# Patent

## Title
Tube expander for heat exchanger coil units

## Abstract

A tube expander for heat exchanger coil units according to which a tubular expansion process is conducted. In one aspect, the tube expander includes a fixture, which includes a back unit and first and second door assemblies movably connected thereto. One or more heat exchanger coil units are adapted to be connected to each of the first and second door assemblies. In another aspect, the fixture is adjustable to accommodate different heat exchanger coil units. In yet another aspect, the tubular expansion process is not permitted when the first or second door assembly is closed and a sensor does not sense the presence of a latch bar.

## Background
TECHNICAL FIELD
The present disclosure relates in general to heat exchanger coil units and, in particular, to a tube expander for heat exchanger coil units.
BACKGROUND
A tube expander may be a ram-driven machine typically used in the manufacture of heat exchanger components. The tube expander uses multiple tipped expander rods to form interference fits between tubes and a stack of fins by expanding the tubes into the fins. The finished assembly is often referred to as a slab or coil, and may also be referred to as a heat exchanger coil unit (or “coil unit”). The coil unit may have an initial configuration in which it is a loose assembly of tubes and fins, and a finished configuration in which the tubes are expanded and form interference fits between the tubes and fins. In a vertical tube expander, the coil unit, in its initial configuration that includes a loose assembly of tubes and fins, is placed under a collection of vertically oriented, fixed center, tipped expander rods. Upon actuation, the tipped expander rods are rammed into the open ends of the tubes in the assembly, and the tubes are expanded. The tube ends are flared, the expander rods are withdrawn, and the coil unit, now in its finished configuration, is removed and replaced with another loose tube-and-fin assembly the tubes of which are ready to be expanded.
In some cases, one or more sets of individual doors are provided with the vertical tube expander, which doors vary in height and are not connected to the vertical tube expander. Each door is used to secure the loaded, or installed, position of the coil unit(s) within the vertical tube expander. An operator may “square” a set of door mounting points, snug side constraints to the coil unit(s), and adjust the door hinges for a proper fit. However, after the coil unit(s) have been installed within the vertical tube expander, an operator must wait until the tubular expansion process within the coil unit(s) is completed and the coil units are in their finished configuration before removing the coil units and then using the door to secure the loaded, or installed, position of one or more additional coil units (in their initial, loose tube-and-fin configuration) within the vertical tube expander. Such a “load-then-wait” process increases the time it takes to manufacture several coil units. Further, if the door is not properly locked, the door may accidentally open during the tubular expansion process, that is, during the ramming of the tipped expander rods into the respective open ends of the tubes in the loose assembly and the subsequent expansion of the tubes. Additionally, for each coil unit having a different height, width, or depth, the vertical tube expander must be reconfigured to accept and contain the associated loose tube-and-fin assembly such that the tubes are precisely located, relative to the tipped expander rods. Typical reconfiguration procedures increase the time it takes to manufacture coil units having variances in height, width, or depth.
Therefore, what is needed is an apparatus, kit, system, or method that addresses one or more of the above-described issues, and/or one or more other issues.



BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a tube expander for heat exchanger coil units according to an exemplary embodiment.
FIG. 2 is a perspective view of a fixture of the tube expander of FIG. 1 according to an exemplary embodiment, the fixture including a plurality of back units, a plurality of left door units, and a plurality of right door units.
FIG. 3 is a perspective view of one of the back units of the fixture of FIGS. 1 and 2, according to an exemplary embodiment.
FIGS. 4 and 5 are additional perspective views of the back unit of FIG. 3, according to an exemplary embodiment.
FIGS. 6 and 7 are perspective views of a right hinge plate assembly of the back unit of FIGS. 3-5, according to an exemplary embodiment.
FIG. 8 is a perspective view of one of the right door units of the fixture of FIGS. 1 and 2, according to an exemplary embodiment.
FIGS. 9 and 10 are additional perspective views of the right door unit of FIG. 8, according to an exemplary embodiment.
FIG. 11 is a front elevational view of the fixture of FIGS. 1 and 2, according to an exemplary embodiment.
FIG. 12 is a top plan view of the fixture of FIGS. 1, 2, and 11, according to an exemplary embodiment.
FIG. 13 is a right side elevational view of the fixture of FIGS. 1, 2, 11, and 12, according to an exemplary embodiment.
FIG. 14 is a left side elevational view of the fixture of FIGS. 1, 2, and 11-13, according to an exemplary embodiment.
FIG. 15 is a diagrammatic illustration of components of the tube expander of FIG. 1, according to an exemplary embodiment.
FIG. 16 is a flow chart illustration of a method of expanding tubes in respective ones of a plurality of heat exchanger coil units, according to an exemplary embodiment.
FIG. 17 is a perspective view of the fixture of FIGS. 1, 2, and 11-14 during a step of the method of FIG. 16, according to an exemplary embodiment.
FIGS. 18a-18e are diagrammatic views of the fixture of FIGS. 1, 2, 11-14, and 17 during different steps of the method of FIG. 16, according to respective exemplary embodiments.
FIG. 19 is a flow chart illustration of a method of securing a door assembly, according to an exemplary embodiment.
FIG. 20 is a sectional view of components of the tube expander of FIG. 1 during a step of the method of FIG. 19, according to an exemplary embodiment.
FIG. 21A is flow chart illustration of a method of adjusting the fixture of FIGS. 1, 2, and 11-14 to accommodate coil units of different sizes, according to an exemplary embodiment.
FIG. 21B is a perspective view of a coil unit and dimensions thereof, according to an exemplary embodiment.
FIG. 22 is a perspective view of the fixture of FIGS. 1, 2, 11-14, and 17 during a step of the method of FIG. 21A, according to an exemplary embodiment.
FIG. 23 is a top plan view of a portion of the right door unit of FIGS. 8-10 during another step of the method of FIG. 21A, according to an exemplary embodiment.
FIG. 24 is an elevational view of the hinge plate assembly of FIGS. 6 and 7 during the other step of the method of FIG. 21A, according to an exemplary embodiment.
FIG. 25 is a perspective view of a portion of the right door unit of FIGS. 8-10 during yet another step of the method of FIG. 21A, according to an exemplary embodiment.
FIGS. 26a and 26b are perspective views of a fixture of the tube expander of FIG. 1, according to another exemplary embodiment.
FIG. 27 is a perspective view of a fixture of the tube expander of FIG. 1, according to yet another exemplary embodiment.
FIG. 28 is a diagrammatic illustration of components of the fixture of FIG. 27 and the tube expander of FIG. 1, according to an exemplary embodiment.
FIG. 29 is a top plan view of the fixture of FIG. 27, according to an exemplary embodiment.
FIG. 30 is a front elevational view of a portion of the fixture of FIGS. 27 and 29, according to an exemplary embodiment.
FIG. 31 is a left side elevational view of a portion of the fixture of FIGS. 27, 29, and 30, according to an exemplary embodiment.
FIG. 32 is a diagrammatic illustration of a node for implementing one or more exemplary embodiments of the present disclosure, according to an exemplary embodiment.



