WO2019085439A1 - 加热装置、加热方法以及轴系装配方法 - Google Patents

加热装置、加热方法以及轴系装配方法 Download PDF

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Publication number
WO2019085439A1
WO2019085439A1 PCT/CN2018/087411 CN2018087411W WO2019085439A1 WO 2019085439 A1 WO2019085439 A1 WO 2019085439A1 CN 2018087411 W CN2018087411 W CN 2018087411W WO 2019085439 A1 WO2019085439 A1 WO 2019085439A1
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WO
WIPO (PCT)
Prior art keywords
heating
heated
flexible
heating film
rotating shaft
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Application number
PCT/CN2018/087411
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English (en)
French (fr)
Inventor
马盛骏
Original Assignee
北京金风科创风电设备有限公司
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Publication of WO2019085439A1 publication Critical patent/WO2019085439A1/zh

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    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00—Ohmic-resistance heating
    • H05B3/20—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater
    • H05B3/34—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater flexible, e.g. heating nets or webs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P11/00—Connecting or disconnecting metal parts or objects by metal-working techniques not otherwise provided for 
    • B23P11/02—Connecting or disconnecting metal parts or objects by metal-working techniques not otherwise provided for  by first expanding and then shrinking or vice versa, e.g. by using pressure fluids; by making force fits
    • B23P11/025—Connecting or disconnecting metal parts or objects by metal-working techniques not otherwise provided for  by first expanding and then shrinking or vice versa, e.g. by using pressure fluids; by making force fits by using heat or cold
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
    • F03D—WIND MOTORS
    • F03D13/00—Assembly, mounting or commissioning of wind motors; Arrangements specially adapted for transporting wind motor components
    • F03D13/10—Assembly of wind motors; Arrangements for erecting wind motors
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00—Ohmic-resistance heating
    • H05B3/02—Details
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B6/00—Heating by electric, magnetic or electromagnetic fields
    • H05B6/02—Induction heating
    • H05B6/10—Induction heating apparatus, other than furnaces, for specific applications
    • 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
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/70—Wind energy
    • Y02E10/72—Wind turbines with rotation axis in wind direction

Definitions

  • the invention relates to the field of wind turbine shafting assembly. More particularly, the present invention relates to a heating device for heating a large-scale, large-mass, variable-diameter, non-equal-section member to be heated such as a rotating shaft of a wind power generator, and using the heating device A method of heating a component to be heated, and a method of assembling a generator shafting.
  • the wind power generator includes a stator main shaft that supports the stator and a rotating shaft that supports the rotor, and the stator main shaft and the rotating shaft are relatively rotatably assembled by bearings.
  • a large direct-drive permanent magnet wind turbine with an outer rotor structure is connected to the stator support flange.
  • the two bearings, the front bearing and the rear bearing, are mounted by the interference fit between the generator stator main shaft and the generator rotating shaft.
  • the front bearing is located between the stator main shaft and the small diameter end of the rotating shaft; the rear bearing is located between the main shaft of the stator and the large diameter end of the rotating shaft.
  • the middle flange on the rotating shaft is used for connection with the impeller hub, and the vanes are fixed on the impeller hub, and the generator rotor is indirectly driven by the rotating shaft.
  • the front bearing uses a tapered roller bearing (abbreviated as BT bearing), and the rear bearing uses a cylindrical roller bearing (referred to as NJ bearing).
  • BT bearing tapered roller bearing
  • NJ bearing cylindrical roller bearing
  • the temperature difference method is generally adopted, and the bearing interference is assembled between the stator main shaft 1 and the rotating shaft 2.
  • the assembly method of the BT bearing 40 and the NJ bearing 30 includes the following steps:
  • the generator stator main shaft 1 is vertically fixed on the mounting table, and the inner ring 31 of the NJ bearing 30 is heated and expanded to meet the required expansion amount by means of an induction heater, and then it is fitted into the stator main shaft. 1;
  • the inner ring cage of the BT bearing and the rolling body 42 are heated and expanded by a heater to a required expansion amount, and then inserted between the stator main shaft 1 and the small diameter end 202 of the rotating shaft 2;
  • the prior art assembly process is also susceptible to fatal damage to the shafting.
  • the rotating shaft 2 weighing several tons is dropped from above the stator main shaft 1 by the large-scale driving hoisting device, and during the lifting and falling process, since there is no specific concrete measure, the rotation is performed.
  • the outer ring of the NJ bearing 30 on the shaft 2 and the retainer rolling element 32 and the inner ring 31 of the NJ bearing on the stator main shaft cannot be accurately aligned, and inevitably, the rolling element cage and the bearing inner ring 31 collide. This causes damage to the NJ bearing 30, resulting in a significant reduction in service life.
  • it causes serious damage to the bearing components, thereby directly reducing the performance of the wind turbine and increasing the assembly cost.
  • Fig. 11 is a cross-sectional view of the heating furnace.
  • the patent uses an electric resistance furnace to heat the air, and uses circulating hot air as a heat transfer medium to heat the rotating shaft, thereby solving various problems existing in the conventional oil bath method and induction heating method.
  • the patent proposes that during the process of the rotating shaft 2 being fitted to the stator main shaft 1, the front and rear bearings are always integral, avoiding the impact between the bearing cage and the inner ring of the bearing.
  • the heating furnace of the patent has problems such as large volume, high height, large scale of hoisting, high plant height, large floor space, high cost, and safety hazards in the work process.
  • the preheating of the heating furnace and the rotation of the centrifugal fan have a large energy consumption and a certain noise.
  • a bearing mounting surface on which the bearing outer ring of the BT bearing 40 is attached to the small-diameter end 202 of the rotating shaft 2 and a bearing outer ring of the NJ bearing 30 are attached to the bearing mounting surface of the large-diameter end 201 of the rotating shaft 2
  • the method of cold loading is generally adopted.
  • a large temperature difference with the surrounding environment causes a large amount of condensed water to be instantaneously formed on the outer ring of the bearing. After the bearing outer ring is fitted into the rotating shaft 2, a certain amount of moisture remains between the mounting faces.
  • the present invention provides a novel heating device and a shafting assembly method.
  • the present invention provides a novel heating device and heating method and a shafting assembly method.
  • a heating device for heating a component to be heated comprising: a flexible heating film embedded with a flexible electric heating element for coating a surface of the component to be heated Heating the component to be heated; and vacuuming the system for pumping the interior of the flexible heating film with the flexible heating film sealingly coated on the surface of the component to be heated Vacuuming, the flexible heating film is closely attached to the surface of the member to be heated; a control unit controls the heating operation of the flexible heating film and the operation of the vacuuming system.
  • a method for heating a member to be heated comprising the step of coating a surface of the member to be heated with a flexible heating film, the flexible heating film Buried with a flexible electric heating element; sealing the flexible heating film and evacuating the inside of the flexible heating film by using a vacuuming system, so that the flexible heating film is closely attached to the surface of the component to be heated; A flexible heating film heats the component to be heated.
  • a shaft assembly method for a wind power generator may include a stator main shaft, a rotating shaft, a rear bearing, and a front bearing, and the method may include: a flexible heating film is coated on the entire surface of the rotating shaft, a plurality of induction heaters are arranged in a plurality of bolt holes of the outer flange of the rotating shaft; the flexible heating film is sealed, and the flexible heating film is sealed inside Vacuuming; heating the rotating shaft with the flexible heating film and the induction heater.
  • the technical scheme of the invention breaks through the conventional ideas of medium heating, electric heating and induction heating, and develops a new shaft assembly process to further save energy and process equipment, completely adopting the heating method in the prior art, adopting compounding
  • the physics field cooperates with the cylinder to control the expansion method to solve the problem of the thermal assembly process of the variable diameter and non-equal section cylinder shaft system.
  • the vacuum system, the electric heating system and the electromagnetic induction system cooperate to solve the large-scale ring of the traditional industrial large-scale motor.
  • the uneven heating and expansion of the heat transfer of non-equal thickness castings causes the deformation and distortion of the components, which solves the problem that the large scale of the large-scale heating furnace has a large radial dimension and the convective heat transfer in the furnace is controlled by the large flow area and the driving fan.
  • the problem of low heat exchange rate caused by the consumption limitation, and the fact that the motor operation of the centrifugal fan in the industrial production plant process equipment inevitably causes noise pollution is eliminated, the use of the vehicle is reduced, thereby saving the power consumption of the plant and reducing the noise caused by the movement of the vehicle. , reducing the safety of workers caused by aerial work Risks.
  • the distortion of the components caused by the uneven expansion during the heating process is avoided in the case of ensuring uniform expansion of the shaft system, so that the assembly quality of the shafting assembly can be improved, and the assembly equipment cost can be greatly reduced.
  • FIG. 1 is a view showing an example of a stator main shaft of a large permanent magnet direct drive wind power generator in the prior art
  • FIG. 2 is a view showing an example of a rotating shaft of a large permanent magnet direct drive wind power generator in the prior art
  • 3 to 10 are schematic views showing a process of bearing assembly of a stator main shaft and a rotating shaft in the prior art
  • Figure 11 is a schematic view of a prior art heating furnace
  • Figure 12 is a partially cutaway perspective view of a rotating shaft in accordance with an exemplary embodiment of the present invention.
  • Figure 13 is a partial cross-sectional view of a rotating shaft in accordance with an exemplary embodiment of the present invention.
  • Figure 14 is an exemplary schematic view of heating a rotating shaft using a heating device according to an embodiment of the present invention.
  • 15 and 16 respectively show examples in which a plurality of induction heaters are connected in parallel and in series;
  • Figure 17 is a partial cross-sectional view showing a compressive stress at a large end flange of a rotating shaft
  • Figure 18 is a partial cross-sectional view showing the state of heat at the large end flange of the rotating shaft.
