Fin stacking apparatus

Provided is a fin stacking apparatus, which is configured to stack a fin having a flat-plate shape and a plurality of holes formed therein. The fin stacking apparatus includes: a plurality of stacking pins to be inserted into the plurality of holes of the fin; a suction plate which is arranged above the plurality of stacking pins and is configured to suck the fin through a plurality of holes formed in the suction plate; and a roller arranged in a slide region on the suction plate where a flat surface portion of the fin moves.

CROSS REFERENCE TO RELATED APPLICATION

This application is a U.S. national stage application of PCT/JP2016/053637 filed on Feb. 8, 2016, the contents of which are incorporated herein by reference.

TECHNICAL FIELD

The present invention relates to a fin stacking apparatus configured to move and stack a fin for a heat exchanger.

BACKGROUND ART

The term “fin stacking” refers to an action of receiving a fin, which is conveyed from a press machine, through penetration of stacking pins into the fin to stack the fins. The fin stacking is summarized herebelow. A fin having been delivered from a press machine moves on a suction plate, which has a plurality of holes formed therein, while being sucked by the suction plate. After the movement of the fin, the suction plate moves up and down. Along with the up and down movement of the suction plate, the fin is cut by a cutter arranged near an outlet of the press machine, and the fin falls. The fallen fin is received with so-called stacking pins which are bars each having a needle-shaped tip, and fins are sequentially stacked. In a related-art fin stacking apparatus, a fin is moved by a plate, which has a plurality of holes formed therein and is configured to suck the fin (for example, see Patent Literature 1).

CITATION LIST

Patent Literature

Patent Literature 1: Japanese Unexamined Patent Application Publication No. Hei 4-17333

SUMMARY OF INVENTION

Technical Problem

In the fin stacking apparatus disclosed in Patent Literature 1, when the suction plate sucks a fin to move the fin, there may occur a phenomenon which is called buckling, in which the fin is bent in the course of movement. When the fin moves on the suction plate, a frictional force is generated between the suction plate and the fin. The fin is moved by a pushing force from the press machine, thus a part of the plate with the generated frictional force cannot move further. As a result, there is a case where the fin is bent between a driving point and a point of action of the frictional force.

The present invention has been made to solve the above-mentioned problem, and has an object to provide a fin stacking apparatus capable of moving a fin without causing buckling when the fin moves on a suction plate.

Solution to Problem

According to one embodiment of the present invention, there is provided a fin stacking apparatus, which is configured to stack a fin having a flat-plate shape and a plurality of holes formed therein, including; a plurality of stacking pins to be inserted into the plurality of holes of the fin; a suction plate which is arranged above the plurality of stacking pins and is configured to suck the fin through a plurality of holes formed in the suction plate; and a roller arranged in a slide region on the suction plate where a flat surface portion of the fin moves.

Advantageous Effects of Invention

According to the fin stacking apparatus of one embodiment of the present invention, the roller is provided in the region where the flat surface portion of the fin moves and slides. Thus, a frictional force to be generated between the fin, which moves on the suction plate, and the suction plate can be reduced, thereby being capable of moving the fin without causing buckling.

DESCRIPTION OF EMBODIMENTS

FIG. 1is a front view of a fin stacking apparatus according to Embodiment 1 of the present invention. A fin stacking apparatus1includes a fin stacking unit20and a suction unit10which is arranged above the fin stacking unit20in a Z-axis. The fin stacking unit20includes a base21, an elevator22, and a plurality of stacking pins23. The stacking pins23are installed on the base21so as to penetrate through the elevator22and have respective tips thereof oriented upward in the Z-axis. The suction unit10includes a suction plate12, rollers13, a suction box14, and a blower15. The suction box14is arranged on the suction plate12. The blower15is arranged on the suction box14.

The suction plate12has a plurality of holes for sucking a fin30. Further, the suction plate12has a plurality of holes for bringing the rollers13into contact with the fin30. The suction box14is arranged on the suction plate12to cause suction by the blower15, which is arranged on the suction box14, to act entirely on the suction plate12. The elevator22is positioned around upper portions of the stacking pins23, and fallen fins30are sequentially stacked on the elevator22. At this time, an uppermost surface of stacked fins31is detected by a sensor (not shown), and the elevator22is lowered so as to maintain the uppermost surface at a certain position.

