A method for repairing the guide vane sleeve of the water guide mechanism of a hydropower station unit

Abstract

A method for inspecting and repairing a guide vane sleeve of a water guide mechanism of a hydropower station unit comprises placing a support plate on a support ring at the lower end of a guide vane lower sleeve and fine-tuning the length of each adjustable leg, moving a fixing device so that the fixing device abuts against the inner wall of the guide vane lower sleeve, adjusting the position of a milling cutter by a lifting platform and a feed control system, starting a working motor and a rotation control system, rotating the milling cutter around the center of a rotating base and performing an annular milling process, stopping the rotation control system and the working motor after the process is completed, and setting a dial indicator on the milling cutter to check the roundness and concentricity of the guide vane lower sleeve step shaft diameter after processing; the present invention can effectively improve the quality and efficiency of the inspection and repair of the guide vane sleeve hole, ensure that the gap between the guide vane sleeve hole and the guide vane shaft neck is within a design range, and thereby ensure the safe and stable operation of the hydro-turbine generator set.

Description

Technical Field

[0001] The invention relates to the field of hydropower station component maintenance methods, and in particular to a method for repairing a guide vane shaft sleeve of a water guide mechanism of a hydropower station unit. Background Art

[0002] The water guide mechanism is an important component of a hydro-generator set. It can regulate the flow rate through the machine, cut off the water flow, start and stop the machine, and adjust the output of the unit. The quality of its maintenance is of great significance to the safe and stable operation of large hydro-generator sets.

[0003] The water guide mechanism of a large hydropower station unit is difficult to open and close during operation, and the opening and closing torque of the water guide mechanism is large, which has an adverse effect on the unit's regulation. At the same time, during long-term operation, the unit is susceptible to cavitation and scratches at the guide vane sleeve hole step due to hydraulic cavitation and wear from hard debris, posing a serious threat and hidden danger to the safe and stable operation of the hydropower unit. Therefore, during routine maintenance work, the guide vane sleeve hole step area needs to be processed to expand its inner diameter. Defective areas such as cavitation and scratches need to be repaired by welding and then polishing. In current work, the method used to repair guide vane sleeve hole defects is usually to first manually repair the defects by welding and then manually polishing. This method not only generates a large amount of noise, dust, and harmful smoke during operation, but is also labor-intensive, inefficient, and has low repair quality. Therefore, it is necessary to design a guide vane sleeve repair method for the water guide mechanism of a hydropower station unit, which can be used for the guide vane sleeve hole milling process. Summary of the Invention

[0004] In view of the technical problems existing in the background technology, the present invention provides a guide vane shaft sleeve maintenance method for the water guide mechanism of a hydropower station unit, which can effectively improve the quality and efficiency of the guide vane shaft sleeve hole maintenance, ensure that the gap between the guide vane shaft sleeve hole and the guide vane shaft neck is within the design range, and thus ensure the safe and stable operation of the hydro-turbine generator set.

[0005] In order to solve the above technical problems, the present invention adopts the following technical solutions:

[0006] Base comprises support, castor, and frame upper is provided with guide rail, and support and conveyer frames movable end contact site are provided with recoil spring or rubber cushion, and castor is arranged on the pin of base bottom four, to carry mobile handler location.

[0007] The method comprises the following steps:

[0008] Step 1. Place the support plate on the support ring at the lower end of the guide vane lower sleeve;

[0009] Step 2: Fine-tune the length of each adjustable leg to keep the support plate level and control the overall error within 0.02mm / m;

[0010] Step 3. Move the fixing device so that it contacts the inner wall of the guide vane lower sleeve, or directly clamp the fixing device to the upper end opening of the guide vane lower sleeve;

[0011] Step 4. Adjust the height of the milling cutter by adjusting the position of the lifting platform;

[0012] Step 5: Adjust the position of the sliding plate through the feed control system and finally determine the feed amount of the milling cutter;

[0013] Step 6: After the position of the milling cutter is finally determined, start the working motor and make the milling cutter rotate at high speed for milling;

[0014] Step 7. Start the rotation control system to make the milling cutter rotate around the center of the rotating base and perform circular processing;

[0015] Step 8. After processing, stop the rotation control system and working motor, set up a dial indicator on the milling cutter to check the roundness and concentricity of the step shaft diameter of the guide vane lower sleeve after processing.