  • the inventors of the present invention have proposed a new type of concept based on the concept of reducing noise pollution, reducing environmental pollution, reducing production cost, energy saving and environmental protection, and green manufacturing. Heating device, heating method, and shafting assembly method.
  • the heating device and the heating method proposed by the present invention will be described in detail with reference to the accompanying drawings by taking a rotating shaft of a non-equal cross section and a non-equal thickness as an example.
  • the embodiment of the present invention still uses the rear bearing between the stator main shaft and the rotating shaft during the setting process. "One whole" idea.
  • Figure 12 is a partially cutaway perspective view of a rotating shaft in accordance with an exemplary embodiment of the present invention.
  • Figure 13 is a partial cross-sectional view of a rotating shaft in accordance with an exemplary embodiment of the present invention.
  • the rotating shaft 2 includes a non-equal-section, non-equal-thickness cylinder including a large diameter end 201 and a small diameter end 202.
  • a large end flange 203 is provided on the outer surface of the large diameter end 201 of the barrel, and a plurality of bolt holes are formed for connection with the rotor holder.
  • a middle flange 204 is provided at a substantially central portion of the rotating shaft, and a plurality of bolt holes are formed for connection with the hub.
  • the inner surface of the large diameter end 201 is the rear bearing mounting surface 205
  • the inner surface of the small diameter end 202 is the front bearing mounting surface 206.
  • Fig. 14 is an exemplary schematic view of heating the rotating shaft 2 using a heating device according to an embodiment of the present invention.
  • Figures 15 and 16 show schematic views of the parallel connection and series connection of the induction heaters in the flange bolt holes, respectively.
  • a heating apparatus includes a flexible heating film 500, an evacuation system 600, an electromagnetic induction heating unit 700, and a control unit 800.
  • the flexible heating film 500 may be formed in a bag shape or a sheet shape over the entire surface of the member to be heated (the rotating shaft 2).
  • a flexible electric heating element is embedded in the flexible heating film 500, and after being energized, heat can be dissipated to heat the coated rotating shaft 2.
  • the flexible heating film 500 may be formed of a flexible heat resistant material such as a silicone rubber material.
  • the flexible electric heating element is laid in the flexible heat-resistant material, and can be formed into a flexible film having a thickness of about 1.5 mm to 3 mm by fluidizing the flexible heat-resistant material and the flexible electric heating element integrally.
  • the flexible heating film 500 in order to facilitate coating the flexible heating film 500 on the entire surface of the rotating shaft 2, includes a first heating film 510 and a second heating film 520.
  • the first heating film 510 covers the outer surface of the rotating shaft 2
  • the second heating film 520 covers the inner surface of the rotating shaft 2, and then abuts at the large diameter end 201 and the small diameter end 202, respectively, and the butting portions are respectively sealed and sealed by a sealing material.
  • the seal ring 530 can be formed at the butt joint by a heat resistant rubber bonding material.
  • the butt joint can be adhesively sealed with a vacuum sealing tape.
  • the flexible heating film 500 may be of a unitary structure or may be divided into a plurality of pieces, and each of the segments may have various shapes as long as the components to be heated can be completely covered and sealed after splicing. .
  • the evacuation system 600 is for evacuating the inside of the flexible heating film 500 such that the flexible heating film 500 is closely attached to the surface of the rotating shaft 2.
  • the evacuation system 600 may be connected at the abutment of the first heating film 510 and the second heating film 520.
  • the present invention is not limited thereto, and the evacuation system 600 may be disposed at any position of the flexible heating film 500.
  • vacuuming is performed by the vacuuming system 600, on the one hand, the flexible heating film 500 can be closely attached to the entire surface of the irregular rotating shaft 2, so that the corner position of the flange root and the like can be flexible.
  • the heating film 500 is closely attached to be efficiently heated in a heat conduction manner.
  • the flexible heating film 500 can be quickly separated from the rotating shaft 2 as a whole, which not only facilitates the installation and removal of the flexible heating film 500, but also avoids the use of other means (for example, bonding) to heat the flexible heating.
  • the film 500 needs to be peeled off when attached to the rotating shaft 2 to cause damage to the flexible heating film 500 and contamination or damage to the surface of the rotating shaft 2, so that the flexible heating film 500 can be reused and the surface of the rotating shaft 2 can be cleaned.
  • a first temperature sensor 540 may be disposed on the surface of the rotating shaft 2 to detect the wall surface temperature of the rotating shaft 2.
  • the inside of the flexible heating film 500 may be provided with a second temperature sensor 550, a piezoelectric sensor (for example, a piezoelectric polymer material sensor) 560, and the like.
  • the control unit 800 can control the heating power or the heating temperature of the flexible heating film 500 according to the temperature signal fed back by the first temperature sensor 540 and the second temperature sensor 550, and determine the flexible heating film 500 according to the pressure value sensed by the piezoelectric sensor 560.
  • the fitting condition of the respective portions of the rotating shaft 2 is rotated, and the operation of the vacuuming system 600 is controlled accordingly.
  • the inside of the flexible heating film 500 can be continuously evacuated by the vacuuming system 600.
  • the pressure value sensed by the piezoelectric sensor 560 still does not reach the predetermined value in the case where the vacuum is continuously applied, it can be judged that there is a leak somewhere in the flexible heating film 500.
  • the leak position can be judged according to the sensed value of the piezoelectric sensor at different positions, and corresponding sealing measures are taken, for example, sealing the portion with a vacuum sealant.
  • the seal of the flexible heating film 500 is relatively easily leaked, and therefore, a part of the piezoelectric sensor 560 can be disposed at the seal of the flexible heating film 500.
  • the piezoelectric sensor 560 may be a polyvinylidene fluoride (PVDF) piezoelectric sensor.
  • the PDVF can also be utilized as the flexible material of the heating film 500.
  • the piezoelectric characteristics of the flexible heating film 500 itself can be directly utilized to detect the contact state of the flexible heating film 500 with the rotating shaft 2.
  • the temperature sensor and the piezoelectric sensor are not necessarily integrally formed with the flexible heating film 500, and may be additionally provided on the surface of the rotating shaft 2 or on the inner surface of the flexible heating film 500.
  • An electromagnetic induction heating unit 700 may be disposed in the large end flange 203 and the middle flange 204 for heating the large end flange 203 and the middle flange 204.
  • the electromagnetic induction heating unit 700 may include a plurality of inductors 710, a magnet wire 720 that connects the plurality of induction heaters 710, an induction heating power source 730, and the like.
  • a plurality of induction heaters 710 are respectively disposed in the bolt holes of the flanges, and may be connected in parallel or in series by magnet wires 720 (as shown in FIGS. 15 and 16).
  • the induction heating power source 730 applies alternating current to the plurality of induction heaters 710 such that the induction heater 710 generates heat due to the short-circuit current through the flange bolt hole walls.
  • the rotating shaft 2 when the rotating shaft 2 is heated and expanded by the flexible heating film 500, although the flexible heating film 500 is tightly coated on the entire surface of the rotating shaft 2, the rotating shaft 2 can be quickly and efficiently Heating, however, since the rotating shaft 2 is a large-scale, non-equal-thick variable-section cylindrical structure, at the positions of the large-end flange 203 and the middle flange 204, the radial thickness is increased, and heat is transferred to the deep portion of the thickness of the cylinder. The speed is slower. Therefore, when the inner surface of the rotating shaft 2 is expanded by heat, the outer cylindrical portion of the rotating shaft 2 at the root of the flange is slower than the expansion speed of the inner cylindrical portion due to the slow heating. Thereby, the expansion of the inner cylindrical portion is restrained, so that the inner cylindrical portion is subjected to the compressive stress applied by the outer cylindrical body.
  • Figure 17 shows a partial cross-sectional view of the large end flange of the rotating shaft 2.
  • a compressive stress as indicated by arrow 210 in the figure
  • the expansion speed of the cylinder is inconsistent, causing distortion of the rotating shaft cylinder. Therefore, in order to make the entire cylinder expand uniformly, it is necessary to remove the obstacle caused by the restraint on the expansion of the flange root.
  • Embodiments of the present invention propose that by heating the flange, the flange is "first" expanded by heat, which is the "way” for the expansion of the flange of the flange root, and the restriction and restraint caused by the expansion of the cylinder at the flange is released.
  • an electromagnetic induction heater is disposed in the large end flange 203 and the middle flange 204 such that the flange absorbs heat by electromagnetic eddy current induction while being heated by the flexible heating film 500.
  • embodiments of the present invention utilize the skin effect of electromagnetic induction heating with an induction heater 710 disposed in the bolt holes of the flange.
  • FIG. 18 schematically shows a schematic view of the induction heater 710 disposed in the bolt hole of the large end flange 203.
  • the induction heater 710 heats the bolt holes of the flange, and heat is transferred from the hole wall of the bolt hole in the thickness direction, so that the flange is heated by the flexible heating film 500 on the outer surface, the upper surface and the lower surface. At the same time, it is also heated from the hole wall of the bolt hole, so that the flange body is thermally expanded prior to the cylinder at the root of the flange, and the compressive stress of the outer flange against the root cylinder is withdrawn.
  • the induction heater 710 may be disposed eccentrically with respect to the axis of the bolt hole, closer to the flange root in the bolt hole. As shown in Fig. 18, the induction heater 710 is disposed closer to the inner side wall surface of the bolt hole. Due to the proximity effect, the penetration current of the inner side wall of the bolt hole penetrates more deeply, so that it is easier to transfer heat to the inner flange root.
  • the flexible heating film 500 is not only coated on the radially outer surface of the flange, but also tightly wrapped on the upper and lower surfaces of the flange axial direction, so that the three outer surfaces of the flange At the same time, it is heated (as indicated by arrows 230, 240, and 250 in the figure) to avoid the end effect caused by insufficient heat at the end, and to prevent the flange from being twisted due to the radial expansion of the flange surface.
  • the respective induction heaters 710 disposed in the large end flange 203 or the middle flange 204 may be connected in parallel to each other.
