EP2205374B1 - Process for producing a turbulence apparatus and apparatus for carrying out the process - Google Patents

Process for producing a turbulence apparatus and apparatus for carrying out the process Download PDF

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Publication number
EP2205374B1
EP2205374B1 EP08802729A EP08802729A EP2205374B1 EP 2205374 B1 EP2205374 B1 EP 2205374B1 EP 08802729 A EP08802729 A EP 08802729A EP 08802729 A EP08802729 A EP 08802729A EP 2205374 B1 EP2205374 B1 EP 2205374B1
Authority
EP
European Patent Office
Prior art keywords
turbulence
rib
turbulence device
station
strip
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Not-in-force
Application number
EP08802729A
Other languages
German (de)
French (fr)
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EP2205374A1 (en
Inventor
Jens Paulik
Jürgen Hägele
Werner Oswald
Achim Utz
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Mahle Behr GmbH and Co KG
Original Assignee
Behr GmbH and Co KG
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Publication date
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Publication of EP2205374A1 publication Critical patent/EP2205374A1/en
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Publication of EP2205374B1 publication Critical patent/EP2205374B1/en
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D13/00—Corrugating sheet metal, rods or profiles; Bending sheet metal, rods or profiles into wave form
    • B21D13/04—Corrugating sheet metal, rods or profiles; Bending sheet metal, rods or profiles into wave form by rolling
    • B21D13/045—Corrugating sheet metal, rods or profiles; Bending sheet metal, rods or profiles into wave form by rolling the corrugations being parallel to the feeding movement
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D53/00—Making other particular articles
    • B21D53/02—Making other particular articles heat exchangers or parts thereof, e.g. radiators, condensers fins, headers
    • B21D53/04—Making other particular articles heat exchangers or parts thereof, e.g. radiators, condensers fins, headers of sheet metal
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F3/00—Plate-like or laminated elements; Assemblies of plate-like or laminated elements
    • F28F3/02—Elements or assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with recesses, with corrugations
    • F28F3/025—Elements or assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with recesses, with corrugations the means being corrugated, plate-like elements
    • F28F3/027—Elements or assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with recesses, with corrugations the means being corrugated, plate-like elements with openings, e.g. louvered corrugated fins; Assemblies of corrugated strips
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/4935—Heat exchanger or boiler making
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/53—Means to assemble or disassemble
    • Y10T29/53113—Heat exchanger
    • Y10T29/53122—Heat exchanger including deforming means
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/12—All metal or with adjacent metals
    • Y10T428/1241—Nonplanar uniform thickness or nonlinear uniform diameter [e.g., L-shape]
    • Y10T428/12417—Intersecting corrugating or dimples not in a single line [e.g., waffle form, etc.]

