CN113828886A - Automatic brazing equipment for large-scale steam generator rotor coil and using method thereof - Google Patents
Automatic brazing equipment for large-scale steam generator rotor coil and using method thereof Download PDFInfo
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- CN113828886A CN113828886A CN202111042257.XA CN202111042257A CN113828886A CN 113828886 A CN113828886 A CN 113828886A CN 202111042257 A CN202111042257 A CN 202111042257A CN 113828886 A CN113828886 A CN 113828886A
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- end line
- corner block
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K3/00—Tools, devices, or special appurtenances for soldering, e.g. brazing, or unsoldering, not specially adapted for particular methods
- B23K3/04—Heating appliances
- B23K3/047—Heating appliances electric
- B23K3/0475—Heating appliances electric using induction effects, e.g. Kelvin or skin effects
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K3/00—Tools, devices, or special appurtenances for soldering, e.g. brazing, or unsoldering, not specially adapted for particular methods
- B23K3/08—Auxiliary devices therefor
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K3/00—Tools, devices, or special appurtenances for soldering, e.g. brazing, or unsoldering, not specially adapted for particular methods
- B23K3/08—Auxiliary devices therefor
- B23K3/087—Soldering or brazing jigs, fixtures or clamping means
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Abstract
The invention discloses automatic brazing equipment for a large-scale steam generator rotor coil and a using method thereof. The invention solves the problems of complex manufacturing process, poor brazing quality stability, large manual operation labor amount, long production period, low production efficiency and the like in the prior art.
Description
Technical Field
The invention relates to the technical field of production and manufacturing of large-scale steam turbine generator rotor coils, in particular to automatic brazing equipment for large-scale steam turbine generator rotor coils and a using method thereof.
Background
At present, the rotor coil structure of a large-scale steam turbine generator mainly has two types: bending type and four-corner assembly welding type structures.
The bending type structural coil has the following problems: 1) the thickness of R in the bending part is obviously increased; 2) the controllability of the total length of the coil is poor, and the end parts are uneven; 3) the manual operation of the joint brazing is completed, and the brazing quality is greatly influenced by the skill of a welder; 4) the coil end is formed into a single manual arc striking or a single arc pressing, so that the operation labor amount is large.
The coil with the four-corner assembly welding type structure has the advantages that the end part forming quality is good, the phenomenon of R thickening in a corner is avoided, and the overall size is controlled; therefore, the trend of the development of the rotor coil structure of the large-scale steam turbine generator is formed, for example, the 600MW and above series of machine types all adopt coils with a four-corner assembly welding type structure. The problem that exists in the present four corners assembly welding formula structure coil manufacturing process: 1) the four-corner assembly welding type coil manufacturing process is relatively complicated: brazing of an end line part and a corner block → brazing of a single end line part and a straight line part into a U shape → brazing of a U-shaped half coil and a straight line part into a ring → coil cleaning → PT flaw detection → manual arc striking → packaging and warehousing; 2) the manufacturing process is operated manually, the brazing quality stability is poor, and the operation labor amount is large; 3) the number of joints is large, and the brazing workload is large; 4) the welded joints are subjected to PT flaw detection completely, and the production period is long; 5) gaps among the end strands of the coil are uneven, repeated shaping is needed in the subsequent rotor coil inserting process, and the production efficiency is low.
Therefore, the stability of the brazing quality of the joint becomes a key factor for restricting the quality of the rotor coil and the stable operation of the unit, and the brazing efficiency becomes a bottleneck for influencing the output of the motor rotor. Therefore, the forming process of the four-corner assembly welding type structure coil is optimized, and meanwhile, the automatic assembly welding mode which is high in production efficiency and stable and reliable in brazing quality is adopted, so that the selection is inevitable.
Disclosure of Invention
In order to overcome the defects of the prior art, the invention provides automatic brazing equipment for large-scale steam generator rotor coils and a using method thereof, and solves the problems of complex manufacturing process, poor brazing quality stability, large manual operation labor amount, long production period, low production efficiency and the like in the prior art.
The technical scheme adopted by the invention for solving the problems is as follows:
the end line part-corner block integrated structure-straight line part automatic brazing equipment can braze the end line part and the corner block, and can braze the end line part-corner block integrated structure subjected to brazing treatment by the end line part-corner block automatic brazing equipment to the straight line part.
According to the invention, the automatic brazing equipment for the end line part, the automatic brazing equipment for the corner block and the integrated structure for the end line part and the corner block, and the automatic brazing equipment for the straight line part are designed, and are matched with each other to realize the automatic brazing of the large-scale steam generator rotor coil, so that the equipment quantity, the process steps and the operation labor amount are greatly reduced; the production automation degree is high, and the brazing quality stability is good, so that the manufacturing process is simple and convenient, the production period is reduced, and the production efficiency is obviously improved.
As a preferred technical scheme, the automatic brazing equipment for the end line part-corner block comprises a first control system, a first group of welding platforms, a workpiece supporting piece arranged on the first group of welding platforms, and a first group of welding systems arranged above the first group of welding platforms, wherein the first group of welding systems comprise a workpiece pressing device, a workpiece side face abutting device and a first heating system which are electrically connected with the first control system respectively.
The workpiece pressing device and the workpiece side pressing device are used for positioning and fixing the end line part and the corner block and facilitating position adjustment, and the end line part and the corner block are brazed through the first heating system, so that the brazing quality is guaranteed. The workpiece supporting piece bears the end line part corner block integrated structure after brazing treatment.