  • the respective induction heaters 710 disposed in the large end flange 203 or the middle flange 204 may also be connected to each other in series.
  • the induction heating power source 730 can apply an alternating current to the induction heater 710 through a magnet wire 720.
  • the induction heating power source 730 can employ a power frequency induction heating power source.
  • the thickness of the current penetration depth layer can be controlled by the frequency of the applied induced current to control the heating rate.
  • the three systems of vacuuming system, electric heating system and induction heating system work together on the flange, so that the outer flange is firstly heated and expanded.
  • the thermal expansion of the root cylinder withdraws the compressive stress (expansion resistance), which relieves the expansion constraint of the large end flange on the rear bearing mounting surface of the rotating shaft, and suppresses the distortion of the cylinder caused by the uneven heating expansion rate of the cylinder.
  • the outer surface of the flexible heating film 500 may be covered with a heat insulating material after the flexible heating film 500 is coated on the rotating shaft 2.
  • the flexible heating film 500 is coated on the entire surface of the rotating shaft 2, the first temperature sensor 540, the second temperature sensor 550, and the piezoelectric sensor 560 are disposed at the position to be detected, and the suction of the vacuuming system 600 is disposed. Pipeline. According to an embodiment of the present invention, the second temperature sensor 550 and the pressure sensor 560 may be embedded in the flexible heating film 500. At the seal of the flexible heating film 500, a vacuum sealant can be used for adhesive sealing and sealing.
  • the first temperature sensor 540, the second temperature sensor 550, and the pressure sensor 560 may be evenly disposed over the entire cladding surface to detect pressure and temperature at each location. However, in order to reduce the number of pressure sensors and temperature sensors, the first temperature sensor 540, the second temperature sensor 550, and the pressure sensor 560 may be selectively disposed at specific positions.
  • the pressure sensor 560 may be mainly disposed at a sealing position or a seal vicinity of the flexible heating film 500 and a reduced diameter position, for example, disposed at a flange root, a joint of the boss and the cylinder, and the like.
  • the induction heating unit 700 is also arranged on the rotating shaft 2.
  • the flexible heating film 500 is partially opened at a position corresponding to the bolt hole, and then the plurality of induction heaters 710 are placed in the bolt holes, and A plurality of induction heaters are connected in series or in parallel using a magnet wire 720, and then the opening is closed by a vacuum sealant.
  • induction heaters 710 it is also possible to arrange a plurality of induction heaters 710 first, and connect the plurality of induction heaters 710 in series or in parallel by the electromagnetic wires 720, and then connect them to the induction heating power source 730 through a lead wire from a position of the flexible heating film 500. .
  • the induction heater 710 When the induction heater 710 is disposed, the induction heater 710 is eccentrically disposed with respect to the center of the bolt hole such that the induction heater 710 is closer to the flange root.
  • the order of arranging the flexible heating film 500, the vacuuming system 600, and the induction heating unit 700 is not specific or unique, and the induction heating unit 700 may be disposed first, then the flexible heating film 500 and the vacuuming system 600 may be disposed, or may be arranged first. After the flexible heating film 500 and the induction heating unit 700, the evacuation system 600 is disposed.
  • the control unit 800 determines whether the flexible heating film 500 has only been attached to the surface of the rotating shaft 2 based on the sensed value of the piezoelectric sensor 560.
  • the flexible heating film 500 and the induction heating unit 700 may be activated to perform a heating operation.
  • the cylinder is divided into the outer cylinder portion and the inner cylinder portion by the center of mass of the cylinder thickness, in the process of thermal expansion of the cylinder of the rotating shaft 2, if the expansion speed of the inner cylinder portion is greater than that of the outer cylinder portion The expansion speed, then the outer cylinder portion will exert compressive stress on the inner cylinder portion, and the inner cylinder portion will expand outward to form a restraint. As a result, the two ends of the cylinder body are generally twisted outward to form a bell mouth shape. Therefore, in order to release this restraint, it is necessary to first expand the outer cylinder portion.
  • one general concept of controlling the flexible heating film 500 and the induction heating unit 700 is to control the speed of heat transfer from the inner side surface of the cylinder and the cylinder from the cylinder in the radial direction of the cylinder.
  • the rate at which the outer surface heats inwardly causes the center of mass to reach a set temperature due to heat absorption from the outside of the barrel equal to or slightly greater than the time required for the center of mass to absorb heat from the inside of the barrel to the same temperature. According to this principle, the amount of heat required for heating at various positions of the barrel and the time required to reach the set temperature can be calculated, whereby the heating power or heating temperature of the flexible heating film 500 and the induction heating unit 700 can be controlled accordingly. heating time.
  • the flexible heating film 500 closely adheres to the surface of the rotating shaft 2, and there is no air thermal resistance between the surface of the rotating shaft 2, and therefore, the flexible heating film 500 rapidly heats up after being energized and conducts direct heat conduction with the rotating shaft 2. Since the outside of the flexible heating film 500 is also covered with the heat insulating material, the heat generated by the flexible heating film 500 is transmitted to the rotating shaft 2 with almost no loss. According to the mass, density, thermal conductivity and specific heat capacity of the rotating shaft 2, it is possible to determine the amount of heat to be absorbed and the required heating time, etc., when the rotating shaft is heated to a desired temperature.
  • constant power heating may be performed after the rotating shaft 2 is subjected to constant power heating to a set wall temperature. Therefore, the heating power of the electric heating element can be determined according to the heating method taken.
  • the electric heating element is a heating element of the flexible heating film 500. Before selecting the electric heating element, the material of the electric heating element and the connection manner thereof can be determined according to the determined power and the supply voltage. The material of the electric heating element should be selected to meet the requirements: high resistivity, small temperature coefficient of resistance, sufficient heat resistance and high temperature strength, and small thermal expansion coefficient.
  • the heating time required for the wall temperature to reach 80 ° C can be calculated under a constant heating power.
  • the rotating shaft 2 can be calculated.
  • the wall thickness of the centroid is located at this moment of temperature.
  • the rotating shaft 2 is further subjected to constant wall temperature heating, and the rate of rise of the temperature in the middle portion of the wall thickness of the rotating shaft 2 is determined by the thermal conductivity, density and specific heat capacity of the material of the rotating shaft 2.
  • the entire heating time of the rotating shaft can be determined using the Heisler diagram or the approximate fitting formula in Heat Transfer Theory, Heat Transfer Handbook.
  • the heating power or heating temperature of the electric heating element of the flexible heating film 500 can be relatively high.
  • the heating temperature of the heating element in the flexible heating film 500 can be heated compared to other positions.
  • the temperature is higher, for example, 10 ° C higher, so that the rate of rise of the centroid temperature at positions of different thicknesses is as uniform as possible, thereby reducing the distortion of the barrel and weakening the stress due to the temperature difference.
  • the cylinder here is simultaneously heated by the induction heating and the electric resistance heating.
  • the induction heater 710 located in the bolt hole when the frequency of the induction heating is different, the electromagnetic heating depth induced on the inner wall of the bolt hole is also different, and therefore, the heat generated by the induction heating can be controlled by controlling the frequency of the induction heating and The amount of heating power.
  • the respective induction heaters 710 may be connected in series or in parallel to perform induction heating by the same current or the same frequency. Further, in the case where the portion located inside the bolt hole is thick, each of the induction heaters 710 may be placed closer to the flange root in the bolt hole.
  • an induction heater 710 is disposed in each of two adjacent bolt holes, and when the inner wall of the bolt hole is heated, heat is radiated to the periphery from the inner wall of the bolt hole. Therefore, for the portion of the flange between the two adjacent bolt holes, heat is absorbed from both bolt holes at the same time, so that the heat conduction path for obtaining heat from the heat source is shortened. At the same time, for the cylinder of the flange root, since the heat is directly transferred from the inner wall of the bolt hole to the flange according to heat transfer, the heat conduction path of the portion from the heat source is shortened compared with the prior art induction heating method, thereby The time required for the root to reach the same temperature is shorter.
  • the cylinder at the flange is thick, since the provided induction heater 710 is heated together with the flexible heating film 500, a large thickness position can be realized for each portion of the cylinder.
  • the rate of rise of the center of mass temperature is as close as possible to the rate of rise of the center of mass at the position where the thickness is small, and preferably causes the outer cylinder to expand first, releasing the restraint caused by the expansion of the inner cylinder.
  • the temperature of the rotating shaft 2 can be monitored by the first temperature sensor 540 during heating.
  • a pressure gauge value of the vacuum system 600 itself a sensed value of the piezoelectric sensor 560, a heating temperature of the flexible heating film 500, a heating temperature of the flexible heating film 500, and a temperature difference of the rotating shaft 2 may be used.
  • the degree of adhesion of the flexible heating film 500 to the rotating shaft 2 is judged. For example, if the reading of the piezoelectric sensor 560 is lowered by a predetermined value, it may be determined that the flexible heating film 500 may be damaged and leaked there; if the temperature of the flexible heating film 500 is sharply increased, it may be judged here and the rotating shaft.
  • the fitting of 2 is not tight enough to cause the thermal resistance to rise and the heat cannot be transferred to the rotating shaft 2 very quickly; similarly, if the temperature difference between the surface of the flexible heating film 500 and the rotating shaft 2 is greater than a predetermined value, it can be judged as here.
  • the fit is not tight. Therefore, the flexible heating film 500 at the corresponding position can be inspected and subjected to a sealing process, and the operation of the vacuuming system 600 is activated accordingly.
  • the rotating shaft 2 is suspended above the stator main shaft 1, on which the entire rear bearing 30 has been heat-sleeved on the stator main shaft 1 Rear bearing mounting surface.
  • the rotating shaft 2 is dropped, the large diameter end 201 of the rotating shaft 2 is fitted to the outer circumference of the bearing outer ring of the rear bearing 30.
