RU2528240C1 - Method of manufacturing of heating unit body with cavity for coolant - Google Patents

Abstract

FIELD: power engineering.

SUBSTANCE: method is proposed to manufacture a body of a heating unit with a cavity for coolant, including cutting of flat parts of inner and outer bodies, formation of inner and outer bodies with openings for combustion and ash chambers by means of bending and welding of flat parts, installation of the inner body into the outer one with formation of a coolant cavity at least between their side walls, and also a frame for installation of a boiling deck and sealing of the cavity between inner and outer bodies by means of welding. The bottom and side walls of the inner body are formed from a single flat part by means of its welding, then the rear wall of the inner body is welded to them, at the same time connection of the bodies in the upper part is made by means of bending, at least at side walls of the inner body, shelves that are then welded to appropriate walls of the outer body.

EFFECT: simplified process of manufacturing of a heating unit body and reduced probability of manufacturing defects.

6 cl, 3 dwg

Description

The invention relates to heat engineering and can be used for the manufacture of heating devices with a cavity for a coolant, intended for heating residential buildings, industrial premises and individual residential buildings, including equipped with a heating system with natural circulation, mainly for devices with a horizontal combustion chamber.

Heating devices with a cavity for the coolant are made with a vertical combustion chamber, in which the length of the combustion chamber is less than its height, and with a horizontal combustion chamber, in which the length of the combustion chamber is greater than its height, for example, a water heater according to RF patent No. 2187766, 06/26/2000 g., IPC F24H 1/24 and RF patent No. 29989, 01/28/2003, IPC F24H 1/26.

Heating devices have various design features. In the simplest version, the heating apparatus comprises a hollow body with internal and external walls, equipped with a nozzle for supplying to its cavity and for removing the heat carrier, which serves when filling with water with a water jacket. In the housing there is a combustion chamber with a loading door, a gas duct and an ash chamber. Housings of heating devices are made of sheet steel by cutting flat parts and their connections.

Heating apparatuses are known whose bodies are made of flat parts by welding them, for example, a Cooper heating boiler manufactured by KO Teplodar LLC (Operation manual. Cooper heating boiler OK-15, OK-20, OK -30, OVK-10, OVK-18. Teplodar, Novosibirsk, 2012).

A large number of welding operations requires significant costs for the welding process, control of the welds and materials for welding, and also increases the likelihood of welding defects.

Most often, the cases of heating apparatus with a cavity for the coolant are made of steel by bending and welding. Such a method is used, for example, in the manufacture of the case of Uragan heating apparatus manufactured by Thermocraft (Heating apparatus URAGAN. Operation manual, 2011), and in the manufacture of Sibteploenergomash LLC heating apparatus with horizontal and vertical combustion chambers "Karakan" (Combined solid-fuel hot water heating apparatus KARAKAN with instantaneous water heater. Passport and manual for selection, installation and operation, Novosibirsk, 2011). A method of manufacturing a Karakan-15 apparatus with a horizontal combustion chamber is adopted as a prototype.

The specified apparatus contains a housing having side walls, a rear wall, a front wall with openings for the furnace and ash chambers and the bottom. The hollow body is formed by the inner and outer cases and is equipped with a nozzle for supplying to its cavity and removal of the coolant. A hob is installed on the body. The casing is surrounded by a combustion chamber with a loading door, a gas duct and an ash chamber. The combustion chamber is separated from the gas duct by a hollow heat-exchange element, in communication with the cavity of the housing. On the rear wall there is a hole for the exit of flue gases.

The body of the apparatus is made as follows. Cut out the flat parts of the inner and outer shells, then form the inner and outer shells with openings for the furnace and ash chambers by bending and welding the flat parts, install the inner shell in the outer one with the formation of at least between their side walls cavity for the coolant, and the framework of the outer casing for installing the hob, perform sealing by welding the cavity between the inner and outer casings.

In the specified prototype method, the cavity for the coolant is formed by all the walls and the bottom of the inner and outer cases. The cutting of the back and side walls of the inner and outer cases is performed in the form of single flat workpieces. The back and side walls of the inner case are formed from a single flat part by bending it. Then, the bottom of the inner casing and the heat exchange element are welded to them. The outer casing is likewise formed.

Details of the front walls are welded to the housings to form openings in the furnace and ash chambers. In this case, the sides of the openings in the casing into the furnace and ash chambers are formed by the side walls of the inner casing. The remaining structural elements of the apparatus are connected by welding. Sealing the cavity is carried out in a manner traditional for such apparatuses - by welding strips-bridges between the walls of the inner and outer shells.

The prototype has the following disadvantages.

