CN1660538A - Laser method for repairing rotor shaft of generator and steam turbine and dedicated device - Google Patents
Laser method for repairing rotor shaft of generator and steam turbine and dedicated device Download PDFInfo
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- CN1660538A CN1660538A CN 200410021196 CN200410021196A CN1660538A CN 1660538 A CN1660538 A CN 1660538A CN 200410021196 CN200410021196 CN 200410021196 CN 200410021196 A CN200410021196 A CN 200410021196A CN 1660538 A CN1660538 A CN 1660538A
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Abstract
An in-situ laser repairing method for the rotor shaft of electric generator or turbine includes such steps as nondestructive inspection and cleaning, laser smelting for repairing, and mechanical shaping. It features that after the alloy powder is attached to the rotating rotor shaft, the laser beam is used to radiate the rotor shaft and the water is used as cooling medium, the stepless speed regulator is cooperating with the winder of in-situ electric generator set, and when it is mached, the rotor shaft is static and the cutting tool is moving around it.
Description
Technical field:
The present invention relates to the recovery technique of generator, steam turbine rotor shaft, a kind of method that adopts laser casting technology field repair generator, steam turbine rotor shaft is provided especially.
Background technology:
Generator, the steam turbine rotor shaft volume is big, weight is big, and accuracy class height, complex manufacturing technology production cost height, cycle are long.And in case its influence that goes wrong of being in operation is huge.So the design of such rotor is design infinite life, promptly under normal condition of work, can turns round continuously and use more than 20 years.
The manufacturing process that armature spindle is general has monobloc forging formula, sleeve type, combined type and welded type.Any version no matter, its quality requirement is all than higher.Owing under high temperature, high rotating speed, work, require material that higher creep limit, good creep rupture strength and thermal fatigue resistance and fracture property are preferably arranged.The unit that capacity is big more, the requirement of these technical indicators is just strong more.
For the manufacture process of rotor from smelting, forging, the machine of material add, operation such as heat treatment, dynamic balancing all has clear and definite, strict quality requirement.So the manufacturing cost of a roots rotor axle is very high, the manufacturing cycle is also very long.Therefore, be in operation, in a single day rotor goes wrong, and its consequence is very serious.If make again, all be that power plant institute is unaffordable from the duration to the cost.Therefore, must take certain mode to keep in repair.
But be various thermal processing methods such as electric welding, argon arc welding, vibration weldering, all can inevitably crack, injurious effects such as heat affected area tissue inter-variable, residual stress.
In the past, two kinds of solutions were generally arranged: 1, brush plating; 2, diameter of axle car is thin, galleting tile again.These two kinds of methods all have bigger defective.
The prerequisite that diameter of axle car is thin is rotor must be transported to the factory with large-sized processing equipment to repair.Though the method has been removed the superficial layer that damages, solved the problem that repair on diameter of axle surface this time, the diameter of axle attenuated, intensity reduces, and processes nonstandard bearing for high constant the redesign again after must waiting the diameter of axle to process in center, and its harm is conspicuous.
Brush plating is power plant's restorative procedure comparatively commonly used in recent years, has also solved certain problem for power plant really.But its limitation is very big.Such as it be utilize principle,displacement with the metal in the metallic solution attached to diameter of axle surface, the combining form of brushing coating and armature spindle is physical bond, its bond strength is very low.Therefore in actual use, the phenomenon that brushing coating comes off appears.Adopt the plating of bottom copper for avoiding coating to come off, its bond strength is better, but case hardness is low, continues wearing and tearing after the position brush plating of wearing and tearing, so reduction is arranged service life.For example, we directly are exactly the position that is worn again after original brush plating is repaired at the sealing bearing bush that Huaiyin power plant repairs.
The generator in power plant, steam turbine rotor shaft are very heavy, and in general, the axle of 200,000 kW generating sets is that the axle of about 100 tons of gross weights, 300,000 kW generating sets is about 150 tons of gross weights.The length of each rotor is all more than 7～8m.If transport to producer's maintenance, in transportation, a lot of technical difficulties is arranged, also to pay huge cost economically, also there is the problem of device security in the transportation simultaneously.
Existing laser-processing system is one group of bulky, very heavy complete set of equipments that is made of several subsystems such as laser generator, laser machine, water-cooled units.Because component devices is more, structure is very complicated, so laser process equipment all is field mounted equipment basically at present.Installation, the debugging of adding this complete set of equipments are all very inconvenient, do not possess the removable practicality except that vehicle-mounted.
