Hoisting, centering and anti-collision auxiliary system for large hydro-generator rotor and operation method thereof

Abstract

A large hydro-generator rotor hoisting centering anti-collision auxiliary system and operation method, including centering monitoring devices, centering target devices and anti-collision devices, the number of centering monitoring devices is multiple, multiple centering monitoring devices are arranged along the circumference of the stator; the number of centering target devices corresponds to the number of centering monitoring devices, each centering target device is matched with a centering monitoring device, and multiple centering target devices are installed on the upper end surface of the rotor along the circumference of the rotor outer edge; the number of anti-collision devices is multiple, multiple anti-collision devices are installed on the upper end surface of the rotor along the circumference of the rotor outer edge, and the anti-collision device includes an anti-collision strip that moves up and down reciprocally; the centering monitoring device is used to be erected on the base surface of the stator or a hoisting operation platform. The present application can effectively solve the problems of low quantitative monitoring degree, strong artificial dependence and poor real-time performance in the centering monitoring and anti-collision alarm operation in the process of hoisting the rotor of the large hydro-generator of the current large hydropower station.

Description

Technical Field

[0001] This invention belongs to the field of rotor hoisting technology, and specifically relates to a large hydro-generator rotor hoisting alignment and anti-collision auxiliary system and its operation method. Background Technology

[0002] The rotor is an important component of the hydro-generator. During the maintenance of the hydro-generator in a hydropower station, it is necessary to lift out and reinstall the generator rotor. The rotors of the hydro-generators in large hydropower stations usually have large geometric dimensions and equipment tonnage, making the lifting operation difficult and risky.

[0003] For large hydro-generator units, the allowable clearance between the rotor and stator is relatively small during hoisting, requiring a certain level of alignment accuracy. Furthermore, any squeezing or collision between the rotor and stator during hoisting can cause serious equipment damage. Therefore, physical protection must be provided for the rotor and stator during hoisting to prevent direct squeezing or collision in the event of an accident.

[0004] Currently, during the hoisting and reinstallation of the generator rotor, manual plate insertion is mainly used for gap monitoring and collision protection between the stator and rotor. In this process, the maintenance team stands on the stator base with the plate. During rotor hoisting, the workers must continuously move the plate up and down to ensure sufficient clearance between the rotor and stator. If the plate becomes stuck and cannot be moved, they immediately raise their hands and report the issue. After assessing whether the rotor has deviated from its intended direction, the crane team contacts the bridge crane operator for fine-tuning until the hoisting and / or reinstallation is completed. Due to the complex on-site environment, this method relies primarily on manual labor. Gap monitoring and rotor position assessment depend mainly on qualitative judgment by the operators, lacking quantitative analysis. This results in high operational safety risks, cumbersome personnel scheduling, and high labor intensity, leading to low hoisting efficiency, long operation time, and high costs. Summary of the Invention

[0005] In view of the technical problems existing in the background art, the large hydro-generator rotor hoisting alignment and anti-collision auxiliary system and operation method provided by the present invention can effectively solve the problems of low quantitative monitoring, strong reliance on manual labor, and poor real-time performance in the current large hydropower station hydro-generator rotor hoisting process alignment monitoring and anti-collision alarm operation.

[0006] To solve the above-mentioned technical problems, the present invention adopts the following technical solution:

[0007] A large hydro-generator rotor hoisting alignment and anti-collision auxiliary system includes an alignment monitoring device, an alignment target device, and anti-collision devices. Multiple alignment monitoring devices are arranged circumferentially along the stator. The number of alignment target devices corresponds to the number of alignment monitoring devices, with each target device paired with one monitoring device. Multiple alignment target devices are installed circumferentially along the rotor's outer edge on the upper surface of the rotor. Multiple anti-collision devices are also installed circumferentially along the rotor's outer edge on the upper surface of the rotor, and each anti-collision device includes anti-collision strips that reciprocate vertically. The alignment monitoring device is used to be mounted on the stator's base surface or on the hoisting platform.

[0008] In a preferred embodiment, the centering monitoring device includes a tripod, a total station base on top of the tripod, a base plate on the total station base, a level, a point laser emitter, and a turntable base on the base plate, a rotary motor mounted on the turntable base to drive the turntable to rotate, a pitch motor mounted on the turntable base, the pitch motor being connected to and driving a laser rangefinder to perform pitch movements via a rotating shaft, and an tilt sensor mounted on the laser rangefinder.

[0009] In a preferred embodiment, the total station base and base plate are provided with a through hole at their center, which is used for the laser beam emitted by the point laser emitter to pass through, and a foot screw is provided between the total station base and base plate.

[0010] In a preferred embodiment, the target alignment device includes a target plate, a spherical reflective target, a target magnetic holder, and a crosshair laser emitter; the target plate is made of a light-transmitting material, the target plate is equipped with a crosshair, a spherical reflective target is installed at one end of the target plate, a target magnetic holder is installed on the lower side of the other end of the target plate, and a crosshair laser emitter is installed on the upper side of the target plate.

