Common Fault Analysis and Troubleshooting Techniques for Radiator Systems

(1) Minor leakage in the core, undetected during airtightness testing, leading to the product being shipped as qualified.

(2) Leakage at the welded joints of the heat exchanger.

(1) Strictly control airtightness testing by adhering to test pressure and pressure-holding duration requirements. Optimize the design of airtight joints to prevent defects and leakage, ensuring every product leaving the factory meets standards.

(2) Ensure joints are designed to be robust and securely welded.

(1) Insufficient strength of the end covers.

(2) Inadequate fin strength (insufficient material thickness).

(3) Excessive blockage in the heat channels.

(4) Excessive pressure in the heat exchanger’s hot channels.

(5) Lack of overpressure protection in both the system and the heat exchanger core.

(6) Delayed response of the bypass valve.

(1) Use semicircular end covers or add reinforcing ribs to enhance strength.

(2) Incorporate a check valve during product design.

(3) Install a pressure relief valve in the radiator system by the main manufacturer.

(1) Insufficient clearance between the fan and the air guide cover.

(2) Eccentricity during fan rotation, causing friction against one side of the air guide cover.

(1) Design adequate clearance between the fan and the air guide cover; generally, a unilateral gap of about 10 mm is sufficient.

(2) Perform dynamic balancing tests on fans before leaving the factory.

Eccentricity during fan rotation causes uneven stress on the hydraulic motor shaft, leading to wear on the shaft seal over time and resulting in leakage.

Conduct dynamic balancing tests on fans before leaving the factory.

(1) Motor overload.

(2) Poor quality of the motor itself.

(1) Carefully consider the type of motor to be used during the design phase.

(2) Select qualified motor suppliers and inspect motors upon arrival at the factory.

(1) Dimensional deviations in installation holes.

(2) Dimensional deviations in the diagonal measurements of installation holes.

(3) Dimensional deviations or rhomboid deformation of the core after brazing.

(4) Qualified dimensions after tack welding but shrinkage after argon arc welding.

(5) Strict installation dimension requirements by the main manufacturer, exceeding the capabilities of welding processes.

(1) Specify detailed inspection requirements for installation dimensions in drawings and process specifications, including tolerance ranges for diagonal differences.

(2) Inspectors must strictly verify not only the dimensions marked on installation drawings but also compare diagonal measurements to ensure they are within tolerance.

(3) Utilize inspection fixtures.

(4) Consider weld and shrinkage deformation during process or product design.

(5) For exceptionally strict installation dimension requirements from the main manufacturer, adopt post-welding machining methods.