DESC:SELF-ADJUSTMENT FLASH BUTT RESISTANCE WELDING ELECTRODE FOR FIN TO TUBE WELDING

FIELD OF THE INVENTION

[0001] The present disclosure in general relates to the field of resistance welding of fin to tube. More particularly the present disclosure relates to self-adjustment flash butt resistance welding electrode for fin to tube welding.

BACKGROUND OF THE INVENTION:

[0002] H-finned tubes are a type of heat exchanger component that utilizes fins to enhance heat transfer efficiency. These fins are typically attached to a base tube to create a larger surface area for heat exchange. Traditional methods for joining H-fins to tubes may involve processes like soldering, brazing, or fusion welding. However, these methods can have drawbacks, such as limitations on material compatibility, potential for heat damage to the base tube, or challenges in achieving consistent weld quality, particularly for high-volume production.

[0003] H-finned tubes are a cornerstone component in various heat exchanger applications. These tubes are distinguished by their H-shaped fins, which significantly increase the surface area for enhanced heat transfer. Traditionally, attaching these fins to the base tube has relied on methods like soldering, brazing, or fusion welding. While these methods have served their purpose, they come with limitations.

[0004] One key drawback is their compatibility with specific materials. Soldering and brazing might not be suitable for all fin and tube material combinations. Additionally, these techniques can introduce excessive heat during the joining process, potentially damaging the base tube or compromising its properties. Fusion welding, while offering strong joints, can be complex to implement for high-volume production lines, and achieving consistent weld quality can be challenging.

[0005] Therefore, there is a need to introduce a refined approach for H-fin tube manufacturing that addresses the shortcomings of traditional methods. Flash butt resistance welding emerges as a compelling solution for high-volume production lines where efficiency and consistency are paramount. This technique leverages the power of electrical resistance to generate heat precisely at the joint between the fin and the base tube. This localized heating fosters strong and reliable welds while minimizing heat impact on the surrounding areas.

[0006] However, a critical hurdle exists in maximizing the effectiveness of flash butt resistance welding for H-fin applications. Conventional resistance welding electrodes might not be well-suited for the unique geometry of H-fins. This disclosure proposes a specialized electrode that address this challenge and unlock the full potential of flash butt resistance welding for H-fin tube manufacturing.

[0007] These specialized electrodes will be designed to meet three critical objectives. Firstly, they must firmly grip the H-fin on both sides of the tube. This ensures proper alignment during welding and prevents any movement of the fin, which could compromise the joint integrity. Secondly, the electrodes should facilitate efficient current flow. Minimizing power losses at the interface between the electrode and the fin is crucial. This ensures that the maximum amount of electrical energy is converted into heat at the weld joint, leading to optimal welding efficiency. Finally, the design of the electrodes will play a significant role in achieving the desired level of fin penetration into the base tube. The depth of penetration serves as a crucial indicator of weld quality. A deeper penetration signifies a stronger and more reliable weld.

[0008] By addressing these challenges through the introduction of specialized electrodes, the proposed solution aims to revolutionize flash butt resistance welding for H-fin tube production and significantly improve the efficiency and quality of H-fin tube manufacturing.

OBJECTS OF THE INVENTION:

[0009] An object of the present disclosure is to provide an electrode with self-adjustment mechanism to hold fin firmly and carry out flash butt resistance welding between pair of fins and tube.

[0010] Another object of the present disclosure is to provide self-adjustment flash butt resistance welding electrode for fin to tube welding which overcomes shortcomings of the prior art(s).

[0011] Still another object of the present disclosure is to provide self-adjustment flash butt resistance welding electrode for fin to tube welding which significantly improves the efficiency and quality of H-fin tube manufacturing.

SUMMARY OF THE INVENTION

[0012] This summary is provided to introduce concepts related to providing an electrode for flash butt resistance welding. The concepts are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.

[0013] The terminology used herein is to describe particular embodiments only and is not intended to be limiting to example embodiments. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context indicates otherwise. It will be further understood that the terms “comprise”, “comprising”, “includes” and/or “including” when used herein, specify the presence of stated features, steps, operations, elements and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components and/or groups thereof.

[0014] In order that the present invention may be more readily understood, certain terms are first defined. Additional definitions are set forth throughout the detailed description.

[0015] The term “further” is used in the embodiments and claims of the present application. The said term is a well-accepted term to narrow down any principal feature. Therefore, the person skilled in the art would clearly understand the scope of the said term in the context of the present disclosure.

[0016] In accordance with an aspect, fin is placed vertically inside space between both support plates.

[0017] In accordance with an aspect, bottom stopper plate stops fin from falling.

[0018] In accordance with an aspect, when forward pneumatic force applied, fin along with electrode moves towards tube.

[0019] In accordance with an aspect, when fin touches tube, fin is firmly clamped inside electrode due to lever mechanism of movable flap.