Summary of the invention:
The purpose of this invention is to provide a kind of technical scheme of repairing generator, steam turbine rotor shaft at the scene.
The invention provides the on-the-spot laser repair method of a kind of generator, steam turbine rotor shaft, comprise that Non-Destructive Testing and cleaning, laser casting reparation, machine add complex three big processes, is characterized in that:
In the described laser casting repair process:
Laser from directly over irradiation on the armature spindle that rotates, alloyed powder is preset in laser spot front end on the armature spindle of rotation; Utilize the high characteristics of high-power high-energy laser beam focused energy, moment is little molten with work piece surface, makes simultaneously to preset the lip-deep alloy powder of part and melt fully; Rapid solidification after the laser beam flying, the fine and close coating of acquisition and matrix metallurgical binding recovers physical dimension and surface peening etc.;
Use the cooling medium of on-the-spot water source, be equipped with heavy refrigeration source in order to remove from as the packaged type laser-processing system;
Barring gear coupling by stepless speed regulation and on-site generated power unit makes armature spindle reach the required linear velocity requirement of laser melting coating, realizes the original place reparation;
Described machine adds in the complex process:
With static armature spindle is benchmark, and cutting element carries out finishing relative to the cutting way that armature spindle rotates to armature spindle, and this just can remove from from work such as generator, steam turbine dismounting armature spindle and carrying armature spindles, realizes the original place complex.
This is to utilize laser melting coating to recover its abrasion size, carries out the new process program of complex with on-the-spot machining equipment.
The present invention also provides the used special equipment of on-the-spot laser repair method of a kind of generator, steam turbine rotor shaft, it is characterized in that comprising laser-processing system, armature spindle retinue process equipment;
Described laser-processing system is made of laser generator (11), laser machine, automatic powder feeding device, stepless speed regulation; Laser generator (11) Cooling System Design adopts the open type water-cooled, and inlet connects on-the-spot water source, and outlet is discharging directly; The laser that laser generator (11) produces changes direction by laser machine, and vertical irradiation is above armature spindle (4), and the outlet of automatic powder feeding device powder feeding pipe (25) places the front end of laser spot; Stepless speed regulation is connected on the barring gear of on-site generated power unit;
Described armature spindle conformal process equipment by with armature spindle (4) be benchmark detent mechanism (31), can constitute around wheel rim knife rest assembly (32), the driving mechanism (33) that armature spindle (4) rotates; It is on the detent mechanism of benchmark that described wheel rim knife rest assembly (32) is fixed in armature spindle (4), and driving mechanism (33) joins with wheel rim knife rest assembly (32); To realize that cutting element is relative to workpiece---rotating of armature spindle (4).
The used special equipment of on-the-spot laser repair method of generator provided by the invention, steam turbine rotor shaft, its laser machine is made of base (12), combination column (13), crossbeam (14), combination lens barrel (15), combination lens barrel (15) is formed by connecting by vertical lens barrel (153), horizontal lens barrel (154) and vertical flexible lens barrel (155) activity, and the speculum (151), the focus lamp (152) that are provided with in crossbeam (14) and the combination lens barrel (15) constitute light path.Adopt combination column (13) both can change the height of column, be convenient to carrying again.Vertically lens barrel (153) can move horizontally on crossbeam (14) with horizontal lens barrel (154) and can rotate around vertical lens barrel (153), and to realize two dimension adjustment, vertically flexible lens barrel (155) can stretch up and down, focuses with realization.
The used special equipment of on-the-spot laser repair method of generator provided by the invention, steam turbine rotor shaft, is with bell-mouthed powder feeding pipe (25) to constitute at rotating disk (21), the scraper plate (24) that its automatic powder feeding device drives by hopper (23), by motor (22); Hopper (23) is positioned at the side top of rotating disk (21), scraper plate (24) places the top of the opposite side of rotating disk (21), and be close to rotating disk (21), the horn mouth of powder feeding pipe (25) places rotating disk (21) below scraper plate (24) one sides, the bell-mouthed edge that is centered close to rotating disk (21).Open the feed opening of hopper (23) in the time of starter motor (22), powder is delivered to the other end by the rotating disk (21) that rotates, and is scraped by scraper plate (24), delivers to the front end of laser spot on the rotor through powder feeding pipe (25).