[0011] In a preferred embodiment, the laser beam emitted by the crosshair laser emitter is a visible crosshair laser beam, which coincides with the crosshair target. The vertical laser beam is perpendicular to the target plate surface and passes through the center of the spherical reflective target. The horizontal laser beam is tangent to the outer edge of the rotor.

[0012] In a preferred embodiment, the anti-collision device further includes a base, with multiple guide wheels mounted on the upright plate at one end of the base. Anti-collision strip assemblies are inserted between the multiple guide wheels, and the anti-collision strip assemblies slide with the guide wheels. The anti-collision strip assemblies are locked to the base by locking components. A pressure sensor is provided on the anti-collision strip assembly. A rotor connecting mechanism is provided at the other end of the base, which is used to detachably install on the top surface of the rotor.

[0013] In a preferred embodiment, the rotor connection mechanism includes a universal adjusting foot connected to the base plate. An adjusting handle is mounted on the screw head of the universal adjusting foot, and the adjusting handle is used to adjust the extension amount of the universal adjusting foot. The rotor connection mechanism also includes a switchable magnetic base, a shank screw, a tailstock plate, a guide rod, and a locking box-type linear bearing. The locking box-type linear bearing is mounted on the base and connected to the tailstock plate via the guide rod. A shank screw is provided on the tailstock plate and connected to the switchable magnetic base.

[0014] In a preferred embodiment, the anti-collision strip assembly is composed of several anti-collision strips spliced ​​together, with adjacent anti-collision strips being detachably connected. Guide grooves that cooperate with guide wheels are provided on both sides of the anti-collision strip, and an adsorption magnet and a pressure sensor are provided on the back of the anti-collision strip. The adsorption magnet is used to adsorb onto the outer cylindrical surface of the rotor; the contact of the pressure sensor protrudes from the surface of the anti-collision strip but is not higher than the adsorption surface of the adsorption magnet.

[0015] In a preferred embodiment, the pressure sensor is electrically connected to the wireless terminal module, which is mounted on the base. The wireless terminal module receives the pressure signal from the sensor and transmits it wirelessly to the router. The router is electrically connected to the server, which displays the pressure value on a screen for use by crane operators as a reference for adjusting the rotor position and attitude during the hoisting process.

[0016] An operation method for a large hydro-generator rotor hoisting and alignment anti-collision auxiliary system, comprising the following steps:

[0017] Step 1, set up the centering monitoring device: Set up multiple centering monitoring devices on the base surface of the stator or on the hoisting operation platform. During the setup, observe the level and first use the tripod to coarsely level the centering monitoring device, and then use the leveling screws on the total station base to finely level the centering monitoring device.

[0018] Step 2, calibrate the rotation angle of the centering monitoring device: By controlling the rotary motor and the pitch motor, the ranging laser beam emitted by the laser rangefinder is made to illuminate the inner edge of the stator, and the laser rangefinder is made to measure the maximum value. At this time, the current position of the rotary motor is calibrated as zero, that is, the rotation angle is 0.

[0019] Step 3, Calibrate the alignment monitoring device:

[0020] Scenario 1: If the centering monitoring device is installed on the base surface of the stator or on the hoisting platform and there are already fixed points with measured and marked coordinates, then proceed to step 2 for all installed centering monitoring devices.

[0021] Scenario 2: If the centering monitoring device is installed at any point on the stator base or hoisting platform, then select one of the centering monitoring devices and execute step 2. Then, by controlling the slewing motor and the pitch motor, the ranging laser beam emitted by the laser rangefinder is directed to the installation point of the other centering monitoring device.

[0022] Step 4, Rotor Attitude Alignment: By controlling the rotary motor and pitch motor, the ranging laser beam emitted by the laser rangefinder is directed to illuminate the spherical reflective target surface on the corresponding centering target device, making the ranging laser beam perpendicular to the spherical reflective target surface, i.e., presenting a point laser spot on the spherical reflective target surface. At this time, based on the data measured by the laser rangefinder and the pitch angle measured by the tilt sensor, the rotor attitude is adjusted accordingly. α By combining the relative height difference between the laser rangefinder probe and the upper surface of the stator obtained in step 2, the relative height difference between the center of the spherical reflective target on the current alignment target device and the upper surface of the stator can be obtained. By measuring the relative height difference between the center of the spherical reflective target on the alignment target device at multiple points and the upper surface of the stator, the height difference of each point is fed back to the hoisting operator. This will clarify the tilt of the rotor end face and the stator end face at this time. By adjusting, when the relative height difference between the center of the spherical reflective target on the alignment target device at multiple points and the upper surface of the stator is consistent, the rotor position is leveled, that is, the rotor axis is parallel to the stator axis at this time.

