WO2021234188A1 - Procédé et système de forge pour un axe principal d'aérogénérateur - Google Patents

Procédé et système de forge pour un axe principal d'aérogénérateur Download PDF

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Publication number
WO2021234188A1
WO2021234188A1 PCT/ES2020/070333 ES2020070333W WO2021234188A1 WO 2021234188 A1 WO2021234188 A1 WO 2021234188A1 ES 2020070333 W ES2020070333 W ES 2020070333W WO 2021234188 A1 WO2021234188 A1 WO 2021234188A1
Authority
WO
WIPO (PCT)
Prior art keywords
forging
upsetter
piece
die
main shaft
Prior art date
Application number
PCT/ES2020/070333
Other languages
English (en)
Spanish (es)
Inventor
Eugenio ARRIZABALAGA
Original Assignee
Lekunberri De Corte, S.L.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Lekunberri De Corte, S.L. filed Critical Lekunberri De Corte, S.L.
Priority to PCT/ES2020/070333 priority Critical patent/WO2021234188A1/fr
Publication of WO2021234188A1 publication Critical patent/WO2021234188A1/fr

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K1/00—Making machine elements
    • B21K1/06—Making machine elements axles or shafts
    • B21K1/063—Making machine elements axles or shafts hollow
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C23/00—Extruding metal; Impact extrusion
    • B21C23/02—Making uncoated products
    • B21C23/20—Making uncoated products by backward extrusion
    • B21C23/205—Making products of generally elongated shape
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J13/00—Details of machines for forging, pressing, or hammering
    • B21J13/02—Dies or mountings therefor
    • B21J13/03—Die mountings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
    • B21J5/06—Methods for forging, hammering, or pressing; Special equipment or accessories therefor for performing particular operations
    • B21J5/08—Upsetting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
    • B21J5/06—Methods for forging, hammering, or pressing; Special equipment or accessories therefor for performing particular operations
    • B21J5/10—Piercing billets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J9/00—Forging presses
    • B21J9/02—Special design or construction
    • B21J9/04—Piercing presses
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J9/00—Forging presses
    • B21J9/02—Special design or construction
    • B21J9/06—Swaging presses; Upsetting presses
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K23/00—Making other articles
    • B21K23/04—Making other articles flanged articles

