Marine generator assembly method

Abstract

The present invention discloses a method for assembling a marine generator, comprising the following steps: step 1: pressing a stator into a machine base; step 2: assembling an excitation control system and assembling stator lead cables; step 3: installing and wiring a rotor module, heating the exciter rotor and then putting it on a rotating shaft, heating a fan base and then putting it on the rotating shaft, and installing a fan on the fan base, so that the fan can play a role in cooling when the generator is running; after the fan is installed, a dynamic balancing test is performed on the entire rotor to detect the balance degree; by fixing the stator and the iron core in the last step, it is avoided that the stator iron core cannot be moved if a problem is found during assembly, and the improved device can correct the problem in time after it is found.

Description

Technical Field

[0001] The invention belongs to the technical field of marine generators, and particularly relates to an assembly method of a marine generator. Background Art

[0002] A generator is a mechanical device that converts other forms of energy into electrical energy. Driven by a turbine, steam turbine, diesel engine, or other power machinery, it converts energy generated by water flow, air flow, fuel combustion, or nuclear fission into mechanical energy, which is then transmitted to the generator, which then converts it into electrical energy. Generators have a wide range of applications in industrial and agricultural production, national defense, science and technology, and daily life. In recent years, the use of diesel generator sets on ships has increased. In addition to being used as conventional ship power generators, they are also increasingly used for electric propulsion. Due to their unique advantages, full or semi-electric propulsion has become a common practice on ships weighing thousands of tons or more. Marine generators use seawater to cool the fuel to achieve the performance required by diesel engines.

[0003] During the processing of existing marine generators, the stator is generally pressed into the machine base and then welded to fix it. However, during the later inspection, if a problem is found, the stator can no longer be easily moved, resulting in the need for further disassembly, which wastes time. After the rotor is assembled, in order to check its stable operation, it is generally tested after being installed in the stator. If a problem is found, it is inconvenient to disassemble it, the process is cumbersome and the assembly efficiency is slow. In addition, in order to improve the cleaning effect of the generator end cover bearing during assembly, kerosene is traditionally used to clean the bearing, but kerosene has a strong odor and pollutes the water surface environment. For this reason, we propose a marine generator assembly method. Summary of the Invention

[0004] The object of the present invention is to provide a method for assembling a marine generator to solve the problems raised in the above background technology.

[0005] To achieve the above-mentioned object, the present invention provides the following technical solution: a method for assembling a marine generator, comprising the following steps:

[0006] Step 1: Press the stator into the base;

[0007] Step 2: Assemble the excitation control system and stator lead cables;

[0008] Step 3: Install and wire the rotor module, heat the exciter rotor and put it on the shaft, heat the fan base and put it on the shaft, install the fan on the fan base, and perform a dynamic balancing test on the rotor;

[0009] Step 4: Remove the fan, install the rotor into the stator, and then install the fan;

[0010] Step 5: Install the excitation pole;

[0011] Step 6: Install the front and rear end covers of the generator, clean the bearing bushings and bearing shells with hydrocarbon cleaning agent, and install the bearings at the bearing stops at the front and rear ends of the shaft;

[0012] Step 7: The generator is tested and then inspected;

[0013] Step 8: Fix the stator core to the base and spray the surface of the generator with topcoat.

[0014] Preferably, in step 1, the screw holes on the machine base are first processed for wire rewinding, then the stator is hoisted, the press is started to press the stator into the machine base, and the stator core is repainted.

[0015] Preferably, in step 2, the generator leads are led out to the outlet box, the generator cables and the base are fixedly connected to the outlet box, the current transformer is assembled with a bus bar and then connected to the outlet box, and the current transformer base plate and the base are fixed after being coated with vaseline.

[0016] Preferably, in step three, the exciter rotor is heated and then put on the rotating shaft, and is pressed into place using a horizontal press if necessary.

[0017] Preferably, in step five, the excitation pole is mounted on the non-driving end cover, and then the excitation lead terminal block is installed, and finally the excitation main lead wire and the terminal block connecting piece are firmly soldered.

[0018] Preferably, when installing the bearing in step six, the rolling bearing is cleaned and then heated, and then the heated rolling bearing is placed on the output bearing position of the rotor. After the rolling bearing is cooled to room temperature, the end cover is matched with the rolling bearing.

[0019] Preferably, the busbar is fixed to the angle plate of the current transformer by bolts, and the bolts pass through the angle plate and a portion of the busbar that overlaps the imide tape.

[0020] Preferably, in step seven, after checking and confirming that all wiring and components inside the generator are correctly installed, the external cover is installed, and a sealing rubber must be affixed to the cover before installation.

[0021] Preferably, in step eight, the surface of the generator is cleaned with a hydrocarbon cleaning agent, then blown dry with compressed air, the defects are polished, the generator is sprayed with paint and dried after polishing, and then put into storage after inspection.

