CN109216003B - Distribution transformer oil tank adaptive to operation of welding robot and design and processing method thereof - Google Patents
Distribution transformer oil tank adaptive to operation of welding robot and design and processing method thereof Download PDFInfo
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Abstract
The invention provides a distribution transformation oil tank adaptive to a welding robot and a design and processing method thereof.A three-layer framework with distinct layers comprises a bottom part, a main framework part and a tank edge part which are sequentially connected from bottom to top, and the welding seams of semi-finished products of the oil tank are all arranged on the outer sides, so that a manipulator welding gun can work conveniently; the tank bottom panel is integrally formed, the tank bottom cutting right angle is formed by slotting by a triangle method, the main body framework is positioned by a groove method, and a standard process flow is provided for a transformer manufacturer and the production efficiency of the transformer manufacturer is improved by the design method and the structural design of the oil tank framework; the problem that a welding gun is difficult to enter when a welding robot works on the traditional oil tank is solved; the standardized work of uniformly planning the matched tools of various types is facilitated for welding robot manufacturers; the production cost is reduced, and the production precision and the aesthetic degree of the product are reasonably controlled.
Description
Technical Field
The invention relates to the field of distribution transformer oil tank equipment, in particular to a distribution transformer oil tank adaptive to operation of a welding robot and a design and processing method thereof.
Background
At present, the production of the domestic distribution transformer oil tank mainly depends on manpower, and the common process of the traditional manual welding of the oil tank comprises the following steps:
1. the workshop is according to the drawing to main steel sheet, the unloading is carried out to structure (angle steel, channel-section steel, steel pipe etc.) material, the steel sheet mainly relies on contour cutter or the work of plasma flame cutting bed, we use plasma flame cutting machine processing case lid steel sheet as an example, the flame shower nozzle diameter of conventional plasma flame cutting is between 8 ~ 15mm, 5 ~ 10 mm's former flat board (including opening the flat board) can be burnt out to the dynamics of flame cutting under this condition, but the steel sheet thickness that burns out is big more, cutting speed is fast just more just means that the demand power of cutting machine is also big more, the diameter that leads to jet flame is also big more, to the former flat board about 6mm, from the leftover bits about 10 ~ 15mm that generally will be reserved to the leftover bits of edge blanking, the purpose is to prevent that the flame from empting, many burrs of the material that cuts out lead to the condition that can't. The whole original flat plate with the thickness of 6mm can cause material waste (for example, cutting two groups of materials by one plate) with the width of 40-60 mm and the length of 6000mm, the waste condition is not small, for the open flat plate with relatively high heat sensitivity, in addition to the waste of raw materials, the heat deformation of the cut steel plate causes troubles for various transformer manufacturers, and the condition of the transformer with larger capacity is more obvious. In summary, the defects of the conventional oil tank initial processing are mainly serious waste of residual materials and low finished product yield of the processed oil tank.
2. And further processing the raw materials after the primary processing, which is mainly embodied in the working procedures of bending, shearing, perforating and the like of the materials subjected to the primary processing in the first step. Besides the above disadvantages, the step also has the serious waste of manpower and material resources, and we take the example of processing the tank edge of a conventional distribution transformer as follows: the method comprises the steps of selecting the type of angle steel used by a box edge, cutting and breaking the steel by using a sawing machine, correcting perpendicularity, polishing a cutting section, assembling and welding four steel channels into a blank of the box edge, correcting assembly and welding deviation, performing full welding, removing slag, polishing a welding line, drilling by using a drilling machine, and polishing again after drilling. After the processes are completed, the box edge is subjected to deep processing, other situations (such as machine fatigue wear, human errors and the like) are not considered in the middle, the field investigation shows that generally the work is performed according to the traditional deep processing method, only the box edge needs about 8-9 scattered processes to be completed, on average, each small process of a skilled worker needs about 10-15 min to complete, the time for transferring and transporting materials is added in the middle, nearly 2h is wasted in the processing of the box edge, and the problems that the number of workers is small in many factories, the work is added with shifts and points are always caused, the efficiency is always poor, the process is complicated, the process time is long, and the waste of manpower and material resources is serious.
