Large wind power main shaft welded by rolled plates and preparation method of large wind power main shaft

Abstract

The invention belongs to the technical field of large wind power spindles, and discloses a rolled plate welded large wind power spindle and a manufacturing method thereof.The rolled plate welded large wind power spindle comprises a front bearing ring, a flange plate is integrally connected to the front end of the front bearing ring, and a thrust ring is integrally connected to the joint of the front bearing ring and the flange plate; the end, away from the flange plate, of the front bearing ring is integrally connected with at least one middle transition ring, the tail end of the last-stage middle transition ring is integrally connected with a rear bearing ring, center holes are coaxially formed in the front bearing ring, the middle transition rings and the rear bearing ring respectively, and the diameters of the inner surfaces of the center holes are consistent. The invention has the advantages of simple production process, light overall weight, high strength, low price and flexible specification change.

Description

Technical Field

[0001] The present invention belongs to the technical field of large-scale wind turbine main shafts, and in particular, relates to a large-scale wind turbine main shaft welded by rolled plates and a preparation method thereof. Background Art

[0002] At present, there are several common types of wind turbine main shafts: one is the wind turbine main shaft produced by die forging technology, the metal fibers are continuous, complete and of good quality, but large wind turbine main shafts are difficult to produce; the second is the wind turbine main shaft produced by free forging technology, the metal fibers of this main shaft are broken in large quantities, on the one hand, the fatigue strength is low, and on the other hand, the production of large main shafts is also difficult; the third is the wind turbine main shaft produced by casting technology, the main shaft produced by this technology has good processability, but the metal structure is loose, and there are pores. These defects are on the surface of the main shaft, which is particularly harmful, easy to produce stress concentration, and easy to fatigue damage. In addition, due to the loose metal structure, there is a risk of fracture, which causes the wind wheel installed on the wind turbine main shaft to be at risk of falling; in order to overcome these difficulties, the measure often taken is to increase the size, resulting in a significant increase in the weight of the wind turbine main shaft produced, which is very unfavorable for the work of the wind turbine main shaft working at high altitudes, especially for floating offshore wind power. Summary of the invention

[0003] The main technical problem to be solved by the present invention is to provide a large-scale wind turbine main shaft welded by coil plate and a preparation method thereof, the overall production process is simple, and it has light weight, high strength, low price and flexible specification changes.

[0004] In order to solve the above technical problems, the present invention provides the following technical solutions: A large-scale wind turbine main shaft welded by rolled plate comprises a front bearing ring, a flange is integrally connected to the front end of the front bearing ring, a thrust ring is integrally connected to the connection between the front bearing ring and the flange, at least one intermediate transition ring is integrally connected to the end of the front bearing ring away from the flange, a rear bearing ring is integrally connected to the terminal end of the last intermediate transition ring, and center holes are coaxially opened inside the front bearing ring, and the inner surfaces of the center holes have the same diameter.

[0005] The following is a further optimization of the above technical solution by the present invention: A first welding protrusion is integrally connected to an end face of the flange close to the front bearing ring. The cross-section of the first welding protrusion is triangular. Second welding surfaces arranged obliquely are respectively provided on both sides of the first welding protrusion, and an angle a1 between the second welding surfaces on both sides of the first welding protrusion is 153±1°.

[0006] Further optimization: A second welding protrusion is integrally connected to an end face of the front bearing ring close to the flange plate, the cross-section of the second welding protrusion is triangular, and third welding surfaces arranged obliquely are respectively provided on both sides of the second welding protrusion, and the angle a2 between the third welding surfaces on both sides of the second welding protrusion is 153±1°.

[0007] Further optimization: A third welding protrusion is integrally connected to one end face of the front bearing ring close to the intermediate transition ring, the cross-section of the third welding protrusion is triangular, and fourth welding surfaces arranged obliquely are respectively provided on both sides of the third welding protrusion, and the angle a3 between the fourth welding surfaces on both sides of the third welding protrusion is 144±1°.

[0008] Further optimization: A fourth welding protrusion is integrally connected to one end face of the intermediate transition ring close to the front bearing ring, the cross-section of the fourth welding protrusion is triangular, and fifth welding surfaces arranged obliquely are respectively provided on both sides of the fourth welding protrusion, and the angle a4 between the fifth welding surfaces on both sides of the fourth welding protrusion is 144±1°.

[0009] Further optimization: A fifth welding protrusion is integrally connected to one end face of the intermediate transition ring close to the rear bearing ring, the cross-section of the fifth welding protrusion is triangular, and sixth welding surfaces arranged obliquely are respectively provided on both sides of the fifth welding protrusion, and an angle a5 between the sixth welding surfaces on both sides of the fifth welding protrusion is 137±1°.