[0022] Compared with the prior art, the present invention has the following beneficial effects:

[0023] By fixing the stator and the iron core in the final step, it is avoided that the stator iron core cannot be moved if problems are found during assembly. After the device is improved, it can be corrected in time after problems are found, ensuring that the stator position is installed more accurately and improving the assembly effect. When the rotor is assembled into the stator, the rotor is tested after being connected to the fan, which is convenient for detecting the impact of the fan on the rotor, reducing the inconvenience of connecting the rotor to the fan for testing after being assembled into the stator. If problems are found, the rotor needs to be disassembled. When cleaning the bearings, hydrocarbon cleaning is used. Compared with traditional kerosene, it has better cleaning effect, less odor impact, and is more environmentally friendly. In addition, the device can be well used on ships by sealing and rust-proofing different parts, reducing the corrosion effect of water surface on the generator and extending the service life of the device. The device conversion steps are simple and easy to improve production efficiency. DETAILED DESCRIPTION

[0024] The following is a clear and complete description of the technical solutions in the embodiments of the present invention. Obviously, the embodiments described are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making any creative efforts are within the scope of protection of the present invention.

[0025] Example 1

[0026] The present invention provides a technical solution: a method for assembling a marine generator, characterized by comprising the following steps:

[0027] Step 1: Press the stator into the base to facilitate convenient installation and fixation of the stator;

[0028] Step 2: Assemble the excitation control system and stator lead cables;

[0029] Step 3: Install and wire the rotor module. After heating the exciter rotor, put it on the gear of the excitation shaft. After heating the fan seat, put it on the gear of the fan seat. Install the fan on the fan seat. During the test, the operation of the rotor can be better detected and the dynamic balance test of the rotor can be performed.

[0030] Step 4: Remove the fan, install the rotor into the stator, and then install the fan. Remove the fan first to facilitate the installation of the rotor into the stator.

[0031] Step 5: Install the excitation pole;

[0032] Step 6: Install the front and rear end covers of the generator, clean the bearing bushes and bearing shells with hydrocarbon cleaning agent, install the bearings at the bearing stops at the front and rear ends of the shaft, and clean the bearing bushes and bearing shells with hydrocarbon cleaning agent to improve the cleaning effect of the bearings and reduce the impact of impurities on the bearings;

[0033] Step 7: The generator is tested and then inspected to facilitate testing of the device;

[0034] Step 8: The stator core is fixed to the base to better limit the movement of the stator core, and the surface of the generator is sprayed with topcoat to improve the rust-proof effect of the device.

[0035] Preferably, in step one, the screw holes on the machine base are first processed with wire rewinding to improve the thread strength of the screw holes, and then the stator is lifted, the press is started to press the stator into the machine base, and the stator core is repainted to achieve better rust prevention effect.

[0036] Preferably, in step 2, the generator leads are led out to the outlet box, the generator cables and the base are fixedly connected to the outlet box, the current transformer is assembled with a bus bar and then connected to the outlet box, and the current transformer base plate and the base are fixed after being coated with vaseline.

[0037] Preferably, the busbar is fixed to the angle plate of the current transformer by bolts, and the bolts pass through the angle plate and the busbar and partially overlap the imide tape to facilitate better insulation effect.

[0038] Preferably, in step three, the exciter rotor is heated and then put on the rotating shaft, and is pressed into place using a horizontal press if necessary.

[0039] Preferably, in step five, the excitation pole is mounted on the non-driving end cover, and then the excitation lead terminal block is installed, and finally the excitation main lead wire and the terminal block connecting piece are firmly soldered.

[0040] Preferably, when installing the bearing in step six, the rolling bearing is cleaned and heated, and then the heated rolling bearing is placed on the output bearing position of the rotor. After the rolling bearing cools to room temperature, the end cover is matched with the rolling bearing for better matching effect during installation.

[0041] Preferably, in step seven, after checking and confirming that all wiring and components inside the generator are correctly installed, the external cover is installed. Before the cover is installed, a sealing rubber must be affixed to facilitate better sealing and improve the waterproof effect after assembly.

[0042] Preferably, in step seven, the shaft extension or flange is subjected to rust prevention and wrapping treatment to facilitate better rust prevention effect.

[0043] Preferably, in step eight, the surface of the generator is cleaned with a hydrocarbon cleaning agent, then blown dry with compressed air, and the defects are polished. After polishing, the paint is sprayed and dried to facilitate better painting effects and reduce paint defects. The generator is then inspected and put into storage.

[0044] Example 2

[0045] The present invention provides a technical solution: a method for assembling a marine generator, characterized by comprising the following steps:

[0046] Step 1: First, clean the paint on the stator surface, apply anti-rust paint to the areas where the anti-rust paint has fallen off, and press the stator into the base to facilitate convenient installation and fixation of the stator;

[0047] Step 2: Assemble the excitation control system and stator lead cables;

[0048] Step 3: After heating the exciter rotor, put it on the shaft. After heating the fan base, put it on the shaft. Install the fan on the fan base. During the test, the operation of the rotor can be better detected and the dynamic balance test of the rotor can be performed.