1. Welding the bottom of the inner case to its side walls and connecting the bodies by welding the jumper strips require significant time and materials to perform welding operations, control welds and cut the jumper strips. In this case, welding defects may occur.

The technical result of the invention is to simplify the manufacturing process of the housing of the heating apparatus and reduce the likelihood of manufacturing defects.

The specified technical result is achieved as follows. In the known method of manufacturing the housing of the heating apparatus with a cavity for the coolant, as in the prototype, including cutting flat parts of the inner and outer shells, forming the inner and outer shells with openings for the furnace and ash chambers by bending and welding the flat parts, installing the inner shell in the outer with the formation, at least between their side walls of the cavity for the coolant, as well as the framework for installing the cooking floor and sealing by welding the cavity between the inner and outer cases, in contrast to the prototype, the following is done: the bottom and side walls of the inner case are formed from a single flat part by bending it, then the back wall of the inner case is welded to them, and the connection of the bodies in the upper part is performed by bending, at least on the side walls the inner case of the shelves, which are then welded to the corresponding walls of the outer case.

In the proposed method, the cavity for the coolant can be formed by all the walls and the bottom of the inner and outer cases, or only the walls, or some of the walls, or some of the walls and the bottom. In addition, the cavity for the coolant is supplemented by a heat exchange element connected to one, two or three walls of the inner case.

In addition, the back and side walls of the outer casing are formed from a single flat part by bending it or the bottom and the side walls of the outer casing are formed from a single flat part by bending it, or the front and side walls of the outer casing are formed from a single flat part by bending it, or the front, side and rear walls of the outer casing are formed from a single flat part by bending it, and the connection of the casing from the front side is performed by bending the shelves on the side walls of the outer casing, which are then welded added to the elements of the front wall of the outer shell and in places and openings in the combustion chamber ash - to the side walls of the inner housing.

When forming the front and side walls or the front, side and rear walls of the outer casing from a single flat blank, openings for the furnace and ash chambers are cut out on the front wall.

An example implementation of the method is illustrated by the drawings. In Fig.1 presents a General view of the heating apparatus with a cavity for the coolant in the context, in Fig.2 is a front view in section, in Fig.3 is a top view in section.

The drawing shows: 1 - loading door, 2 - front wall of the housing, 3 - frame, 4, 9, 17, 19 - folding shelves, 5 - combustion chamber, 6 - heat transfer element, 7 - hob, 8 - gas duct, 10 - chimney, 11 - cavity for the coolant (water jacket), 12 - rear wall of the housing, 13 - grate, 14 - ash chamber, 15 - ash box, 16 - bottom, 18 - side wall of the housing. The drawings indicate the radii of the bending angles R.

The heating apparatus comprises a housing formed by inner and outer housings, with hollow side 18, rear 12, front 2 walls and bottom 16. A cooker 7 is placed on the housing in a frame 3 of the walls 2, 12, 18 of the outer housing. A duct is located in the housing 8, the combustion chamber 5, the ash chamber 14 and the grate 13. The combustion chamber 5 is equipped with a loading door 1, an ash box 15 is installed in the ash chamber 14. The combustion chamber 5 with the gas duct 8 separates the housing element - heat exchange element 6.

Between the inner and outer cases there is a cavity 11 for the coolant. The cavity of the heat exchange element 6 is in communication with the cavity 11 of the housing on three sides — the ends of the hollow heat exchange element 6 are fixed to the rear 12 and side 18 walls of the inner housing.

On the rear wall 12 of the casing there is an opening for installing the chimney 10. In the outer casing there are openings for supplying cold water and for removing hot water from the water jacket (not shown in the drawings).

A method of manufacturing a housing of the apparatus is as follows.

Flat steel parts of the inner and outer shells of the required dimensions with all the necessary grooves and openings, including for the removal and supply of the coolant, for installing the heat exchange element 6, are cut out of steel sheets of the estimated thickness on guillotine shears, press equipment, as well as by laser or plasma cutting. installation of the chimney 10. The bottom 16 and side walls 18 of the inner casing, as well as the side 18 and rear 12 walls of the outer casing, are cut in the form of single flat blanks. When cutting parts, the dimensions of the shelves 4, 9, 17, 19, which are bent on the walls of the case, are taken into account to connect the cases and the frame 3 from the walls of the outer case for installing the hob 7.