DETAILED DESCRIPTION
In an exemplary embodiment, as illustrated in FIG. 1, a tube expander for heat exchanger coil units is generally referred to by the reference numeral 10 and includes a frame 12 mounted on a base 14. An actuator 16 is connected to the frame 12. The right door actuator 16 includes a rod 16a, which is adapted to reciprocate relative to a cylinder 16b. To so reciprocate, the rod 16a is adapted to extend out from, and retract into, an end of the cylinder 16b. In an exemplary embodiment, the actuator 16 is a hydraulic actuator. In an exemplary embodiment, the actuator 16 is a ram-style actuator. A pressure plate 18 is connected to the rod 16a of the actuator 16. The pressure plate 18 is adapted to move vertically in response to the movement of the rod 16a. The frame 12 includes vertically-extending guide rods 20a and 20b, which extend through the pressure plate 18. The rods 20a and 20b are adapted to guide the pressure plate 18 during its vertical movement.
A plurality of expander rods 22 extend downward from the pressure plate 18. Although not shown, the respective lower end portions of the expander rods 22 are tipped, that is, include downwardly-directed bullet-shaped ends that are adapted to expand tubes of a tube-and-fin assembly so that interference fits are created, between the tubes and the fins, in response to the vertical downward movement of the rod 16a, the pressure plate 18, and the expander rods 22. The expander rods 22 extend through a plurality of openings (not shown), which are formed in a stationary guide plate 24, so that the lower end portions of the expander rods 22 are aligned with the tubes to be expanded. In an exemplary embodiment, the expander rods 22 extend through one or more additional guide plates (not shown), which are vertically positioned between the pressure plate 21 and the stationary guide plate 24. In an exemplary embodiment, the guide rods 20a and 20b are connected to the stationary guide plate 24.
A horizontal support 26 is mounted to the base 14 via downwardly-extending structural members 28. The frame 12 further includes parallel-spaced vertical supports 30a and 30b. T-tracks 32a and 32b are connected to the vertical supports 30a and 30b, respectively (the T-track 32a is shown in FIG. 2). In several exemplary embodiments, each of the T-tracks 32a and 32b is omitted in favor of a single, constrained, replaceable bar including a plurality of vertically-spaced threaded holes formed therein. An upper shroud 34 is connected to the frame 12 and/or the stationary guide plate 24. The upper shroud 34 includes a plurality of openings (not shown) formed therethrough; the openings are aligned with respective ones of the openings formed through the stationary guide plate 24 so that the expander rods 22 are permitted to extend through the upper shroud 34. In an exemplary embodiment, at least one of the stationary guide plate 24 and the upper shroud 34 is omitted from the tube expander 10. Post assemblies 36a and 36b are mounted on the base 14 and include rods 36aa and 36ba , respectively, which rods extend upwards and are connected to the upper shroud 34.
A fixture 40 is connected to the frame 12 and is vertically disposed between the upper shroud 34 and the horizontal support 26. The fixture 40 includes back units 42a, 42b, and 42c, a left door assembly 44, and a right door assembly 46. The back units 42a, 42b, and 42c are connected to the T-tracks 32a and 32b, thereby connecting the fixture 40 to the frame 12. The fixture 40 defines an internal region 48, which is positioned below the expander rods 22. Each of the back units 42a, 42b, and 42c at least partially defines the internal region 48. Representative heat exchanger coil units, or coil units, 50a and 50b are connected to the left door assembly 44. As will be described in further detail below, the coil units 50a and 50b are adapted to be loaded or installed in the internal region 48 in order to undergo a tubular expansion process using the expander rods 22. Two coil units identical to the coil units 50a and 50b are adapted to be connected to the right door assembly 46, and are adapted to be loaded or installed in the internal region 48 in order to undergo a tubular expansion process using the expander rods 22. As will be described in further detail below, instead of the coil units 50a and 50b, one or more other types or sizes of coil units may be connected to the left door assembly 44. Likewise, instead of coil units that are identical to the coil units 50a and 50b, one or more other types or sizes of coil units may be connected to the left door assembly 44. In several exemplary embodiments, the left door assembly 44 and the right door assembly 46 are mirror images of each other about the centerline of the set of expander rods 22.
In an exemplary embodiment, as illustrated in FIG. 2 with continuing reference to FIG. 1, the left door assembly 44 includes left door units 52a, 52b, and 52c, a left door lower shroud 54 connected to the left door unit 52a, and a left door brace 56, which is connected to each of the left door units 52a, 52b, and 52c. The left door units 52a, 52b, and 52care movably connected to the back units 42a, 42b, and 42c, respectively. As shown in FIG. 2, the left door units 52a, 52b, and 52c are hingedly connected to the back units 42a, 42b, and 42c, respectively. The left door units 52a, 52b, and 52c are hingedly connected on the respective left side portions of the back units 52a, 52b, and 52c, as viewed in FIG. 2. Similarly, the right door assembly 46 includes right door units 58a, 58b, and 58c, a right door lower shroud 60 connected to the right door unit 58a, and a right door brace 62, which is connected to each of the right door units 58a, 58b, and 58c. The right door units 58a, 58b, and 58c are movably connected to the back units 42a, 42b, and 42c, respectively. As shown in FIG. 2, the right door units 58a, 58b, and 58c are hingedly connected to the back units 42a, 42b, and 42c, respectively. The right door units 58a, 58b, and 58c are hingedly connected on the respective right side portions (opposing the left side portions) of the back units 52a, 52b, and 52c, as viewed in FIG. 2.
A receiver 64 is positioned on a horizontally-extending surface 54a defined by the left door lower shroud 54. The receiver 64 includes a U-shaped cavity 64a adapted to receive a 180-degree hairpin bend of one of the tubes in the coil unit 50b. The receiver 64 supports the coil unit 50b when the coil unit 50b is connected to the left door assembly 44. Although not shown, additional receivers, each of which is identical to the receiver 64, are positioned on the horizontally-extending surface 54a to receive respective hairpin bends of the other tubes of the coil unit 50b, as well as tubes of the coil unit 50a. Likewise, a receiver 66 is positioned on a horizontally-extending surface 60a defined by the right door lower shroud 60. The receiver 66 includes a U-shaped cavity 66a adapted to receive a 180-degree hairpin bend of one of the tubes in one of the coil units adapted to be connected to the right door assembly 46; the receiver 66 supports the one coil unit when the one coil unit is connected to the right door assembly 46. Although not shown, additional receivers, each of which is identical to the receiver 66, are positioned on the horizontally-extending surface 60a to receive respective hairpin bends of the other tubes of the one coil unit, as well as tubes of the other of the coil units adapted to be connected to the right door assembly 46.
In an exemplary embodiment, as illustrated in FIGS. 3-5 with continuing reference to FIGS. 1 and 2, the back unit 42c includes a back plate 68 having a left end portion 68a and a right end portion 68b, and defining a front surface 68c and a back surface 68d. A through opening 68e (shown in FIG. 5) is formed through the plate 68 at the right end portion 68b thereof. Likewise, a through opening 68f (shown in FIG. 4) identical to the through opening 68e, and vertically aligned therewith, is formed through the plate 68 at the left end portion 68a thereof. A left hinge plate assembly 70a is connected to the plate 68 at the left end portion 68a thereof, and extends from the front surface 68c. Likewise, a right hinge plate assembly 70b is connected to the plate 68 at the right end portion 68b thereof, and extends from the front surface 68c. Parallel-spaced horizontal supports 72a and 72b extend along the back surface 68d of the plate 68, and between the end portions 68a and 68b. The horizontal supports 72a and 72b are connected to the plate 68. Horizontally-extending track mount members 74a and 74b are connected to, and spaced in a parallel relation from, the horizontal supports 72a and 72b, respectively. Pluralities of spacers 76a and 76b maintain the respective parallel spacings between the track mount member 74a and the horizontal support 72a, and between the track mount member 74b and the horizontal support 72b. The quantity of spacers in the each of the respective pluralities of spacers 76a and 76b may vary. T-track connectors 78a and 78b are connected to opposing ends, respectively, of the track mount member 74a. Likewise, T-track connectors 78c and 78c are connected to opposing ends, respectively, of the track mount member 74b. 
In an exemplary embodiment, as illustrated in FIGS. 6 and 7 with continuing reference to FIGS. 1-5, the right hinge plate assembly 70b is configured to provide the hinged connection between the back unit 42c and the right door unit 58c, with the hinged connection's hinge axis being located on the right side of the back unit 42c. The right hinge plate assembly 70b includes a hinge plate 80 connected to the plate 68 and having a proximal end 80a and a distal end 80b. The proximal end 80a engages the front surface 68c of the plate 68 so that the hinge plate 80 is perpendicular to the front surface 68c. A U-shaped cut-out 80c is formed in the distal end 80b of the hinge plate 80. The hinge plate 80 defines parallel spaced and vertically-extending inside and outside surfaces 80d and 80e. Pin supports 82a and 82b are connected to, and extend from, the outside surface 80e. The pin support 82a is located at the upper portion of the distal end 80b of the hinge plate 80, and the pin support 82b is located at the lower portion of the distal end 80b. Hinge pins 84a and 84b extend vertically upwards from the pin supports 82a and 82b, respectively. The hinge pins 84a and 84b are coaxial (or axially aligned). The coaxial hinge pins 84a and 84b of the right hinge plate assembly 70b are axially aligned with the hinge axis of the hinged connection between the back unit 42c and the right door unit 58c. 
The plate 80 further includes a recess 80f, which is formed in the vertically-extending surface 80d and positioned above the U-shaped cut-out 80c. The recess 80f extends from the distal end 80b and towards the proximal end 80a. A surface 80g is defined by the recess 80f, the surface 80g being laterally offset from the vertically-extending surface 80d. A slot 80h is formed in the surface 80g and through the plate 80. The slot 80h extends within the recess 80f and between the ends 80a and 80b of the plate 80. A slot 80i is formed in the surface 80e and into the plate 80. The slot 80i is larger than, and overlaps, the slot 80h to thereby define an internal shoulder 80j that tracks the slot 80h and faces away from the vertically-extending surface 80d. Parallel-spaced detents 80ka, 80kb, 80kc, 80kd, and 80ke are formed in the surface 80d, as well as in the surface 80g and the slot 80h. Each of the detents 80ka-80ke extends in a direction that is perpendicular to the direction of extension of each of the recess 80f and the slot 80h. Each of the detents 80ka-80ke defines a respective pair of surfaces 80l and 80m, which are coplanar and interrupted by the slot 80h. 
A latch keeper 86 is connected to the hinge plate 80. The latch keeper 86 includes a block 86a and protrusion 86b extending therefrom. A slot 86c is formed in the protrusion 86b, and is adjacent the block 86a. The protrusion 86b defines an angularly-extending surface 86d, which extends from the slot 86c to a distal end 86e of the protrusion 86b. The angularly-extending surface 86d extends so that the lateral thickness of the protrusion 86b decreases from the slot 86c to the distal end 86e. A rib 86f extends from a vertically-extending side surface 86g of the protrusion 86b; the side surface 86g is opposite the slot 86c. The rib 86f extends vertically along the side surface 86g. A through opening 86h extends from a back surface 86i defined by the block 86a, through the block 86a, and to the slot 86c. 
The latch keeper 86 is connected to the hinge plate 80 via a nut, such as T-nut 88, which is disposed in the slots 80h and 80i. The T-nut 88 includes an external shoulder 88a, which engages the internal shoulder 80j of the plate 80 so that a portion 88b of the T-nut 88 extends within the slot 80h, and a portion 88c extends within the slot 80i. The block 86a of the latch keeper 86 engages the surface 80d of the plate 80, and a fastener 90 extends through the block 86a and threadably engages the T-nut 88, thereby connecting the latch keeper 86 to the hinge plate 80. As shown in FIGS. 6 and 7, the rib 86f extends within the detent 80ka so that the rib 86f engages, or is at least proximate, the corresponding pair of surfaces 80l and 80m defined by the detent 80ka. The protrusion 86b extends within the recess 80f so that the surface 86g engages, or is at least proximate, the surface 80g. As a result of the extension of the rib 86f within the detent 80ka, the extension of the protrusion 86b within the recess 86f, and the threaded engagement between the fastener 90 and the T-nut 88, the position of the latch keeper 86 is locked, relative to the hinge plate 80. The extension of the rib 86f within the detent 80ka prevents relative movement between the latch keeper 86 and the hinge plate 80 in the depth direction as viewed in FIGS. 6 and 7, that is, in a direction that extends either from the proximal end 80a to the distal end 80b or vice versa. The extension of the protrusion 86b within the recess 80f prevents relative movement between the latch keeper 86 and the hinge plate 80 in a vertical direction as viewed in FIGS. 6 and 7. The threaded engagement between the fastener 90 and the T-nut 88 prevents relative movement between the latch keeper 86 and the hinge plate in a lateral direction as viewed in FIGS. 6 and 7.
A sensor 92 is connected to the latch keeper 86. The sensor 92 extends within the through opening 86h so that a face 92a of the sensor 92 is adjacent, or at least proximate, the slot 86c of the latch keeper 86. The sensor 92 extends from the back surface 86i of the block 86a, and a cable 92b extends away from a back end 92c of the sensor 92. As shown in FIGS. 4 and 5, the cable 92b extends through the through opening 68e. Via at least the cable 92b, the sensor 92 is in communication with a control unit 94 (shown in at least FIGS. 11, 15, and 17). In an exemplary embodiment, the sensor 92 is a proximity sensor.
The left hinge plate assembly 70a is identical to the right hinge plate assembly 70b, except that the left hinge plate assembly 70a is configured to provide the hinged connection between the back unit 42c and the left door unit 52c, with the hinged connection's hinge axis being located on the left side of the back unit 42c. Therefore, the left hinge plate assembly 70a will not be described in further detail. The left hinge plate assembly 70a includes the same components of the right hinge plate assembly 70b, which same components are given the same reference numerals. The left hinge plate assembly 70a is connected to the plate 68 of the back unit 42c in a manner identical to the above-described manner in which the right hinge plate assembly 70b is connected to the plate 68. As shown in FIG. 3, the cable 92b of the sensor 92 of the left hinge plate assembly 70a extends through the through opening 68f that is formed through the plate 68 and vertically aligned with the through opening 68e. Via at least the cable 92b of the sensor 92 of the right hinge plate assembly 70b, the sensor 92 is in communication with the control unit 94 shown in at least FIGS. 11, 15, and 17. The coaxial hinge pins 84a and 84b of the left hinge plate assembly 70a are axially aligned with the hinge axis of the hinged connection between the back unit 42c and the left door unit 52c. 
Each of the back units 42a and 42b is identical to the back unit 42c. Therefore, the back units 42a and 42b will not be described in further detail. Each of the back units 42a and 42b includes the same components of the back unit 42c, which same components are given the same reference numerals.
In an exemplary embodiment, as illustrated in FIGS. 8-10 with continuing reference to FIGS. 1-7, the right door unit 58c includes a door plate 96 having opposing end portions 96a and 96b, and defining a vertically-extending inside surface 96c and a vertically-extending outside surface 96d. A plurality of vertically-extending channels, or detents 96e, are formed in the inside surface 96c at, and proximate, the end portion 96a; the detents 96e extend along the height of the inside surface 96c. In an exemplary embodiment, each of the detents 96e is spaced from at least one other detent 96e adjacent thereto by a predetermined increment. Likewise, a plurality of vertically-extending channels, or detents 96f, are formed in the inside surface 96c at, and proximate the end portion 96b; the detents 96f extend along the height of the inside surface 96c. In an exemplary embodiment, each of the detents 96f is spaced from at least one other detent 96f adjacent thereto by a predetermined increment. A middle region 96ca of the inside surface 96c is defined between the pluralities of detents 96e and 96f. Parallel-spaced and horizontally-extending slots 96ga and 96gb are formed in the detents 96e and through the plate 96a. Likewise, parallel-spaced and horizontally-extending slots 96ha and 96hb are formed in the detents 96f and through the plate 96. A plurality of vertically-extending channels, or detents 96i, are formed in the middle region 96ca of the inside surface 96c; the detents 96i extend along the height of the inside surface 96c. In an exemplary embodiment, each of the detents 96i is spaced from at least one other detent 96i adjacent thereto by a predetermined increment. Parallel-spaced and horizontally-extending slots 96ja and 96jb are formed in the detents 96i and through the plate 96. In an exemplary embodiment, the plate 96 of the right door unit 58c is identical to the above-described plate 68 of the back unit 42c. 
Outside spacer blocks 98a and 98b, which include respective ribs 98aa and 98ba extending vertically along the respective backsides thereof, are connected to the plate 96 so that the ribs 98aa and 98ab extend within respective ones of the detents 96e and 96f. In an exemplary embodiment, the outside spacer block 98a is connected to the plate 96 via fasteners 100a and 100b, which extend through the outside spacer block 98a and into the slots 96ga and 96gb, respectively, and threadably engage respective nuts, such as respective T-nuts, which are at least partially disposed in the slots 96ga and 96gb. The T-nut at least partially disposed in the slot 96gb is shown in FIG. 9 and referred to by the reference numeral 101. In an exemplary embodiment, the outside spacer block 98b is connected to the plate 96 via fasteners 102a and 102b, which extend through the outside spacer block 98b and into the slots 96ha and 96hb, respectively, and threadably engage respective nuts, such as respective T-nuts, which are at least partially disposed in the slots 96ha and 96hb. Since each of the detents 96e is spaced from at least one other detent 96e adjacent thereto by a predetermined increment, the detents 96e correspond to a plurality of predetermined positions, each of which is a predetermined position at which the outside spacer block 98a is adapted to be connected to the right door unit 58c, each of the predetermined positions being spaced from at least one other predetermined position adjacent thereto by the predetermined increment (the spacing between each adjacent pair of the detents 96e). Since each of the detents 96f is spaced from at least one other detent 96f adjacent thereto by a predetermined increment, the detents 96f correspond to a plurality of predetermined positions, each of which is a predetermined position at which the outside spacer block 98b is adapted to be connected to the right door unit 58c, each of the predetermined positions being spaced from at least one other predetermined position adjacent thereto by the predetermined increment (the spacing between each adjacent pair of the detents 96f).
A center spacer block 104, which includes a rib 104a extending vertically along the backside thereof, is connected to the plate 96 so that the rib 104a extends within one of the detents 96i. In an exemplary embodiment, the center spacer block 104 is connected to the plate 96 via fasteners 106a and 106b, which extend through the center spacer block 104 and into the slots 96ja and 96jb, respectively, and threadably engage respective nuts, such as respective T-nuts, which are at least partially disposed in the slots 96ja and 96jb. The T-nut at least partially disposed in the slot 96jb is shown in FIG. 9 and referred to by the reference numeral 108. Since each of the detents 96i is spaced from at least one other detent 96i adjacent thereto by a predetermined increment, the detents 96i correspond to a plurality of predetermined positions, each of which is a predetermined position at which the center spacer block 104 is adapted to be connected to the right door unit 58c, each of the predetermined positions being spaced from at least one other predetermined position adjacent thereto by the predetermined increment (the spacing between each adjacent pair of the detents 96i).
