CN113458736B - Method for manufacturing rotating wheel of water turbine - Google Patents
Method for manufacturing rotating wheel of water turbine Download PDFInfo
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- CN113458736B CN113458736B CN202110857349.7A CN202110857349A CN113458736B CN 113458736 B CN113458736 B CN 113458736B CN 202110857349 A CN202110857349 A CN 202110857349A CN 113458736 B CN113458736 B CN 113458736B
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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 invention discloses a preparation method of a water turbine runner, belonging to the technical field of water turbines and being characterized by comprising the following steps: a. designing a rotating wheel into three module structures of an upper shroud blade disc, a lower ring blade disc and an insert, and respectively determining the sizes of the three module structures; b. respectively designing positioning references of the insert and the upper shroud blade disc, and designing positioning references of the lower ring blade disc; c. firstly, checking through a checking sample plate, and then respectively detecting an insert molded line, an upper shroud blade disc molded line and a lower ring blade disc molded line through a laser tracker; d. assembling and welding the runner. Aiming at the runner with a long and narrow flow channel and a narrow space, the runner is arranged into an insert type blade disc structure, and the position of a welding line is changed, so that the welding deposition amount is greatly reduced, the welding efficiency is improved, the welding period is shortened, and the welding quality is improved.
Description
Technical Field
The invention relates to the technical field of water turbines, in particular to a preparation method of a water turbine runner.
Background
The runner is widely applied to the hydropower manufacturing industry, and the traditional structure of the water turbine runner generally adopts a crown, a lower ring and a blade cast-weld structure. The runner structure has long and narrow flow channel, large wrap angle of the blade and narrow space, so that the welding process is poor, the production efficiency is low and the product quality is unstable.
Because the runner structure has a great influence on welding manufacturability, casting, processing and relief grinding, the runner structure needs to be continuously optimized. At present, the optimization of the structure of the rotating wheel has a plurality of difficulties, which mainly comprise: the runner adopts an upper crown, a lower ring and a blade structure, the welding and relief grinding amount of the runner is large, and particularly, the runner with a long and narrow flow channel and a narrow space can not be even welded; aiming at the narrow space rotating wheel, the traditional structure is adopted, the sight line at the root part of a welding line is poor, and the welding quality cannot be ensured; the short column structure of the upper crown and the lower ring is adopted, the welding manufacturability cannot be obviously improved, and the welding amount is still large; the upper crown or the lower ring is adopted to be of a segmented structure, so that the welding amount cannot be effectively reduced, the welding and manufacturing process is complex, and the manufacturing period is long.
Chinese patent publication No. CN 105332846A, 2016, 02, 17 discloses a method for manufacturing a turbine runner, which is characterized in that: the method comprises the following specific steps:
the method comprises the following steps: designing: a blade body with reasonable design;
step two: casting: die-casting the blade body to obtain an initial blank of the blade body;
step three: and (3) heat treatment: carrying out heat treatment on the initial blank of the blade body;
step four: surface processing: performing surface cutting processing to obtain a refined blank;
step five: finish machining: performing surface anticorrosion treatment on the refined blank, and then performing heat treatment and grinding processing to finish the industrial manufacturing of the blade body;
step six: and (3) transportation: transporting all blade bodies required by one water turbine runner to a water turbine runner mounting position on a dam;
step seven: assembling: splicing the blade bodies together by adopting a temporary fastening piece, and then winding the upper crown and the lower ring of the spliced body by utilizing a prestressed wire winding robot according to the designed pre-tightening process requirement to form a complete water turbine runner;
step eight: protection treatment: sealing and protecting a combined seam formed by splicing the upper crown part and the lower ring part of each blade body on the water turbine runner; then, carrying out sealing protection treatment on the steel wire layers on the surfaces of the upper crown part and the lower ring part of the water turbine;
step nine: finishing treatment: at the in-situ working position of the water turbine runner, a temporary driving device and a grinding tool are adopted to carry out finish machining on the surface of the water turbine runner;
step ten: debugging: and performing dynamic and static balance debugging at the in-situ working position of the rotating wheel of the water turbine until the requirements are met.
The method for manufacturing the water turbine runner disclosed by the patent document solves the engineering problem that the water turbine runner is huge in weight and cannot be transported, and is convenient for partially disassembling, repairing or replacing the damaged part. However, the problems of low welding efficiency and poor welding quality still exist for the runner with a long and narrow flow channel and a narrow space.