[0016] In the preferred solution, in Step 2, the adjustable leg includes a support rod, the upper end of the support rod is provided with a threaded connecting column, the lower end of the support rod is provided with a non-slip base, and threaded connecting heads are correspondingly provided at the four corners of the lower end surface of the base plate. The threaded connecting column is threadedly connected to the threaded connecting head and fine-tunes the installation length of the adjustable leg.

[0017] In a preferred embodiment, the fixed base includes a fixed plate, both sides of which are detachably connected to the base plate by bolts, a fixed ring is provided at the center of the fixed plate, a slot is provided on the fixed ring, and a ball bearing is provided at the center of the fixed ring;

[0018] The rotating base includes a rotating table, the lower end surface of the rotating table is provided with a corresponding rail and is engaged with the slot, the center position of the rotating table is provided with a corresponding pin and is inserted into the ball bearing, the lower end of the rotating table is provided with an annular gear plate and is engaged with the rotation control system.

[0019] In the preferred solution, in Step 7, the rotation control system includes a connecting rod, one end of which is provided with a bevel gear and meshed with the annular gear plate, the other end of the connecting rod is connected to the first gear, a second gear is provided below the first gear and is connected to each other through a transmission chain, the second gear is connected to the rotating motor through a transmission shaft, and the rotating motor is installed on the lower end surface of the base plate.

[0020] In a preferred embodiment, in Step 5, the feed control system includes a screw rod, which is installed in the rotating base. The screw rod can rotate freely around its own axis and has a first handle at one end. Second screw rods are vertically installed on both sides of the screw rod.

[0021] There are corresponding strip holes on both sides of the sliding plate and the second screw passes through. The second screw is provided with a second limit nut to lock the position of the sliding plate. The lower end surface of the sliding plate is fixedly connected to the transmission assembly and is sleeved on the screw rod. The screw rod rotates and drives the transmission assembly and the sliding plate to slide back and forth along the screw rod.

[0022] In the preferred solution, a lifting gear plate is provided on the front of the back plate, the lifting platform is clamped on the lifting gear plate and meshed with the lifting gear plate, a second handle is provided on the side of the lifting platform to control the lifting platform to slide vertically along the back plate, a working motor is provided on the upper end face of the lifting platform to control the rotation of the milling cutter, and a power supply and control system are provided in the control box and are electrically connected to the working motor.

[0023] This patent can achieve the following beneficial effects:

[0024] 1. This device uses automated tooling to process the step diameter of the guide vane lower sleeve hole, which can reduce labor intensity, reduce the generation of noise, dust and harmful smoke, and improve the on-site working environment while also improving maintenance efficiency, thereby further shortening the maintenance period;

[0025] 2. All components of the device are detachable, which not only improves the adaptability of the device but also facilitates its subsequent maintenance and repair;

[0026] 3. This device replaces traditional manual operation with automated machinery, and its work quality is significantly higher than that of manual labor, ensuring the processing quality of the shaft sleeve hole under the guide vane of the hydropower station. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The present invention will be further described below with reference to the accompanying drawings and examples:

[0028] Figure 1 This is a schematic diagram of the overall structure of the present invention (installation method 1);

[0029] Figure 2 This is an enlarged schematic diagram of the adjustable legs and fixing device structure of the present invention;

[0030] Figure 3 This is a schematic diagram of the structure of the main working parts of the present invention;

[0031] Figure 4 This is a schematic diagram of the structure of the main working parts of the present invention Figure 2 ;

[0032] Figure 5 This is an exploded schematic diagram of the internal structure of the present invention;

[0033] Figure 6 Schematic diagram of the explosion of the internal structure of the present invention Figure 2 ;

[0034] Figure 7 This is a schematic diagram of the overall structure of the present invention (installation method 2).