Parallel-spaced horizontal supports 110a and 110b extend along the outside surface 96dof the plate 96, and between the opposing end portions 96a and 96b thereof. The horizontal supports 110a and 110b are connected to the plate 96. A door support 112a is connected to the horizontal support 110a at the end thereof proximate the end portion 96a of the plate 96. The door support 112a includes a block 112aa and a beam 112ab extending therefrom. The beam 112ab is generally perpendicular to the plate 96. A plurality of linear-aligned through openings 112ac are formed through the block 112aa and the beam 112ab. A through opening 112ad is formed through the block 112aa. The door support 112a is connected to the horizontal support 110a via fasteners 114a and 114b, which extend at least within each of the horizontal support 110a and an adjacent pair of the through openings 112ac. In an exemplary embodiment, each of the fasteners 114a and 114b includes a dowel pin. Likewise, a door support 112b is connected to the horizontal support 110b at the end thereof proximate the end portion 96a of the plate 96. The door support 112 includes a block 112ba and a beam 112bb extending therefrom. The beam 112bb is generally perpendicular to the plate 96. A plurality of linearly-aligned through openings 112bc are formed through the block 112ba and the beam 112bb. A through opening 112bd is formed through the block 112ba. The door support 112b is connected to the horizontal support 110b via fasteners 116a and 116b, which extend at least within each of the horizontal support 110b and an adjacent pair of the through openings 112bc. In an exemplary embodiment, each of the fasteners 116a and 116b includes a dowel pin.
The door supports 112a and 112b are spaced in a parallel relation. The through openings 112ad and 112bd are coaxial (or axially aligned). The coaxial through openings 112ad and 112bd are axially aligned with the hinge axis of the hinged connection between the back unit 42c and the right door unit 58c. The linearly-aligned through openings 112ac are coaxial, or axially aligned, with respective ones of the linearly-aligned through openings 112bc. In an exemplary embodiment, the door supports 112a and 112b are identical to each other. A strut 118 extends vertically between the door supports 112a and 112b. 
As shown in FIGS. 9 and 10, opposing latch brackets 120a and 120b are connected to the outside surface 96d at the end portion 96b of the plate 96. The opposing latch brackets 120a and 120b are vertically disposed between the horizontal supports 110a and 110b. The latch brackets 120a and 120b are proximate the horizontal supports 110a and 110b, respectively, and extend along respective portions thereof. A slot 122 is defined between the latch brackets 120a and 120b. A latch bar 124 is operably coupled to the plate 96. In particular, in an exemplary embodiment, the latch bar 124 is slidably disposed between the latch brackets 120a and 120b. The latch bar 124 defines opposing end surfaces 124a and 124b, an angularly-extending engagement surface 124c proximate the end surface 124a and the edge of the end portion 96b of the plate 96, and a back surface 124d extending between the end surfaces 124a and 124b. A handle 126 extends from the back surface 124d, and is perpendicular to the latch bar 124. The handle 126 extends through the slot 122. An end bracket 128 is connected to the outside surface 96d and engages respective ends of the latch brackets 120a and 120b that are opposite each of the end surface 124a and the angularly-extending engagement surface 124c of the latch bar 124. A latch spring 130 is disposed between the latch brackets 120a and 120b, and extends axially between the end bracket 128 and the end surface 124b of the latch bar 124. In an exemplary embodiment, the latch spring 130 is a helical spring. The latch spring 130 is adapted to apply a biasing force against the latch bar 124, urging the latch bar 124 to move away from the end bracket 128. In several exemplary embodiments, additional hardware maintains the position of the latch spring 130 between the latch brackets 120a and 120b; for example, a rod may extend from the end bracket 128, through the latch spring 130 and into the latch bar 124, with the latch bar 124 being movable relative to each of the end bracket 128 and the rod extending therefrom.
Each of the right door units 58a and 58b is identical to the right door unit 58c. Therefore, the right door units 58a and 58b will not be described in further detail. Each of the right door units 58a and 58b includes the same components of the right door unit 58c, which same components are given the same reference numerals.
The left door units 52a, 52b, and 52c are identical to the right door units 58a, 58b, and 58c, respectively, except that the left door units 52a, 52b, and 52c are configured to be hingedly connected on the respective left sides of the back units 42a, 42b, and 42c on the left side thereof, as viewed in FIG. 2, rather than on the respective right sides. Therefore, the left door units 52a, 52b, and 52c will not be described in further detail. Each of the left door units 52a, 52b, and 52c includes the same components of the right door unit 58c, which same components are given the same reference numerals.
In an exemplary embodiment, as illustrated in FIG. 11 with continuing reference to FIGS. 1-10, the tube expander 40 includes a control panel 132, which is in communication with the control unit 94. In an exemplary embodiment, the control panel 132 is mounted on stanchion 134. In an exemplary embodiment, the control unit 94 is connected to a vertically-extending wall of the structure in which the tube expander 10 is positioned. In an exemplary embodiment, the control unit 94 is connected to the frame 12 of the tube expander 10. In several exemplary embodiments, the control unit 94 is part of the control panel 132, or vice versa.
In several exemplary embodiments, one or more of the sensors 92 are wireless sensors, and the respective cables 92b thereof are omitted in favor of respective wireless transmitters; in several exemplary embodiments, the control unit 94 or the control panel 132, includes a wireless signal receiver that is in communication with the wireless sensors.
In several exemplary embodiments, the control panel 132 is, or includes, a handheld control module, which is either wireless or retractably suspended from a ceiling of the structure in which the tube expander 10 is positioned.
In an exemplary embodiment, as illustrated in FIGS. 11-14 as well as FIGS. 1 and 2, with continuing reference to FIGS. 3-10, when the fixture 40 is in an assembled condition, the connectors 78a and 78c of each of the back units 42a, 42b, and 42c are connected to the T-track 32a. Likewise, the connectors 78b and 78d of each of the back units 42a, 42b, and 42c are connected to the T-track 32b. As a result, each of the back units 42a, 42b, and 42c is connected to the frame 12 of the tube expander 10.
The hinge pins 84a and 84b of the back unit 42c extend upwards through the through openings 112ad and 112bd , respectively, of the door supports 112a and 112b of the right door unit 58c. The pin supports 82a and 82b engage and support the blocks 112aa and 112ba, respectively. As a result, the right door unit 58c is hingedly connected to the back unit 42c. The right door unit 58a is hingedly connected to the back unit 42a in a manner identical to the above-described manner in which the right door unit 58c is hingedly connected to the back unit 42a. Likewise, the right door unit 58b is hingedly connected to the back unit 42b in a manner identical to the above-described manner in which the right door unit 58c is hingedly connected to the back unit 42a. The respective hinge pins 84a and 84b, and the respective through openings 112ad and 112bd, of the right door units 58a, 58b, and 58c, are all coaxial. The left door units 52a, 52b, and 52c are hingedly connected to the back units 42a, 42b, and 42c, respectively, in a manner identical to the above-described manner in which the right door units 58a, 58b, and 58c are hingedly connected to the back units 42a, 42b, and 42c, respectively. The respective hinge pins 84a and 84b, and the respective through openings 112ad and 112bd, of the left door units 52a, 52b, and 52c, are all coaxial.
The lower end portion of the left door brace 56 is connected to the horizontal support 110a of the left door unit 52a. The left door brace 56 extends upwards from the horizontal support 110a of the left door unit 52a, and is connected to the horizontal supports 110a and 110b of the left door unit 52b. The left door brace 56 extends upwards from the horizontal support 110a of the left door unit 52b, and is connected to the horizontal supports 110a and 110b of the left door unit 52c. The left door brace 56 connects the left door units 52a, 52b, and 52c together so that the left door units 52a, 52b, and 52c pivot together about a hinge axis 136. The hinge axis 136 is the hinge axis for the respective hinged connections between the left door units 52a, 52b, and 52c, and the back units 42a, 42b, and 42c, respectively, on the respective left sides of the back units 42a, 42b, and 42c (as viewed in FIG. 11). The respective hinge pins 84a and 84b, and the through openings 112ad and 112bd, of the left door units 52a, 52b, and 52c are all coaxial, or axially aligned, with the hinge axis 136. The left door brace 56 includes handle portions 56a and 56b to facilitate the pivoting movement of the left door assembly 44. The left door lower shroud 54 is connected to the left door unit 52a via one or more components thereof including, for example, the horizontal support 110b of the left door unit 52a. 
The lower end portion of the right door brace 62 is connected to the horizontal support 110a of the right door unit 58a. The right door brace 62 extends upwards from the horizontal support 110a of the right door unit 58a, and is connected to the horizontal supports 110a and 110b of the right door unit 58b. The right door brace 62 extends upwards from the horizontal support 110a of the right door unit 58b, and is connected to the horizontal supports 110a and 110b of the right door unit 58c. The right door brace 62 connects the right door units 58a, 58b, and 58c together so that the right door units 58a, 58b, and 58c pivot together about a hinge axis 138. The hinge axis 138 is the hinge axis for the respective hinged connections between the right door units 58a, 58b, and 58c, and the back units 42a, 42b, and 42c, respectively, on the respective right sides of the back units 42a, 42b, and 42c (as viewed in FIG. 11). The respective hinge pins 84a and 84b, and the through openings 112ad and 112bd, of the right door units 58a, 58b, and 58c are all coaxial, or axially aligned, with the hinge axis 138. The right door brace 62 includes handle portions 62a and 62b to facilitate the pivoting movement of the right door assembly 46. The right door lower shroud 60 is connected to the right door unit 58a via one or more components thereof including, for example, the horizontal support 110b of the right door unit 58a. 
In an exemplary embodiment, as illustrated in FIG. 15 with continuing reference to FIGS. 1-14, and as described above, the control panel 132 is in communication with the control unit 94. The actuator 16 is in communication with the control unit 94. The respective pairs of sensors 92 of the back units 42a, 42b, and 42c are in communication with the control unit 94. In an exemplary embodiment, the sensors 92 are in communication with the control unit 94 via at least the respective cables 92b. In an exemplary embodiment, the sensors 92 are electrically coupled in parallel to the control unit 94. In an exemplary embodiment, each of the pairs of sensors 92 of the back units 42a, 42b, and 42c are electrically coupled in parallel to the control unit 94. In an exemplary embodiment, for each of the back units 42a, 42b, and 42c, the control unit 94 is configured to determine if either one of the sensors 92 in the corresponding pair of the sensors 92, or the other of the sensors 92, senses the presence or extension of the latch bar 124 within the slot 86c. In an exemplary embodiment, each of the pairs of sensors 92 of the back units 42a, 42b, and 42c are electrically coupled in parallel to the control unit 94 and, for each of the back units 42a, 42b, and 42c, the control unit 94 is configured to determine if either one of the sensors 92 in the corresponding pair of the sensors 92, or the other of the sensors 92, senses the presence or extension of the latch bar 124 within the slot 86c. In an exemplary embodiment, the control unit 94 controls the operation of at least the actuator 16. In an exemplary embodiment, the operator of the tube expander 10 uses the control panel 132 to control the operation of at least the actuator 16.
In an exemplary embodiment, as illustrated in FIG. 16 with continuing reference to FIGS. 1-15, a method of operating the tube expander 10 is generally referred to by the reference numeral 140. In several exemplary embodiments, the method 140 may be referred to as a method of expanding tubes in respective ones of a plurality of heat exchanger coil units. The method 140 includes at step 140a installing the coil units 50a and 50b in the left door assembly 44. After the step 140a, at step 140b the left door assembly 44 is closed so that the coil units 50a and 50b are disposed in the internal region 48 for tubular expansion therein. After the step 140b, at step 140c the respective pluralities of tubes in the coil units 50a and 50b are expanded using the expander rods 22 of the tube expander 10. During the step 140c, at step 140d two coil units are installed in the right door assembly 46. After the step 140c, at step 140e the left door assembly 44 is opened to remove the coil units 50a and 50b from the internal region 48. After the step 140e, at step 140f the right door assembly 46 is closed so that the two coil units installed therein are disposed in the internal region 48 for tubular expansion therein. After the step 140f, at step 140g the respective pluralities of tubes in the two coil units installed in the right door assembly 46 are expanded using the expander rods 22 of the tube expander 10. During the step 140g, at step 140h another two coil units are installed in the left door assembly 44. After the step 140g, at step 140i the right door assembly 46 is opened to remove the two coil units installed in the right door assembly 46 from the internal region 48. In several exemplary embodiments, the steps 140b-140i are repeated until all coil units to be expanded have undergone the tubular expansion process.
In several exemplary embodiments, instead of installing coil units in the left door assembly 44 at the steps 140b and 140h, and installing coil units in the right door assembly 46 at the step 140f, coil units may be installed in the right door assembly 46 at the steps 140b and 140h, and coil units may be installed in the left door assembly 44 at the step 140f. In several exemplary embodiments, the method 140 may be modified by replacing the left door assembly 44 in the steps 140a-140i with the right door assembly 46, and vice versa. In several exemplary embodiments, coil units installed in the right door assembly 46 may undergo a tubular expansion process before any coil units installed in the left door assembly 44 undergo a tubular expansion process. In several exemplary embodiments, in the method 140 as described in greater detail below, all references to the left door assembly 44 may be replaced with the right door assembly 46, and vice versa.
In an exemplary embodiment, as illustrated in FIG. 17 with continuing reference to FIGS. 1-16, to install the coil units 50a and 50b in the left door assembly 44 at the step 140a, the coil unit 50a is positioned against the respective inside surfaces 96c of the plates 96, and between the center spacer block 104 and the outside spacer block 98a of each of the left door units 52a, 52b, and 52c. The rib 104a of the center spacer block 104 extends within one of the detents 96i, and the rib 98aa of the outside spacer block 98a extends within one of the detents 96e, so that the spacing between the blocks 104 and 98a is generally equal to, slightly greater than, or slightly less than, the width of the coil unit 50a. As a result, the coil unit 50a fits snugly between the respective sets of the blocks 104 and 98a of the left door units 52a, 52b, and 52c, thereby connecting the coil unit 50a to the left door assembly 44. The 180-degree hairpin bends of the tubes in the coil unit 50a are received by respective ones of the U-shaped cavities 64a of the receivers 64, and the receivers 64 support the coil unit 50a (the receivers 64 are not shown in FIG. 17). Likewise, the coil unit 50b is positioned against the respective inside surfaces 96c of the plates 96, and between the center spacer block 104 and the outside spacer block 98b of each of the left door units 52a, 52b, and 52c. The rib 104a of the center spacer block 104 extends within one of the detents 96i, and the rib 98ba of the outside spacer block 98b extends within one of the detents 96e, so that the spacing between the blocks 104 and 98b is generally equal to, slightly greater than, or slightly less than, the width of the coil unit 50b. As a result, the coil unit 50b fits snugly between the respective sets of the blocks 104 and 98b of the left door units 52a, 52b, and 52c, thereby connecting the coil unit 50b to the left door assembly 44. The 180-degree hairpin bends of the tubes in the coil unit 50b are received by respective ones of the U-shaped cavities 64a of the receivers 64, and the receivers 64 support the coil unit 50b (the receivers 64 are not shown in FIG. 17). In an exemplary embodiment, at the step 140a, each of the coil units 50a and 50b is in an initial configuration in which it is a loose assembly of tubes and fins, and the tubes thereof are not yet expanded. In several exemplary embodiments, at the step 140a, straps, bands, or other elements may be used to further secure the coil units 50a and 50b within the left door assembly 44. In an exemplary embodiment, respective straps or bands may be connected to the plates 96 of the left door units 52a, 52b, and 52c, and at the step 140a the straps or bands may be disposed around the coil units 50a and 50b to further secure the coil units 50a and 50b within the left door assembly 44.
In an exemplary embodiment, as illustrated in FIG. 18a with continuing reference to FIGS. 1-17, to close the left door assembly 44 so that the coil units 50a and 50b are disposed in the internal region 48 at the step 140b, the left door assembly 44 is pivoted about the hinge axis 136, moving in a counterclockwise direction as indicated by an arrow 141 in FIG. 18a. In an exemplary embodiment, the left door brace 56 facilitates pivoting the left door assembly 44 about the hinge axis 136. As the left door assembly 44 continues to pivot, the respective angularly-extending engagement surfaces 124c of the latch bars 124 engage and slide across the corresponding angularly-extending surfaces 86d of the respective latch keepers 86 of the right hinge plate assemblies 70b of the back units 42a, 42b, and 42c. In response to this sliding engagement, each of the latch bars 24 slides, relative to the corresponding opposing latch brackets 120a and 120b and towards the corresponding end bracket 128. As a result, the corresponding spring 130 is compressed, or further compressed, between the corresponding end bracket 128 and the corresponding end surface 124b of the latch bar 24. As the left door assembly 44 continues to pivot, each of the latch bars 24 slides past the corresponding angularly-extending surface 86d of the latch keeper 86, permitting the corresponding spring 130 to extend and push the latch bar 24 into the slot 86c of the latch keeper 86. As a result, the left door units 52a, 52b, and 52c are secured to the back units 42a, 42b, and 42c, respectively, the left door assembly 44 is closed, and the coil units 50a and 50b are disposed in the internal region 48 of the fixture 40.
In an exemplary embodiment, as illustrated in FIG. 18b with continuing reference to FIGS. 1-18a, to expand the respective pluralities of tubes in the coil units 50a and 50b at the step 140c, the control panel 132 is used to control the actuator 16 via the control unit 94. In particular, the control unit 94 causes the rod 16a to extend out of the cylinder 16b and move downwards, as viewed in FIG. 1. The pressure plate 18 moves downward in response to the downward movement of the rod 16a, causing the expander rods 22 to also move downward, as indicated by an arrow 142 in FIG. 18b. The expander rods 22 move downward into the open ends of the tubes in the coil units 50a and 50b, expanding the tubes into the fins and forming interference fits therebetween. The control unit 94 then causes the rod 16a to retract back into the cylinder 16b, withdrawing the expander rods 22 out of the expanded tubes. At this point, each of the coil units 50a and 50b is in a finished configuration in which the tubes are expanded and connected to the fins via the interference fits to provide appropriate thermal conductivity across the tube-and-fin connections.
In an exemplary embodiment, as illustrated in FIG. 18b with continuing reference to FIGS. 1-18a, at the step 140d two coil units, which are referred to by reference numerals 144a and 144b, are installed in the right door assembly 46. The coil units 144a and 144b are installed in the right door assembly 46 at the step 140d in a manner substantially identical to the above-described manner in which the coil units 50a and 50b are installed in the left door assembly 44 at the step 140a. Therefore, the step 140d will not be described in further detail. In an exemplary embodiment, the step 140d is carried out during the step 140c, as indicated above and in FIG. 16. In an exemplary embodiment, the step 140d is carried out before, or after, the step 140c. In an exemplary embodiment, the step 140d is carried out before the step 140c, during the step 140c, after the step 140c, or any combination thereof.