Disclosure of Invention
Aiming at the runner with a long and narrow flow channel and a narrow space, the runner is arranged into an insert type blade disc structure, and the position of a welding seam is changed, so that the welding deposition amount is greatly reduced, the welding efficiency is improved, the welding period is shortened, and the welding quality is improved.
The invention is realized by the following technical scheme:
a preparation method of a water turbine runner is characterized by comprising the following steps:
a. designing a rotating wheel into three module structures of an upper shroud blade disc, a lower ring blade disc and an insert, and respectively determining the sizes of the upper shroud blade disc, the lower ring blade disc and the insert;
b. the method comprises the following steps of respectively designing positioning references of an insert and an upper shroud blade disc, designing a three-point positioning reference to position the insert and the upper shroud blade disc to obtain a combined body, designing a positioning reference of a lower ring blade disc, and designing a three-point positioning reference to position the lower ring blade disc of a rotating wheel and the combined body;
c. firstly, checking through a checking sample plate, and then respectively detecting an insert molded line, an upper shroud blade disc molded line and a lower ring blade disc molded line through a laser tracker;
d. assembling and welding the rotating wheel, assembling the insert and the upper shroud blade disc through the reference block, assembling a combined body formed by the insert and the upper shroud blade disc and the lower ring blade disc through the positioning pin, and then welding.
In the step a, the sizes of the upper shroud blade disc, the lower ring blade disc and the insert are determined according to the pitch, the wrap angle and the molded line of the rotating wheel.
In the step b, the step of designing the positioning reference of the insert specifically means that a first point is arranged at the front end of the insert, a second point is arranged in the middle of the insert, a third point is arranged at the rear end of the insert, the linear distance between the first point and the third point is 1480mm, the first point and the third point are located on the same side of the insert, and the second point is located on the other side.
In the step d, the rotating wheel welding specifically comprises the following steps:
s1, preheating before welding, namely respectively preheating an upper shroud blade disc, a lower ring blade disc and an insert by a far infrared electric heating device or flame, wherein the preheating temperature is 80-150 ℃;
s2, calibrating the length of a welding seam section, wherein the length of the section is 500mm, the welding seam formed by the insert and the upper shroud leaf disc is divided into 3 sections, the welding seam formed by the lower ring leaf disc and the upper shroud leaf disc is divided into 6 sections, and the thickness of the welding seam is 15mm;
s3, welding the middle section, the outer section and the inner section in the welding sequence of the welding seam formed by the insert and the upper shroud blade disc; the welding sequence of the welding seam formed by the lower ring blade disc and the upper shroud blade disc is that the middle 4 section is welded firstly, then the 5 th section on the outer side is welded, and finally the 6 th section on the inner side is welded;
s4, cleaning the welded seam by using a steel wire brush or a pneumatic shovel after welding;
and S5, welding according to the welding sequence calibrated in the step S3, adjusting the welding position after the thickness of the welding seam of each section of welding seam reaches 15mm, welding the next section of welding seam, alternately finishing the welding of the runner welding seam according to the welding sequence, simultaneously hammering the welding process, and performing post-welding stress relief heat treatment after the welding is finished.
In the step b, the positioning reference design of the upper shroud leaf disc specifically means that three points are found on the disc surface of the upper shroud leaf disc, and the three points and a connecting line of the circle center of the upper shroud leaf disc form an angle of 120 degrees with each other.
In the step b, the positioning reference design of the lower ring blade disc specifically means that three points are found on the disc surface of the lower ring blade disc, and the three points and a connecting line of the circle center of the lower ring blade disc form an angle of 120 degrees with each other.
In the step c, the checking through the checking sample plate specifically means that gaps between the insert and the upper shroud blade disc and gaps between the lower ring blade disc and the upper shroud blade disc are respectively checked through the checking sample plate, so that the gaps are all smaller than 1mm.
