CN102865177B - A kind of structure of knockdown impingement type hydraulic generator runner and manufacture method - Google Patents
A kind of structure of knockdown impingement type hydraulic generator runner and manufacture method Download PDFInfo
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- CN102865177B CN102865177B CN201210338809.6A CN201210338809A CN102865177B CN 102865177 B CN102865177 B CN 102865177B CN 201210338809 A CN201210338809 A CN 201210338809A CN 102865177 B CN102865177 B CN 102865177B
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- 238000005495 investment casting Methods 0.000 claims abstract description 6
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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Abstract
The present invention relates to a kind of structure and manufacture method of impingement type hydraulic generator runner of fabricated structure, especially bucket parts are by the structure of the fabricated structure impingement type hydraulic generator runner of double wheel hub clamping structure and manufacture, overcome the shortcoming of the high and welded structure runner Security deficiency of solid forging cake blank processing cost.This runner is provided with bucket parts, wheel hub, and wheel hub is two disk wheel hub clamping structures, and bucket parts one end is located between two disk wheel hub clamping structures, is interconnected between adjacent bucket parts.Bucket parts of the present invention adopt the single manufactures of kinds of processes method such as electroslag casting process, precision casting technology or Forging Technology, and runner bucket parts blank facilitates digital control processing, and bucket water conservancy molded line is accurate, and runner is exerted oneself height.Adopt the digital control processing of single bucket independence, do not use large-sized numerical control process equipment, and can process by multi-position simultaneously, improve the work efficiency of impact runner, shorten the process-cycle, make processing cost reduce simultaneously.
Description
Technical Field
The invention relates to a structure and a manufacturing method of an impact type hydraulic generator rotating wheel with a combined structure, in particular to a structure and a manufacturing process of the impact type hydraulic generator rotating wheel with a combined structure, wherein a bucket part is clamped by a double hub.
Background
With the structural adjustment of the country to the electric power construction and the attention to the environmental protection, the active development of hydropower has become a guideline for the construction of the electric power industry in China. The water and electricity belongs to renewable clean energy, develops the water and electricity, improves the design, manufacture and production capacity of a large high-water-head impact type water turbine unit, and is the demand for promoting the development of national economy and mechanical industry.
With the improvement of the output of the water turbine, the water head of the hydropower station is higher and higher, and the technology of the high-water-head water turbine is mainly embodied by the manufacturing of an impact runner of the high-water-head water turbine. The runner bucket is a core component of an impulse type hydropower station, and the efficiency, the service life and the use safety of a water turbine are directly influenced by the manufacturing level of the runner bucket, so that the research and the development of the runner manufacturing technology are highly emphasized in all countries in the world.
For a high-water-head impact type rotating wheel, the diameter of the high-water-head impact type rotating wheel is generally 0.6-4 m, the larger diameter can reach more than 6 m, the main danger in use is that a bucket root is cracked, the bucket is cracked through a hub to cause bucket flying, and major safety accidents occur. Meanwhile, the rotating wheel has higher manufacturing cost and higher requirements on the service life.
There are generally four production processes for producing an impulse runner in China:
1. integral sand casting: the method has the advantages that the production cost is low, and the defects that the material has defects caused by the process, the service life is short, the use safety is not high, and the bucket flying accident is easy to generate;
2. the runner is formed by split casting and welding, namely the hub and the water bucket are respectively and independently manufactured, and then the hub and the water bucket are connected into an integral combined runner by riveting or welding: its advantages are low cost and low safety. When the runner runs, the water bucket is subjected to the action of the pulse alternating load of the water jet, and a welding seam between the water bucket and the hub is fatigued and cracked;
3. integrally casting a cake-shaped blank, and performing numerical control machining forming: the advantages are that the manufacturing cost is slightly low, the molded line is accurate and has good output, the defects are that the service life is short and the safety is poor;
4. forging a round cake blank, and carrying out numerical control machining forming: the advantages are good accurate output of molded line, long service life, good safety and high cost. Currently, this is the main manufacturing process for high head wheels.
