An automatic data acquisition device for measuring the welding deformation of stator positioning ribs

Abstract

An automatic data acquisition device for measuring the welding deformation of stator positioning ribs, which includes a probe, a probe fixing bracket, a signal acquisition device, a terminal computer, an automatic analysis software, an output device, an alarm device and a monitoring bracket; each set of monitoring brackets consists of a bracket fixing frame, a bracket base and a bracket traveling mechanism, and is fixed on the lower ring plate of the stator ring plate; the probe fixing bracket includes a supporting block, an adjustable cushion block and a probe holder, the supporting block is welded and fixed on the bracket fixing frame, the adjustable cushion block is installed on the supporting block, the probe holder is welded and fixed at the front end of the adjustable cushion block, and the probe is fixed on the probe holder; the signal acquisition device and the alarm device are fixed on the bracket base and are connected to the terminal computer through signals; the signal acquisition device is connected to the probe; the terminal computer is installed with the automatic analysis software. This automatic acquisition device can automatically measure, automatically record, automatically analyze and give real-time alarms, and can conduct real-time monitoring during the welding of the stator positioning ribs of the hydrogenerator.

Description

Technical Field:

[0001] The present invention relates to the technical field of the assembly of hydroelectric generating unit equipment, and particularly relates to an automatic acquisition and automatic alarm device for the welding deformation data of positioning ribs in on-site laminated stator assembly. Background Art:

[0002] The stators of large hydro-generating units all arrive at the site in scattered parts and are assembled into a whole through a series of processes at the construction site. The installation of positioning ribs is one of the most critical processes in stator assembly, and the quality thereof will directly affect the quality of the next process in stator assembly - the stacking of the stator core. With the continuous improvement of the standards for the safe operation of hydroelectric power stations and power grids, the standards for key data such as the radius and roundness of on-site laminated stator assembly are also getting higher and higher. As the process with the highest precision in stator assembly and even in the assembly of generator components, the radius and chord distance data of positioning ribs are particularly important. When welding the positioning rib support blocks after adjustment and acceptance, the deformation control during the process is extremely important, that is, for the change of a single positioning rib during the welding of the support block, and also for the overall roundness change of the stator ring plate during the welding of the entire circle of support blocks. The radius and chord distance data of the positioning ribs after welding the positioning rib support blocks are the key to determining the overall dimensions of the stator, and it is difficult to rework and the control difficulty is extremely high. The measurement, analysis and processing methods for the welding deformation data of positioning ribs are mainly realized through the following steps:

[0003] (1) Measurement of pre-welding value: Generally, the acceptance data of positioning rib installation are the pre-welding data of the positioning ribs.

[0004] (2) Welding process monitoring: Generally, a "circle measuring frame + dial indicator" is used for radius and roundness measurement, and a chord distance measuring tool is used for chord distance detection. After each welding process or each support block is welded, the dimensions of a single positioning rib or the entire circle of positioning ribs are measured.

[0005] (3) Welding deformation control: During the welding process, welders cannot monitor and check in real time whether deformation occurs. It is necessary to judge whether the positioning ribs are deformed through data analysis when measuring the dimensions of a single positioning rib and the entire circle of positioning ribs after each welding process or each support block is welded.

[0006] (4) Welding deformation treatment:

[0007] 1) Deformation within a small range: Adjust the welding process, welding technology, and the swing welding direction of the welding rod.

[0008] 2) Larger or large-range deformation: Remove the weld of the support block, readjust and accept the positioning ribs again, and then re-weld the support block.

[0009] In actual construction, due to the generally large size and height of the generators of large hydro-generator units, a large number of positioning bars, and also a large number of stator ring plate layers, there are extremely many positioning bar support blocks. Correspondingly, there are relatively many measurement data such as the radius and chord distance of the positioning bars, and high precision requirements. The commonly used deformation measurement methods have the following problems:

[0010] 1) During the welding process, welders cannot monitor and check in real time whether deformation occurs, and cannot discover and adjust in real time during the welding process to avoid dimensional changes. The data measurement after welding can only cause rework.

[0011] 2) For each welding process and each welded support block, dimensional measurement is required. The measurement is interspersed with the welding process, and the number of measurements is relatively large, directly affecting the continuity of welding and prolonging the welding construction period.