[0035] In the figure: base plate 1, threaded connector 101, fixed base 2, fixed plate 201, bolt 202, fixed ring 203, slot 204, ball bearing 205, adjustable leg 3, support rod 301, threaded connection column 302, anti-slip base 303, guide vane lower sleeve 4, support ring 401, support plate 5, fixing device 6, fixed cam 601, first screw 602, first limit nut 603, feed control system 7, screw rod 701, first handle 702, second screw 7 03, second limiting nut 704, transmission assembly 705, lifting platform 8, second handle 801, rotating base 9, rotating platform 901, rail 902, latch 903, annular gear plate 904, back plate 10, lifting gear plate 101, rotation control system 11, connecting rod 111, first gear 112, second gear 113, transmission chain 114, rotating motor 115, bevel gear 116, milling cutter 12, sliding plate 13, strip hole 131, control box 14, working motor 15. DETAILED DESCRIPTION

[0036] like Figure 1As shown, a method for repairing a guide vane sleeve of a water guide mechanism of a hydropower station unit is used. The method adopts a milling processing device, including a base plate 1, a fixed base 2, a rotating base 9, a lifting platform 8 and a support plate 5. The support plate 5 is placed as a whole on a support ring 401 at the lower end of the guide vane lower sleeve 4. Fixing devices 6 are installed at the four corners of the upper end surface of the base plate 1 and abut against the inner wall of the guide vane lower sleeve 4. Adjustable legs 3 are vertically connected to the four corners of the lower end surface of the base plate 1. The other ends of the legs are placed on the support plate 5. A fixed base 2 is installed at the center of the upper end surface of the base plate 1. A rotating base 9 is installed on the fixed base 2. The rotating base 9 is controlled by a rotation control system 11 and rotates around its own axis.

[0037] A sliding plate 13 is placed on the upper end surface of the rotating base 9. The sliding plate 13 is controlled by the feed control system 7 and slides in the radial direction. A back plate 10 is vertically mounted on the upper end surface of the sliding plate 13. The front surface of the back plate 10 is slidably connected to the lifting platform 8. A control box 14 is fixedly mounted on the back surface of the back plate 10. A milling cutter 12 is mounted on the lower end surface of the lifting platform 8.

[0038] When the device is working, the base plate 1 is first placed on the support ring 401, and then the base plate 1 is placed on the support plate 5 through the adjustable legs 3. The entire device is fixed by the fixing device 6, and the height of the lifting platform 8 and the position of the sliding plate 13 are adjusted to adjust the milling cutter 12 to a suitable position. Finally, the working motor 15 and the rotation control system 11 are started, and the milling cutter 12 performs annular milling processing around the lower guide vane sleeve 4.

[0039] The preferred solution is Figure 2 As shown, the adjustable leg 3 includes a support rod 301, the upper end of the support rod 301 is provided with a threaded connection column 302, the lower end of the support rod 301 is provided with a non-slip base 303, and the four corners of the lower end surface of the base plate 1 are correspondingly provided with threaded connectors 101. The threaded connection column 302 is threadedly connected to the threaded connector 101 and fine-tunes the installation length of the adjustable leg 3; the fixing device 6 includes a first screw 602, which is installed at the four corners of the upper end surface of the base plate 1. A fixed cam 601 is sleeved on the first screw 602, and a first limit nut 603 is further provided on the first screw 602 to lock the rotation angle of the fixed cam 601;

[0040] When placing the base plate 1, first place it on the support plate 5 through the adjustable legs 3, and then fine-tune the length of the adjustable legs 3 at the four corners to keep the base plate 1 level. After the adjustment is completed, rotate the cam 601 and tighten the first limit nut 603 to make the cam 601 abut against the inner wall of the guide vane lower sleeve 4 to prevent the device from moving during milling and affecting the processing accuracy.