[0020] In accordance with an aspect, after firm clamping of fin, current is allowed to flow through electrodes placed on both sides of tube. Thus welding is carried out between pair of fins and tube.

[0021] In accordance with an aspect, after reversing the pneumatic force, automatically fin is released due to spring mechanism of movable flap.
Thus, according to the present invention there is provided an apparatus for a flash butt resistance welding process of fins to tubes which comprises a taper holder (1) configured to securely grip a fin during the welding process; a base plate (2) securely connected with the taper holder (1) through press fit mechanism; a plurality of support plates (3, 4), communicatively coupled to the base plate (2) using fasteners (9) to create a rigid structure; and a movable flap (5) mounted on the support plate (4) with a fastener (7) and a compression springs (8) to attain a self-adjusting mechanism.

[0022] The taper holder (1) is made of material including a copper alloy to minimize power loss due to its high electrical conductivity. The base plate (2) and the taper holder (1) are additionally secured with screws for enhanced safety. The compression springs (8) are positioned between the support plate (4) and the movable flap (5) to facilitate self-adjustment. A shim (6), a consumable spare part is mounted on the movable flap (5) and serves as a wear plate during the welding process. A plurality of nipples (10) are communicatively coupled with the taper holder (1), and the plurality of support plates (3,4) enable the circulation of chilled water through the apparatus for temperature control during welding. The fin is clamped due to lever mechanism of movable flap (5) after forward pneumatic force is applied. At least 70% of the fin surface area is in contact with a copper electrode while clamping. The fin is released due to spring mechanism after reversing the pneumatic force.

[0023] To further understand the characteristics and technical contents of the present subject matter, a description relating thereto will be made with reference to the accompanying drawings. However, the drawings are illustrative only but not used to limit the scope of the present subject matter.

[0024] Various objects, features, aspects, and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

[0025] The illustrated embodiments of the present disclosure will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout. The following description is intended only by way of example, and simply illustrates certain selected embodiments of devices, systems, and processes that are consistent with the subject matter as claimed herein, wherein:

Figure 1a illustrates a side view of self-adjustment flash butt resistance welding electrode.
Figure 1b illustrates a front view of self-adjustment flash butt resistance welding electrode.
Figure 2 shows a perspective view of Fin.
Figure 3 shows final product after resistance welding.

[0026] The figures depict embodiments of the disclosure for purposes of illustration only. One skilled in the art will readily recognize from the following description that alternative embodiments of the assembly as illustrated herein may be employed without departing from the principles of the disclosure described herein.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE PRESENT INVENTION WITH REFERENCE TO THE ACCOMPANYING DRAWINGS

[0027] A few aspects of the present disclosure are explained in detail below with reference to the various figures. Example implementations are described to illustrate the disclosed subject matter, not to limit its scope, which is defined by the claims. Those of ordinary skill in the art will recognize a number of equivalent variations of the various features provided in the description that follows.

[0028] Figure 1a and Figure 1b illustrates a side view and front view respectively of the present disclosure. The present disclosure is designed to revolutionize flash butt resistance welding for H-fin tube manufacturing. The apparatus addresses the limitations encountered with conventional resistance welding electrodes when dealing with the unique geometry of H-fins. By incorporating innovative features, the present apparatus aims to achieve efficient, high-quality, and high-volume H-fin welding.

[0029] The apparatus is comprised of several key components that work in unison to achieve optimal H-fin welding. A critical element is a taper holder (1). This component plays a dual role. Firstly, it is crafted from a copper alloy to minimize power loss during the welding process. Copper's high electrical conductivity ensures that a maximum amount of electrical energy is converted into heat at the weld joint, promoting efficient welding. Secondly, the taper holder (1) is specifically designed to securely grip an H-fin on both sides. This secure grip serves two purposes: it minimizes water leakage from the cooling system and ensures proper alignment of the H-fin with the base tube for optimal weld quality.

[0030] The base plate (2) forms a robust foundation for the taper holder. A press-fit mechanism securely joins the base plate (2) and the taper holder (1), creating a strong initial connection. However, for enhanced safety and to withstand the forces exerted during welding, additional screws further reinforce this connection. The support plates (3, 4) (designated Support Plate-I and Support Plate-II) are joined to the base plate using Allen screws (9).

[0031] The support plates (3, 4) create a rigid and stable structure that can handle the pressure and heat generated during the welding process. The movable flap (5) being mounted on the support Plate (4) using a special screw (7), the movable flap (5) incorporates a self-adjusting mechanism that plays a crucial role in accommodating variations in H-fin thickness. A plurality of compression springs (8) are strategically positioned between the support plate and the movable flap. This configuration allows the movable flap to adjust automatically, ensuring that the H-fin receives optimal pressure regardless of slight thickness variations. This self-adjusting feature helps to achieve consistent and reliable weld quality across a range of H-fins.

