Large-diameter conical wind power tower section of the wheel strong spinning type incremental forming process

Abstract

A kind of super-large diameter conical wind power tower section of cylinder piece's pair of wheel strong power spinning type progressive forming process, pair of wheel spinning adopts multiple pairs of spinning wheel and is uniformly distributed along the circumference of cylindrical blank, while processing the inner and outer surfaces of cylindrical blank, through predetermined path, spinning wheel group processes from inside and outside at the same height, and in order to the stability of processing process, through multiple passes, progressive processing is carried out;In the process of pair of wheel spinning, the cylindrical blank is hardened by thinning, and the performance is improved;Without using welding splicing and other processing methods, processing efficiency is high, and the effect is good;Cope with large size processing piece, without preparing different size core mold, processing flexibility is high, and cost is low;Its forming piece has the advantages of high surface quality, light overall weight, high strength, high near-net forming material utilization rate.

Description

TECHNICAL FIELD

[0001] The present application belongs to the field of efficient and high-performance material-saving machining of large wind power conical towers, and particularly relates to a super-large power conical wind tower section with a super-large diameter for supporting a wind turbine at the top of the wind tower. BACKGROUND

[0002] Wind turbines with a super-large diameter have high requirements for the performance of wind tower towers, but the manufacturing process of wind tower towers is complex, the performance of the produced wind tower towers is poor, the weight of the tower is large, and a large amount of steel is consumed, which is difficult to meet the actual demand.

[0003] The commonly used production and manufacturing method of wind tower towers at present is to use sheet metal as raw material, use traditional process to manufacture in blocks, and then splice and weld; or use sheet metal bending and rolling methods, and use welding methods to connect joints, for example, the method of manufacturing and transporting a segmented wind turbine tower in Chinese patent (publication number: CN 108301982 B) uses a segmented tower manufacturing and welding method to change the direction of the steel plate to roll into a tower section and stack and weld in a certain way; the method of manufacturing a polygonal wind tower in Chinese patent (publication number: CN 105484945 B) uses a bending machine to fold LP steel plates into a polygonal segment structure and splices and welds the segments into a polygonal tower. Such production and manufacturing methods have longitudinal welds or one or more circumferential welds. When welding, local high temperatures are generated, which can affect the shape and performance of the surrounding materials. Each longitudinal weld can reduce the strength of the cylinder by about 1 / 2, and each circumferential weld can reduce the strength of the cylinder by about 1 / 3. Various defects exist at the welds, and a large amount of welding can cause the weight of the parts to be large and the production time to be long.

[0004] The splicing and welding method widely used in the production and manufacturing of wind tower towers has the following disadvantages: (1) The process of splicing and welding the conical tower sheet metal parts in the circumferential and axial directions causes the manufacturing and installation process to be complex and results in a large amount of material waste. (2) Splicing and welding multiple tower parts results in a large number of welding positions and a long welding process, which affects production efficiency. (3) Because there are a large number of welds on the tower, the tower cylinder structure is heavy, the size precision of the welding position is poor, and the strength of the welds is poor. Therefore, a new production and manufacturing method is urgently needed to achieve high-quality and efficient production of super-large diameter wind towers. SUMMARY

[0005] In order to overcome the above-mentioned prior art defects, the purpose of the present application is to provide a super large diameter conical wind power tower section of the wheel strong spinning type incremental forming process, through the wheel strong spinning way, when the wheel spinning, when coping with different sizes of tower cylinder, without adding different size core mold, at the same time, through adjusting the spinning path, the production of different shape and length of tower cylinder is completed, the production equipment design is flexible, the cost is saved, the applicability is improved; at the same time, because there is no welding seam in the processing process of single tower section, welding is not needed, the production time is saved, the production efficiency is improved, the size accuracy and overall strength of the cylinder are also improved, which has the advantages of low cost, high production efficiency, high size accuracy of formed parts, high strength, near net forming and reducing material waste.

[0006] In order to achieve the above-mentioned purpose, the technical scheme adopted by the present application is:

[0007] The super large diameter conical wind power tower section of the wheel strong spinning type incremental forming process places the cylindrical blank on the spinning equipment, and then spins it into a conical wind power tower with the wall thickness being thin at the top and thick at the bottom, comprising the following steps:

[0008] Firstly, the cylindrical blank 1 is clamped on the internal expansion clamp 6 of the spinning equipment, the internal expansion clamp 6 is connected to the spinning equipment main shaft 7, and the cylindrical blank 1 is fixed on the internal expansion clamp 6 through the pin 5;

[0009] Secondly, the spinning equipment main shaft 7 is started, the spinning equipment main shaft 7 drives the cylindrical blank 1 to rotate through the internal expansion clamp 6, the inner and outer spinning wheels of the spinning wheel 4 start radial feeding from the uppermost end or the lowermost end of the cylindrical blank 1, and the servo motor 2 drives the spinning wheel 4 to rotate actively through the planetary gear reducer 3, the spinning wheel 4 bites into the cylindrical blank 1 until the predetermined position;

[0010] Thirdly, the spinning wheel 4 is axially inclined in different directions by the inner and outer spinning wheels, and the vertical height of the inner and outer spinning wheels remains consistent;

[0011] Fourthly, the spinning wheel 4 repeatedly and incrementally completes the thinning and shaping work according to the first to third steps, and in the last pass, the spinning thinning slightly exceeds the final target;

[0012] Fifthly, the first to third steps are repeated, and the spinning wheel 4 completes a pass of shape correction spinning according to the corresponding path of the final target;

[0013] Sixthly, the cylindrical blank 1 is unloaded from the internal expansion clamp 6 and cut from the spinning position root to obtain the wind power tower section 8.