[0023] Step 5, Rotor and Stator Alignment: By controlling the rotary motor and pitch motor, the ranging laser beam emitted by the laser rangefinder is directed to illuminate the spherical reflective target surface on the corresponding alignment target device, making the ranging laser beam perpendicular to the spherical reflective target surface, i.e., presenting a point laser spot on the spherical reflective target surface. At this time, based on the data measured by the laser rangefinder and the rotation angle of the rotary motor... β This allows us to determine the coordinates of the center of the spherical reflective target on the current alignment target device relative to the lifting plan. Since the coordinates of the center of the circle containing the center of the spherical reflective target on different alignment target devices on the lifting plan are the coordinates of the rotor axis relative to the lifting plan, once the coordinates of the center of the spherical reflective target on all alignment target devices relative to the lifting plan are obtained, the coordinates of the rotor axis relative to the lifting plan can be determined. Combined with the coordinates of the stator axis relative to the lifting plan obtained in step 3, this provides quantitative guidance for the lifting operators to adjust the crane's movement.

[0024] Step 6, Install anti-collision devices:

[0025] Step 6.1: Place this anti-collision device on the top surface of the rotor, and adjust the installation posture of this anti-collision device by rotating the adjustment handle and the screw with handle so that the base plate is parallel to the top surface of the rotor, so as to ensure that the anti-collision strip assembly is perpendicular to the end surface of the rotor when it is inserted.

[0026] Step 6.2: Select the number of anti-collision strips to install based on the height of the rotor, and assemble several anti-collision strips into an anti-collision strip assembly;

[0027] Step 6.3: Install the anti-collision strip assembly. When the anti-collision strip assembly is inserted, the side with the adsorption magnet faces the outer cylindrical surface of the rotor. Adjust the installation position of this anti-collision device so that the adsorption magnet of the anti-collision strip assembly is adsorbed onto the outer cylindrical surface of the rotor.

[0028] Step 6.4: Lock the guide rod with the linear bearing of the locking box slider and turn on the switch of the magnetic base to make the anti-collision device adsorb and fix it.

[0029] Step 6.5: Following the operating methods of steps 6.1-6.4, install multiple anti-collision devices on the top surface of the rotor, with the multiple anti-collision devices evenly distributed on the top surface of the rotor;

[0030] Step 7, Alignment Monitoring: After the rotor and stator are aligned, the rotor is hoisted. Steps 4 and 5 can be repeated at any time and position to monitor the rotor's position and orientation in real time.

[0031] Simultaneously, anti-collision monitoring is performed: During rotor hoisting and assembly, the wireless terminal module in each anti-collision device is only used to receive signals emitted by the pressure sensors installed on the anti-collision strip assembly of that device; by receiving signal information from the wireless terminal modules installed on the anti-collision devices at different positions on the rotor, the location where the gap between the rotor and stator is too small can be identified. When the gap between the rotor and stator is too small, the pressure sensor is compressed. When the pressure exceeds the set threshold, an alarm signal will be issued on the display screen connected to the server to realize the real-time early warning function. When the pressure value detected by the pressure sensor exceeds the limit, it proves that the rotor hoisting is not stable; at the same time, the anti-collision strip assembly is used to provide physical protection for the rotor to avoid direct collision between the rotor and the stator.

[0032] This patent can achieve the following beneficial effects:

[0033] This invention, through the cooperation of a centering monitoring device and a centering target device, can measure the tilt of the upper surface of the generator rotor and its axial position, thereby achieving centering monitoring. Anti-collision devices are evenly distributed along the circumferential edge of the rotor on the upper surface, preventing direct crushing and collision between the rotor and stator in the event of an accident during hoisting. This invention effectively solves the problems of low quantitative monitoring, high reliance on manual labor, and poor real-time performance in current centering monitoring and anti-collision alarm operations during the hoisting of turbine generator rotors in large hydropower stations. Attached Figure Description

[0034] The present invention will be further described below with reference to the accompanying drawings and embodiments:

[0035] Figure 1 This is a system layout diagram of the present invention;

[0036] Figure 2 This is a three-dimensional structural diagram of the centering monitoring device of the present invention;

[0037] Figure 3 This is a diagram showing the top structure layout of the centering monitoring device of the present invention;

[0038] Figure 4 This is a structural diagram of the target alignment device of the present invention;

[0039] Figure 5 This is a schematic diagram illustrating the calibration principle of the centering monitoring device of the present invention. Figure 1 ;

[0040] Figure 6 for Figure 5 A bird's-eye view;

[0041] Figure 7 This is a schematic diagram illustrating the calibration principle of the centering monitoring device of the present invention. Figure 2 ;

[0042] Figure 8 for Figure 7 A bird's-eye view;

[0043] Figure 9 This is a schematic diagram illustrating the calibration principle of the centering monitoring device of the present invention. Figure 3 ;

[0044] Figure 10 for Figure 9 A bird's-eye view;

[0045] Figure 11 This is a three-dimensional structural diagram of the anti-collision device of the present invention;

[0046] Figure 12 This is a three-dimensional structural diagram of the anti-collision strip assembly of the present invention;

[0047] Figure 13 This is a three-dimensional structural diagram of the anti-collision strip of the present invention.