Definitions

  • the present invention is directed to a method and a system for forging a main shaft of a wind turbine, and more specifically to a method that makes it possible to manufacture the main shaft of a wind turbine by means of a reverse extrusion process and the specific tooling used. in the forging process.
  • renewable energy sector is currently one of those that arouses the greatest interest in society and has become one of the areas of technology with greater technical development and future projection.
  • wind energy has developed with particular intensity in recent years thanks to its excellent performance and versatility.
  • wind turbines installed in wind power parks have three blades mounted on a rotor that transmits the power generated in the form of torque to an electric generator through a main shaft or main transmission shaft.
  • the main transmission shaft is not only subjected to torsional loads due to the torque it transmits, it is also subjected to bending loads produced by the structural function of the main shaft, resulting in a state of combined bending and torsion loads. .
  • the inner part around the neutral fiber of the shaft does not contribute to supporting the loads, so it can be removed from the part without the resulting hollow main shaft losing performance with respect to a solid shaft.
  • Hollow main shafts are used in certain applications in other technical fields, where the shafts are comparatively smaller than main shafts for wind turbines, and are generally made by turning or boring the inside of the main shaft.
  • the present invention proposes a solution to the above problems by means of a forging method and a forging system for forging the main shaft of a wind turbine as defined in the independent claims.
  • the invention provides a forging method for forging a hollow wind turbine main shaft by means of a forging system from a cylindrical part with an upper end and a lower end, wherein the forging method comprises the steps of: introducing the piece into a cylindrical die of the forging system with the longitudinal axis of the piece arranged substantially vertically; substantially aligning the longitudinal axis of the piece with the longitudinal axis of the die by means of a centering device of the forging system; forming a cavity in the upper end of the piece by means of an upsetter of the forging system; extrude the part by applying pressure to the bottom of the cavity by means of an extrusion punch of the forging system.
  • the present forging method allows the manufacture of a large hollow main shaft for a wind turbine without loss of material or with minimal loss of material, resulting in a light and strong main shaft that for a given value of resistance requires less material than other known main shafts.
  • the lightness of the main shaft is especially advantageous for installing the wind turbine transmission in a nacelle arranged at a high height, which can also reduce the stress on the wind turbine tower and the work required to raise the main shaft compared to the work needed to lift a heavier mainshaft.
  • the manufacture of the main shaft requires much less material, and produces less waste, such as chips, which cannot be used and increases the final cost of manufacture.
  • main shaft hollow main shaft, transmission shaft or simply shaft
  • This substantially elongated element in addition to transmitting the torque of the rotor, which produces torsional loads, also has a structural function, for which reason it is also subjected to bending stresses.
  • the main axes which are physical elements for transmitting power in a wind turbine, should not be confused with the longitudinal axes, which are referred to in other parts of this document, and which refer to the longitudinal geometric axes of certain elements, as for example, the longitudinal axis of a cylindrical matrix.
  • the main axis of the wind turbine is obtained from the part obtained by means of the forging method from a cylindrical part, preferably a cylindrical bar;
  • the part undergoes a transformation from its initial state as a blank, for example in the form of a cylindrical bar, to the state of a final part, to which additional transformations can be applied, for example treatments thermal, to obtain the main axis of the wind turbine;
  • the condition of a cylindrical part should not be interpreted strictly, but rather as an elongated shape with an approximately circular section, although in other embodiments it may also have a polygonal section.
  • the material of the part is preferably a metal or a metallic alloy, with steel being especially preferable.
  • the piece Due to the configuration or elongated shape of the piece, it has two ends, which when arranged vertically, are called the upper end and the lower end; the longitudinal axis passes through both ends, preferably through the geometric axis of symmetry of the piece. With this vertical orientation, the part is inserted into a die with an open upper part, a closed lower part and between them a carved cylindrical hole that approximately reproduces the desired shape of the main axis in negative. Vertical orientation should be understood as the direction perpendicular to the horizontal plane or ground plane.
  • the claimed forging method comprises a reverse extrusion step, which requires applying pressure by means of an extrusion punch to achieve an elongation of the piece in the direction of its longitudinal axis. For this reason, it is necessary to correctly align the longitudinal axis of the piece with the longitudinal axis of the cylindrical die; This is achieved by moving the part until the longitudinal axes of the part and the die coincide by means of a centering element, whose function is to push the part up to the longitudinal axis of the die and once there serve as support for the part;
  • This centering element in a particular embodiment is shaped like a fork and moves between a position of alignment and a retracted position.