[0049] Step 4: Remove the fan, install the rotor into the stator, and then install the fan to facilitate the installation of the rotor into the stator;

[0050] Step 5: Install the excitation pole;

[0051] Step 6: Install the bearing and end cover at the output bearing of the rotor, and clean the bearing bushing and bearing shell with hydrocarbon cleaning agent to improve the cleaning effect of the bearing and reduce the impact of impurities on the bearing;

[0052] Step 7: The generator is tested and then inspected to facilitate testing of the device;

[0053] Step 8: The stator core is fixed to the base to better limit the movement of the stator core, and the surface of the generator is sprayed with topcoat to improve the rust-proof effect of the device.

[0054] Preferably, in step one, the screw holes on the machine base are first processed with wire rewinding to improve the thread strength of the screw holes, and then the stator is lifted, the press is started to press the stator into the machine base, and the stator core is repainted to achieve better rust prevention effect.

[0055] Preferably, in step 2, the generator leads are led out of the paper outlet box, the generator cables and the base are fixedly connected to the outlet box, the current transformer is assembled with a bus bar and then connected to the outlet box, and the current transformer base plate and the base are fixed after being coated with vaseline.

[0056] Preferably, the busbar is fixed to the angle plate of the current transformer by bolts, and the bolts pass through the angle plate and the busbar and are partially covered with mica tape to facilitate better insulation effect.

[0057] Preferably, in step three, the exciter rotor is heated and kept warm, and then the output bearing is put on, aligned with the keyway of the base, and the output bearing is pressed into the keyway using a horizontal press to facilitate inspection of the rotor.

[0058] Preferably, in step five, the excitation pole is mounted on the non-driving end cover, and then the excitation lead terminal block is installed, and finally the excitation main lead wire and the terminal block connecting piece are firmly soldered.

[0059] Preferably, when installing the bearing in step six, the rolling bearing is cleaned and then heated, and then the heated rolling bearing is placed on the output bearing position of the rotor. After the rolling bearing cools to room temperature, the end cover is matched with the rolling bearing, and then the sliding bearing is assembled to improve the rotation effect.

[0060] Preferably, in step seven, after checking and confirming that all wiring and components inside the generator are correctly installed, check and clean the inside of the generator to prevent foreign matter from being left behind, apply primer to places where the primer has fallen off, and install the external cover. Before installing the cover, a sealing rubber must be applied to facilitate better sealing and improve the waterproof effect after assembly.

[0061] Preferably, in step seven, the shaft extension or flange is subjected to rust prevention and wrapping treatment to facilitate better rust prevention effect.

[0062] Preferably, in step eight, the surface of the generator is cleaned with a hydrocarbon cleaning agent, then blown dry with compressed air, and the defects are polished. After polishing, different paint colors are sprayed on the base to apply topcoat, and then dried to facilitate better painting effects and reduce paint defects. After inspection, it is put into storage.

[0063] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. A method for assembling a marine generator, characterized in that: The steps include: Step 1: Press the stator into the base; Step 2: Assemble the excitation control system and stator lead cables; Lead the generator leads to the outlet box, connect the generator cable and the base to the outlet box, assemble the current transformer with the bus bar and connect it to the outlet box, and apply vaseline to the current transformer base and then fix it; The busbar is fixed to the angle plate of the current transformer by means of bolts, wherein the bolts pass through the angle plate and a portion of the busbar half-lapped with insulating tape; Step 3: Install and wire the rotor module, heat the exciter rotor and put it on the shaft, heat the fan base and put it on the shaft, install the fan on the fan base, and perform a dynamic balancing test on the rotor; Step 4: Remove the fan, install the rotor into the stator, and then install the fan; Step 5: Install the excitation pole, lead wire and cable assembly; install the excitation pole to the non-drive end cover, then install the excitation lead terminal block, and finally solder the excitation main lead wire and the terminal block connector firmly; Step 6: Install the front and rear end covers of the generator, clean the bearing bushings and bearing shells with hydrocarbon cleaning agent, and install the bearings at the bearing stops at the front and rear ends of the shaft; Step 7: The generator is tested and then inspected; Step 8: Fix the stator core to the base and spray the surface of the generator with topcoat.

2. A method for assembling a marine generator according to claim 1, characterized in that: In step one, first, the screw holes on the machine base are processed for thread rewinding, then the stator is lifted, the press is started to press the stator into the machine base, and the stator core is repainted.

3. The method for assembling a marine generator according to claim 1, wherein: In step three, the exciter rotor is heated and fitted onto the shaft, which is then pressed into place using a horizontal press.

4. The method for assembling a marine generator according to claim 1, wherein: When installing the bearing in step six, clean the rolling bearing and heat it, then put the heated rolling bearing on the output bearing position of the rotor. After the rolling bearing cools to room temperature, match the end cover with the rolling bearing.

5. The method for assembling a marine generator according to claim 1, characterized in that: In step seven, after checking and confirming that all wiring and components inside the generator are installed correctly, install the external cover. Before installing the cover, a sealing rubber must be applied.

6. The method for assembling a marine generator according to claim 1, characterized in that: In step seven, the shaft extension or flange is treated with rust prevention and wrapping.

7. The method for assembling a marine generator according to claim 1, characterized in that: In step eight, the surface of the generator is cleaned with hydrocarbon cleaning agent, then blown dry with compressed air, the defects are polished, painted and dried after polishing, and then put into storage after inspection.