As a preferred technical solution, the first heating system includes a first temperature sensor and a first induction heating device.
The joints adopt medium-frequency induction automatic brazing, and the temperature rise of the joints is monitored in real time in the brazing process, so that the brazing quality is ensured.
As a preferable technical solution, the automatic brazing equipment for the linear part, which is an integrated structure of the end part line part corner block, comprises a second control system, a second group of welding platforms, a slide rail, a linear part supporting system arranged above the slide rail, and an end part line part supporting member arranged above the slide rail, wherein the second group of welding platforms comprise a linear part pressing device, an end part line part side surface tightening device, and a second heating system which are electrically connected with the second control system respectively.
The end line part supporting piece supports the end line part corner block integrated structure, the straight line part pressing device, the end line part pressing device and the end line part side face abutting device position and assemble the end line part corner block integrated structure and the straight line part, position adjustment is facilitated, automatic brazing is conducted on the end line part corner block integrated structure and the straight line part through the second heating system, and brazing quality is guaranteed.
As a preferred technical solution, the second set of welding platforms, the linear portion supporting system and the end line portion supporting member are all mounted on the slide rail.
The automatic adjustment device is convenient for driving the linear part supporting piece and the end part line part supporting piece to be synchronously and automatically adjusted in position, and is also convenient for accommodating the data line and the cable cloth below the sliding rail, so that the disorder of cables and the like is reduced, and the occurrence of faults is reduced.
As a preferred technical solution, the second heating system includes a second temperature sensor and a second induction heating device.
The joints adopt medium-frequency induction automatic brazing, and the temperature rise of the joints is monitored in real time in the brazing process, so that the brazing quality is ensured.
As a preferable technical solution, the second set of bonding stages further includes an MZ axis movable in the Z-axis direction and an MY axis movable in the Y-axis direction, the tip line portion side abutting device is movable in the X-axis direction, and the MZ axis and the MY axis are electrically connected to the second control system, respectively.
The size, the position and the like of the end line part corner block integrated structure and the straight line part can be adjusted in real time conveniently, so that the butt joint gap of workpieces during brazing can be better ensured.
As a preferable technical solution, both the linear portion supporting system and the end portion line portion supporting member can be locked with the slide rail.
This facilitates the fixing of the linear portion support system and the end portion line portion support member, thereby better ensuring the positioning effect of the end portion line portion corner block integrated structure and the linear portion.
The use method of the automatic brazing equipment for the large-scale steam generator rotor coil comprises the following steps:
s1, placing the end line part and the corner block at the position of the first group welding system workpiece;
s2, operating the first control system, and controlling the pressing device and the side pressing device to position and assemble the end line part and the corner block;
s3, solder is preset at the joint of the end line part and the corner block;
and S4, operating the first control system, and controlling the first heating system to braze the end line part and the corner block.
The workpiece supporting piece bears the end line part corner block integrated structure after brazing treatment. The workpiece pressing device and the workpiece side face jacking device are used for positioning the end line part and the corner block and facilitating position adjustment, the first heating system is used for brazing, automation control is facilitated, and brazing quality is guaranteed more conveniently.
As a preferred technical solution, the method further comprises the following steps:
s5, placing the end line part and corner block integrated structure subjected to the brazing treatment of the automatic end line part and corner block brazing equipment on an end line part support;
s6, placing the straight line part on the straight line part supporting system, operating the second control system, and controlling the straight line part pressing device, the end line part pressing device and the end line part side pressing device to position and assemble the end line part-corner block integrated structure and the straight line part after the end line part-corner block automatic brazing equipment is used for brazing;
s7, solder is preset at the butt joint of the end line part corner block integrated structure and the straight line part;
and S8, operating the second control system, and controlling the second heating system to braze the end line part corner block integrated structure and the straight line part.
The end line part supporting piece supports the end line part corner block integrated structure, the straight line part pressing device, the end line part pressing device and the end line part side face abutting device position and assemble the end line part corner block integrated structure and the straight line part, position adjustment is facilitated, the second heating system is brazed, automation control is facilitated, and brazing quality is guaranteed more favorably.
According to the invention, the automatic end line part-corner block brazing equipment and the automatic end line part-corner block brazing equipment which are integrated are designed, and are matched with each other to realize automatic brazing of the large-scale steam generator rotor coil, so that the equipment quantity, the process steps and the operation labor amount are reduced, the production automation degree is high, the brazing quality is good in stability, the manufacturing process is simple and convenient, the production period is reduced, and the production efficiency is obviously improved.