[0012] 3) The dimensional measurement during the welding process of each process is affected by manual intervention, level deviation, etc., with large measurement difficulty, poor precision, long measurement period, a large amount of data, and great analysis difficulty. Summary of the Invention:

[0013] The problem to be solved by the present invention is to provide a real-time monitoring device for the welding of stator positioning bars of hydro-generators, which is convenient to operate, with automatic measurement, automatic recording, automatic analysis, and real-time alarm, aiming at the above deficiencies.

[0014] To solve the above problems, the technical solution adopted by the present invention is:

[0015] The present invention provides an automatic data acquisition device for measuring the welding deformation of stator positioning bars. The acquisition device includes a probe, a probe fixing bracket, a signal acquisition device, a terminal computer, an automatic analysis software, an output device, an alarm device, and a monitoring bracket; each set of monitoring brackets consists of a bracket fixing frame, a bracket base, and a bracket traveling mechanism. The bracket fixing frame is welded on the bracket base, and two sets of bracket traveling mechanisms are symmetrically installed on the left and right below. The bracket base is fixed on the lower ring plate of the stator ring plate through a limit pin; the probe fixing bracket includes a support block, an adjustable cushion block, a probe holder, and fixing screws. The support block is welded and fixed on the bracket fixing frame, the adjustable cushion block is installed on the support block through the fixing screws, the probe holder is welded and fixed at the front end of the adjustable cushion block, and the probe is fixed on the probe holder; the signal acquisition device and the alarm device are fixed on the bracket base; the signal acquisition device is connected to the probe and transmits signals to the terminal computer through wired / wireless signals; the alarm device is connected to the computer terminal through wired / wireless signals; the terminal computer is installed with an automatic analysis software; the terminal computer is arranged at the measurement station; the output device is connected to the terminal computer.

[0016] The support block is of a square structure, made of a steel plate with a thickness of 20 mm - 30 mm, and is evenly distributed with four M10 screw holes.

[0017] The adjustable cushion block is of square structure and is made of a steel plate with a thickness of 10 mm, and four strip-shaped holes are evenly distributed.

[0018] The vertical distance from the probe to the surface of the positioning rib is 3 mm ± 1 mm.

[0019] The center line of the probe holder coincides with the center line of the adjustable cushion block.

[0020] A round hole matching the probe is opened on the probe holder, and both ends of the probe are fastened with nuts after passing through the probe holder.

[0021] On each set of support fixing frames, two groups of probes are arranged in two columns from top to bottom. One group of 3 probes is arranged from top to bottom on the front of the corresponding positioning rib, and the other group of 3 probes is arranged from top to bottom on the side of the corresponding positioning rib.

[0022] The signal acquisition device is connected to the probe with a signal transmission cable.

[0023] The alarm device is fastened with a foundation seat, and the backing plate is welded on the support base.

[0024] Compared with the prior art, the present invention has the following beneficial effects:

[0025] 1. The present invention can monitor the change of dimensional data of the positioning rib during the welding process in real time, realize real-time monitoring, whole-process monitoring and automatic data recording, and can realize functions of automatic measurement, automatic data acquisition, automatic data recording, automatic data editing, automatic analysis and automatic alarm.

[0026] 2. The present invention can set the warning value of the deformation data. When the real-time monitoring data reaches the warning value, it automatically alarms through the sound and light effects of the alarm device, reminding the monitoring personnel and welding operators to stop immediately and make process adjustments as early as possible, avoiding weld gouging and rework operations.

[0027] 3. The present invention can greatly simplify the measurement procedure, reduce the number of measurement personnel, reduce the human measurement error, avoid the occurrence of errors in manual recording and editing, and greatly shorten the measurement time. The present invention can improve the measurement accuracy, and the measurement data is improved from the accuracy of dial indicator reading (0.01 mm) to the micron (1 μm = 0.001 mm) level.

[0028] 4. The present invention can avoid the interference between the measurement operation and the welding process, and make the welding operation continuous.

[0029] 5. According to the measurement requirements of the measurement part, the present invention can arrange multiple probes in two columns from top to bottom on the support for combined measurement, monitor the dimensional changes of the front and side of the positioning rib, and simultaneously measure the changes of the radius data and chord distance data of the multi-layer ring plate positioning rib.