3. The combined welding and full welding are carried out on the materials which are subjected to deep processing, the defect and the problem of the one-step processing are more obvious, the processing precision and the error are mainly existed, the traditional manual welding can not achieve the purpose that the manual control precision is accurate to within two decimal points, the limit is often approached within 0.1-0.5 mm, although the use of the actual transformer oil tank can not be greatly influenced, the equipment which needs the precise matching of a platform sleeve and a combined box transformer is changed, and the equipment belongs to the problem in the obvious matching aspect. In addition, the appearance of the conventional manually welded oil tank often has very thick and obvious welding seams and even welding beading, which causes extremely bad influence on the aesthetic degree of independently used station transformers, station transformers and the like.
In conclusion, a large amount of manpower and material resources are needed from blanking, cutting, bending, assembly welding, full welding to final acid-washing phosphating painting, the production efficiency is low, the material waste is serious, the quality of the finished product is uneven, and the yield is low.
In recent years, manufacturers begin to use a robot welding mode to replace manual welding, but because the oil tank welding robot technology is not mature, an effective solution cannot be provided for a traditional oil tank structure and a welding mode, the oil tank structure designed under the traditional manual welding mode is basically used at present, so that a set of standardized tool solution is difficult to provide for various robot manufacturers, the general operation condition of a temporarily changed tool is frequently blocked, the welding capability of the robot cannot be exerted, the actual effect is very small, and the transformer manufacturers cannot realize primary expected capacity improvement and product upgrading.
Disclosure of Invention
The invention provides a distribution transformer oil tank design method adaptive to welding robot operation and a distribution transformer oil tank, aiming at the existing technical problems.
In order to achieve the purpose of the invention, the technical scheme adopted by the invention is as follows:
a method for processing and designing a distribution transformer oil tank adaptive to operation of a welding robot comprises the following steps:
1. initial design: according to the calculation result of the transformer calculation sheet, determining the overall dimension of the main body frame, and correspondingly required heat dissipation value, frame structure stress and expansion coefficient of the heat dissipation device:
oil tank main part frame overall dimension: the transformer oil tank height calculation method comprises an oil tank framework and a heat dissipation device, and is characterized in that the calculation is performed according to a conventional transformer calculation list when the size of the oil tank is designed at the initial stage, and the oil tank height meets a general formula
H＝H0+2He+Hd+H1H represents the height of the fuel tank, H0Represents the height of the iron core window HeRepresents the maximum width of the yoke, HdRepresenting the height of the foot pad, H1Representing the height of the reserved space, namely the height of an oil tank is equal to the height of an iron core window, the maximum sheet width of an iron yoke, the height of a pad and the height of the reserved space; the width of the oil tank satisfies the formula B ═ D + B1B represents the width of the oil tank, D represents the diameter of the outer coil, B1Representing the width of the reserved space, namely the width of the oil tank is equal to the diameter of the outer coil and the width of the reserved space; the length of the oil tank satisfies the formula L ═ D +2M0+B2L represents the length of the oil tank, D represents the diameter of the outer coil, M0Represents the center distance of the center post of the core, B2The outer coil pair oil tank gap representing A, C phases in the long axis direction, namely the oil tank length is equal to the outer coil diameter + the center distance of the iron core center post + the outer coil pair oil tank gap representing A, C phases in the long axis direction;
heat dissipation value: the heat dissipation value that the oil tank needs to reach then mainly depends on the temperature rise, this wherein mainly includes the average temperature rise of coil to oil, the selection of oil tank heat radiating area:
the average temperature rise of the coil to the oil is determined by adopting a test method to determine the temperature rise function relation of the coil surface to the transformer oil, and T is adoptedx1＝k·qnCalculation of where Tx1Representing the temperature rise of the coil to the transformer oil, wherein k is a coefficient; n is an index, determined by experiment; q is the unit heat load of the coil surface, and q is 1.032Pa+P0Calculation of PaIs represented byCalculating the load loss, P, of the coil0Representing the no-load loss of the transformer, and calculating the load loss Pa of the coil and the no-load loss P of the transformer at 75 DEG C0The value of q can be determined, and the calculation formula of the total average temperature rise is T ═ Tx1+TΔj+TΔyWherein T isx1For the temperature rise of the coil to the transformer oil, TΔj＝Kjqn1，TΔy＝K1q, i.e. average temperature rise-coil temperature rise + insulation temperature rise correction + number of layers insulation correction for transformer oil, Kj、K1Is a coefficient, q is a unit heat load of the coil surface, n1The total number of layers of the outer coil of the oil removing channel is the layer insulation thickness, namely the insulation temperature rise correction is the coefficient of the total number of layers of the outer coil of the oil removing channel per unit heat load of the surface of the coil, and the layer number insulation correction is the coefficient of the total number of layers of the insulation thickness of the coil per unit heat load of the surface of the coil;