  • the rear bearing outer ring is usually made of a material having a higher hardness such as stainless steel and has a considerable thickness, even when the rotating shaft 2 falls, the large diameter end 201 and the rear bearing 30 are outside the bearing. The ring collision does not cause serious damage to the outer ring of the bearing, thereby avoiding damage to the cage and the rolling elements. Further, by arranging the guide strips on the large diameter end 201, the large diameter end 201 of the rotating shaft 2 can be aligned with the bearing outer ring of the rear bearing 30 to avoid collision between the two.
  • the edge of the bearing outer ring of the rear bearing 30 is provided with a chamfer, which can guide the assembly of the large diameter end of the rotating shaft 2 and the rear bearing 30, and can be inverted even in the case of less precise alignment.
  • the angle guides the cooperation of the two to avoid repeatedly lifting the rotating shaft 2 to fall.
  • the bearing inner ring of the front bearing 40 and the cage are heated and assembled on the small end of the stator main shaft, and then the bearing outer ring of the front bearing 40 is mounted on the rotating shaft 2
  • the front bearing is mounted on the surface to complete the assembly of the entire shafting.
  • the time during which the heated rotating shaft 2 is cooled to the original state at normal temperature usually takes 12-15 hours, and therefore, the rotating shaft 2 is set to the stator. After the main shaft 1, there is sufficient operation time to mount the front bearing 40 between the small-diameter end 202 of the rotating shaft 2 and the small end of the stator main shaft 1 in a state where the rotating shaft 2 is kept inflated and the fitting interference is satisfied.
  • the rear bearing 30 attached to the large-diameter end 201 of the rotating shaft 2 is fitted to the rear bearing 30 in a state where the rotating shaft 2 is thermally expanded, instead of cooling the rear bearing 30 to the rotating state as in the prior art.
  • the large end of the shaft 2 prevents the condensation water from condensing on the bearing assembly surface, and at the same time avoids the moisture entering the lubricating grease and causing the deterioration of the lubricating grease.
  • the heating device of the embodiment of the present invention by providing a vacuuming system, an electric heating system, and an induction heating system, the composite physics is used to cooperate with the cylinder to control the expansion of the cylinder.
  • an induction heating unit it is advantageous to utilize the skin effect and the proximity effect of the induction heating to effectively ensure that the outer flange of the rotating shaft is "first" expanded relative to the flange of the flange root, and the “expansion of the flange of the flange root” ", “release” constraints on the expansion of the flange root cylinder, to avoid distortion of the cylinder, to ensure the quality of the shaft assembly.
  • the embodiment of the invention abandons the conventional industrial method of heating the large-scale, large-weight, non-equal-section rotating shaft by the oil bath method, avoiding environmental pollution caused by heating oil, product pollution, etc., and subsequent heating oil treatment.
  • the cost problem brings about the damage caused by the oil bath method to the protective oil of bearings, rotating shafts and other components. Therefore, it is more environmentally friendly, energy-saving and emission-reducing, safe and reliable, and conforms to the concept of sustainable development.
  • Embodiments of the present invention abandon the conventional industrial use of electromagnetic induction heating to heat such a large-scale, large-weight, non-equal-section rotating shaft, avoiding the skin effect caused by the electromagnetic induction heating method and the temperature brought about by the proximity effect Uneven distribution and uneven expansion cause distortion and deformation of the cylinder.
  • the embodiment of the present invention also discards the way in which the large-scale heating of the large-scale components is adopted in a conventional industry, thereby reducing the energy consumed by the preheating of the furnace body and reducing the electric energy consumed by the operation of the centrifugal fan;
  • the hoisting of the furnace cover and the rotating shaft reduces the number of times of hoisting and driving, saves the process and the power consumed thereby, and improves the work efficiency; in addition, the traditional large-sized heating furnace needs to occupy a large plant area and operation space, and often needs to be built.
  • the construction cost is very high, however, when applying the heating device and the heating method of the embodiment of the invention, it does not need to occupy a large plant area and operation space, saving the enterprise