In an exemplary embodiment, as illustrated in FIG. 18c with continuing reference to FIGS. 1-18b, to open the left door assembly 44 to remove the coil units 50a and 50b from the internal region 48 at the step 140e, an operator moves the respective handles 126 of the left door units 52a, 52b, and 52c within the corresponding slots 122 so that the corresponding latch bars 124 slide out of the corresponding slots 86c of the latch keepers 86 of the right hinge plate assemblies 70b. As a result, the respective springs 130 of the left door units 52a, 52b, and 52c are compressed or further compressed. While each of the latch bars 124 are not disposed in the corresponding slot 86c, the left door assembly 44 is pivoted about the hinge axis 136 in a clockwise direction, as indicated by arrow 146 in FIG. 18c. As a result, the left door assembly 44 is opened and the coil units 50a and 50b are removed from the internal region 48.
In an exemplary embodiment, as illustrated in FIG. 18d with continuing reference to FIGS. 1-18c, at the step 140f the right door assembly 46 is closed so that the coil units 144a and 144b are disposed in the internal region 48 for tubular expansion therein. The right door assembly 46 is closed by pivoting the right door assembly 46 about the hinge axis 138 in a clockwise direction, as indicated by an arrow 148 in FIG. 18d. The right door assembly 46 is closed at the step 140f in a manner substantially identical to the above-described manner in which the left door assembly 44 is closed at the step 140b. Therefore, the step 140f will not be described in further detail.
In an exemplary embodiment, as illustrated in FIG. 18d with continuing reference to FIGS. 1-18c, to expand the respective pluralities of tubes in the coil units 144a and 144b at the step 140g, the control unit 94 causes the rod 16a to extend out of the cylinder 16b and move downwards. The pressure plate 18 moves downward in response to the downward movement of the rod 16a, causing the expander rods 22 to also move downward, as indicated by an arrow 150 in FIG. 18d. The step 140g is substantially identical to the step 140c and therefore will not be described in further detail.
In an exemplary embodiment, as illustrated in FIG. 18d with continuing reference to FIGS. 1-18c, at the step 140h another two coil units, which are referred to by reference numerals 152a and 152b, are installed in the left door assembly 44. To do so, the coil units 50a and 50b must first be removed from the left door assembly 44, as indicated by an arrow 154 in FIG. 18d. To so remove the coil units 50a and 50b, one or more of the respective center spacer blocks 104, and the outside spacer blocks 98a and 98b, may be disconnected from the corresponding plates 96 of the left door units 52a, 52b, and 52c. After the removal of the coil units 50a and 50b, the coil units 152a and 152b are installed in the left door assembly 44, as indicated by an arrow 156 in FIG. 18d. The coil units 152a and 152b are installed in the left door assembly 44 at the step 140h in a manner identical to the above-described manner in which the coil units 50a and 50b are installed in the left door assembly 44 at the step 140a. Therefore, the step 140h will not be described in further detail. In an exemplary embodiment, the step 140h is carried out during the step 140g, as indicated above and in FIG. 16. In an exemplary embodiment, the step 140h is carried out before, or after, the step 140g. In an exemplary embodiment, the step 140h is carried out before the step 140g, during the step 140g, after the step 140g, or any combination thereof.
In an exemplary embodiment, as illustrated in FIG. 18e with continuing reference to FIGS. 1-18d, at the step 140i the right door assembly 46 is opened so that the coil units 144a and 144b are removed from the internal region 48. The right door assembly 46 is opened by pivoting the right door assembly 46 about the hinge axis 138 in a counterclockwise direction, as indicated by an arrow 158 in FIG. 18e. The right door assembly 46 is opened at the step 140i in a manner substantially identical to the above-described manner in which the left door assembly 44 is opened at the step 140e. Therefore, the step 140i will not be described in further detail.
In several exemplary embodiments, the execution of the method 140, and/or the operation of the tube expander 10 including the operation of the fixture 40, greatly decreases the time it takes to manufacture several coil units because the operator of the tube expander 10 does not have to wait until the tubular expansion process is completed for one or more coil units before installing one or more other coil units in the fixture 40; in several exemplary embodiments, the “load-then-wait” process is eliminated.
In several exemplary embodiments, one or more coil units may be installed in the left door assembly 44 and prepared for a tubular expansion process independently of any activities or processes related to one or more other coil units that may be installed in the right door assembly 46, including any tubular expansion process using the tube expander 10. In several exemplary embodiments, one or more coil units may be installed in the right door assembly 46 and prepared for a tubular expansion process independently of any activities or processes related to one or more other coil units that may be installed in the left door assembly 44, including any tubular expansion process using the tube expander 10.
In several exemplary embodiments, the execution of the method 140, and/or the operation of the tube expander 10 including the operation of the fixture 40, allows the operator to process coil units rather than wait during the tubular expansion process.
In several exemplary embodiments, the execution of the method 140, and/or the operation of the tube expander 10 including the operation of the fixture 40, provides at least two coil unit loading or installation points (the door assemblies 44 and 46) on the fixture 40, where the operator can unload and load coil units at one point (one of the door assemblies 44 and 46) while a tubular expansion process occurs at the other point (the other of door assemblies 44 and 46).
In several exemplary embodiments, the lower shroud 54 and the receivers 64 allow for the installation of one or more coil units in the left door assembly 44 to be independent of any installation of one or more other coil units in the right door assembly 46. In several exemplary embodiments, the lower shroud 60 and the receivers 66 allow for the installation of one or more coil units in the right door assembly 46 to be independent of any installation of one or more other coil units in the left door assembly 44.
In several exemplary embodiments, the execution of the method 140, and/or the operation of the tube expander 10 including the operation of the fixture 40, significantly shortens machine cycle time while increasing production capacity.
In several exemplary embodiments, the execution of the method 140, and/or the operation of the tube expander 10 including the operation of the fixture 40, provides a shuttle loading system with two loading points, wherein an operator can unload and load coil units while the tube expander 10 is operating.
In an exemplary embodiment, as illustrated in FIG. 19 with continuing reference to FIGS. 1-18, a flow chart illustration of a method of securing either the left door assembly 44 or the right door assembly to the back units 42a, 42b, and 42c is generally referred to by the reference numeral 160. In an exemplary embodiment, the step 140b of the method 140 includes the method 160. In an exemplary embodiment, the step 140f of the method 140 includes the method 160.
The method 160 will be described below with respect to securing the left door assembly 44 to the back units 42a, 42b, and 42c, but it is understood that the method 160 applies in the same manner to securing the right door assembly 46 to the back units 42a, 42b, and 42c. 
As shown in FIG. 19, the method 160 includes at step 160a closing the left door assembly 44 to place coil unit(s) installed therein (e.g., the coil units 50a and 50b, or the coil units 152a and 152b) in the internal region 48 for tubular expansion therein. At step 160b, the latch bars 124 are engaged with the respective latch keepers 86. At step 160c, it is determined whether the latch bars 24 are fully engaged with the respective latch keepers 86. If not, then at step 160d the actuator 16 is deactivated and any ongoing tubular expansion process using the tube expander 10 is stopped, and/or any planned tubular expansion process using the tube expander 10 is not permitted to begin. If it is determined at the step 160c that the latch bars 24 are fully engaged with the respective latch keepers 86, then at step 160e any ongoing and/or planned tubular expansion processes using the tube expander 10 is permitted.
In an exemplary embodiment, the step 160a is identical to the above-described step 140b of the method 140. Therefore, the step 160a will not be described in further detail.
In an exemplary embodiment, at the step 160b, the latch bars 124 of the left door assembly 44 are engaged with the respective latch keepers 86 of the right hinge plate assemblies 70b of the back units 42a, 42b, and 42c. More particularly, at the step 160b, the handles 126 are gripped and moved within the slots 122, respectively, causing the latch bars 124 to move horizontally. The handles 126 are moved horizontally towards the respective latch keepers 86 and away from the respective end brackets 128 so that the latch bars 124 extend within the respective slots 86c and thus the latch bars 124 are engaged with the respective latch keepers 86. In an exemplary embodiment, the step 160b is omitted from the method 160 because the springs 130 move the latch bars 124 horizontally and towards the latch keepers 86 so that the latch bars 124 extend within the respective slots 86c, as described above in connection with the step 140b. In an exemplary embodiment, the step 160b is part of the step 160a. In an exemplary embodiment, the steps 160a and 160b are combined.
In an exemplary embodiment, as illustrated in FIGS. 19 and 20 with continuing reference to FIGS. 1-18, to determine whether the latch bars 124 are fully engaged with the respective latch keepers 86 at the step 160c, it is determined at 160c a whether one of the sensors 92 of the back unit 42a senses the presence of the corresponding latch bar 124 in the corresponding slot 86c, it is determined at 160cb whether one of the sensors 92 of the back unit 42b senses the presence of the corresponding latch bar 124 in the corresponding slot 86c, and it is determined at 160cc whether one of the sensors 92 of the back unit 42c senses the presence of the corresponding latch bar 124 in the corresponding slot 86c. If it is determined at any one of the steps 160ca , 160cb, and 160cc that one of the sensors 92 does not sense the presence of the corresponding latch bar 124, then the step 160d is executed. In several exemplary embodiments, the control unit 94 automatically makes the determination at the step 160c, including the respective determinations at the steps 160ca, 160cb, and 160cc, based on the communication of the control unit 94 with each pair of sensors 92 in the back units 42a, 42b, and 42c. Since the left door assembly 44 is closed at the step 160a, it is impossible for the right door assembly 46 to be closed and the latch bars 124 of the right door assembly 46 to be fully engaged with the respective latch keepers 86; thus, the determination at each of the steps 160ca, 160cb, and 106cc is directed to determining whether the sensor 92 of the hinge plate assembly 70b senses the presence of the corresponding latch bar 24 of the left door unit 52a, 52b, or 52c. 
In an exemplary embodiment, as shown in FIG. 20, the sensor 92 is a proximity sensor and operates to determine whether an object (that is, the latch bar 124) is close enough to the face 92a of the sensor 92. In an exemplary embodiment, the sensors 92 are electrically coupled in parallel to the control unit 94. In an exemplary embodiment, each of the pairs of sensors 92 of the back units 42a, 42b, and 42care electrically coupled in parallel to the control unit 94. In an exemplary embodiment, at the step 160c, for each of the back units 42a, 42b, and 42c, the control unit 94 determines if one of the sensors 92 in the corresponding pair of the sensors 92 senses the presence or extension of the latch bar 124 within the slot 86c. If not, then at the step 160c the control unit 94 determines that the latch bars 124 of the left door assembly 44 are not fully engaged with the respective latch keepers 86 and the step 160d is executed.
In an exemplary embodiment, at the step 160d, the control unit 94 does not permit the actuator 16 of the tube expander 10 to operate to conduct the tubular expansion process within the heat exchanger coil units 50a and 50b when the left door assembly 44 is closed and one or more of the respective sensors 92 of the hinge plate assemblies 70b do not sense the presence of the corresponding latch bar 124 of the left door assembly within the slot 86c, regardless of whether the latch bar 124 extends within the slot 86c. 
In an exemplary embodiment, at the step 160d, a status indicator on the left door assembly 44 emits light to indicate that all of the latch bars 124 of the left door assembly 44 are not fully engaged with the respective latch keepers 86. In an exemplary embodiment, each of the left door units 52a, 52b, and 52c includes a status indicator; at the step 160d, at least one of the status indicators emits light to indicate that the corresponding left door unit 52a, 52b, or 52c is not fully engaged. In an exemplary embodiment, at the step 160d, one or more status indicators on the left door assembly 44, the control unit 94, the control panel 132, or any combination thereof, emit light to indicate that not all of the latch bars 124 of the left door assembly 44 are fully engaged with the respective latch keepers 86.
In an exemplary embodiment, if it is determined at each of the steps 160ca, 160cb, and 160cc that one of the sensors 92 does indeed sense the presence of the corresponding latch bar 124, then the step 160e is executed. In an exemplary embodiment, if at the step 160c the control unit 94 determines that, for each of the back units 42a, 42b, and 42c, one of the sensors 92 in the corresponding pair of the sensors 92 senses the presence or extension of the latch bar 124 within the slot 86c, then at the step 160c the control unit 94 determines that the latch bars 124 of the left door assembly 44 are fully engaged with the respective latch keepers 86 and the step 160e is executed.
In an exemplary embodiment, at the step 160e, the control unit 94 permits the actuator 16 of the tube expander 10 to operate to conduct the tubular expansion process within the heat exchanger coil units 50 and 50b when the left door assembly 44 is closed, the latch bars 124 of the left door assembly 44 extend within the corresponding slots 86c, and each of the sensors 92 of the respective hinge plate assemblies 70b senses the presence of the corresponding latch bar 124 within the slot 86c. 
In an exemplary embodiment, at the step 160e, a status indicator on the left door assembly 44 emits light to indicate that the latch bars 124 of the left door assembly 44 are fully engaged with the respective latch keepers 86. In an exemplary embodiment, each of the left door units 52a, 52b, and 52c includes a status indicator; at the step 160e, each status indicator emits light to indicate that the corresponding left door unit 52a, 52b, or 52c is fully engaged. In an exemplary embodiment, at the step 160e, one or more status indicators on the left door assembly 44, the control unit 94, the control panel 132, or any combination thereof, emit light to indicate that the latch bars 124 of the left door assembly 44 are fully engaged with the respective latch keepers 86.
In several exemplary embodiments, the execution of the method 160, and/or the operation of the tube expander 10 including the operation of the fixture 40, ensures that the left door assembly 44 does not accidentally open during a tubular expansion process. In several exemplary embodiments, the execution of the method 160, and/or the operation of the tube expander 10 including the operation of the fixture 40, improves operator safety. In several exemplary embodiments, the execution of the method 160, and/or the operation of the tube expander 10 including the operation of the fixture 40, prevents the occurrence of a destructive tubular expansion process due to an unconstrained coil unit, that is, a coil unit connected to the left door assembly 44 when the left door assembly 44 is not secured to the back units 42a, 42b, and 42c. 
In an exemplary embodiment, as illustrated in FIGS. 21A and 21B with continuing reference to FIGS. 1-20, a method of adjusting the fixture 40 to accommodate different sizes of coil units is generally referred to by the reference numeral 162. The method 162 includes adjusting the fixture 40 to accommodate the height H of a coil unit 163 at step 162a, adjusting the fixture 40 to accommodate the width W of the coil unit 163 at step 162b, and adjusting the fixture 40 to accommodate the depth D of the coil unit 163 at step 162c. The method 162, or one or more of the steps 162a, 162b, and 162c, may be necessary due to variances in one or more of the height H, the width W, and the depth D of the coil unit 53 and other coil units, such as the coil unit 50a shown in FIG. 17.
In an exemplary embodiment, as illustrated in FIG. 22 with continuing reference to FIGS. 1-21B, to adjust the fixture 40 to accommodate the height H of a coil unit at the step 162a, one or both of the back units 42b and 42c are removed if the height H of the coil unit to be expanded is less than the height H of, for example, the coil unit 50a shown in FIG. 17. The removal of one or both of the back units 42b and 42c is dependent upon the degree to which the height H of the coil unit to be expanded is less than the height H of, for example, the coil unit 50a shown in FIG. 17. If the back unit 42c is removed, the left door unit 52c and the right door unit 58c are also removed. If the back unit 42b is also removed, the left door unit 52b and the right door unit 58b are also removed. In several exemplary embodiments, the fixture 40 is described as including modules 164a, 164b, and 164c. In several exemplary embodiments, the modules 164a, 164b, and 164c are identical. The module 164a is the combination of the back unit 42a, the left door unit 52a hingedly connected to the back unit 42a, and the right door unit 58a hingedly connected to the back unit 42a. The module 164b is the combination of the back unit 42b, the left door unit 52b hingedly connected to the back unit 42b, and the right door unit 58b hingedly connected to the back unit 42b. The module 164c is the combination of the back unit 42c, the left door unit 52c hingedly connected to the back unit 42c, and the right door unit 58c hingedly connected to the back unit 42c. In an exemplary embodiment, to adjust the fixture 40 to accommodate the height H of a coil unit at the step 162a, at least one other module identical to the module 164c is connected to the T-tracks 32a and 32b in a manner identical to the above-described manner in which the module 164c, and in particular the back unit 42c, is connected to the T-tracks 32a and 32b. The at least one other module identical to the module 164c is positioned above the module 164c. The number of other modules to add to the fixture 40 is dependent upon the degree to which the height H of the coil unit to be expanded is greater than the height H of, for example, the coil unit 50a shown in FIG. 17. Additionally, to adjust the fixture 40 to accommodate the height H of the coil unit to be expanded, the respective vertical positions of each of the modules 164b and 164c may be adjusted by moving the module 164b or 164c up or down a predetermined increment, which predetermined increment corresponds to the vertical spacing between each pair of vertically adjacent mount points along each of the T-tracks 32a and 32b. 
In an exemplary embodiment, as indicated in FIG. 22, the fixture 40 includes at least one module, that is, the module 164a, and is centered around a repeating, fixed height module mounted on, or connected to, the T-tracks 32a and 32b. In several exemplary embodiments, the T-tracks 32a and 32b include mount points with one-inch centers. The connection of the T-tracks 32a and 32b to the frame 12, and the respective connections between the T-tracks 32a and 32b and one or more of the modules 164a, 164b, and 164c, and optionally one or more other modules identical to the module 164a, 164b, or 164c, eliminate the need for an operator to establish horizontal alignment in the direction indicated by arrows 166 in FIG. 22. In several exemplary embodiments, the modules 164a, 164b, and 164c are a common, interchangeable, lightweight set of components, which are easy to connect to, and remove from, the frame 12. In several exemplary embodiments, the modules 164a, 164b, and 164c provide improved machine setup time and reduced downtime between jobs.
In an exemplary embodiment, instead of, or in addition to modules identical to the module 164a, 164b, or 164c, the fixture 40 includes a module having a height that is less than the height of the module 164a, 164b, or 164c, such as a module having a height that is about half of the height of the module 164a, 164b, or 164c. In an exemplary embodiment, instead of, or in addition to modules identical to the module 164a, 164b, or 164c, the fixture 40 includes a module having a height that is greater than the height of the module 164a, 164b, or 164c. 
In an exemplary embodiment, if coils cannot be expanded because the coils are too tall for the module 164a but too short for the combination of the modules 164b and 164a, or if coils cannot be expanded because the coils are too tall for the combination of the modules 164a and 164b but too short for the combination of the modules 164a, 164b, and 164c, an extension, such as a 4-inch high extension, for the backplate 68 of the module 164b or 164c is inserted and held with dowel pins; a corresponding embodiment of the door plate 96 accommodates this height extension.
In an exemplary embodiment, as illustrated in FIGS. 23 and 24 with continuing reference to FIGS. 1-22, to adjust the fixture 40 to accommodate the depth D of a coil unit at the step 162b, the respective positions of the inside surfaces 96c of the plates 96 are adjusted, relative to the corresponding pairs of door supports 112a and 112b, and the respective positions of the latch keepers 86 are also adjusted, relative to the corresponding hinge plates 80.