[0010] Further optimization: A sixth welding protrusion is integrally connected to one end face of the rear bearing ring close to the intermediate transition ring, the cross-section of the sixth welding protrusion is triangular, and seventh welding surfaces arranged obliquely are respectively provided on both sides of the sixth welding protrusion, and the angle a6 between the seventh welding surfaces on both sides of the sixth welding protrusion is 137±1°.

[0011] The present invention also provides a method for preparing a large-scale wind turbine main shaft by plate rolling welding, which is used to prepare the above-mentioned large-scale wind turbine main shaft by plate rolling welding, and the preparation method includes a flange preparation process, a bearing ring preparation process and a splicing preparation process; The flange preparation process is carried out as follows: F1. Cutting: Use computer to draw the production drawing of flange, and cut the production drawing into multiple pieces of preliminary processing plates with the center of the circle as the axis, and obtain the cutting size of each preliminary processing plate; the cutting drawing of each preliminary processing plate is in the shape of an arc plate; F2. Prepare raw materials: Cut the steel plates according to the blanking size of each preliminary processed plate to obtain preliminary processed plates, and then process the first welding surface on both sides of each preliminary processed plate. The first welding surface is inclined, and the inclination angle of the first welding surface is 30°; F3, welding: multiple pieces of preliminary processed plates are butt-jointed in sequence, at which point a first welding cavity is formed between two corresponding first welding surfaces, and the angle between the two side surfaces of the first welding cavity is 60°, and then a deposition welding process is used in the first welding cavity to weld to obtain a circular plate-shaped preliminary sheet material; F4, forming: feeding the preliminary sheet material obtained in step F3 into a pressure forming machine, and then using a pressing die to press the preliminary sheet material to obtain a flange blank; F5. Machining: Machining the flange blank prepared in step F4 according to the size requirements of the production drawing, and then drilling flange holes on the flange blank using a drilling machine to obtain the flange.

[0012] The bearing ring preparation process is carried out according to the following steps: Z1. Cutting: Cut the steel plate to obtain a square steel plate according to the axial length and circumference of the bearing ring to be produced. The thickness of the square steel plate is 200-300mm; Z2, processing the butt welding surface of the rolled plate: processing the butt welding surface at the long sides of both sides of the square steel plate obtained in step Z1, the butt welding surface is inclined, and the inclination angle of the butt welding surface is 30°; Z3, initial rolling: a plate rolling machine is used to roll the square steel plate prepared in step Z2 into a cylindrical tube with a through hole in the center. At this time, the butt welding surfaces on both sides of the square steel plate are butted to form a weld chamber; the inclined angle between the butt welding surfaces on both sides of the weld chamber is 60°; Z4. Welding: Multiple accumulation welding processes are used in the weld chamber. After each set of accumulation welding is completed, the weld needs to be cooled and slag removed, and then the weld is subjected to metal flaw detection. After meeting the requirements, the next accumulation welding is carried out. The accumulation welding, cooling, slag removal and metal flaw detection processes are repeated until the weld chamber is filled with molten solder, the welding process is completed, and the steel plate roll is made; Z5, fine coiling: the steel plate coil obtained in step Z4 is sent to the plate rolling machine again, and the steel plate coil is reshaped into a cylindrical shape; Z6, machining: machining the steel plate roll that has been shaped in step Z5 according to the size requirements of the production drawing, so that the dimensions of the steel plate roll meet the requirements of the production drawing, and the bearing ring is obtained; Z7, Processing and welding bulges: Use machine tools to process and weld bulges on both end surfaces of the bearing ring; According to the production drawings of the front bearing ring, the intermediate transition ring and the rear bearing ring, the corresponding front bearing ring, the intermediate transition ring and the rear bearing ring can be manufactured by repeating the above steps Z1-Z7.

[0013] Further optimization: The splicing preparation process is carried out as follows: P1. First, the flange and the front bearing ring are coaxially arranged, and then the first welding protrusion on the flange is butted with the second welding protrusion on the front bearing ring. At this time, two upper and lower second welding cavities are formed between the first welding protrusion and the second welding protrusion. The angle between the second welding surface and the third welding surface in each second welding cavity is 27±1°; the two second welding cavities are welded by the deposition welding process; P2. Then, the intermediate transition ring and the front bearing ring are arranged coaxially, and the fourth welding protrusion on the intermediate transition ring is butted with the third welding protrusion on the front bearing ring. At this time, two upper and lower third welding cavities are formed between the fourth welding protrusion and the third welding protrusion. The angle between the fourth welding surface and the fifth welding surface in each third welding cavity is 36±1°; the two third welding cavities are welded by the deposition welding process; P3. Then, the rear bearing ring and the intermediate transition ring are coaxially arranged, and the sixth welding protrusion on the rear bearing ring is butted with the fifth welding protrusion on the intermediate transition ring. At this time, two upper and lower fourth welding cavities are formed between the sixth welding protrusion and the fifth welding protrusion. The angle between the sixth welding surface and the seventh welding surface in each fourth welding cavity is 43±1°; the two fourth welding cavities are welded by the deposition welding process; P4. Place the thrust ring on the flange and close to the front bearing ring. The thrust ring and the flange are fixedly connected by welding. P5. A connecting plate is arranged in the center hole of the rear bearing ring and at a position far away from the intermediate transition ring. The connecting plate and the inner surface of the center hole are fixedly connected by welding. Finally, a large-scale wind turbine main shaft with rolled plate welding is obtained.