  • the construction cost is adopted; when the technical solution of the invention is adopted, the centrifugal fan is not needed, the noise caused by the operation of the centrifugal fan is avoided, the noise caused by the driving movement is reduced, the noise pollution is reduced, and more importantly, the worker can be on the ground. Do not need to climb a few meters high like a conventional furnace Top, reducing the security risks caused by high-altitude operations.
  • the heating device, the heating method, and the shafting assembly method utilize three systems of vacuuming system, electric heating system, and induction heating system while saving energy and environmental protection, reducing plant occupation area, and reducing equipment manufacturing cost. Synergistically, it solves the heating problem and assembly problem of large-scale non-equal-section non-equal-thickness castings of large motors, and avoids the convection heat flow of the heating furnace.
  • the main flow velocity is limited by the large flow area and the heat exchange rate caused by the energy consumption limitation of the driving fan.
  • the problem solves the problem that the asymmetric expansion and asymmetric deformation caused by electromagnetic induction eddy current heating cause installation difficulties and the installation stress become the imbalance of the operation-induced vibration quality, improve the assembly quality of the shafting, and ensure the safe operation and improvement of the wind turbine. Unit life.
  • the heating apparatus and the heating method of the present invention are not limited to the embodiment, and the heating apparatus of the present invention can be used for heating various types.
  • the member to be heated having an irregular shape, a non-equal cross section, and a non-equal thickness, for example, can be used to heat a member to be heated having a body portion and a boss portion, a member to be heated having a barrel body and an outer flange, and the like. It is apparent that the heating device and the heating method of the present invention are also suitable for heating a member to be heated having a regular shape.

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Abstract

本发明提供了一种用于风力发电机的大型轴系部件的加热装置、加热方法以及轴系装配方法。所述加热装置包括：柔性加热膜，用于包覆在所述待加热部件的表面上；抽真空系统，用于在所述柔性加热膜密封地包覆在所述待加热部件上的情况下，对所述柔性加热膜的内部抽真空；控制单元，控制柔性加热膜的加热操作以及所述抽真空系统的操作。根据本发明的技术方案，解决了传统加热方法和装配方法存在的加热不均导致的装配质量问题，并且更加节能环保。

Description

加热装置、加热方法以及轴系装配方法 技术领域
本发明涉及风力发电机轴系装配领域。更具体地，本发明涉及一种用于对诸如风力发电机的转动轴这样的大尺度、大质量、变径、非等截面的待加热部件进行加热的加热装置以及使用该加热装置对这种待加热部件进行加热的方法，以及对发电机轴系进行装配的方法。
背景技术
风力发电机包括支撑定子的定子主轴和支撑转子的转动轴，定子主轴和转动轴通过轴承可相对旋转地装配在一起。以外转子结构的大型直驱永磁风力发电机为例，发电机定子主轴与定子支架法兰连接。发电机定子主轴和发电机转动轴之间前后两端通过过盈配合安装两个轴承，即前轴承和后轴承。前轴承位于定子主轴和转动轴小径端之间；后轴承位于定子主轴与转动轴的大径端之间。转动轴上的中法兰用于与叶轮轮毂连接，叶片固定在叶轮轮毂上，通过转动轴间接驱动发电机转子。通常情况下，前轴承采用圆锥滚子轴承(简称BT轴承)，后轴承采用圆柱滚子轴承(简称NJ轴承)。图1和图2分别是风力直驱永磁发电机的定子主轴1的主视图和转动轴2的立体图。
对于BT轴承和NJ轴承的装配一般采用温差法，将轴承过盈装配在定子主轴1和转动轴2之间。
如图3-10所示，BT轴承40和NJ轴承30的装配方法大约包括如下步骤：
(1)如图3所示，将发电机定子主轴1垂直固定在安装台上，借助感应加热器将NJ轴承30的内圈31加热膨大至满足要求的膨胀量后，将其套入定子主轴1；
(2)如图4和图5所示，借助冷却柜将NJ轴承30的外圈及保持架滚动体32和BT轴承40的第一外圈41冷却收缩至满足要求的收缩量后，分别装入发电机转动轴2的大径端201的轴承安装面和小径端202的轴承安装面；
(3)如图6和图7所示，将安装有NJ轴承的外圈及保持架滚动体32和BT轴承的第一外圈41的转动轴2套在定子主轴1上，并使NJ轴承的外 圈及保持架滚动体32套在NJ轴承的内圈31上；
(4)如图8所示，借助加热器将BT轴承的内圈保持架及滚动体42加热膨大至满足要求的膨胀量后，装入定子主轴1和转动轴2的小径端202之间；
(5)如图9所示，最后，采用冷冻柜冷却BT轴承的第二外圈43后，将第二外圈43放入定子主轴1和转动轴2的小径端202之间。
至此，如图10所示，待轴承温度恢复到室温状态时，发电机的定子主轴1、转动轴2、前轴承40和后轴承30相互配合在一起形成一个整体，发电机的定子主轴、转动轴2和轴承之间形成过盈配合。
然而，对于大型风力发电机的轴系中的这种大尺度、不规则形状的部件的加热一直以来是本领域技术人员所面临的难题。现有技术中采用的油浴法不仅存在环境污染问题，还会损坏轴承的防护油。电加热法则难以实现这种大部件的均匀膨胀。
除了上面提到的加热难题之外，现有技术中的装配过程也容易对轴系造成致命损伤。当将加热后的转动轴装配到定子主轴上时，利用大型行车吊装设备将重达几吨重的转动轴2从定子主轴1上方下落，在吊装下落过程中，由于没有可视化的具体措施，转动轴2上的NJ轴承30的外圈和保持架滚动体32与定子主轴上的NJ轴承的内圈31无法实现精确的对准，不可避免地会出现滚动体保持架与轴承内圈31的撞击，导致NJ轴承30的损伤，使得使用寿命显著降低。此外，在多次撞击的情况下，更是导致了轴承部件的严重损害，因此，直接降低了风力发电机的性能，且提高了装配成本。
本发明的发明人设计了一种加热炉以及利用该加热炉对轴承进行装配的方法，记载在已授权专利CN103078454B中，图11是该加热炉的截面图。该专利采用电阻炉加热空气，以循环的热空气作为传热介质，对转动轴进行加热，解决了传统的油浴法、感应加热法中存在的各种问题。同时，该专利提出了在转动轴2套装到定子主轴1上的过程中，前后轴承始终是一个整体，避免了轴承保持架与轴承内圈之间的撞击。
然而，该专利中的这种加热炉存在体积大、高度大、吊装行车规模大、厂房高度大、占地面积大、成本高以及工作过程存在安全隐患等问题。并且，加热炉的预热以及离心风机的旋转等耗能较大，还有一定噪声。
此外，在将在BT轴承40的轴承外圈安装在转动轴2的小径端202的轴 承安装面上以及将NJ轴承30的轴承外圈安装于转动轴2的大径端201的轴承安装面上时，一般采用冷装的方法。然而，当将轴承外圈从冷柜中取出时，与周围环境的较大温差使得轴承外圈上瞬间形成大量冷凝水。在将轴承外圈装入转动轴2后，在装配面之间留存了一定量的湿气。同时，凝结在轴承外圈内表面上的水气进入滚动体保持架中的润滑油脂中。实践中，在将故障轴系拆开后，发现在轴承外圈与转动轴2的轴承安装面之间存在大量锈迹，有的甚至出现大面积的腐蚀，并且润滑油脂变质失效。因此，现有技术中将轴承外圈冷装到转动轴2的方式大大减缓了轴系的使用寿命。
为了解决现有技术中存在的难题，本发明提供了一种新型的加热装置以及轴系装配方法。
发明内容
为了解决现有技术中的大尺度、大重量、变径非等截面的铸件的加热以及装配难题，本发明提供了一种新型的加热装置和加热方法以及轴系装配方法。
根据本发明的一方面，提供了一种用于加热待加热部件的加热装置，所述加热装置可包括：柔性加热膜，埋设有柔性电热元件，用于包覆在所述待加热部件的表面上，以对所述待加热部件进行加热；抽真空系统，用于在所述柔性加热膜密封地包覆在所述待加热部件的表面上的情况下，对所述柔性加热膜的内部抽真空，使所述柔性加热膜紧密贴附在所述待加热部件的表面上；控制单元，控制所述柔性加热膜的加热操作以及所述抽真空系统的操作。