Definitions

  • the present invention relates to a method for producing a turbulence device for receiving at least one flow channel of a heat exchanger of a motor vehicle with the following method steps:
  • a first method step at least one essentially meander-shaped turbulence device is formed from a substantially endlessly flat sheet metal stiffener by means of at least one deforming machining operation Produces substantially smooth walls, wherein a longitudinal direction of the walls is substantially parallel to a feed direction of the sheet metal stiffeners.
  • wall sections are deformed at least at an angle ⁇ with respect to the feed direction such that undercuts with respect to the feed direction arise.
  • the invention relates to a device for carrying out a method according to one of claims 1 to 10 with at least one set of rollers for successive forming of the sheet metal stiffener, in particular the sheet metal blank in a substantially meandering turbulence device with substantially smooth walls, with at least one device with embossing rollers for deforming the wall sections at least at an angle ⁇ with respect to the feed direction such that undercuts with respect to the feed direction and at least one device for cutting the turbulence device to a predetermined length.
  • the charge air supplied to the engine is cooled as needed by means of a heat exchanger such as a charge air cooler. Furthermore, a part of the recirculated exhaust gas, which, for example, the charge air is supplied again by means of a heat exchanger, such as an exhaust gas cooler cooled.
  • a heat exchanger such as an exhaust gas cooler cooled.
  • the charge air and / or the exhaust gas can also be cooled in a heat exchanger, which is a combination of a charge air cooler and an exhaust gas cooler.
  • corrugated fins in particular internal corrugated fins
  • the corrugated fins are introduced into the flow channels, in particular the tubes, such as pushed or shot.
  • the ribs must be optimized so that on the one hand the heat exchanger performance achieved is increased and on the other hand, a pressure drop is minimized.
  • Such a turbulence device is for example in the unpublished DE 10 2007 014 138.8 shown.
  • the ribs essentially have a meandering structure, wherein this meandering structure is superimposed on a substantially undulating structure in a plane offset by 90 °.
  • embossments are introduced into the walls, so that flow passage openings can be formed. These impressions are introduced in a plane substantially perpendicular to the longitudinal direction of the turbulence device. In this way, undercuts occur in the direction of a plane which is substantially perpendicular to the longitudinal direction of the turbulence plane.
  • the hollow chamber profile has on the outside of cooling ribs which are deformed transversely to the longitudinal extent of the base profile. However, the cooling fins are shifted from those of the basic profile. For this purpose, a comb-like deformation tool is placed on the profile and at the same time all adjacent cooling fins are subjected to a corresponding deformation force.
  • a folded multi-chamber flat tube known from the DE 102 12 300 A1 is a folded multi-chamber flat tube known. This is a self-contained profile, which has a greater strength than an open structure of a turbulence device, which is then inserted into a tube.
  • the folded multi - chamber flat tube of the DE 102 12 300 A1 is produced by a continuous manufacturing process such as rotary die-cutting. Slits are cut or punched in a flat sheet metal strip. The punching of the breakthroughs takes place in time on a separate tool station before the supply of the smooth belt to the tube forming machine. Punching is thus carried out before the formation of the tube.
  • a device for producing sheet metal parts for air conditioning ducts is known.
  • a sheet metal strip is unwound from a coil and transferred in a continuous or quasi-continuous pass under stepwise deformation in a continuous rib.
  • the trapezoidal profile is only smooth. Subsequently, a separation of the metal strip in a shaving unit and then only the beaded sheet metal strip is bent to a channel.
  • turbulence devices such as inner corrugated fins
  • a transverse rolling process Due to the limited length, such a process may require the manufacture of several short turbulence devices, which subsequently have to be individually introduced into the tubes of the heat exchangers. This results in equally high production times and production costs, in particular by the assembly.
  • the processes have different cycle times, so that in particular the time-consuming punching process takes longer than the longitudinal rolling process for producing the precursor of the turbulence device with only smooth walls.
  • An inventive method for producing a turbulence device for receiving in at least one flow channel of a heat exchanger, in particular a charge air cooler and / or an exhaust gas cooler, a motor vehicle is provided.
  • the method has the following method steps:
  • At least one substantially meander-shaped turbulence device with substantially smooth walls is produced from a substantially endless planar sheet metal stiffener by means of at least one forming machining operation, wherein a longitudinal direction of the walls runs substantially parallel to a feed direction of the sheet metal stiffener.
  • the cutting to length is carried out before the first process step.
  • the length of the turbulence device can be generated even before the formation of the meander-shaped structure.
  • the die fixation for a precise cut can be made particularly advantageous in this way.
  • the cutting to length is carried out between the first method step and the second method step. In this way, the cutting takes place as late as possible, so that subsequent deformation operations have no effect on the cutting edge and in this way particularly advantageous inaccuracies can be avoided.
  • At least one cut is made in the meander-shaped turbulence device before the wall sections are deformed.
  • the cut is introduced at an angle ⁇ .
  • the angle ⁇ influences the course of the cutting edge of the undercuts with respect to the rolling direction.
  • deformations in the turbulence device can be introduced particularly advantageously, such as openings for flowing through a fluid flow in which turbulence is generated, such as charge air and / or exhaust gas or a coolant, such as air.
  • the turbulence of the fluid and in particular thus the heat transfer increases at a reasonable increase in the pressure loss.
  • the angle ⁇ and / or the angle ⁇ assumes values of 0 ° to 90 °, in particular of 0.5 ° to 80 °.
  • the first method step is a rolling method, in particular a longitudinal rolling method.
  • turbulence devices, in particular ribs can be produced with an arbitrarily predetermined length.
  • the first method step comprises 2 to 40 intermediate steps, in particular 2 to 35 intermediate steps, in particular 2 to 30 intermediate steps, and comprises these.
  • the sheet metal stiffener is processed successively such that the width of the thus produced substantially smooth turbulence device has a smaller turbulence device width than in the preceding intermediate step.
  • the sheet metal stiffeners are processed so gently, in particular reshaped, so that gradually the meandering structure is formed and the sheet thickness of the entire turbulence device generated is substantially equal, so that there are no unwanted cracks and material thinning in particular.
  • the intermediate steps are longitudinal rolling process steps. In this way it can be ensured particularly advantageous that turbulence devices can be created in any desired length.
  • the turbulence device has a sheet thickness of 0.05 mm to 0.35 mm, in particular from 0.05 mm to 0.25 mm, in particular from 0.06 mm to 0.2 mm, in particular of 0.06 mm to 0.15 mm.
  • a sheet thickness of 0.05 mm to 0.35 mm, in particular from 0.05 mm to 0.25 mm, in particular from 0.06 mm to 0.2 mm, in particular of 0.06 mm to 0.15 mm.
  • strip material for the sheet metal stiffeners is unwound from a coil and then guided so that the strip material is essentially flat.
  • the strip material can be stored in a particularly advantageous space-saving manner and yet substantially flat strip material is provided for the formation of the turbulence device.
  • the device has at least one set of rollers for the successive shaping of the sheet metal stiffener in a substantially meandering turbulence device with substantially smooth walls.
  • At least one device with embossing rollers which may consist of one to four pairs of rollers for deforming the wall sections at least at an angle ⁇ with respect to the feed direction such that undercuts with respect to the feed direction arise.
  • At least one device for cutting the turbulence device to a predetermined length is provided.
  • the device for cutting is downstream of the roller set and upstream of the embossing rollers.
  • the device for carrying out the method is designed such that the device for cutting is connected upstream of the embossing rollers.
  • a decoiler stores stock material to be processed and / or a dancer element is located between a band entry station, in particular for guiding in rolls and arranged for alignment, tightening and to avoid waves and the decoiler.
  • the wound up as a coil strip material can be fed vorteilhalft a Bandeinviervorraum.
  • a transfer station for transferring the finished turbulence device to a further station, in particular a mounting station for mounting the turbulence device in at least one heat exchanger tube of the station downstream with the embossing rollers.
  • the turbulence devices in particular the turbulence ribs after their production particularly advantageous, quickly and inexpensively mounted in ready flow channels for heat exchangers, in particular heat exchanger tubes, in particular be injected.
  • FIG. 1a shows a turbulence rib 1.
  • the turbulence rib 1 has a rib width RB as well as a rib length RL.
  • the turbulence rib 1 is substantially meander-shaped and has a number of valleys 4, as well as appropriately trained, associated mountains 5, with a respective valley 4 and a mountain 5 alternate.
  • the ridge 5 is essentially a rib valley 4 rotated by 180 °.
  • the ridge valleys 4 and the ridge ridges 5 have ridge impressions 3, which are embossed into the ribbed mountains 5 and / or the ridge valleys 4.
  • Rib indentations have substantially a pyramidal, in particular the shape of a 4-sided pyramid or, in another embodiment, may have the shape of a cuboid.
  • the ribbed mountains 5 and the rib valleys are bounded by rib walls 2.
  • Regarding the turbulence rib 1 is on the unpublished DE 10 2007 014 138.8 the applicant, which is hereby expressly applicable to the disclosure of this application.
  • the turbulence rib 1 is formed of a metallic material such as aluminum or steel such as stainless steel. Further, the turbulence rib 1 may be formed of another material having a good heat conduction property.
  • FIG. 1b shows a side view of an apparatus 10 for producing the turbulence rib 1.
  • the same features are provided with the same reference numerals as in the previous figures.
  • the device 10 for producing the turbulence rib 1 has a unwinding reel 12 with a coil 11.
  • the coil 11 comprises the wound sheet metal strip material.
  • the apparatus 10 comprises a dancer element 13, a belt entry station 14, a number of roller pairs 15, a station 16 for cutting to length and a station with embossing rollers 18.
  • the device 10 may additionally comprise a conveyor belt 19 and / or a transfer station 17 for transferring the strip material after cutting to length in the station 16 to the embossing roller 18 have.
  • the strip material is unwound from the unwinding reel 12.
  • the dancer element 13 causes the tape to be always substantially evenly tensioned when fed to the tape entry station 14.
  • the sheet metal stiffener is fed to the station 15 with the roller pairs.
  • the pairs of rollers cause the rib height RH of the turbulence rib 1 to be successively formed and the rib valleys 4 and the rib tops 5 to be joined to the corresponding rib width RB, and after passing through the station 15 with the roller pairs, the turbulence rib is formed as a smooth rib, in particular without Rib impressions 3 is formed.
  • the station 15 on 18 pairs of rollers. In another embodiment, the station 15 has more than 18 or, in another embodiment, less than 18 pairs of rollers.
  • the cutting of the turbulence ribs 1 to the desired length is carried out.
  • the tailor-made turbulence rib 1 is fed to the station 18 with the embossing rollers. In the station 18, finally, cuts and the rib impressions 3 are introduced into the turbulence rib 1. Only after this operation, the turbulence rib 1 has the appropriate shape, as in FIG. 1a is shown.
  • the turbulence ribs 1 thus produced are fed to a mounting station, such as for example for mounting the ribs in the flow channels, such as the heat exchanger tubes.
  • FIGS. 2a, 2b, 2c . 2d, 2e, 2f and 2g show 7 roller pairs 20.1 to 26.1 and the correspondingly formed sheet metal stiffeners 20.2 to 26.2. Identical features are provided with the same reference numerals as in the previous figures.
  • FIGS. 2a to 2g It is shown how the rib width gradually decreases from the sheet metal stiffener with the rib width RB0 of the sheet metal strip 20.2 via the steps 21.2, 22.2, 23.2, 24.2, 25.2 and 26.2, wherein the rib width RB1 smaller than the rib width RB0 and the rib width RB2 is smaller than that Rib width RB1.
  • the rib width RB3 is smaller than the rib width RB2, and the rib width RB4 is smaller than the rib width RB3.
  • the rib width RB5 is smaller than the rib width RB4 and the rib width RB6 is smaller than the rib width RB5.
  • the rib height RH increases from the machining step 20.2 to the machining step 26.2.
  • the associated roller pairs with the respective rollers 20.1, 21.1, 22.1, 23.1, 24.1, 25.1, 26.1 have the corresponding roller shapes to produce the associated fin precursors.
  • a smooth rib is present, but still has no rib impressions 3 or undercuts and cuts.
  • FIG. 3 an isometric view of the cutting device 16 and the conveyor belt 31 and the embossing rollers 18 is shown.
  • the smooth rib 30 thus produced is transported via a second conveyor belt 31 in the direction of the guide elements 33.
  • Guide elements 32 ensure that the smooth rib 30 is already roughly aligned.
  • the guide trough member 33 is formed substantially comb-like that comb teeth substantially correspond to the shape of the ribs 5, so that the unspecified tine elements the guide trough element 33 in the ribs 5 can intervene.
  • a first embossing roll 1834 and a second embossing roll 1835 are shown, cooperate and reshape the smooth rib 30 such that the rib impressions 3 as well as any cuts and other deformations are introduced into the smooth rib 30 and in this way the finished turbulence rib 1 is formed.
  • the embossing roller station 18 and thus the introduction of the rib impressions 3 is carried out in particular in at least one pair of rollers, in particular in one to four pairs of rollers.
  • FIGS. 4a, 4b show a side view in the sectional view and a front view in the sectional view. Identical features are provided with the same reference numerals as in the previous figures.
  • the embossing roll station 18 has a first embossing roll 1834 and a second embossing roll 1835.
  • the embossing roller station 18 and thus the introduction of the rib impressions 3 by means of at least one pair of rollers, in particular by means of one to four pairs of rollers.
  • the generated smooth rib 30 is formed into the finished turbulence rib 1.
  • a sequence of unspecified first and second teeth causes the rib valleys 4 and ribs 5 to be displaced in a transverse direction QR that is substantially at an angle ⁇ with respect to the rib longitudinal direction RLR.
  • the angle ⁇ assumes values of 0 ° to 90 °, in particular values of 0.5 ° to 80 °.
  • the rib impressions 3 such as the dislocations and / or incisions or the gills and / or the deep undulations or similar shapes, are introduced into the smooth rib 30, so that the turbulence rib 1 is produced in this way.
  • FIG. 5 is shown another processing station, which can be additionally switched on. Identical features are provided with the same reference numerals as in the previous figures.
  • the additional processing station 50 is a rotary blanking station. It is upstream of the roller set station 15. For example, after guiding and before producing the smooth rib 30 with punching rollers 51, which have a multiplicity of punches 54, the sheet metal stiffeners are machined such that incisions 53 or free cutting or punching are introduced into the sheet metal stiffeners 52 before the smooth rib 30 is produced become.
  • FIG. 6 shows a side view of another embodiment for manufacturing the turbulence device 1 with a different sequence of stations, in contrast to FIG. 1b , Identical features are provided with the same reference numerals as in the previous figures.
  • the sheet metal stiffener 9 is cut to length after being guided in the belt infeed station 14 in the station 16 and then fed to the roller pairs 15 in the transfer station.
  • the smooth rib 30 is first generated.
  • the finishing operation for the turbulence rib 1 in the embossing rolls 18 is carried out essentially immediately thereafter.
  • the finished turbulence ribs 1 are supplied, for example, the assembly station for mounting in the heat exchangers.
  • the method and / or the device are used to produce longitudinally rolled inner ribs which consist of a combination of one or more smooth areas with one or more areas with dislocations and / or indentations and / or indentations and / or gills and / or or deep undulations provided.
  • the Embossing roller is arranged in particular between the roller set for the smooth rib and the station 16 for cutting.
  • the introduction of the dislocations and / or indentations and / or with incisions and / or gills and / or deep undulations can take place in two ways:
  • the embossing roller is designed such that it stands out from the smooth ribs and comes into engagement only in the areas where dislocations and / or indentations and / or incisions and / or gills and / or deep undulations are to be introduced.
  • the dislocations and / or indentations and / or incisions and / or gills and / or deep undulations on the embossing roller are arranged such that seen over the circumference of the embossing roller a plurality of smooth regions are arranged and the embossing roller is substantially in constant use ,
  • At least one inner corrugated rib is produced, which is produced by a combination of smooth areas and areas with dislocations and / or indentations and / or indentations and / or gills and / or deep corrugations or the like. has a high performance with less pressure loss and which is in addition to cut down in the smooth areas substantially easier.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • General Engineering & Computer Science (AREA)
  • Shaping Metal By Deep-Drawing, Or The Like (AREA)
  • Heat-Exchange Devices With Radiators And Conduit Assemblies (AREA)
  • Metal Rolling (AREA)

Abstract

A process for producing a turbulence device (1) which is to be mounted in at least one flow duct of a heat exchanger of a motor vehicle includes the steps of, in a first process step, at least one shaping operation is used to produce at least one substantially meandering turbulence device (30) with substantially smooth walls (2) from a substantially continuously planar sheared strip (9), wherein a longitudinal direction (RLR) of the walls runs substantially parallel to a forward feed direction (VSR) of the sheared strip (9), and in a second process step, wall sections are deformed at least by an angle (α) in relation to the forward feed direction (VSR), in such a way that undercuts (3) are produced in relation to the forward feed direction (VSR, RLR), wherein the substantially continuously planar sheared strip (9) is cut into turbulence devices (1) of predetermined lengths before carrying out the second process step.