  • the centering device is moved to the alignment position by pushing the part into the correct position by means of the fork.
  • an upsetter forms a cavity by applying pressure to the upper end of the part; for this, the upsetter comprises a point or protrusion that is nailed on the upper end of the piece.
  • the cavity formed does not have to be too deep, since its function is to serve as a guide for the extrusion punch.
  • the tip of the extrusion punch is inserted into the cavity of the part and pressure is applied in the longitudinal direction of the part; Under pressure, the material of the part cannot move or expand through the lower part of the die gap and is plastically deformed in the only place where the movement is not blocked, that is, by the open upper part of the die, so that the elongation of the piece occurs in the longitudinal direction.
  • the method further comprises the step of: forming a flange at the upper end of the piece by pressing the upper end of the piece by means of a crushing hammer of the forging system.
  • the matrix comprises a perimeter recess in its upper part that allows a greater expansion of the material, advantageously with the desired shape of the flange; the upper end of the piece is pressed by means of a crushing hammer, a tool that allows the pressure to be distributed on the desired surface; thus, when pressing the upper end of the piece, this part is plastically deformed and expands towards the only available place, that is, the space that remains in the perimeter recess of the die.
  • the method further comprises the step of: upsetting the flange by pressing the upper end of the piece by means of the upsetting.
  • this operation is carried out by means of the upsetter, which for this purpose comprises a surface of revolution with the desired profile. In this way it is possible to carry out with the same tool both the operation of terminating the flange formation such as cavity formation.
  • the method further comprises the step of: compressing the lower end of the piece against the die by means of a crushing hammer of the forging system.
  • the elongated shape of the part is particularly unstable when it is arranged vertically, so there is a risk that once the longitudinal axis of the part is aligned with the longitudinal axis of the die, the part will move and lose the correct position. .
  • forging operations prevent the centering device from staying in contact with the part, so to ensure that the part is held in position, the lower end of the part is slightly flattened against the bottom of the die, to achieve its deformation and immobilize the part temporarily.
  • the method further comprises the step of: removing the crushing mallet.
  • removing a tool for example the crushing hammer
  • the upsetter and / or the extrusion punch removing the tool is equivalent to separating it from the press
  • the centering device simply separate it from the area to prevent it from being damaged or preventing the forging operation
  • introducing a tool should be understood as the opposite process, that is, assembling it so that it can perform its function.
  • the crushing hammer is specially configured to apply pressure on a wide surface, but it is not used to carry out the upsetting or extrusion steps; For this reason, it is advisable to remove the crushing hammer before using another tool.
  • the method further comprises the step of: removing the centering device.
  • the forging operations do not allow the centering device to be in contact with the part in its alignment position, so it is advantageous to remove the centering device to its retracted position.
  • the method further comprises the steps of: introducing the upsetter; remove the upsetter.
  • the upsetter is another tool that must be inserted or removed from the work area depending on the stage of the process that is being executed.
  • the method further comprises the steps of: inserting the extrusion punch; remove the extrusion punch.
  • the cavity is formed by means of at least one rotary movement of the upsetter.
  • the main axis of the wind turbine is a mechanical element that in operation is in rotation, so for reasons of balance and limitation of vibrations it is convenient that it have a geometry of revolution along its longitudinal axis.
  • the invention provides a forging system for forging a wind turbine main shaft by means of a forging method according to any of the preceding claims from a cylindrical part, wherein the system comprises: a cylindrical die; a centering device configured to align the longitudinal axis of the part with the longitudinal axis of the die; an upsetter configured at least to form a cavity at the upper end of the part; an extrusion punch configured to extrude the part.
  • the forging system comprises a cylindrical die closed at the bottom and open at the top, forming a cylindrical hollow carved that reproduces approximately the shape of the main axis, and a plurality of tools that are used to exert pressure on the part, or in the case of the centering device to move the part. Both the tools and the matrix can be rigidly attached to a frame or structure or they can be mobile and interchangeable depending on the characteristics of each main shaft to be manufactured.
  • the forging system comprises elements of an existing forging device.
  • one or more elements of the forging system are obtained by adapting already existing elements.
  • the system enables the steps of the described method to be completed quickly and efficiently.
  • the system also comprises a crushing hammer configured to form a flange on the part.
  • the crushing hammer is a tool that is used in the forging system to carry out the operations described above.
  • the crushing hammer has a pressure surface substantially larger than the cross section of the part before it is subjected to the forging method.
