CN111532514A - 一种大型水轮发电机磁轭冲片无油防锈包装方法 - Google Patents

一种大型水轮发电机磁轭冲片无油防锈包装方法 Download PDF

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CN111532514A
CN111532514A CN202010375960.1A CN202010375960A CN111532514A CN 111532514 A CN111532514 A CN 111532514A CN 202010375960 A CN202010375960 A CN 202010375960A CN 111532514 A CN111532514 A CN 111532514A
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周帅
徐善清
王子林
邓小民
苗旺
李鹏
李佳贺
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Harbin Electric Machinery Co Ltd
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Abstract

本发明公开一种大型水轮发电机磁轭冲片无油防锈包装方法，具有优异的防锈性能与防水防潮性能，能够在凝露、高温高湿较为恶劣的环境下保障大型水轮发电机磁轭冲片在运输与存放过程中的防锈效果；相对涂油防锈包装，无油防锈包装更加环保、清洁，磁轭冲片在电站免清洗，节省大量的清洗成本，拆开包装即可直接叠片安装，加快电站磁轭冲片安装效率。

Description

一种大型水轮发电机磁轭冲片无油防锈包装方法
技术领域
本发明涉及水轮发电机领域，尤其涉及一种大型水轮发电机磁轭冲片无油防锈包装方法。
背景技术
磁轭冲片是水轮发电机的重要组成部分，在其运输与存放过程中防止发生锈蚀是十分重要的。由于运输与存放时间较长，且期间可能经历凝露、高温高湿、雨雪等严重影响防锈质量的环境，磁轭冲片一般采用表面涂覆防锈油的方式进行防锈包装，磁轭冲片在电站叠装前进行清洗除油。由于一台水轮发电机的磁轭冲片数目巨大，且大型水轮发电机单张磁轭冲片较大较重，在电站对磁轭冲片清洗除油耗费大量的人力物力以及大量的清洗时间，严重制约电站的安装进度，并且污染环境、存在不安全因素。采用一种清洁、无油、免清洗的磁轭冲片防锈方法已成为电站迫切的愿望。
发明内容
为解决上述问题，本发明提供一种大型水轮发电机磁轭冲片无油防锈包装方法。本发明是通过以下技术方案实现的：
(1)清洗磁轭冲片：采用连续型清洗烘干设备与水基清洗剂对磁轭冲片进行清洗，清洗后的磁轭冲片干净、干燥、无锈蚀、无任何油污、油脂、沉淀物、汗迹、手印、清洗残留痕迹。用于清洗磁轭冲片的清洗剂不能含有硫化物和氯化物。清洗过程环境相对湿度不得高于85％，冲片基材温度要高于空气露点温度3℃以上。环境应清洁，无灰尘飞扬，环境空气洁净度达到一般整洁干净。
(2)叠放磁轭冲片：在磁轭冲片摞放拍上预先垫放一层双面气相防锈纸，气相防锈纸的尺寸要大于磁轭冲片，然后每隔5张磁轭冲片压放一层双面气相防锈纸，叠码到120片后，在最上面再铺放一层双面气相防锈纸。操作人员必须戴干净橡胶手套，避免操作人员在搬运过程中对干净的磁轭冲片表面造成污染。叠放过程环境相对湿度不得高于85％，冲片基材温度要高于空气露点温度3℃以上。环境应清洁，无灰尘飞扬，环境空气洁净度达到一般整洁干净。
(3)拉伸膜缠绕封闭：用防锈拉伸膜对叠放好的磁轭冲片进行拉紧缠绕、包裹封闭。缠绕过程环境相对湿度不得高于85％，冲片基材温度要高于空气露点温度3℃以上。环境应清洁，无灰尘飞扬，环境空气洁净度达到一般整洁干净。
(4)铺放缓冲材料与包装材料：在磁轭冲片与包装箱接触的木方上预先铺放胶皮，胶皮的尺寸要大于接触木方的尺寸。胶皮表面上不能残留任何硬质颗粒物，避免硌破包装膜。依次放铝箔复合膜袋，气相防锈膜袋与一层气相防锈纸。