[0030] In summary, the key technology of the present invention lies in utilizing the gap measurement characteristic of the probe. By arranging a monitoring bracket beside the positioning rib, the distance between the probe on the monitoring bracket and the measurement part changes, generating different electrical signals. Then, through the functions of electrical signal acquisition, conversion, and recording, and by means of the developed software, the original shape of the measurement part is edited into reference points. Through the analysis function of the collected data, the functions of precise measurement, real-time recording, automatic analysis, and automatic alarm are realized. Description of the Drawings:

[0031] Figure 1 is a schematic diagram of the structural layout of the present invention;

[0032] Figure 2 is a schematic diagram of the deformation measurement and monitoring of the radius chord distance of the positioning rib of the present invention;

[0033] Figure 3 is a schematic diagram of the deformation measurement and monitoring of the perpendicularity of the positioning rib of the present invention;

[0034] Figure 4 is a schematic diagram of the installation structure of the probe and the probe fixing bracket of the present invention;

[0035] Figure 5 is a top view of the probe fixing bracket of the present invention;

[0036] Figure 6 is a schematic diagram of the installation structure of the monitoring bracket of the present invention;

[0037] Figure 7 is a top view of the installation structure of the monitoring bracket of the present invention.

[0038] Reference Signs:

[0039] 1 - Circle Measuring Frame, 2 - Stator Ring Plate, 3 - Positioning Rib, 4 - Probe, 5 - Probe Fixing Bracket, 6 - Signal Acquisition Device, 7 - Terminal Computer, 8 - Output Device, 9 - Alarm Device, 10 - Positioning Rib Support Block, 11 - Support Block, 12 - Adjustable Pad, 13 - Probe Frame, 14 - Fixing Screw, 15 - Bracket Fixing Frame, 16 - Bracket Base, 17 - Limit Pin, 18 - Bracket Traveling Mechanism. Detailed Embodiments:

[0040] The present invention will be further described below in conjunction with the specific embodiments. The specific embodiments are further explanations of the principle of the present invention and do not limit the present invention in any way. Technologies identical or similar to the present invention do not exceed the scope of protection of the present invention.

[0041] See Figures 1 to 7, the present invention provides an automatic data acquisition device for measuring the welding deformation of stator positioning ribs. The automatic acquisition device includes a probe 4, a probe fixing bracket 5, a signal acquisition device 6, a terminal computer 7, an automatic analysis software, an output device 8, an alarm device 9, and a monitoring bracket. The number of monitoring brackets can be set according to the measurement requirements. In this embodiment, six sets of monitoring brackets are provided. Each set of monitoring brackets consists of a bracket fixing frame 15, a bracket base 16, and a bracket traveling mechanism 18. The bracket fixing frame 15 is welded on the bracket base 16, and two sets of bracket traveling mechanisms 18 are symmetrically installed on the left and right below. Four pin holes are provided on the bracket base 16, and the bracket base 16 is fixed on the lower ring plate of the stator ring plate 2 through a limit pin 17. The probe fixing bracket 5 includes a support block 11, an adjustable cushion block 12, a probe holder 13, and a fixing screw 14. The support block 11 is a square structure made of a steel plate with a thickness of 20 mm - 30 mm, and four M10 screw holes are evenly distributed and welded to the bracket fixing frame 15. The adjustable cushion block 12 is a square structure made of a steel plate with a thickness of 10 mm, and four strip holes are evenly distributed and installed on the support block 11 through 4 fixing screws 14. The probe holder 13 is welded and fixed at the front end of the adjustable cushion block 12, and its center line coincides with the center line of the adjustable cushion block 12. A round hole matching the probe 4 is provided on the probe holder 13. After the probe 4 passes through the probe holder 13, both ends are fastened with nuts. The probe fixing bracket 5 is fixed on the bracket fixing frame 15 by the support block 11 thereon. The probe 4 is a general term for proximity sensors that detect without contacting the detection object. It is a device with the ability to sense the approach of an object. It uses a displacement sensor's sensitivity to an approaching object to identify the approach of the object, and can detect the movement and presence information of the detection object and convert it into an electrical signal.

[0042] The said probe 4 is installed and fixed on the bracket fixing frame 15 through the probe fixing bracket 5. The vertical distance from the probe 4 to the surface of the positioning rib 3 is 3 mm ± 1 mm, and the measurement accuracy is generally 1 μm = 0.001 mm. According to the measurement requirements of the measurement part, multiple probes 4 can be arranged in two columns from top to bottom on each bracket fixing frame 15 for combined measurement. In this embodiment, two groups of probes 4 are arranged in two columns from top to bottom on each bracket fixing frame 15. One group of 3 probes 4 is arranged from top to bottom on the front of the corresponding positioning rib 3 to measure the radius change of the positioning rib 3 during the welding process. Another group of 3 probes 4 is arranged from top to bottom on the side of the corresponding positioning rib 3 to measure the chord distance change of the positioning rib during the welding process.

