Heat Exchanger Industry
A need arose in the automobile heat exchanger industry in the late 1970’s to develop a new measurement system for gauging radiator and heater core louvered cooling fins. The specific gauging requirement was for measuring louver angle, quickly and accurately.This measurement is important because proper louver angle insures better air flow with optimum heat transfer. Such accuracy requirements were driven by the tighter engineering specifications needed to accommodate vehicle styling changes (i.e., smaller frontal areas and lighter weights materials);and the need for more efficient cooling of high performance engines.
In 1979, Jodon developed the Louver Angle Checking System (LAC-1000). It was quickly adopted by Original Equipment Manufacturers (OEMs) throughout the industry. Today, the Jodon LAC-2000,the new P.C. version of the original Louver Angle Checking System, is in use at virtually every OEM production facility in the world.
Since then there have been other “difficult to measure” parts for which Jodon has been asked to develop systems. All of these measurement systems use non-contact technology and computers (PCs) to control the sensors and collect the data. The computer capability of each of Jodon’s systems permits the incorporation of Statistical Process Control (SPC) programming. The SPC helps engineers to control the assembly line process very accurately.
In today’s high-tech manufacturing environment, it is essential that SPC capabilities be readily available and easy to use. Such is the case with each of the Jodon heat exchanger measurement systems. Compliance with virtually all quality systems, including the ISO & QS-9000 Series of Manufacturing Standards, is greatly enhanced using these state-of-the-art non-contact measurement systems.
Louver Angle Measurement System
The Model LAC-2000 system is an off-line gauge that measures louver angle and the percent bulk transmission. The percent bulk transmission is the amount of light measured at the peak angle. This is used to detect when excess burrs have accumulated, which would restrict air flow. This gauge is used to inspect new form rolls, to align the form rolls properly (phase or timing) in the fin machine and to monitor the wear of the form rolls. The daily use of this system provides inspectors and maintenance personnel with the capability to know when a fin machine is operating less than satisfactorily. A typical fin angle test requires approximately 1 minute to complete.
Convolution Profiling System
With automated core building machines commonly in use, tight dimensional tolerances have become common. These tight dimensional tolerances can quickly result in stackup interference during assembly, or poor tube-to-fin bonding during brazing. To insure that the convoluted fin conforms to specifications, a system was designed by Jodon to gauge all key mechanical parameters of the fin. The off-line system, called the Convolution Profiling System, Model CPS-2000, accepts a convoluted fin strip with a length equal to 2-3 revolutions of the form roll. The CPS-2000 is used to qualify new fin machines and form rolls, analyze brazing problems, and perform daily height checks. After making a few keyboard entries, the system’s three motorized linear stages and two laser sensors are activated to precisely measure the convoluted strip.Parameters such as convolution height, radius of curvature, convolution density, and convolution symmetry (slant) are gauged and displayed. Those measurements are made at one to three planes across the face of the strip, on as many convolutions as the operator selects. Depending upon the number of convolutions to be inspected and the number of passes across the strip, a CPS-2000 test requires 1-5 minutes to complete. Once started, the entire process is fully automatic.
Tube Profiling System
To ensure proper assembly of the heat exchanger core, the cooling tubes must also conform to tight tolerances. Failure to meet precise tolerances can result in mechanical interference during core assembly, leaks in the tube-to-header bond, or poor tube-to-fin bonding during the brazing operation.The Tube Profiling System, Model TPS-2000, is an off-line gauging system designed to automatically measure important dimensional aspects of the tube. It is industrially packaged so that it can be next to the tube millfor immediate feedback to the operator. On an audit basis it measures tubelength, height, radii of curvature (2), lands (2), and crown (3 parameters). Once activated, the system’s two motorized linear stages, one motorized rotary stage, and the laser sensor automatically measure the tube and present the results on the PC monitor. A typical tube profile test is completed in approximately 1 minute.
Hand-held Convolution Counter
Model CFC-201
The Jodon Personal Convolution Counter offers a new innovation in field usage. This portable/mobile unit is convenient in audit checking the convolution (or fin) count of convoluted strips.It is similarly useful in making tub-and-plate core assembly fin count checks. It is battery powered.
Calibration and Machine Certification
The entire family of heat exchanger gauges produced by Jodon includes provisions for automatic machine calibration,or operator installed calibration devices. All printouts reflect the date and time that calibration procedures were performed. Automatic drop-down menus prompt the operator when unscheduled calibrations may be necessary.To satisfy certain quality and process standards (e.g., ISO-9000) annual machine re-certifications may be required. Jodon maintains a technical staff for performing those important worldwide quality system requirements as an optional service to their customers.
For Quality Gauging Systems, Call Jodon!
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