(5)磁轭冲片装袋与固定：将叠放好的磁轭冲片整体吊入气相防锈膜袋与铝箔复合膜袋中，并利用镀锌螺杆穿过磁轭冲片自身的孔将磁轭冲片固定形成整体，固定过程不得破坏包装袋，。
(6)放置气相防锈粉与变色硅胶干燥剂：在气相防锈膜袋内部，围绕磁轭冲片均匀放置无纺布袋装的气相防锈粉与无纺布袋包装的变色硅胶干燥剂。
(7)抽真空、热合密封气相防锈膜，热合密封应连续，无漏封，密封宽度均匀，密封宽度5-10mm为宜。
(8)抽真空、热合密封铝箔复合膜，热合密封应连续，无漏封，密封宽度均匀，密封宽度5-10mm为宜。
(9)用木方与螺杆进行整体固定，不得破坏密封好的包装袋，封箱。
技术效果
大型水轮发电机磁轭冲片无油防锈包装方法，兼顾了防锈、防潮、防水因素，具有良好的防锈、防潮、防水性能，能够在凝露、高温高湿等较为恶劣的环境下保障大型水轮发电机磁轭冲片在运输与存放过程中的防锈效果。本发明操作简便、清洁，具有良好的应用前景。
大型水轮发电机磁轭冲片无油防锈包装不使用防锈油进行防锈，彻底省去了单片重量较重、数量巨大的磁轭冲片涂覆与去除防锈油的沉重工作，解放了劳动力。包装过程因不使用防锈油而变得环保、清洁、简便、效率高；在电站去包装过程中磁轭冲片开箱后免去利用有机溶剂清洗防锈油的工作，节约了大量的清洗成本，拆开包装即可直接叠片安装，使大型水轮发电机磁轭冲片的清洗除油工作不再成为磁轭冲片安装的制约因素，加快了电站磁轭冲片安装效率。同时，因不使用有机溶剂而避免了污染环境、危害操作人员身心健康以及火灾危险问题。
具体实施方式
本发明以某个水电站磁轭冲片无油防锈包装为例，具体包装步骤如下：
1)清洗磁轭冲片：采用连续型清洗、烘干设备以及水基清洗剂对磁轭冲片进行清洗，清洗后的磁轭冲片应干净、干燥、无锈蚀、无任何油污、油脂、沉淀物、汗迹、手印、清洗残留痕迹。用于清洗磁轭冲片的清洗剂不能含有硫化物和氯化物。清洗过程环境相对湿度不得高于85％，冲片基材温度要高于空气露点温度3℃以上。环境应清洁，无灰尘飞扬，环境空气洁净度达到一般整洁干净。
2)叠放磁轭冲片：在磁轭冲片摞放拍上预先垫放一张双面气相防锈纸(幅宽1.2m)，每张气相防锈纸的长度要略大于磁轭冲片，每隔5张磁轭冲片压放一张双面气相防锈纸，规整叠码至120片后，在最上面再铺放一张双面气相防锈纸。操作人员必须戴干净橡胶手套，避免操作人员在搬运过程中对干净的磁轭冲片表面造成污染。夹放气相防锈纸的磁轭冲片在空气中停放不能超过4h。叠放过程环境相对湿度不得高于85％，冲片基材温度要高于空气露点温度3℃以上。环境应清洁，无灰尘飞扬，环境空气洁净度达到一般整洁干净。
3)拉伸膜缠绕封闭：用防锈拉伸膜(幅宽500mm)对叠放好的磁轭冲片进行拉紧缠绕、包裹封闭，并需在36h内装入气相防锈膜袋、铝箔复合膜袋进行抽真空热合密封。缠绕过程环境相对湿度不得高于85％，冲片基材温度要高于空气露点温度3℃以上。环境应清洁，无灰尘飞扬，环境空气洁净度达到一般整洁干净。
4)铺放缓冲材料与包装材料：在磁轭冲片与包装箱接触的木方上铺放5mm厚胶皮，胶皮的尺寸要大于接触木方的尺寸。胶皮表面上不能残留任何硬质颗粒物，避免硌破包装膜。依次放铝箔复合膜袋(PET/AL/PA/PE四层结构，膜厚≥140μm)，气相防锈膜袋与一层双面气相防锈纸。
5)磁轭冲片装袋与固定：将叠放好的磁轭冲片整体吊入气相防锈膜袋与铝箔复合膜袋中，并利用镀锌螺杆穿过磁轭冲片自身的孔将磁轭冲片固定形成整体，固定过程不得破坏包装袋。
6)放置气相防锈粉与变色硅胶干燥剂：在气相防锈膜袋内部，围绕磁轭冲片均匀放置200g(10袋，每袋20g)无纺布袋装的气相防锈粉与1.5kg变色硅胶干燥剂，不得堆放在一起；
7)抽真空、热合密封气相防锈膜：利用手钳式封口机对气相防锈膜袋进行热合密封，预留抽真空口；在预留的抽真空口，采用吸尘器对气相防锈膜袋抽真空，然后马上热封。
8)抽真空、热合密封铝箔复合膜：利用连续型履带式封口机对铝箔复合膜袋进行热合密封，预留抽真空口；在预留的抽真空口，采用吸尘器对铝箔复合膜袋抽真空，然后马上热封。
9)用木方与螺杆进行整体固定，不得破坏密封好的包装袋，封箱。