根据本发明的另一方面，本发明提供了一种用于加热待加热部件的方法，所述方法可包括如下步骤：用柔性加热膜包覆所述待加热部件的表面，所述柔性加热膜中埋设有柔性电热元件；将所述柔性加热膜密封并利用抽真空系统对柔性加热膜的内部抽真空，使所述柔性加热膜紧密贴附在所述待加热部件的表面上；利用所述柔性加热膜对所述待加热部件进行加热。
根据本发明的又一方面，提供了一种用于风力发电机的轴系装配方法，所述轴系可包括定子主轴、转动轴、后轴承和前轴承，所述方法可包括：在所述转动轴的整个表面上包覆柔性加热膜，在所述转动轴的外法兰的多个螺栓孔中布置多个感应加热器；将所述柔性加热膜密封，并对所述柔性加热膜内部抽真空；利用所述柔性加热膜和所述感应加热器对转动轴进行加热。
本发明的技术方案突破了传统的介质加热和电加热以及感应加热的常规思路，开发了新的轴系装配工艺过程更进一步节能的工艺装备，完全不采用现有技术中的加热方式，采用复合物理场协同作用于筒体控制膨胀的方法解决变径、非等截面筒体轴系热装配工艺问题，利用真空系统、电加热系统和电磁感应系统协同作用，解决了传统工业大型电机大尺度环形非等厚铸件热传导的加热膨胀不均导致部件变形扭曲的问题，解决了传统工业大型空气加热炉历史以来由于大型加热炉空间径向尺度大、炉内对流换热受制于流动面积大和驱动风机能耗限制导致的换热速率低的问题，并且消除了工业生产车间过程装备中的离心风机的电机运转必然产生噪音污染的事实，减少了行车使用从而节省了厂用电并减少行车移动造成的噪音，减少了工人高空作业带来的人身安全隐患。
根据本发明的技术方案，在保证轴系膨胀均匀的情况下避免了加热过程中膨胀不均导致的部件扭曲变形，从而能够在提高轴系装配质量的同时，还能极大地降低装配设备成本。
附图说明
通过下面结合附图对本发明的实施例进行描述，本发明的上述和其他目的和特点将会变得更加清楚，其中：
图1是现有技术中大型永磁直驱风力发电机的定子主轴的示例图；
图2是现有技术中大型永磁直驱风力发电机的转动轴的示例图；
图3-图10示出了现有技术中定子主轴与转动轴进行轴承装配的过程示意图；
图11是现有技术中的加热炉的示意图；
图12是根据本发明示例性实施例的转动轴的局部剖开立体图；
图13是根据本发明示例性实施例的转动轴的局部剖面图；
图14是利用根据本发明实施例的加热装置对转动轴进行加热的示例性示意图；
图15和图16分别示出了多个感应加热器并联连接和串联连接的示例；
图17示出了转动轴的大端法兰处具有压应力的局部截面示意图；
图18示出了转动轴的大端法兰处的受热状况的局部截面示意图。
附图中：1-定子主轴，2-转动轴；201-转动轴的大径端；202-转动轴的小径端；203-大端法兰；204-中法兰；205-后轴承安装面；206-前轴承安装面；30-后轴承；31-后轴承内圈，32-后轴承的外圈及保持架滚动体；40-前轴承；41-前轴承的第一外圈；42-前轴承的内圈及保持架滚动体；43-前轴承的第二外圈；500-柔性加热膜；510-第一加热膜；520-第二加热膜；540-第一温度传感器；550-第二温度传感器；560-压电传感器；600-抽真空系统；700-感应加热单元；710-感应加热器；720-电磁线；730-感应加热电源；800-控制单元；210-压应力；230、240、250-热传导方向。
具体实施方式
为了解决现有技术中存在的各种问题，本发明的发明人本着能够减少噪声污染、减少环境污染、降低生产成本、节能环保、绿色制造的可持续发展的理念，提出了一种新型的加热装置、加热方法以及轴系装配方法。
下面以加热非等截面、非等厚度的转动轴为例来参照附图详细描述本发明提出的加热装置以及加热方法。为了避免在转动轴套装到定子主轴的过程中，轴承内圈和轴承外圈相互碰撞而导致轴承损坏的问题，本发明的实施例仍然采用在套装过程中定子主轴与转动轴间的后轴承是“一个整体”的思路。
图12是根据本发明示例性实施例的转动轴的局部剖开立体图。图13是根据本发明示例性实施例的转动轴的局部剖面图。
如图12和13所示，转动轴2包括非等截面、非等厚度的筒体，该筒体包括大径端201和小径端202。在筒体的大径端201的外表面上设置有大端法兰203，并且形成有多个螺栓孔，用于与转子支架相连接。在转动轴的大概中部的位置设置有中法兰204，并且形成有多个螺栓孔，用于与轮毂连接。大径端201的内表面为后轴承安装面205，小径端202的内表面为前轴承安装面206。
图14是利用根据本发明实施例的加热装置对转动轴2进行加热的示例性示意图。图15和图16分别示出了法兰螺栓孔中的感应加热器并联连接和串联连接的示意图。
如图14-16所示，根据本发明实施例的加热装置包括柔性加热膜500、抽真空系统600、电磁感应加热单元700以及控制单元800。
柔性加热膜500可形成为袋状或片状，包覆在待加热部件(转动轴2) 的整个表面上。在柔性加热膜500中埋设有柔性电热元件，通电后可以散发热量，从而对所包覆的转动轴2进行加热。柔性加热膜500可以由柔性耐热材料形成，例如，硅橡胶材料。在柔性耐热材料中铺设柔性电热元件，可通过使柔性耐热材料与柔性电热元件流态化一体成型，形成为厚度大约1.5mm-3mm的柔性薄膜。
在图14所示的示例性实施例中，为了便于将柔性加热膜500包覆在转动轴2的整个表面上，柔性加热膜500包括第一加热膜510和第二加热膜520。第一加热膜510覆盖转动轴2的外侧表面，第二加热膜520覆盖转动轴2的内侧表面，然后分别在大径端201和小径端202处对接，对接处分别利用密封材料进行粘接密封。可以利用耐热橡胶粘接材料在对接边界处形成密封环530。例如，可以采用真空密封胶带将对接处粘接密封。根据待加热部件的形状和构造，柔性加热膜500可以为一体结构，也可以分为多片，并且各个分片可具有各种形状，只要拼接后能够将待加热部件完全包覆并密封即可。
抽真空系统600用于对柔性加热膜500的内部抽真空，使得柔性加热膜500紧紧贴附在转动轴2的表面上。在图14所示的示例中，抽真空系统600可以连接在第一加热膜510和第二加热膜520的对接处。但是，本发明不限于此，抽真空系统600可以设置在柔性加热膜500的任意位置处。根据本发明的实施例，利用抽真空系统600抽真空，一方面能够使柔性加热膜500紧紧贴附在不规则的转动轴2的整个表面上，使得法兰根部等拐角位置均能与柔性加热膜500紧密贴附，从而以热传导的方式有效加热。另一方面，当真空泄压后，柔性加热膜500能够整体上快速与转动轴2分离，不仅便于安装和拆除柔性加热膜500，还能避免采用其他手段(例如，粘接法)将柔性加热膜500贴附到转动轴2上时需要撕除而导致柔性加热膜500损坏以及对转动轴2的表面造成的污染或损坏，使得能够重复使用柔性加热膜500且保证转动轴2表面清洁无损。
可在转动轴2的表面上设置第一温度传感器540，以检测转动轴2的壁面温度。柔性加热膜500的内部除了埋设有电热元件外，还可设置有第二温度传感器550、压电传感器(例如高分子压电材料传感器)560等。控制单元800可以根据第一温度传感器540、第二温度传感器550反馈的温度信号控制柔性加热膜500的加热功率或加热温度，以及根据压电传感器560感测的压力值，判断柔性加热膜500与转动轴2的各个部分的贴合状况，并据此控制 抽真空系统600的操作。在根据压电传感器560的压力值判断柔性加热膜500内部的真空度不符合要求的情况下，可以通过抽真空系统600对柔性加热膜500的内部持续抽真空。当在持续抽真空的情况下，压电传感器560感测的压力值仍然没有达到预定值的情况下，可以判断柔性加热膜500某处存在泄露。可以根据不同位置处的压电传感器的感测值来判断泄露位置，并采取相应的密封措施，例如，采用真空密封胶对该处进行密封处理。通常情况下，柔性加热膜500的封口处相对容易泄露，因此，可以将一部分压电传感器560布置在柔性加热膜500的封口处。
压电传感器560可以是聚偏氟乙烯(PVDF)压电传感器。作为示例，也可以利用PDVF作为加热膜500的柔性材料，在这种情况下，可以直接利用柔性加热膜500本身的压电特性来检测柔性加热膜500与转动轴2的接触状况。然而，温度传感器和压电传感器不必与柔性加热膜500一体形成，也可以另外设置在转动轴2的表面上或柔性加热膜500的内表面上。
电磁感应加热单元700可设置在大端法兰203以及中法兰204中，用于对大端法兰203以及中法兰204进行加热。电磁感应加热单元700可包括多个感应器710、连接多个感应加热器710的电磁线720、感应加热电源730等。多个感应加热器710分别布置在法兰的螺栓孔中，可通过电磁线720并联连接或串联连接(如图15和16所示)。感应加热电源730将交流电施加到多个感应加热器710，使得感应加热器710通过法兰螺栓孔壁由于短路电流而发热。
在本发明的实施例中，当采用柔性加热膜500对转动轴2进行加热膨胀时，虽然柔性加热膜500紧紧包覆在转动轴2的整个表面上，能够对转动轴2进行快速有效的加热，但是，由于转动轴2为大尺度、非等厚变截面圆筒结构，在大端法兰203和中法兰204的位置，径向厚度增大，热量传递到筒体厚度的深层处的速度较慢，因此，当转动轴2的内表面由于受热而膨胀时，转动轴2的位于法兰根部的外侧筒体部分由于受热较慢而膨胀速度慢于内侧筒体部分的膨胀速度，从而会对内侧筒体部分的膨胀造成束缚，使得内侧筒体部分受到外侧筒体施加的压应力。
图17示出了转动轴2的大端法兰处的局部截面示意图。如图17所示，对于大端法兰203的根部位置的筒体部分，当径向内侧受热膨胀而径向外侧由于受热较慢而不能率先膨胀的情况下，膨胀较慢的位置会对内侧筒体部分 的向外膨胀施加压应力(如图中箭头210所示)，对该处筒体的膨胀形成束缚，阻碍筒体的胀大，使得法兰处的筒体的膨胀速度与其他位置的筒体的膨胀速度不一致，造成转动轴筒体的扭曲变形。因此，要想让整个筒体均匀一致的膨胀，需要解除这个束缚对法兰根部筒体膨胀造成的障碍。
本发明的实施例提出，通过对法兰进行加热，使法兰受热“率先”膨胀，为法兰根部筒体的膨胀“让路”，解除对法兰处筒体的膨胀造成的限制和束缚。
根据本发明的实施例，在大端法兰203和中法兰204中设置电磁感应加热器，使法兰在通过柔性加热膜500受热的同时，还通过电磁涡流感应产热而吸收热量。具体地，本发明的实施例利用了电磁感应加热的集肤效应，在法兰的螺栓孔设置感应加热器710。图18示意性示出了感应加热器710设置在大端法兰203的螺栓孔中的示意图。利用集肤效应，感应加热器710对法兰的螺栓孔加热，热量从螺栓孔的孔壁沿着厚度方向传递，使得法兰在外表面、上表面和下表面三个表面通过柔性加热膜500而受热的同时，还从螺栓孔的孔壁处受热，从而使得法兰本体先于法兰根部的筒体受热膨胀，撤离外法兰对根部圆筒的压应力。
优选地，由于法兰盘位于螺栓孔内侧的部分的径向厚度较大，感应加热器710可以设置为相对于螺栓孔的轴线偏心设置，在螺栓孔中更靠近法兰根部。如图18所示，感应加热器710更靠近螺栓孔内侧壁面设置，由于临近效应，螺栓孔内侧壁的感应电流的穿透深度更大，从而更容易向内侧的法兰根部传递热量。对于大端法兰203而言，柔性加热膜500不仅包覆在法兰径向外表面上，还紧紧包覆在法兰轴向的上表面和下表面上，使得法兰三个外表面同时受热(如图中箭头230、240、250所示)，避免端部受热不足而导致的端部效应，防止法兰面径向膨胀较多而导致的法兰扭曲。