The used special equipment of on-the-spot laser repair method of generator provided by the invention, steam turbine rotor shaft, its stepless speed regulation is made of buncher, speed regulator, sprocket wheel, speed regulator is electrically connected with buncher, buncher chain link wheel, sprocket wheel connects the axle head of the barring gear motor of on-site generated power unit; To change the barring gear rotating speed of motor, make armature spindle (4) reach the required linear velocity of laser melting coating.
The on-the-spot laser repair method of generator provided by the invention, steam turbine rotor shaft and the advantage of special equipment thereof are:
Have the advantage of utilizing laser melting and coating process to repair the diameter of axle of steam turbine, generator (22):
Laser melt-casting coating and matrix are metallurgical binding, and bond strength is not less than 90% of former base material;
Matrix material public surface in laser processing procedure is little molten, and little crucible zone is 0.05～0.1mm, and the matrix heat affected area is minimum, is generally 0.1～0.2mm;
Molded layer and matrix all do not have thick cast sturcture, molded layer and Interface Microstructure densification thereof, and crystal grain is tiny, does not have defectives such as hole, slag inclusion, crackle;
Substrate temperature is no more than 80 ℃ in the laser processing procedure, does not have thermal deformation after the Laser Processing;
The laser casting technological controllability is good, easily realizes automation control;
Laser melt-casting coating can be made up of multilayer, and bottom and matrix wellability are good, bond strength is high; The intermediate layer has certain intensity and hardness, crack resistance is good; Surface layer has antiscour, performance such as wear-resistant and corrosion-resistant, makes the equipment after the reparation more secure on safety and serviceability;
In addition, realize that original place laser casting reparation and machine add complex, shorten repairing efficiency, exempt handling labour and make risk, saved time, human and material resources to a great extent.
Description of drawings:
Fig. 1 is the structural representation of laser conduction mechanism;
Fig. 2 is the structural representation of automatic powder feeding device;
Fig. 3 is the structural representation of armature spindle conformal process equipment.
The specific embodiment:
Embodiment modular laser processing machine and armature spindle conformal process equipment
The modular laser processing machine is made of laser generator (11), laser machine, automatic powder feeding device, stepless speed regulation:
Laser generator (11) Cooling System Design adopts the open type water-cooled, and inlet connects on-the-spot water source, and outlet is discharging directly;
Laser machine (as shown in Figure 1) is made of base (12), one-level column (131), secondary column (132), crossbeam (14), combination lens barrel (15), combination lens barrel (15) is formed by connecting by vertical lens barrel (153), horizontal lens barrel (154) and vertical flexible lens barrel (155) activity, and the speculum (151), the focus lamp (152) that are provided with in crossbeam (14) and the combination lens barrel (15) constitute light path.
Vertical flexible lens barrel (155) can stretch up and down, with the fine setting focal length; Vertical lens barrel (153) can move horizontally on crossbeam (14), and horizontal lens barrel (154) can be adjusted laser spot to realize two dimension around vertical lens barrel (153) rotation;
Rotating disk (21), the scraper plate (24) that automatic powder feeding device (as shown in Figure 2) drives by hopper (23), by motor (22), be with bell-mouthed powder feeding pipe (25) to constitute; Hopper (23) is positioned at the side top of rotating disk (21), scraper plate (24) places the top of the opposite side of rotating disk (21), and be close to rotating disk (21), the horn mouth of powder feeding pipe (25) places rotating disk (21) below scraper plate (24) one sides, the bell-mouthed edge that is centered close to rotating disk (21); Open the feed opening of hopper (23) in the time of starter motor (22), powder is delivered to the other end by the rotating disk (21) that rotates, and is scraped by scraper plate (24), delivers to the front end of laser spot on the rotor through powder feeding pipe (25);
Stepless speed regulation is made of buncher, speed regulator, sprocket wheel, and speed regulator is electrically connected with buncher, buncher chain link wheel, and sprocket wheel connects the axle head of the barring gear motor of on-site generated power unit; To change the barring gear rotating speed of motor, make armature spindle reach the required linear velocity of laser melting coating.