At present, the manufacturing of high-water-head impact type rotating wheels at home and abroad mainly adopts a technological method of forging blanks and then carrying out numerical control machining, because the forging technology can effectively reduce the defects of the rotating wheels and improve the use safety of the rotating wheels. However, the process has great problems in actual production, firstly, the processing amount of the forge piece is large, and the material utilization rate is less than 50 percent; secondly, for producing a large-scale impact type rotating wheel, because the diameter of the wheel is large, the required forging stock can be produced by a large-scale forging press of ten thousand tons, so that the manufacturing cost of the rotating wheel is extremely high.
Disclosure of Invention
The invention provides a structure of a combined impact type hydraulic generator rotating wheel and a manufacturing method thereof, aiming at overcoming the defects of high processing cost of an integrally forged round cake blank and insufficient safety of the rotating wheel with a welded structure.
The technical scheme of the invention is as follows:
the utility model provides a modular structure of impacted style hydraulic generator runner, this runner is equipped with: the bucket comprises bucket parts and hubs, wherein the hubs are two disc hub clamping structures, one end of each bucket part is clamped between the two disc hub clamping structures, and the adjacent bucket parts are connected with each other.
The structure of the combined impact type hydraulic generator runner is characterized in that a bucket part is connected with a hub in one or more combination modes:
(1) at the connecting position of the hub and the bucket part, the hub and the bucket part are fixed through a corresponding through hole and a corresponding connecting piece;
(2) at the connecting position of the hub and the bucket part, the hub and the bucket part are fixed through a corresponding non-through hole and a corresponding connecting piece;
(3) the hub and the bucket part are positioned by a cylindrical boss and a corresponding groove at the connecting position of the hub and the bucket part;
(4) at the connecting position of the hub and the bucket part, the hub and the bucket part are positioned by an inclined strip-shaped boss and a corresponding groove;
(5) and at the connecting position of the hub and the bucket part, the hub and the bucket part are positioned by a trapezoidal boss and a corresponding groove.
In the structure of the combined impact type hydraulic generator runner, in the connection mode (1), the hub and the bucket part are fastened and clamped through the through holes by using a whole bolt or a riveting piece.
In the connection mode (2), the hub and the bucket part are fixed through a non-through hole by a bolt or a riveting piece on two sides respectively.
The combined impact type hydraulic generator runner structure increases the clamping area of the hub through the placement of the cushion blocks between the bolts and the hub.
The structure of the combined impact type hydraulic generator runner adopts one or more than one combination mode for connection between adjacent bucket parts:
(1) two sides of each bucket component are respectively provided with a wedge-shaped groove, and adjacent bucket components are connected in a matching way through an X-shaped wedge block and the wedge-shaped grooves;
(2) two sides of each bucket part are respectively provided with a wedge-shaped groove and a wedge-shaped boss, and adjacent bucket parts are directly connected in a matching way through the wedge-shaped grooves and the wedge-shaped bosses;
(3) two sides of each bucket part are respectively provided with a semi-wedge-shaped groove and a semi-wedge-shaped boss, and adjacent bucket parts are directly connected in a matching way through the semi-wedge-shaped grooves and the semi-wedge-shaped bosses;
(4) the adjacent surfaces on the two sides of the bucket component are respectively provided with an adjacent surface boss and an adjacent surface groove, and the adjacent surface bosses and the adjacent surface grooves are matched for accurate axial positioning of the bucket component.
In the structure of the combined impact type hydraulic generator runner, in the connection mode (4), the boss on the adjacent surface and the groove on the adjacent surface are respectively of a trapezoidal structure which inclines from the end part of the bucket part to the root part of the bucket.
The combined impact type hydraulic generator rotating wheel structure is characterized in that when the combined impact type hydraulic generator rotating wheel has larger transmission torque, the root of the bucket component adopts a gear-shaped structure, and a central force transmission component is additionally arranged to be matched with the gear-shaped structure at the root of the bucket component.
In the structure of the combined impact type hydraulic generator runner, the central force transmission component is connected with the hub in a bolt or riveting mode, and the bucket component is in tooth joint with the central force transmission component and transmits torque to the central shaft.