[0014] The spinning wheel 4 is connected to the planetary gear reducer 3, the input shaft of the planetary gear reducer 3 is connected with the servo motor 2, the rotating speed of the servo motor 2 can be adjusted, so that the linear speed of the cylindrical blank 1 rotation and the spinning wheel linear speed are consistent.

[0015] The spinning wheel 4 in the processing of the cylindrical blank 1 is processed by the strong spinning wheel, the thinning amount of each pass is referred to the size and material of the wind tower cylinder section, so that it can be stably processed, and the plasticity is completed in a multi-pass progressive manner.

[0016] The spinning wheel 4 in the processing of the cylindrical blank 1 is processed by the strong spinning wheel, the spinning wheel is completed by the reverse spinning from top to bottom, or the spinning is completed by the positive spinning from bottom to top.

[0017] The cylindrical blank 1 is fixed on the internal expansion clamp 6 by the pins 5 distributed in the circumferential direction.

[0018] The spinning wheel spinning adopts a plurality of spinning wheels 4 which are uniformly and symmetrically distributed along the circumferential direction of the cylindrical blank 1, and processes the inner and outer surfaces of the cylindrical blank 1.

[0019] Compared with the prior art, the present application realizes the manufacturing of large-size wind tower cylinder by the principle of spinning wheel spinning, and has the following advantages:

[0020] (1) The present application uses the strong spinning wheel spinning to process the large-size wind tower cylinder section, the requirement for the equipment is relatively low, and the method is an integral near-net forming method, the production efficiency is high, and the metal material is not wasted by multiple welding.

[0021] (2) The strong spinning wheel spinning adopted by the present application is a metal plastic forming method, there is no welding seam on the formed part of the wind tower cylinder section, the formed part is light in weight and high in forming precision, and the strength of the formed part is higher after the plastic deformation occurs.

[0022] (3) In order to cope with the metal springback caused by plastic forming in the processing process of the present application, the gradual spinning forming is first carried out with a thinning rate slightly exceeding the forming target to reserve the springback space, and the last pass is carried out with the forming target thinning rate for straightening, further improving the forming precision. BRIEF DESCRIPTION OF DRAWINGS

[0023] Figure 1 It is a spinning wheel spinning flowchart of the present application.

[0024] Figure 2 It is a first step schematic diagram of the spinning wheel spinning forming process of the present application.

[0025] Figure 3 It is a second step schematic diagram of the spinning wheel spinning forming process of the present application.

[0026] Figure 4The third step schematic diagram of the wheel spinning forming process of the present application.

[0027] Figure 5 The fourth step schematic diagram of the wheel spinning forming process of the present application.

[0028] Figure 6 The final effect diagram of the wheel spinning of the present application.

[0029] Figure 7 The schematic diagram of another direction spinning process of the present application.

[0030] Figure 8 The appearance schematic diagram of the wind power tower drum segment after the wheel spinning of the present application. DETAILED DESCRIPTION

[0031] The present application will be described in detail below with examples and drawings.

[0032] Referring to Figure 1 A large-diameter tapered wind power tower drum segment spinning forming process, the wheel spinning adopts multiple pairs of spinning wheels which are uniformly distributed along the circumference of the cylindrical blank, and the inner and outer surfaces of the cylindrical blank are processed, and the gradual forming is completed through multiple passes of spinning along the predetermined path, which specifically includes the following steps:

[0033] The first step, referring to Figure 2 The cylindrical blank 1 is clamped on the inner expanding clamp 6 of the spinning equipment, the inner expanding clamp 6 is connected to the spinning equipment main shaft 7, and the cylindrical blank 1 is fixed on the inner expanding clamp 6 through the pin 5;

[0034] The second step, referring to Figure 3 , the spinning equipment main shaft 7 is started, the spinning equipment main shaft 7 drives the cylindrical blank 1 to rotate through the inner expanding clamp 6, the inner and outer spinning wheels of the spinning wheel 4 start to feed radially from the lowermost end of the cylindrical blank 1, and the servo motor 2 drives the spinning wheel 4 to rotate through the planetary gear reducer 3, the spinning wheel 4 bites into the cylindrical blank 1 until the predetermined position;

[0035] The third step, referring to Figure 4 In order to achieve the tapered tower drum shape with thinner wall thickness at the top and thicker wall thickness at the bottom, the spinning wheel 4 is divided into inner and outer spinning wheels which are axially and obliquely fed in different directions, but in order to ensure the stability of the wheel spinning process, the vertical height of the inner and outer spinning wheels remains consistent;