More particularly, as shown in FIG. 23, the predetermined position of the inside surface 96c of the plate 96, relative to the pair of door supports 112a and 112b, corresponds to a coil unit that has a relatively large depth D. In an exemplary embodiment, the predetermined position of the inside surface 96c, relative to the pair of door supports 112a and 112b, corresponds to a coil unit having a depth D that accommodates six (6) rows of tubes; this predetermined position is referred to as predetermined position E6 in FIG. 23. If the depth D of the coil unit to be installed in the corresponding door assembly 44 or 46 is less than that of a coil unit that has six (6) rows of tubes, the fixture 40 is adjusted by disconnecting the horizontal supports 110a and 110b from the door supports 112a and 112b. Relative movement between the horizontal supports 110a and 110b, and the door supports 112a and 112b, is then effected, thereby shifting the position of the inside surface 96c of the plate 96 to which the horizontal supports 110a and 110b are connected. The horizontal supports 110a and 110b are reconnected to the door supports 112a and 112b, respectively, but using different pairs of the linearly-aligned through openings 112ac and 112bc. If the coil unit to be installed in the corresponding door assembly 44 or 46 has five (5) rows of tubes, the horizontal supports 110a and 110b, and thus the plate 96, are shifted to the left, as viewed in FIG. 23, by a predetermined increment X, which corresponds to the center-to-center spacing between adjacent ones of the through openings 112ac or 112bc. This shift to the left by the increment X results in the predetermined position of the inside surface 96c, relative to the door supports 112a and 112b, corresponding to a coil unit having a depth D that accommodates five (5) rows of tubes; this predetermined position is referred to as predetermined position D5 in FIG. 23. The predetermined positions C4, B3, and A2 in FIG. 23 refer to positions of the inside surface 96c, relative to the door supports 112a and 112b, corresponding to coil units have depths D that accommodate four (4) row of coils, three (3) rows of coils, and two (2) rows of coils, respectively.
As noted above, to execute the step 162b, in addition to adjusting the respective positions of the inside surfaces 96c of the plates 96, the respective predetermined positions of the latch keepers 86 are also adjusted accordingly. More particularly, as shown in FIG. 24, the position of the latch keeper 86, relative to the hinge plate 80, corresponds to a coil unit having a depth D that accommodates two (2) rows of tubes; this position is referred to as position A2 in FIG. 24. The rib 86f of the latch keeper 86 extends within the detent 80ka so that the rib 86f engages, or is at least proximate, the corresponding pair of surfaces 801 and 80m defined by the detent 80ka. If the depth D of the coil unit to be positioned in the internal region 48 is greater than that of a coil unit that has two (2) rows of tubes, the fixture 40 is adjusted by disconnecting the latch keeper 86 from the hinge plate 80, and moving the latch keeper 86 to the right, as viewed in FIG. 24. The latch keeper 86 is then reconnected to the hinge plate 80, but with the rib 86f extending within one of the detents 80kb, 80kc, 80kd, and 80ke (rather than the detent 80ka). If the coil unit to be positioned in the internal region 48 has three (3) rows of tubes, the latch keeper 86 is disconnected from the hinge plate 80 and shifted to the right, as viewed in FIG. 24, by a predetermined increment equal to the increment X in FIG. 23 and thus also referred to by the increment X in FIG. 24; the increment X corresponds to the center-to-center spacing between adjacent ones of the detents 80ka, 80kb, 80kc, 80kd, and 80ke. The latch keeper 86 is then reconnected to the hinge plate 80. This shift to the right by the increment X, and subsequent reconnection, results in the rib 86f extending within the detent 80kb so that the rib 86f engages, or is at least proximate, the corresponding pair of surfaces 80l and 80m defined by the detent 80kb; this position of the latch keeper 86 accommodates a coil unit having a depth D that accommodates three (3) rows of tubes, and is referred to as predetermined position B3 in FIG. 24. The predetermined positions C4, D5, and E6 in FIG. 24 refer to positions of the latch keeper 86, relative to the hinge plate 80, corresponding to coil units have depths D that accommodate four (4) row of coils, five (5) rows of coils, and six (6) rows of coils, respectively. The predetermined positions A2, B3, C4, D5, and E6 of the latch keeper 86 in FIG. 24 correspond to the predetermined positions A2, B3, C4, D5, and E6, respectively, of the insider surface 96c of the plate 96 in FIG. 23.
In an exemplary embodiment, as illustrated in FIG. 25 with continuing reference to FIGS. 1-24, to adjust the fixture 40 to accommodate the width W of a coil unit at the step 162c, the respective predetermined positions of one or more of the center spacer block 104 and the outside spacer blocks 98a and 98b are adjusted. If the width W of the coil unit to be connected to the corresponding door assembly 44 or 46, and to be positioned between the center block 104 and the outside spacer block 98a, is greater than the width of the coil unit 144a, then the outside spacer block 98a is disconnected from the plate 96 and moved to the left, as viewed in FIG. 25 and indicated by an arrow 168. The outside spacer block 98a is reconnected to the plate 96 with the rib 98aa extending in a different one of the detents 96e, at a predetermined position that is closer to the end portion 96a of the plate 96. Conversely, if the width W of the coil unit to be connected to the corresponding door assembly 44 or 46 is less than the width of the coil unit 144a, then the outside spacer block 98a is disconnected from the plate 96 and moved to the right, as viewed in FIG. 25 and indicated by an arrow 170. The outside spacer block 98a is reconnected to the plate 96 with the rib 98aa extending in a different one of the detents 96e, at a predetermined position that is farther away from the end portion 96a of the plate 96. Similarly, if the width W of the coil unit to be connected to the corresponding door assembly 44 or 46, and to be positioned between the center block 104 and the outside spacer block 98b, is greater than the width of the coil unit 144b, then the outside spacer block 98b is disconnected from the plate 96 and moved to the right, as viewed in FIG. 25 and indicated by an arrow 172. The outside spacer block 98b is reconnected to the plate 96 with the rib 98ba extending in a different one of the detents 96f, at a predetermined position that is closer to the end portion 96b of the plate 96. Conversely, if the width W of the coil unit to be connected to the corresponding door assembly 44 or 46 is less than the width of the coil unit 144b, then the outside spacer block 98b is disconnected from the plate 96 and moved to the left, as viewed in FIG. 25 and indicated by an arrow 174. The outside spacer block 98b is reconnected to the plate 96 with the rib 98ba extending in a different one of the detents 96f, at a predetermined position that is farther away from the end portion 96b of the plate 96. Additionally, the position of the center spacer block 104 may be slightly adjusted in either of the directions indicated by arrows 176 and 178 so that the rib 104a extends in either of the outside ones of the detents 96i. 
In an exemplary embodiment, at the step 162c, if the width W of the coil unit to be connected to the corresponding door assembly 44 or 46 is greater than the maximum allowable spacing between the center spacer block 104 and the outside spacer block 98a or 98b, the center block 104 may be removed and the coil unit may be snugly fit between the outside spacer blocks 98a and 98b to connect the coil unit to the door assembly 44 or 46, in accordance with the foregoing.
In an exemplary embodiment, at the step 162c, if the respective widths W of the coil units to be connected to the corresponding door assembly 44 or 46 are small enough, one or more additional spacer blocks, each of which is similar to the center spacer block 104 or the outside spacer block 98a or 98b, may be connected to the plate 96 so that three (3) or more coil units may be connected to the door assembly 44 or 46.
In several exemplary embodiments, the execution of the method 162, and/or the operation of the tube expander 10 including the operation of the fixture 40, provide side-to-side constraints that fit into detents spaced apart by one half of the side-to-side rod space interval. These constraints create a width for the coil equivalent to its design width plus permitted tolerance and slight clearance. Moreover, these side constraints may be relocated quickly. In several exemplary embodiments, for depth, the fixture 40 incorporates a fixed center hinge with quick change pin-and-hole mount features for the closing door such that the door can be mounted to create multiple constraining depths, plus tolerance and fit clearance, on the fixed interval of the machine rod spacing. In several exemplary embodiments, the door latch is designed to be quick release and detents located on the machine depth interval are designed to accommodate the various alignments of the door.
In several exemplary embodiments, a door assembly back is selectively placed on a mounting hub connected to a T-Track with fixed interval mounting points. In several exemplary embodiments, the hub mounting and precise T-Track fit create a repeatable positioning, adjustment-free positioning of the door that precisely aligns the coil unit containment feature described above to the expansion ram and vertical rods. Additionally, the pivot axis of the each door module is aligned with all other installed modules. In several exemplary embodiments, these features produce a repeatable, quality product by reducing operator involvement, improving changeover speed between jobs, and minimizing damage to the machine due to misalignment.
In an exemplary embodiment, as illustrated in FIGS. 26a and 26b with continuing reference to FIGS. 1-25, a fixture adapted to be connected to the frame 12 of the tube expander 10 is generally referred to by the reference numeral 180. The fixture 180 includes several components that are identical to corresponding components of the fixture 40; these identical components are given the same reference numerals. Like the fixture 40, the fixture 180 is vertically disposed between the upper shroud 34 (not shown in FIGS. 26a and 26b) and the horizontal support 26. In the fixture 180 illustrated in FIGS. 26a and 26b, instead of being hingedly connected, each of the left door assembly 44 and the right door assembly 46 is movably connected to the back units 42a, 42b, and 42c by being slidably connected to the back units 42a, 42b, and 42c. 
In several exemplary embodiments, the method 140 is executed using the fixture 180 in a manner substantially similar to the above-described manner in which the method 140 is executed using the fixture 40, except that neither the left door assembly 44 nor the right door assembly 46 pivots about a hinge axis. Instead, to close the left door assembly 44 so that the coil units 50a and 50b are disposed in the internal region 48, the left door assembly 44 is slid, relative to the back units 42a, 42b, and 42c and in a direction indicated by an arrow 182 in FIG. 26b. The left door assembly 44 is so slid until the coil units 50a and 50b are positioned in front of the internal region 48, at which point the left door assembly 44 is translated forwards, relative to the back units 42a, 42b, and 42c and in a direction indicated by an arrow 184 in FIG. 26b, to position the coil units 50a and 50b in the internal region 48. After the tubular expansion process is completed for the coil units 50a and 50b, the left door assembly 44 is moved in a direction opposite that indicated by the arrow 184, followed by movement in a direction opposite that indicated by the arrow 182. Likewise, to close the right door assembly 46 so that the coil units 144a and 144b are disposed in the internal region 48, the left door assembly 44 is slid, relative to the back units 42a, 42b, and 42c and in a direction opposite that indicated by the arrow 182 in FIG. 26b. The right door assembly 46 is so slid until the coil units 144a and 144b are positioned in front of the internal region 48, at which point the right door assembly 46 is translated forwards, relative to the back units 42a, 42b, and 42c and in a direction indicated by an arrow 184 in FIG. 26b. After the tubular expansion process is completed for the coil units 144a and 144b, the right door assembly 46 is in a direction opposite that indicated by the arrow 184, followed by movement in a direction indicated by the arrow 182.
In several exemplary embodiments, the execution of the method 140, and/or the operation of the tube expander 10 including the operation of the fixture 180, provides a shuttle loading system with two loading points, wherein an operator can unload and load coil units while the tube expander 10 is operating.
In several exemplary embodiments, the method 160 is executed using the fixture 180 in a manner substantially similar to the above-described manner in which the method 140 is executed using the fixture 40.
In several exemplary embodiments, the method 162 is executed using the fixture 180 in a manner substantially similar to the above-described manner in which the method 140 is executed using the fixture 40.
In an exemplary embodiment, as illustrated in FIGS. 27-31 with continuing reference to FIGS. 1-26b, a fixture is generally referred to by the reference numeral 185 and includes most of the components of the fixture 40, which components are given the same reference numerals. As shown in FIG. 28, the fixture 40 includes at least one left door actuator 186, at least one right door actuator 188, left latch actuators 190a, 190b, and 190c, and right latch actuators 192a, 192b, and 192c, all of which are in communication with the control unit 94. In an exemplary embodiment, one or more of the actuators 186, 188, 190a, 190b, 190c, 192a, 192b, and 192c are pneumatic actuators. In an exemplary embodiment, one or more of the actuators 186, 188, 190a, 190b, 190c, 192a, 192b, and 192c are hydraulic actuators.
As shown in FIGS. 27 and 29-31, a horizontally-extending support 194 is connected to the frame 12, and extends outward to the right of the fixture 185, as viewed in FIGS. 27 and 29. A horizontally-extending support 196 is connected to the frame 12, and extends outward to the left of the fixture 185, as viewed in FIGS. 27 and 29.
The right door actuator 188 is connected to the horizontally-extending support 194. More particularly, the right door actuator 188 includes a rod 188a, which is adapted to reciprocate relative to a cylinder 188b. To so reciprocate, the rod 188a is adapted to extend out from, and retract into, an end of the cylinder 188b. The other end of the cylinder 188b is pivotably coupled to a distal end portion 194a of the horizontally-extending support 194. The distal end of the rod 188a is pivotably connected to a protrusion 198, which extends from a right door brace 200. In the fixture 185, the right door brace 62 is omitted in favor of the right door brace 200. In the fixture 185, the right door brace 200 is connected to each of the right door units 58a, 58b, and 58c. The lower end portion of the right door brace 200 is connected to the horizontal support 110a of the right door unit 58a. The right door brace 200 extends upwards from the horizontal support 110a of the right door unit 58a, and is connected to the horizontal support 110a of the right door unit 58b. The right door brace 200 extends upwards from the horizontal support 110a of the right door unit 58b, and is connected to the horizontal support 110a of the right door unit 58c. The right door brace 200 connects the right door units 58a, 58b, and 58c together so that the right door units 58a, 58b, and 58c pivot together about the hinge axis 138.
The left door actuator 186 is connected to the horizontally-extending support 196. More particularly, the left door actuator 186 includes a rod 186a, which is adapted to reciprocate relative to a cylinder 186b. To so reciprocate, the rod 186a is adapted to extend out from, and retract into, an end of the cylinder 186b. The other end of the cylinder 186b is pivotably coupled to a distal end portion 196a of the horizontally-extending support 196. The distal end of the rod 186a is pivotably connected to a protrusion 202, which extends from a left door brace 204. In the fixture 185, the left door brace 56 is omitted in favor of the left door brace 204. In the fixture 185, the left door brace 204 is connected to each of the left door units 52a, 52b, and 52c. The lower end portion of the left door brace 204 is connected to the horizontal support 110a of the left door unit 52a. The left door brace 204 extends upwards from the horizontal support 110a of the left door unit 52a, and is connected to the horizontal support 110a of the left door unit 52b. The left door brace 204 extends upwards from the horizontal support 110a of the left door unit 52b, and is connected to the horizontal support 110a of the left door unit 52c. The left door brace 204 connects the left door units 52a, 52b, and 52c together so that the left door units 52a, 52b, and 52c pivot together about the hinge axis 136.
As shown most clearly in FIG. 30, the right latch actuators 192a, 192b, and 192c are connected to the respective end brackets 128 of the right door units 58a, 58b, and 58c. The right latch actuators 192a, 192b, and 192c include actuating members 192aa, 192ba, and 192ca, respectively, which are adapted to operably engage the respective latch bars 124 of the right door units 58a, 58b, and 58c. As shown most clearly in FIG. 31, the left latch actuators 190a, 190b, and 190c are connected to the respective end brackets 128 of the left door units 52a, 52b, and 52c. The left latch actuators 190a, 190b, and 190c include actuating members 190aa, 190ba, and 190ca, respectively, which are adapted to operably engage the respective latch bars 124 of the left door units 52a, 52b, and 52c. In several exemplary embodiments, all of the springs 130 are omitted from the fixture 185 in favor of the actuators 190a, 190b, 190c, 192a, 192b, and 192c. 
In several exemplary embodiments, with continuing reference to FIGS. 1-31, the operation of the fixture 185 is substantially identical to the above-described operation of the fixture 40 except that, instead of an operator manually opening and closing the right door assembly 46, the right door actuator 188 operates to open and close the right door assembly 46. To close the right door assembly 46, the control unit 94 causes the rod 188a to extend out of the cylinder 188b. During the extension of the rod 188a, relative pivoting motion occurs between the protrusion 200 and the rod 188a, and the cylinder 188b also pivots, relative to the horizontal-extending support 194 and in a counterclockwise direction as viewed in FIG. 29. The rod 188a continues to extend until the right door assembly 46 has pivoted, about the hinge axis 138 and in a clockwise direction as viewed in FIG. 29, so that the right door assembly 46 is closed and the coil units installed in the right door assembly (e.g., the coil units 144a and 144b) are positioned in the internal region 48. This closed position of the right door assembly 46 is shown in FIG. 29. Before, during, and/or after this pivoting movement of the right door assembly 46, the control unit 94 causes the actuators 192a, 192b, and 192c to engage the respective latch bars 124 of the right door units 58a, 58b, and 58c. The actuating members 192aa, 192ba, and 192bc move, relative to the respective end brackets 128, and engage the respective latch bars 124, causing the latch bars 124 to slide into the respective slots 86c for full latch engagement. As a result, an operator does not have to manually ensure full latch engagement using the handles 126.
To open the right door assembly 46, the latch bars 124 are disengaged from the slots 86c, respectively, using the actuators 192a, 192b, and 192c and/or the handles 126. If the actuators 192a, 192b, and 192c are used, the actuating members 192aa, 192ba, and 192ca are connected to the latch bars 124, respectively, and the control unit 94 causes the actuating members 192aa, 192ba, and 192ca to retract. The control unit 94 causes the rod 188a to retract into the cylinder 188b, thereby causing the right door assembly 46 to pivot about the hinge axis 138, in a counterclockwise direction as viewed in FIG. 29.
Similarly, instead of an operator manually opening and closing the left door assembly 44, the left door actuator 186 operates to open and close the left door assembly 44. To close the left door assembly 44, the control unit 94 causes the rod 186a to extend out of the cylinder 186b. During the extension of the rod 186a, relative pivoting motion occurs between the protrusion 202 and the rod 186a, and the cylinder 186b also pivots, relative to the horizontal-extending support 196 and in a clockwise direction as viewed in FIG. 29. The rod 186a continues to extend until the left door assembly 44 has pivoted, about the hinge axis 136 and in a counterclockwise direction as viewed in FIG. 29, so that the left door assembly 44 is closed and the coil units installed in the right door assembly (e.g., the coil units 50a and 50b) are positioned in the internal region 48. Before, during, and/or after this pivoting movement of the left door assembly 44, the control unit 94 causes the actuators 190a, 190b, and 190c to engage the respective latch bars 124 of the left door units 52a, 52b, and 52c. The actuating members 190aa, 190ba, and 190bc move, relative to the respective end brackets 128, and engage the respective latch bars 124, causing the latch bars 124 to slide into the respective slots 86c for full latch engagement. As a result, an operator does not have to manually ensure full latch engagement using the handles 126.
