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Computer Assisted Induction
   Aluminum Brazing
R. C. Goldstein, V. S. Nemkov, R. T. Ruffini
   Centre for Induction Technology, Inc.
            www.induction.org


                                               1
Overview
• Automotive Heat Exchangers
• Pipe to Tube Brazing
• Computer Simulation of Induction Brazing
  of Pipe to Tube Joints
• Optimization of Induction Coil
• Conclusions

                                             2
Automotive Heat Exchangers
• Used for thermal
  management in many
  areas of the car
  –   Oil Coolers
  –   Powertrain
  –   Air Conditioning
  –   Dehumidifiers
  –   etc.


                               3
Heat Exchanger Manufacturing
• Assembling of heat exchanger bodies
• Brazing of body in a controlled atmosphere
  furnace
• Attachment of various components for
  connection to different cars
  – Nylon tanks
  – Aluminum pipes with connection blocks (most
    common)

                                                  4
Pipe to Tube Brazing
• Clamshell Inductors
  – Problems with electrical
    contacts
  – Complicated mechanical design
• “Horseshoe-Hairpin”
  Inductors
  – Non-uniform heating in
    circumference
  – Complicated magnetic field
    distribution

                                    5
Pipe to Tube Induction Brazing Installation
      using “Horseshoe-Hairpin” Coil
                          Connection Block


                          Pipe

                          Joint
                          Fluxtrol A Magnetic
                          Flux Controller
                          Copper Coil

                          Tube

                          Header
                          Body
                                                6
Computer Simulation of Pipe to
          Tube Brazing
• Not possible to simulate all processes due to
  process complexity
• 2-D approach can not be used for
  Horseshoe-Hairpin inductors
• 3-D electromagnetic simulation used to
  study heat sources (most controllable factor)


                                              7
1/4 of a Heat Exchanger Brazing
              Coil
              Pipe
                      Tube

                      Fluxtrol A Magnetic
                      Flux Controller

                     Copper Coil



                             Heat Exchanger
                             Header

                                              8
Main Variables in this System

•   Coil and Concentrator Dimensions
•   Coil Position
•   Contact in the Brazing Joint
•   Coil Crossover


                                       9
Different Crossovers


+      +          +        .



.       .         .        +




                               10
Existing Induction Coil with
    Diagonal Crossover




No Contact      Good Contact
                               11
Existing Induction Coil with
     Horizontal Crossover




No Contact       Good Contact
                                 12
Current Density Distribution for
  Optimized Induction Coil




                                   13
New Induction Coil




                     14
Conclusions
• Induction aluminum brazing of heat exchanger
  joints can be a very complicated process
• 3-D computer electromagnetic simulation
  provided good information regarding the heating
  process
• Optimized induction coil and process was more
  robust and produced higher quality joints
• Further study should be made using 3-D coupled
  electromagnetic plus thermal simulation

                                                    15

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Aluminum Brazing Presentation Utilizing Magnetic Field Controllers

  • 1. Computer Assisted Induction Aluminum Brazing R. C. Goldstein, V. S. Nemkov, R. T. Ruffini Centre for Induction Technology, Inc. www.induction.org 1
  • 2. Overview • Automotive Heat Exchangers • Pipe to Tube Brazing • Computer Simulation of Induction Brazing of Pipe to Tube Joints • Optimization of Induction Coil • Conclusions 2
  • 3. Automotive Heat Exchangers • Used for thermal management in many areas of the car – Oil Coolers – Powertrain – Air Conditioning – Dehumidifiers – etc. 3
  • 4. Heat Exchanger Manufacturing • Assembling of heat exchanger bodies • Brazing of body in a controlled atmosphere furnace • Attachment of various components for connection to different cars – Nylon tanks – Aluminum pipes with connection blocks (most common) 4
  • 5. Pipe to Tube Brazing • Clamshell Inductors – Problems with electrical contacts – Complicated mechanical design • “Horseshoe-Hairpin” Inductors – Non-uniform heating in circumference – Complicated magnetic field distribution 5
  • 6. Pipe to Tube Induction Brazing Installation using “Horseshoe-Hairpin” Coil Connection Block Pipe Joint Fluxtrol A Magnetic Flux Controller Copper Coil Tube Header Body 6
  • 7. Computer Simulation of Pipe to Tube Brazing • Not possible to simulate all processes due to process complexity • 2-D approach can not be used for Horseshoe-Hairpin inductors • 3-D electromagnetic simulation used to study heat sources (most controllable factor) 7
  • 8. 1/4 of a Heat Exchanger Brazing Coil Pipe Tube Fluxtrol A Magnetic Flux Controller Copper Coil Heat Exchanger Header 8
  • 9. Main Variables in this System • Coil and Concentrator Dimensions • Coil Position • Contact in the Brazing Joint • Coil Crossover 9
  • 10. Different Crossovers + + + . . . . + 10
  • 11. Existing Induction Coil with Diagonal Crossover No Contact Good Contact 11
  • 12. Existing Induction Coil with Horizontal Crossover No Contact Good Contact 12
  • 13. Current Density Distribution for Optimized Induction Coil 13
  • 15. Conclusions • Induction aluminum brazing of heat exchanger joints can be a very complicated process • 3-D computer electromagnetic simulation provided good information regarding the heating process • Optimized induction coil and process was more robust and produced higher quality joints • Further study should be made using 3-D coupled electromagnetic plus thermal simulation 15