Description

Die vorliegende Erfindung betrifft ein Verfahren zur Herstellung einer Turbulenzvorrichtung zur Aufnahme in zumindest einem Strömungskanal eines Wärmetauschers eines Kraftfahrzeugs mit folgenden Verfahrensschritten: In einem ersten Verfahrensschritt werden aus einer im Wesentlichen endlos ebenen Blechsteifen mittels zumindest eines umformenden Bearbeitungsvorgangs zumindest eine im Wesentlichen mäanderförmig ausgebildete Turbulenzvorrichtung mit im Wesentlich glatten Wänden erzeugt, wobei eine Längsrichtung der Wände im Wesentlichen parallel zu einer Vorschubrichtung der Blechsteifen verläuft. In einem zweiten Verfahrensschritt werden Wandabschnitte zumindest unter einem Winkel α bezüglich der Vorschubrichtung verformt derart, dass Hinterschneidungen bezüglich der Vorschubrichtung entstehen.The present invention relates to a method for producing a turbulence device for receiving at least one flow channel of a heat exchanger of a motor vehicle with the following method steps: In a first method step, at least one essentially meander-shaped turbulence device is formed from a substantially endlessly flat sheet metal stiffener by means of at least one deforming machining operation Produces substantially smooth walls, wherein a longitudinal direction of the walls is substantially parallel to a feed direction of the sheet metal stiffeners. In a second method step wall sections are deformed at least at an angle α with respect to the feed direction such that undercuts with respect to the feed direction arise.

Femer betrifft die Erfindung eine Vorrichtung zur Durchführung eines Verfahrens nach einem der Ansprüche 1 bis 10 mit zumindest einem Rollensatz zum sukzessiven Umformen des Blechsteifens, insbesondere der Blechplatine in eine im Wesentlichen mäanderförmige Turbulenzvorrichtung mit im Wesentlichen glatten Wänden, mit zumindest einer Vorrichtung mit Prägewalzen zum Verformen der Wandabschnitte zumindest unter einem Winkel α bezüglich der Vorschubrichtung derart, dass Hinterschneidungen bezüglich der Vorschubrichtung entstehen sowie zumindest eine Vorrichtung zum Zuschneiden der Turbulenzvorrichtung auf eine vorgegebene Länge.Furthermore, the invention relates to a device for carrying out a method according to one of claims 1 to 10 with at least one set of rollers for successive forming of the sheet metal stiffener, in particular the sheet metal blank in a substantially meandering turbulence device with substantially smooth walls, with at least one device with embossing rollers for deforming the wall sections at least at an angle α with respect to the feed direction such that undercuts with respect to the feed direction and at least one device for cutting the turbulence device to a predetermined length.

Bei Wärmetauschern für Kraftfahrzeuge, wie beispielsweise Pkws oder Nkws wird die Ladeluft, die dem Motor zugeführt wird, nach Bedarf mittels eines Wärmetauschers, wie beispielsweise eines Ladeluftkühlers gekühlt. Femer wird auch ein Teil des rückgeführten Abgases, das beispielsweise der Ladeluft wieder zugeführt wird mittels eines Wärmetauschers, wie beispielsweise eines Abgaskühlers gekühlt. Die Ladeluft und/oder das Abgas können auch in einem Wärmetauscher gekühlt werden, der eine Kombination aus einem Ladeluftkühler und einem Abgaskühler darstellt.In heat exchangers for automobiles such as cars or commercial vehicles, the charge air supplied to the engine is cooled as needed by means of a heat exchanger such as a charge air cooler. Furthermore, a part of the recirculated exhaust gas, which, for example, the charge air is supplied again by means of a heat exchanger, such as an exhaust gas cooler cooled. The charge air and / or the exhaust gas can also be cooled in a heat exchanger, which is a combination of a charge air cooler and an exhaust gas cooler.

Zur Erhöhung der Wärmeübertragungsleistung werden in den Strömungskanälen des Wärmetauschers, insbesondere des Ladeluftkühlers und/oder des Abgaskühlers Turbulenzvorrichtungen, wie beispielsweise gewellte Rippen, insbesondere Innenwellrippen, in den Strömungskanälen angeordnet. Die Wellrippen werden dazu in die Strömungskanäle, insbesondere die Rohre eingebracht, wie beispielsweise eingeschoben oder eingeschossen.To increase the heat transfer capacity turbulence devices, such as corrugated fins, in particular internal corrugated fins, are arranged in the flow channels in the flow channels of the heat exchanger, in particular the charge air cooler and / or the exhaust gas cooler. The corrugated fins are introduced into the flow channels, in particular the tubes, such as pushed or shot.

Die Rippen müssen dahingehend optimiert werden, dass zum einen die erzielte Wärmetauscherleistung erhöht wird und zum anderen ein Druckabfall minimiert wird.The ribs must be optimized so that on the one hand the heat exchanger performance achieved is increased and on the other hand, a pressure drop is minimized.

Eine derartige Turbulenzvorrichtung ist beispielsweise in der unveröffentlichten DE 10 2007 014 138.8 dargestellt. Die Rippen weisen dabei im Wesentlichen eine mäanderförmige Struktur auf, wobei dieser mäanderförmigen Struktur in einer, um 90 versetzten Ebene eine im Wesentlichen wellenförmige Struktur überlagert ist.Such a turbulence device is for example in the unpublished DE 10 2007 014 138.8 shown. The ribs essentially have a meandering structure, wherein this meandering structure is superimposed on a substantially undulating structure in a plane offset by 90 °.

Femer sind in die Wände Einprägungen eingebracht, so dass Strömungsdurchtrittsöffnungen ausgebildet werden können. Diese Einprägungen sind in einer Ebene im Wesentlichen senkrecht zur Längsrichtung der Turbulenzvorrichtung eingebracht. Auf diese Weise entstehen Hinterschneidungen in Richtung einer Ebene, die im Wesentlichen senkrecht zur Längsrichtung der Turbulenzebene ist.Furthermore, embossments are introduced into the walls, so that flow passage openings can be formed. These impressions are introduced in a plane substantially perpendicular to the longitudinal direction of the turbulence device. In this way, undercuts occur in the direction of a plane which is substantially perpendicular to the longitudinal direction of the turbulence plane.

Aus der DE 102 12 799 C1 ist ein Hohlkammerprofil aus Metall für Wärmetauscher bekannt. Das Hohlkammerprofil weist auf der Außenseite Kühlrippen auf, die quer zur Längsausdehnung des Grundprofils verformt sind. Die Kühlrippen werden dabei allerdings aus denen des Grundprofils verschoben. Dazu wird ein kammartiges Verformungswerkzeug auf das Profil aufgesetzt und gleichzeitig werden alle nebeneinander liegenden Kühlrippen mit einer entsprechenden Verformungskraft beaufschlagt.From the DE 102 12 799 C1 is a hollow chamber profile made of metal for heat exchangers known. The hollow chamber profile has on the outside of cooling ribs which are deformed transversely to the longitudinal extent of the base profile. However, the cooling fins are shifted from those of the basic profile. For this purpose, a comb-like deformation tool is placed on the profile and at the same time all adjacent cooling fins are subjected to a corresponding deformation force.

Aus der DE 102 12 300 A1 ist ein gefalztes Mehrkammerflachrohr bekannt. Hierbei handelt es sich um ein in sich geschlossenes Profil, das eine größere Festigkeit aufweist als eine offene Struktur einer Turbulenzvorrichtung, die anschließend in ein Rohr eingeschoben wird. Das gefalzte Mehrkammerflachrohr der DE 102 12 300 A1 wird mittels eines kontinuierlichen Herstellungsverfahrens, wie beispielsweise Rotationsstanzen hergestellt. Schlitze werden in ein flaches Blechband geschnitten oder gestanzt. Das Stanzen der Durchbrüche erfolgt dabei im Takt auf einer separaten Werkzeugstation vor der Zuführung des Glattbands zur Rohrformmaschine. Ein Stanzen erfolgt somit vor dem Ausbilden des Rohres.From the DE 102 12 300 A1 is a folded multi-chamber flat tube known. This is a self-contained profile, which has a greater strength than an open structure of a turbulence device, which is then inserted into a tube. The folded multi - chamber flat tube of the DE 102 12 300 A1 is produced by a continuous manufacturing process such as rotary die-cutting. Slits are cut or punched in a flat sheet metal strip. The punching of the breakthroughs takes place in time on a separate tool station before the supply of the smooth belt to the tube forming machine. Punching is thus carried out before the formation of the tube.

Aus der DE 201 02 056 U1 ist eine Vorrichtung zum Herstellen von Blechteilen für Klimakanäle bekannt. Hierbei wird ein Blechband von einem Coil abgewickelt und im kontinuierlichen oder quasi kontinuierlichen Durchlauf unter stufenweiser Verformung in eine Endlosrippe überführt. Das Trapezprofil ist lediglich glatt. Anschließend erfolgt ein Abtrennen des Blechbands in einer Schereinheit und anschließend erst wird das gesickte Blechband zu einem Kanal gebogen.From the DE 201 02 056 U1 a device for producing sheet metal parts for air conditioning ducts is known. Here, a sheet metal strip is unwound from a coil and transferred in a continuous or quasi-continuous pass under stepwise deformation in a continuous rib. The trapezoidal profile is only smooth. Subsequently, a separation of the metal strip in a shaving unit and then only the beaded sheet metal strip is bent to a channel.