Compared with the prior art, the invention has the following beneficial effects:
(1) according to the invention, the automatic brazing equipment for the end line part, the automatic brazing equipment for the corner block and the integrated structure for the end line part and the corner block, and the automatic brazing equipment for the straight line part are designed, and are matched with each other to realize the automatic brazing of the large-scale steam generator rotor coil, so that the equipment quantity, the process steps and the operation labor amount are greatly reduced; the production automation degree is high, and the brazing quality stability is good, so that the manufacturing process is simple and convenient, the production period is reduced, and the production efficiency is obviously improved;
(2) the workpiece pressing device and the workpiece side face jacking device are used for positioning and fixing the end line part and the corner block and are convenient for position adjustment, the end line part and the corner block are brazed through the first heating system, the brazing quality is favorably ensured, and the workpiece supporting piece bears an integrated structure of the end line part and the corner block after brazing treatment;
(3) the joint adopts medium-frequency induction automatic brazing, and the temperature rise of the joint is monitored in real time in the brazing process, so that the brazing quality is ensured;
(4) the end line part supporting piece supports the end line part corner block integrated structure, the linear part pressing device, the end line part pressing device and the end line part side face abutting device position and assemble the end line part corner block integrated structure and the linear part, position adjustment is facilitated, automatic brazing is carried out on the end line part corner block integrated structure and the linear part through the second heating system, and brazing quality is guaranteed;
(5) the invention is convenient for driving the linear part supporting piece and the end part line part supporting piece to be synchronously and automatically adjusted in position and also convenient for accommodating the data line and the cable below the sliding rail, thereby reducing the disorder of cables and the like and reducing the occurrence of faults;
(6) the invention is convenient for real-time adjustment according to the size, the position and the like of the integrated structure of the end line part corner block and the straight line part, so as to better ensure the butt joint gap of workpieces during brazing;
(7) the invention is convenient for fixing the linear part supporting system and the end part line part supporting piece, thereby better ensuring the positioning effect of the end part line part corner block integrated structure and the linear part.
Drawings
FIG. 1 is a drawing of an end line section-corner block automated brazing apparatus;
FIG. 2 is a view of an end line corner block integrated structure-straight line portion automatic brazing apparatus;
FIG. 3 is an enlarged view of a portion of FIG. 2;
FIG. 4 is a drawing of a straight section support system in an end line section corner block integrated configuration-straight section automated brazing apparatus;
FIG. 5 is a drawing of an end portion wire support fixture in an end portion wire corner block integrated structure-straight portion automated brazing apparatus;
FIG. 6 is a view of an assembly welding platform in an end line corner block integrated structure-straight line portion automatic brazing device.
Reference numbers and corresponding part names in the drawings: 1-a first set of welding stations; 2-a workpiece support; 3-a first control system; 4-a first set of welding systems; 5-a first heating system; 6, a workpiece pressing device; 7, a workpiece side face jacking device; 8-a second set of welding stations; 9-a slide rail; 10-a linear portion support system; 11-end line section support; 12-an induction heating device; 13 — a second control system; 14-a strand support; 15-linear portion support; 16-a coil angle adjustment system; 17-fixing the clamp on the linear part; 18-coil width adjustment system; 19-a locking device; 20-control panel; 21-MZ axis; 22-MY axis; 24-straight line part pressing device; 25-end line portion pressing means; 26-end line portion side tightening device; 27 — a second heating system; 28-infrared thermometer; 29-linear part positioning reference part; 30-end line portion support clamping fixture.
Detailed Description
The present invention will be described in further detail with reference to examples and drawings, but the present invention is not limited to these examples.
Example 1
As shown in fig. 1 to 6, the automatic brazing equipment for the large-scale steam generator rotor coil comprises an end line part-corner block automatic brazing equipment and an end line part-corner block integrated structure-straight line part automatic brazing equipment, wherein the end line part-corner block automatic brazing equipment can braze an end line part and a corner block, and the end line part-corner block integrated structure-straight line part automatic brazing equipment can braze an end line part-corner block integrated structure subjected to brazing treatment by the end line part-corner block automatic brazing equipment and a straight line part.
According to the invention, the automatic brazing equipment for the end line part, the automatic brazing equipment for the corner block and the integrated structure for the end line part and the corner block, and the automatic brazing equipment for the straight line part are designed, and are matched with each other to realize the automatic brazing of the large-scale steam generator rotor coil, so that the equipment quantity, the process steps and the operation labor amount are greatly reduced; the production automation degree is high, and the brazing quality stability is good, so that the manufacturing process is simple and convenient, the production period is reduced, and the production efficiency is obviously improved.
As a preferred technical solution, the automatic brazing equipment for the end line part-corner block comprises a first control system 3, a first group of welding platforms 1, a workpiece support member 2 arranged on the first group of welding platforms 1, and a first group of welding systems 4 arranged above the first group of welding platforms 1, wherein the first group of welding systems 4 comprises a workpiece pressing device 6, a workpiece side surface abutting device 7, and a first heating system 5 which are electrically connected with the first control system 3 respectively.
The workpiece pressing device 6 and the workpiece side pressing device 7 are used for positioning and fixing the end line part and the corner block and facilitating position adjustment, and the end line part and the corner block are brazed through the first heating system 5, so that the brazing quality is guaranteed. The work support 2 carries the end line portion corner block integrated structure after the brazing process.
As a preferred solution, the first heating system 5 comprises a first temperature sensor and a first induction heating device.
The joints adopt medium-frequency induction automatic brazing, and the temperature rise of the joints is monitored in real time in the brazing process, so that the brazing quality is ensured.
As a preferable technical solution, the automatic brazing equipment for the straight line part in the integrated structure of the end line part corner block comprises a second control system 13, a second group of welding platforms 8, a slide rail 9, a straight line part supporting system 10 arranged above the slide rail 9, and an end line part supporting member 11 arranged above the slide rail 9, wherein the second group of welding platforms 8 comprises a straight line part pressing device 24, an end line part pressing device 25, an end line part side pressing device 26, and a second heating system 27, which are respectively electrically connected with the second control system 13.
