return tube assembly device, and performing a pipe expanding process on the straight portion of the return tube to which the brazing ring is coupled. The coupling of the brazing ring on the return tube is performed using the return tube assembly device.