Aus der GB 2346105A ist ein Verfahren und eine Vorrichtung zum Herstellen von Blechteilen bekannt. Hierbei werden Wendabschnitte unter einem Winkel bezüglich der Verschubrichtung an ein Blechband verfernt.From the GB 2346105A is a method and an apparatus for producing sheet metal parts known. In this case, turning sections are placed at an angle with respect to the displacement direction of a metal strip.

Es ist ferner bekannt, eine Rippe mittels eines Stanzprozesses herzustellen. Hierbei treten jedoch hohe Fertigungszeiten und dem entsprechend hohe Fertigungskosten auf. Darüber hinaus muss für jede Rippenlänge ein eigenes Werkzeug beschafft werden. Femer müssen Ersatzwerkzeuge bereitgehalten werden.It is also known to produce a rib by means of a stamping process. However, this involves high production times and the correspondingly high production costs. In addition, a separate tool must be procured for each rib length. Furthermore, replacement tools must be kept ready.

Darüber hinaus ist es bekannt, in einem Querwalzprozess Turbulenzvorrichtungen, wie beispielsweise Innenwellrippen herzustellen. Aufgrund der begrenzten Länge müssen bei einem derartigen Prozess unter Umständen mehrere kurze Turbulenzvorrichtungen herstellt werden, die anschließend einzeln in die Rohre der Wärmetauscher eingeführt werden müssen. Hierbei entstehen ebenso hohe Fertigungszeiten und Fertigungskosten, insbesondere durch die Montage. Femer ist es bekannt den glatten Teil der Rippe mittels eines Längswalzprozesses herzustellen und anschließend die Versetzungen quer zur Längsrichtung der Rippe sowie eventuelle Schnitte für Durchtrittsöffnungen mittels eines anschließenden Stanzprozesses einzubringen. Die Prozesse haben jedoch unterschiedliche Taktzeiten, so dass insbesondere der zeitintensivere Stanzprozess länger dauert als der Längswalzprozess zum Herstellen der Vorstufe der Turbulenzvorrichtung mit lediglich glatten Wänden. Aufgrund des dünnen Ausgangsmaterials ist insbesondere das Ablängen der Turbulenzvorrichtungen auf eine vorgegebene, beliebig frei wählbare Länge schwierig, da die Bereiche in denen ein Schnitt durch die Turbulenzvorrichtung erfolgt, exakt fixiert werden müssen, um einen exakten Schnitt im Wesentlichen ohne Schnittgrate zu erhalten, da die Schnittgrate die Wärmeübertragungsleistung senken und den Druckverlust erhöhen würden. Ein derartiges Ablängen soll an einer beliebigen Stelle der Turbufenzvorrichtung erfolgen können. Aufgrund der komplexen Struktur der Turbulenzvorrichtung mit Hinterschnitten und Versetzungen ist diese Schnittoperation problematisch.Moreover, it is known to produce turbulence devices, such as inner corrugated fins, in a transverse rolling process. Due to the limited length, such a process may require the manufacture of several short turbulence devices, which subsequently have to be individually introduced into the tubes of the heat exchangers. This results in equally high production times and production costs, in particular by the assembly. Furthermore, it is known to produce the smooth part of the rib by means of a longitudinal rolling process and then to introduce the displacements transversely to the longitudinal direction of the rib and any cuts for passage openings by means of a subsequent punching process. However, the processes have different cycle times, so that in particular the time-consuming punching process takes longer than the longitudinal rolling process for producing the precursor of the turbulence device with only smooth walls. Due to the thin starting material in particular the cutting of the turbulence devices to a predetermined, arbitrarily freely selectable length is difficult because the areas in which a cut through the turbulence device must be precisely fixed to obtain an exact cut substantially without burrs, as the burrs would lower the heat transfer efficiency and increase the pressure loss. Such a cutting should be able to take place at any point of the turbulence device. Due to the complex structure of the turbulence device with undercuts and dislocations, this cutting operation is problematic.

Es ist Aufgabe der vorliegenden Erfindung, ein Verfahren zur Herstellung einer Turbulenzvorrichtung zum Einschieben in einen Wärmetauscher zu verbessern. Insbesondere ist es Aufgabe der vorliegenden Erfindung, ein Verfahren sowie eine Vorrichtung bereit zu stellen, bei dem Turbulenzvorrichtungen mit einer beliebig vorgegebenen Länge und mit einem im Wesentlichen mäanderartigen Profil, welches über Schnitte und/oder Versetzungen und Einprägungen im Wesentlichen quer zur Längsrichtung der Turbulenzvorrichtung verfügt, im Wesentlichen ohne Schnittgrate an den Schnittstellen herzustellen.It is an object of the present invention to improve a method for producing a turbulence device for insertion into a heat exchanger. In particular, it is an object of the present invention to provide a method and a device in which turbulence devices with an arbitrary predetermined length and with a substantially meander-like profile, which has cuts and / or dislocations and impressions substantially transverse to the longitudinal direction of the turbulence device , essentially without burrs at the interfaces.

Diese Aufgabe wird durch die Merkmale der Ansprüche 1 und 11 gelöst.This object is solved by the features of claims 1 and 11.

Es wird ein erfindungsgemäßes Verfahren zur Herstellung einer Turbulenzvorrichtung zur Aufnahme in zumindest einem Strömungskanal eines Wärmetauscher, insbesondere eines Ladeluftkühlers und/oder eines Abgaskühlers, eines Kraftfahrzeugs bereitgestellt. Das Verfahren weist dabei die folgenden Verfahrensschritte auf:An inventive method for producing a turbulence device for receiving in at least one flow channel of a heat exchanger, in particular a charge air cooler and / or an exhaust gas cooler, a motor vehicle is provided. The method has the following method steps:

In einem ersten Verfahrensschritt werden aus einem im Wesentlichen endlosen ebenen Blechsteifen mittels zumindest eines umformenden Bearbeitungsvorgangs zumindest eine im Wesentlichen mäanderförmig ausgebildete Turbulenzvorrichtung mit im Wesentlichen glatten Wänden erzeugt, wobei eine Längsrichtung der Wände im Wesentlichen parallel zu einer Vorschubrichtung des Blechsteifens verläuft. In einem zweiten Verfahrensschritt werden Wandabschnitte zumindest unter einem Winkel α bezüglich der Vorschubrichtung verformt derart, dass Hinterschneidungen bezüglich der Vorschubrichtung entstehen. Ein Zuschneiden auf Länge des im Wesentlichen endlosen Blechsteifens in Turbulenzvorrichtungen vorgegebener Länge erfolgt vor der Durchführung des zweiten Verfahrensschritts.In a first method step, at least one substantially meander-shaped turbulence device with substantially smooth walls is produced from a substantially endless planar sheet metal stiffener by means of at least one forming machining operation, wherein a longitudinal direction of the walls runs substantially parallel to a feed direction of the sheet metal stiffener. In a second process step Wall sections deformed at least at an angle α with respect to the feed direction such that undercuts with respect to the feed direction arise. Cutting to length of the substantially endless sheet metal stiffener in turbulence devices of predetermined length takes place before the second method step is carried out.

In einer vorteilhaften Weiterbildung der Erfindung erfolgt das Zuschneiden auf Länge vor dem ersten Verfahrensschritt. Auf diese Weise kann die Länge der Turbulenzvorrichtung bereits vor dem Ausbilden der mäanderförmig ausgebildeten Struktur erzeugt werden. Die Matrize Fixierung für einen exakten Schnitt kann auf diese Weise besonders vorteilhaft einfach ausgebildet werden.In an advantageous development of the invention, the cutting to length is carried out before the first process step. In this way, the length of the turbulence device can be generated even before the formation of the meander-shaped structure. The die fixation for a precise cut can be made particularly advantageous in this way.

In einer vorteilhaften Weiterbildung der Erfindung erfolgt das Zuschneiden auf Länge zwischen dem ersten Verfahrensschritt und dem zweiten Verfahrensschritt. Auf diese Weise erfolgt das Zuschneiden so spät wie möglich, so dass sich anschließende Verformungsoperationen keine Auswirkungen mehr auf die Schnittkante haben und auf diese Weise besonders vorteilhaft Ungenauigkeiten vermieden werden können.In an advantageous development of the invention, the cutting to length is carried out between the first method step and the second method step. In this way, the cutting takes place as late as possible, so that subsequent deformation operations have no effect on the cutting edge and in this way particularly advantageous inaccuracies can be avoided.

In einer besonders vorteilhaften Weiterbildung der Erfindung wird vor dem Verformen der Wandabschnitte zumindest ein Schnitt in die mäanderförmig ausgebildete Turbulenzvorrichtung eingebracht. Insbesondere wird der Schnitt unter einem Winkel β eingebracht. Insbesondere beeinflusst der Winkel β den Verlauf der Schnittkante der Hinterschneidungen in Bezug auf die Walzrichtung. Auf diese Weise können Verformungen in die Turbulenzvorrichtung besonders vorteilhaft eingebracht werden, wie beispielsweise Öffnungen zum Durchströmen von einem Fluidstrom, in dem eine Turbulenz erzeugt wird, wie beispielsweise Ladeluft und/oder Abgas oder ein Kühlmittel, wie beispielsweise Luft. Auf diese Weise wird die Turbulenz des Fluids und insbesondere somit die Wärmeübertragung, erhöht bei vertretbarem Ansteigen des Druckverlustes.In a particularly advantageous development of the invention, at least one cut is made in the meander-shaped turbulence device before the wall sections are deformed. In particular, the cut is introduced at an angle β. In particular, the angle β influences the course of the cutting edge of the undercuts with respect to the rolling direction. In this way, deformations in the turbulence device can be introduced particularly advantageously, such as openings for flowing through a fluid flow in which turbulence is generated, such as charge air and / or exhaust gas or a coolant, such as air. In this way, the turbulence of the fluid and in particular thus the heat transfer, increases at a reasonable increase in the pressure loss.