[0014] The present invention adopts the above technical scheme, which is ingenious in conception and reasonable in structure. The flange and the front bearing ring are welded and fixed by a stacking welding process in two second welding cavities, the intermediate transition ring and the front bearing ring are welded and fixed by a stacking welding process in two third welding cavities, and the rear bearing ring and the intermediate transition ring are welded and fixed by a stacking welding process in two fourth welding cavities. This can improve the connection strength between the flange, the front bearing ring, the intermediate transition ring and the rear bearing ring, improve the use effect, and each connection point can facilitate welding processing while ensuring the connection strength through two welding cavities, reduce stress concentration, and improve the overall structural strength after welding.

[0015] The flange in the present invention adopts a plurality of arc-shaped preliminary processing plates which are welded into a circular plate-shaped preliminary plate material, and then a pressing mold is used to press the preliminary plate material to obtain a flange blank, and then the flange blank is machined according to the size requirements of the production drawing to finally obtain the flange, so that the overall structure of the flange is simple, and the manufacturing and production are convenient, and it is suitable for preparing super-large flanges.

[0016] In the present invention, the front bearing ring, the middle transition ring and the rear bearing ring are all made of square high-quality steel plates through a rolling operation to obtain a cylindrical tube shape with a through hole in the center, and then the butt welding surfaces on both sides of the square steel plate are butt-welded, and a rolling machine is used to reshape the steel plate roll again to improve the dimensional accuracy of the steel plate roll, and then the steel plate roll is precisely machined by machining to finally obtain the finished product, so that the overall structure is simple, convenient for manufacturing and production, and can ensure the overall structural strength.

[0017] The present invention has a simple overall structure and a simple production process. The large wind turbine main shaft produced is light in weight, high in strength, and flexible in specification. It can be widely used in various types of wind turbine main shafts, especially large and extra-large offshore floating wind turbine main shafts.

[0018] The present invention is further described below in conjunction with the accompanying drawings and embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 It is a schematic diagram of the overall structure of an embodiment of the present invention; Figure 2 A side view of a flange in an embodiment of the present invention; Figure 3 is a side view of a front bearing ring in an embodiment of the present invention; Figure 4 is a cross-sectional view of a front bearing ring in an embodiment of the present invention; Figure 5 is a cross-sectional view of a flange in an embodiment of the present invention; Figure 6 is a cross-sectional view of an intermediate transition ring in an embodiment of the present invention; Figure 7 2 is a cross-sectional view of the rear bearing ring in an embodiment of the present invention.

[0020] In the figure: 1-flange; 101-preliminary processing plate; 102-thrust shoulder; 103-first welding protrusion; 2-thrust ring; 3-front bearing ring; 301-second welding protrusion; 302-third welding protrusion; 4-intermediate transition ring; 401-fourth welding protrusion; 402-fifth welding protrusion; 5-rear bearing ring; 501-sixth welding protrusion; 6-connecting plate; 7-center hole. DETAILED DESCRIPTION

[0021] like Figure 1-7As shown: a large-scale wind turbine main shaft welded by rolled plate, including a front bearing ring 3, the front end of the front bearing ring 3 is integrally connected with a flange 1, the connection between the front bearing ring 3 and the flange 1 is integrally connected with a thrust ring 2, the end of the front bearing ring 3 away from the flange 1 is integrally connected with at least one section of intermediate transition ring 4, the terminal end of the last-stage intermediate transition ring 4 is integrally connected with a rear bearing ring 5, the interiors of the front bearing ring 3, the intermediate transition ring 4 and the rear bearing ring 5 are respectively coaxially opened with center holes 7, and the inner surface diameters of the center holes 7 are consistent.

[0022] In this embodiment, the flange 1 is made by welding a plurality of preliminary processed plates 101, and the preliminary processed plates 101 are made of high-quality alloy steel.