the heat dissipation area of the oil tank is basically equal to the sum of all the external surface areas of the oil tank, the sum of the external surface areas of the oil tank mentioned herein comprises the sum of the total areas of an oil tank framework, a tank cover, a tank bottom and a heat dissipation device, namely all iron exposed in the air, and the size of the heat dissipation device is mainly selected according to the height of the designed oil tank and the heat dissipation coefficient of a single-chip heat dissipation device provided by a manufacturer of the heat dissipation device: the height of the oil tank determines the height selection interval of the heat dissipation device, the heat dissipation coefficient of the single-chip heat dissipation device determines the specification of the heat dissipation device, and the appearance of the oil tank is different because different heat dissipation coefficients determine different expansion coefficients;
frame structure stress: whether the manufactured oil tank can meet the capabilities of stretch resistance, compression resistance, torsion resistance and the like of a corresponding draught point in structure or not, and the distribution transformation only considers the gravity brought by the weight of the oil tank body under most conditions, wherein the gravity comprises the weight of oil, the weight of the oil tank body and the weight of accessories;
frame structure stress: whether the manufactured oil tank can meet the tensile resistance, compression resistance and torsion resistance of a corresponding draught point in structure or not, and the distribution transformation only considers the gravity brought by the weight of the oil tank body under most conditions, wherein the gravity comprises the weight of oil, the weight of the oil tank body and the weight of accessories;
formula for oil reuseGOil weight＝GFE/7.8+GCUIn which G is determinedFEIs the total weight G of the silicon steel sheets in the transformerCUThe total weight of the copper wire with insulation in the transformer is Gqs＝kq·(GFE+GCU)，GqsWeight of the body, kqRepresenting the transformer body sundry factor, namely the weight of the transformer body sundry factor (the total weight of silicon steel sheets and the total weight of copper wires with insulation), wherein the sundry factor interval of the pure copper transformer is between 1.14 and 1.16; the weight of the accessory is GAttachment weight＝Gs+Gt+Gc+Gj，GAttachment weightRepresenting the weight of the accessory, GsHeavy as radiator GtRepresenting the weight of the casing, GcRepresenting the weight of the conservator, GjRepresenting the net oil weight, namely the weight of an accessory is equal to the weight of a radiator, the weight of a sleeve, the weight of an oil conservator and the net oil weight;
coefficient of expansion of heat dissipating device: the main influence factors depend on the manufacturing raw materials of the heat dissipation device, the heat dissipation device is processed by adopting a Q235 cold-rolled steel plate, and the expansion coefficient of the material can be 10.6-12.2 multiplied by 10 at the temperature of 20-100 DEG C-6K is calculated, wherein K represents the Fahrenheit temperature of the corresponding material when the expansion coefficient is calculated, and the heat dissipation coefficients of the transformer heat dissipation devices corresponding to different temperatures are different; the thickness can be properly selected according to the size and the bearing capacity of the oil tank, the heat dissipation device made of cold-rolled steel plates with the thickness of 1.2mm is selected when the capacity of the transformer is below 1600kVA, and the cold-rolled steel plates with the thickness of 1.5mm can be selected when the capacity is above 1600 kVA; the forming process and the manufacturing type of the national power grid and the industrial department have related standards, the industries are unified, and the detailed description is omitted here;
2. the oil tank skeleton design, according to main body frame overall dimension requirement, confirms the size of oil tank skeleton subassembly, the oil tank skeleton is divided according to three component, is the bottom of the case part, main part skeleton portion and case respectively along the part:
the tank bottom part is designed in an integrated forming mode, a cubic structure with an opening at the upper end is defined by a tank bottom steel plate and peripheral baffles, right-angle grooves are formed in four corners of the tank bottom part through a whole steel plate, four baffles are bent in a stamping mode, butt joint edges among the baffles are welded, triangular grooves are formed in the corner ends of the right-angle grooves of the whole steel plate, the purpose of forming the triangular grooves is that the tank bottom steel plate directly enters a stamping integrated machine to be directly forged and formed after being cut, triangular grooves are reserved to enable stamped and folded parts to be removed, the overall shape of the tank bottom part is regular, the subsequent robot welding operation is facilitated, and meanwhile the attractiveness degree of an overall oil tank is increased;