In einer besonders vorteilhaften Weiterbildung nimmt der Winkel α und/oder der Winkel β Werte von 0° bis 90°, insbesondere von 0,5° bis 80° an.In a particularly advantageous development, the angle α and / or the angle β assumes values of 0 ° to 90 °, in particular of 0.5 ° to 80 °.

In einer besonders vorteilhaften Weiterbildung der Erfindung ist der erste Verfahrensschritt ein Walzverfahren, insbesondere ein Längswalzverfahren. Auf diese Weise können Turbulenzvorrichtungen, insbesondere Rippen mit einer beliebig vorgebbaren Länge hergestellt werden.In a particularly advantageous development of the invention, the first method step is a rolling method, in particular a longitudinal rolling method. In this way, turbulence devices, in particular ribs can be produced with an arbitrarily predetermined length.

In einer vorteilhaften Weiterbildung der Erfindung weist der erste Verfahrensschritt 2 bis 40 Zwischenschritte, insbesondere 2 bis 35 Zwischenschritte, insbesondere 2 bis 30 Zwischenschritte auf und umfasst diese. In den Zwischenschritten wird der Blechsteifen sukzessive derart bearbeitet, dass die Breite der so erzeugten im Wesentlichen glatten Turbulenzvorrichtung eine geringere Turbulenzvorrichtungsbreite aufweist als im vorhergehenden Zwischenschritt. Auf diese Weise wird der Blechsteifen derart schonend bearbeitet, insbesondere umgeformt, so dass allmählich die mäanderförmige Struktur entsteht und die Blechdicke der gesamten erzeugten Turbulenzvorrichtung im Wesentlichen gleich ist, so dass es insbesondere zu keinen ungewollten Rissen und Materialausdünnungen kommt.In an advantageous development of the invention, the first method step comprises 2 to 40 intermediate steps, in particular 2 to 35 intermediate steps, in particular 2 to 30 intermediate steps, and comprises these. In the intermediate steps, the sheet metal stiffener is processed successively such that the width of the thus produced substantially smooth turbulence device has a smaller turbulence device width than in the preceding intermediate step. In this way, the sheet metal stiffeners are processed so gently, in particular reshaped, so that gradually the meandering structure is formed and the sheet thickness of the entire turbulence device generated is substantially equal, so that there are no unwanted cracks and material thinning in particular.

In einer besonders vorteilhaften Weiterbildung der Erfindung sind die Zwischenschritte Längswalzverfahrensschritte. Auf diese Weise kann besonders vorteilhaft sichergestellt werden, dass Turbulenzvorrichtungen in einer beliebig vorgebbaren Länge erstellt werden können.In a particularly advantageous development of the invention, the intermediate steps are longitudinal rolling process steps. In this way it can be ensured particularly advantageous that turbulence devices can be created in any desired length.

In einer vorteilhaften Weiterbildung der Erfindung weist die Turbulenzvorrichtung eine Blechdicke von 0,05 mm bis 0,35 mm, insbesondere von 0,05 mm bis 0,25 mm, insbesondere von 0,06 mm bis 0,2 mm, insbesondere von 0,06 mm bis 0,15 mm auf. Auf diese Weise kann durch die Verwendung von dünnem Material besonders vorteilhaft Material eingespart werden und auf diese Weise wertvoller Rohstoff eingespart und Kosten besonders vorteilhaft gesenkt werden.In an advantageous embodiment of the invention, the turbulence device has a sheet thickness of 0.05 mm to 0.35 mm, in particular from 0.05 mm to 0.25 mm, in particular from 0.06 mm to 0.2 mm, in particular of 0.06 mm to 0.15 mm. In this way, can be saved by the use of thin material particularly advantageous material and saved in this way valuable raw material and costs are lowered particularly advantageous.

In einer vorteilhaften Weiterbildung der Erfindung wird Bandmaterial für die Blechsteifen von einem Coil abgewickelt und anschließend geführt, dass das Bandmaterial im Wesentlichen eben ist. Auf diese Weise kann das Bandmaterial besonders vorteilhaft platzsparend bevorratet werden und dennoch wird im Wesentlichen ebenes Bandmaterial zur Ausbildung der Turbulenzvorrichtung zur Verfügung gestellt.In an advantageous development of the invention, strip material for the sheet metal stiffeners is unwound from a coil and then guided so that the strip material is essentially flat. In this way, the strip material can be stored in a particularly advantageous space-saving manner and yet substantially flat strip material is provided for the formation of the turbulence device.

Femer wird erfindungsgemäß eine Vorrichtung zur Durchführung eines Verfahrens nach einem der Ansprüche 1 bis 10 zur Verfügung gestellt. Die Vorrichtung weist zumindest einen Rollensatz zum sukzessiven Umformen des Blechsteifens in eine im Wesentlichen mäanderförmige Turbulenzvorrichtung mit im Wesentlichen glatten Wänden auf. Zumindest eine Vorrichtung mit Prägewalzen, die aus ein bis vier Rollenpaaren bestehen können zum Verformen der Wandabschnitte zumindest unter einem Winkel α bezüglich der Vorschubrichtung derart, dass Hinterschneidungen bezüglich der Vorschubrichtung entstehen. Zumindest eine Vorrichtung zum Zuschneiden der Turbulenzvorrichtung auf eine vorgegebene Länge vorgesehen. Die Vorrichtung zum Zuschneiden ist dem Rollensatz nachgeschaltet und den Prägewalzen vorgeschaltet. In einer anderen Ausführung ist die Vorrichtung zur Durchführung des Verfahrens derart ausgebildet, dass die Vorrichtung zum Zuschneiden dem Prägewalzen vorgeschaltet ist.Furthermore, an apparatus for carrying out a method according to one of claims 1 to 10 is provided according to the invention. The device has at least one set of rollers for the successive shaping of the sheet metal stiffener in a substantially meandering turbulence device with substantially smooth walls. At least one device with embossing rollers, which may consist of one to four pairs of rollers for deforming the wall sections at least at an angle α with respect to the feed direction such that undercuts with respect to the feed direction arise. At least one device for cutting the turbulence device to a predetermined length is provided. The device for cutting is downstream of the roller set and upstream of the embossing rollers. In another embodiment, the device for carrying out the method is designed such that the device for cutting is connected upstream of the embossing rollers.

In einer vorteilhaften Weiterbildung der Erfindung bevorratet eine Abwickelhaspel zu verarbeitendes Bandmaterial und/oder ein Tänzerelement ist zwischen einer Bandeinlaufstation insbesondere zur Führung in Walzen sowie zur Ausrichtung, Straffung sowie zur Vermeidung von Wellen und der Abwickelhaspel angeordnet. Auf diese Weise kann das als Coil aufgewickelte Bandmaterial besonders vorteilhalft einer Bandeinlaufvorrichtung zugeführt werden.In an advantageous development of the invention, a decoiler stores stock material to be processed and / or a dancer element is located between a band entry station, in particular for guiding in rolls and arranged for alignment, tightening and to avoid waves and the decoiler. In this way, the wound up as a coil strip material can be fed vorteilhalft a Bandeinlaufvorrichtung.

In einer vorteilhaften Weiterbildung der Erfindung ist eine Übergabestation zur Übergabe der fertigen Turbulenzvorrichtung an eine weitere Station, insbesondere eine Montagestation zur Montage der Turbulenzvorrichtung in zumindest ein Wärmetauscherrohr der Station mit den Prägewalzen nachgeordnet. Auf diese Weise können die Turbulenzvorrichtungen, insbesondere die Turbulenzrippen nach ihrer Herstellung besonders vorteilhaft, schnell und kostengünstig in bereit stehende Strömungskanäle für Wärmetauscher, insbesondere Wärmetauscherrohre montiert, insbesondere eingeschossen werden.In an advantageous embodiment of the invention, a transfer station for transferring the finished turbulence device to a further station, in particular a mounting station for mounting the turbulence device in at least one heat exchanger tube of the station downstream with the embossing rollers. In this way, the turbulence devices, in particular the turbulence ribs after their production particularly advantageous, quickly and inexpensively mounted in ready flow channels for heat exchangers, in particular heat exchanger tubes, in particular be injected.

Weitere vorteilhafte Ausgestaltungen der Erfindung ergeben sich aus den Unteransprüchen und aus der Zeichnung. Die Gegenstände der Unteransprüche beziehen sich sowohl auf das erfindungsgemäße Verfahren zur Herstellung einer Turbulenzvorrichtung als auch auf die erfindungsgemäße Vorrichtung zur Durchführung des Verfahrens als auch auf die erfindungsgemäße Turbulenzvorrichtung, insbesondere die Turbulenzrippe.Further advantageous embodiments of the invention will become apparent from the dependent claims and from the drawing. The subject matters of the subclaims relate both to the method according to the invention for producing a turbulence device and to the device according to the invention for carrying out the method and to the turbulence device according to the invention, in particular the turbulence rib.