Then form the inner body by bending and welding. The bottom 16 and the side walls 18 are made by bending a single flat part with bending radii R. The radii of the bending angles R in the drawings are increased for clarity. To the bottom 16 and side walls 18 are welded back wall 12 of the inner housing. A heat-exchange element is welded to the side walls 18 of the inner casing 6. On the front side of the apparatus, the parts of the front wall 2 of the casing are welded to the side walls 18 to form two openings - into the furnace 5 and ash 14 of the chamber. In this case, the inner side walls of the chambers 5 and 14 and the sides of the openings in these chambers on the front wall 2 of the casing are formed by the side walls 18 of the inner casing.

Bending of parts is carried out on a bending machine or press. On the upper edges of the front 2, rear 12 and side 18 walls of the inner case, the shelves 4, 9, 17 are bent to connect the cases (Fig. 1, 2).

The outer casing is also formed by bending and welding. A single flat billet is bent, forming the rear 12 and side 18 of the wall of the outer casing. The bottom 16 is welded to the indicated walls. On the side walls 18 of the outer casing, the shelves 19 are unbent from the front of the apparatus (Fig. 3). Three strips are welded to the bent shelves 19 — parts of the front wall 2 of the outer casing with the formation of two openings — into the furnace 5 and the ash 14 of the chamber.

Then, the inner case is installed in the outer one with the formation of a cavity 9 for the coolant between their walls and the shelves 4, 9, 17 bent on the walls of the inner case are welded to the upper part of the walls of the outer case with the formation of a frame 3 for installing the cooking floor 7. To seal the connection between the inner and the hulls are welded to the joints of the hulls, and in the upper part, not two welds are made, as in the prototype, along the contour of the inner and outer hulls, and one seam is along the contour of the outer hull. Folding the shelves 4, 9, 17, 19 to connect the housings simplifies the manufacturing process of the housing and reduces the risk of defects inherent in welding, since a separate cutting operation of lintel strips is excluded and the number of welds is reduced.

The advantages of the proposed method are most evident in the manufacture of apparatus bodies with a horizontal combustion chamber.

Compare the length of the welds in the apparatus manufactured by the prototype method and the proposed method. The difference between them is equal to:

Dpr-Diz = 4A + B-2H,

Where

DPR - the length of the welds in the apparatus manufactured by the prototype method;

Diz - the length of the welds in the apparatus manufactured by the proposed method;

A is the length of the inner casing (combustion chamber);

B is the width of the inner casing (combustion chamber);

H is the height of the inner casing (distance from the bottom of the ash chamber to the plane of the hob).

Reducing the length of the welds according to the invention takes place under the condition: Dpr-Dis> 0, i.e. provided 2H <4A + B.

For devices with a vertical combustion chamber, usually A = B, therefore Dpr-Diz> 0 at H <2.5 A. Thus, the proposed method has an advantage over the prototype for devices with a height exceeding the length of no more than 2.5 times , i.e. for almost all manufactured devices.

For devices with a combustion chamber of horizontal type A> H, therefore Dpr-Dis> 0. The proposed method has an advantage over the prototype for all devices with a horizontal combustion chamber and leads to the greatest savings in labor costs and materials used.

Depending on the design of the apparatus, the door is then fixed to the combustion chamber 5 and other parts are fixed until the complete design of the apparatus is formed.

Thus, the present invention allows to obtain a technical result - a simplification of the manufacturing process of the housing of the heating apparatus and the reduction of possible manufacturing defects.

Claims (6)

1. A method of manufacturing a housing of a heating apparatus with a cavity for a coolant, including cutting flat parts of the inner and outer shells, forming the inner and outer shells with openings for the furnace and ash chambers by bending and welding the flat parts, installing the inner shell in the outer with the formation of at least at least between their side walls of the cavity for the coolant, as well as the framework for installing the cooking floor and sealing by welding the cavity between the inner and outer cases, characterized in that the bottom and side walls of the inner case are formed from a single flat part by bending it, then the back wall of the inner case is welded to them, while the connection of the cases in the upper part is performed by folding, at least, on the side walls of the inner case of the shelves, which are then welded to the corresponding walls of the outer casing. 2. The method according to claim 1, characterized in that the rear and side walls of the outer casing are formed from a single flat part by bending it. 3. The method according to claim 1, characterized in that the bottom and side walls of the outer casing are formed from a single flat part by bending it. 4. The method according to claim 1, characterized in that the front and side walls of the outer casing are formed from a single flat part by bending it. 5. The method according to claim 1, characterized in that the front, side and rear walls of the outer casing are formed from a single flat part by bending it. 6. The method according to claim 2, characterized in that the connection of the housings from the front side is performed by folding the shelves on the side walls of the outer casing, which are then welded to the elements of the front wall of the outer casing, and in the places of the openings in the furnace and ash chamber to the side walls inner case.

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