[0041] The preferred solution is Figures 3 to 6As shown, the fixed base 2 includes a fixed plate 201, and both sides of the fixed plate 201 are detachably connected to the base plate 1 by bolts 202. A fixed ring 203 is provided at the center of the fixed plate 201, and a slot 204 is provided on the fixed ring 203. A ball bearing 205 is provided at the center of the fixed ring 203; the rotating base 9 includes a rotating table 901, and a rail 902 is provided on the lower end surface of the rotating table 901 and is engaged with the slot 204. A latch 903 is provided at the center of the rotating table 901 and is inserted into the ball bearing 2 05, an annular gear plate 904 is provided at the lower end of the rotating platform 901 and is meshed with the rotation control system 11; the rotation control system 11 includes a connecting rod 111, one end of the connecting rod 111 is provided with a bevel gear 116 and is meshed with the annular gear plate 904, the other end of the connecting rod 111 is connected to a first gear 112, a second gear 113 is provided below the first gear 112 and is connected to each other through a transmission chain 114, the second gear 113 is connected to a rotating motor 115 through a transmission shaft, and the rotating motor 115 is installed on the lower end surface of the base plate 1;

[0042] When the device is working, the fixed plate 201 and the rotating table 901 are plugged into each other. When the rotating motor 115 is turned on, the rotating motor 115 drives the second gear 113 to rotate, and the second gear 113 drives the first gear 112 to rotate synchronously through the transmission chain 114. The first gear 112 drives the connecting rod 111 and the bevel gear 116 to rotate around its own axis. The rotation of the bevel gear 116 drives the annular gear plate 904 and the rotating base 9 to rotate, and then drives the back plate 10 and the milling cutter 12 to rotate around the axis of the rotating base 9.

[0043] The preferred solution is Figures 3 to 6 As shown, the feed control system 7 includes a screw rod 701, which is installed in the rotating base 9. The screw rod 701 can rotate freely around its own axis and has a first handle 702 at one end. Second screw rods 703 are vertically installed on both sides of the screw rod 701.

[0044] The sliding plate 13 has strip-shaped holes 131 on both sides thereof through which the second screw rod 703 passes. The second screw rod 703 is provided with a second limiting nut 704 to lock the position of the sliding plate 13. The lower end surface of the sliding plate 13 is fixedly connected to the transmission assembly 705 and is sleeved on the screw rod 701. The screw rod 701 rotates and drives the transmission assembly 705 and the sliding plate 13 to slide back and forth along the screw rod 701.

[0045] When the feed amount needs to be adjusted, the first handle 702 can be rotated to drive the screw rod 701 to rotate around its own axis. The rotation of the screw rod 701 drives the transmission assembly 705 and the sliding plate 13 to slide along the screw rod 701, thereby controlling the position of the milling cutter 12 and adjusting the final milling amount.

[0046] The preferred solution is Figures 3 to 6 As shown, a lifting gear plate 101 is provided on the front of the back plate 10, and the lifting platform 8 is clamped on the lifting gear plate 101 and engaged with the lifting gear plate 101. A second handle 801 is provided on the side of the lifting platform 8. By rotating the handle 801, the transmission component inside the lifting platform 8 can be driven to transmit the lifting gear plate 101, thereby driving the lifting platform 8 to slide vertically along the back plate 10 and control the height of the milling cutter 12. A working motor 15 is provided on the upper end face of the lifting platform 8 and controls the rotation of the milling cutter 12. A power supply and a control system are provided in the control box 14 and are electrically connected to the working motor 15.

[0047] Example 1

[0048] Step 1: Place the support plate 5 on the support ring 401 at the lower end of the guide vane lower sleeve 4;

[0049] Step 2: Fine-tune the length of each adjustable leg 3 to keep the support plate 5 level, with the overall error controlled within 0.019 mm / m;

[0050] Step 3. Move the fixing device 6 so that it contacts the inner wall of the guide vane lower sleeve 4. Adjust the position of the support plate 5 and move it to the center position. The deviation should be controlled within 0.015mm.