[0048] In the diagram: 1. Alignment monitoring device; 2. Alignment target device; 3. Collision avoidance device; 4. Stator; 5. Lifting platform; 6. Rotor; 7. Ranging laser beam; 8. Vertical alignment laser beam.

[0049] Tripod 101, Total station base 102, Base plate 103, Turntable base 104, Turning frame 105, Level 106, Rotary motor 107, Pitch motor 108, Rotating shaft 109, Point laser emitter 110, Laser rangefinder 111, Tilt sensor 112;

[0050] Target plate 201, spherical reflective target 202, target magnetic holder 203, crosshair laser emitter 204, crosshair 2011.

[0051] Base 301, universal adjusting foot 302, adjusting handle 303, linear bearing with locking box type slider 304, guide rod 305, tailstock plate 306, switch type magnetic base 307, screw with handle 308, guide wheel 309, set screw 310, wireless terminal module 311, anti-collision strip assembly 312, anti-collision strip 3121, set screw 3122, adsorption magnet 3123, pressure sensor 3124, tenon 31211, mortise 31212, guide groove 31213, slide groove 31214. Detailed Implementation

[0052] Example 1:

[0053] Preferred solutions include Figures 1 to 13 As shown, a large hydro-generator rotor hoisting alignment and anti-collision auxiliary system mainly includes three parts: alignment monitoring device 1, alignment target device 2, and anti-collision device 3. The alignment monitoring device 1 and the alignment target device 2 cooperate to complete alignment monitoring. Its installation structure and working principle are as follows:

[0054] like Figure 1-10 As shown, there are multiple centering monitoring devices 1, which are arranged around the stator 4. The number of centering target devices 2 corresponds to the number of centering monitoring devices 1. Each centering target device 2 is matched with one centering monitoring device 1. Multiple centering target devices 2 are installed on the upper end face of the rotor 6 along the outer edge of the rotor 6.

[0055] Specifically, the centering monitoring device 1 is erected circumferentially on the base surface of the stator 4 or on the hoisting platform 5 along the outer edge of the stator 4. At least three sets of centering monitoring devices 1 need to be erected at different points along the outer edge of the stator 4. There are no special requirements for the foundation on which the centering monitoring device 1 is erected. The erection points of multiple centering monitoring devices 1 on the base surface of the stator 4 or on the hoisting platform 5 can be fixed points with measured and marked precise coordinates, or they can be arbitrary points. The centering target device 2 is magnetically attracted to the upper end face of the rotor 6 along the outer edge of the rotor 6. Each centering target device 2 corresponds to one centering monitoring device 1, and the installation point of the centering target device 2 on the rotor 6 should be as close as possible to the corresponding erection point of the centering monitoring device 1 on the stator 4 or on the hoisting platform 5.

[0056] Furthermore, the centering monitoring device 1 includes a tripod 101, a total station base 102 on the top of the tripod 101, a base plate 103 on the total station base 102, a level 106, a point laser emitter 110 and a turntable base 104 on the base plate 103, a rotary motor 107 on the turntable base 104, the rotary motor 107 is used to drive the rotating frame 105 to rotate, a pitch motor 108 is installed on the rotating frame 105, the pitch motor 108 is connected through a rotating shaft 109 and drives the laser rangefinder 111 to perform pitch movement, and an tilt sensor 112 is installed on the laser rangefinder 111.

[0057] The centering monitoring device 1 in this embodiment includes a tripod 101, a total station base 102, a base plate 103, a turntable base 104, a rotating frame 105, a level 106, a rotary motor 107, a pitch motor 108, a rotating shaft 109, a point laser emitter 110, a laser rangefinder 111, and a tilt sensor 112. The base plate 103 is connected to the tripod 101 via the total station base 102. The level 106, the point laser emitter 110, and the turntable base 104 are mounted on the base plate. A rotary motor 107 is mounted at the center of the turntable base 104, connecting to and driving the rotating frame 105 to rotate. A pitch motor 108 is mounted on the rotating frame 105, connecting to and driving the laser rangefinder 111 to perform pitch movements via the rotating shaft 109. The tilt sensor 112 is mounted on the laser rangefinder 111. In this embodiment, the total station base 102 and the leveling screws 1021 on the total station base 102 are existing general-purpose leveling devices; the rotary motor 107 and pitch motor 108 can be servo motors, steering gears, or other rotary motors capable of precisely controlling the rotation angle, and the rotary motor 107 has an encoder that can output a relative rotation angle value; the laser beams of the point laser emitter 110 and the laser rangefinder 111 are visible light, and the tilt sensor 112 is a single-axis tilt sensor that measures the tilt angle as follows: Figure 5-10 The elevation angle α of the laser rangefinder 111 shown.