the main framework part is four angle steel supports, positioning grooves are formed in the middle positions of erected angle steel, the traditional design method that the angle steel is attached to the bottom of a box and the inner wall of the edge of the box by the outer wall is abandoned, the upper end and the lower end of the angle steel are butted with the bottom of the box and the edge of the box respectively, the grooves are formed in order to facilitate the clamping and positioning of a robot welding tool, the specific operation method is that the box edge and the bottom of the box which need to be welded together are clamped at a certain distance by the clamping tool with a fixed capacity model, the central groove of the angle steel is searched by the framework angle steel clamping tool for initial positioning, the framework angle steel is moved to the distance center between the box edge and the bottom of the box by preprogramming or laser positioning, the distances between the framework angle steel and the welding gaps between the box edge and the bottom of the box are kept consistent or close, the height of an oil tank or the error caused by manual positioning welding due to gravity factor interference is, The welding clearance of the tank edge is kept in the same error level range, so that the problem that a welding gun is difficult to enter when a welding robot works on the traditional oil tank is solved, and the integral welding precision of the oil tank framework is improved;
the box is formed by welding two groups of angle steels together along the part, the two groups are long groups and short groups, each group is formed by two equilateral or inequilateral hot rolled angle steels with the same length, the box is firstly opened and cut by the flowing water cutting and the power punch head for the angle steels along the box, the long and short angle steels are vertically welded into an L shape, and finally two L-shaped semi-finished products are welded into a box edge, so that the working efficiency is greatly improved.
The utility model provides a join in marriage of adaptation welding robot operation becomes oil tank skeleton, it includes the triplex that up connects gradually from down: the box bottom part is integrally formed, a box bottom steel plate and peripheral baffles which are connected in an integrated structure form a cubic structure with an opening at the upper end, right-angle grooves are formed in four corners of the whole steel plate in the machining process, the baffles protruding around are stamped and bent, the butt joint edges between the baffles are welded after forming, and triangular grooves are formed in the corner ends of the right-angle grooves of the whole steel plate before welding; the main framework part is provided with four angle steel brackets, positioning grooves are formed in the middle positions of the angle steel brackets, the upper ends and the lower ends of angle steel are in butt joint welding with the bottom of the tank and the tank along four corner ends respectively, the opening of the angle steel faces the center direction of the oil tank framework and corresponds to the right-angled positions of the four corner ends of the bottom of the tank and the upper end of the tank along the lower end, and a rectangular column cavity is formed by the opening of; the plane of the upper end edge of the box edge is parallel to the steel plate at the bottom of the box.
The transformer calculation sheet is a series of mature calculation processes obtained by correlating a basic calculation formula of a transformer in an excel table in a formula form. By means of the main transformer parameters required by users, such as the user requirement S13-M-100/10/0.4 Dyn 114% type transformer, the total transformer capacity of 100kVA, the rated high voltage of 10kV, the rated low voltage of 0.4kV, the impedance of 4%, the connection group of Dyn11 and the secondary energy efficiency type 13 type transformer can be determined.
The invention has the beneficial effects that:
1. through the design method and the structural design of the oil tank framework, a standard process flow is provided for transformer manufacturers, the production efficiency of the transformer manufacturers is improved, and the manual labor is liberated to a certain extent;
2. the structural design of the oil tank framework facilitates the standardized work of uniformly planning the matched tools of various types by welding robot manufacturers;
3. the design of the oil tank framework reduces the production cost and reasonably controls the production precision and the aesthetic degree of the product.
Drawings
FIG. 1 is a schematic diagram of a distribution transformer tank adapted for operation of a welding robot according to the present invention;
FIG. 2 is a schematic structural view of a whole steel plate before a box bottom part is machined;
fig. 3 is a schematic structural view of an angle bracket.
Detailed Description
The specific method and the manufacturing scheme of the invention for the welding with the matched robot are further explained with reference to the attached figures 1-3.