Claims (1)

1.一种大型水轮发电机磁轭冲片无油防锈包装方法，其特征是：包括如下步骤：
1)清洗磁轭冲片：采用连续型清洗烘干设备与水基清洗剂对磁轭冲片进行清洗，清洗后的磁轭冲片干净、干燥、无锈蚀、无油污、油脂、沉淀物、汗迹、手印、清洗残留痕迹；用于清洗磁轭冲片的清洗剂不含有硫化物和氯化物；清洗过程环境相对湿度不得高于85％，冲片基材温度高于空气露点温度3℃以上，环境清洁，无灰尘飞扬；
2)叠放磁轭冲片：在磁轭冲片摞放拍上预先垫放一层双面气相防锈纸，气相防锈纸的尺寸大于磁轭冲片，然后每隔5张磁轭冲片压放一层双面气相防锈纸，叠码到120片后，在最后叠放的磁轭冲片上面再铺放一层双面气相防锈纸。叠放过程环境相对湿度不得高于85％，冲片基材温度高于空气露点温度3℃以上，无灰尘飞扬；
3)拉伸膜缠绕封闭：用防锈拉伸膜对叠放好的磁轭冲片进行拉紧缠绕、包裹封闭；缠绕过程环境相对湿度不得高于85％，冲片基材温度要高于空气露点温度3℃以上，无灰尘飞扬；
4)铺放缓冲材料与包装材料：在磁轭冲片与包装箱接触的木方上预先铺放胶皮，胶皮的尺寸大于接触木方的尺寸，胶皮材料表面上无残留硬质颗粒物，避免硌破包装膜，依次放铝箔复合膜袋，气相防锈膜袋与一层气相防锈纸；
5)磁轭冲片装袋与固定：将叠放好的磁轭冲片整体吊入气相防锈膜袋与铝箔复合膜袋中，并利用镀锌螺杆穿过磁轭冲片自身的孔将磁轭冲片固定形成整体；
6)放置气相防锈粉与变色硅胶干燥剂：在气相防锈膜袋内部，围绕磁轭冲片均匀放置无纺布袋装的气相防锈粉与无纺布袋包装的变色硅胶干燥剂；
7)抽真空、热合密封气相防锈膜，热合密封应连续，无漏封，密封宽度均匀，密封宽度为5-10mm；
8)抽真空、热合密封铝箔复合膜，热合密封应连续，无漏封，密封宽度均匀，密封宽度为5-10mm；
9)用木方与螺杆进行整体固定，封箱。
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