A wind power hub forming process and forming die

Abstract

The application provides a wind power hub forming process and a forming die; wherein the parting surface of the cover box and the bottom box is different from the conventional parting from the middle position of the spherical surface, the parting surface adopts curved surface parting by rotating the pouring direction of the hub by 90 degrees, so that the core of the variable pitch flange surface in the conventional casting scheme is cancelled, the sand box is matched with the shape, the sand consumption of the casting is reduced, so that the sand-iron ratio is reduced, and the modeling production efficiency is improved due to the absence of the core of the variable pitch flange surface.

Description

Technical Field

[0001] This invention relates to the field of casting technology, specifically to the production of wind turbine casting hubs, and to a wind turbine hub forming process and forming mold. Background Technology

[0002] Currently, the wind turbine casting industry generally adopts a vertical casting method for wind turbine hubs. This means that during casting, the main shaft flange and windward flange are located vertically, while the three pitch flanges are located on the sides. The outer mold used in the forming process typically splits horizontally from the center of the spherical shape, dividing it into upper and lower parts. In addition, the wind turbine hub also has 3-6 side flange cores and 1-2 inner cavity main cores. For details, please refer to existing patent CN202022766217.7, which discloses a wind turbine hub casting system. The system includes an upper sand box, a lower sand box, and a sand core. The upper and lower sand boxes each contain a mold cavity, and the sand core is placed inside the mold cavity. The sand core and the mold cavity form a wind turbine hub forming cavity. During the forming process, a vertical forming process is used. During casting, the main shaft flange and windward flange face of the wind turbine hub are located vertically, while the three pitch flanges are located on the sides. This vertical forming process requires a large amount of resin sand due to the presence of 3-6 side flange cores, resulting in higher production costs. Furthermore, the entire forming process is labor-intensive and inefficient. Summary of the Invention

[0003] To address the shortcomings of existing technologies, the purpose of this invention is to provide a new process for horizontal forming of wind turbine hubs, including a forming mold, which significantly reduces the amount of resin sand used in castings, reduces the labor intensity of workers, and improves production efficiency.

[0004] To achieve the above objectives, the present invention is implemented through the following technical solution:

[0005] In a first aspect, embodiments of the present invention provide a wind turbine hub forming process, wherein the wind turbine hub is tilted at 90° for shaping, the third pitch flange surface is used as the bottom surface during forming, and the main shaft flange surface, the windward flange surface, the first pitch flange surface, and the second pitch flange surface are used as the side surfaces during wind turbine hub forming; the parting surface is used for parting along the curved surfaces of the first pitch flange surface and the second pitch flange surface on the side surface of the wind turbine hub.

[0006] As a further technical solution, the parting surface is approximated by taking a multi-segment line as the parting surface along the curved surfaces of the first and second pitch flanges on the side of the wind turbine hub.

[0007] Secondly, based on the wind turbine hub forming process described above, the present invention also proposes a forming mold, including a bottom box outer mold, a cover box outer mold and a core; the parting surfaces of the bottom box outer mold and the cover box outer mold are parted along the curved surfaces of the first pitch flange surface and the second pitch flange surface on the side of the wind turbine hub.

[0008] As a further technical solution, the parting surfaces of the bottom box outer mold and the cover box outer mold are approximated by multi-segment lines along the curved surfaces of the first pitch flange surface and the second pitch flange surface on the side of the wind turbine hub.

[0009] As a further technical solution, a bottom box conformal sand box is set inside the bottom box outer mold.

[0010] As a further technical solution, a cover box conforming sand box is set inside the outer mold of the cover box.

[0011] As a further technical solution, the bottom box outer mold has an upwardly convex arc-shaped surface along the first pitch flange surface and the second pitch flange surface; the cover box outer mold has a downwardly concave arc-shaped surface along the first pitch flange surface and the second pitch flange surface, and the upwardly convex arc-shaped surface and the downwardly concave arc-shaped surface cooperate with each other.

[0012] As a further technical solution, the clay core is an integral structure.

[0013] As a further technical solution, the clay core is a split structure.

[0014] The beneficial effects of the above embodiments of the present invention are as follows:

[0015] In this invention, the main shaft flange face and the windward flange face of the hub are located on the left and right sides during molding, and one of the pitch flange faces is located at the bottom of the hub. Compared with the traditional wind turbine hub process, the wind turbine hub is tilted at 90° during molding. Furthermore, since the three pitch flange faces of this invention are located on the bottom plane and two sides of the casting position, there will be no interference when the core is dropped. Therefore, the 3-6 side flange cores in the prior art can be eliminated, reducing the labor intensity of workers and improving production efficiency.