[0058] Furthermore, the total station base 102 and the base plate 103 are provided with a through hole at their center, which is used for the laser beam emitted by the point laser emitter 110 to pass through. A foot screw 1021 is provided between the total station base 102 and the base plate 103.

[0059] Furthermore, the target-aligning device 2 includes a target plate 201, a spherical reflective target 202, a target magnetic holder 203, and a crosshair laser emitter 204; the target plate 201 is made of a light-transmitting material, the target plate 201 is provided with a crosshair 2011, the spherical reflective target 202 is installed at one end of the target plate 201, the target magnetic holder 203 is installed on the lower side of the other end of the target plate 201, and the crosshair laser emitter 204 is installed on the upper side of the target plate 201.

[0060] The purpose of using a spherical reflective target 202 is to ensure that during hoisting operations, the rotor 6 at any height can effectively reflect the laser beam emitted by the laser rangefinder 111 in the centering monitoring device 1, thus avoiding the laser ranging error caused by the incident angle of traditional planar targets.

[0061] Furthermore, the laser beam emitted by the crosshair laser emitter 204 is a visible crosshair laser beam, which coincides with the crosshair 2011, and the vertical laser beam is perpendicular to the surface of the target plate and passes through the center of the spherical reflective target 202; the horizontal laser beam of the crosshair laser beam is tangent to the outer edge of the rotor 6.

[0062] The centering target device 2 in this embodiment includes a target plate 201, a spherical reflective target 202, a target magnetic holder 203, and a crosshair laser emitter 204. The target plate 201 is made of a light-transmitting material, and a crosshair 2011 is printed or engraved on its surface. A spherical reflective target 202 is installed at one end of the target plate 201. The purpose of using the spherical reflective target 202 is to ensure that during hoisting operations, the centering target device 2 can effectively reflect the laser beam emitted by the laser rangefinder 111 in the centering monitoring device 1 at any height of the rotor 6, avoiding the laser ranging error caused by the incident angle of traditional planar targets. A target magnetic holder 203 is installed on the lower side of the other end, and a crosshair laser emitter 204 is installed on the upper side. The target magnetic holder 203 is used to magnetically attach the centering target device 2 to the upper end face of the rotor 6, i.e., the top surface. The target magnetic holder 203 is a common switch-type magnetic holder used in the machinery industry. The crosshair laser emitter 204 is a commonly used laser generator module in the field, used to calibrate the installation position of the target alignment device 2. The laser beam emitted by the crosshair laser emitter 204 is a visible crosshair laser beam. The installation position of the crosshair laser emitter 204 should ensure that the emitted crosshair laser beam coincides with the crosshair 2011 on the target plate 201, and the vertical laser beam is perpendicular to the surface of the target plate and passes through the center of the spherical reflective target 202.

[0063] Before hoisting, the centering target device 2 is magnetically attached to the upper surface of the rotor 6 along the outer circumference of the rotor 6. Before installing the centering target device 2, its position must be adjusted so that the spherical reflector 202 extends beyond the outer edge of the rotor 6, and the horizontal laser beam emitted by the crosshair laser emitter 204 is tangent to the outer edge of the rotor 6. After the position of the centering target device 2 is adjusted, the magnetic switch of the target magnetic holder 203 is turned on, allowing the centering target device 2 to adhere to the rotor 6. The number of centering target devices 2 installed along the outer circumference of the rotor 6 corresponds to the number of centering monitoring devices 1 being installed. The installation position of the centering target device 2 should be as close as possible to the corresponding centering monitoring device 1 to ensure that the laser beam emitted by the laser rangefinder 111 of the centering monitoring device can be projected onto the spherical surface of the spherical reflector 202 during hoisting. In addition, the mounting bases of the multiple centering target devices 2 should be on the same plane. The purpose is to ensure that the center of the spherical reflective target 202 at different points of the centering target device 2 after installation is concentric with the rotor.

[0064] like Figure 11-13 As shown, the anti-collision device includes a base 301, universal adjusting feet 302, adjusting handle 303, a linear bearing with locking box-type slider 304, guide rod 305, tailstock plate 306, switch-type magnetic base 307, shank screw 308, guide wheel 309, set screw 310, wireless terminal module 311, and anti-collision strip assembly 312. Multiple guide wheels 309 are mounted on the upright plate at one end of the base 301. Anti-collision strip assemblies 312 are inserted between the guide wheels 309, and the anti-collision strip assemblies 312 slide against the guide wheels 309. The anti-collision strip assemblies 312 are locked to the base 301 by locking components. A pressure sensor 3124 or a micro switch is installed on the anti-collision strip assembly 312. A rotor connecting mechanism is provided at the other end of the base 301.