[0023] The two sides of the preliminary processing plate 101 are respectively provided with a first welding surface, the first welding surface is arranged at an inclination, and the inclination angle of the first welding surface is 30°.

[0024] After two adjacent preliminary processed plates 101 are butt-jointed, a first welding cavity is formed between two corresponding first welding surfaces, and the angle between the two side surfaces of the first welding cavity is 60°. The first welding cavity is welded by a deposition welding process.

[0025] Such a design can form a weld at the first welding cavity, and the first welding cavity can accommodate more molten solder, thereby improving the connection strength between two adjacent preliminary processed plates 101 and improving the use effect.

[0026] In this embodiment, four preliminary processing plates 101 are used, and the four preliminary processing plates 101 are welded to form the flange 1, which is convenient for production and processing.

[0027] A step groove is formed on one end surface of the flange 1 away from the front bearing ring 3 , and a thrust shoulder 102 is formed on the flange 1 at the step groove.

[0028] The front bearing ring 3, the intermediate transition ring 4 and the rear bearing ring 5 are respectively made of high-quality steel plates through rolling, welding and machining.

[0029] A first welding protrusion 103 is integrally connected to one end face of the flange 1 close to the front bearing ring 3. The cross section of the first welding protrusion 103 is triangular. Second welding surfaces arranged obliquely are respectively provided on both sides of the first welding protrusion 103, and an angle a1 between the second welding surfaces on both sides of the first welding protrusion 103 is 153±1°.

[0030] A second welding protrusion 301 is integrally connected to one end face of the front bearing ring 3 close to the flange plate 1. The cross-section of the second welding protrusion 301 is triangular. The second welding protrusion 301 is provided with inclined third welding surfaces on both sides, and the angle a2 between the third welding surfaces on both sides of the second welding protrusion 301 is 153±1°.

[0031] With such a design, when the flange 1 and the front bearing ring 3 are butt-welded, the flange 1 and the front bearing ring 3 are first arranged coaxially, and then the first welding protrusion 103 on the flange 1 is butt-welded with the second welding protrusion 301 on the front bearing ring 3. At this time, two upper and lower second welding cavities are formed between the first welding protrusion 103 and the second welding protrusion 301, and the angle between the second welding surface and the third welding surface in each second welding cavity is 27±1°; the two second welding cavities are welded by the stacking welding process.

[0032] The flange 1 and the front bearing ring 3 are welded and fixed to each other by performing a stacking welding process in two second welding cavities, which can improve the connection strength between the flange 1 and the front bearing ring 3 and improve the use effect. In addition, the two second welding cavities can facilitate welding processing while ensuring the connection strength, reduce stress concentration, and improve the overall structural strength after welding.

[0033] A third welding protrusion 302 is integrally connected to one end face of the front bearing ring 3 close to the intermediate transition ring 4. The cross-section of the third welding protrusion 302 is triangular. Fourth welding surfaces arranged obliquely are respectively provided on both sides of the third welding protrusion 302, and an angle a3 between the fourth welding surfaces on both sides of the third welding protrusion 302 is 144±1°.

[0034] A fourth welding protrusion 401 is integrally connected to one end face of the intermediate transition ring 4 close to the front bearing ring 3, and the cross-section of the fourth welding protrusion 401 is triangular. Fifth welding surfaces arranged in an inclined manner are respectively provided on both sides of the fourth welding protrusion 401, and an angle a4 between the fifth welding surfaces on both sides of the fourth welding protrusion 401 is 144±1°.

[0035] With such a design, when the intermediate transition ring 4 and the front bearing ring 3 are butt-welded, the intermediate transition ring 4 and the front bearing ring 3 are first arranged coaxially, and then the fourth welding protrusion 401 on the intermediate transition ring 4 is butt-welded with the third welding protrusion 302 on the front bearing ring 3. At this time, two upper and lower third welding cavities are formed between the fourth welding protrusion 401 and the third welding protrusion 302, and the angle between the fourth welding surface and the fifth welding surface in each third welding cavity is 36±1°; the two third welding cavities are welded by the stacking welding process.

[0036] The intermediate transition ring 4 and the front bearing ring 3 are welded and fixed by a stacking welding process in two third welding cavities, which can improve the connection strength between the intermediate transition ring 4 and the front bearing ring 3 and improve the use effect. In addition, the two third welding cavities can facilitate welding processing while ensuring the connection strength, reduce stress concentration, and improve the overall structural strength after welding.

[0037] A fifth welding protrusion 402 is integrally connected to one end face of the intermediate transition ring 4 close to the rear bearing ring 5. The cross-section of the fifth welding protrusion 402 is triangular. Sixth welding surfaces arranged obliquely are respectively provided on both sides of the fifth welding protrusion 402, and an angle a5 between the sixth welding surfaces on both sides of the fifth welding protrusion 402 is 137±1°.