The manufacturing method of the combined impact type hydraulic generator runner structure comprises the following steps:
(1) the disassembly of the rotating wheel is realized by taking the bucket part as a unit according to a rotating wheel design drawing and selecting materials according to the use requirement;
(2) manufacturing a bucket part, namely manufacturing a bucket part blank by adopting an electroslag casting process, a precision casting process or a forging process;
(3) manufacturing a hub, namely manufacturing the hub by adopting a casting and steel plate welding structure;
(4) carrying out numerical control machining on a bucket and a hub of the combined rotating wheel;
(5) assembling the combined rotating wheel;
(6) and carrying out static balance and dynamic balance detection debugging on the combined rotating wheel.
The invention has the advantages and beneficial effects that:
1. the impact runner bucket with the combined structure can be manufactured singly by adopting various process methods such as an electroslag casting process, an AOD (VOD) precision casting process or a forging process. In particular, the bucket manufactured by adopting the electroslag casting process has the advantages of good quality, long service life, low manufacturing cost, high material utilization rate and the like.
2. According to the manufacturing scheme of the combined rotating wheel, the bucket part is made of stainless steel, the hub and other auxiliary parts can be made of low-carbon high-strength steel, the usage amount of the stainless steel of the whole rotating wheel is reduced, and the manufacturing cost of the rotating wheel is further reduced.
3. The technological scheme of the invention has the advantages of convenient numerical control processing of the rotating wheel bucket component blank, accurate bucket hydraulic molded line and high rotating wheel output. And because the single bucket is adopted for independent numerical control machining, large-scale numerical control machining equipment is not used, and multi-station simultaneous machining can be realized, the machining efficiency of the impact type rotating wheel is improved, the machining period is shortened, and the machining cost is reduced.
4. The technical scheme of the invention does not need large forging equipment to prepare the blank, does not use large numerical control processing equipment, and has simple manufacture, high efficiency and low cost.
5. The invention has the advantages that the flying bucket accident is prevented and the use safety of the rotating wheel is improved by the design of the lug boss, the wedge-shaped lug and the like in use.
6. When the individual bucket is damaged, the rotating wheel can be repaired by replacing part of the bucket, so that the service life of the rotating wheel is prolonged.
7. Aiming at impulse turbine rotating wheels with different sizes, the invention designs a central force transmission component according to the quantity of bucket components and the sizes of other structural components so as to achieve the purpose of improving the force transmission.
Drawings
FIG. 1 is a schematic view of the structure of the combined impact wheel of the present invention (wherein, the left half is an appearance schematic view with a hub, and the right half is a combination schematic view of partially cut bucket parts).
FIG. 2 is a schematic view of a single bucket component construction.
FIG. 3 is a partial cross-sectional schematic view of the bucket and hub connection of FIG. 1.
Fig. 4 is a second form of bucket boss, employing a slanted bar boss.
FIG. 5 is a third form of bucket boss, employing a trapezoidal boss.
FIG. 6 is a second form of bucket component attachment wedge boss.
FIG. 7 is a third form of bucket component attachment wedge boss.
FIG. 8 is a schematic view of the bucket member and hub attachment screw holes on the boss.
Fig. 9 is a sectional view a-a of fig. 8.
FIG. 10 is a schematic view of a first version of the end of a bucket member.
Figure 11 is a schematic view of an alternative central force transfer member for the arrangement of figure 10.
Fig. 12 is a schematic view of a second version of the end of a bucket member.
FIG. 13 is a schematic view of abutment surface projections and abutment surface recesses on a bucket component.
Fig. 14 is a left side view of fig. 13.
Fig. 15 is a right side view of fig. 13.
In the drawings, 1, a bucket component; 2. a cylindrical boss; 3. a non-through hole; 3', a through hole; 4. a wedge-shaped groove; 5. a hub; 6. cushion blocks; 7. bucket hydraulic molded lines; 8. an X-shaped wedge block; 9. a slanted bar boss; 10. a trapezoidal boss; 11. a wedge-shaped boss; 12. a half wedge-shaped groove; 13. a half wedge boss; 14. a central force transfer component; 15. a gear-like structure; 16. an abutment surface boss; 17. adjacent the surface recess.