Armature spindle conformal process equipment (as shown in Figure 3) by with the armature spindle be benchmark detent mechanism (31), can constitute around wheel rim knife rest assembly (32), the driving mechanism (33) that armature spindle rotates; It is on the detent mechanism (31) of benchmark that described wheel rim knife rest assembly (32) is fixed in the armature spindle, and driving mechanism (33) joins with wheel rim knife rest assembly (32); To realize cutting element rotating relative to workpiece.
The site operation process
1, after the equipment that is fit to power plant's maintenance usefulness transports the scene to, laser instrument (11), laser machine are placed the relevant position according to field condition.Open the end cap of generator, to aim at the armature spindle (4) that to process through the combination lens barrel (15) of processing machine, and laser machine fixed, utilize then light along the principle of straightline propagation with laser instrument (11) and laser machine adjustment, so just possessed basic laser melting coating condition.
2, do protection: because generator amature is stayed in the housing, cladding and machine add process all to be finished in housing.So must properly protect, prevent from that powder and other foreign material from dropping in the generator housing to cause the accident.
3, diameter of axle surface fatigue layer is removed in machined: owing to turn round under high speed for a long time, wear surface layer is tired tissue, it must be cleaned out, and could carry out laser melting coating in its surface.In the employing of Weihai power plant is to come turning, the monolateral 0.5mm that removed with the retinue mill.Through beginning laser melting coating after the hardness detection.
4, laser melting coating: according to the material of axle and the selected metal dust DL-02 of performance requirement of armature spindle (4).Determine that according to the physical dimension of axle and the specific (special) requirements of metal dust the technological parameter of laser melting coating is as follows: power: 1500～1600W, sweep speed: 4mm/s, spot diameter φ 3～5mm.Calculating rotary speed according to hot spot sweep speed and diameter of axle φ 450mm is 0.2rpm.Determine that according to sweep speed and powder characteristics the powder amount of automatic powder feeding is 2g/s.
5, machined complex: cladding is afterwards with armature spindle conformal process equipment---and the retinue grinding tool is installed and carries out turning, reserves the correct grinding surplus of monolateral 0.05mm; Change bistrique and grind, finally reach the requirement of producer.Be axiality≤0.02mm, cylindricity≤0.02mm, tapering≤0.02mm.Roughness is Ra0.4.
6, through producer's onsite acceptance, mainly detect index and be mechanical dimension, form and position tolerance, hardness number and all meet the requirements, nondestructive inspection detects and meets relevant criterion.
Claims (5)
1, the on-the-spot laser repair method of a kind of generator, steam turbine rotor shaft comprises that Non-Destructive Testing and cleaning, laser casting reparation, machine add complex three big processes, is characterized in that:
In the described laser casting repair process:
Laser from directly over irradiation on the armature spindle that rotates, alloyed powder is preset in laser spot front end on the armature spindle of rotation,
Use the cooling medium of on-the-spot water source as the packaged type laser-processing system,
Barring gear coupling by stepless speed regulation and on-site generated power unit makes armature spindle reach the required linear velocity requirement of laser melting coating;
Described machine adds in the complex process:
With static armature spindle is benchmark, and cutter is relative to workpiece---the cutting way that armature spindle rotates carries out finishing to armature spindle.
2, the used special equipment of on-the-spot laser repair method of the described generator of a kind of claim 1, steam turbine rotor shaft is characterized in that comprising laser-processing system, armature spindle retinue process equipment;
Described laser-processing system is made of laser generator (11), laser machine, automatic powder feeding device, stepless speed regulation; Laser generator (11) Cooling System Design adopts the open type water-cooled, and inlet connects on-the-spot water source, and outlet is discharging directly; The laser that laser generator (11) produces changes direction by laser machine, and vertical irradiation is above armature spindle (4), and the outlet of the powder feeding pipe of automatic powder feeding device (25) places the front end of laser spot; Stepless speed regulation is connected on the barring gear of on-site generated power unit;
Described armature spindle conformal process equipment by with the armature spindle be benchmark detent mechanism (31), can constitute around wheel rim knife rest assembly (32), the driving mechanism (33) that armature spindle rotates; It is on the detent mechanism (31) of benchmark that described wheel rim knife rest assembly (32) is fixed in the armature spindle, and driving mechanism (33) joins with wheel rim knife rest assembly (32).