To open the left door assembly 44, the latch bars 124 are disengaged from the slots 86c, respectively, using the actuators 190a, 190b, and 190c and/or the handles 126. If the actuators 190a, 190b, and 190c are used, the actuating members 190aa, 190ba, and 190ca are connected to the latch bars 124, respectively, and the control unit 94 causes the actuating members 190aa, 190ba, and 190ca to retract. The control unit 94 causes the rod 186a to retract into the cylinder 186b, thereby causing the left door assembly 44 to pivot about the hinge axis 136, in a clockwise direction as viewed in FIG. 29, until the left door assembly 44 is open. This open position of the left door assembly 44 is shown in FIG. 29.
In several exemplary embodiments, the execution of the methods 140 and 160 using the fixture 185 is substantially identical to the execution of the methods 140 and 160 using the fixture 40, except that the door assemblies 44 and 46 are not manually opened and closed; instead, the control unit 94 uses the actuators 186 and 188 to open and close the door assemblies 44 and 46, respectively. Moreover, in several exemplary embodiments, the control unit 94 uses the actuators 190a, 190b, 190c, 192a, 192b, and 192c to engage the respective latch bars 124 and, in some exemplary embodiments, to disengage the respective latch bars 124.
In several exemplary embodiments, the operation of the fixture 185, and/or the execution of the methods 140 and/or 160 using the fixture 185, further decreases the cycle time of the tube expander 10 while reducing operator fatigue.
In an exemplary embodiment, the actuators 186 and 188 are omitted from the fixture 185 in favor of respective hydraulic motors, which operate to open and close the door assemblies 44 and 46. In several exemplary embodiments, the hydraulic motors are operably coupled to respective actuation linkages. In several exemplary embodiments, each of the actuation linkages is centered vertically and employs a vertically-oriented splined shaft and a corresponding gear. In several exemplary embodiments, the hydraulic motors provide high torque with low RPM. In several exemplary embodiments, the actuator 16 is a hydraulic actuator, and the hydraulic motors run off the hydraulic system of which the actuator 16 is a part.
In several exemplary embodiments, the fixture 40 may initially be a fixture kit, which is assembled in accordance with the foregoing description of the fixture 40; in several exemplary embodiments, the fixture kit may be used to retrofit an existing tube expander. In several exemplary embodiments, the fixture 180 may initially be a fixture kit, which is assembled in accordance with the foregoing description of the fixture 180; in several exemplary embodiments, the fixture kit may be used to retrofit an existing tube expander. In several exemplary embodiments, the fixture 185 may initially be a fixture kit, which is assembled in accordance with the foregoing description of the fixture 185; in several exemplary embodiments, the fixture kit may be used to retrofit an existing tube expander.
In an exemplary embodiment, as illustrated in FIG. 32 with continuing reference to FIGS. 1-31, an illustrative computing device 1000 for implementing one or more embodiments of one or more of the above-described networks, elements, methods and/or steps, and/or any combination thereof, is depicted. The computing device 1000 includes a processor 1000a, an input device 1000b, a storage device 1000c, a video controller 1000d, a system memory 1000e, a display 1000f, and a communication device 1000g, all of which are interconnected by one or more buses 1000h. In several exemplary embodiments, the storage device 1000c may include a floppy drive, hard drive, CD-ROM, optical drive, any other form of storage device and/or any combination thereof. In several exemplary embodiments, the storage device 1000c may include, and/or be capable of receiving, a floppy disk, CD-ROM, DVD-ROM, or any other form of computer readable medium that may contain executable instructions. In an exemplary embodiment, the computer readable medium is a non-transitory tangible media. In several exemplary embodiments, the communication device 1000g may include a modem, network card, or any other device to enable the computing device 1000 to communicate with other computing devices. In several exemplary embodiments, any computing device represents a plurality of interconnected (whether by intranet or Internet) computer systems, including without limitation, personal computers, mainframes, PDAs, smartphones and cell phones.
In several exemplary embodiments, one or both of the control panel 132 and the control unit 94, and/or one or more components thereof, are, or at least include, the computing device 1000 and/or components thereof, and/or one or more computing devices that are substantially similar to the computing device 1000 and/or components thereof. In several exemplary embodiments, one or more of the above-described components of one or more of the computing device 1000, the control panel 132, the control unit 94, and/or one or more components thereof, include respective pluralities of same components.
In several exemplary embodiments, a computer system typically includes at least hardware capable of executing machine readable instructions, as well as the software for executing acts (typically machine-readable instructions) that produce a desired result. In several exemplary embodiments, a computer system may include hybrids of hardware and software, as well as computer sub-systems.
In several exemplary embodiments, hardware generally includes at least processor-capable platforms, such as client-machines (also known as personal computers or servers), and hand-held processing devices (such as smart phones, tablet computers, personal digital assistants (PDAs), or personal computing devices (PCDs), for example). In several exemplary embodiments, hardware may include any physical device that is capable of storing machine-readable instructions, such as memory or other data storage devices. In several exemplary embodiments, other forms of hardware include hardware sub-systems, including transfer devices such as modems, modem cards, ports, and port cards, for example.
In several exemplary embodiments, software includes any machine code stored in any memory medium, such as RAM or ROM, and machine code stored on other devices (such as floppy disks, flash memory, or a CD ROM, for example). In several exemplary embodiments, software may include source or object code. In several exemplary embodiments, software encompasses any set of instructions capable of being executed on a computing device such as, for example, on a client machine or server.
In several exemplary embodiments, combinations of software and hardware could also be used for providing enhanced functionality and performance for certain embodiments of the present disclosure. In an exemplary embodiment, software functions may be directly manufactured into a silicon chip. Accordingly, it should be understood that combinations of hardware and software are also included within the definition of a computer system and are thus envisioned by the present disclosure as possible equivalent structures and equivalent methods.
In several exemplary embodiments, computer readable mediums include, for example, passive data storage, such as a random access memory (RAM) as well as semi-permanent data storage such as a compact disk read only memory (CD-ROM). One or more exemplary embodiments of the present disclosure may be embodied in the RAM of a computer to transform a standard computer into a new specific computing machine. In several exemplary embodiments, data structures are defined organizations of data that may enable an embodiment of the present disclosure. In an exemplary embodiment, a data structure may provide an organization of data, or an organization of executable code.
In several exemplary embodiments, a database may be any standard or proprietary database software. In several exemplary embodiments, the database may have fields, records, data, and other database elements that may be associated through database specific software. In several exemplary embodiments, data may be mapped. In several exemplary embodiments, mapping is the process of associating one data entry with another data entry. In an exemplary embodiment, the data contained in the location of a character file can be mapped to a field in a second table. In several exemplary embodiments, the physical location of the database is not limiting, and the database may be distributed. In an exemplary embodiment, the database may exist remotely from the server, and run on a separate platform. In an exemplary embodiment, the database may be accessible across the Internet. In several exemplary embodiments, more than one database may be implemented.
In several exemplary embodiments, a computer program, such as a plurality of instructions stored on a computer readable medium, such as the system memory 1000e, may be executed by a processor to cause the processor to carry out or implement in whole or in part the operation of the tube expander 10, one or more of the methods 140, 160, and 162, and/or any combination thereof. In several exemplary embodiments, such a processor may include the processor 1000a. In several exemplary embodiments, such a processor may execute the plurality of instructions in connection with a virtual computer system.
A tube expander for heat exchanger coil units is provided that includes a frame; a first back unit connected to the frame, the first back unit at least partially defining an internal region; a first door assembly movably connected to the first back unit and to which at least a first heat exchanger coil unit is adapted to be connected, the first door assembly being movable between: a first position in which the first heat exchanger coil unit is adapted to be disposed in the internal region for tubular expansion therein; and a second position in which the first heat exchanger coil unit is not adapted to be disposed in the internal region; and a second door assembly movably connected to the first back unit and to which at least a second heat exchanger coil unit is adapted to be connected, the second door assembly being movable between: a third position in which the second heat exchanger coil unit is adapted to be disposed in the internal region for tubular expansion therein; and a fourth position in which the second heat exchanger coil unit is not adapted to be disposed in the internal region. In an exemplary embodiment, the first door assembly is in the first position when the second door assembly is in the fourth position, and the second door assembly is in the third position when the first door assembly is in the second position. In an exemplary embodiment, the first back unit includes opposing first and second side portions; wherein the first door assembly is hingedly connected to the first back unit at the first side portion thereof; wherein the second door assembly is hingedly connected to the first back unit at the second side portion thereof; wherein a first hinge axis is defined by the hinged connection between the first door assembly and the first back unit; wherein the first door assembly is permitted to pivot, about the first hinge axis, between the first and second positions; wherein a second hinge axis is defined by the hinged connection between the second door assembly and the first back unit; and wherein the second door assembly is permitted to pivot, about the second hinge axis, between the third and fourth positions. In an exemplary embodiment, the first door assembly is slidably connected to the first back unit, and the second door assembly is slidably connected to the first back unit. In an exemplary embodiment, the first door assembly includes a first left door unit hingedly connected to the first back unit, and the second door assembly includes a first right door unit hingedly connected to the first back unit. In an exemplary embodiment, the tube expander includes a second back unit connected to the frame, the second back unit at least partially defining the internal region; and first and second braces connected to the first and second door assemblies, respectively; wherein the first door assembly further includes a second left door unit hingedly connected to the second back unit; wherein the first brace is connected to each of the first and second left door units; wherein the second door assembly further includes a second right door unit hingedly connected to the second back unit; and wherein the second brace is connected to each of the first and second right door units. In an exemplary embodiment, at least one heat exchanger coil unit has a height, width, and depth; wherein the first door assembly includes a first door unit connected to the first back unit; and a spacer block connected to the first door unit at one of a first plurality of predetermined positions, each of the predetermined positions in the first plurality of predetermined positions being spaced from at least one other predetermined position adjacent thereto by a first predetermined increment; wherein the one of the first plurality of predetermined positions at which the spacer block is connected accommodates the width of the at least one heat exchanger coil unit; wherein the connection between the first back unit and the frame, the connection between the first door unit and the first back unit, and the connection between the spacer block and the first door unit, are configured so that the spacer block is permitted to be disconnected from the first door unit and reconnected thereto at a different one of the first plurality of predetermined positions to accommodate a width of at least one other heat exchanger coil unit. In an exemplary embodiment, the first door unit includes a door plate to which the spacer block is connected; and a door support connected to the door plate and hingedly connected to the first back unit; wherein the position of the door plate, relative to the door support, is adjustable to accommodate the depth of the at least one heat exchanger coil unit; and wherein the door plate is positioned, relative to the door support, at one of a second plurality of predetermined positions, each of the predetermined positions in the second plurality of predetermined positions being spaced from at least one other predetermined position adjacent thereto by a second predetermined increment. In an exemplary embodiment, the first door unit further includes a first latch bar operably coupled to the door plate; wherein the first back unit includes a first hinge plate to which the door support is hingedly connected; a second hinge plate spaced from the first hinge plate; and a latch keeper connected to the second hinge plate and with which the first latch bar is adapted to be engaged; wherein the position of the latch keeper, relative to the second hinge plate, is adjustable to accommodate the depth of the at least one heat exchanger coil unit; and wherein the latch keeper is positioned, relative to the second hinge plate, at one of a third plurality of predetermined positions, each of the predetermined positions in the third plurality of predetermined positions being spaced from at least one other predetermined position adjacent thereto by a third predetermined increment, the third predetermined increment being equal to the second predetermined increment. In an exemplary embodiment, the tube expander includes a plurality of modules, each of which is connected to the frame; wherein the first back unit and the first door unit are part of one module in the plurality of modules; wherein the quantity of the modules in the plurality of modules that are connected to the frame is adjustable to accommodate the height of the at least one heat exchanger coil unit; wherein the first back unit includes at least two connectors; wherein the position of the one module, relative to the frame, is adjustable to accommodate the height of the at least one heat exchanger coil unit; and wherein the at least two connectors are configured so that the one module is connected to the frame at one of a fourth plurality of predetermined positions, each of the predetermined positions in the fourth plurality of predetermined positions being spaced from at least one other predetermined position adjacent thereto by a fourth predetermined increment. In an exemplary embodiment, the tube expander includes an actuator to conduct a tubular expansion process, the actuator being connected to the frame; a control unit in communication with the actuator; a sensor in communication with the control unit, the sensor including a face; a latch bar, which is part of the first door assembly; and a latch keeper connected to the first back unit and to which the sensor is connected, the latch keeper including a slot in which the latch bar is adapted to extend; wherein the face of the sensor is adjacent, or at least proximate, the slot of the latch keeper to sense the presence of the latch bar when the latch bar extends within the slot; and wherein the sensor and the control unit are configured so that: the control unit permits the actuator of the tube expander to operate to conduct the tubular expansion process when: the first door assembly is in the first position, the latch bar extends within the slot, and the sensor senses the presence of the latch bar within the slot; and the control unit does not permit the actuator of the tube expander to operate to conduct the tubular expansion process when the first door assembly is in the first position and the sensor does not sense the presence of the latch bar within the slot.
A tube expander for heat exchanger coil units is provided that includes a frame; and a fixture connected to the frame and to which at least one heat exchanger coil unit is adapted to be connected, the at least one heat exchanger coil unit having a height, width, and depth, the fixture including: a first back unit connected to the frame; a first door unit connected to the first back unit; and a spacer block connected to the first door unit at one of a first plurality of predetermined positions, each of the predetermined positions in the first plurality of predetermined positions being spaced from at least one other predetermined position adjacent thereto by a first predetermined increment; wherein the one of the first plurality of predetermined positions at which the spacer block is connected accommodates the width of the at least one heat exchanger coil unit; and wherein the connection between the first back unit and the frame, the connection between the first door unit and the first back unit, and the connection between the spacer block and the first door unit, are configured so that the spacer block is permitted to be disconnected from the first door unit and reconnected thereto at a different one of the first plurality of predetermined positions to accommodate a width of at least one other heat exchanger coil unit. In an exemplary embodiment, the first door unit includes: a door plate to which the spacer block is connected; and a door support connected to the door plate and hingedly connected to the first back unit; wherein the position of the door plate, relative to the door support, is adjustable to accommodate the depth of the at least one heat exchanger coil unit; and wherein the door plate is positioned, relative to the door support, at one of a second plurality of predetermined positions, each of the predetermined positions in the second plurality of predetermined positions being spaced from at least one other predetermined position adjacent thereto by a second predetermined increment. In an exemplary embodiment, the first door unit further includes a first latch bar operably coupled to the door plate; wherein the first back unit includes: a first hinge plate to which the door support is hingedly connected; a second hinge plate spaced from the first hinge plate; and a latch keeper connected to the second hinge plate and with which the first latch bar is adapted to be engaged; wherein the position of the latch keeper, relative to the second hinge plate, is adjustable to accommodate the depth of the at least one heat exchanger coil unit; and wherein the latch keeper is positioned, relative to the second hinge plate, at one of a third plurality of predetermined positions, each of the predetermined positions in the third plurality of predetermined positions being spaced from at least one other predetermined position adjacent thereto by a third predetermined increment, the third predetermined increment being equal to the second predetermined increment. In an exemplary embodiment, the tube expander includes a plurality of modules, each of which is connected to the frame; wherein the first back unit and the first door unit are part of a module in the plurality of modules; and wherein the quantity of the modules in the plurality of modules that are connected to the frame is adjustable to accommodate the height of the at least one heat exchanger coil unit. In an exemplary embodiment, the first back unit and the first door unit are part of a module; wherein the first back unit includes at least two connectors; and wherein the at least two connectors are configured so that the module is connected to the frame at one of a fourth plurality of predetermined positions, each of the predetermined positions in the fourth plurality of predetermined positions being spaced from at least one other predetermined position adjacent thereto by a fourth predetermined increment. In an exemplary embodiment, the tube expander includes first and second parallel-spaced tracks connected to the frame; wherein the at least two connectors are respectively connected to the first and second parallel-spaced tracks. In an exemplary embodiment, the tube expander includes an actuator to conduct a tubular expansion process, the actuator being connected to the frame; a control unit in communication with the actuator; a sensor in communication with the control unit, the sensor including a face; a latch bar, which is part of the first door unit; and a latch keeper connected to the first back unit and to which the sensor is connected, the latch keeper including a slot in which the latch bar is adapted to extend; wherein the face of the sensor is adjacent, or at least proximate, the slot of the latch keeper to sense the presence of the latch bar when the latch bar extends within the slot; wherein the first door unit has open and closed positions; and wherein the sensor and the control unit are configured so that: the control unit permits the actuator of the tube expander to operate to conduct the tubular expansion process when: the first door unit is in the closed position, the latch bar extends within the slot, and the sensor senses the presence of the latch bar within the slot; and the control unit does not permit the actuator of the tube expander to operate to conduct the tubular expansion process when the first door unit is in the closed position and the sensor does not sense the presence of the latch bar within the slot. In an exemplary embodiment, the first back unit at least partially defines an internal region; and wherein the fixture includes: a first door assembly movably connected to the first back unit and to which at least a first heat exchanger coil unit is adapted to be connected, the first door unit being part of the first door assembly, the first door assembly being movable between: a first position in which the first heat exchanger coil unit is adapted to be disposed in the internal region for tubular expansion therein; and a second position in which the first heat exchanger coil unit is not adapted to be disposed in the internal region; and a second door assembly movably connected to the first back unit and to which at least a second heat exchanger coil unit is adapted to be connected, the second door assembly being movable between: a third position in which the second heat exchanger coil unit is adapted to be disposed in the internal region for tubular expansion therein; and a fourth position in which the second heat exchanger coil unit is not adapted to be disposed in the internal region. In an exemplary embodiment, the first door assembly is in the first position when the second door assembly is in the fourth position; and wherein the second door assembly is in the third position when the first door assembly is in the second position. In an exemplary embodiment, the tube expander a second back unit connected to the frame, the second back unit at least partially defining the internal region; and first and second braces connected to the first and second door assemblies, respectively; wherein the first door unit is hingedly connected to the first back unit; wherein the first door assembly further includes a second door unit hingedly connected to the second back unit; wherein the first brace is connected to each of the first and second door units; wherein the second door assembly includes third and fourth door units hingedly connected to the first and second back units, respectively; and wherein the second brace is connected to each of the third and fourth door units.