Detailed Description
As shown in fig. 1 to 9, the combined impact type hydro-generator runner of the present invention mainly includes: bucket part 1, wheel hub 5 are two disc wheel hub clamping structure, and the one end clamp of bucket part 1 is located between two disc wheel hub clamping structure, interconnect between the adjacent bucket part 1. Wherein,
in the invention, the bucket component 1 and the hub 5 are connected by one or more of the following combination modes:
(1) in the connecting position of hub 5 and bucket 1, hub 5 and bucket 1 are fixed by corresponding through-holes 3' and connectors (fig. 3), such as: the whole bolt or the riveting piece is adopted for fastening and clamping, and the cushion block can be placed between the bolt or the riveting piece and the hub, so that the clamping area of the hub is increased.
(2) In the connecting position of the hub 5 and the bucket element 1, the hub 5 and the bucket element 1 are fixed by corresponding non-through holes 3 and connecting pieces (fig. 3 and 9), such as: both sides are respectively fixed through a bolt or a riveting piece, and a cushion block 6 can be placed between the bolt or the riveting piece and the hub through the bolt or the riveting piece, so that the clamping area of the hub is increased.
(3) In the position of connection of hub 5 to bucket element 1, hub 5 and bucket element 1 are positioned by means of cylindrical projection 2 and corresponding recess (fig. 2, 3, 9).
(4) At the connecting position of the hub 5 and the bucket part 1, the hub 5 and the bucket part 1 are positioned by an inclined strip-shaped boss 9 and a corresponding groove (fig. 4).
(5) In the position of connection of hub 5 to bucket element 1, hub 5 and bucket element 1 are positioned by means of trapezoidal projections 10 and corresponding recesses (fig. 5, 8, 9).
In the invention, adjacent bucket parts 1 are connected by one or more of the following combination modes:
(1) two sides of each bucket component 1 are respectively provided with a wedge-shaped groove 4, and the adjacent bucket components 1 are connected in a matching way through an X-shaped wedge block 8 and the wedge-shaped grooves 4 (figure 2).
(2) Two sides of each bucket component 1 are respectively provided with a wedge-shaped groove 4 and a wedge-shaped boss 11, and adjacent bucket components 1 are directly connected in a matched mode through the wedge-shaped grooves 4 and the wedge-shaped bosses 11 (figure 6), and wedge blocks do not need to be additionally used.
(3) Half wedge recess 12 and half wedge boss 13 are equipped with respectively to bucket part 1 both sides, directly connect through half wedge recess 12 and half wedge boss 13 cooperation between the adjacent bucket part 1 (fig. 7), through changing bucket part side structural style, need not use the voussoir in addition.
The impact runner with the combined structure of the invention is formed by carrying out electroslag casting and numerical control processing on a single bucket part 1 and then connecting the bucket parts in various connection modes, such as: the X-shaped wedges are wedged into the wedge-shaped grooves and/or the wedge-shaped bosses are tightly connected and positioned with each other (the bucket parts 1 are connected in a way shown in figures 4, 5, 6, 7 and 8) to form a runner whole. The integral rotor is then bolted or riveted to the hub, and the hub 5 of the combined rotor engages the bucket element 1 via bosses thereon and transmits torque to the central shaft (the connection between the bucket element 1 and the hub 5 after coupling is shown in fig. 1, 3 and 9). The advantage of this is that when the individual bucket elements 1 are interconnected by the X-shaped wedge and/or wedge-shaped projections, even if the projections on the individual bucket elements 1 are damaged, the torque can be transmitted by the projections on the adjacent bucket elements 1 during the mutual fixing operation between the bucket elements 1, and the occurrence of bucket-off accidents caused by the damage of the individual buckets can be effectively prevented.