The traditional manual welding oil tank does not have a so-called skeleton structure, and only the outer side walls of four angle steels are used for welding the tank edge and the inner wall of the tank bottom together, and then the heat dissipation device (corrugated wall) of the transformer is used for wrapping and welding the tank edge and the outer side of the tank bottom. The traditional welding mode is obviously not suitable for robot welding operation, because the robot needs to be supported by an internal support type tooling part which can rotate freely on a plane during welding, then a manipulator welding gun welds along a fixed route from the outside to finish the work, and the design scheme of the traditional manual welding oil tank adopts an internal welding mode (namely four fixed angle steels and the welding of the tank edge and the tank bottom need to be completely welded and fixed in the oil tank), which is against the working characteristics of the robot welding.
The utility model provides a join in marriage of adaptation welding robot operation becomes oil tank skeleton, it includes the triplex that up connects gradually from down: the tank bottom part 1, the main body framework part 2 and the tank edge part 3 are different from the conventional manual welding of the tank bottom of the oil tank which is a pure flat plate and the periphery of which is welded with a baffle plate, the tank bottom part of the oil tank is designed in an integrated mode, a tank bottom steel plate 4 and the periphery baffle plate 5 which are connected in an integrated mode are enclosed into a cubic structure with an opening at the upper end, a right-angle groove is formed in four corners of a whole steel plate in the machining process, the baffle plate 5 which is protruded at the periphery is punched and bent, and the butt joint edge between the baffle plates is welded after the forming, compared with the conventional method for manually welding the baffle plates at the four sides, a plurality of steps are omitted, unnecessary welding seams are also reduced, a triangular groove 6 is formed at the corner end of the right-angle groove of the whole steel plate before welding, the purpose of forming the triangular groove 6 is to facilitate the right-angle joint of two adjacent, even the welding gun head is irreversibly damaged, and the integral aesthetic degree of the oil tank is increased after welding is finished; the main framework part 2 is four angle steel supports, the middle positions of the angle steel supports are provided with positioning grooves 7, the upper ends and the lower ends of the angle steel are respectively in butt joint welding with the bottom of the tank and the tank along four corner ends, the opening of the angle steel faces to the center direction of the oil tank framework and corresponds to the right-angled positions of the four corner ends of the bottom of the tank at the lower end and the tank at the upper end, a rectangular column cavity is defined, and the method is different from the existing method that the inside or the outside of the angle steel needs to; the plane of the upper end edge of the box edge is parallel to the steel plate at the bottom of the box.
A design and processing method of a distribution transformer oil tank adaptive to operation of a welding robot comprises the following steps:
step 1: performing basic confirmation calculation on the model of the transformer, including determining data such as iron core parameters, coil parameters and the like, determining an internal structure, and estimating the size of an oil tank;
and a step 2: determining the final overall dimension of the oil tank according to the heat dissipation value required by the oil tank, the frame structure stress and the expansion coefficient of the heat dissipation device;
step 3: carry out structural design to adaptation robot welded oil tank, mainly to this big major constituent part of oil tank skeleton:
the bottom part of the tank, the bottom steel plate of the tank and the baffle all around are designed as an integrated piece, the right angle fluting of the bottom steel plate of the tank is respectively designed with triangular fluting, the purpose of opening the triangular fluting is because the bottom steel plate of the tank is cut and then directly enters the stamping integrated machine to be directly forged and formed, leave the triangular groove and can remove the part which is stamped and folded, the tank bottom which is bent and formed is arranged on a tool, and the welding seam all around of the tank bottom is welded by a robot to complete the welding of the baffle all around of the tank bottom, the design not only facilitates the subsequent robot welding operation, but also increases the aesthetic degree of the whole oil tank;
the main body framework part is an angle steel support with a groove in the middle, the geometric centers of two edges of four equal-side angle steels are provided with semicircular grooves, an internal support type tool can directly control the gun feeding allowance of a robot welding gun and the relative welding positions of the transformer box edge and the box bottom by a method for grabbing and positioning the framework angle steel in the subsequent processing process, the traditional design method that the angle steel is attached to the box bottom and the inner wall of the box edge by the outer wall is abandoned, the box bottom and the box edge are butted up and down, and the groove is formed for the purpose of facilitating the tool clamping and positioning and keeping the welding gaps of the main framework angle steel and the box bottom and the box edge in the same error level category; the box edge angle steel tapping mode adopts flow cutting and power punches to tap and cut, the angle steel tapping mode formed by the box edge is designed to use double punches to tap equidistant holes (the distance between the double punches is an integral multiple of 50mm in general) at a certain distance from the edge of a section, the section enters the box edge in a whole manner, the section is cut and cut by flow cutting and directly enters a punch press to tap, the cut section is put on a fixed tool to be directly welded by a robot, and finally, slag removal and polishing are carried out for one time, so that the box edge manufacturing work is completed;
and step 4: after the design is finished, the oil tank framework can be processed by utilizing an adaptive welding robot tool according to the design requirement, then the oil tank framework is welded in a splicing way, the oil tank framework is fixed by utilizing an oil tank framework internal support tool after the design is finished, the corrugated wall is grabbed by utilizing a mechanical arm, an angle steel central groove is searched by utilizing a framework angle steel clamping tool for initial positioning, the framework angle steel is moved to the distance center between the tank edge and the tank bottom by utilizing preprogramming or laser positioning, the distance between the framework angle steel and the welding gap between the tank edge and the tank bottom is kept consistent or close, the phenomenon that the height of the oil tank or the welding seam error is overlarge due to the interference of gravity factors in manual positioning welding is avoided, the welding gaps between the main framework angle steel and the tank bottom and the tank edge can be kept in the same error level range by utilizing the positioning mode and the robot welding, and the corrugated, and finishing the processing of the whole oil tank.