[0016] This invention significantly reduces the amount of resin sand used in the casting process and lowers production costs by changing the parting method and using a molding sand box. Attached Figure Description

[0017] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an improper limitation of the invention.

[0018] Figure 1 , Figure 2 , Figure 3 The structure of the base box of this invention is shown below:

[0019] Figure 4 , Figure 5 , Figure 6 The structure of the lid box of the present invention is shown below:

[0020] Figure 7 This is the structure of the main body of the present invention:

[0021] In the diagram: 1. Bottom box outer mold, 2. Bottom box conformal sand box, 3. Cover box outer mold, 4. Cover box conformal sand box, 5. Mud core. Detailed Implementation

[0022] It should be noted that the following detailed description is illustrative and intended to provide further explanation of the invention. Unless otherwise specified, all technical and scientific terms used in this invention have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0023] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of exemplary embodiments according to the invention. As used herein, unless otherwise expressly indicated by the invention, the singular form is also intended to include the plural form. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0024] For ease of description, the use of the words "upper" and "lower" in this invention only indicates that they correspond to the upper and lower directions of the accompanying drawings and do not limit the structure. They are merely for the purpose of describing the invention and simplifying the description, and do not indicate or imply that the device or component referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention.

[0025] As described in the background section, the wind turbine hub casting industry currently adopts a vertical manufacturing method. During casting, the main shaft flange and windward flange face of the wind turbine hub are vertically aligned, while the three pitch flanges are located on the sides. The outer mold used in the forming process typically splits horizontally from the center of the spherical shape, dividing the mold into upper and lower parts. In addition, the wind turbine hub also has 3-6 side flange cores and 1-2 inner cavity cores. This vertical forming process, due to the presence of 3-6 side flange cores, requires a large amount of resin sand, resulting in high production costs. Furthermore, the entire forming process is labor-intensive and inefficient. To address these technical problems, this invention proposes a horizontal forming process and mold for wind turbine hubs.

[0026] The existing wind turbine hub includes a hub body, on which three pitch flange faces, one main shaft flange face, and one windward flange face are provided. For ease of description, in this embodiment, the three pitch flange faces are defined as the first pitch flange face, the second pitch flange face, and the third pitch flange face, respectively. It should be noted that the first, second, and third mentioned here are only used to distinguish the three pitch flange faces, and do not require or imply any such actual relationship or order among these pitch flange faces.

[0027] To address the problems existing in the vertical manufacturing process of wind turbine hubs in the prior art, this embodiment proposes a new horizontal manufacturing process for wind turbine hubs. By tilting the hub at a 90° angle, the main shaft flange, two pitch flanges, and one front flange are rotated to the sides, while the other pitch flange is rotated to the bottom. The parting line is formed along the curved surfaces of the two pitch flanges on the side of the hub, or alternatively, a multi-segment approximation of the curved surface can be taken along these surfaces. By changing the parting method and using a molding sand box, the amount of resin sand used in the casting process is significantly reduced, lowering production costs. Furthermore, by eliminating the 3-6 side flange cores, the labor intensity of the molding process is greatly reduced, improving production efficiency.

[0028] Specifically, the wind turbine hub is tilted 90° for shaping. The main shaft flange, windward flange, first pitch flange, and second pitch flange are rotated to the side of the hub body, while the third pitch flange is rotated to the bottom of the hub body. The parting line of the upper and lower molds is formed along the curved surfaces of the first and second pitch flanges on the side of the hub, or alternatively, a multi-segment line approximating a curved surface can be used along the first and second pitch flanges on the side of the hub. By changing the parting method and using a molding sand box, the amount of resin sand used in the casting process is significantly reduced, lowering production costs. Simultaneously, the elimination of 3-6 side flange cores greatly reduces the labor intensity of the molding process and improves production efficiency.

[0029] To achieve the above process, this embodiment also provides a molding die, such as... Figure 1 , Figure 2 , Figure 3 , Figure 4 , Figure 5 , Figure 6 , Figure 7 As shown, it includes a bottom box outer mold, a bottom box conformal sand box, a top box outer mold, a top box conformal sand box, and a mud core;

[0030] like Figure 1 , Figure 2 , Figure 3As shown, both the bottom box outer mold and the cover box outer mold are curved surface parting lines, not horizontal surface parting lines. Specifically, the parting surfaces of the bottom box outer mold and the cover box outer mold are formed along the curved surfaces of the first pitch flange surface and the second pitch flange surface on the side of the wind turbine hub. Alternatively, the parting surfaces of the bottom box outer mold and the cover box outer mold can be approximated by taking polysegment lines to form curved surfaces along the curved surfaces of the first pitch flange surface and the second pitch flange surface on the side of the wind turbine hub.