The beneficial effects of the invention are mainly shown in the following aspects:
1. the method comprises the following steps that a, a rotating wheel is designed into three module structures of an upper shroud blade disc, a lower ring blade disc and an insert, and the sizes of the upper shroud blade disc, the lower ring blade disc and the insert are respectively determined; b. the method comprises the following steps of designing positioning standards for an insert and an upper shroud blade disc respectively, designing a three-point positioning standard to position the insert and the upper shroud blade disc to obtain a combined body, designing a positioning standard for a lower ring blade disc, and designing a three-point positioning standard to position the lower ring blade disc of a rotating wheel and the combined body; c. firstly, checking through a checking sample plate, and then respectively detecting an insert molded line, an upper shroud blade disc molded line and a lower ring blade disc molded line through a laser tracker; d. the runner assembly and welding, assemble insert and upper shroud leaf dish through the benchmark piece, assemble the combination that insert and upper shroud leaf dish formed and lower ring blade dish through the locating pin, then weld, as a complete technical scheme, compared with the prior art, to the long and narrow and small runner in space of runner, through setting the runner to insert formula leaf dish structure, change the welding seam position, thereby reduced the welding deposition volume by a wide margin, improved welding efficiency, shorten welding cycle, improved welding quality.
2. According to the invention, the rotating wheel is designed into three module structures of the upper shroud bladed disc, the lower ring bladed disc and the insert, so that the welding amount is reduced by 60%, and the relief grinding amount is reduced by 70%, thereby effectively improving the production efficiency.
3. According to the invention, through changing the position of the welding seam, the welding seam of the blade, the upper crown and the root part of the lower ring in the prior art is changed into the welding seam of the middle part of the insert, and the welding seam is far away from the maximum working stress area of the runner, so that the welding manufacturability is better, the integral one-step welding is adopted, the working procedures are reduced, and the problem caused by the complexity of the working procedures is avoided.
4. In step d, the wheel welding specifically comprises: s1, preheating before welding, namely respectively preheating an upper shroud blade disc, a lower ring blade disc and an insert by a far infrared electric heating device or flame, wherein the preheating temperature is 80-150 ℃; s2, calibrating the length of a welding seam section, wherein the length of the section is 500mm, the welding seam formed by the insert and the upper shroud leaf disc is divided into 3 sections, the welding seam formed by the lower ring leaf disc and the upper shroud leaf disc is divided into 6 sections, and the thickness of the welding seam is 15mm; s3, welding the middle section, the outer section and the inner section in the welding sequence of the welding seam formed by the insert and the upper shroud blade disc; the welding sequence of the welding seam formed by the lower ring blade disc and the upper shroud blade disc is that the middle 4 section is welded firstly, then the 5 th section on the outer side is welded, and finally the 6 th section on the inner side is welded; s4, cleaning the welded seam by using a steel wire brush or a pneumatic shovel after welding; and S5, welding according to the welding sequence calibrated in the step S3, adjusting the welding position after the thickness of the welding seam of each section reaches 15mm, welding the next section of welding seam, alternately finishing the welding of the runner welding seam according to the welding sequence, hammering simultaneously in the welding process, and performing post-welding stress relief heat treatment after the welding is finished.
5. According to the invention, the positioning reference design is respectively carried out on the insert and the upper shroud blade disc, the three-point positioning reference is designed to position the insert and the upper shroud blade disc to obtain a combined body, the positioning reference design is carried out on the lower ring blade disc, the three-point positioning reference is designed to position the lower ring blade disc of the rotating wheel and the combined body, so that the insert and the upper shroud blade disc can be accurately positioned, the lower ring blade disc and the combined body can be accurately positioned, the precision is ensured, and the welding quality is improved.
6. According to the invention, the inspection is carried out through the inspection sample plate, and then the insert molded line, the upper shroud blade disc molded line and the lower ring blade disc molded line are respectively detected through the laser tracker, so that the size requirement of the insert type blade disc structure is realized, and the welding quality is favorably improved.
Drawings
The invention will be further described in detail with reference to the drawings and the detailed description, wherein:
FIG. 1 is a block flow diagram of the present invention.
