Technology of radiator production
Technology of radiator production includes the following technological processes for production of the main parts, units, etc.:
- production of supporting plates for tanks, uprights and other parts by cold pressing, machine work and welding;
- production of radiator cooling tubes on tube rolling machines;
- production of cooling plates, strips and assembling of radiator cores on automatic assembling machines, semi-automatic devices and assembly stands;
- fixing of supporting plates;
- soldering of radiator cores in special thermoovens;
- soldering of supporting plates on special stands;
- assembling, assembling-soldering of radiators on special stands for assembling;
- chemical treatment of cores and radiators in units of conveyer type;
- test on leakproofness on stands for hydro-testing;
- heat treatment in gas ovens of standardization and drying;
- painting with enamel or water paint by compressed-air atomizing, with polymeric powder paint by tribostatic sputtering in the chamber, then polymerization in the;
- packing of integrated radiator products into multiway metal package, wooden boxes, pallets and crimped cardboard.
Main technologies that are used in manufacturing: cold pressing, machine work, moulding of plastic, soldering, welding, assemblin, chemical treatment, galvanizing, painting and packing.
The new production technologies in our enterprise are: production of cooling plates («Splitter-Fin”, baking of radiator cores inactive gas–flux sphere, test of radiators on leakproofness by dry method, painting of radiators with powder polymeric paint, usage of low-temperature solders and less acid-active fluxes.
Production of cooling plates
Production of cooling plates (Splitter-Fin) is made on the line for corrugating and soldering of copper strip with thickness 25-40 mkm of the firm “Outocumpu” (Sweden) and includes the following:
- strip decoiling with unit - collector
- strip end welding with welding machine
- strip length cutting on 2-4 strips (separate for inner and outer strips of plate)
- production of plate: corrugating, forming, application of soldering paste, soldering with heating rollers
- coiling of finished plate on the coil
- cutting of plate
Average productivity of the unit for plate production is about 30-60 м/мин. Technology of the firm “Outocumpu” is unique, and there no analogues in Russia.
Painting of radiators
Painting of radiators is effected with polymeric powder paint in special chambers of tribostatic sputtering. The process of painting with polymeric powder paint is effected be tribostatic sputtering and is base on the electrization of paint’s elements, their transportation by compressed air to the painted product, forming of covering at temperature 120-2000С – fusion and polymerization in electrothermal unit.
The paticular features and advantages of usage of this painting technology: high anticorrosion properties, resistance to the acids and alkali, broad bandwidth of covering thickness and themperature range of work -60…+150оС, durability on mechanical effects, high ornamentability.
Moreover technologe of polymeric powder painting is zero-emission, due to reusability of powder, efficient and ecologically clean.
Soldering of radiator cores
Soldering of radiator cores take place in soldering oven in active gas sphere. Simultaneous soldering of 4 cores, type of heating – convection. The machine for soldering of core; productiveness – 210 pcs. in a shift.
Moreover we use new fluxes and solders at soldering process, such as:
- non-corrosive flux ФНП2, ФНП7, ФНП8
- paste-like solder ПОС50 (firm “VAYKO LTD”).
Fluxes are made as water solution (concentrate). Flux dousn’t consist of zink chloride and other chlorides. Hence cleaning and neutralization is not required after soldering. Non-corrosive fluxes are made on the base of salts of hydrobromic acid and ammines and there are no corrosion-active remains after soldering. It makes possible to improve employees’ conditions of work and ecology of production.