[0038] A sixth welding protrusion 501 is integrally connected to one end face of the rear bearing ring 5 close to the intermediate transition ring 4. The cross-section of the sixth welding protrusion 501 is triangular. Seventh welding surfaces arranged obliquely are respectively provided on both sides of the sixth welding protrusion 501, and an angle a6 between the seventh welding surfaces on both sides of the sixth welding protrusion 501 is 137±1°.

[0039] With such a design, when the rear bearing ring 5 and the intermediate transition ring 4 are butt-welded, first, the rear bearing ring 5 and the intermediate transition ring 4 are coaxially arranged, and then the sixth welding protrusion 501 on the rear bearing ring 5 is butt-welded with the fifth welding protrusion 402 on the intermediate transition ring 4. At this time, two upper and lower fourth welding cavities are formed between the sixth welding protrusion 501 and the fifth welding protrusion 402, and the angle between the sixth welding surface and the seventh welding surface in each fourth welding cavity is 43±1°; the two fourth welding cavities are welded by the stacking welding process.

[0040] The rear bearing ring 5 and the intermediate transition ring 4 are welded and fixed by a stacking welding process in two fourth welding cavities, which can improve the connection strength between the rear bearing ring 5 and the intermediate transition ring 4 and improve the use effect. In addition, the two fourth welding cavities can facilitate welding processing while ensuring the connection strength, reduce stress concentration, and improve the overall structural strength after welding.

[0041] In this embodiment, the thrust ring 2 is sleeved on the flange 1 and is close to the front bearing ring 3. The thrust ring 2 and the flange 1 are fixedly connected by welding.

[0042] A connecting plate 6 is integrally connected in the center hole 7 of the rear bearing ring 5 and at a position away from the intermediate transition ring 4 , and a spacing distance is set between a side of the connecting plate 6 away from the intermediate transition ring 4 and a side of the rear bearing ring 5 away from the intermediate transition ring 4 .

[0043] In this embodiment, the connecting plate 6 is integrally connected to the center hole 7 of the rear bearing ring 5 by welding.

[0044] The present invention also provides a method for preparing a large-scale wind turbine main shaft by roll plate welding, which is used to prepare the above-mentioned large-scale wind turbine main shaft by roll plate welding. The preparation method includes a flange preparation process, a bearing ring preparation process and a splicing preparation process.

[0045] The flange preparation process is carried out as follows: F1. Cutting: A production drawing of the flange 1 is drawn by computer, and the production drawing is cut into a plurality of preliminary processing plates 101 with the center of a circle as the axis, and the cutting size of each preliminary processing plate 101 is obtained.

[0046] In this embodiment, the preliminary processed plate 101 is divided into four pieces, and the cutting drawings of the four preliminary processed plates 101 are in the shape of arc plates.

[0047] F2. Prepare raw materials: Cut the steel plates according to the cutting size of each preliminary processed plate 101 to obtain the preliminary processed plates 101, and then process the first welding surface on both side surfaces of each preliminary processed plate 101. The first welding surface is inclined, and the inclination angle of the first welding surface is 30°.

[0048] F3. Welding: The four preliminary processed plates 101 are butt-jointed in sequence. At this time, a first welding cavity is formed between two corresponding first welding surfaces, and the angle between the two side surfaces of the first welding cavity is 60°. Then, a deposition welding process is used to weld in the first welding cavity to obtain a circular plate-shaped preliminary sheet material.

[0049] In step F3, multiple stacking welding is performed in the first welding cavity. After each set of stacking welding is completed, the weld needs to be cooled and the slag is removed, and then the weld is subjected to metal flaw detection. If it meets the requirements, the next stacking welding is performed. The stacking welding, cooling, slag removal and metal flaw detection processes are repeated until the first welding cavity is filled with molten solder and the welding process is completed.

[0050] F4. Forming: The preliminary sheet material obtained in step F3 is fed into a pressure forming machine, and then the preliminary sheet material is pressed by a pressing die to obtain a flange blank.

[0051] F5. Machining: According to the size requirements of the production drawing, the flange blank prepared in step F4 is machined by using a lathe and a milling machine, so that the dimensions of the flange blank meet the requirements of the production drawing, and then a flange hole is drilled on the flange blank by using a drilling machine to obtain flange 1.

[0052] The bearing ring preparation process is carried out according to the following steps: Z1. Cutting: Cut the high-quality steel plate into square steel plates according to the axial length and circumference of the bearing ring to be produced. The length of the square steel plate matches the axial length of the bearing ring to be produced; the width of the square steel plate matches the circumference of the bearing ring to be produced, and the thickness of the square steel plate is 200-300mm.