[0065] In this embodiment, universal adjusting feet 302 are threadedly connected to both sides of the front end of the base plate 301. Adjusting handles 303 are installed on the screw heads of the universal adjusting feet 302. Rotating the adjusting handles 303 adjusts the extension amount of the universal adjusting feet 302. A locking box-type linear bearing 304 is mounted on the bottom surface of the rear end of the base plate 301. A guide rod 305 is installed inside the locking box-type linear bearing 304. A tailstock plate 306 is connected to the extended end of the guide rod 305. The tailstock plate 306 can be pushed and pulled to adjust its position within the stroke range of the guide rod 305. The locking wrench on the linear bearing 304 can lock the guide rod 305. The tail plate 306 is connected to the shank screw 308 by thread. The end of the shank screw 308 is connected to the switch magnetic base 307 through a T-slot. The base plate 301 is also equipped with a wireless terminal module 311. Several sets of guide wheels 309 are installed on both sides of the upright plate of the base 301. The anti-collision strip assembly 312 can be inserted from the top and guided by the guide wheels 309. After the anti-collision strip assembly 312 is inserted, it is locked by the set screw 310 installed on the upright plate of the base 301.

[0066] Furthermore, the anti-collision strip assembly 312 is composed of several anti-collision strips 3121 spliced ​​together, with adjacent anti-collision strips 3121 being detachably connected. The anti-collision strips 3121 are provided with guide grooves 31213 on both sides that cooperate with the guide wheels 309. The back of the anti-collision strips 3121 is provided with an adsorption magnet 3123 and a pressure sensor 3124. The adsorption magnet 3123 is used to adsorb onto the outer cylindrical surface of the rotor 6. The contact of the pressure sensor 3124 protrudes from the surface of the anti-collision strip 3121 but is not higher than the adsorption surface of the adsorption magnet 3123.

[0067] In this embodiment, the anti-collision strip assembly 312 is composed of several anti-collision strips 3121 spliced ​​together. The required number of splices is determined by the required height of the rotor 6 to be protected. The two ends of the anti-collision strips 3121 have ball heads or other forms of mortise and tenon structures that can be used for splicing with each other. A set screw 3122 is installed at the splice of every two anti-collision strips to prevent the anti-collision strips 3121 from slipping off. Preferably, the upper and lower ends of the anti-collision strips 3121 are respectively provided with mortise grooves 31212 and tenons 31211. Two adjacent anti-collision strips 3121 are connected by mortise and tenon joints of mortise grooves 31212 and tenons 31211, and the connection between mortise grooves 31212 and tenons 31211 is locked by set screws 3122.

[0068] The anti-collision strip 3121 has guide grooves 31213 on both sides that mate with the guide wheel 309; the front side of the anti-collision strip 3121 has a sliding groove 31214 that mates with the set screw 310; and two ends of the back side of the anti-collision strip 3121 are equipped with adsorption magnets 3123. When the adsorption magnets 3123 at both ends of a single anti-collision strip 3121 are attracted to the outer cylindrical surface of the rotor 6, the adsorption force provided by the adsorption magnets 3123 is only used to generate the frictional force required to prevent the anti-collision strip 3121 from falling due to gravity. A micro switch or pressure sensor 3124 is mounted on the middle of the back of the anti-collision strip 3121 through a mounting groove. The contact of the micro switch or pressure sensor 3124 protrudes from the surface of the anti-collision strip 3121 but does not exceed the adsorption surface of the adsorption magnet 3123. The purpose is that if the gap between the rotor 6 and the stator 4 is too small during the hoisting process, the rotor 6 will press against the anti-collision strip assembly 312, the anti-collision strip 3121 will deform, and the contact of the micro switch or pressure sensor 3124 will contact the surface of the rotor 6 and activate, triggering a warning signal.

[0069] Furthermore, the pressure sensor 3124 is a pressure sensor, and the pressure sensor 3124 is electrically connected to the wireless terminal module 311, which is mounted on the base 301. The wireless terminal module 311 is used to receive the pressure signal from the sensor and transmit the pressure signal wirelessly to the router. The router is electrically connected to the server, and the server displays the pressure value on the screen for use by the crane operator as a reference for adjusting the rotor position and attitude during the hoisting process.

[0070] In this embodiment, the pressure sensor is an L10j type pressure sensor. The wireless terminal module 311 is a Zigbee wireless terminal module. The pressure sensor outputs a 1~1.5mV / V signal. An HDO7mV signal isolation transmitter converts the mV signal into a standard 4~20mA signal before connecting it to the Zigbee wireless terminal module. The signal is then sent to the server via the wireless network for unified processing.

[0071] The operation method and steps for the anti-collision auxiliary system for the hoisting and alignment of a large hydro-generator rotor are as follows:

[0072] Step 1, setting up the centering monitoring device 1: Set up multiple centering monitoring devices 1 on the base surface of the stator 4 or on the hoisting operation platform 5. During the setup, observe the level 106, first use the tripod 101 to coarsely level the centering monitoring device 1, and then use the level screws 1021 on the total station base 102 to finely level the centering monitoring device 1.

[0073] If there are already fixed points on the base surface of the stator 4 or on the hoisting platform 5 with precise coordinates measured and marked, then when the centering monitoring device 1 is installed, the spot of the vertically aligned laser beam 8 emitted by the point laser emitter 110 should fall on the fixed point mark.