The end line part supporting piece 11 supports the end line part corner block integrated structure, the straight line part pressing device 24, the end line part pressing device 25 and the end line part side face abutting device 26 position and assemble the end line part corner block integrated structure and the straight line part, position adjustment is facilitated, automatic brazing is conducted on the end line part corner block integrated structure and the straight line part through the second heating system 27, and brazing quality is guaranteed.
As a preferred technical solution, the second set of welding platforms 8, the linear portion support system 10 and the end line portion support 11 are all mounted on the slide rail 9.
This facilitates the automatic adjustment of the positions of the linear portion supporting member 15 and the end portion line portion supporting member 11 in synchronization, and also facilitates the accommodation of the data line and the cable below the slide rail 9, thereby reducing the mess of cables and the like and reducing the occurrence of failures.
As a preferred solution, the second heating system 27 comprises a second temperature sensor and a second induction heating device.
The joints adopt medium-frequency induction automatic brazing, and the temperature rise of the joints is monitored in real time in the brazing process, so that the brazing quality is ensured.
As a preferable technical solution, the second set of bonding stages further includes an MZ axis 21 movable in the Z-axis direction, and a MY axis 22 movable in the Y-axis direction, the tip line portion side tightening device 26 is movable in the X-axis direction, and the MZ axis 21 and the MY axis 22 are electrically connected to the second control system 13, respectively.
The size, the position and the like of the end line part corner block integrated structure and the straight line part can be adjusted in real time conveniently, so that the butt joint gap of workpieces during brazing can be better ensured.
As a preferred solution, both the linear portion support system 10 and the end line portion support 11 can be locked with the slide rail 9.
This facilitates the fixing of the line section support system 10 and the end line section support 11, thereby better ensuring the positioning effect of the end line section corner block integrated structure and the line section.
Example 2
As shown in fig. 1 to fig. 6, as a further optimization of embodiment 1, this embodiment includes all the technical features of embodiment 1, and in addition, this embodiment further includes the following technical features:
the use method of the automatic brazing equipment for the large-scale steam generator rotor coil comprises the following steps:
s1, placing the end line part and the corner block at the workpiece positioning part of the first group welding system 4;
s2, operating the first control system 3, controlling the pressing device and the side pressing device to position and assemble the end line part and the corner block;
s3, solder is preset at the joint of the end line part and the corner block;
s4, the first control system 3 is operated to control the first heating system 5 to braze the end line portion to the corner block.
The work support 2 carries the end line portion corner block integrated structure after the brazing process. The workpiece pressing device 6 and the workpiece side pressing device 7 are used for positioning the end line part and the corner block and facilitating position adjustment, the first heating system 5 is used for brazing, automation control is facilitated, and brazing quality is guaranteed more conveniently. In step S3, a brazing sheet is preferably pre-set to facilitate automated operation.
As a preferred technical solution, the method further comprises the following steps:
s5, placing the end line part and corner block integrated structure after the end line part and corner block automatic brazing equipment is brazed on an end line part support 11;
s6, placing the straight line part on the straight line part supporting system 10, operating the second control system 13, controlling the straight line part pressing device 24, the end line part pressing device 25 and the end line part side surface abutting device 26 to position and assemble the end line part-corner block integrated structure and the straight line part after the end line part-corner block automatic brazing equipment is used for brazing;
s7, solder is preset at the butt joint of the end line part corner block integrated structure and the straight line part;
s8, the second control system 13 is operated to control the second heating system 27 to solder the end portion corner block integrated structure to the straight portion.
The end line part supporting piece 11 supports the end line part corner block integrated structure, the straight line part pressing device 24, the end line part pressing device 25 and the end line part side face abutting device 26 position and assemble the end line part corner block integrated structure and the straight line part, position adjustment is facilitated, the second heating system 27 is used for brazing, automation control is facilitated, and brazing quality is guaranteed more favorably.
According to the invention, the automatic end line part-corner block brazing equipment and the automatic end line part-corner block brazing equipment which are integrated are designed, and are matched with each other to realize automatic brazing of the large-scale steam generator rotor coil, so that the equipment quantity, the process steps and the operation labor amount are reduced, the production automation degree is high, the brazing quality is good in stability, the manufacturing process is simple and convenient, the production period is reduced, and the production efficiency is obviously improved.
Example 3
As shown in fig. 1 to 6, this embodiment provides a more detailed implementation manner on the basis of embodiments 1 and 2.
Because the four-corner assembly welding type structural coil becomes the inevitable trend of the development of the rotor coil of the large-scale steam turbine generator, the coil assembly welding process is optimized, and the automatic assembly welding equipment which has strong adaptability, high production efficiency and stable and reliable brazing quality tends to be designed and manufactured. According to the structural characteristics of the rotor coil of the turbonator, namely the overall similarity, the small change of the size of a single piece and the change along with the shape of a shaft in the coil inserting assembly process; the automatic brazing equipment for the rotor coil is divided into two parts: the automatic brazing device comprises an end line part-corner block automatic brazing device and a straight line part automatic brazing device in an integrated structure of the end line part-corner block after arc pressing.
The optimization of the coil assembly welding process, the design of the automatic coil brazing equipment, the function of the automatic rotor coil brazing equipment and the application of the automatic coil brazing equipment are sequentially explained.
1. Optimized coil assembly welding process
And (3) an optimized assembly welding procedure: automatic brazing of the end part line part and the two corner blocks → whole group arc pressing of the integrated structure of the end part line part corner blocks → automatic brazing of the linear part circle → packaging and warehousing of the integrated structure of the end part line part corner blocks after arc pressing.