[0051] Step 4: Adjust the height of the milling cutter 12 by adjusting the position of the lifting platform 8;

[0052] Step 5: Adjust the position of the sliding plate 13 through the feed control system 7, and finally determine the feed amount of the milling cutter 12;

[0053] Step 6: After the position of the milling cutter 12 is finally determined, the working motor 15 is started and the milling cutter 12 is rotated at high speed for milling. The working speed of the milling cutter 12 is set to 5800 r / min.

[0054] Step 7: Start the rotation control system 11 to make the milling cutter 12 rotate around the center of the rotating base 9 and perform annular processing. The speed of the rotating base 9 is controlled at 2 r / min.

[0055] Step 8: After the processing is completed, stop the rotation control system 11 and the working motor 15, and set up a dial indicator on the milling cutter 12 to check the roundness and concentricity of the step shaft diameter of the guide vane lower sleeve 4 after processing.

[0056] Example 2

[0057] Step 1. Move the fixing device 6 so that it is directly connected to the upper end opening of the lower blade sleeve 4. Adjust the position of the support plate 5 and move it to the center position. The deviation is controlled within 0.02mm.

[0058] Step 2: Adjust the height of the milling cutter 12 by adjusting the position of the lifting platform 8;

[0059] Step 3, adjust the position of the sliding plate 13 through the feed control system 7, and finally determine the feed amount of the milling cutter 12;

[0060] Step 4: After the position of the milling cutter 12 is finally determined, the working motor 15 is started and the milling cutter 12 is rotated at high speed for milling. The working speed of the milling cutter 12 is set to 6000 r / min.

[0061] Step 5: Start the rotation control system 11 to make the milling cutter 12 rotate around the center of the rotating base 9 and perform annular processing. The speed of the rotating base 9 is controlled at 3 r / min.

[0062] Step 6: After the processing is completed, stop the rotation control system 11 and the working motor 15, and set up a dial indicator on the milling cutter 12 to check the roundness and concentricity of the step shaft diameter of the guide vane lower sleeve 4 after processing.

[0063] The above embodiments are merely preferred technical solutions of the present invention and should not be construed as limiting the present invention. The various technical features described in the present invention may be combined with one another without conflict. The scope of protection of the present invention shall be the technical solutions described in the claims, including equivalent alternatives to the technical features of the technical solutions described in the claims. Equivalent alternatives and improvements within this scope are also within the scope of protection of the present invention.

Claims

1. A method for repairing the guide vane sleeve of the water guide mechanism of a hydropower station unit, characterized in that: The method adopts a milling processing device, which includes a base plate (1), a fixed base (2), a rotating base (9), a lifting platform (8) and a support plate (5). The four corners of the upper end surface of the base plate (1) are provided with fixing devices (6) and are against the inner wall of the guide vane lower shaft sleeve (4). The four corners of the lower end surface of the base plate (1) are vertically connected with adjustable legs (3), and the other ends of the legs are placed on the support plate (5). The center position of the upper end surface of the base plate (1) is provided with a fixed base (2), and the rotating base (9) is provided on the fixed base (2). The base (9) is controlled by a rotation control system (11) and rotates around its own axis; a sliding plate (13) is placed on the upper end surface of the rotating base (9), and the sliding plate (13) is controlled by a feed control system (7) and slides in a radial direction, a back plate (10) is vertically installed on the upper end surface of the sliding plate (13), the front of the back plate (10) is slidably connected to the lifting platform (8), a control box (14) is fixedly installed on the back of the back plate (10), a milling cutter (12) is installed on the lower end surface of the lifting platform (8), and a working motor (15) is installed on the upper end surface of the lifting platform (8); The method comprises the following steps: Step 1. Place the support plate (5) on the support ring (401) at the lower end of the guide vane lower sleeve (4); Step 2, fine-tune the length of each adjustable leg (3) to keep the support plate (5) level and control the overall error within the range of 0.02 mm / m; Step 3, move the fixing device (6) so that the fixing device (6) abuts against the inner wall of the guide vane lower shaft sleeve (4), or directly clamp the fixing device (6) at the upper end opening of the guide vane lower shaft sleeve (4); Step 4, adjust the height of the milling cutter (12) by adjusting the position of the lifting platform (8); Step 5, adjusting the position of the sliding plate (13) through the feed control system (7), and finally determining the feed amount of the milling cutter (12); Step 6: After the position of the milling cutter (12) is finally determined, the working motor (15) is started and the milling cutter (12) is rotated at high speed to perform the milling process; Step 7, start the rotation control system (11), so that the milling cutter (12) rotates around the center of the rotating base (9) and performs annular processing; Step 8: After the processing is completed, stop the rotation control system (11) and the working motor (15), and set up a dial indicator on the milling cutter (12) to check the roundness and concentricity of the step shaft diameter of the guide vane lower sleeve (4) after processing.