如图15所示，设置在大端法兰203或中法兰204中的各个感应加热器710可以相互并联连接。如图16所示，设置在大端法兰203或中法兰204中的各个感应加热器710也可以相互串联连接。通过相互并联或串联，使得各个感应加热器710中的流过的电流大小相同，从而提高法兰受热的均匀度。感应加热电源730可以通过电磁线720对感应加热器710施加交流电。感应加热电源730可以采用工频感应加热电源。可以通过施加的感应电流的频率来控制电流穿透深度层的厚度，从而控制加热速度。
对于法兰部的筒体而言，通过电阻加热以及感应加热，使得抽真空系统、 电加热系统、感应加热系统三大系统协同作用于法兰处，使得外法兰率先受热膨胀，为法兰根部筒体的受热膨胀撤离压应力(膨胀阻力)，解除了大端法兰对转动轴的后轴承安装表面的膨胀束缚，抑制了筒体受热不均膨胀速度不均导致的筒体扭曲变形，从而解决变径、非等截面筒体的加热膨胀问题。
此外，为了避免在对转动轴加热过程中热量向周围环境散热，还可在将柔性加热膜500包覆在转动轴2上之后，在柔性加热膜500的外表面上覆盖一层绝热保温材料。
下面，详细描述利用根据本发明实施例的加热装置加热转动轴的方法。
首先，将柔性加热膜500包覆在转动轴2的整个表面上，将第一温度传感器540、第二温度传感器550和压电传感器560布置在待检测位置，并布置抽真空系统600的吸气管路。根据本发明的实施例，第二温度传感器550和压力传感器560可埋设在柔性加热膜500中。在柔性加热膜500的封口处，可用真空密封胶进行粘接封口和密封。
第一温度传感器540、第二温度传感器550和压力传感器560可以均匀布置在整个包覆表面上，以检测每一个位置处的压力和温度。然而，为了减少压力传感器和温度传感器的数量，可选择性地在特定位置布置第一温度传感器540、第二温度传感器550和压力传感器560。例如，压力传感器560可主要布置在柔性加热膜500的封口位置或封口附近以及变径位置，例如，布置在法兰根部，凸台与筒体的连接处等。这是因为，在筒体厚度突变的位置，柔性加热膜500容易与转动轴贴合不紧，在柔性加热膜500的封口位置容易出现气体泄漏，从而导致真空度不符合要求。如果通过压力传感器560判断柔性加热膜500在这些位置已经紧紧贴合在转动轴2上，则通常情况下，可以判断柔性加热膜500在其他位置也已经和转动轴2紧紧贴合。
根据本发明的实施例，还在转动轴2上布置感应加热单元700。在柔性加热膜500已经包覆在转动轴2的外表面上的情况下，通过在螺栓孔对应的位置将柔性加热膜500局部开口，然后将多个感应加热器710放置在螺栓孔中，并利用电磁线720将多个感应加热器串联或并联，然后利用真空密封胶将开口封闭。然而，也可以先布置多个感应加热器710，并利用电磁线720将多个感应加热器710串联或并联后，通过引出线从柔性加热膜500的某一位置开口处与感应加热电源730连接。
在布置感应加热器710时，将感应加热器710相对于螺栓孔的中心偏心 设置，使感应加热器710更靠近法兰根部。
上述布置柔性加热膜500、抽真空系统600以及感应加热单元700的顺序不是特定的或唯一的，也可以先布置感应加热单元700，再布置柔性加热膜500和抽真空系统600，还可以先布置柔性加热膜500和感应加热单元700之后，再布置抽真空系统600。
在布置好柔性加热膜500、抽真空系统600以及感应加热单元700之后，利用抽真空系统600对柔性加热膜500的内部抽真空。控制单元800根据压电传感器560的感测值来判断柔性加热膜500是否已经仅仅贴合在转动轴2的表面上。
当完成抽真空操作后，可以启动柔性加热膜500和感应加热单元700执行加热操作。
假如以筒体厚度的质心为界将筒体分为外侧筒体部分和内侧筒体部分，在转动轴2的筒体受热膨胀的过程中，如果内侧筒体部分的膨胀速度大于外侧筒体部分的膨胀速度，那么外侧筒体部分会对内侧筒体部分产生压应力，对内侧筒体部分向外膨胀产生束缚，结果通常导致筒体两端向外侧扭曲而形成喇叭口状。因此，要想解除这种束缚，需要是外侧筒体部分率先膨胀。然而，另一方面，如果内侧筒体部分膨胀速度慢于外侧筒体部分的膨胀速度，那么内侧筒体部分也会对外侧筒体部分的膨胀产生拉应力，约束外侧筒体部分的膨胀。因此，根据本发明的实施例，控制柔性加热膜500和感应加热单元700的一个总体构思是，在筒体的径向方向上，控制从筒体内侧表面向外传热的速度以及从筒体外侧表面向内传热的速度，使得质心处由于从筒体外侧吸热而达到设定温度所需的时间，等于或稍微大于质心处从筒体内侧吸热而达到同样温度所需的时间。根据这一原则，可以计算出筒体各个位置处的加热所需的热量和达到设定温度所需的时间，从而可以据此控制柔性加热膜500和感应加热单元700的加热功率或加热温度以及加热时间。
柔性加热膜500紧密贴合在转动轴2的表面上，与转动轴2的表面之间没有空气热阻，因此，柔性加热膜500在通电后迅速升温并与转动轴2之间进行直接热传导。由于柔性加热膜500的外部还包覆有绝热材料，因此，柔性加热膜500产生的热量几乎无损失地传递给转动轴2。根据转动轴2的质量、密度、导热系数和比热容，可以确定在转动轴受热达到要求的温度时所述需要吸收的热量以及需要的加热时间等。
根据本发明的实施例，可以先对转动轴2实施恒定功率加热达设定壁温后再实施恒定壁温加热。因此，可以根据采取的加热方式确定电热元的加热功率。电热元件是柔性加热膜500的发热元件，在选用电热元件前，可以根据确定的功率、供电电压来确定电热元件的材料及其连接方式。选择电热元件材料应满足要求：具有高的电阻率、小的电阻温度系数、足够的耐热性与高温强度、热膨胀系数小。
以实施全功率加热达到80℃壁温后实施恒壁温加热为例，在确定的恒定加热功率下，可以计算出壁温达到80℃所需要的加热时间，根据这个时间可以计算出转动轴2的壁厚质心位置在此时刻的温度。随后对转动轴2再实施恒壁温加热，转动轴2壁厚中部温度的上升速率由转动轴2的材料的导热系数、密度和比热容构成的热扩散速率确定。可使用《传热学》、《传热学手册》中的海斯勒图或近似拟合公式确定转动轴的整个加热时间。
对于转动轴2的筒体厚度变化的位置(即，筒节位置处)，例如，在小径端202的内表面以及大径端201的内表面上形成有用于支撑前轴承和后轴承的凸台。在该位置，柔性加热膜500的电热元件的加热功率或加热温度可以相对高一些，例如，在法兰处的筒体内表面，柔性加热膜500中的加热元件的加热温度可以比其他位置的加热温度高一些，例如，高10℃，从而使得不同厚度的位置处的质心温度上升速率尽可能一致，从而减小筒体的扭曲变形，消弱由于温度差异导致的应力。对于设置有外法兰的位置处，由于在螺栓孔中设置感应加热器710，此处的筒体通过感应加热和电热阻加热两种方式同时受热。对于位于螺栓孔中的感应加热器710，当感应加热的频率不同时，在螺栓孔内壁上感应的电磁加热深度也相应不同，因此，可以通过控制感应加热的频率来控制感应加热产生的热量以及加热功率的大小。为了使得各个螺栓孔处均匀受热，同步膨胀，可以将各个感应加热器710串联或并联，以通过相同的电流或相同的频率进行感应加热。此外，在位于螺栓孔内侧的部分较厚的情况下，可以将各个感应加热器710在螺栓孔中更靠近法兰根部放置。
根据本发明的实施例，每两个相邻的螺栓孔中都设置有感应加热器710，当螺栓孔内壁受热时，热量会从螺栓孔内壁以辐射状向周围进行热传导。因此，对于法兰的位于两个相邻螺栓孔之间的部分，会同时从两个螺栓孔处吸收热量，从而该部分从热源获得热量的热传导路径变短。同时，对于法兰根 部的筒体，由于热量直接从螺栓孔的内壁直接向法兰根据传热，与现有技术的感应加热方式相比，该部分从热源获得热量的热传导路径缩短，从而法兰根部达到同样温度所需的时间变短。
因此，根据本发明的实施例，虽然法兰处的筒体较厚，但是，由于设置的感应加热器710协同柔性加热膜500一起加热，对于筒体的各个部分，能够实现厚度较大的位置处的质心温度上升速度与厚度较小位置处的质心温度上升速度尽可能一致，并且优选地使得外侧筒体率先膨胀，解除对内侧筒体膨胀造成的束缚。在加热过程中，可通过第一温度传感器540监测转动轴2的温度。同时，可以根据抽真空系统600本身的压力表值、压电传感器560的感测值、柔性加热膜500的加热温度、柔性加热膜500的加热温度与转动轴2的温度差中的至少一种来判断柔性加热膜500与转动轴2的贴合程度。例如，如果压电传感器560的读数降低预定值，则可以判断为该处的柔性加热膜500可能存在破损泄露；如果柔性加热膜500的某处的温度急剧上升，可以判断为此处与转动轴2的贴合不够紧密导致热阻上升而不能很快地将热量传递给转动轴2；同样的，如果柔性加热膜500与转动轴2的表面之间温差大于预定数值，也可以判断为此处贴合不紧。因此，可以检查相应位置处的柔性加热膜500并进行密封处理，相应地启动抽真空系统600操作。根据本发明的实施例，在将转动轴2加热膨胀到预定膨胀量之后，将转动轴2吊到定子主轴1上方，在定子主轴1上，已经将整个后轴承30热套于定子主轴1的后轴承安装面上。当转动轴2下落时，转动轴2的大径端201套装到后轴承30的轴承外圈的外周。
根据本发明的轴系装配方法，由于后轴承外圈通常由不锈钢等硬度较高的材料制成，且具有相当的厚度，即使在转动轴2下落时大径端201与后轴承30的轴承外圈碰撞，也不会对轴承外圈造成严重损伤，由此能够避免对保持架以及滚动体造成破坏。此外，可以通过在大径端201上安装导向条，使转动轴2的大径端201与后轴承30的轴承外圈对准，避免两者发生碰撞。通常情况下，后轴承30的轴承外圈的边缘上设置有倒角，能够引导转动轴2的大径端与后轴承30的装配，即使在对准不那么精确的情况下，也能通过倒角引导两者的配合，避免将转动轴2反复吊起下落。
在将转动轴2套装套定子主轴1上之后，可以将前轴承40的轴承内圈以及保持架加热后套装在定子主轴的小端上，然后将前轴承40的轴承外圈安装 于转动轴2的前轴承安装表面上，从而完成整个轴系的装配。
在实践中，对于重达几吨的转动轴2而言，加热膨胀后的转动轴2在常温下冷却恢复到原始状态的时间通常需要12-15小时，因此，在将转动轴2套装到定子主轴1上之后，有足够的操作时间在转动轴2保持膨胀并且满足装配过盈量的状态下将前轴承40安装于转动轴2的小径端202与定子主轴1的小端之间。因此，与现有技术中将前轴承外圈冷装于转动轴2的小径端的轴承安装面的方式相比，避免了冷凝水凝结在轴承外圈上导致的装配面生锈腐蚀以及润滑油脂变质失效。
同样地，对于安装于转动轴2的大径端201的后轴承30，在转动轴2热膨胀的状态下套装到后轴承30上，而不是如现有技术中那样将后轴承30冷装于转动轴2的大端，避免了冷凝水凝结在轴承装配面上，同时避免了水汽进入润滑油脂而导致润滑油脂变质失效。
根据本发明实施例的加热装置，通过设置抽真空系统、电热系统、感应加热系统，采用复合物理场协同作用于筒体控制筒体膨胀。通过设置感应加热单元，有利地利用感应加热的集肤效应和临近效应，有效地保证转动轴外法兰相对于法兰根部筒体受热“率先”膨胀，对法兰根部筒体的膨胀“让路”，“解除”对法兰根部筒体膨胀造成的约束，避免筒体扭曲变形，保证了轴系装配质量。
本发明的实施例摒弃了传统工业中采用油浴法加热这种大尺度、大重量、非等截面的转动轴的方案，避免了加热油带来的环境污染、产品污染等、后续加热油处理带来的成本问题，避免了油浴法对轴承、转动轴等部件的防护油造成损坏，因此，更加绿色环保、节能减排、安全可靠，符合可持续发展的理念。