Detailed Description
Example 1
Referring to fig. 1, a method for manufacturing a turbine runner includes the following steps:
a. designing a rotating wheel into three module structures of an upper shroud blade disc, a lower ring blade disc and an insert, and respectively determining the sizes of the upper shroud blade disc, the lower ring blade disc and the insert;
b. the method comprises the following steps of designing positioning standards for an insert and an upper shroud blade disc respectively, designing a three-point positioning standard to position the insert and the upper shroud blade disc to obtain a combined body, designing a positioning standard for a lower ring blade disc, and designing a three-point positioning standard to position the lower ring blade disc of a rotating wheel and the combined body;
c. firstly, checking through a checking sample plate, and then respectively detecting an insert molded line, an upper shroud blade disc molded line and a lower ring blade disc molded line through a laser tracker;
d. assembling and welding the rotating wheel, assembling the insert and the upper shroud blade disc through the reference block, assembling a combined body formed by the insert and the upper shroud blade disc and the lower ring blade disc through the positioning pin, and then welding.
a. Designing a rotating wheel into three module structures of an upper shroud blade disc, a lower ring blade disc and an insert, and respectively determining the sizes of the upper shroud blade disc, the lower ring blade disc and the insert; b. the method comprises the following steps of respectively designing positioning references of an insert and an upper shroud blade disc, designing a three-point positioning reference to position the insert and the upper shroud blade disc to obtain a combined body, designing a positioning reference of a lower ring blade disc, and designing a three-point positioning reference to position the lower ring blade disc of a rotating wheel and the combined body; c. firstly, checking through a checking sample plate, and then respectively detecting an insert molded line, an upper shroud blade disc molded line and a lower ring blade disc molded line through a laser tracker; d. the runner assembly and welding, assemble insert and upper shroud leaf dish through the benchmark piece, assemble the combination that insert and upper shroud leaf dish formed and lower ring blade dish through the locating pin, then weld, as a complete technical scheme, compared with the prior art, to the long and narrow and small runner in space of runner, through setting the runner to insert formula leaf dish structure, change the welding seam position, thereby reduced the welding deposition volume by a wide margin, improved welding efficiency, shorten welding cycle, improved welding quality.
Example 2
Referring to fig. 1, a method for manufacturing a turbine runner includes the following steps:
a. designing a rotating wheel into three module structures of an upper shroud blade disc, a lower ring blade disc and an insert, and respectively determining the sizes of the upper shroud blade disc, the lower ring blade disc and the insert;
b. the method comprises the following steps of respectively designing positioning references of an insert and an upper shroud blade disc, designing a three-point positioning reference to position the insert and the upper shroud blade disc to obtain a combined body, designing a positioning reference of a lower ring blade disc, and designing a three-point positioning reference to position the lower ring blade disc of a rotating wheel and the combined body;
c. firstly, checking through a checking sample plate, and then respectively detecting an insert molded line, an upper shroud blade disc molded line and a lower ring blade disc molded line through a laser tracker;
d. assembling and welding the rotating wheel, assembling the insert and the upper shroud blade disc through the reference block, assembling a combined body formed by the insert and the upper shroud blade disc and the lower ring blade disc through the positioning pin, and then welding.
In the step a, the sizes of the upper shroud blade disc, the lower ring blade disc and the insert are determined according to the pitch, the wrap angle and the molded line of the rotating wheel.
In the step b, the step of designing the positioning reference of the insert specifically means that a first point is arranged at the front end of the insert, a second point is arranged in the middle of the insert, a third point is arranged at the rear end of the insert, the linear distance between the first point and the third point is 1480mm, the first point and the third point are located on the same side of the insert, and the second point is located on the other side.
The rotating wheel is designed into three modular structures of the upper shroud impeller disc, the lower ring impeller disc and the insert, so that the welding amount is reduced by 60%, the relief grinding amount is reduced by 70%, and the production efficiency is effectively improved.
Example 3
Referring to fig. 1, a method for manufacturing a turbine runner includes the following steps:
a. designing a rotating wheel into three module structures of an upper shroud blade disc, a lower ring blade disc and an insert, and respectively determining the sizes of the upper shroud blade disc, the lower ring blade disc and the insert;
b. the method comprises the following steps of designing positioning standards for an insert and an upper shroud blade disc respectively, designing a three-point positioning standard to position the insert and the upper shroud blade disc to obtain a combined body, designing a positioning standard for a lower ring blade disc, and designing a three-point positioning standard to position the lower ring blade disc of a rotating wheel and the combined body;
c. firstly, checking through a checking sample plate, and then respectively detecting an insert molded line, an upper shroud blade disc molded line and a lower ring blade disc molded line through a laser tracker;
d. assembling and welding the rotating wheel, assembling the insert and the upper shroud blade disc through the reference block, assembling a combined body formed by the insert and the upper shroud blade disc and the lower ring blade disc through the positioning pin, and then welding.