[0074] Step 2, calibrate the rotation angle of the centering monitoring device 1: By controlling the rotary motor 107 and the pitch motor 108, the ranging laser beam 7 emitted by the laser rangefinder 111 is made to irradiate the inner edge of the stator, and the laser rangefinder 111 is made to measure the maximum value. At this time, the current position of the rotary motor 107 is calibrated as zero, that is, the rotation angle is 0.

[0075] Specifically, let point A be the location where the centering monitoring device 1 is installed. When the laser rangefinder 111 measures the maximum value, the ranging laser beam 7 illuminates point B on the inner edge of the stator 4. Therefore, AB must pass through the axis of the stator. Taking point A, the location of the centering monitoring device 1, as the origin of the coordinate system, the values ​​measured by the laser rangefinder 111 and the pitch angle of the pitch motor 108 measured by the tilt sensor 112 are then used to determine the coordinates. α 0 This allows us to determine the coordinates of point B on the inner edge of stator 4 and the relative height difference between the laser rangefinder 111 probe and the upper surface of stator 4 from the overhead view of the hoisting.

[0076] Step 3, Calibrate the alignment monitoring device 1:

[0077] Scenario 1: If the centering monitoring device 1 is mounted on the base surface of the stator 4 or on the hoisting platform 5 and there are already fixed points with measured and marked precise coordinates, then step 2 shall be performed on all mounted centering monitoring devices 1.

[0078] Now Figure 8Taking the situation shown as an example, the coordinates of points B, D, and F on the inner edge of stator 4 can be obtained from the known coordinate positions A, C, and E. Then, the coordinates of the axis of stator 4 on the lifting top view plane can be determined from points B, D, and F.

[0079] Scenario 2: If the centering monitoring device 1 is installed on the base surface of the stator 4 or at any point on the hoisting platform 5, then select one of the centering monitoring devices 1 to execute step 2. Then, by controlling the rotary motor 107 and the pitch motor 108, the ranging laser beam 7 emitted by the laser rangefinder 111 is directed to the installation point of the other centering monitoring device 1.

[0080] The number of alignment monitoring devices 1 is at least three. The location of the third alignment monitoring device 1 is set as C. Then the ranging laser beam 7 illuminates point D on the inner edge of the stator 4. The light spots of the ranging laser beam 7 emitted by the alignment monitoring device 1 set at point A and the vertical alignment laser beam 8 emitted by the alignment monitoring device 1 set at point C coincide. At this time, the coordinates of point C relative to point A can be determined on the hoisting top view plane by the value measured by the laser rangefinder 111 of the alignment monitoring device 1 set at point A, the pitch angle α of the pitch motor 108 measured by the tilt sensor 112, and the rotation angle β of the slewing motor 107. Repeating the above steps can determine the coordinates of the other alignment monitoring device 1 set points relative to point A on the hoisting top view plane. Then repeat step 3. The operation in case one can determine the coordinates of the axis of the stator 4 on the hoisting top view plane.

[0081] Step 4, Rotor 6 attitude alignment: By controlling the rotary motor 107 and the pitch motor 108, the ranging laser beam 7 emitted by the laser rangefinder 111 is made to illuminate the spherical surface of the spherical reflector 202 on the corresponding centering target device 2, so that the ranging laser beam 7 is perpendicular to the spherical surface of the spherical reflector 202, that is, a point laser spot appears on the spherical surface of the spherical reflector 202. At this time, based on the data measured by the laser rangefinder 111 and the pitch angle measured by the tilt sensor 112 and the pitch angle of the pitch motor 108, the position is adjusted accordingly. α By combining the relative height difference between the laser rangefinder 111 probe and the upper surface of the stator 4 obtained in step 2, the relative height difference between the center of the spherical reflective target 202 on the current alignment target device 2 and the upper surface of the stator 4 can be obtained. By measuring the relative height difference between the center of the spherical reflective target 202 on the alignment target device 2 and the upper surface of the stator 4 at multiple points, and feeding back the height difference of each point to the hoisting operator, the tilt of the end face of the rotor 6 and the end face of the stator 4 at this time can be clearly determined. By adjusting, when the relative height difference between the center of the spherical reflective target 202 on the alignment target device 2 and the upper surface of the stator 4 at multiple points is consistent, the position of the rotor 6 is leveled, that is, the axis of the rotor 6 is parallel to the axis of the stator 4 at this time.