2. Automatic coil brazing equipment design
2.1 end line section and two corner Block automatic brazing Equipment design
1) The equipment meets the requirement of manual feeding;
2) the end line part and the corner block are quickly and accurately positioned, and brazing filler metal is preset manually;
3) automatically pressing and laterally jacking from the upper surface of the workpiece at the joint position respectively;
4) the temperature control system monitors the temperature and the program controls the automatic heating brazing.
2.2 Whole set end line pressure arc design
After the end line part and the corner block are assembled and welded, the whole group of end lines are pressed to the radian required by the graph paper on the end mould.
2.3 design of automatic brazing equipment for straight line part of integrated structure of end line part corner block after arc pressing
1) The straight line part supporting system 10 and the second group of welding platforms 8 are designed on the basis of the same datum plane;
2) the workpiece does not rotate, and the linear part supporting system 10 can realize automatic synchronous adjustment along with the change of the angle, the width and the length of the coil;
3) the second group of welding platforms 8 can automatically rotate along with the change of the angle, the width and the layer height of the coil to adapt to the change of the position of a coil joint, and the automatic heating and brazing are controlled by a program;
4) each time a coil is welded, the respective hold-down devices and side hold-down devices are automatically retracted, the coil is lifted up and placed on the strand support 14, the splice is ground, and the coil is placed on the end wire support 11 after grinding. And continuing to perform assembly welding of the next coil, and directly packaging and warehousing the whole coil after assembly welding.
3. Rotor coil automatic brazing equipment function
3.1 end line section and corner Block brazing apparatus
3.1.1 brazing Process flow
Manually placing the corner block and the end line part to the positioning datum part → automatically pressing the workpiece → automatically heating and brazing → completing the brazing of another corner block in the same way → transferring to a grinding station for grinding the joint.
3.1.2 end line segment-corner Block automatic brazing Equipment configuration and function
The automatic end line part-corner block brazing equipment comprises a first group of welding platforms 1, a workpiece support part 2, a first group of welding systems 4, a first control system 3 and the like; the first welding system 4 comprises an upper clamping device, a lower clamping device (a workpiece pressing device 6), a workpiece side face jacking device 7, a first heating system 5 (provided with a first temperature sensor and first induction heating equipment) and the like.
1) A workpiece positioning block (at least two), an induction heating system, a joint pressing device and a side face jacking device (the pressure is adjustable) are arranged on the first group of welding platforms 1; ensuring the butt joint of the workpieces to be smooth (the flatness is less than or equal to 0.05mm), and automatically heating and brazing the workpieces by a jog switch;
2) the area of the workpiece of the first group of welding platforms 1 is not less than 1.5m multiplied by 1.5m, and the height is not less than 725 mm; the four-corner support can be finely adjusted, leveling is convenient, and the size design meets the brazing of the copper bar with the size of 300-1700 (length) x 35-50 (width) x 4-12 (thickness).
3) The welding can be set into various operation modes such as full-automatic, semi-automatic and manual operation;
4) the welding machine comprises double-output induction heating equipment, wherein the effective output power of the welding machine is 0-40 kW;
5) the first control system 3: the PLC and the touch screen are adopted, coils with response models are selected, all operation parameters can be displayed, and a temperature curve can be displayed; the system can communicate with an upper computer to realize data transmission;
6) the temperature measuring device (with the temperature range of 300-1100 ℃) adopts an optical fiber type infrared temperature measuring sensor and is provided with a laser sighting and a clamping tool with an adjustable position.
The device action process comprises the following steps: pressing a confirmation button of the first control system 3, extending the workpiece side jacking device 7 to position a corner block, manually moving a last corner block and an end line part to the workpiece positioning part of the first group welding system 4, automatically extending the workpiece pressing device 6, pressing and fixing two workpiece joints at the first heating system 5, retracting the workpiece side jacking device 7, presetting brazing filler metal at the joint of the two workpieces, extending the workpiece side jacking device 7 again to jack the workpieces tightly again, automatically heating to complete joint brazing, and monitoring the temperature rise of the joints through infrared temperature measurement in the brazing process. After brazing, the pressing and side propping devices automatically retract, and the integrated structure of the end line part and the corner block after assembly welding is taken out and placed on the workpiece support 2.
3.2 automatic brazing equipment for straight line part of corner block integrated structure at end part line part after arc pressing
3.2.1 brazing Process flow
The adjustment equipment meets the requirement of coil size → an integrated structure of an end part corner block after an arc is pressed manually and a straight line part to a tool and is clamped tightly → the brazing platform automatically rotates to a joint position → the clamp compresses the joint → automatic heating brazing → grinding the joint → an integrated structure of an end part corner block after another straight line part is pressed manually and a next coil is pressed arc → the brazing platform automatically rotates to a joint position → clamping, brazing and grinding the joint → sequentially carrying out assembly welding of the next coil → assembly welding of the whole coil is finished and packaging and warehousing.