3, according to the used special equipment of on-the-spot laser repair method of the described generator of claim 2, steam turbine rotor shaft, it is characterized in that described laser machine is made of base (12), combination column (13), crossbeam (14), combination lens barrel (15), combination lens barrel (15) is formed by connecting by vertical lens barrel (153), horizontal lens barrel (154) and vertical flexible lens barrel (155) activity, and the speculum (151), the focus lamp (152) that are provided with in crossbeam (14) and the combination lens barrel (15) constitute light path.
4,, it is characterized in that rotating disk (21), scraper plate (24) that described automatic powder feeding device drives by hopper (23), by motor (22), be with bell-mouthed powder feeding pipe (25) to constitute according to the used special equipment of on-the-spot laser repair method of the described generator of claim 2, steam turbine rotor shaft; Hopper (23) is positioned at the side top of rotating disk (21), scraper plate (24) places the top of the opposite side of rotating disk (21), and be close to rotating disk (21), the horn mouth of powder feeding pipe (25) places rotating disk (21) below scraper plate (24) one sides, the bell-mouthed edge that is centered close to rotating disk (21) of powder feeding pipe (25).
5, according to the used special equipment of on-the-spot laser repair method of the described generator of claim 2, steam turbine rotor shaft, it is characterized in that described stepless speed regulation is made of buncher, speed regulator, sprocket wheel, speed regulator is electrically connected with buncher, buncher chain link wheel, sprocket wheel connects the axle head of the barring gear motor of on-site generated power unit.
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| Application Number | Priority Date | Filing Date | Title |
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| CN 200410021196 CN1660538A (en) | 2004-02-26 | 2004-02-26 | Laser method for repairing rotor shaft of generator and steam turbine and dedicated device |
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| Application Number | Priority Date | Filing Date | Title |
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| CN 200410021196 CN1660538A (en) | 2004-02-26 | 2004-02-26 | Laser method for repairing rotor shaft of generator and steam turbine and dedicated device |
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| CN1660538A true CN1660538A (en) | 2005-08-31 |
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| CN 200410021196 Pending CN1660538A (en) | 2004-02-26 | 2004-02-26 | Laser method for repairing rotor shaft of generator and steam turbine and dedicated device |
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| CN102166702A (en) * | 2010-12-20 | 2011-08-31 | 昆明理工大学 | Laser cladding repairing method of piston rod |
| CN102218597A (en) * | 2010-04-19 | 2011-10-19 | 王耀民 | Field pitching laser machining system |
| CN102615431A (en) * | 2012-04-12 | 2012-08-01 | 中国人民解放军装甲兵工程学院 | Remanufacturing method for automatic laser cladding of gray cast iron cylinder cover |
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| CN103008967A (en) * | 2012-12-20 | 2013-04-03 | 山东大学 | Reproducing and processing system based on laser fusion covering |
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| CN102166702A (en) * | 2010-12-20 | 2011-08-31 | 昆明理工大学 | Laser cladding repairing method of piston rod |
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| CN102837198A (en) * | 2011-10-28 | 2012-12-26 | 南通天华和睿科技创业有限公司 | Shape-following machining equipment of rotor shaft |
| CN103122459B (en) * | 2011-11-18 | 2016-05-04 | 沈阳大陆激光技术有限公司 | A kind of process that adopts laser melting and coating technique school axle |
| CN103122459A (en) * | 2011-11-18 | 2013-05-29 | 沈阳大陆激光技术有限公司 | Technological method for straightening shaft by laser cladding technology |
| CN102615431A (en) * | 2012-04-12 | 2012-08-01 | 中国人民解放军装甲兵工程学院 | Remanufacturing method for automatic laser cladding of gray cast iron cylinder cover |
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| US10067494B2 (en) | 2015-03-02 | 2018-09-04 | Tongtai Machine & Tool Co., Ltd. | Hybrid computer numerical control machining center and machining method thereof |
| CN106636754A (en) * | 2015-11-03 | 2017-05-10 | 上海闸电燃气轮机发电有限公司 | Split face laser seal coating process in gas turbine cylinder |
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| CN106914463A (en) * | 2017-05-02 | 2017-07-04 | 北京石油化工工程有限公司 | High pressure contains the drip irrigation system of solid instrument |
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| CN110747466A (en) * | 2019-11-29 | 2020-02-04 | 国电四川发电有限公司南桠河水电分公司 | Laser micro-melting continuous casting method for protective coating of water turbine flow surface |
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