The corrugated walls of different models have different heat dissipation coefficients, and the following table lists the corrugated walls of partial models and the heat dissipation and expansion coefficients.
After the scheme is implemented, compared with the manual welding scheme before, the transformers of the same type and workshops adopt the manual welding scheme, the number of manual welding of all personnel for welding the oil tank is 15 in three days and 5 in about 40 in one day, and 0.125 is calculated per person on average; by adopting the novel scheme, the robot team has 2 people, the full welding of 3 transformer oil tanks is completed within 2 days, and 0.75 transformer oil tanks are averagely welded by each person every day. In the aspect of raw materials, compared with a robot team, a workshop for manual welding generates about 5kg of waste materials on average each day, and the waste flat plates are produced by 1.9 tons each year, the robot team adopting the novel scheme saves expenses by about 3.7 ten thousand yuan per year, and the aspects of saving including manpower loss, fixed asset loss, environmental resource loss and the like are not included. In conclusion, the invention has the advantages of incomparable with the traditional manual welding transformer oil tank scheme from the aspects of professional technology, actual production efficiency, product practicability and aesthetic property and future industrial standardization process.
The invention is on the premise of not changing the normal use and function of the transformer oil tank, through the rational design to the structure of the oil tank and the rational type selection collocation to the corollary processing equipment, the advantage of this design method is: the stacking structure of the traditional transformer oil tank is changed into a three-layer framework type scheme with distinct layers, so that the robot welding tool is convenient to clamp and fix; the welding seams of the semi-finished product of the oil tank are all arranged on the outer side, so that the welding gun of a manipulator can work conveniently; the tank bottom panel is integrally formed, the tank bottom cutting right angle is formed by slotting by a triangle method, the main body framework is positioned by a groove method, and a standard process flow is provided for a transformer manufacturer and the production efficiency of the transformer manufacturer is improved by the design method and the structural design of the oil tank framework; the design of the oil tank structure not only solves the problem that a welding gun is difficult to enter when a welding robot works on the traditional oil tank, but also improves the overall welding precision of the oil tank framework; the standardized work of uniformly planning the matched tools of various types is facilitated for welding robot manufacturers; the production cost is reduced, and the production precision and the aesthetic degree of the product are reasonably controlled.
The foregoing is only a preferred embodiment of the present invention, and it should be noted that modifications can be made by those skilled in the art without departing from the principle of the present invention, and these modifications should be construed as the protection scope of the present invention without inventive effort.
Claims (2)
1. The utility model provides a join in marriage of adaptation welding robot operation becomes oil tank skeleton, characterized by, it includes the triplex that up connects gradually from down: the box bottom part is integrally formed, a box bottom steel plate and peripheral baffles which are connected in an integrated structure form a cubic structure with an opening at the upper end, right-angle grooves are formed in four corners of the whole steel plate in the machining process, the baffles protruding around are stamped and bent, the butt joint edges between the baffles are welded after forming, and triangular grooves are formed in the corner ends of the right-angle grooves of the whole steel plate before welding; the main framework part is provided with four angle steel brackets, positioning grooves are formed in the middle positions of the angle steel brackets, the upper ends and the lower ends of angle steel are in butt joint welding with the bottom of the tank and the tank along four corner ends respectively, the opening of the angle steel faces the center direction of the oil tank framework and corresponds to the right-angled positions of the four corner ends of the bottom of the tank and the upper end of the tank along the lower end, and a rectangular column cavity is formed by the opening of; the plane of the upper end edge of the box edge is parallel to the steel plate at the bottom of the box.