A tube expander for one or more heat exchanger coil units is provided that includes a frame; an actuator connected to the frame to conduct a tubular expansion process within the one or more heat exchanger coil units; a control unit in communication with the actuator; a sensor in communication with the control unit, the sensor including a face; a door unit to which the one or more heat exchanger coil units are adapted to be connected, the door unit having open and closed positions and including a latch bar; and a latch keeper connected to the frame and to which the sensor is connected, the latch keeper including a slot in which the latch bar is adapted to extend; wherein the face of the sensor is adjacent, or at least proximate, the slot of the latch keeper to sense the presence of the latch bar when the latch bar extends within the slot; and wherein the sensor and the control unit are configured so that: the control unit permits the actuator of the tube expander to operate to conduct the tubular expansion process within the one or more heat exchanger coil units when: the door unit is in the closed position, the latch bar extends within the slot, and the sensor senses the presence of the latch bar within the slot; and the control unit does not permit the actuator of the tube expander to operate to conduct the tubular expansion process within the one or more heat exchanger coil units when the door is in the closed position and the sensor does not sense the presence of the latch bar within the slot. In an exemplary embodiment, at least one heat exchanger coil unit has a height, width, and depth; wherein the tube expander further includes: a back unit connected to the frame and to which the door unit is connected; and a spacer block connected to the door unit at one of a first plurality of predetermined positions, each of the predetermined positions in the first plurality of predetermined positions being spaced from at least one other predetermined position adjacent thereto by a first predetermined increment; wherein the one of the first plurality of predetermined positions at which the spacer block is connected accommodates the width of the at least one heat exchanger coil unit; wherein the connection between the back unit and the frame, the connection between the door unit and the back unit, and the connection between the spacer block and the door unit, are configured so that the spacer block is permitted to be disconnected from the door unit and reconnected thereto at a different one of the first plurality of predetermined positions to accommodate a width of at least one other heat exchanger coil unit. In an exemplary embodiment, the door unit includes: a door plate to which the spacer block is connected; and a door support connected to the door plate and hingedly connected to the back unit; wherein the position of the door plate, relative to the door support, is adjustable to accommodate the depth of the at least one heat exchanger coil unit; and wherein the door plate is positioned, relative to the door support, at one of a second plurality of predetermined positions, each of the predetermined positions in the second plurality of predetermined positions being spaced from at least one other predetermined position adjacent thereto by a second predetermined increment. In an exemplary embodiment, the door unit further includes a first latch bar operably coupled to the door plate; wherein the back unit includes: a first hinge plate to which the door support is hingedly connected; a second hinge plate spaced from the first hinge plate; and a latch keeper connected to the second hinge plate and with which the first latch bar is adapted to be engaged; wherein the position of the latch keeper, relative to the second hinge plate, is adjustable to accommodate the depth of the at least one heat exchanger coil unit; and wherein the latch keeper is positioned, relative to the second hinge plate, at one of a third plurality of predetermined positions, each of the predetermined positions in the third plurality of predetermined positions being spaced from at least one other predetermined position adjacent thereto by a third predetermined increment, the third predetermined increment being equal to the second predetermined increment. In an exemplary embodiment, the tube expander includes a plurality of modules, each of which is connected to the frame; wherein the back unit and the door unit are part of one module in the plurality of modules; and wherein the quantity of the modules in the plurality of modules that are connected to the frame is adjustable to accommodate the height of the at least one heat exchanger coil unit. In an exemplary embodiment, the back unit includes at least two connectors; wherein the back unit and the door unit are part of a module; wherein the position of the module, relative to the frame, is adjustable to accommodate the height of the at least one heat exchanger coil unit; and wherein the at least two connectors are configured so that the one module is connected to the frame at one of a fourth plurality of predetermined positions, each of the predetermined positions in the fourth plurality of predetermined positions being spaced from at least one other predetermined position adjacent thereto by a fourth predetermined increment. In an exemplary embodiment, the back unit at least partially defines an internal region; and wherein the fixture includes: a first door assembly movably connected to the back unit and to which at least a first heat exchanger coil unit is adapted to be connected, the door unit being part of the first door assembly, the first door assembly being movable between: a first position in which the first heat exchanger coil unit is adapted to be disposed in the internal region for tubular expansion therein; and a second position in which the first heat exchanger coil unit is not adapted to be disposed in the internal region; and a second door assembly movably connected to the back unit and to which at least a second heat exchanger coil unit is adapted to be connected, the second door assembly being movable between: a third position in which the second heat exchanger coil unit is adapted to be disposed in the internal region for tubular expansion therein; and a fourth position in which the second heat exchanger coil unit is not adapted to be disposed in the internal region. In an exemplary embodiment, the first door assembly is in the first position when the second door assembly is in the fourth position; and wherein the second door assembly is in the third position when the first door assembly is in the second position. In an exemplary embodiment, the tube expander includes another back unit connected to the frame, the another back unit at least partially defining the internal region; and first and second braces connected to the first and second door assemblies, respectively; wherein the door unit is hingedly connected to the back unit; wherein the first door assembly further includes another door unit hingedly connected to the another back unit; wherein the first brace is connected to each of the door unit and the another door unit; wherein the second door assembly includes two door units hingedly connected to the back unit and the another back unit, respectively; and wherein the second brace is connected to each of the two door units.
A fixture kit for a tube expander for heat exchanger coil units is provided that includes a first back unit adapted to be connected to the tube expander; a first door assembly adapted to be movably connected to the first back unit and to which at least a first heat exchanger coil unit is adapted to be connected; and a second door assembly adapted to be movably connected to the first back unit and to which at least a second heat exchanger coil unit is adapted to be connected; wherein, when the first back unit is connected to the tube expander and each of the first and second door assemblies is movably connected to the first back unit: the first back unit at least partially defines an internal region; the first door assembly has: a first position in which the first heat exchanger coil unit is adapted to be disposed in the internal region for tubular expansion therein; and a second position in which the first heat exchanger coil unit is not adapted to be disposed in the internal region; and the second door assembly has: a third position in which the second heat exchanger coil unit is adapted to be disposed in the internal region for tubular expansion therein; and a fourth position in which the second heat exchanger coil unit is not adapted to be disposed in the internal region. In an exemplary embodiment, the first door assembly is in the first position when the second door assembly is in the fourth position; and wherein the second door assembly is in the third position when the first door assembly is in the second position. In an exemplary embodiment, the first back unit includes opposing first and second side portions; wherein the first door assembly is adapted to be hingedly connected to the first back unit at the first side portion thereof; wherein the second door assembly is adapted to be hingedly connected to the first back unit at the second side portion thereof; wherein, when the first back unit is connected to the tube expander and each of the first and second door assemblies is hingedly connected to the first back unit: a first hinge axis is defined by the hinged connection between the first door assembly and the first back unit; the first door assembly is permitted to pivot, about the first hinge axis, between the first and second positions; a second hinge axis is defined by the hinged connection between the second door assembly and the first back unit; and the second door assembly is permitted to pivot, about the second hinge axis, between the third and fourth positions. In an exemplary embodiment, the first door assembly is adapted to be slidably connected to the first back unit; and wherein the second door assembly is adapted to be slidably connected to the first back unit. In an exemplary embodiment, the first door assembly includes a first left door unit adapted to be hingedly connected to the first back unit; and wherein the second door assembly includes a first right door unit adapted to be hingedly connected to the first back unit. In an exemplary embodiment, the fixture kit includes a second back unit adapted to be connected to the tube expander; and first and second braces adapted to be connected to the first and second door assemblies, respectively; wherein the first door assembly further includes a second left door unit adapted to be hingedly connected to the second back unit; wherein the first brace is adapted to be connected to each of the first and second left door units; wherein the second door assembly further includes a second right door unit adapted to be hingedly connected to the second back unit; and wherein the second brace is adapted to be connected to each of the first and second right door units.
A fixture kit is provided to which at least one heat exchanger coil unit is adapted to be connected, the at least one heat exchanger coil unit having a height, width, and depth, the fixture being adapted to be connected to a frame of a tube expander, the fixture kit including a first back unit adapted to be connected to the frame of the tube expander; a first door unit adapted to be connected to the first back unit; and a spacer block adapted to be connected to the first door unit at one of a first plurality of predetermined positions, each of the predetermined positions in the first plurality of predetermined positions being spaced from at least one other predetermined position adjacent thereto by a first predetermined increment; wherein the one of the first plurality of predetermined positions at which the spacer block is adapted to be connected accommodates the width of the at least one heat exchanger coil unit; wherein, when the first back unit is connected to the tube expander and the first door unit is connected to the first back unit, the first door unit and the spacer block are configured so that the spacer block is permitted to be disconnected from the first door unit and reconnected thereto at a different one of the first plurality of predetermined positions to accommodate a width of at least one other heat exchanger coil unit. In an exemplary embodiment, the first door unit includes: a door plate to which the spacer block is adapted to be connected; and a door support connected to the door plate and adapted to be hingedly connected to the first back unit; wherein the position of the door plate, relative to the door support, is adjustable to accommodate the depth of the at least one heat exchanger coil unit; and wherein the door plate is positioned, relative to the door support, at one of a second plurality of predetermined positions, each of the predetermined positions in the second plurality of predetermined positions being spaced from at least one other predetermined position adjacent thereto by a second predetermined increment. In an exemplary embodiment, the first door unit further includes a first latch bar operably coupled to the door plate; wherein the first back unit includes: a first hinge plate to which the door support is adapted to be hingedly connected; a second hinge plate spaced from the first hinge plate; and a latch keeper connected to the second hinge plate and with which the first latch bar is adapted to be engaged; wherein the position of the latch keeper, relative to the second hinge plate, is adjustable to accommodate the depth of the at least one heat exchanger coil unit; and wherein the latch keeper is positioned, relative to the second hinge plate, at one of a third plurality of predetermined positions, each of the predetermined positions in the third plurality of predetermined positions being spaced from at least one other predetermined position adjacent thereto by a third predetermined increment, the third predetermined increment being equal to the second predetermined increment. In an exemplary embodiment, the fixture kit includes a plurality of modules, each of which is adapted to be connected to the frame of the tube expander; wherein the first back unit and the first door unit are part of a module in the plurality of modules; and wherein the quantity of the modules in the plurality of modules that are connected to the frame of the tube expander is adjustable to accommodate the height of the at least one heat exchanger coil unit. In an exemplary embodiment, the first back unit and the first door unit are part of a module; wherein the first back unit includes at least two connectors; and wherein the at least two connectors are configured so that the module is adapted to be connected to the frame of the tube expander at one of a fourth plurality of predetermined positions, each of the predetermined positions in the fourth plurality of predetermined positions being spaced from at least one other predetermined position adjacent thereto by a fourth predetermined increment. In an exemplary embodiment, each of the at least two connectors is configured to be connected to a track.
A latch kit for a tube expander for one or more heat exchanger coil units is provided, the tube expander including an actuator to conduct a tubular expansion process within the one or more heat exchanger coil units, the tube expander further including a door to which the one or more heat exchanger coil units are adapted to be connected, the door including a latch bar and having open and closed positions, the latch kit including a control unit adapted to be in communication with the actuator; a sensor adapted to be in communication with the control unit, the sensor including a face; a latch keeper to which the sensor is adapted to be connected, the latch keeper including a slot in which the latch bar is adapted to extend; wherein, when the sensor is connected to the latch keeper, the face of the sensor is adjacent, or at least proximate, the slot of the latch keeper to sense the presence of the latch bar when the latch bar extends within the slot; wherein the sensor and the control unit are configured so that, when the control unit is in communication with the actuator and the sensor is in communication with the control unit: the control unit permits the actuator of the tube expander to operate to conduct the tubular expansion process within the one or more heat exchanger coil units when: the door is in the closed position, the latch bar extends within the slot, and the sensor senses the presence of the latch bar within the slot; and the control unit does not permit the actuator of the tube expander to operate to conduct the tubular expansion process within the one or more heat exchanger coil units when the door is in the closed position and the sensor does not sense the presence of the latch bar within the slot.
It is understood that variations may be made in the foregoing without departing from the scope of the disclosure.
In several exemplary embodiments, the elements and teachings of the various illustrative exemplary embodiments may be combined in whole or in part in some or all of the illustrative exemplary embodiments. In addition, one or more of the elements and teachings of the various illustrative exemplary embodiments may be omitted, at least in part, and/or combined, at least in part, with one or more of the other elements and teachings of the various illustrative embodiments.
Any spatial references such as, for example, “upper,” “lower,” “above,” “below,” “between,” “bottom,” “vertical,” “horizontal,” “angular,” “upward,” “downward,” “side-to-side,” “left-to-right,” “left,” “right,” “right-to-left,” “top-to-bottom,” “bottom-to-top,” “top,” “bottom,” “bottom-up,” “top-down,” etc., are for the purpose of illustration only and do not limit the specific orientation or location of the structure described above.
In several exemplary embodiments, while different steps, processes, and procedures are described as appearing as distinct acts, one or more of the steps, one or more of the processes, and/or one or more of the procedures may also be performed in different orders, simultaneously and/or sequentially. In several exemplary embodiments, the steps, processes and/or procedures may be merged into one or more steps, processes and/or procedures. In several exemplary embodiments, one or more of the operational steps in each embodiment may be omitted. Moreover, in some instances, some features of the present disclosure may be employed without a corresponding use of the other features. Moreover, one or more of the above-described embodiments and/or variations may be combined in whole or in part with any one or more of the other above-described embodiments and/or variations.
Although several exemplary embodiments have been described in detail above, the embodiments described are exemplary only and are not limiting, and those skilled in the art will readily appreciate that many other modifications, changes and/or substitutions are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of the present disclosure. Accordingly, all such modifications, changes and/or substitutions are intended to be included within the scope of this disclosure as defined in the following claims. In the claims, any means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures.

