Analysis and Modification of Heatex Model H2 Heat Exchanger

Abstract: The product H2 is a new heat exchanger produced, manufactured and sold by Heatex. It has an excellent surface efficiency, in large parts because of its slim features. The slim features does however have a drawback. It isn’t as mechanically stable and robust as its earlier cousins. The product tends to deform plastically in lifting conditions, especially the heavier versions needs extra support or, in some cases, had to be assembled on site. The purpose of this project is to find out which of the H2 product series that cannot be lifted at their present state and modify these so that the assembly can be done on Heatex main production facility. The analysis was done in a FEM-based program according to the wishes of Heatex. The CAD models were collected and modified to reduce the amount of elements and nodes required by the FEM-based program. The results did not correspond particularly well with real life testing. If testing of one product of H2-series can gather sufficient data the results can hopefully be used to extrapolate between real life data and the other models of H2. The modification was done largely deploying Ulrich and Eppingers product design and development process. The modified heat exchanger will be built in steel instead of aluminum. The beams will be made out of two separate pieces welded together, preferable before they are delivered to Heatex. To change production the least amount possible the raw material steel beams should be delivered in pieces the same length as the current aluminum beams. The beams are then cut into appropriate size for production and the ends are drilled in drill fixtures. The end plates will be modified to fit the new beams. The rivets are then fastened at a 90° angle from the aluminum beams. The finished steel heat exchanger should be significantly more robust than its current counterpart however further testing is required.