FIG. 2is a perspective view of the roller of the fin stacking apparatus according to Embodiment 1 of the present invention. The roller13includes a cylindrical portion40and flange portions41formed on side surfaces of the cylindrical portion40. The rollers13are arranged so that contact surfaces42are brought into contact with a region where a flat surface portion of the fin30moves and slides on the suction plate12. Therefore, the rollers13cause the flange portions41to be partially exposed through the holes of the suction plate12. It is preferred that the rollers13be made of the same material as the fin30. For example, the material may include aluminum or aluminum alloy. Materials of the rollers13and the fin30are the same, therefore being capable of preventing adhesion of substances which are different from the fin30to the surface of the fin30. However, the material of the rollers13may be different from that of the fin30in consideration of abrasion resistance achieving tolerance for a long-time use, contact property with the fin30, or easiness in formation of grooves in the contact surface. Further, the rollers13necessarily need not be made of a single material.

FIG. 3is a top view of the fin of the fin stacking apparatus according to Embodiment 1 of the present invention. As in the fin30illustrated inFIG. 3, the fin30which is conveyed from a press machine2is divided along a direction parallel to a advancing direction, that is, an X-direction. Further, the fin30has stacking holes32formed at predetermined intervals along the advancing direction, that is, the X-direction. The fin30has flat surface portions33between both edges of the fin30in a Y-direction and the stacking holes32.

Next, an operation is described with reference toFIG. 1toFIG. 3. First, suction by the blower15is started. The suction box14causes the suction by the blower15to act entirely on the suction plate12. Next, the press machine2is started to deliver the fin30from the press machine2.

FIG. 4andFIG. 5are views for illustrating a fin conveyance mechanism for conveyance of the fin by the press machine to the fin stacking apparatus according to Embodiment 1 of the present invention.FIG. 4andFIG. 5are partial enlarged views of an inside of the press machine, and detailed illustration thereof is omitted. The movement of the fin30on the suction plate12is performed by the pushing force of the press machine2.

Herein, a change in speed during the movement of the fin30is described. The delivery of the fin30by the press machine2is performed by a link mechanism using cams.FIG. 4is an enlarged view for illustrating the link mechanism arranged in the press machine2.FIG. 5is a view for illustrating a state after rotation of cams51ofFIG. 4. The conveyance of the fin30by the press machine2is performed through repetition of the state ofFIG. 4and the state ofFIG. 5. Therefore, the fin30repeats acceleration and deceleration each time a fin conveyance portion50performs a reciprocating motion. The fin30moves with repetition of acceleration and deceleration each time the cams51of the press machine2perform one cycle of operation.

FIG. 6is a partial front view for illustrating the fin stacking apparatus according to Embodiment 1 of the present invention during operation.FIG. 7is a partial enlarged perspective view for illustrating the fin stacking apparatus according to Embodiment 1 of the present invention during operation. InFIG. 7, the suction plate12is omitted. The fin30delivered from the press machine2moves in the advancing direction under a state of being sucked to a lower surface of the suction plate12. At this time, the flange portions41of the rollers13are brought into contact with the flat surface portions33of the fin30at the contact surfaces42being side surfaces, which are cylindrical peripheral surfaces of the flange portions41as illustrated inFIG. 7.

The fin30stably moves on the suction surface of the suction plate12by the rollers13. The fin30having been delivered to a predetermined length is cut by a cutoff unit3. Substantially at the same timing with the cutting, the suction operation by the blower15is stopped, and immediately thereafter, the suction plate12moves up and down in a vertical direction. After that, the fin30falls while being guided so that the stacking pins23penetrate through the stacking holes32illustrated inFIG. 3. Then, the fin30is placed on the elevator22. The elevator22is positioned around an upper portion of the stacking pin23, and the fallen fins30are sequentially stacked on the elevator22. At this time, an uppermost surface of the stacked fins31is detected by a sensor (not shown), and the elevator22is lowered so that the uppermost surface is maintained at a certain position. The above-mentioned operation is repeated to proceed stacking.