3.2.2 end line part corner block integrated structure after arc pressing-straight line part automatic brazing equipment composition and function
The automatic brazing equipment for the straight line parts is composed of a ground slide rail 9, 7 groups of straight line part supporting systems 10, 2 end line part supporting pieces 11, 4 second groups of welding platforms 8, a second control system 13, 2 induction heating equipment 12 and the like, and all data lines and cables are arranged below the ground slide rail. The device is designed in size to meet the following automatic brazing of large-sized coils. Coil lumen length (L) range: 5000-9800 mm; coil angle (ψ) variation range: 50-180 degrees; coil layer height (h) variation range: 80-150 mm; coil base radius (R) range: r is 400-470 mm;
3.2.2.1 straight section support system 10
1) The coil linear part is supported in sections, the distance between every two support systems is less than or equal to 1.5m, the support systems can be adjusted on a guide rail at will according to the length change of the coil, the guide rail is provided with a graduated scale, and the linear part support system 10 can be relatively locked with the locking device 19;
2) in order to meet the change of different coil sizes, the coil angle adjusting system 16 and the coil width adjusting system 18 are used for synchronously and automatically adjusting the coil to the required size of the coil.
3) The linear part support 15 bears the weight of the workpiece more than 2t and is provided with a linear part fixing clamp 17;
4) the strand support 14: a single strand coil for supporting the back of welding joint of polishing has the autogiration support, can retract when not needing, and the support can be opened automatically when needing, holds the work piece.
3.2.2.2 end line section support 11
1) The end wire part supporting piece 11 moves on the guide rail along with the length of the coil and can be locked relative to the guide rail;
2) the end arc support adopts a fixed arc design, so that the end arc support is matched with the arc of a workpiece, the support arc can be quickly replaced, and the figure is 5;
3) the soldering operation position of the coil joint is in the range of 700 mm-1000 mm (from the ground), so that the operation of workers is facilitated;
3.2.2.3 second group of welding stations 8
1) The left side and the right side of the two ends of the device are respectively provided with a second group of welding platforms 8, the brazing operation position on each brazing platform is automatically adjusted to adapt to the change of the joint position of a single coil strand (the up-and-down movement is realized through an MZ shaft 21, the left-and-right movement is realized through an MY shaft 22, and the front-and-back movement is realized through an end line part side tightening device 26);
2) each assembly welding platform is provided with a coil joint butt joint reference surface (the flatness is less than or equal to 0.05mm), a linear part positioning reference part 29, a second heating system 27, an infrared thermometer 28 (the temperature range is 300-1100 ℃), a linear part pressing device 24, an end part line part pressing device 25 and an end part line part side face abutting device 26 (the pressure is adjustable), so that accurate positioning, flat butt joint and automatic heating and brazing are realized;
3) the welding working head can be finely adjusted front and back, left and right, and up and down relative to the joint position, so that the joint can be clamped and brazed under the non-ideal butt joint state;
4) each assembly welding platform is provided with a cooling water jacket (circulating water) so as to facilitate quick cooling of the welded joint;
5) the temperature measuring device (the temperature range is 300-1100 ℃) adopts an optical fiber type infrared temperature measuring sensor, and the temperature measuring device is provided with a laser sighting and a clamping tool with an adjustable position;
6) an induction coil and an insulating fixed support are arranged on the assembly welding platform, the induction coil is convenient to add brazing filler metal due to the design, and the insulating fixed support can ensure the rigid support of the coil;
7) welding modes of operation include fully automatic, semi-automatic, and manual.
3.2.2.4 control system
The second control system 13 is used for controlling and setting the whole set of equipment, and adopts a PLC and a touch screen (not less than 14 inches);
1) the motion unit of the equipment mainly adopts a plurality of servo shafts to realize synchronous control, so that the automatic adjustment of coils with different sizes is met, and the self-setting and changing of coils with different types are also met;
2) the infrared temperature control auto-induction brazing temperature rise, power and brazing time;
3) the main tool can realize automatic model changing, and the change of the length, the height, the angle and the width of coils of different specifications and products in different models can be met;
4) the digital induction heating equipment can realize power mode automatic heating and can also realize temperature control mode heating, so that the equipment has wider adaptability;
5) the automatic brazing heating parameter monitoring system is integrated with a data acquisition system, so that the real-time monitoring of the automatic brazing heating parameters can be realized, and the management and control of production nodes and the traceability of joint quality are facilitated;
5) the equipment can record the curve of the brazing process, and process parameters can be conveniently and timely adjusted according to wire gauges with different specifications and sizes;
6) the automatic connection of intelligent function and manual compensation function can be realized to equipment, and the purpose is under the circumstances of single strand shaping quality super poor, switches rapidly that manual mode comes the not enough of compensation equipment automatic program, can also continue the automatic assembly welding procedure of operation afterwards, avoids unnecessary equipment to return to the reference.
The device action process comprises the following steps: opening a second control system 13, and selecting a corresponding assembly welding program according to the unit model; each station control panel 20 is switched to a manual activation state; and (4) opening the parameter returning mode to sequentially enable all axes of the machine tool from top to bottom, and closing the parameter returning mode after returning to the reference point. Then, each station operation panel is switched to an automatic state; and selecting a required program according to the coil number, stopping pressing the circulation (indicating program zero clearing) after the downloading is successful, pressing the circulation to start, and moving each shaft to a program set position. Pressing the control panel 20 confirmation button, both MY spindle 21 and MZ spindle 22 move to the safe position; pressing the control panel 20 confirmation button again moves both the MY and MZ axes to the brazing position. Manually arranging an end line part corner block after arc pressing to be integrally structured on the end line part supporting piece 11, arranging a straight line part on the straight line part supporting system 10, and arranging a butt joint of the two on a second heating system 27; pressing a control panel confirmation button, extending the end line part side abutting device 26, assembling the linear part and the end line part corner block into an integrated structure, and starting the action of the linear part pressing device 24 to press the linear part; the end line part side tightening device 26 retracts to preset brazing filler metal; the end line portion side tightening means 26 is again extended to tighten the joint; the end line portion pressing means 25 starts to act to press the end line portion; and (4) automatically heating and brazing. After brazing, the pressing devices and the side face jacking devices automatically retract, then the strand coil after being welded is manually lifted and placed on the strand supporting piece 14, oxide skin and brazing filler metal in a joint area are polished to be accumulated, and dust is removed while polishing. After cleaning, the coil of strand is placed on the end wire support mold 30. The control panel 20 is continuously started to confirm the button, and another straight line part and another end line part corner block integrated structure after arc pressing are manually arranged, so that the assembly welding of the whole coil is sequentially completed.