In the step a, the sizes of the upper shroud blade disc, the lower ring blade disc and the insert are determined according to the pitch, the wrap angle and the molded line of the rotating wheel.
In the step b, the step of designing the positioning reference of the insert specifically means that a first point is arranged at the front end of the insert, a second point is arranged in the middle of the insert, a third point is arranged at the rear end of the insert, the linear distance between the first point and the third point is 1480mm, the first point and the third point are located on the same side of the insert, and the second point is located on the other side.
In the step d, the rotating wheel welding specifically comprises the following steps:
s1, preheating before welding, namely respectively preheating an upper shroud blade disc, a lower ring blade disc and an insert by a far infrared electric heating device or flame, wherein the preheating temperature is 80 ℃;
s2, calibrating the length of a welding seam section, wherein the length of the section is 500mm, the welding seam formed by the insert and the upper shroud leaf disc is divided into 3 sections, the welding seam formed by the lower ring leaf disc and the upper shroud leaf disc is divided into 6 sections, and the thickness of the welding seam is 15mm;
s3, welding the middle section, the outer section and the inner section in the welding sequence of the welding seam formed by the insert and the upper shroud blade disc; the welding sequence of the welding seam formed by the lower ring blade disc and the upper shroud blade disc is that the middle section is welded firstly, then the 5 th section on the outer side is welded, and finally the 6 th section on the inner side is welded;
s4, cleaning the welded seam by using a steel wire brush or a wind shovel after welding;
and S5, welding according to the welding sequence calibrated in the step S3, adjusting the welding position after the thickness of the welding seam of each section of welding seam reaches 15mm, welding the next section of welding seam, alternately finishing the welding of the runner welding seam according to the welding sequence, simultaneously hammering the welding process, and performing post-welding stress relief heat treatment after the welding is finished.
Through the change of the welding seam position, the welding seam of the blade, the upper crown and the root welding seam of the lower ring in the prior art is changed into the welding seam of the middle part of the insert, the welding seam is far away from the maximum working stress area of the runner, the welding manufacturability is better, the integrity is adopted for one-time welding, the working procedures are reduced, and the problem caused by the complexity of the working procedures is avoided.
Example 4
Referring to fig. 1, a method for manufacturing a turbine runner includes the following steps:
a. designing a rotating wheel into three module structures of an upper shroud blade disc, a lower ring blade disc and an insert, and respectively determining the sizes of the upper shroud blade disc, the lower ring blade disc and the insert;
b. the method comprises the following steps of respectively designing positioning references of an insert and an upper shroud blade disc, designing a three-point positioning reference to position the insert and the upper shroud blade disc to obtain a combined body, designing a positioning reference of a lower ring blade disc, and designing a three-point positioning reference to position the lower ring blade disc of a rotating wheel and the combined body;
c. firstly, checking through a checking sample plate, and then respectively detecting an insert molded line, an upper shroud blade disc molded line and a lower ring blade disc molded line through a laser tracker;
d. assembling and welding the rotating wheel, assembling the insert and the upper shroud blade disc through the reference block, assembling a combined body formed by the insert and the upper shroud blade disc and the lower ring blade disc through the positioning pin, and then welding.
In the step a, the sizes of the upper shroud blade disc, the lower ring blade disc and the insert are determined according to the pitch, the wrap angle and the molded line of the rotating wheel.
In the step b, the step of designing the positioning reference of the insert specifically means that a first point is arranged at the front end of the insert, a second point is arranged in the middle of the insert, a third point is arranged at the rear end of the insert, the linear distance between the first point and the third point is 1480mm, the first point and the third point are located on the same side of the insert, and the second point is located on the other side.
In the step d, the rotating wheel welding specifically comprises the following steps:
s1, preheating before welding, namely respectively preheating an upper shroud blade disc, a lower ring blade disc and an insert by a far infrared electric heating device or flame, wherein the preheating temperature is 110 ℃;
s2, calibrating the length of a welding seam segment, wherein the length of the segment is 500mm, the welding seam formed by the insert and the upper shroud blade disc is divided into 3 sections, the welding seam formed by the lower ring blade disc and the upper shroud blade disc is divided into 6 sections, and the thickness of the welding seam is 15mm;
s3, welding the middle section, the outer section and the inner section in the welding sequence of the welding seam formed by the insert and the upper shroud blade disc; the welding sequence of the welding seam formed by the lower ring blade disc and the upper shroud blade disc is that the middle section is welded firstly, then the 5 th section on the outer side is welded, and finally the 6 th section on the inner side is welded;
s4, cleaning the welded seam by using a steel wire brush or a pneumatic shovel after welding;
and S5, welding according to the welding sequence calibrated in the step S3, adjusting the welding position after the thickness of the welding seam of each section of welding seam reaches 15mm, welding the next section of welding seam, alternately finishing the welding of the runner welding seam according to the welding sequence, simultaneously hammering the welding process, and performing post-welding stress relief heat treatment after the welding is finished.