[0043] The signal acquisition device 6 is a transmitting device that collects and summarizes the electrical signals transmitted by the probes, amplifies the electrical signals, and transmits them wirelessly. The signal acquisition device 6 is fixed on the bracket base 16 at the bottom of the bracket fixing frame 15. The signal acquisition device 6 is connected to the probe 4 by a signal transmission cable, and is used to receive data collected by a single or multiple probes 4, and also has the function of supplying power to the probe 4, and then transmits the signals to the terminal computer 7 through wired / wireless signals. The alarm device 9 is a red warning light, which is clamped by a base seat, and the backing plate is welded on the bracket base 16. It is connected to the terminal computer 7 through wired / wireless, and can receive the alarm signal provided by the terminal computer 7 and emit a sound and light effect as a prompt signal. The terminal computer 7 is arranged at the measurement station, and the terminal computer 7 is installed with automatic analysis software. The terminal computer 7 has a wireless signal receiving function, receives and converts the electrical signals of the probe 4 collected by the signal acquisition device 6 into digital signals, and provides the collected and converted data signals to the automatic analysis software. By using the analysis function of the software, it realizes the functions of data acquisition, sorting, editing, and analysis, outputs intuitive graph / table analysis results, discriminates the authenticity of the collected data, discriminates the measured values and deviation values of the components, and whether they meet the accuracy requirements. In addition, according to the set warning value, when the data is close to the warning value, an alarm signal is sent to the alarm device 9, and at the same time, the terminal computer 7 reminds the operator in a flashing screen manner. The output device 8 is a printer, which is connected to the terminal computer 7 and can transmit or print the data result graph / table according to the construction needs.

[0044] This automatic acquisition device utilizes the gap measurement characteristics of the probe 4. By fixing the distance change between the probe 4 and the measurement part on the positioning ribs 3 of the hydrogenerator stator, different electrical signals are generated; then through the functions of electrical signal acquisition, conversion, and recording, and through the developed software, the original shape of the measurement part is edited as a reference point. Through the analysis function of the collected data, it realizes the functions of precise measurement, real-time recording, automatic analysis, implementation monitoring, and automatic alarm.

[0045] The specific implementation of automatic acquisition, automatic analysis, and automatic alarm during the welding process of the positioning ribs 3 using this data automatic acquisition device is as follows:

[0046] 1) Installation of the automatic acquisition device for welding deformation measurement data of the positioning ribs 3

[0047] Before installing the positioning ribs 3, install the generator stator frame and the stator circle measuring frame 1 in the pit, and adjust the data such as the center and verticality of the stator circle measuring frame 1 to meet the specification requirements. Then, after the positioning ribs 3 pass the acceptance and before starting to weld the positioning rib supports 10, install the automatic acquisition device for welding deformation measurement data.

[0048] Fabricate and assemble the monitoring bracket. The monitoring bracket is formed by welding the bracket fixing frame 15, the bracket base 16, and the bracket traveling mechanism 18. Determine the number of sets to be fabricated according to the number of welders. In this embodiment, 6 welders are arranged to weld the positioning rib support blocks 10 simultaneously, and 6 sets of monitoring brackets need to be fabricated and assembled. Then place the 6 assembled monitoring brackets on the lower ring plate of the stator ring plate 2, and fix the bracket base 16 to the lower ring plate of the stator ring plate 2 through the limit pin 17. Then weld and fix the support block 11 on the probe fixing bracket 5 to the bracket fixing frame 15. Install the probe 4 on the probe fixing bracket 5. The gap between the probe 4 and the measuring part on the positioning rib 3 can be temporarily not adjusted. Install and fix the signal acquisition device 6 and the alarm device 9 on the bracket base 16, and connect the probe 4 and the signal acquisition device 6 with a signal transmission cable.

[0049] Start the signal acquisition device 6 and the probe 4, start the computer terminal 7, and start the alarm device 9. Use an iron sheet or a feeler gauge to pass by the probe 4 to test the signal transmission and acquisition, the operation of the software, and the sound and light effect function of the alarm device 9. After the test, reset all the signals.

