fa hairpin receiver problem

8/13/2019 FA Hairpin Receiver Problem

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Quality Control

Hairpin Leak & Damage @ Expander & Brazing StationDate: 16-Nov-09

Problem: Leaks and hairpin free-length damage & deformation are reported from the field as well asseen during regular coil shop QC inspection.

YY Analysis:

WHY - Leaks and hairpin free-length damage & deformation (see Table 1.0 )

WHAT WHO WHEN1. Handling of coils in the Sub-cooler & Header tube results to damage

1.1. Operators are handling the coils in the headers during processing& movement.

1.1.1. Coils have almost no provision (side rails) for handling

during assembly process in the shop-floor. (see Table #2.0 ) Retrain CS operators & coaters on handling and emphasize

on not holding on to sub-coolers.PRODUCTION

CS-Nov 14Done

CC-Nov 18

1.2. Damage during forklift transport or bumped by forklift while instaging area

Design special rack for coils MFG ENGG/PRODUCTION

Mar 10

Study provision of fence in coil shop staging area. MFG ENGG Jan 10

2. Header tubes vibrate during transport and operations2.1. Poor clamping/support design of header tube assemblies.

Product engineering is now providing header tube clamps. PRODUCTENGG Nov 9Done

3. Expander Machine yields poor swaging (see Table 5.0 ) PRODUCTION/

MFG ENGG 1 st Wk Dec

3.1. Machine Set-up - Ongoing study and analysis on the root-cause3.2. Coil orientation - same

4. Extra Deep Swaging in brazing area extends up to the endplate collar4.1. Manual swaging tool is not standardized-some are too lengthy (see

Table 4.0 ).4.1.1. No swaging design rule

Swaging rule defined and to be put into CS spec. - QC/MFG ENGG/PRODUCTION

Nov 19

Manual Swaging tool to be standardized and to be put intospec.

MFG ENGG Dec 12

Best Partner expander machine with 7mm swagingdepth is ongoing reduction of swage depth as perdesign rule.

PRODUCTION /MAINTENANCE

Nov 23

4.2. Manual swaging of braze operator4.2.1. Expander machine is not swaging/flaring all tubes

4.2.1.1. Material Problem Primarily happens on Mettubematerial Get more data for the comparison between vendors.

Only Sumitomo is running now. QC

/PRODUCTIONNov 2309

4.2.1.2. Machine Problem same as above-

4.2.2. Operator widens hairpin free-length opening to accommodateheader process tubes

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Table 1.0 Photos of Hairpin Free-Length Damage / Deformation

#1 Free-length deformation. Notethe lack of swage section in the stemin the upper tube.CAC1-3 Assembly Line

#2 Free-length damageCAC1-3 Assembly Line

#3 Free-length deformationCAC1-3 Assembly Line

#4 Process tube pushed all the wayof the entire hairpin free length.Note, there is no more visible swagesection in the stem. This is similarto #8 belowCAC1-1 Assembly Line

#5 Leak @ the endplate collararea.Field- Log-In S3G-AA-048-2009

#6 Free-length deformationField- Log-In S3G-AA-096-2009

#7 Hairpin leak at end plate junction.Field - Log-In S3G-AA-106-2009

#8 Leak @ the endplate collararea. Note, there is no morevisible swage section in the stem.Field -Log-In S3G-AA-105-2009

#9 Leak @ the endplate collar area.Field -Log-In S3G-AA-096-2009

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Table 2.0 Photos of process punched holes in the header main tube

1' t( (o!e )'*in +rom t(e (o!e ,1 "enteri$ a!read. /1 16 a2a. +rom t(e "enter

Ho!e ,1 re+eren"e po$ition

13 t( (o!e )'6in +rom t(e (o!e ,1 "enteri$ a!read. /3 3' a2a. +rom t(e "enter

1* t( (o!e )'4in +rom t(e (o!e ,1 "enteri$ a!read. /1 4 a2a. +rom t(e "enter

5oi! Hand!ing in 5S

Table 3.0 Photos of process tubes misaligned with the hairpin free-length port.

ro"e$$ t#%e$ not a!igned 2it( t(e(airpin +ree-!engt( port$



Table 4.0 Photos of non-standard swaging/flaring tools used in CS. Non-$tandard $a2ing g!aring p#n"(too!$ #$ed in 5oi! $(op %razing area

Table 5.0 Photos of good and bad swaging before brazing.

Bad S2aging S2age in one $ide o+ t(et#%e on!.

er+e"t S2aging & 7!aring

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fa hairpin receiver problem

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