Heat exchanger assembly
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Solution Overview
Problem
Existing dry cooler assemblies face challenges in withstanding external forces such as strong winds and maintaining efficiency due to the need for robust frames and sealed enclosures, while also requiring simplified manufacturing processes to reduce production costs.
Innovation Solution
A heat exchanger assembly with a weldless frame composed of interconnected bent sheet metal components, including legs, transversal members, and upstanding members, which are connected without welding to provide structural support and sealing, while also allowing for efficient heat exchange through V-configured heat exchanger panels and fan systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a robust frame with welding is used to withstand strong winds, then the strength and stability of the dry cooler assembly is improved, but the manufacturing complexity and production cost increase
Solution Approach 1:
The frame is divided into multiple discrete components including legs, transversal members, upstanding members, and enclosing panels that can be manufactured separately and assembled without welding. Each component can be produced independently using standard fabrication processes, reducing manufacturing complexity while maintaining overall structural strength through mechanical connection design.
Solution Approach 2:
Mechanical connectors and joining mechanisms serve as intermediaries between frame components, replacing direct welding connections. These intermediaries enable assembly without welding operations while providing sufficient structural strength to withstand wind loads, thus resolving the contradiction between ease of manufacture and frame strength.
2Reliability
If an enclosed space with sealing is implemented to maximize heat rejection efficiency, then the heat exchange efficiency is improved, but the manufacturing complexity increases
Solution Approach 1:
The enclosed space is created using separate enclosing panels that can be manufactured and sealed independently. This segmentation allows each panel to be produced with standardized sealing features, reducing the overall manufacturing complexity compared to creating a fully integrated sealed structure, while still achieving the necessary enclosure for efficient heat rejection.
Solution Approach 2:
Sealing mechanisms using flexible gaskets or thin film seals are employed at the joints between enclosing panels. These flexible sealing elements can accommodate manufacturing tolerances and thermal expansion, providing reliable sealing for heat rejection efficiency without requiring complex rigid sealed structures, thus maintaining ease of manufacture.
3Stability of the object's composition
If welding is used to connect frame components, then the structural integrity is improved, but the production cost and assembly time increase
Solution Approach 1:
The frame structure is segmented into pre-fabricated components with standardized connection interfaces. This segmentation allows components to be assembled through simple mechanical connections rather than time-consuming welding operations, reducing assembly time while maintaining structural integrity through proper connection design.
Solution Approach 2:
Welding operations are replaced with mechanical connection systems such as bolted joints, interlocking features, or snap-fit connections. This substitution eliminates the need for specialized welding equipment and skilled welders, significantly reducing assembly time and production cost while maintaining sufficient structural integrity for the application.
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 solution enhances the ability of dry cooler assemblies to withstand external forces without generating excessive stress, reduces assembly costs by eliminating welding, and maintains efficiency through a sealed and mechanically sealed enclosure, thereby improving durability and cost-effectiveness.
Implementation Method 1
the fluid transfers its heat into the ambient air pulled into the dry cooler
Implementation Method 2
heat into the ambient air pulled into the dry cooler. The heated air is then discharged
Implementation Method 3
a fan for pulling air into the enclosed space of the heat exchanger assembly via at least one of the first and second heat exchanger panels
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
A heat exchanger assembly has a frame including: a plurality of legs; first and second lower transversal members extending perpendicular to and interconnecting the legs; a plurality of upstanding members extending upwardly from respective ones of the legs, a lower end of each upstanding member being connected to a corresponding leg at a junction therebetween; an upper transversal member interconnecting upper ends of the upstanding members; and an upper frame assembly. The frame components are weldlessly connected to one another. First and second heat exchanger panels exchange heat with air pulled into the heat exchanger assembly and are disposed in a V-configuration. An upper end of each heat exchanger panel is connected to upper retaining members of the upper frame assembly. A fan pulls air into the enclosed space of the heat exchanger assembly via at least one of the heat exchanger panels.