4. Application of automatic coil brazing equipment
The rotor coil which is firstly assembled and welded by adopting automatic brazing equipment is 600MW series products. And automatically assembling and welding the end line part and the corner block brazing equipment after the end line part is subjected to oxygen-free annealing. Selecting a corresponding workpiece automatic assembly welding program in the first control system 3, switching to an automatic state, and automatically returning a pressing cylinder and a positioning cylinder of the machine tool to the original point; manually feeding the end line part and the corner block to the position of the first group of welding systems 4, inching an operation button of the equipment, automatically pressing the workpiece, manually presetting brazing filler metal, automatically jacking the workpiece, and automatically heating to complete joint brazing. And the brazing of the whole group of the end line parts and the corner blocks is completed in sequence.
The integral structure of the whole group of end line part corner blocks is transferred to an arc pressing station to finish an end arc forming process in a whole group of arc pressing mode; the process has the advantages that the whole set of end line parts (14-18 turns) is high in arc pressing efficiency, the formed arc is high in quality, and the accuracy of radian can be effectively compensated through adjustment of the size of the arc pressing mould.
Selecting an integrated structure of an end line part corner block after arc pressing and an automatic brazing program of a straight line part according to the specification of a coil, and firstly switching an operation panel of each station to a manual activation manual state; the back-reference mode is turned on to return the axes of the device to the reference point in the order from top to bottom, and then the back-reference mode is turned off. Each station control panel 20 is switched to an automatic state; and selecting a corresponding program from the editing programs according to the serial numbers of the coils, pressing a cycle starting key, and automatically opening the brazing station. And (3) manually arranging an end line part corner block after arc pressing to the end line part supporting piece 11, manually arranging a straight line part to the straight line part supporting system 10, placing a butt joint of the straight line part and the straight line part at the second heating system 27, manually presetting brazing filler metal, inching equipment, automatically pressing the straight line part and the end line part, tightly pressing the joint by using an end line part side face abutting device 26, and automatically heating to finish joint brazing. After brazing, the hold-down devices and the side hold-down devices are automatically retracted, the coil is then lifted onto the strand support 14, and the joint area is manually sanded for oxide scale and braze buildup. The cleaned strand is placed on the end wire support fixture 30 and the assembly welding of the next coil is completed in sequence.
The linear part supporting system 10 can automatically adjust the size according to the length and the angle of the coil, and the second group welding platform 8 automatically adjusts the size according to the change of the included angle of the coil to adapt to the change of the brazing positions of different coils. The end wire portion supporter 11 can be automatically adjusted in height according to the change of the coil model to facilitate the end shaping.
The coil angle adjustment system 16, the linear portion fixing jig 17, the coil width adjustment system 18, and the locking device 19 preferably cooperate to accomplish the above-described functions.
From the use effect of the automatic brazing equipment, the brazing quality stability of the joint is improved, and the primary qualified rate of PT flaw detection is more than 98%; the polishing amount of the joint is reduced by more than 50%, the production efficiency is improved by 30%, and the operation labor amount is reduced by more than 30%. The total length of the coil is controlled, the deviation of the total length is +/-2 mm, and the inter-strand gap is not more than 4 mm. The process mode is popularized to the production and manufacturing of rotor coils of other models of turbonators.
Compared with the prior art, the invention has the following advantages:
the device has strong adaptability, and can meet the requirement of automatic brazing of the rotor coils of the prior 600W and above series of steam turbine generators in a factory;
the quality of the joint after automatic brazing is equivalent to that of a base metal, and the brazing quality stability is improved by adopting a medium-frequency induction automatic brazing process;
the connector brazing adopts a temperature control mode or a power mode, the infrared temperature measuring probe monitors the temperature rise of the connector in the whole process, the stability of the brazing quality is ensured by parameters after process evaluation, and the dependence on the welding technology is reduced;
the coil end of the invention has high forming quality, the maximum turn-to-turn gap is not more than 4mm, and the total branch deviation of the coil is not more than +/-3 mm. The whole coil is directly packaged and put in storage after assembly welding and cleaning, so that the integral forming quality of the coil is guaranteed;
the production efficiency of the invention is improved by more than 30 percent; the coil manufacturing process is optimized, and the operation labor amount of coil transfer, polishing and the like is reduced;
according to the end part line part corner block integrated structure after arc pressing and the straight line part brazing equipment, a workpiece does not rotate, the straight line part supporting system 10 can automatically change the shape, and the second group of welding platforms 8 can be synchronously and automatically adjusted along with the straight line part supporting system 10 to meet the requirements of products with different specifications and the changes of the lengths, the heights, the angles and the broadband of coils with different numbers; the occupation of tools and equipment is reduced, and a large amount of cost of special tools needed by coils of different types is saved.