本发明的实施例摒弃了传统工业中采用电磁感应加热法加热这种大尺度、大重量、非等截面的转动轴的方案，避免了电磁感应加热法的集肤效应和临近效应带来的温度分布不均、膨胀不均匀导致筒体扭曲变形等问题。
本发明的实施例还摒弃了传统工业中采用大型加热炉对这种大尺度部件进行加热的方式，因此，减少了炉体预热消耗的能量，减少了离心风机运转消耗的电能；不需要反复吊装炉盖和转动轴，减少吊装行车的使用次数，节省了工序和由此消耗的电能，提高了工作效率；此外，传统的大型加热炉需要占用较大的厂房面积和操作空间，往往需要建造20多米高的厂房，并需要 安装相应高度的吊装行车，建设成本非常高，然而，应用本发明实施例的加热装置和加热方法时，不需要占用很大的厂房面积和操作空间，为企业节省了建设成本；采用本发明的技术方案时，不需要使用离心风机，避免了离心风机运转导致的噪声，减少了行车移动造成的噪声，减少了噪声污染；更重要的是，工人可以在地面上进行操作，不需要像采用传统加热炉那样需要爬到几米高的炉顶上，减少了高空作业带来的安全隐患。
总之，根据本发明实施例的加热装置、加热方法以及轴系装配方法，在节能环保、减少厂房占用面积，减少装备制造成本的同时，利用抽真空系统、电加热系统、感应加热系统三大系统协同作用，解决了大型电机的大尺度非等截面非等厚铸件的加热问题以及装配问题，避免了加热炉对流换热主流流速受制于流通面积大和驱动风机能耗限制导致的换热速率低的问题，解决了电磁感应涡流加热产生的非对称膨胀、非对称变形造成安装困难以及安装应力成为运行诱发振动质量不平衡的问题，提高轴系装配质量，保证了风力发电机组的安全运行、提高了机组使用寿命。
虽然已经参照附图以加热转动轴为例详细描述了本发明的示例性实施例，但是本发明的加热装置和加热方法并不限于所述实施例，本发明的加热装置可以用于加热各种具有不规则形状、非等截面、非等厚度的待加热部件，例如，可以用于加热具有本体部和凸起部的待加热部件、具有筒体和外法兰的待加热部件等等。显然，本发明的加热装置和加热方法也适于加热具有规则形状的待加热部件。
因此，本发明的保护范围不受限于上述实施例，本领域技术人员可以根据本发明的精神和原理对本发明的技术方案进行各种修改和变型。

Claims (20)

  1. 一种用于加热待加热部件的加热装置，其特征在于，所述加热装置包括：
    柔性加热膜(500)，埋设有柔性电热元件，用于包覆在所述待加热部件的表面上，以对所述待加热部件进行加热；
    抽真空系统(600)，用于在所述柔性加热膜(500)密封地包覆在所述待加热部件的表面上的情况下，对所述柔性加热膜(500)的内部抽真空，使所述柔性加热膜(500)紧密贴附在所述待加热部件的表面上；
    控制单元(800)，控制所述柔性加热膜(500)的加热操作以及所述抽真空系统(600)的操作。
  2. 如权利要求1所述的加热装置，其特征在于，所述加热装置还包括压电传感器(560)，所述压电传感器(560)埋设在所述柔性加热膜(500)中，或者贴附在所述柔性加热膜(500)的内表面与所述待加热部件的表面之间，所述控制单元(800)根据所述压电传感器(560)的感测值控制所述抽真空系统(600)和/或判断所述柔性加热膜(500)的泄露位置。
  3. 如权利要求2所述的加热装置，其特征在于，所述加热装置还包括第一温度传感器(540)和第二温度传感器(550)，所述第一温度触感器(540)用于感测待加热部件的温度，所述第二温度传感器(550)用于感测所述柔性加热膜(500)的加热温度，所述控制单元(800)被构造为：
    根据所述第一温度传感器(540)和所述第二温度传感器(550)的感测值，控制所述柔性加热膜(500)的加热操作，和/或
    根据所述压电传感器(560)的感测值、所述第二温度传感器(550)的感测值、所述第一温度传感器(540)的感测值与所述第二温度传感器(550)的感测值之间的差值中的至少一种来控制抽真空系统(600)的操作或判断所述柔性加热膜(500)是否存在泄露。
  4. 如权利要求3所述的加热装置，其特征在于，所述柔性加热膜(500)为袋状或片状，并具有封口边缘，所述压电传感器(560)布置在所述封口边缘的周围。
  5. 如权利要求3所述的加热装置，其特征在于，所述待加热部件为筒状结构并具有筒体，所述柔性加热膜(500)包括包覆所述筒体的外侧表面的第 一加热膜(510)以及包覆所述筒体的内侧表面的第二加热膜(520)，所述压电传感器(560)布置在所述第一加热膜(510)和所述第二加热膜(520)的对接处周围。
  6. 如权利要求3所述的加热装置，其特征在于，所述待加热部件包括本体部和从所述本体部凸出的凸出部，所述凸出部中设置有安装孔，所述加热装置还包括感应加热单元(700)，所述感应加热单元(700)包括感应加热器(710)，所述感应加热器(710)用于布置在所述安装孔中。
  7. 如权利要求6所述的加热装置，其特征在于，所述压电传感器(560)布置在所述凸出部与所述本体部连接的位置处。
  8. 如权利要求1-4中任一项所述的加热装置，其特征在于，所述待加热部件包括筒体以及设置在所述筒体上的外法兰(203、204)，所述外法兰(203、204)具有多个螺栓孔，所述加热装置还包括感应加热单元(700)，所述感应加热单元(700)包括多个感应加热器(710)，所述多个感应加热器(710)用于分别设置在所述多个螺栓孔中。
  9. 如权利要求8所述的加热装置，其特征在于，所述感应加热器(710)在所述螺栓孔中设置为更靠近所述筒体，所述感应加热器(710)利用电磁感应的集肤效应，或者电磁感应的集肤效应和临近效应对所述外法兰(203、204)进行加热，通过所述外法兰(203、204)向所述筒体导热，使所外法兰(203、204)先于所述筒体膨胀，解除所述外法兰(203、204)对所述筒体膨胀时施加的压应力。
  10. 如权利要求8所述的加热装置，其特征在于，所述感应加热单元(700)还包括连接所述多个感应加热器(710)的电磁线(720)以及感应加热电源(730)，所述多个感应加热器(710)通过所述电磁线(720)相互串联或并联。
  11. 如权利要求8中所述的加热装置，其特征在于，所述待加热部件为风力发电机的转动轴(2)。
  12. 如权利要求8所述的加热装置，其特征在于，所述控制单元(800))被构造为执行如下操作中的至少一个：
    在对所述待加热部件加热的过程中，首先使柔性加热膜(500)以恒定功率对待加热部件进行加热，在所述待加热部件的壁温达到预定值后，以恒壁温方式对所述待加热部件进行加热；
    在所述感应加热器(710)布置在所述螺栓孔中的情况下，控制所述感应加热器(710)以及所述柔性加热膜(500)协同对所述待加热部件进行加热；
    在协同加热过程中，控制所述柔性加热膜(500)的加热温度或加热功率、所述感应加热器(710)的感应频率，使得在所述筒体的径向厚度的质心位置，从所述筒体的外侧表面吸收热量而达到设定温度的速度，稍大于或等于从所述筒体的内侧表面吸收热量而达到同样的设定温度的速度。
  13. 一种用于加热待加热部件的方法，其特征在于，所述方法包括如下步骤：
    用柔性加热膜(500)包覆所述待加热部件的表面，所述柔性加热膜(500)中埋设有柔性电热元件；
    将所述柔性加热膜(500)密封并利用抽真空系统(600)对柔性加热膜(500)的内部抽真空，使所述柔性加热膜(500)紧密贴附在所述待加热部件的表面上；
    利用所述柔性加热膜(500)对所述待加热部件进行加热。
  14. 如权利要求13所述的方法，其特征在于，所述柔性加热膜(500)中埋设有压电传感器(560)，或者在所述柔性加热膜(500)与所述待加热部件之间设置有压电传感器(560)，所述方法还包括如下步骤：根据所述压电传感器(560)的感测值，对所述柔性加热膜(500)的内部抽真空和/或检查所述柔性加热膜(500)的泄露位置。
  15. 如权利要求14所述的方法，其特征在于，在所述待加热部件的表面上设置有第一温度传感器(540)，在所述柔性加热膜(500)中埋设有第二温度传感器(550)，所述第一温度触感器(540)用于感测所述待加热部件的壁温，所述第二温度传感器(560)用于感测所述柔性加热膜(500)的加热温度，所述方法还包括：在对所述待加热部件进行加热的过程中，
    根据所述第一温度传感器(540)和所述第二温度传感器(550)的感测值控制所述柔性加热膜(500)的加热操作；
    根据所述压电传感器(560)的感测值、所述第二温度传感器(550)的感测值、所述第一温度传感器(540)的感测值与所述第二温度传感器(550)的感测值之间的差值中的至少一种来控制所述抽真空系统(600)的操作或判断所述柔性加热膜(500)是否存在泄露。
  16. 如权利要求13-15中任一项权利要求所述的方法，其特征在于，所 述待加热部件包括本体部和从所述本体部凸出的凸出部，所述凸出部中设置有安装孔，所述方法还包括：在所述安装孔中布置感应加热器(710)并利用所述感应加热器(710)以及所述柔性加热膜(500)对所述待加热部件进行协同加热。
  17. 如权利要求16所述的方法，其特征在于，所述本体部为筒体，所述凸出部为设置在所述筒体上的外法兰(203、204)，安装孔为设置在所述外法兰(203、204)上的多个螺栓孔，所述方法还包括如下步骤中的至少一个：
    将所述感应加热器(710)在所述安装孔中偏心布置为更靠近所述本体部；
    在对所述待加热部件加热的过程中，首先使柔性加热膜(500)以恒定功率对待加热部件进行加热，在所述待加热部件的壁温达到预定值后，以恒壁温方式对所述待加热部件进行加热；
    在对所述待加热部件协同加热的过程中，利用包覆在所述外法兰(203、204)的径向外表面、轴向上表面和轴向下表面的所述柔性加热膜(500)以及设置在螺栓孔中的所述感应加热器(710)对所述待加热部件进行协同加热；
    所述感应加热器(710)利用电磁感应的集肤效应和临近效应对所述外法兰(203、204)进行加热，通过所述外法兰(203、204)向所述筒体导热，使所外法兰(203、204)先于所述筒体膨胀，解除所述外法兰(203、204)对所述筒体膨胀施加的压应力。
  18. 一种用于风力发电机的轴系装配方法，所述轴系包括定子主轴(1)、转动轴(2)、后轴承(30)和前轴承(40)，其特征在于，所述方法包括：
    在所述转动轴(2)的整个表面上包覆柔性加热膜(500)，
    在所述转动轴(2)的外法兰(203、204)的多个螺栓孔中布置多个感应加热器(710)；
    将所述柔性加热膜(500)密封，并对所述柔性加热膜(500)内部抽真空；
    利用所述柔性加热膜(500)和所述感应加热器(710)对转动轴(2)进行加热。
  19. 如权利要求18所述的轴系装配方法，其在特征在于，所述方法还包括：将加热膨胀后的所述转动轴(2)套装到已经套装了所述后轴承(30)的所述定子主轴(1)上，使所述转动轴(2)的后端装配到所述后轴承(30)的轴承外圈上。
  20. 如权利要求19所述的轴系装配方法，其特征在于，所述方法还包括：
    在所述转动轴(2)处于膨胀并且满足装配过盈量的状态下，将所述前轴承(40)装配到所述转动轴(2)的前端与所述定子主轴(1)的前端之间。
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