In the step b, the step of designing the positioning reference of the upper shroud leaf disc specifically means that three points are found on the disc surface of the upper shroud leaf disc, and the three points and a connecting line of the circle center of the upper shroud leaf disc form an angle of 120 degrees with each other.
The specific welding mode adopted in the step d has the technical effects that the welding deformation is not more than 3mm, and the welding residual stress is not more than 120MPa, so that the welding quality is further improved.
Example 5
Referring to fig. 1, a method for manufacturing a turbine runner includes the following steps:
a. designing a rotating wheel into three module structures of an upper shroud blade disc, a lower ring blade disc and an insert, and respectively determining the sizes of the upper shroud blade disc, the lower ring blade disc and the insert;
b. the method comprises the following steps of respectively designing positioning references of an insert and an upper shroud blade disc, designing a three-point positioning reference to position the insert and the upper shroud blade disc to obtain a combined body, designing a positioning reference of a lower ring blade disc, and designing a three-point positioning reference to position the lower ring blade disc of a rotating wheel and the combined body;
c. firstly, checking through a checking sample plate, and then respectively detecting an insert molded line, an upper shroud blade disc molded line and a lower ring blade disc molded line through a laser tracker;
d. assembling and welding the rotating wheel, assembling the insert and the upper shroud blade disc through the reference block, assembling a combined body formed by the insert and the upper shroud blade disc and the lower ring blade disc through the positioning pin, and then welding.
In the step a, the sizes of the upper shroud blade disc, the lower ring blade disc and the insert are determined according to the pitch, the wrap angle and the molded line of the rotating wheel.
In the step b, the step of designing the positioning reference of the insert specifically means that a first point is arranged at the front end of the insert, a second point is arranged in the middle of the insert, a third point is arranged at the rear end of the insert, the linear distance between the first point and the third point is 1480mm, the first point and the third point are located on the same side of the insert, and the second point is located on the other side.
In the step d, the rotating wheel welding specifically comprises the following steps:
s1, preheating before welding, namely respectively preheating an upper shroud blade disc, a lower ring blade disc and an insert by a far infrared electric heating device or flame, wherein the preheating temperature is 130 ℃;
s2, calibrating the length of a welding seam section, wherein the length of the section is 500mm, the welding seam formed by the insert and the upper shroud leaf disc is divided into 3 sections, the welding seam formed by the lower ring leaf disc and the upper shroud leaf disc is divided into 6 sections, and the thickness of the welding seam is 15mm;
s3, welding the middle section, the outer section and the inner section in the welding sequence of the welding seam formed by the insert and the upper shroud blade disc; the welding sequence of the welding seam formed by the lower ring blade disc and the upper shroud blade disc is that the middle section is welded firstly, then the 5 th section on the outer side is welded, and finally the 6 th section on the inner side is welded;
s4, cleaning the welded seam by using a steel wire brush or a pneumatic shovel after welding;
and S5, welding according to the welding sequence calibrated in the step S3, adjusting the welding position after the thickness of the welding seam of each section of welding seam reaches 15mm, welding the next section of welding seam, alternately completing the welding of the runner welding seam according to the welding sequence, simultaneously adopting hammering in the welding process, and performing post-welding stress relief heat treatment after the welding is completed.
In the step b, the positioning reference design of the upper shroud leaf disc specifically means that three points are found on the disc surface of the upper shroud leaf disc, and the three points and a connecting line of the circle center of the upper shroud leaf disc form an angle of 120 degrees with each other.
In the step b, the positioning reference design of the lower ring blade disc specifically means that three points are found on the disc surface of the lower ring blade disc, and the three points and a connecting line of the circle center of the lower ring blade disc form an angle of 120 degrees with each other.