When the transmission torque of the impulse turbine runner with the combined structure is larger, special force transmission requirements are required on the runner structure, the root of the bucket component 1 can be designed to be a gear-shaped structure 15 (shown in figures 10 and 12), a central force transmission component 14 (shown in figure 11) is additionally arranged to be matched with the bucket component 1 in figure 10, or the direction of the gear of the central force transmission component 14 is opposite to that of figure 11 and is matched with the gear-shaped structure at the root of the bucket component 1 in figure 12. The central force transmission component 14 is connected with the hub 5 through a bolt or a riveting mode, the bucket component 1 is in tooth joint (meshing) with the central force transmission component 14, torque is transmitted to a central shaft, the requirement on the strength of the hub is further reduced, and all-round firm connection is realized.
When the bosses in the forms of fig. 4 and 5 are adopted, the inclination angles of the bosses are designed according to requirements; the hub 5 and the bucket component 1 adopt a structure (figure 3) of non-through type hole 3 connection, through type hole 3' connection and cylindrical boss 2 matching connection, so that the safety and reliability are improved. To avoid breakage, the bolts or rivets connecting and clamping bucket component 1 and hub 5 are not subjected to the radial shear force of the runner, but only to the tensile stress. Thus, the spacer 6 in fig. 9 is added in design. Hub 5 and bucket part 1 adopt non-through hole 3 to be connected, trapezoidal boss 10 cooperation is connected structure (fig. 9) to increase cushion 6, pass cushion 6, hub 5 (or pass trapezoidal boss 10 of bucket part 1 simultaneously) through the bolt, make the bolt not direct with the hub contact, further prevent that it from receiving the shearing force and taking place the danger of damage.
As shown in fig. 13-15, the abutment surfaces between adjacent bucket components 1 are provided with abutment surface projections 16 and abutment surface recesses 17, respectively, the abutment surface projections 16 and abutment surface recesses 17 cooperating for accurate axial positioning of the bucket components 1. The abutment surface projections 16 and the abutment surface recesses 17 are each of a trapezoidal configuration with a slight inclination from the end of the bucket component 1 to the bucket root. The upstream surface of the bucket part 1 is provided with an abutment surface boss 16 or an abutment surface groove 17, and the downstream surface of the bucket part 1 is provided with an abutment surface groove 17 or an abutment surface boss 16 which is matched with the upstream surface. In this embodiment, the abutment surface boss 16 is provided on the upstream surface, and the abutment surface recess 17 is provided on the downstream surface.
In the invention, the manufacturing process route of the impact type hydraulic generator runner with the combined structure is as follows:
(1) the disassembly of the rotating wheel is realized by taking the bucket part as a unit according to a rotating wheel design drawing and selecting the main parts and the accessory materials according to the use requirements;
(2) manufacturing a bucket part, namely manufacturing a bucket part blank by adopting an electroslag casting process, an AOD (VOD) precision casting process or a forging process, and mainly manufacturing a bucket by adopting the electroslag casting process;
(3) manufacturing a wheel hub, namely manufacturing the wheel hub by adopting a casting and steel plate welding structure, and mainly adopting the steel plate welding structure;
(4) carrying out numerical control machining on a bucket and a hub of the combined rotating wheel;
(5) assembling the combined rotating wheel;
(6) and carrying out static balance and dynamic balance detection debugging on the combined rotating wheel.
According to the manufacturing scheme of the combined rotating wheel, the bucket water conservancy molded line 7 is accurate, and the rotating wheel has high output. The bucket component, the hub and other auxiliary parts can be made of different materials, so that the use amount of stainless steel is reduced, and the manufacturing cost of the runner is further reduced.
The embodiment result shows that the rotating wheel manufactured by the invention not only has good blank quality, but also has long service life; the numerical control machining process is simple; the material utilization rate is high; the double-metal material can be adopted, the production and processing cost is very low, safety accidents such as a bucket flying and the like can be effectively prevented, and the use safety of the rotating wheel is ensured.