[0053] In this embodiment, the square steel plate is made of Q235 steel plate.

[0054] Z2. Processing the butt welding surface of the rolled plate: processing the butt welding surface at the long sides of both sides of the square steel plate obtained in step Z1. The butt welding surface is arranged along the length direction of the square steel plate. The butt welding surface is inclined, and the inclination angle of the butt welding surface is 30°.

[0055] Z3. Initial rolling: Use a plate rolling machine to roll the square steel plate prepared in step Z2 into a cylindrical shape with a through hole in the center, and make the butt welding surfaces on both sides of the square steel plate butt to form a weld chamber; at this time, the inclination angle between the butt welding surfaces on both sides of the weld chamber is 60°.

[0056] Z4. Welding: Multiple deposition welding processes are used in the weld chamber. After each set of deposition welding is completed, the weld needs to be cooled and slag removed, and then the weld is subjected to metal flaw detection. If it meets the requirements, the next deposition welding is carried out. The deposition welding, cooling, slag removal and metal flaw detection processes are repeated until the weld chamber is filled with molten solder, the welding process is completed, and the steel plate roll is made.

[0057] Z5. Fine rolling: The steel plate roll obtained in step Z4 is sent to the plate rolling machine again, and the steel plate roll is reshaped into a cylindrical shape.

[0058] Z6. Machining: According to the size requirements of the production drawings, the steel plate roll that has been shaped in step Z5 is machined using a lathe and a milling machine so that the dimensions of the steel plate roll meet the requirements of the production drawings and the bearing ring is obtained.

[0059] Z7. Processing and welding protrusions: Use machine tools to process and weld protrusions on both end surfaces of the bearing ring.

[0060] In this embodiment, according to the production drawings of the front bearing ring 3, the intermediate transition ring 4 and the rear bearing ring 5, the corresponding front bearing ring 3, the intermediate transition ring 4 and the rear bearing ring 5 can be manufactured by repeating the above steps Z1-Z7, wherein the angle a2 between the third welding surfaces on both sides of the second welding protrusion 301 on the front bearing ring 3 is 153±1°; the angle a3 between the fourth welding surfaces on both sides of the third welding protrusion 302 is 144±1°; The angle a4 between the fifth welding surfaces on both sides of the fourth welding protrusion 401 on the intermediate transition ring 4 is 144±1°; the angle a5 between the sixth welding surfaces on both sides of the fifth welding protrusion 402 is 137±1°; An angle a6 between the seventh welding surfaces on both sides of the sixth welding protrusion 501 on the rear bearing ring 5 is 137±1°.

[0061] The splicing preparation process is carried out in the following steps: P1. First, the flange 1 and the front bearing ring 3 are coaxially arranged, and then the first welding protrusion 103 on the flange 1 is connected with the second welding protrusion 301 on the front bearing ring 3. At this time, two upper and lower second welding cavities are formed between the first welding protrusion 103 and the second welding protrusion 301. The angle between the second welding surface and the third welding surface in each second welding cavity is 27±1°; the two second welding cavities are welded by the deposition welding process.

[0062] P2. Then, the intermediate transition ring 4 is coaxially arranged with the front bearing ring 3, and the fourth welding protrusion 401 on the intermediate transition ring 4 is butted with the third welding protrusion 302 on the front bearing ring 3. At this time, two upper and lower third welding cavities are formed between the fourth welding protrusion 401 and the third welding protrusion 302. The angle between the fourth welding surface and the fifth welding surface in each third welding cavity is 36±1°; the two third welding cavities are welded by the stacking welding process.

[0063] P3. Then, the rear bearing ring 5 and the intermediate transition ring 4 are coaxially arranged, so that the sixth welding protrusion 501 on the rear bearing ring 5 is butted against the fifth welding protrusion 402 on the intermediate transition ring 4. At this time, two upper and lower fourth welding cavities are formed between the sixth welding protrusion 501 and the fifth welding protrusion 402. The angle between the sixth welding surface and the seventh welding surface in each fourth welding cavity is 43±1°; the two fourth welding cavities are welded by the stacking welding process.

[0064] P4. Sleeve the thrust ring 2 on the flange 1 and close to the front bearing ring 3. The thrust ring 2 and the flange 1 are fixedly connected by welding.

[0065] A connecting plate 6 is arranged in the center hole 7 of P5 and the rear bearing ring 5 and away from the intermediate transition ring 4. The connecting plate 6 is fixedly connected to the inner surface of the center hole 7 by welding. Finally, a large wind turbine main shaft with rolled plate welding is obtained.