Carry out the design of location benchmark to inserting and upper shroud bladed disk respectively, design three point location benchmark and make insert and go up the shroud bladed disk and fix a position and obtain the assembly, carry out the design of location benchmark to the lower ring bladed disk, design three point location benchmark and make runner lower ring bladed disk and assembly fix a position, make insert and can carry out accurate location with the upper shroud bladed disk, accurate location can be carried out with the assembly to the lower ring bladed disk, and guarantee precision improves welding quality.
Example 6
Referring to fig. 1, a method for manufacturing a turbine runner includes the following steps:
a. designing a rotating wheel into three module structures of an upper shroud blade disc, a lower ring blade disc and an insert, and respectively determining the sizes of the upper shroud blade disc, the lower ring blade disc and the insert;
b. the method comprises the following steps of designing positioning standards for an insert and an upper shroud blade disc respectively, designing a three-point positioning standard to position the insert and the upper shroud blade disc to obtain a combined body, designing a positioning standard for a lower ring blade disc, and designing a three-point positioning standard to position the lower ring blade disc of a rotating wheel and the combined body;
c. firstly, checking through a checking sample plate, and then respectively detecting an insert molded line, an upper shroud blade disc molded line and a lower ring blade disc molded line through a laser tracker;
d. assembling and welding the rotating wheel, assembling the insert and the upper shroud blade disc through the reference block, assembling a combined body formed by the insert and the upper shroud blade disc and the lower ring blade disc through the positioning pin, and then welding.
In the step a, the sizes of the upper shroud blade disc, the lower ring blade disc and the insert are determined according to the pitch, the wrap angle and the molded line of the rotating wheel.
In the step b, the step of designing the positioning reference of the insert specifically means that a first point is arranged at the front end of the insert, a second point is arranged in the middle of the insert, a third point is arranged at the rear end of the insert, the linear distance between the first point and the third point is 1480mm, the first point and the third point are located on the same side of the insert, and the second point is located on the other side.
In the step d, the rotating wheel welding specifically comprises the following steps:
s1, preheating before welding, namely respectively preheating an upper shroud blade disc, a lower ring blade disc and an insert by a far infrared electric heating device or flame, wherein the preheating temperature is 150 ℃;
s2, calibrating the length of a welding seam segment, wherein the length of the segment is 500mm, the welding seam formed by the insert and the upper shroud blade disc is divided into 3 sections, the welding seam formed by the lower ring blade disc and the upper shroud blade disc is divided into 6 sections, and the thickness of the welding seam is 15mm;
s3, welding the middle section, the outer section and the inner section in the welding sequence of the welding seam formed by the insert and the upper shroud blade disc; the welding sequence of the welding seam formed by the lower ring blade disc and the upper shroud blade disc is that the middle section is welded firstly, then the 5 th section on the outer side is welded, and finally the 6 th section on the inner side is welded;
s4, cleaning the welded seam by using a steel wire brush or a wind shovel after welding;
and S5, welding according to the welding sequence calibrated in the step S3, adjusting the welding position after the thickness of the welding seam of each section of welding seam reaches 15mm, welding the next section of welding seam, alternately finishing the welding of the runner welding seam according to the welding sequence, simultaneously hammering the welding process, and performing post-welding stress relief heat treatment after the welding is finished.
In the step b, the step of designing the positioning reference of the upper shroud leaf disc specifically means that three points are found on the disc surface of the upper shroud leaf disc, and the three points and a connecting line of the circle center of the upper shroud leaf disc form an angle of 120 degrees with each other.
In the step b, the positioning reference design of the lower ring blade disc specifically means that three points are found on the disc surface of the lower ring blade disc, and the three points and a connecting line of the circle center of the lower ring blade disc form an angle of 120 degrees with each other.
In the step c, the checking through the checking sample plate specifically means that gaps between the insert and the upper shroud blade disc and gaps between the lower ring blade disc and the upper shroud blade disc are respectively checked through the checking sample plate, so that the gaps are all smaller than 1mm.
The inspection sample plate is firstly used for inspection, and then the laser tracker is used for respectively detecting the insert molded line, the upper shroud blade disc molded line and the lower ring blade disc molded line, so that the size requirement of the insert type blade disc structure is realized, and the welding quality is favorably improved.