[0050] 2) Use of the automatic data acquisition device for measuring the welding deformation of the positioning rib 3

[0051] Ⅰ. After each set of monitoring brackets corresponds to the positioning rib 3, adjust the distance between the probe 4 and the measuring surface of the positioning rib 3 to be 3 mm ± 1 mm. One group of 3 probes 4 are arranged from top to bottom corresponding to the front of the positioning rib 3 to monitor the radius and perpendicularity changes during the welding process of the positioning rib 3. After the distance is adjusted to be qualified, reset the probe 4 to zero; another group of 3 probes 4 are arranged from top to bottom corresponding to the side of the positioning rib 3 to monitor the chord distance and side perpendicularity changes during the welding process of the positioning rib 3. After the distance is adjusted to be qualified, reset the probe 4 to zero.

[0052] Ⅱ. Before welding each positioning rib support block 10, reset all the probes 4 to zero. During the welding process, through the precise measurement, real-time recording, automatic analysis, real-time monitoring, and automatic alarm functions of the present invention, monitor the welding deformation situation in real time. When the deformation warning value is reached, an automatic alarm is given to remind the operating welder to stop in time, and by adjusting the welding process, the welding deformation is controlled.

[0053] Ⅲ. After each welding process is completed, pull out the limit pin 17, move the monitoring bracket to a new welding position, and repeat the above procedure to monitor the deformation of the new positioning rib 3 during welding.

Claims

1. An automatic data acquisition device for measuring the welding deformation of stator positioning ribs. The acquisition device includes a probe (4), a probe fixing bracket (5), a signal acquisition device (6), a terminal computer (7), an automatic analysis software, an output device (8), an alarm device (9), and a monitoring bracket, and is characterized in that: Each set of monitoring brackets consists of a bracket fixing frame (15), a bracket base (16), and a bracket traveling mechanism (18). The bracket fixing frame (15) is welded on the bracket base (16), and two sets of bracket traveling mechanisms (18) are symmetrically installed on the left and right below the bracket base (16). The bracket base (16) is fixed on the lower ring plate of the stator ring plate (2) through a limit pin (17). On each set of bracket fixing frames (15), two groups of probes (4) are arranged in two columns from top to bottom. One group of 3 probes (4) is arranged from top to bottom on the front of the corresponding positioning rib (3), and the other group of 3 probes (4) is arranged from top to bottom on the side of the corresponding positioning rib (3). The probe fixing bracket (5) includes a support block (11), an adjustable spacer (12), a probe holder (13), and a fixing screw (14). The support block (11) is welded and fixed on the bracket fixing frame (15). Four strip holes are evenly distributed on the adjustable spacer (12), and the adjustable spacer (12) is installed on the support block (11) through the fixing screw (14). The probe holder (13) is welded and fixed at the front end of the adjustable spacer (12), and the probe (4) is fixed on the probe holder (13). The signal acquisition device (6) and the alarm device (9) are fixed on the bracket base (16). The signal acquisition device (6) is connected to the probe (4) and transmits signals to the terminal computer (7) through wired / wireless signals. The alarm device (9) is connected to the computer terminal (7) through wired / wireless signals. The terminal computer (7) is installed with automatic analysis software. The terminal computer (7) is arranged at the measurement station. The output device (8) is connected to the terminal computer (7).

2. The automatic data acquisition device for measuring the welding deformation of the stator positioning ribs according to claim 1, wherein: The support block (11) is of a square structure and is made of a steel plate with a thickness of 20 mm - 30 mm, and four M10 screw holes are evenly distributed.

3. An automatic data acquisition device for measuring the welding deformation of the stator positioning ribs according to claim 1, characterized in that: The adjustable spacer (12) is of a square structure and is made of a steel plate with a thickness of 10 mm.

4. The automatic data acquisition device for measuring the welding deformation of the stator positioning ribs according to claim 1, characterized in that: The vertical distance from the probe (4) to the surface of the positioning rib (3) is 3 mm ± 1 mm.

5. An automatic data acquisition device for measuring the welding deformation of stator positioning ribs according to claim 1, characterized in that: The center line of the probe holder (13) coincides with the center line of the adjustable spacer (12).

6. The automatic data acquisition device for measuring the welding deformation of the stator positioning ribs according to claim 1, wherein: A round hole matching the probe (4) is opened on the probe holder (13), and both ends of the probe (4) are fastened with nuts after passing through the probe holder (13).

7. An automatic data acquisition device for measuring the welding deformation of stator positioning ribs according to claim 1, characterized in that: The signal acquisition device (6) is connected to the probe (4) with a signal transmission cable.

8. An automatic data acquisition device for measuring the welding deformation of stator positioning ribs according to claim 1, characterized in that: The alarm device (9) is clamped with a foundation seat, and the backing plate is welded on the bracket base (16).

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