## Claims

1. A tube expander for heat exchanger coil units, the tube expander comprising:
a frame;
a first back unit connected to the frame, the first back unit at least partially defining an internal region;
a first door assembly movably connected to the first back unit and to which at least a first heat exchanger coil unit is adapted to be connected, the first door assembly being movable between:
a first position in which the first heat exchanger coil unit is adapted to be disposed in the internal region for tubular expansion therein; and
a second position in which the first heat exchanger coil unit is not adapted to be disposed in the internal region;

and
a second door assembly movably connected to the first back unit and to which at least a second heat exchanger coil unit is adapted to be connected, the second door assembly being movable between:
a third position in which the second heat exchanger coil unit is adapted to be disposed in the internal region for tubular expansion therein; and
a fourth position in which the second heat exchanger coil unit is not adapted to be disposed in the internal region.

2. The tube expander of claim 1, wherein the first door assembly is in the first position when the second door assembly is in the fourth position; and
wherein the second door assembly is in the third position when the first door assembly is in the second position.

3. The tube expander of claim 1, wherein the first back unit comprises opposing first and second side portions;
wherein the first door assembly is hingedly connected to the first back unit at the first side portion thereof;
wherein the second door assembly is hingedly connected to the first back unit at the second side portion thereof;
wherein a first hinge axis is defined by the hinged connection between the first door assembly and the first back unit;
wherein the first door assembly is permitted to pivot, about the first hinge axis, between the first and second positions;
wherein a second hinge axis is defined by the hinged connection between the second door assembly and the first back unit; and
wherein the second door assembly is permitted to pivot, about the second hinge axis, between the third and fourth positions.

4. The tube expander of claim 1, wherein the first door assembly is slidably connected to the first back unit; and
wherein the second door assembly is slidably connected to the first back unit.

5. The tube expander of claim 1, wherein the first door assembly comprises a first left door unit hingedly connected to the first back unit; and
wherein the second door assembly comprises a first right door unit hingedly connected to the first back unit.

6. The tube expander of claim 5, further comprising:
a second back unit connected to the frame, the second back unit at least partially defining the internal region; and
first and second braces connected to the first and second door assemblies, respectively;
wherein the first door assembly further comprises a second left door unit hingedly connected to the second back unit;
wherein the first brace is connected to each of the first and second left door units;
wherein the second door assembly further comprises a second right door unit hingedly connected to the second back unit; and
wherein the second brace is connected to each of the first and second right door units.

7. The tube expander of claim 1, wherein at least one heat exchanger coil unit has a height, width, and depth;
wherein the first door assembly comprises:
a first door unit connected to the first back unit; and
a spacer block connected to the first door unit at one of a first plurality of predetermined positions, each of the predetermined positions in the first plurality of predetermined positions being spaced from at least one other predetermined position adjacent thereto by a first predetermined increment;

wherein the one of the first plurality of predetermined positions at which the spacer block is connected accommodates the width of the at least one heat exchanger coil unit;
wherein the connection between the first back unit and the frame, the connection between the first door unit and the first back unit, and the connection between the spacer block and the first door unit, are configured so that the spacer block is permitted to be disconnected from the first door unit and reconnected thereto at a different one of the first plurality of predetermined positions to accommodate a width of at least one other heat exchanger coil unit.

8. The tube expander of claim 7, wherein the first door unit comprises:
a door plate to which the spacer block is connected; and
a door support connected to the door plate and hingedly connected to the first back unit;
wherein the position of the door plate, relative to the door support, is adjustable to accommodate the depth of the at least one heat exchanger coil unit;
and
wherein the door plate is positioned, relative to the door support, at one of a second plurality of predetermined positions, each of the predetermined positions in the second plurality of predetermined positions being spaced from at least one other predetermined position adjacent thereto by a second predetermined increment.

9. The tube expander of claim 8, wherein the first door unit further comprises a first latch bar operably coupled to the door plate;
wherein the first back unit comprises:
a first hinge plate to which the door support is hingedly connected;
a second hinge plate spaced from the first hinge plate; and
a latch keeper connected to the second hinge plate and with which the first latch bar is adapted to be engaged;
wherein the position of the latch keeper, relative to the second hinge plate, is adjustable to accommodate the depth of the at least one heat exchanger coil unit; and
wherein the latch keeper is positioned, relative to the second hinge plate, at one of a third plurality of predetermined positions, each of the predetermined positions in the third plurality of predetermined positions being spaced from at least one other predetermined position adjacent thereto by a third predetermined increment, the third predetermined increment being equal to the second predetermined increment.

10. The tube expander of claim 7, further comprising a plurality of modules, each of which is connected to the frame;
wherein the first back unit and the first door unit are part of one module in the plurality of modules;
wherein the quantity of the modules in the plurality of modules that are connected to the frame is adjustable to accommodate the height of the at least one heat exchanger coil unit;
wherein the first back unit comprises at least two connectors;
wherein the position of the one module, relative to the frame, is adjustable to accommodate the height of the at least one heat exchanger coil unit; and
wherein the at least two connectors are configured so that the one module is connected to the frame at one of a fourth plurality of predetermined positions, each of the predetermined positions in the fourth plurality of predetermined positions being spaced from at least one other predetermined position adjacent thereto by a fourth predetermined increment.

11. The tube expander of claim 1, further comprising:
an actuator to conduct a tubular expansion process, the actuator being connected to the frame;
a control unit in communication with the actuator;
a sensor in communication with the control unit, the sensor comprising a face;
a latch bar, which is part of the first door assembly; and
a latch keeper connected to the first back unit and to which the sensor is connected, the latch keeper comprising a slot in which the latch bar is adapted to extend;
wherein the face of the sensor is adjacent, or at least proximate, the slot of the latch keeper to sense the presence of the latch bar when the latch bar extends within the slot; and
wherein the sensor and the control unit are configured so that:
the control unit permits the actuator of the tube expander to operate to conduct the tubular expansion process when:
the first door assembly is in the first position,
the latch bar extends within the slot, and
the sensor senses the presence of the latch bar within the slot; and

the control unit does not permit the actuator of the tube expander to operate to conduct the tubular expansion process when the first door assembly is in the first position and the sensor does not sense the presence of the latch bar within the slot.

12. A tube expander for heat exchanger coil units, the tube expander comprising:
a frame; and
a fixture connected to the frame and to which at least one heat exchanger coil unit is adapted to be connected, the at least one heat exchanger coil unit having a height, width, and depth, the fixture comprising:
a first back unit connected to the frame;
a first door unit connected to the first back unit; and
a spacer block connected to the first door unit at one of a first plurality of predetermined positions, each of the predetermined positions in the first plurality of predetermined positions being spaced from at least one other predetermined position adjacent thereto by a first predetermined increment;

wherein the one of the first plurality of predetermined positions at which the spacer block is connected accommodates the width of the at least one heat exchanger coil unit; and
wherein the connection between the first back unit and the frame, the connection between the first door unit and the first back unit, and the connection between the spacer block and the first door unit, are configured so that the spacer block is permitted to be disconnected from the first door unit and reconnected thereto at a different one of the first plurality of predetermined positions to accommodate a width of at least one other heat exchanger coil unit.

13. The tube expander of claim 12, wherein the first door unit comprises:
a door plate to which the spacer block is connected; and
a door support connected to the door plate and hingedly connected to the first back unit;
wherein the position of the door plate, relative to the door support, is adjustable to accommodate the depth of the at least one heat exchanger coil unit;
and
wherein the door plate is positioned, relative to the door support, at one of a second plurality of predetermined positions, each of the predetermined positions in the second plurality of predetermined positions being spaced from at least one other predetermined position adjacent thereto by a second predetermined increment.

14. The tube expander of claim 13, wherein the first door unit further comprises a first latch bar operably coupled to the door plate;
wherein the first back unit comprises:
a first hinge plate to which the door support is hingedly connected;
a second hinge plate spaced from the first hinge plate; and
a latch keeper connected to the second hinge plate and with which the first latch bar is adapted to be engaged;
wherein the position of the latch keeper, relative to the second hinge plate, is adjustable to accommodate the depth of the at least one heat exchanger coil unit; and
wherein the latch keeper is positioned, relative to the second hinge plate, at one of a third plurality of predetermined positions, each of the predetermined positions in the third plurality of predetermined positions being spaced from at least one other predetermined position adjacent thereto by a third predetermined increment, the third predetermined increment being equal to the second predetermined increment.

15. The tube expander of claim 12, further comprising a plurality of modules, each of which is connected to the frame;
wherein the first back unit and the first door unit are part of a module in the plurality of modules; and
wherein the quantity of the modules in the plurality of modules that are connected to the frame is adjustable to accommodate the height of the at least one heat exchanger coil unit.

16. The tube expander of claim 12, wherein the first back unit and the first door unit are part of a module;
wherein the first back unit comprises at least two connectors; and
wherein the at least two connectors are configured so that the module is connected to the frame at one of a fourth plurality of predetermined positions, each of the predetermined positions in the fourth plurality of predetermined positions being spaced from at least one other predetermined position adjacent thereto by a fourth predetermined increment.

17. The tube expander of claim 16, further comprising first and second parallel-spaced tracks connected to the frame;
wherein the at least two connectors are respectively connected to the first and second parallel-spaced tracks.

18. The tube expander of claim 12, further comprising:
an actuator to conduct a tubular expansion process, the actuator being connected to the frame;
a control unit in communication with the actuator;
a sensor in communication with the control unit, the sensor comprising a face;
a latch bar, which is part of the first door unit; and
a latch keeper connected to the first back unit and to which the sensor is connected, the latch keeper comprising a slot in which the latch bar is adapted to extend;
wherein the face of the sensor is adjacent, or at least proximate, the slot of the latch keeper to sense the presence of the latch bar when the latch bar extends within the slot;
wherein the first door unit has open and closed positions; and
wherein the sensor and the control unit are configured so that:
the control unit permits the actuator of the tube expander to operate to conduct the tubular expansion process when:
the first door unit is in the closed position,
the latch bar extends within the slot, and
the sensor senses the presence of the latch bar within the slot; and

the control unit does not permit the actuator of the tube expander to operate to conduct the tubular expansion process when the first door unit is in the closed position and the sensor does not sense the presence of the latch bar within the slot.

19. The tube expander of claim 12, wherein the first back unit at least partially defines an internal region; and
wherein the fixture comprises:
a first door assembly movably connected to the first back unit and to which at least a first heat exchanger coil unit is adapted to be connected, the first door unit being part of the first door assembly, the first door assembly being movable between:
a first position in which the first heat exchanger coil unit is adapted to be disposed in the internal region for tubular expansion therein; and
a second position in which the first heat exchanger coil unit is not adapted to be disposed in the internal region;

and
a second door assembly movably connected to the first back unit and to which at least a second heat exchanger coil unit is adapted to be connected, the second door assembly being movable between:
a third position in which the second heat exchanger coil unit is adapted to be disposed in the internal region for tubular expansion therein; and
a fourth position in which the second heat exchanger coil unit is not adapted to be disposed in the internal region.

20. The tube expander of claim 19, wherein the first door assembly is in the first position when the second door assembly is in the fourth position; and
wherein the second door assembly is in the third position when the first door assembly is in the second position.

21. The tube expander of claim 19, further comprising:
a second back unit connected to the frame, the second back unit at least partially defining the internal region; and
first and second braces connected to the first and second door assemblies, respectively;
wherein the first door unit is hingedly connected to the first back unit;
wherein the first door assembly further comprises a second door unit hingedly connected to the second back unit;
wherein the first brace is connected to each of the first and second door units;
wherein the second door assembly comprises third and fourth door units hingedly connected to the first and second back units, respectively; and
wherein the second brace is connected to each of the third and fourth door units.

22. A tube expander for one or more heat exchanger coil units, the tube expander comprising:
a frame;
an actuator connected to the frame to conduct a tubular expansion process within the one or more heat exchanger coil units;
a control unit in communication with the actuator;
a sensor in communication with the control unit, the sensor comprising a face;
a door unit to which the one or more heat exchanger coil units are adapted to be connected, the door unit having open and closed positions and comprising a latch bar; and
a latch keeper connected to the frame and to which the sensor is connected, the latch keeper comprising a slot in which the latch bar is adapted to extend;
wherein the face of the sensor is adjacent, or at least proximate, the slot of the latch keeper to sense the presence of the latch bar when the latch bar extends within the slot; and
wherein the sensor and the control unit are configured so that:
the control unit permits the actuator of the tube expander to operate to conduct the tubular expansion process within the one or more heat exchanger coil units when:
the door unit is in the closed position,
the latch bar extends within the slot, and
the sensor senses the presence of the latch bar within the slot; and

the control unit does not permit the actuator of the tube expander to operate to conduct the tubular expansion process within the one or more heat exchanger coil units when the door is in the closed position and the sensor does not sense the presence of the latch bar within the slot.

23. The tube expander of claim 22, wherein at least one heat exchanger coil unit has a height, width, and depth;
wherein the tube expander further comprises:
a back unit connected to the frame and to which the door unit is connected; and
a spacer block connected to the door unit at one of a first plurality of predetermined positions, each of the predetermined positions in the first plurality of predetermined positions being spaced from at least one other predetermined position adjacent thereto by a first predetermined increment;
wherein the one of the first plurality of predetermined positions at which the spacer block is connected accommodates the width of the at least one heat exchanger coil unit;
wherein the connection between the back unit and the frame, the connection between the door unit and the back unit, and the connection between the spacer block and the door unit, are configured so that the spacer block is permitted to be disconnected from the door unit and reconnected thereto at a different one of the first plurality of predetermined positions to accommodate a width of at least one other heat exchanger coil unit.

24. The tube expander of claim 23, wherein the door unit comprises:
a door plate to which the spacer block is connected; and
a door support connected to the door plate and hingedly connected to the back unit;
wherein the position of the door plate, relative to the door support, is adjustable to accommodate the depth of the at least one heat exchanger coil unit;
and
wherein the door plate is positioned, relative to the door support, at one of a second plurality of predetermined positions, each of the predetermined positions in the second plurality of predetermined positions being spaced from at least one other predetermined position adjacent thereto by a second predetermined increment.

25. The tube expander of claim 24, wherein the door unit further comprises a first latch bar operably coupled to the door plate;
wherein the back unit comprises:
a first hinge plate to which the door support is hingedly connected;
a second hinge plate spaced from the first hinge plate; and
a latch keeper connected to the second hinge plate and with which the first latch bar is adapted to be engaged;
wherein the position of the latch keeper, relative to the second hinge plate, is adjustable to accommodate the depth of the at least one heat exchanger coil unit; and
wherein the latch keeper is positioned, relative to the second hinge plate, at one of a third plurality of predetermined positions, each of the predetermined positions in the third plurality of predetermined positions being spaced from at least one other predetermined position adjacent thereto by a third predetermined increment, the third predetermined increment being equal to the second predetermined increment.

26. The tube expander of claim 23, further comprising a plurality of modules, each of which is connected to the frame;
wherein the back unit and the door unit are part of one module in the plurality of modules; and
wherein the quantity of the modules in the plurality of modules that are connected to the frame is adjustable to accommodate the height of the at least one heat exchanger coil unit.

27. The tube expander of claim 23, wherein the back unit comprises at least two connectors;
wherein the back unit and the door unit are part of a module;
wherein the position of the module, relative to the frame, is adjustable to accommodate the height of the at least one heat exchanger coil unit; and
wherein the at least two connectors are configured so that the one module is connected to the frame at one of a fourth plurality of predetermined positions, each of the predetermined positions in the fourth plurality of predetermined positions being spaced from at least one other predetermined position adjacent thereto by a fourth predetermined increment.

28. The tube expander of claim 22, wherein the back unit at least partially defines an internal region; and
wherein the fixture comprises:
a first door assembly movably connected to the back unit and to which at least a first heat exchanger coil unit is adapted to be connected, the door unit being part of the first door assembly, the first door assembly being movable between:
a first position in which the first heat exchanger coil unit is adapted to be disposed in the internal region for tubular expansion therein; and
a second position in which the first heat exchanger coil unit is not adapted to be disposed in the internal region;

and
a second door assembly movably connected to the back unit and to which at least a second heat exchanger coil unit is adapted to be connected, the second door assembly being movable between:
a third position in which the second heat exchanger coil unit is adapted to be disposed in the internal region for tubular expansion therein; and
a fourth position in which the second heat exchanger coil unit is not adapted to be disposed in the internal region.

29. The tube expander of claim 28, wherein the first door assembly is in the first position when the second door assembly is in the fourth position; and
wherein the second door assembly is in the third position when the first door assembly is in the second position.

30. The tube expander of claim 28, further comprising:
another back unit connected to the frame, the another back unit at least partially defining the internal region; and
first and second braces connected to the first and second door assemblies, respectively;
wherein the door unit is hingedly connected to the back unit;
wherein the first door assembly further comprises another door unit hingedly connected to the another back unit;
wherein the first brace is connected to each of the door unit and the another door unit;
wherein the second door assembly comprises two door units hingedly connected to the back unit and the another back unit, respectively; and
wherein the second brace is connected to each of the two door units.