The fin is a fundamental component of a heat sink, primarily responsible for the heat transfer process. In production, a fin forming machine is specialized equipment used to continuously process coiled aluminum foil into fins. After the fins are stamped and formed, they must be cut to the designed dimensions. The efficiency and quality of the cutting process directly impact production progress and product quality. The automatic cutting technology for fins in plate-fin heat exchangers centers on the use of integrated mechatronic precision equipment to accurately cut fins to a set length during the continuous forming process, thereby achieving high-efficiency, high-precision, and high-quality production. This technology is a critical link in the automated production line.
I. Core Technology and Working Principle
The automatic cutting system typically consists of a feeding mechanism, a clamping and positioning mechanism, a cutting mechanism, and a control system.
The cutting mechanism is the core component and mainly employs two motion modes:
1.Reciprocating Vertical Shear Type
(1)Description: The upper and lower blades perform vertical relative motion, shearing the material in a scissor-like action.
(2)Characteristics: The structure is relatively straightforward, and this method is widely used.
2.Press-and-Horizontal Shear Type
(1)Description: The upper blade presses down vertically to hold the fin in place, then the lower blade moves horizontally to complete the shear.
(2)Characteristics: The shearing process is more stable, helping to prevent lifting, tilting, or burring of the fin during cutting, resulting in high cut quality.
The positioning and clamping mechanism is crucial for ensuring a clean, flat cut. Setting up clamping devices (e.g., pneumatic cylinders) on both sides of the shear point can effectively prevent fin deformation caused by shear forces.
The control system often utilizes a PLC (Programmable Logic Controller) in conjunction with a servo system to achieve precise control over feed length and synchronized timing between the cutting action and the overall machine operation.
II. Typical Automated Cutting Process
The entire automated cutting process generally follows these steps:
1.Forming and Conveying
(1)The metal strip (e.g., aluminum foil) is continuously roll-formed into a corrugated fin strip by the forming machine.
(2)The conveying mechanism steadily transports the fin strip to the cutting station.
2.Length Setting and Positioning
(1)The feed length is precisely controlled, either by counting fin crests via an encoder or through servo-based length setting.
(2)When the fin reaches the preset length, feeding pauses.
(3)The clamping/pressing mechanism activates, securely holding the fin from above/below or both sides.
3.Cutting Execution
(1)The control system sends a command to actuate the cutting mechanism (e.g., pneumatic cylinder, servo motor with eccentric wheel).
(2)The blades complete one precise cutting cycle.
4.Discharge and Reset
(1)The cut fin individual is collected or transferred to the next station.
(2)The clamping mechanism releases, all components reset, and the system prepares for the next cycle.
III. Technical Advantages and Challenges
This technology can replace traditional manual or semi-automatic shearing primarily due to its significant advantages and its ability to overcome certain process challenges.
Main Advantages:
1.High Efficiency, Stable Cycle Time: Enables continuous production, significantly increasing output capacity.
2.Excellent Consistency in Quality: Produces clean, flat cuts without burrs or curling, which facilitates subsequent vacuum brazing and ensures heat exchanger sealing integrity.
3.High Precision: Achieves accurate length control, reducing material waste.
4.High Degree of Automation: Reduces labor intensity and reliance on operator skill.
Key Challenges and Optimization Directions:
1.Preventing Fin Deformation: Fins with large wave heights or lower rigidity are prone to curling or twisting during cutting. Optimization strategies include improving blade design (e.g., combined insert-type blade bodies), optimizing shear clearance and speed, and enhancing clamping and support near the shear point.
2.Equipment Versatility and Flexibility: The system needs to adapt to fins of different wave heights, pitches, and thicknesses. Some designs improve adaptability through modular, adjustable positioning plates, limit blocks, and clamping jaws.
3.Coordinated System Control: Ensuring precise timing synchronization between feeding, stopping, clamping, and cutting actions during high-speed operation to prevent pulling or jamming of the material.
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