Ausführungsbeispiele der Erfindung sind in der Zeichnung dargestellt und werden im Folgenden näher erläutert, wobei eine Beschränkung der Erfindung hierdurch nicht erfolgen soll. Es zeigen

Figur 1a:
eine Turbulenzvorrichtung, insbesondere eine Turbulenzrippe;
Figur 1b:
eine Seitenansicht einer Vorrichtung zur Herstellung der Turbu- lenzrippe;
Figuren 2a, 2b, 2c, 2d, 2e, 2f, 2g:
sieben Rollenpaaren und die entsprechend damit umgeformten Blechsteifen;
Figur 3:
eine schematische isometrische Darstellung der Schnittvorrich- tung in der Ausführung, dass diese zwischen den Rollenpaaren zur Herstellung der Rippen mit glatten Wänden und vor den Prä- gewalzen angeordnet ist;
Figuren 4a, 4b:
Prägewalzen zum Einbringen der Schnitte und Hinterschneidun- gen bzw. Verformungen;
Figur 5:
eine weitere Bearbeitungsstation zum Einbringen von Schlitzen und Ausprägungen;
Figur 6:
eine Seitenansicht einer anderen Ausführungsform, wobei die Station zum Ablängen im Gegensatz zur Figur 1b vor den Rollen- paaren angeordnet ist.
Embodiments of the invention are illustrated in the drawings and will be explained in more detail below, with a limitation of the invention is not intended to take place. Show it
FIG. 1a
a turbulence device, in particular a turbulence rib;
FIG. 1b
a side view of an apparatus for producing the turbulence rib;
FIGS. 2a, 2b, 2c, 2d, 2e, 2f, 2g:
seven pairs of rollers and the correspondingly formed sheet metal stiffeners;
FIG. 3:
a schematic isometric view of the cutting device in the embodiment that it is arranged between the pairs of rollers for producing the smooth-walled ribs and before the embossing rollers;
FIGS. 4a, 4b:
Embossing rollers for inserting the cuts and undercuts or deformations;
FIG. 5:
another processing station for introducing slots and shapes;
FIG. 6:
a side view of another embodiment, wherein the station for cutting in contrast to FIG. 1b is arranged in front of the roller pairs.

Figur 1a zeigt eine Turbulenzrippe 1. Die Turbulenzrippe 1 weist eine Rippenbreite RB so wie eine Rippenlänge RL auf. Die Turbulenzrippe 1 ist im Wesentlichen mäanderförmig ausgebildet und weist eine Anzahl von Tälern 4, sowie entsprechend ausgebildete, zugeordnete Berge 5 auf, wobei sich jeweils ein Tal 4 und ein Berg 5 abwechseln. FIG. 1a shows a turbulence rib 1. The turbulence rib 1 has a rib width RB as well as a rib length RL. The turbulence rib 1 is substantially meander-shaped and has a number of valleys 4, as well as appropriately trained, associated mountains 5, with a respective valley 4 and a mountain 5 alternate.

Der Berg 5 ist im Wesentlichen ein um 180° gedrehtes Rippental 4. Die Rippentäler 4 sowie die Rippenberge 5 weisen Rippeneinprägungen 3 auf, die in die Rippenberge 5 bzw. die Rippentäler 4 eingeprägt sind. Rippeneinprägungen weisen im Wesentlichen eine pyramidenförmige, insbesondere die Form einer 4-seitigen Pyramide auf oder können in einer anderen Ausführungsform die Form eines Quaders aufweisen. Die Rippenberge 5 bzw. die Rippentäler sind von Rippenwänden 2 begrenzt. Bezüglich der Turbulenzrippe 1 wird auf die unveröffentlichte DE 10 2007 014 138.8 der Anmelderin verwiesen, die hiermit ausdrücklich zum Offenbarungsgehalt dieser Anmeldung gilt. Die Turbulenzrippe 1 ist aus einem metallischen Material, wie beispielsweise aus Aluminium oder aus Stahl, wie beispielsweise Edelstahl ausgebildet. Femer kann die Turbulenzrippe 1 aus einem anderen Material ausgebildet sein, das eine gute Wärmeleiteigenschaft aufweist.The ridge 5 is essentially a rib valley 4 rotated by 180 °. The ridge valleys 4 and the ridge ridges 5 have ridge impressions 3, which are embossed into the ribbed mountains 5 and / or the ridge valleys 4. Rib indentations have substantially a pyramidal, in particular the shape of a 4-sided pyramid or, in another embodiment, may have the shape of a cuboid. The ribbed mountains 5 and the rib valleys are bounded by rib walls 2. Regarding the turbulence rib 1 is on the unpublished DE 10 2007 014 138.8 the applicant, which is hereby expressly applicable to the disclosure of this application. The turbulence rib 1 is formed of a metallic material such as aluminum or steel such as stainless steel. Further, the turbulence rib 1 may be formed of another material having a good heat conduction property.

Figur 1b zeigt eine Seitenansicht einer Vorrichtung 10 zur Herstellung der Turbulenzrippe 1. Gleiche Merkmale sind mit den gleichen Bezugszeichen versehen, wie in den vorherigen Figuren. FIG. 1b shows a side view of an apparatus 10 for producing the turbulence rib 1. The same features are provided with the same reference numerals as in the previous figures.

Die Vorrichtung 10 zur Herstellung der Turbulenzrippe 1 weist eine Abrollhaspel 12 mit einem Coil 11 auf. Der Coil 11 umfasst das aufgewickelte Blechbandmaterial. Femer umfasst die Vorrichtung 10 ein Tänzerelement 13, eine Bandeinlaufstation 14, eine Anzahl von Rollenpaaren 15, eine Station zum Ablängen 16 und eine Station mit Prägewalzen 18. Femer kann die Vorrichtung 10 zusätzlich ein Förderband 19 und/oder eine Übergabestation 17 zur Übergabe des Bandmaterials nach dem Ablängen in der Station 16 an die Prägewalzenstation 18 aufweisen.The device 10 for producing the turbulence rib 1 has a unwinding reel 12 with a coil 11. The coil 11 comprises the wound sheet metal strip material. Furthermore, the apparatus 10 comprises a dancer element 13, a belt entry station 14, a number of roller pairs 15, a station 16 for cutting to length and a station with embossing rollers 18. Furthermore, the device 10 may additionally comprise a conveyor belt 19 and / or a transfer station 17 for transferring the strip material after cutting to length in the station 16 to the embossing roller 18 have.

Das Bandmaterial wird von der Abrollhaspel 12 abgewickelt. Das Tänzerelement 13 bewirkt, dass das Band immer im Wesentlichen gleichmäßig gespannt ist, wenn es Bandeinlaufstation 14 zugeführt wird.The strip material is unwound from the unwinding reel 12. The dancer element 13 causes the tape to be always substantially evenly tensioned when fed to the tape entry station 14.

Nach dem Zuführen des Blechmaterials in die Bandeinlaufstation 14 wird der Blechsteifen der Station 15 mit den Rollenpaaren zugeführt. In der Station 15 bewirken die Rollenpaare, dass sukzessive die Rippenhöhe RH der Turbulenzrippe 1 ausgebildet sowie die Rippentäler 4 und die Rippenberge 5 die zugehörige Rippenbreite RB sukzessive hergestellt wird und nach dem Durchlaufen der Station 15 mit den Rollenpaaren die Turbulenzrippe als Glattrippe, insbesondere ohne die Rippeneinprägungen 3 ausgebildet ist. Im dargestellten Ausführungsbeispiel weist die Station 15 18 Rollenpaare auf. In einer anderen Ausführungsform weist die Station 15 mehr als 18 bzw. in einer anderen Ausführungsform weniger als 18 Rollenpaare auf.After the sheet material has been fed into the belt entry station 14, the sheet metal stiffener is fed to the station 15 with the roller pairs. In the station 15, the pairs of rollers cause the rib height RH of the turbulence rib 1 to be successively formed and the rib valleys 4 and the rib tops 5 to be joined to the corresponding rib width RB, and after passing through the station 15 with the roller pairs, the turbulence rib is formed as a smooth rib, in particular without Rib impressions 3 is formed. In the illustrated embodiment, the station 15 on 18 pairs of rollers. In another embodiment, the station 15 has more than 18 or, in another embodiment, less than 18 pairs of rollers.

In der Station 16 erfolgt das Ablängen der Turbulenzrippen 1 auf die entsprechend gewünschte Länge. Die Turbulenzrippe 1 weist nach dem Ablängen auf die entsprechende Rippenlänge RL noch keine Rippeneinprägungen 3 auf.In the station 16, the cutting of the turbulence ribs 1 to the desired length is carried out. The turbulence rib 1, after cutting to the corresponding rib length RL, still has no rib impressions 3.

Mittels der Übergabestation 17 wird die fertig zugeschnittene Turbulenzrippe 1 der Station 18 mit den Prägewalzen zugeführt. In der Station 18 werden schließlich Schnitte und die Rippeneinprägungen 3 in die Turbulenzrippe 1 eingebracht. Erst nach dieser Operation weist die Turbulenzrippe 1 die entsprechende Form auf, wie sie in Figur 1a dargestellt ist. Mittels eines Förderbands und einer Zuführeinrichtung 19 werden die so erzeugten Turbulenzrippen 1 einer Montagestation, wie beispielsweise zur Montage der Rippen in die Strömungskanäle, wie beispielsweise die Wärmetauscherrohre zugeführt.By means of the transfer station 17, the tailor-made turbulence rib 1 is fed to the station 18 with the embossing rollers. In the station 18, finally, cuts and the rib impressions 3 are introduced into the turbulence rib 1. Only after this operation, the turbulence rib 1 has the appropriate shape, as in FIG. 1a is shown. By means of a conveyor belt and a feed device 19, the turbulence ribs 1 thus produced are fed to a mounting station, such as for example for mounting the ribs in the flow channels, such as the heat exchanger tubes.

Figuren 2a, 2b, 2c , 2d, 2e, 2f sowie 2g zeigen 7 Rollenpaare 20.1 bis 26.1 und die entsprechend damit umgeformten Blechsteifen 20.2 bis 26.2. Gleiche Merkmale sind mit den gleichen Bezugszeichen versehen, wie in den vorherigen Figuren. FIGS. 2a, 2b, 2c . 2d, 2e, 2f and 2g show 7 roller pairs 20.1 to 26.1 and the correspondingly formed sheet metal stiffeners 20.2 to 26.2. Identical features are provided with the same reference numerals as in the previous figures.