[0032] The present disclosure also incorporates additional features to enhance its functionality and durability. A consumable spare part, the shim (6), is mounted on the movable flap (5). It acts as a wear plate during the welding process. As the H-fin is clamped and released during multiple welding cycles, the shim (6) experiences wear and tear. By incorporating a replaceable shim, the core components of the apparatus are protected, minimizing downtime and maintenance costs.

[0033] A plurality of nipples (10) are strategically located on the taper holder, support plates (3, 4), to facilitate the circulation of chilled water through the apparatus. This chilled water circulation system plays a vital role in temperature control during the welding process. By regulating the temperature, the system helps to prevent overheating of the electrodes and surrounding components, ensuring consistent weld quality and minimizing the risk of damage to the H-fin or base tube.

[0034] Figure 2 illustrates a perspective view of the fin. The lever mechanism of the movable flap (5) clamps the H-fin (Figure 2) upon application of a forward pneumatic force. This clamping ensures that at least 70% of the fin surface area comes into contact with the copper electrode, creating a low-resistance path for current flow from the source. This optimal contact area fosters proper welding conditions for achieving a strong and reliable joint in the final product (Figure 3). Once the welding process is complete, the spring mechanism within the movable flap is activated by reversing the pneumatic force, thereby releasing the H-fin. The consumable shim (6) can be easily replaced when necessary to maintain optimal performance and minimize wear on the core components.

ADVANTAGES OF INVENTION

[0035] The advantage of the present invention is that it significantly improves the efficiency and quality of H-fin tube manufacturing.

[0036] Another, advantage of the present invention is that it is efficient and high-quality H-fin tube production which address leakage, power loss, self-adjustment, and wear issues.

[0037] Yet another advantage of the present invention is that it has the potential to significantly improve the efficiency and reliability of H-fin welding in high-volume manufacturing environments.

WORKING OF INVENTION

[0038] The newly invented self-adjustment flush butt resistance welding electrode will provide higher productivity and quality with respect to soundness of weld joints as depth of fusion and load test as per IBR regulations.

TEST RESULT

(1)

(2)

(3)

[0039] By comparing the present invention with these alternative methods, a comprehensive assessment can be made regarding its advantages, including reduced time, enhanced safety, and improved precision in dismantling and replacing governing valve cover components. This comparison is crucial for showcasing the innovative and practical benefits of the present invention over traditional or other existing approaches in the field.

[0040] Although the present disclosure has been illustrated and described in detail by means of the preferred exemplary embodiment, the present disclosure is not limited by the disclosed examples, and other variations can be derived therefrom by a person skilled in the art without departing from the scope of protection of the present disclosure. Also, the above description does not provide specific details of the manufacture or design of the various components. Those of skill in the art are familiar with such details, and unless departures from those techniques are set out, techniques, known, related art or later developed designs and materials should be employed. Those in the art are capable of choosing suitable manufacturing and design details.

[0041] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting to the present disclosure. It would be appreciated that several of the above-disclosed and other features and functions, or alternatives thereof, may be combined into other systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may subsequently be made by those skilled in the art without departing from the scope of the present disclosure as encompassed by the following claims. While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.
,CLAIMS:We Claim:


1. An apparatus for a flash butt resistance welding process of fins to tubes, comprising:
a taper holder (1) configured to securely grip a fin during the welding process;
a base plate (2) securely connected with the taper holder (1) through press fit mechanism;
a plurality of support plates (3, 4), communicatively coupled to the base plate (2) using fasteners (9) to create a rigid structure; and
a movable flap (5) mounted on the support plate (4) with a fastener (7) and a compression spring (8) to attain a self-adjusting mechanism.

2. The apparatus as claimed in claim 1, wherein the taper holder (1) is made of material including a copper alloy to minimize power loss due to its high electrical conductivity.

3. The apparatus as claimed in claim 1 or claim 2, wherein the base plate (2) and the taper holder (1) are additionally secured with screws for enhanced safety.

4. The apparatus as claimed in claims 2-3, wherein the compression springs (8) are positioned between the support plate (4) and the movable flap (5) to facilitate self-adjustment.

5. The apparatus as claimed in claims 2-4, wherein a shim (6), a consumable spare part is mounted on the movable flap (5) and serves as a wear plate during the welding process.

6. The apparatus as claimed in claims 2-5, wherein a plurality of nipples (10) are communicatively coupled with the taper holder (1), and the plurality of support plates (3, 4) enable the circulation of chilled water through the apparatus for temperature control during welding.

7. The apparatus as claimed in claims 2-6, wherein the fin is clamped due to lever mechanism of movable flap (5) after forward pneumatic force is applied.

8. The apparatus as claimed in claims 2-7, wherein at least 70% of the fin surface area is in contact with a copper electrode while clamping.

9. The apparatus as claimed in claims 2-8, wherein the fin is released due to spring mechanism after reversing the pneumatic force.