  • the crushing hammer has a substantially blunt surface and with a surface comparable to that of the part flange.
  • the system also comprises a hydraulic press configured to apply pressure to any of: the crushing hammer, the upsetter, the extrusion punch.
  • a hydraulic press configured to apply pressure to any of: the crushing hammer, the upsetter, the extrusion punch.
  • the compression work of any of the tools is carried out by means of a hydraulic press that acts on the tools.
  • the extrusion punch has freedom of movement in the horizontal plane.
  • the freedom of movement of the extrusion punch allows its position to be precisely aligned with respect to the axis of the part. In this way, an inhomogeneous distribution of material in the extrusion stage can be avoided, which can potentially generate fractures in the part.
  • the upsetter is rotatable.
  • the rotary movement makes it possible to form a geometry of revolution in the flange of the part. Even more advantageously, the rotary movement facilitates the formation of the cavity.
  • the system also comprises a system for guiding the rotary upsetter.
  • the guiding system makes it possible to maintain the alignment of the upsetter with respect to the longitudinal axis of the part and / or the die. In this way, despite the movement of the rotary upsetter, it is possible to make the cavity with great precision.
  • Figure 1 This figure shows the stage of aligning the part.
  • Figure 2 This figure shows the stage of compressing the lower end of the part.
  • Figures 3a-3b These figures show the stage of forming the flange and removing the crushing hammer.
  • Figures 4a-4c These figures show the steps of inserting the upsetter, forming the cavity and upsetting the flange, and removing the upsetter.
  • FIGS 5a-5b These figures show the steps of inserting the extrusion punch and extruding the part.
  • the forging system (10) comprises a die (1), a hydraulic press (4) and a plurality of tools.
  • the hydraulic press (4) is a Ryazan press capable of applying an equivalent pressure of up to thirteen thousand tons, and the tools include a crushing hammer (3), an upsetting tool (5), an extrusion punch (6) and a centering device. (2).
  • the piece (7) is initially a steel bar with a diameter that is a function of the final desired dimensions of the main shaft. Before starting the forging operation, the part (7) is heated to a temperature between 800 ° C and 1300 ° C to achieve a plastic behavior of the steel.
  • the matrix (1) is configured as a hollow cylindrical piece of a material harder than the alloy of the piece; the matrix (1) is open at the top and closed at the bottom, and between them is the cylindrical hollow carved with a profile that roughly reproduces the shape of the main shaft. Furthermore, a profile having a shape corresponding to a flange (8) is carved in the mouth or upper part of the die (1).
  • the centering device (2) is configured as a fork that pushes the part (7) towards the desired position.
  • the centering device (2) moves parallel to the horizontal plane so as not to obstruct the forging operations.
  • the crushing hammer (3) has a conical shape with a base and a vertex, where the base is widened and blunt to distribute the pressure over a larger surface and to be able to form the flange (8).
  • the vertex is extended in the form of a cylindrical rod so that the press (4) can apply pressure on the crushing hammer (3).
  • the upsetter (5) has a cylindrical shape with frustoconical flares at the ends of the cylinder.
  • the end of the upsetter (5) that presses on the piece (7) has a tip or protrusion that allows a cavity (9) to be made at the upper end of the piece (7).
  • the upsetter (5) also has a guide that allows the upsetter (5) to maintain a position coaxial with the longitudinal axis of the die (1) while rotating.
  • the extrusion punch (6) has a substantially elongated shape of a length greater than the part (7), and with a narrow but blunt tip, configured to apply pressure.
  • the Figure 1 shows how alignment can be achieved by means of the centering device (2), which moves parallel to the horizontal plane and pushes the part (7) to the desired position.
  • Figure 2 shows how, with the part (7) in the correct position, without removing the centering device (2), the crushing hammer (3) is inserted between the press and the upper end of the part (7), and the press (4) applies pressure in such a way that it compresses the lower end of the part (7) a few millimeters, produces a deformation and temporarily prevents the part (7) from being misaligned.
  • the centering device (2) is removed.
  • Figure 3a shows how the flange (8) is formed at the upper end of the piece (7) by pressing with the press (4) until the edge of the upper end of the piece (7) reaches the level of the upper edge of the matrix (1).
  • Figure 3b shows how the crushing hammer (3) is removed.
  • Figure 4a shows the introduction of the rotary upsetter (5) with the tip oriented towards the upper end of the piece (7);
  • Figure 4b shows how the tip of the upsetter (5) forms a cavity (9) in the part (7), while upsetting the flange (8).
  • the upsetter (5) is removed, as shown in Figure 4c.
  • Figure 5a shows the introduction of the extrusion punch (6) into the cavity (9) of the part (7);
  • Figure 5b it can be seen how pressure is applied with the hydraulic press (4) to achieve the extrusion of the part (7), and how the part (7) is stretched by the effect of pressure, increasing its length; This can be seen in the gap between the edge of the die (1) and the flange (8) of the part (7).
  • the extrusion punch (6) is removed, and the part (7) can be extracted from the die (1). To do this, the part (7) is lifted with the help of an ejector, and the part (7) rests vertically on a specific support that prevents it from being deformed.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Forging (AREA)