In a case where a length of the fin30increases in the X-direction inFIG. 3, a frictional force, which is generated between the suction plate12and the fin30during the movement, increases. However, any length of the fin30can be employed by sequentially increasing the number of rollers13to be installed by the amount of increase in length of the fin30. The same also applies with respect to an increase in number of fins30in a row direction.

As described above, the rollers13rotate during the operation of the fin stacking apparatus to reduce friction between the suction plate12and the fin30. Accordingly, buckling of the fin30during the movement can be prevented so that stacking can be performed without any error. In the related-art fin stacking apparatus, there is a case where buckling may occur during the movement of the fin30. As a result, there has been a disadvantage that the stacking pins23are not placed in the stacking holes32during the operation of the fin stacking apparatus, or that the fin30collides with the stacking pins23during the movement. However, in the fin stacking apparatus according to Embodiment 1 of the present invention, such a phenomenon can be prevented by rotating the rollers13.

FIG. 8is a top view of a fin stacking apparatus according to Embodiment 2 of the present invention. InFIG. 8, the suction box14and the blower15are omitted. As illustrated in the top view ofFIG. 8, motors16are connected to the rollers13, and the rollers13are rotated by the motors16being drive sources. Further, the motors16are controlled in rotation speed by a motor controller17. A position of the motor controller17may be set at any position, and is not limited to the position illustrated inFIG. 1. In the fin stacking apparatus according to Embodiment 1 of the present invention, the rollers13are freely rotated in accordance with the movement of the fin30in contact with the rollers13. In Embodiment 2 of the present invention, description is made of a configuration in which the motors16are used to rotate the rollers13always at a constant speed to perform stacking. Other configurations of the fin stacking apparatus1are the same as those illustrated inFIG. 1toFIG. 7.

First, the rollers13are rotated by driving of the motors16. At the same time, the blower15starts suction. The suction box14causes the suction by the blower15to act entirely on the suction plate12. Next, the press machine2is started to deliver the fin30from the press machine2.

When the fin30is moved, the motor controller17controls the motors16so that the rollers13are always rotated at a speed which is equal to a maximum value of the moving speed of the fin30by the press machine2. The motors16rotate the rollers13in a roller rotation direction44illustrated inFIG. 6andFIG. 7, and the rollers13transmit a driving force (propulsion force) to the fin30in a fin advancing direction X1.

FIG. 9is a graph for showing a relationship between a conveyance speed for conveyance of the fin by the press machine and a rotational speed by the rollers in the fin stacking apparatus according to Embodiment 2 of the present invention. In a case where the moving speed of the fin30by the rollers13is lower than the conveyance speed by the press machine2, there is a fear in that the contact surfaces42of the rollers13generate resistance against the movement of the fin to cause buckling. Thus, it is necessary to have a configuration by which the moving effect by the rollers13can be obtained in any state of the conveyance speed for conveyance of the fin30by the press machine2. Therefore, in Embodiment 2 of the present invention, as illustrated inFIG. 9, the rotational speed of the rollers13with respect to the conveyance speed for conveyance of the fin30by the press machine2is controlled to be at a constant speed with a maximum value of the conveyance speed by the press machine2as a reference. Through the control method described above, a sufficient moving effect for movement of the fin30by the rollers13can be obtained.

As described above, the rollers13are always rotated at a constant rotation speed during the operation of the fin stacking apparatus to always perform the movement of the fin30by the press machine2. As a result, buckling of the fin30during the movement can be prevented, and stacking can be performed without any error. In the related-art fin stacking apparatus, there has been a case of causing buckling of the fin30during the movement, and there has been a disadvantage that the stacking pins23are not placed in the stacking holes32during the operation of the fin stacking apparatus, or that the fin30collides with the stacking pins23during the movement. However, in the fin stacking apparatus according to Embodiment 2 of the present invention, such a phenomenon can be prevented by always rotating the rollers13.

In the fin stacking apparatus according to Embodiment 2 of the present invention, stacking is performed under the state in which the rotational speed of the rollers13is always constant. In Embodiment 3 of the present invention, description is made of a configuration in which the rotational speed of the rollers13is changed during stacking. The configuration and operation of the fin stacking apparatus1itself is unchanged from those of Embodiment 2 of the present invention, and only the control method for the rotation speed of the motors16through use of the motor controller17is changed for use.