2. The method for repairing the guide vane sleeve of the water guide mechanism of a hydropower station unit according to claim 1, characterized in that: In Step 2, the adjustable leg (3) includes a support rod (301), the upper end of the support rod (301) is provided with a threaded connection column (302), the lower end of the support rod (301) is provided with an anti-slip base (303), and the four corners of the lower end surface of the base plate (1) are correspondingly provided with threaded connectors (101), and the threaded connection column (302) is threadedly connected to the threaded connector (101) to fine-tune the installation length of the adjustable leg (3).

3. The method for repairing the guide vane sleeve of the water guide mechanism of a hydropower station unit according to claim 1, characterized in that: The fixed base (2) includes a fixed plate (201), both sides of the fixed plate (201) are detachably connected to the base plate (1) via bolts (202), a fixed ring (203) is provided at the center of the fixed plate (201), a slot (204) is provided on the fixed ring (203), and a ball bearing (205) is provided at the center of the fixed ring (203); The rotating base (9) includes a rotating platform (901), a lower end surface of the rotating platform (901) is provided with a corresponding clamping rail (902) and is clamped with a clamping slot (204), a central position of the rotating platform (901) is provided with a corresponding latch (903) and is inserted into a ball bearing (205), and a ring gear plate (904) is provided at the lower end of the rotating platform (901) and is meshed with the rotation control system (11).

4. The method for repairing the guide vane sleeve of the water guide mechanism of a hydropower station unit according to claim 1, characterized in that: In Step 7, the rotation control system (11) includes a connecting rod (111), one end of the connecting rod (111) is provided with a bevel gear (116) and is meshed with the annular gear plate (904), the other end of the connecting rod (111) is connected to a first gear (112), a second gear (113) is provided below the first gear (112) and is connected to each other through a transmission chain (114), the second gear (113) is connected to a rotating motor (115) through a transmission shaft, and the rotating motor (115) is installed on the lower end surface of the base plate (1).

5. The method for repairing the guide vane sleeve of the water guide mechanism of a hydropower station unit according to claim 1, characterized in that: In Step 5, the feed control system (7) includes a screw (701), which is installed in the rotating base (9). The screw (701) can rotate freely around its own axis and has a first handle (702) at one end. Second screws (703) are vertically installed on both sides of the screw (701); The sliding plate (13) is provided with strip-shaped holes (131) on both sides thereof and passes through the second screw rod (703). The second screw rod (703) is provided with a second limiting nut (704) and locks the position of the sliding plate (13). The lower end surface of the sliding plate (13) is fixedly connected with a transmission assembly (705) and is sleeved on the screw rod (701). The screw rod (701) rotates and drives the transmission assembly (705) and the sliding plate (13) to slide forward and backward along the screw rod (701).

6. The method for repairing the guide vane sleeve of the water guide mechanism of a hydropower station unit according to claim 1, characterized in that: A lifting tooth plate (101) is provided on the front of the back plate (10), the lifting platform (8) is clamped on the lifting tooth plate (101) and meshed with the lifting tooth plate (101), a second handle (801) is provided on the side of the lifting platform (8) and controls the lifting platform (8) to slide vertically along the back plate (10), a working motor (15) is provided on the upper end surface of the lifting platform (8) and controls the milling cutter (12) to rotate, and a power supply and a control system are provided in the control box (14) and are electrically connected to the working motor (15).

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