Abstract

La présente invention concerne un procédé et un système pour forger un axe principal d'un aérogénérateur, et plus spécifiquement un procédé qui permet de fabriquer l'axe principal d'un aérogénérateur au moyen d'un procédé d'extrusion inverse et l'outillage spécifique qui est utilisé dans le procédé de forge.
PCT/ES2020/070333 2020-05-21 2020-05-21 Procédé et système de forge pour un axe principal d'aérogénérateur WO2021234188A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PCT/ES2020/070333 WO2021234188A1 (fr) 2020-05-21 2020-05-21 Procédé et système de forge pour un axe principal d'aérogénérateur

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/ES2020/070333 WO2021234188A1 (fr) 2020-05-21 2020-05-21 Procédé et système de forge pour un axe principal d'aérogénérateur

Publications (1)

Publication Number Publication Date
WO2021234188A1 true WO2021234188A1 (fr) 2021-11-25

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Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/ES2020/070333 WO2021234188A1 (fr) 2020-05-21 2020-05-21 Procédé et système de forge pour un axe principal d'aérogénérateur

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN115446242A (zh) * 2022-09-05 2022-12-09 中国第一重型机械股份公司 一种超大型风机轴锻造模具及锻造方法
CN116060562A (zh) * 2023-03-07 2023-05-05 张家港广大特材股份有限公司 一种奥氏体耐酸合金钢轴件锻造拔长工艺
WO2024174897A1 (fr) * 2023-02-23 2024-08-29 振宏重工(江苏)股份有限公司 Procédé de forgeage par profilage combiné pour arbre principal d'éolienne à grande échelle

Citations (9)

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Publication number Priority date Publication date Assignee Title
US20030019269A1 (en) * 2000-02-09 2003-01-30 Bernhard Rolf Method and a press cylinder device for producing a hollow body
DE102006019234A1 (de) * 2005-06-14 2006-12-28 IFUTEC Ingenieurbüro für Umformtechnik GmbH Verfahren zur Umformung eines Massivelements
FR2899499A1 (fr) * 2006-04-11 2007-10-12 Manoir Ind Soc Par Actions Sim Procede d'extrusion de precision de pieces metalliques creuses et dispositif associe
KR20130041432A (ko) * 2011-10-17 2013-04-25 주식회사 센트랄 일체형 중공 드라이브 샤프트의 성형장치 및 성형방법
EP2591866A1 (fr) * 2011-11-13 2013-05-15 Gesenkschmiede Schneider GmbH Procédé de fabrication d'une pièce creuse à rotation symétrique et pièce creuse fabriquée ensuite
CN108273953A (zh) * 2017-12-29 2018-07-13 太仓久进汽车零部件有限公司 汽车dct变速器输入外轴深孔冷锻坯成形工艺
US20180318910A1 (en) * 2016-02-05 2018-11-08 Nippon Steel & Sumitomo Metal Corporation Method for manufacturing tubular member
EP3421153A1 (fr) * 2017-06-26 2019-01-02 ThyssenKrupp Metalúrgica Campo Limpo Ltda. Procédé de forgeage, arbre de rotor et moteur électrique
CN109290503A (zh) * 2018-08-27 2019-02-01 山东莱芜金雷风电科技股份有限公司 大mw风电主轴的空心近成型的锻造方法

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20030019269A1 (en) * 2000-02-09 2003-01-30 Bernhard Rolf Method and a press cylinder device for producing a hollow body
DE102006019234A1 (de) * 2005-06-14 2006-12-28 IFUTEC Ingenieurbüro für Umformtechnik GmbH Verfahren zur Umformung eines Massivelements
FR2899499A1 (fr) * 2006-04-11 2007-10-12 Manoir Ind Soc Par Actions Sim Procede d'extrusion de precision de pieces metalliques creuses et dispositif associe
KR20130041432A (ko) * 2011-10-17 2013-04-25 주식회사 센트랄 일체형 중공 드라이브 샤프트의 성형장치 및 성형방법
EP2591866A1 (fr) * 2011-11-13 2013-05-15 Gesenkschmiede Schneider GmbH Procédé de fabrication d'une pièce creuse à rotation symétrique et pièce creuse fabriquée ensuite
US20180318910A1 (en) * 2016-02-05 2018-11-08 Nippon Steel & Sumitomo Metal Corporation Method for manufacturing tubular member
EP3421153A1 (fr) * 2017-06-26 2019-01-02 ThyssenKrupp Metalúrgica Campo Limpo Ltda. Procédé de forgeage, arbre de rotor et moteur électrique
CN108273953A (zh) * 2017-12-29 2018-07-13 太仓久进汽车零部件有限公司 汽车dct变速器输入外轴深孔冷锻坯成形工艺
CN109290503A (zh) * 2018-08-27 2019-02-01 山东莱芜金雷风电科技股份有限公司 大mw风电主轴的空心近成型的锻造方法

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN115446242A (zh) * 2022-09-05 2022-12-09 中国第一重型机械股份公司 一种超大型风机轴锻造模具及锻造方法
WO2024174897A1 (fr) * 2023-02-23 2024-08-29 振宏重工(江苏)股份有限公司 Procédé de forgeage par profilage combiné pour arbre principal d'éolienne à grande échelle
CN116060562A (zh) * 2023-03-07 2023-05-05 张家港广大特材股份有限公司 一种奥氏体耐酸合金钢轴件锻造拔长工艺

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