2. A design and processing method of a distribution transformer oil tank adaptive to operation of a welding robot is characterized by comprising the following steps:
(1) initial design: according to the calculation result of the transformer calculation sheet, determining the overall dimension of the main body frame, and correspondingly required heat dissipation value, frame structure stress and expansion coefficient of the heat dissipation device:
oil tank main part frame overall dimension: including oil tank skeleton and heat abstractor two parts, when the size of initial design oil tank according to conventional transformer calculation list calculate can, the oil tank height satisfies general formula H ═ H0+2He+Hd+H1H represents the height of the fuel tank, H0Represents the height of the iron core window HeRepresents the maximum width of the yoke, HdRepresenting the height of the foot pad, H1Representing the height of the reserved space, namely the height of an oil tank is equal to the height of an iron core window, the maximum sheet width of an iron yoke, the height of a pad and the height of the reserved space; the width of the oil tank satisfies the formula B ═ D + B1B represents the width of the oil tank, D represents the diameter of the outer coil, B1Representing the width of the reserved space, namely the width of the oil tank is equal to the diameter of the outer coil and the width of the reserved space; the length of the oil tank is satisfiedFormula L ═ D +2M0+B2L represents the length of the oil tank, D represents the diameter of the outer coil, M0Represents the center distance of the center post of the core, B2The outer coil pair oil tank gap representing A, C phases in the long axis direction, namely the oil tank length is equal to the outer coil diameter + the center distance of the iron core center post + the outer coil pair oil tank gap representing A, C phases in the long axis direction;
heat dissipation value: the heat dissipation value that the oil tank needs to reach then mainly depends on the temperature rise, this wherein mainly includes the average temperature rise of coil to oil, the selection of oil tank heat radiating area:
the average temperature rise of the coil to the oil is determined by adopting a test method to determine the temperature rise function relation of the coil surface to the transformer oil, and T is adoptedx1＝k·qnCalculation of where Tx1Representing the temperature rise of the coil to the transformer oil, wherein k is a coefficient; n is an index, determined by experiment; q is the unit heat load of the coil surface, and q is 1.032Pa+P0Calculation of PaRepresenting the load loss, P, of the calculated coil0Representing the no-load loss of the transformer, and calculating the load loss Pa of the coil and the no-load loss P of the transformer at 75 DEG C0The value of q can be determined, and the calculation formula of the total average temperature rise is T ═ Tx1+TΔj+TΔyWherein T isx1For the temperature rise of the coil to the transformer oil, TΔj＝Kjqn1，TΔy＝K1q, i.e. average temperature rise-coil temperature rise + insulation temperature rise correction + number of layers insulation correction for transformer oil, Kj、K1Is a coefficient, q is a unit heat load of the coil surface, n1The total number of layers of the outer coil of the oil removing channel is the layer insulation thickness, namely the insulation temperature rise correction is the coefficient of the total number of layers of the outer coil of the oil removing channel per unit heat load of the surface of the coil, and the layer number insulation correction is the coefficient of the total number of layers of the insulation thickness of the coil per unit heat load of the surface of the coil;
the heat dissipation area of the oil tank is basically equal to the sum of all the external surface areas of the oil tank, the sum of the external surface areas of the oil tank mentioned herein comprises the sum of the total areas of an oil tank framework, a tank cover, a tank bottom and a heat dissipation device, namely all iron exposed in the air, and the size of the heat dissipation device is mainly selected according to the height of the designed oil tank and the heat dissipation coefficient of a single-chip heat dissipation device provided by a manufacturer of the heat dissipation device: the height of the oil tank determines the height selection interval of the heat dissipation device, the heat dissipation coefficient of the single-chip heat dissipation device determines the specification of the heat dissipation device, and the appearance of the oil tank is different because different heat dissipation coefficients determine different expansion coefficients;
frame structure stress: whether the manufactured oil tank can meet the tensile resistance, compression resistance and torsion resistance of a corresponding draught point in structure or not, and the distribution transformation only considers the gravity brought by the weight of the oil tank body under most conditions, wherein the gravity comprises the weight of oil, the weight of the oil tank body and the weight of accessories;