[0066] For those skilled in the art, according to the teachings of the present invention, without departing from the principles and spirit of the present invention, changes, modifications, substitutions and variations made to the implementation methods are still within the protection scope of the present invention.

Claims

1. A large wind turbine main shaft welded by coil plate, characterized in that: The invention comprises a front bearing ring (3), the front end of the front bearing ring (3) is integrally connected to a flange (1), a thrust ring (2) is integrally connected to the connection between the front bearing ring (3) and the flange (1), at least one intermediate transition ring (4) is integrally connected to the end of the front bearing ring (3) away from the flange (1), a rear bearing ring (5) is integrally connected to the end of the last intermediate transition ring (4), and the front bearing ring (3), the intermediate transition ring (4) and the rear bearing ring (5) are coaxially provided with center holes (7) in their interiors, and the inner surfaces of the center holes (7) have the same diameter.

2. A large-scale wind turbine main shaft welded by coiled plate welding according to claim 1, characterized in that: A first welding protrusion (103) is integrally connected to an end surface of the flange (1) close to the front bearing ring (3); the cross section of the first welding protrusion (103) is triangular; second welding surfaces arranged in an inclined manner are respectively provided on both sides of the first welding protrusion (103); and an angle a1 between the second welding surfaces on both sides of the first welding protrusion (103) is 153±1°.

3. A large-scale wind turbine main shaft welded by coiled plate according to claim 2, characterized in that: A second welding protrusion (301) is integrally connected to an end surface of the front bearing ring (3) close to the flange (1); the cross section of the second welding protrusion (301) is triangular; third welding surfaces arranged in an inclined manner are respectively provided on both sides of the second welding protrusion (301); and an angle a2 between the third welding surfaces on both sides of the second welding protrusion (301) is 153±1°.

4. A large-scale wind turbine main shaft welded by coiled plate according to claim 3, characterized in that: A third welding protrusion (302) is integrally connected to one end surface of the front bearing ring (3) close to the intermediate transition ring (4); the cross section of the third welding protrusion (302) is triangular; fourth welding surfaces arranged in an inclined manner are respectively provided on both sides of the third welding protrusion (302); and an angle a3 between the fourth welding surfaces on both sides of the third welding protrusion (302) is 144±1°.

5. A large-scale wind turbine main shaft welded by coiled plate according to claim 4, characterized in that: A fourth welding protrusion (401) is integrally connected to an end surface of the intermediate transition ring (4) close to the front bearing ring (3); the cross section of the fourth welding protrusion (401) is triangular; fifth welding surfaces arranged in an inclined manner are respectively provided on both sides of the fourth welding protrusion (401); and an angle a4 between the fifth welding surfaces on both sides of the fourth welding protrusion (401) is 144±1°.

6. A large-scale wind turbine main shaft welded by coiled plate according to claim 5, characterized in that: A fifth welding protrusion (402) is integrally connected to an end surface of the intermediate transition ring (4) close to the rear bearing ring (5); the cross section of the fifth welding protrusion (402) is triangular; sixth welding surfaces arranged in an inclined manner are respectively provided on both sides of the fifth welding protrusion (402); and an angle a5 between the sixth welding surfaces on both sides of the fifth welding protrusion (402) is 137±1°.

7. A large-scale wind turbine main shaft welded by coiled plate according to claim 6, characterized in that: A sixth welding protrusion (501) is integrally connected to an end surface of the rear bearing ring (5) close to the intermediate transition ring (4); the cross section of the sixth welding protrusion (501) is triangular; and seventh welding surfaces arranged in an inclined manner are respectively provided on both sides of the sixth welding protrusion (501); and an angle a6 between the seventh welding surfaces on both sides of the sixth welding protrusion (501) is 137±1°.

8. A method for preparing a large-scale wind turbine main shaft by coil welding, used for preparing a large-scale wind turbine main shaft by coil welding as claimed in claim 7, characterized in that: The preparation method includes a flange preparation process, a bearing ring preparation process and a splicing preparation process; The flange preparation process is carried out as follows: F1. Cutting: A production drawing of the flange (1) is drawn by computer, and the production drawing is cut into a plurality of preliminary processing plates (101) with the center of the circle as the axis, and the cutting size of each preliminary processing plate (101) is obtained; the cutting drawing of each preliminary processing plate (101) is in the shape of an arc plate; F2. Prepare raw materials: Cut the steel plate according to the blanking size of each preliminary processed plate (101) to obtain the preliminary processed plate (101), and then process the first welding surface on both side surfaces of each preliminary processed plate (101), wherein the first welding surface is arranged obliquely, and the inclination angle of the first welding surface is 30°; F3, welding: multiple pieces of preliminary processed plates (101) are butt-jointed in sequence, wherein two corresponding first welding surfaces form a first welding cavity, and the angle between the two side surfaces of the first welding cavity is 60°, and then a deposition welding process is used to weld in the first welding cavity to obtain a circular plate-shaped preliminary plate material; F4, forming: feeding the preliminary sheet material obtained in step F3 into a pressure forming machine, and then using a pressing die to press the preliminary sheet material to obtain a flange blank; F5. Machining: Machining the flange blank prepared in step F4 according to the size requirements of the production drawing, and then drilling flange holes on the flange blank using a drilling machine to obtain a flange (1).