[0036] The fourth step, referring to Figure 5 The spinning wheel 4 repeatedly and gradually completes the thinning and shaping work according to the first to third steps, and in the last pass, the spinning thinning slightly exceeds the final target;

[0037] The spinning roller 4 in the fourth step is spun one pass with a feed amount slightly exceeding the final target, in order to deal with the springback of the metal material after spinning is completed, so as to reduce the deviation of the final result;

[0038] In the fifth step, the first and third steps are repeated, and the spinning roller 4 is again spun one pass with the corresponding path of the final target to improve the final spinning precision, as shown in Figure 6 ;

[0039] In the sixth step, the cylindrical workpiece blank 1 is unloaded from the internal expansion clamp 6 and cut from the bottom of the spinning position to obtain the wind power tower cylinder segment 8, as shown in Figure 8 .

[0040] The spinning roller 4 is connected to the planetary gear reducer 3 through a transmission shaft and a key, the input shaft of the planetary gear reducer is connected to the servo motor 2, and the rotational speed of the servo motor 2 is adjustable, so that the linear speed of the cylindrical wall workpiece rotation is consistent with the linear speed of the spinning roller.

[0041] In the processing of the spinning roller 4 to the cylindrical workpiece blank 1, in order to ensure the stability of the whole processing process, the thinning amount of each pass is in accordance with the size and material of the wind power tower cylinder segment, so that it can be stably processed, and the plasticity is completed in a multi-pass progressive manner.

[0042] Referring to Figure 3 , Figure 7 , in the processing of the spinning roller 4 to the cylindrical workpiece blank 1, the spinning roller can be completed by reverse spinning from top to bottom, or by forward spinning from bottom to top.

[0043] The cylindrical workpiece blank 1 is fixed on the internal expansion clamp 6 by the pins 5 distributed symmetrically around the circumference, so as to prevent the relative sliding between the cylindrical workpiece blank 1 and the internal expansion clamp 6 during rotation.

[0044] The pair of spinning rollers are uniformly and symmetrically distributed around the circumference of the cylindrical workpiece blank 1, and the inner and outer surfaces of the workpiece are processed at the same time.

[0045] The above embodiments are only used to illustrate the technical solutions of the present application, and are not limited to the protection scope of the present application. Although the present application has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solutions of the present application can be modified or replaced by equivalents, and still fall within the protection scope of the present application.

Claims

1. A pair of wheel power spinning type incremental forming process for a super-large diameter conical wind power tower section, characterized in that, The application discloses a method for spinning a cylindrical blank into a tapered wind tower drum with a wall thickness gradually decreasing from top to bottom. In the first step, the cylindrical blank (1) is clamped on the inner expanding clamp (6) of the spinning device, the inner expanding clamp (6) is connected to the main shaft (7) of the spinning device, and the cylindrical blank (1) is fixed on the inner expanding clamp (6) through the pin (5). In the second step, the main shaft (7) of the spinning device is started, the cylindrical blank (1) is driven to rotate by the inner expanding clamp (6), the inner and outer rollers of the roller (4) start radial feeding from the lowermost or uppermost periphery of the cylindrical blank (1), meanwhile, the servo motor (2) drives the roller (4) to rotate actively through the planetary gear reducer (3), the roller (4) bites into the cylindrical blank (1) until the predetermined position. In the third step, the roller (4) is axially and obliquely fed in different directions, and the vertical height of the inner and outer rollers remains unchanged. In the fourth step, the roller (4) gradually completes the thinning and shaping work in the first to third steps, and the spinning thinning slightly exceeds the final target in the last pass. In the fifth step, the first to third steps are repeated, and the roller (4) completes one pass of the shaping spinning according to the corresponding path of the final target. In the sixth step, the cylindrical blank (1) is unloaded from the inner expanding clamp (6) and cut from the spinning position, thereby obtaining the wind tower drum section (8). The roller (4) is connected to the planetary gear reducer (3), the input shaft of the planetary gear reducer (3) is connected to the servo motor (2), the rotating speed of the servo motor (2) can be adjusted, so that the linear speed of the cylindrical blank (1) and the linear speed of the roller are consistent. In the processing of the roller (4) to the cylindrical blank (1), the thinning amount of each pass is referenced to the size and material of the wind tower drum section, so that the processing can be stable, and the thinning plasticity is completed in a multi-pass progressive manner. In the processing of the roller (4) to the cylindrical blank (1), the roller is completed by reverse spinning from top to bottom or by forward spinning from bottom to top.

2. The process of claim 1, wherein: The cylindrical blank (1) is fixed on the inner expanding clamp (6) by the circumferentially symmetrically distributed pins (5).

3. The process of claim 1, wherein: The multi-pair roller (4) is uniformly and symmetrically distributed along the circumference of the cylindrical blank (1), and the inner and outer surfaces of the cylindrical blank (1) are processed.

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