The invention can carry out assembly welding and polishing around the edge, integrates a dust collection system, meets the requirement of the environmental protection standard of an operation site, and avoids occupying a special polishing room.
As described above, the present invention can be preferably realized.
All features disclosed in all embodiments in this specification, or all methods or process steps implicitly disclosed, may be combined and/or expanded, or substituted, in any way, except for mutually exclusive features and/or steps.
The foregoing is only a preferred embodiment of the present invention, and the present invention is not limited thereto in any way, and any simple modification, equivalent replacement and improvement made to the above embodiment within the spirit and principle of the present invention still fall within the protection scope of the present invention.
Claims (10)
1. The automatic brazing equipment for the large-scale steam generator rotor coil is characterized by comprising end line part-corner block automatic brazing equipment and an end line part-corner block integrated structure-linear part automatic brazing equipment, wherein the end line part-corner block automatic brazing equipment can braze an end line part and a corner block, and the end line part-corner block integrated structure-linear part automatic brazing equipment can braze the end line part-corner block integrated structure subjected to brazing treatment by the end line part-corner block automatic brazing equipment and the linear part.
2. The automatic brazing equipment for the large-scale steam generating rotor coil according to claim 1, wherein the automatic brazing equipment for the end line part and the corner block comprises a first control system, a first group of welding platforms, a workpiece support piece arranged on the first group of welding platforms, and a first group of welding systems arranged above the first group of welding platforms, wherein the first group of welding systems comprise a workpiece pressing device, a workpiece side face abutting device and a first heating system which are respectively and electrically connected with the first control system.
3. The large scale steam turbine rotor coil automated brazing apparatus according to claim 2, wherein the first heating system comprises a first temperature sensor and a first induction heating apparatus.
4. The automatic brazing equipment for the large-scale steam generating rotor coil according to any one of claims 1 to 3, wherein the automatic brazing equipment for the straight line part, which is an integrated structure of the end line part corner block, comprises a second control system, a slide rail, a second group of welding platforms, a straight line part supporting system arranged above the slide rail and an end line part supporting piece arranged above the slide rail, and the second group of welding platforms comprise a straight line part pressing device, an end line part side face pressing device and a second heating system which are respectively and electrically connected with the second control system.
5. The automated large scale steam turbine rotor coil brazing apparatus according to claim 4, wherein the second set of welding platforms, the linear portion support system and the end wire portion support members are all mounted on the slide rails.
6. The large scale steam turbine rotor coil automated brazing apparatus according to claim 5, wherein the second heating system comprises a second temperature sensor and a second induction heating apparatus.
7. The automatic brazing device for large steam generating rotor coils according to claim 6, wherein the second set of welding platforms further comprises an MZ shaft capable of moving in a Z-axis direction and a MY shaft capable of moving in a Y-axis direction, the terminal wire portion side tightening device is capable of moving in an X-axis direction, and the MZ shaft and the MY shaft are electrically connected with the second control system respectively.
8. The automatic brazing apparatus for large scale steam turbine rotor coils according to claim 7, wherein the linear portion supporting member and the end line portion supporting member are lockable with the slide rail.
9. Use of an automatic brazing apparatus for large steam turbine rotor coils according to any one of claims 4 to 8, characterized in that it comprises the following steps:
s1, placing the end line part and the corner block at the position of the first group welding system workpiece;
s2, operating the first control system, and controlling the pressing device and the side pressing device to position and assemble the end line part and the corner block;
s3, solder is preset at the joint of the end line part and the corner block;
and S4, operating the first control system, and controlling the first heating system to braze the end line part and the corner block.
10. The use method of the large steam generator rotor coil automatic brazing equipment according to claim 9, characterized by further comprising the following steps:
s5, placing the end line part and corner block integrated structure subjected to the brazing treatment of the automatic end line part and corner block brazing equipment on an end line part support;
s6, placing the straight line part on the straight line part supporting system, operating the second control system, and controlling the straight line part pressing device, the end line part pressing device and the end line part side pressing device to position and assemble the end line part-corner block integrated structure and the straight line part after the end line part-corner block automatic brazing equipment is used for brazing;
s7, solder is preset at the butt joint of the end line part corner block integrated structure and the straight line part;
and S8, operating the second control system, and controlling the second heating system to braze the end line part corner block integrated structure and the straight line part.
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| CN202111042257.XA CN113828886B (en) | 2021-09-07 | 2021-09-07 | Automatic brazing equipment for rotor coil of large steam turbine generator and using method thereof |
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| US20170341190A1 (en) * | 2016-05-26 | 2017-11-30 | Doosan Heavy Industries Construction Co., Ltd. | Processing unit for a stator bar of a generator and welding method using the same |
| CN207239532U (en) * | 2017-08-14 | 2018-04-17 | 杭州杭发发电设备有限公司 | Electric generator rotor coil group welds positioning mould |
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| JP2004222493A (en) * | 2002-12-26 | 2004-08-05 | Fuji Electric Systems Co Ltd | Brazing apparatus for rotor coil and brazing method for same |
| CN101108437A (en) * | 2007-08-22 | 2008-01-23 | 天津市天发重型水电设备制造有限公司 | Soldering machine with movable rotating function |
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| US20170341190A1 (en) * | 2016-05-26 | 2017-11-30 | Doosan Heavy Industries Construction Co., Ltd. | Processing unit for a stator bar of a generator and welding method using the same |
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