9. The method for preparing a large wind turbine main shaft by coil welding according to claim 8, characterized in that: The bearing ring preparation process is carried out according to the following steps: Z1. Cutting: Cut the steel plate to obtain a square steel plate according to the axial length and circumference of the bearing ring to be produced. The thickness of the square steel plate is 200-300mm; Z2, processing the butt welding surface of the rolled plate: processing the butt welding surface at the long sides of both sides of the square steel plate obtained in step Z1, the butt welding surface is inclined, and the inclination angle of the butt welding surface is 30°; Z3, initial rolling: a plate rolling machine is used to roll the square steel plate prepared in step Z2 into a cylindrical tube with a through hole in the center. At this time, the butt welding surfaces on both sides of the square steel plate are butted to form a weld chamber; the inclined angle between the butt welding surfaces on both sides of the weld chamber is 60°; Z4. Welding: Multiple accumulation welding processes are used in the weld chamber. After each set of accumulation welding is completed, the weld needs to be cooled and slag removed, and then the weld is subjected to metal flaw detection. After meeting the requirements, the next accumulation welding is carried out. The accumulation welding, cooling, slag removal and metal flaw detection processes are repeated until the weld chamber is filled with molten solder, the welding process is completed, and the steel plate roll is made; Z5, fine coiling: the steel plate coil obtained in step Z4 is sent to the plate rolling machine again, and the steel plate coil is reshaped into a cylindrical shape; Z6, machining: machining the steel plate roll that has been shaped in step Z5 according to the size requirements of the production drawing, so that the dimensions of the steel plate roll meet the requirements of the production drawing, and the bearing ring is obtained; Z7, Processing and welding bulges: Use machine tools to process and weld bulges on both end surfaces of the bearing ring; According to the production drawings of the front bearing ring (3), the intermediate transition ring (4) and the rear bearing ring (5), the above steps Z1 to Z7 can be repeated to obtain the corresponding front bearing ring (3), the intermediate transition ring (4) and the rear bearing ring (5).

10. The method for preparing a large wind turbine main shaft by coil welding according to claim 9, characterized in that: The splicing preparation process is carried out in the following steps: P1. First, the flange (1) and the front bearing ring (3) are arranged coaxially, and then the first welding protrusion (103) on the flange (1) is butted against the second welding protrusion (301) on the front bearing ring (3). At this time, two upper and lower second welding cavities are formed between the first welding protrusion (103) and the second welding protrusion (301), and the angle between the second welding surface and the third welding surface in each second welding cavity is 27±1°; the two second welding cavities are welded by using a deposition welding process; P2. Then, the intermediate transition ring (4) and the front bearing ring (3) are arranged coaxially, and the fourth welding protrusion (401) on the intermediate transition ring (4) is butted against the third welding protrusion (302) on the front bearing ring (3). At this time, two upper and lower third welding cavities are formed between the fourth welding protrusion (401) and the third welding protrusion (302), and the angle between the fourth welding surface and the fifth welding surface in each third welding cavity is 36±1°; the two third welding cavities are welded by using a deposition welding process; P3, then the rear bearing ring (5) and the intermediate transition ring (4) are arranged coaxially, and the sixth welding protrusion (501) on the rear bearing ring (5) is butted against the fifth welding protrusion (402) on the intermediate transition ring (4), and two upper and lower fourth welding cavities are formed between the sixth welding protrusion (501) and the fifth welding protrusion (402), and the angle between the sixth welding surface and the seventh welding surface in each fourth welding cavity is 43±1°; the two fourth welding cavities are welded by using a deposition welding process; P4. The thrust ring (2) is sleeved on the flange (1) at a position close to the front bearing ring (3), and the thrust ring (2) and the flange (1) are fixedly connected by welding; P5, a connecting plate (6) is arranged in the center hole (7) of the rear bearing ring (5) and at a position away from the intermediate transition ring (4), and the connecting plate (6) and the inner surface of the center hole (7) are fixedly connected by welding; finally, a large-scale wind turbine main shaft with rolled plate welding is obtained.

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