Claims (4)
1. The utility model provides a modular structure of impacted style hydraulic generator runner which characterized in that, this runner is equipped with: the bucket comprises a bucket component and hubs, wherein the hubs are two disc hub clamping structures, one end of the bucket component is clamped between the two disc hub clamping structures, and adjacent bucket components are connected with each other; the bucket part is manufactured by an electroslag casting process, a precision casting process or a forging process, the hub adopts a casting and steel plate welding structure, and the specific structure adopts one of the following a) and b):
a) at a first connecting position of the hub (5) and the bucket part (1), the hub (5) and the bucket part (1) are fixed through a corresponding through hole (3') and a connecting piece; at a second connecting position of the hub (5) and the bucket part (1), the hub (5) and the bucket part (1) are fixed through a corresponding non-through hole (3) and a connecting piece; at a third connecting position of the hub (5) and the bucket component (1), the hub (5) and the bucket component (1) are positioned through the cylindrical boss (2) and the corresponding groove;
two sides of each bucket component (1) are respectively provided with a wedge-shaped groove (4), and adjacent bucket components (1) are connected in a matching way through an X-shaped wedge block (8) and the wedge-shaped grooves (4);
b) two sides of each bucket component (1) are respectively provided with a wedge-shaped groove (4), and adjacent bucket components (1) are connected in a matching way through an X-shaped wedge block (8) and the wedge-shaped grooves (4);
the bucket is characterized in that a first connecting position of a hub (5) and a bucket component (1) is formed, the hub (5) and the bucket component (1) are positioned through a trapezoidal boss (10) and a corresponding groove, two sides of the first connecting position are fixed through a bolt or a riveting piece respectively, and a cushion block (6) is arranged between the bolt or the riveting piece corresponding to the trapezoidal boss (10) and the hub; at a second connecting position of the hub (5) and the bucket part (1), the hub (5) and the bucket part (1) are fixed through a corresponding non-through hole (3) and a connecting piece.
2. The combined impact-type hydraulic generator runner structure according to claim 1, wherein when the combined impact-type hydraulic generator runner has a large torque transmission, the root of the bucket component is in a gear-shaped structure, and a central force transmission component is additionally arranged to be matched with the gear-shaped structure at the root of the bucket component.
3. The structure of a combined impulse turbine generator rotor according to claim 2, wherein the central force transmitting member is bolted or riveted to the hub, and the bucket member is engaged with the central force transmitting member to transmit torque to the central shaft.
4. The method of manufacturing a structure of a combined impulse hydro-generator runner according to claim 1, comprising the steps of:
(1) the disassembly of the rotating wheel is realized by taking the bucket part as a unit according to a rotating wheel design drawing and selecting materials according to the use requirement;
(2) manufacturing a bucket part, namely manufacturing a bucket part blank by adopting an electroslag casting process, a precision casting process or a forging process;
(3) manufacturing a hub, namely manufacturing the hub by adopting a casting and steel plate welding structure;
(4) carrying out numerical control machining on a bucket and a hub of the combined rotating wheel;
(5) assembling the combined rotating wheel;
(6) and carrying out static balance and dynamic balance detection debugging on the combined rotating wheel.
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201210338809.6A CN102865177B (en) | 2012-09-13 | 2012-09-13 | A kind of structure of knockdown impingement type hydraulic generator runner and manufacture method |
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| CN201210338809.6A CN102865177B (en) | 2012-09-13 | 2012-09-13 | A kind of structure of knockdown impingement type hydraulic generator runner and manufacture method |
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| CN102865177B true CN102865177B (en) | 2015-08-26 |
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| CN112922765B (en) * | 2021-04-13 | 2022-06-21 | 哈尔滨电机厂有限责任公司 | Manufacturing process method of split runner of large-scale impulse turbine |
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| CN113560830B (en) * | 2021-08-30 | 2023-06-30 | 沈阳市盛华特种铸造有限公司 | Method for manufacturing electroslag casting type impact type rotating wheel |
| CN113958438A (en) * | 2021-10-20 | 2022-01-21 | 哈尔滨电机厂有限责任公司 | Pelton turbine of mechanical combination mode |
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