[0031] Furthermore, such as Figure 1 , Figure 2 , Figure 3 As shown, the outer mold of the bottom box has an upwardly convex arc-shaped surface along the first pitch flange surface and the second pitch flange surface; as Figure 4 , Figure 5 , Figure 6 As shown, the outer mold of the cover box has a downwardly recessed arc-shaped surface along the first pitch flange surface and the second pitch flange surface. The upwardly convex arc-shaped surface and the downwardly recessed arc-shaped surface cooperate to serve as the parting surface during wheel hub forming.

[0032] Furthermore, such as Figure 1 , Figure 2 , Figure 3 , Figure 4 , Figure 5 , Figure 6 As shown, based on the actual shapes of the bottom box outer mold and the top box outer mold, the mold also includes a dedicated bottom box molding sand box and a top box molding sand box. The bottom box molding sand box, together with the bottom box outer mold, forms the lower mold for casting, and the top box molding sand box, together with the top box outer mold, forms the upper mold for casting. The upper mold, lower mold, and main body core are combined to form the wind turbine hub forming cavity. In this embodiment, it is required that the bottom box molding sand box and the top box molding sand box minimize the amount of sand they consume, thereby reducing the total amount of resin sand used and lowering production costs.

[0033] Furthermore, such as Figure 7 As shown, in this embodiment, the main core, the bottom molded sand box, and the top molded sand box together realize the casting of the wheel hub. In this embodiment, the main core can be divided into upper and lower parts according to the actual production situation, or it can be made into an integral core.

[0034] In this embodiment, since the three pitch flange faces are located at the bottom plane and two sides of the casting position respectively, there will be no interference when the mud core is dropped. Therefore, 3-6 side flange mud cores can be eliminated, reducing the labor intensity of workers and improving production efficiency.

[0035] In summary, this invention discloses a novel process that significantly reduces the amount of resin sand used in castings and lowers the labor intensity of workers by changing the traditional parting method for wind turbine hub castings, thereby improving production efficiency.

[0036] Finally, it should be noted that relational terms such as first and second are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations.

[0037] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A wind turbine hub forming process, characterized in that, The wind turbine hub is tilted at a 90° angle for shaping, with the third pitch flange face as the bottom surface during molding, and the main shaft flange face, windward flange face, first pitch flange face, and second pitch flange face as the sides of the wind turbine hub during molding; and the parting surface is formed along the curved surfaces of the first and second pitch flange faces on the side of the wind turbine hub during molding.

2. The wind turbine hub forming process as described in claim 1, characterized in that, The parting surface is approximated by taking a polyline approach to the curved surface of the first and second pitch flange surfaces on the side of the wind turbine hub.

3. The forming mold for the wind turbine hub forming process as described in any one of claims 1-2, comprising a bottom box outer mold, a cover box outer mold, and a core; characterized in that, The parting surfaces of the bottom box outer mold and the top box outer mold are formed along the curved surfaces of the first pitch flange surface and the second pitch flange surface on the side of the wind turbine hub.

4. The forming mold for the wind turbine hub forming process as described in claim 3, characterized in that, The parting surfaces of the bottom box outer mold and the top box outer mold are approximated by multi-segment lines along the curved surfaces of the first pitch flange surface and the second pitch flange surface on the side of the wind turbine hub.

5. The forming mold for the wind turbine hub forming process as described in claim 3, characterized in that, A bottom box conformal sand box is set inside the outer mold of the bottom box.

6. The forming mold for the wind turbine hub forming process as described in claim 3, characterized in that, The outer mold of the cover box is equipped with a cover box conformal sand box.

7. The forming mold for the wind turbine hub forming process as described in claim 3, characterized in that, The bottom box outer mold has an upwardly convex arc-shaped surface along the first pitch flange surface and the second pitch flange surface; the top box outer mold has a downwardly concave arc-shaped surface along the first pitch flange surface and the second pitch flange surface, and the upwardly convex arc-shaped surface and the downwardly concave arc-shaped surface cooperate with each other.

8. The forming mold for the wind turbine hub forming process as described in claim 3, characterized in that, The aforementioned mud core has an integral structure.

9. The forming mold for the wind turbine hub forming process as described in claim 3, characterized in that, The aforementioned mud core has a split structure.

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