Claims (5)
1. A preparation method of a water turbine runner is characterized by comprising the following steps:
a. designing a rotating wheel into three module structures of an upper shroud blade disc, a lower ring blade disc and an insert, and respectively determining the sizes of the upper shroud blade disc, the lower ring blade disc and the insert;
b. the method comprises the following steps of designing positioning standards for an insert and an upper shroud blade disc respectively, designing a three-point positioning standard to position the insert and the upper shroud blade disc to obtain a combined body, designing a positioning standard for a lower ring blade disc, and designing a three-point positioning standard to position the lower ring blade disc of a rotating wheel and the combined body;
c. firstly, checking through a checking sample plate, and then respectively detecting an insert molded line, an upper shroud blade disc molded line and a lower ring blade disc molded line through a laser tracker;
d. assembling and welding the rotating wheel, namely assembling the insert and the upper shroud blade disc through a reference block, assembling a combined body formed by the insert and the upper shroud blade disc and the lower ring blade disc through a positioning pin, and then welding;
in the step b, the step of designing the positioning reference of the insert specifically means that a first point is arranged at the front end of the insert, a second point is arranged in the middle of the insert, a third point is arranged at the rear end of the insert, the linear distance between the first point and the third point is 1480mm, the first point and the third point are positioned on the same side of the insert, and the second point is positioned on the other side;
in the step d, the rotating wheel welding specifically comprises the following steps:
s1, preheating before welding, namely respectively preheating an upper shroud blade disc, a lower ring blade disc and an insert by a far infrared electric heating device or flame, wherein the preheating temperature is 80-150 ℃;
s2, calibrating the length of a welding seam segment, wherein the length of the segment is 500mm, the welding seam formed by the insert and the upper shroud blade disc is divided into 3 sections, the welding seam formed by the lower ring blade disc and the upper shroud blade disc is divided into 6 sections, and the thickness of the welding seam is 15mm;
s3, welding the middle section, the outer section and the inner section in the welding sequence of the welding seam formed by the insert and the upper shroud blade disc; the welding sequence of the welding seam formed by the lower ring blade disc and the upper shroud blade disc is that the middle section is welded firstly, then the 5 th section on the outer side is welded, and finally the 6 th section on the inner side is welded;
s4, cleaning the welded seam by using a steel wire brush or a pneumatic shovel after welding;
and S5, welding according to the welding sequence calibrated in the step S3, adjusting the welding position after the thickness of the welding seam of each section of welding seam reaches 15mm, welding the next section of welding seam, alternately finishing the welding of the runner welding seam according to the welding sequence, simultaneously hammering the welding process, and performing post-welding stress relief heat treatment after the welding is finished.
2. The method for manufacturing a turbine runner according to claim 1, wherein: in the step a, the sizes of the upper shroud blade disc, the lower ring blade disc and the insert are determined according to the pitch, the wrap angle and the molded line of the rotating wheel.
3. The method for manufacturing a turbine runner according to claim 1, wherein: in the step b, the step of designing the positioning reference of the upper shroud leaf disc specifically means that three points are found on the disc surface of the upper shroud leaf disc, and the three points and a connecting line of the circle center of the upper shroud leaf disc form an angle of 120 degrees with each other.
4. The method for manufacturing a turbine runner according to claim 1, wherein: in the step b, the positioning reference design of the lower ring blade disc specifically means that three points are found on the disc surface of the lower ring blade disc, and the three points and a connecting line of the circle center of the lower ring blade disc form an angle of 120 degrees with each other.
5. The method for manufacturing a turbine runner according to claim 1, wherein: in the step c, the checking through the checking sample plate specifically means that gaps between the insert and the upper shroud blade disc and gaps between the lower ring blade disc and the upper shroud blade disc are respectively checked through the checking sample plate, so that the gaps are all smaller than 1mm.
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| CN114012342B (en) * | 2021-12-10 | 2023-05-26 | 东方电气集团东方电机有限公司 | Water turbine runner positioning and welding method based on wedge-shaped auxiliary device |
| CN114473302B (en) * | 2022-02-24 | 2024-01-30 | 浙江振兴阿祥集团有限公司 | Production process of water turbine volute seat ring |
| CN116900537B (en) * | 2023-09-13 | 2024-03-19 | 哈尔滨电机厂有限责任公司 | Method for manufacturing small-opening water pump turbine runner split-fan cast-weld |
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