In den Figuren 2a bis 2g ist dargestellt, wie aus dem Blechsteifen mit der Rippenbreite RB0 des Blechbands 20.2 über die Schritte 21.2, 22.2, 23.2, 24.2, 25.2 und 26.2 die Rippenbreite allmählich abnimmt, wobei die Rippenbreite RB1 kleiner als die Rippenbreite RB0 und die Rippenbreite RB2 kleiner ist als die Rippenbreite RB1. Die Rippenbreite RB3 ist geringer als die Rippenbreite RB2 und die Rippenbreite RB4 ist geringer als die Rippenbreite RB3. Ebenso ist die Rippenbreite RB5 geringer als die Rippenbreite RB4 und die Rippenbreite RB6 ist geringer als die Rippenbreite RB5. Dagegen nimmt die Rippenhöhe RH vom Bearbeitungsschritt 20.2 bis zum Bearbeitungsschritt 26.2 zu. Die zugehörigen Rollenpaare mit den entsprechenden Rollen 20.1, 21.1, 22.1, 23.1, 24.1, 25.1, 26.1 haben die entsprechenden Rollenformen, um die zugehörigen Rippenvorstufen zu erzeugen. Nach dem Bearbeitungsschritt 26.2 ist eine Glattrippe vorhanden, die jedoch noch keine Rippeneinprägungen 3 bzw. Hinterschnitte und Einschnitte aufweist.In the FIGS. 2a to 2g It is shown how the rib width gradually decreases from the sheet metal stiffener with the rib width RB0 of the sheet metal strip 20.2 via the steps 21.2, 22.2, 23.2, 24.2, 25.2 and 26.2, wherein the rib width RB1 smaller than the rib width RB0 and the rib width RB2 is smaller than that Rib width RB1. The rib width RB3 is smaller than the rib width RB2, and the rib width RB4 is smaller than the rib width RB3. Also, the rib width RB5 is smaller than the rib width RB4 and the rib width RB6 is smaller than the rib width RB5. On the other hand, the rib height RH increases from the machining step 20.2 to the machining step 26.2. The associated roller pairs with the respective rollers 20.1, 21.1, 22.1, 23.1, 24.1, 25.1, 26.1 have the corresponding roller shapes to produce the associated fin precursors. After the processing step 26.2 a smooth rib is present, but still has no rib impressions 3 or undercuts and cuts.

In Figur 3 ist eine isometrische Darstellung der Schnittvorrichtung 16 sowie des Förderbandes 31 und der Prägewalzen 18 dargestellt. Nach dem Zuschneiden der Glattrippe 30 auf die richtige Länge in der Station zum Ablängen 16 wird die so erzeugte Glattrippe 30 über ein zweites Förderband 31 in Richtung der Führungselemente 33 transportiert. Führungsleitelemente 32 gewährleisten dabei, dass die Glattrippe 30 bereits grob ausgerichtet wird. Mittels des Führungsrinnenelements 33 erfolgt die Feinpositionierung und Feinausrichtung der Glattrippe 30. Das Führungsrinnenelement 33 ist im Wesentlichen derart kammartig ausgebildet, dass Kammzinken im Wesentlichen der Form der Rippenberge 5 entsprechen, so dass die nicht näher bezeichneten Zinkenelemente das Führungsrinnenelement 33 in die Rippenberge 5 eingreifen können. Auf diese Weise erfolgt die genaue Positionierung bevor die Glattrippe 30 zur Weiterbearbeitung der Prägewalzenstation 18 zugeführt wird. Schematisch sind hierbei eine erste Prägewalze 1834 und eine zweite Prägewalze 1835 dargestellt, zusammenwirken und die Glattrippe 30 derart umformen, dass die Rippeneinprägungen 3 sowie eventuelle Schnitte und andere Verformungen in die Glattrippe 30 eingebracht werden und auf diese Weise die fertige Turbulenzrippe 1 entsteht. Die Prägewalzenstation 18 und damit das Einbringen der Rippeneinprägungen 3 wird insbesondere in zumindest einem Rollenpaar, insbesondere in ein bis vier Rollenpaaren, ausgeführt.In FIG. 3 an isometric view of the cutting device 16 and the conveyor belt 31 and the embossing rollers 18 is shown. After cutting the smooth rib 30 to the correct length in the station for cutting 16, the smooth rib 30 thus produced is transported via a second conveyor belt 31 in the direction of the guide elements 33. Guide elements 32 ensure that the smooth rib 30 is already roughly aligned. By means of the guide trough element 33, the fine positioning and fine alignment of the smooth rib 30. The guide trough member 33 is formed substantially comb-like that comb teeth substantially correspond to the shape of the ribs 5, so that the unspecified tine elements the guide trough element 33 in the ribs 5 can intervene. In this way, the exact positioning before the smooth rib 30 is supplied for further processing of the embossing roll station 18. Schematically, a first embossing roll 1834 and a second embossing roll 1835 are shown, cooperate and reshape the smooth rib 30 such that the rib impressions 3 as well as any cuts and other deformations are introduced into the smooth rib 30 and in this way the finished turbulence rib 1 is formed. The embossing roller station 18 and thus the introduction of the rib impressions 3 is carried out in particular in at least one pair of rollers, in particular in one to four pairs of rollers.

Die Figuren 4a, 4b zeigen eine Seitenansicht in der Schnittdarstellung sowie eine Vorderansicht in der Schnittdarstellung. Gleiche Merkmale sind mit den gleichen Bezugszeichen versehen wie in den vorherigen Figuren.The FIGS. 4a, 4b show a side view in the sectional view and a front view in the sectional view. Identical features are provided with the same reference numerals as in the previous figures.

Die Prägewalzenstation 18 weist eine erste Prägewalze 1834 sowie eine zweite Prägewalze 1835 auf. Die Prägewalzenstation 18 und somit das Einbringen der Rippeneinprägungen 3 erfolgt mittels zumindest einem Rollenpaar, insbesondere mittels ein bis vier Rollenpaaren. Zwischen der ersten Prägewalze 1834 und der zweiten Prägewalze 1835 wird die erzeugte Glattrippe 30 in die fertige Turbulenzrippe 1 umgeformt. Eine Abfolge von nicht näher bezeichneten ersten und zweiten Zähnen bewirkt, dass die Rippentäler 4 bzw. die Rippenberge 5 in einer Querrichtung QR, die im Wesentlichen einen Winkel α bezüglich der Rippenlängsrichtung RLR aufweist, versetzt werden. Der Winkel α nimmt Werte von 0° bis 90°, insbesondere Werte von 0,5° bis 80° an. Auf diese Weise werden die Rippeneinprägungen 3, wie beispielsweise die Versetzungen und/oder Einschneidungen bzw. die Kiemen und/oder die Tiefenwellungen oder Formen ähnlicher Art in die Glattrippe 30 eingebracht, so dass auf diese Weise die Turbulenzrippe 1 erzeugt wird.The embossing roll station 18 has a first embossing roll 1834 and a second embossing roll 1835. The embossing roller station 18 and thus the introduction of the rib impressions 3 by means of at least one pair of rollers, in particular by means of one to four pairs of rollers. Between the first embossing roller 1834 and the second embossing roller 1835, the generated smooth rib 30 is formed into the finished turbulence rib 1. A sequence of unspecified first and second teeth causes the rib valleys 4 and ribs 5 to be displaced in a transverse direction QR that is substantially at an angle α with respect to the rib longitudinal direction RLR. The angle α assumes values of 0 ° to 90 °, in particular values of 0.5 ° to 80 °. In this way, the rib impressions 3, such as the dislocations and / or incisions or the gills and / or the deep undulations or similar shapes, are introduced into the smooth rib 30, so that the turbulence rib 1 is produced in this way.

In Figur 5 ist eine weitere Bearbeitungsstation gezeigt, die zusätzlich zugeschaltet werden kann. Gleiche Merkmale sind mit den gleichen Bezugszeichen versehen wie in den vorherigen Figuren.In FIG. 5 is shown another processing station, which can be additionally switched on. Identical features are provided with the same reference numerals as in the previous figures.

Die zusätzliche Bearbeitungsstation 50 ist eine Rotationsstanz- bzw. Walzstanzstation. Sie ist der Rollensatzstation 15 vorgeschaltet. So wird beispielsweise der Blechsteifen nach dem Führen und vor der Herstellung der Glattrippe 30 mit Stanzwalzen 51, die eine Vielzahl von Stempeln 54 aufweisen, derart bearbeitet, dass Einschneidungen 53 bzw. Freischneidungen oder Ausstanzungen bereits vor dem Erzeugen der Glattrippe 30 in den Blechsteifen 52 eingebracht werden.The additional processing station 50 is a rotary blanking station. It is upstream of the roller set station 15. For example, after guiding and before producing the smooth rib 30 with punching rollers 51, which have a multiplicity of punches 54, the sheet metal stiffeners are machined such that incisions 53 or free cutting or punching are introduced into the sheet metal stiffeners 52 before the smooth rib 30 is produced become.

Figur 6 zeigt eine Seitenansicht einer anderen Ausführungsvorrichtung zur Fertigung der Turbulenzvorrichtung 1 mit einer anderen Abfolge der Stationen, im Unterschied zur Figur 1b. Gleiche Merkmale sind mit den gleichen Bezugszeichen versehen wie in den vorherigen Figuren. FIG. 6 shows a side view of another embodiment for manufacturing the turbulence device 1 with a different sequence of stations, in contrast to FIG. 1b , Identical features are provided with the same reference numerals as in the previous figures.