formula G for oil reuseOil weight＝GFE/7.8+GCUIn which G is determinedFEIs the total weight G of the silicon steel sheets in the transformerCUThe total weight of the copper wire with insulation in the transformer is Gqs＝kq·(GFE+GCU)，GqsWeight of the body, kqRepresenting the transformer body sundry factor, namely the weight of the transformer body sundry factor (the total weight of silicon steel sheets and the total weight of copper wires with insulation), wherein the sundry factor interval of the pure copper transformer is between 1.14 and 1.16; the weight of the accessory is GAttachment weight＝Gs+Gt+Gc+Gj，GAttachment weightRepresenting the weight of the accessory, GsHeavy as radiator GtRepresenting the weight of the casing, GcRepresenting the weight of the conservator, GjRepresenting the net oil weight, namely the weight of an accessory is equal to the weight of a radiator, the weight of a sleeve, the weight of an oil conservator and the net oil weight;
coefficient of expansion of heat dissipating device: the main influence factors depend on the manufacturing raw materials of the heat dissipation device, the heat dissipation device is processed by adopting a Q235 cold-rolled steel plate, and the expansion coefficient of the material can be 10.6-12.2 multiplied by 10 at the temperature of 20-100 DEG C-6K is calculated, wherein K represents the Fahrenheit temperature of the corresponding material when the expansion coefficient is calculated, and the heat dissipation coefficients of the transformer heat dissipation devices corresponding to different temperatures are different; the thickness can be properly selected according to the size and the bearing capacity of the oil tank, the heat dissipation device made of cold-rolled steel plates with the thickness of 1.2mm is selected for the transformer capacity below 1600kVA, and the thickness of 1.5 is selected for the transformer capacity above 1600kVAmm cold-rolled steel sheets;
(2) the oil tank skeleton design, according to main body frame overall dimension requirement, confirms the size of oil tank skeleton subassembly, the oil tank skeleton is divided according to three component, is the bottom of the case part, main part skeleton portion and case respectively along the part: the tank bottom part is designed in an integrated forming mode, a cubic structure with an opening at the upper end is defined by a tank bottom steel plate and peripheral baffles, right-angle grooves are formed in four corners of the tank bottom part through a whole steel plate, four baffles are bent in a stamping mode, butt joint edges among the baffles are welded, triangular grooves are formed in the corner ends of the right-angle grooves of the whole steel plate, the purpose of forming the triangular grooves is that the tank bottom steel plate directly enters a stamping integrated machine to be directly forged and formed after being cut, triangular grooves are reserved to enable stamped and folded parts to be removed, the overall shape of the tank bottom part is regular, the subsequent robot welding operation is facilitated, and meanwhile the attractiveness degree of an overall oil tank is increased;
the main framework part is four angle steel supports, positioning grooves are formed in the middle positions of erected angle steel, the traditional design method that the angle steel is attached to the bottom of a box and the inner wall of the edge of the box by the outer wall is abandoned, the upper end and the lower end of the angle steel are butted with the bottom of the box and the edge of the box respectively, the grooves are formed in order to facilitate the clamping and positioning of a robot welding tool, the specific operation method is that the box edge and the bottom of the box which need to be welded together are clamped at a certain distance by the clamping tool with a fixed capacity model, the central groove of the angle steel is searched by the framework angle steel clamping tool for initial positioning, the framework angle steel is moved to the distance center between the box edge and the bottom of the box by preprogramming or laser positioning, the distances between the framework angle steel and the welding gaps between the box edge and the bottom of the box are kept consistent or close, the height of an oil tank or the error caused by manual positioning welding due to gravity factor interference is, The welding clearance of the tank edge is kept in the same error level range, so that the problem that a welding gun is difficult to enter when a welding robot works on the traditional oil tank is solved, and the integral welding precision of the oil tank framework is improved;
the box edge part is formed by welding two groups of angle steels in a splicing way, the two groups are a long group and a short group, each group consists of two equilateral or inequilateral hot rolled angle steels with the same length, the box edge angle steel is firstly subjected to hole opening and truncation by using a flowing water cutting and power punch, the long and short angle steels are vertically spliced into an L shape in pairs, and finally two L-shaped semi-finished products are spliced and welded into the box edge.
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