In Embodiment 2 of the present invention, as illustrated inFIG. 9, the rotational speed of the rollers13with respect to the conveyance speed for conveyance of the fin30by the press machine2is controlled to be at a constant speed with a maximum value of the conveyance speed by the press machine2as a reference. However, there may occur a difference between the conveyance speed by the press machine2and the rotational speed by the rollers13when the conveyance speed by the press machine2is not maximum. The sufficient moving effect can be obtained even in such a state. However, there is a fear of any disadvantage such as abrasion of the contact surfaces42of the rollers13due to the difference in the moving speed. Thus, it is assumed that the possibility of causing the disadvantage is reduced as the conveyance speed by the press machine2is close to the rotational speed by the rollers13, thereby obtaining the moving effect by the rollers13in a stable state.

FIG. 10is a graph for showing a relationship between a conveyance speed for conveyance of the fin by the press machine and a rotational speed by the rollers in a fin stacking apparatus according to Embodiment 3 of the present invention. Through the control of the motors16, as illustrated inFIG. 10, the rotation speed of the motors16is changed in accordance with the change in conveyance speed for conveyance of the fin30by the press machine2to change the rotational speed of the rollers13, thereby being capable of achieving the movement of the fin30in a more stable state. For example, the control for the rotation speed of the motors16may be performed in accordance with the moving speed of the fin30through use of a sensor (not shown). Alternatively, the change in conveyance speed by the press machine2may be obtained in advance as data, and the data may be used for the control for the rotation speed of the motor16. Further, the plurality of rollers13, which are arrayed in the slide region of the suction plate12where the flat surface portion of the fin moves, may be set in advance so that the rotational speed of the rollers13is increased in the moving direction of the fin. That is, the rollers have rotational speeds different from each other.

As described above, the movement of the fin30can be more stabilized by changing the rotation speed of the motor16in accordance with the change in conveyance speed for conveyance of the fin30by the press machine2during the operation of the fin stacking apparatus to change the rotational speed of the rollers13. Through the more stabilized movement of the fin30, buckling of the fin30during the movement can be prevented, and stacking can be performed without any error.

FIG. 11is a view for illustrating an example of grooves added to the contact surfaces of the rollers of the fin stacking apparatus according to Embodiment 4 of the present invention. In Embodiments 1 to 3 of the present invention, the contact surfaces42of the rollers13are flat surfaces. In Embodiment 4 of the present invention, description is made of a case where grooves43are added to the contact surfaces42of the rollers13. The configuration and operation of the fin stacking apparatus itself are unchanged, and only the contact surfaces42of the rollers13are changed for use.

The rollers13of the fin stacking apparatus1give a driving force in the fin advancing direction X1to the fin30, which moves on the suction plate, by a frictional force between the contact surfaces42and the contact surfaces of the fin30. The grooves43are added to the contact surfaces42of the rollers13to increase the frictional force with respect to the contact surfaces of the fin30, thereby giving a larger driving force to the fin30. For example, the grooves43having an inclination with respect to a Y-axis is formed at equal intervals in the contact surfaces42of the rollers13as illustrated inFIG. 11.

Protrusions and recesses are formed in the contact surfaces42of the rollers13. Thus, it is assumed that the frictional force generated between the rollers13and the fin30is increased, and the rollers13can accurately hold the fin30. Therefore, the moving effect by the rollers13with respect to the conveyance of the fin30by the press machine is increased, thereby further improving the stackability.

The present invention is not limited to the above-mentioned embodiments. Further, components of the embodiments include components which are replaceable and are obvious to be replaced while maintaining the identity of the invention. Further, the plurality of modification examples described in the embodiments can be combined as appropriate within the range which is obvious to a person skilled in the art. For example, in the embodiments of the present invention, the flange portions are formed on side surfaces of the cylindrical portion of the roller. However, a cylindrical shape having only the cylindrical portion may also be employed. Further, the grooves having an inclination with respect to the Y-axis and being arranged at equal intervals in Embodiment 4 of the present invention may be parallel to the Y-axis.

REFERENCE SIGNS LIST