Im Unterschied zur Figur 1b wird der Blechsteifen 9 nach dem Führen in der Bandeinlaufstation 14 in der Station 16 abgelängt und anschließend in der Übergabestation den Rollenpaaren 15 zugeführt. In den Rollenpaaren 15 wird zunächst die Glattrippe 30 erzeugt. Nach dem Erzeugen der Glattrippe 30 wird im Wesentlichen direkt im Anschluss die Fertigbearbeitung zur Turbulenzrippe 1 in den Prägewalzen 18 durchgeführt. Über das erste Förderband 19 werden die so fertigen Turbulenzrippen 1 beispielsweise der Montagestation zur Montage in den Wärmetauschern zugeführt.In contrast to FIG. 1b the sheet metal stiffener 9 is cut to length after being guided in the belt infeed station 14 in the station 16 and then fed to the roller pairs 15 in the transfer station. In the pairs of rollers 15, the smooth rib 30 is first generated. After the smooth rib 30 has been produced, the finishing operation for the turbulence rib 1 in the embossing rolls 18 is carried out essentially immediately thereafter. About the first conveyor belt 19, the finished turbulence ribs 1 are supplied, for example, the assembly station for mounting in the heat exchangers.

In einer Weiterbildung oder Alternative der Erfindung werden mit dem Verfahren und/oder der Vorrichtung längsgewalzte Innenrippen hergestellt, die aus einer Kombination von einer oder mehreren Glattbereichen mit einer oder mehreren Bereichen mit Versetzungen und/oder Einprägungen und/oder Einschneidungen und/oder Kiemen und/oder Tiefenwellungen versehen. Die Prägewalze ist dabei insbesondere zwischen dem Rollensatz für die Glattrippe und der Station 16 zum Ablängen angeordnet. Das Einbringen der Versetzungen und/oder Einprägungen und/oder mit Einschneidungen und/oder Kiemen und/oder Tiefenwellungen kann dabei auf zwei Arten erfolgen:In a further development or alternative of the invention, the method and / or the device are used to produce longitudinally rolled inner ribs which consist of a combination of one or more smooth areas with one or more areas with dislocations and / or indentations and / or indentations and / or gills and / or or deep undulations provided. The Embossing roller is arranged in particular between the roller set for the smooth rib and the station 16 for cutting. The introduction of the dislocations and / or indentations and / or with incisions and / or gills and / or deep undulations can take place in two ways:

Bei einer Ausgestaltung ist die Prägewalze derart ausgebildet, dass sie sich von den Glattrippen abhebt und nur dann in den Bereichen zum Eingriff kommt, an denen Versetzungen und/oder Einprägungen und/oder Einschneidungen und/oder Kiemen und/oder Tiefenwellungen eingebracht werden sollen.In one embodiment, the embossing roller is designed such that it stands out from the smooth ribs and comes into engagement only in the areas where dislocations and / or indentations and / or incisions and / or gills and / or deep undulations are to be introduced.

Bei einer anderen Alternative sind die Versetzungen und/oder Einprägungen und/oder Einschneidungen und/oder Kiemen und/oder Tiefenwellungen an der Prägewalze derart angeordnet, dass über den Umfang der Prägewalze gesehen mehrere Glattbereiche angeordnet sind und die Prägewalze dabei im Wesentlichen in ständigem Einsatz ist.In another alternative, the dislocations and / or indentations and / or incisions and / or gills and / or deep undulations on the embossing roller are arranged such that seen over the circumference of the embossing roller a plurality of smooth regions are arranged and the embossing roller is substantially in constant use ,

In einer vorteilhaften Weiterbildung wird zumindest eine Innenwellrippe hergestellt, die durch eine Kombination von Glattbereichen und Bereichen mit Versetzungen und/oder Einprägungen und/oder Einschneidungen und/oder Kiemen und/oder Tiefenwellungen o.ä. eine hohe Leistung bei geringerem Druckverlust aufweist und die zusätzlich in den Glattbereichen im Wesentlichen einfacher abzulängen ist.In an advantageous development, at least one inner corrugated rib is produced, which is produced by a combination of smooth areas and areas with dislocations and / or indentations and / or indentations and / or gills and / or deep corrugations or the like. has a high performance with less pressure loss and which is in addition to cut down in the smooth areas substantially easier.

Die Merkmale der verschiedenen Ausführungsbeispiele sind beliebig miteinander kombinierbar. Die Erfindung ist auch für andere als die gezeigten Gebiete einsetzbar.The features of the various embodiments can be combined with each other. The invention can also be used for other than the areas shown.

Claims (13)

  1. A process for producing a turbulence device (1) which is to be mounted in at least one flow duct of a heat exchanger of a motor vehicle, comprising the following process steps:
    - in a first process step, at least one shaping operation is used to produce at least one substantially meandering turbulence device (30) with substantially smooth walls (2) from a substantially continuously planar sheared strip (9), wherein a longitudinal direction (RLR) of the walls runs substantially parallel to a forward feed direction (VSR) of the sheared strip (9),
    - in a second process step, wall sections are deformed at least by an angle (α) in relation to the forward feed direction (VSR), in such a way that undercuts (3) are produced in relation to the forward feed direction (VSR, RLR),
    characterized in that the substantially continuous sheared strip (9) is cut into turbulence devices (1) of predetermined lengths before the second process step is carried out.
  2. The process as claimed in claim 1, characterized in that cutting to length is performed prior to the first process step.
  3. The process as claimed in claim 1, characterized in that cutting to length is performed between the first process step and the second process step.
  4. The process as claimed in one of the preceding claims, characterized in that at least one cut, and in particular the cut at an angle (β), is introduced into the meandering turbulence device (30) prior to the deformation of the wall sections.
  5. The process as claimed in claim 4, characterized in that the angle (α) and/or the angle (β) assume values from 0° to 90°, in particular from 0.5° to 80°.
  6. The process as claimed in one of the preceding claims, characterized in that the first process step is a rolling process.
  7. The process as claimed in one of the preceding claims, characterized in that the first process step comprises 2 to 40 intermediate steps, in particular 2 to 35 intermediate steps, in which the sheared strip (9) is successively machined in such a way that the width (RB) of the substantially smooth turbulence device (30) thus produced has a smaller turbulence device width (RB) than in the preceding intermediate step.
  8. The process as claimed in claim 7, characterized in that the intermediate steps are longitudinal rolling process steps.
  9. The process as claimed in one of the preceding claims, characterised in that the turbulence device (1, 30) has a sheet metal thickness from 0.05 mm to 0.35 mm, in particular from 0.05 mm to 0.25 mm, in particular from 0.06 mm to 0.20 mm, in particular from 0.06 to 0.15 mm.
  10. The process as claimed in one of the preceding claims, characterized in that strip material for the sheared strip (9) is wound oft from a coil (11) and is then led in such a way that the sheared strip (9) is substantially planar.
  11. An apparatus for carrying out the process as claimed in one of claims 1 to 10, comprising
    - at least one set of rollers (15, 20.1, 21.1, 22.1, 23.1, 24.1, 25.1, 26.1) for successively shaping the sheared strip (9) into a substantially meandering turbulence device (30) with substantially smooth walls (2),
    - at least one apparatus with stamping rollers (18) for deforming the wall sections at least by an angle (α) in relation to the forward feed direction (VSR), in such a way that undercuts (3) are produced in relation to the forward feed direction (VSR),
    - at least one apparatus (16) for cutting the turbulence devices (1, 30) to a predetermined length,
    characterized in that the apparatus (16) for cutting to length is connected to the outlet side of the set of rollers (15) and the inlet side of the roller stamping dies (18).
  12. The apparatus as claimed in claim 11, characterized in that a take-off reel (12) stores strip material to be processed and/or a dancer element (13) is arranged between a strip inlet station (14) and the take-off reel (12).
  13. The apparatus as claimed in one of claims 11 or 12, characterized in that a transfer station (17) is assigned to the outlet side of the station with the roller stamping dies (18) for transferring the finished turbulence device (1) or the preprocessed turbulence device (30) to a further station, in particular an assembly station for fitting the turbulence device in at least one heat exchanger tube.
EP08802729A 2007-10-09 2008-10-01 Process for producing a turbulence apparatus and apparatus for carrying out the process Not-in-force EP2205374B1 (en)

Applications Claiming Priority (2)

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DE102007048474A DE102007048474A1 (en) 2007-10-09 2007-10-09 Method for producing a turbulence device, device for carrying out the method, turbulence device
PCT/EP2008/008310 WO2009049771A1 (en) 2007-10-09 2008-10-01 Process for producing a turbulence apparatus, apparatus for carrying out the process, and turbulence apparatus

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EP2205374B1 true EP2205374B1 (en) 2011-06-15

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EP (1) EP2205374B1 (en)
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AT (1) ATE512733T1 (en)
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WO (1) WO2009049771A1 (en)

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JP6742504B2 (en) * 2017-03-07 2020-08-19 株式会社Ihi Aircraft radiator
JP6546681B1 (en) * 2018-05-16 2019-07-17 モリテックスチール株式会社 Metal foil and laminate having the same

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US3421353A (en) * 1967-10-12 1969-01-14 Robertson Co H H Method and apparatus for making corrugated building sheets
US4047417A (en) * 1975-10-16 1977-09-13 Johns-Manville Corporation Deeply embossed sheet product and method and apparatus for the production thereof
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DE4028438C2 (en) * 1990-09-07 1994-12-22 Behr Gmbh & Co Process for manufacturing heat exchangers
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GB9901723D0 (en) * 1999-01-26 1999-03-17 Metsec Plc Metal strip
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DE20102056U1 (en) 2001-01-31 2001-05-10 Lta Lufttechnische Komponenten Device for producing sheet metal parts for air conditioning ducts
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DE102008015064A1 (en) * 2007-03-23 2008-09-25 Behr Gmbh & Co. Kg Turbulence insert for cooling gaseous medium i.e. loaded air of charge air cooler, has side wall with impressions, which are limited by side surfaces, where breadth of impressions increases in transverse direction till maximum breadth

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DE102007048474A1 (en) 2009-04-16
CN101821033B (en) 2013-02-13
ATE512733T1 (en) 2011-07-15
CN101821033A (en) 2010-09-01
US8701289B2 (en) 2014-04-22
WO2009049771A1 (en) 2009-04-23
EP2205374A1 (en) 2010-07-14
US20100218922A1 (en) 2010-09-02

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