[0082] Step 5, centering rotor 6 and stator 4: By controlling the rotary motor 107 and the pitch motor 108, the ranging laser beam 7 emitted by the laser rangefinder 111 is made to illuminate the spherical surface of the spherical reflector 202 on the corresponding centering target device 2, so that the ranging laser beam 7 is perpendicular to the spherical surface of the spherical reflector 202, that is, a point laser spot appears on the spherical surface of the spherical reflector 202. At this time, based on the data measured by the laser rangefinder 111 and the rotation angle of the rotary motor 107... β By doing so, the coordinates of the center of the spherical reflective target 202 on the target device 2 and the lifting plan can be obtained. Since the coordinates of the center of the circle containing the center of the spherical reflective target 202 on the target device 2 at different points on the lifting plan are the coordinates of the rotor 6 axis on the lifting plan, by obtaining the coordinates of the center of the spherical reflective target 202 on all target devices 2 and the lifting plan, the coordinates of the rotor 6 axis on the lifting plan can be known. Combined with the coordinates of the stator 4 axis on the lifting plan obtained in step 3, the lifting operators can be quantitatively guided to adjust the crane movement.

[0083] Step 6, Install anti-collision devices:

[0084] Step 6.1: Place the anti-collision device on the top surface of the rotor, and adjust the installation posture of the anti-collision device by rotating the adjusting handle 303 and the screw with handle 308 so that the base plate 301 is parallel to the top surface of the rotor 6, so as to ensure that the anti-collision strip assembly 312 is perpendicular to the end surface of the rotor 6 when it is inserted.

[0085] Step 6.2: Select the number of anti-collision strips 3121 to be installed according to the height of rotor 6, and assemble several anti-collision strips 3121 into anti-collision strip assembly 312;

[0086] Step 6.3: Install the anti-collision strip assembly 312. When the anti-collision strip assembly 312 is inserted, the side with the adsorption magnet 3123 faces the outer cylindrical surface of the rotor 6. Adjust the installation position of this anti-collision device so that the anti-collision strip assembly 312 and the adsorption magnet 3123 are adsorbed onto the outer cylindrical surface of the rotor 6.

[0087] Step 6.4: Lock the guide rod 305 by locking the linear bearing 304 with locking box type slider and turn on the switch type magnetic base 307 to make the anti-collision device adsorb and fix it.

[0088] Step 6.5: Following the operating methods of steps 6.1-6.4, install multiple anti-collision devices on the top surface of rotor 6, with the multiple anti-collision devices evenly distributed on the top surface of rotor 6;

[0089] Step 7, Alignment Monitoring: After aligning rotor 6 and stator 4, rotor 6 begins hoisting. Steps 4 and 5 can be repeated at any time and position to monitor the rotor 6's position and orientation in real time. The main reason for requiring at least three sets of alignment monitoring devices 1 and alignment target devices 2 is that at least three arbitrary installation point coordinates are needed to determine the end-plane orientation of stator 4 and rotor 6 respectively. Therefore, the above implementation example only shows the case with three alignment monitoring devices 1 and alignment target devices 2. Setting more alignment monitoring devices 1 and alignment target devices 2 can provide more verification or interpolation data for the alignment operation, but the specific implementation remains the same as the steps described above.

[0090] Simultaneously, anti-collision monitoring is performed: When the rotor 6 is hoisted and assembled, the wireless terminal module 311 in each anti-collision device is only used to receive signals emitted by the pressure sensor installed on the anti-collision strip assembly 312 of that anti-collision device; by the signal information received by the wireless terminal module 311 on the anti-collision devices installed at different positions on the rotor 6, it can be determined where the gap between the rotor 6 and the stator 4 is too small. When the gap between the rotor 6 and the stator 4 is too small, the pressure sensor is squeezed. When the pressure exceeds the set threshold, an alarm signal will be issued on the display screen connected to the server to realize the real-time early warning function. When the pressure value detected by the pressure sensor exceeds the limit, it proves that the rotor hoisting is not stable; at the same time, the anti-collision strip assembly 312 is used to provide physical protection for the rotor 6 to avoid direct collision between the rotor 6 and the stator 4.

[0091] The above embodiments are merely preferred technical solutions of the present invention and should not be considered as limitations on the present invention. The scope of protection of the present invention should be limited to the technical solutions described in the claims, including equivalent substitutions of the technical features described in the claims. That is, equivalent substitutions and improvements within this scope are also within the scope of protection of the present invention.

Claims

1. A large hydro-generator rotor hoisting and alignment anti-collision auxiliary system, characterized in that: It includes a centering monitoring device (1), a centering target device (2), and an anti-collision device (3). There are multiple centering monitoring devices (1), and multiple centering monitoring devices (1) are arranged around the stator (4). The number of centering target devices (2) corresponds to the number of centering monitoring devices (1). Each centering target device (2) is matched with one centering monitoring device (1). Multiple centering target devices (2) are installed circumferentially along the outer edge of the rotor (6) on the upper end face of the rotor (6). There are multiple anti-collision devices (3). Multiple anti-collision devices (3) are installed circumferentially along the outer edge of the rotor (6) on the upper end face of the rotor (6). The anti-collision device (3) includes anti-collision strips (312) that move up and down. The centering monitoring device (1) is used to be mounted on the base surface of the stator (4) or on the hoisting operation platform (5). The target-aligning device (2) includes a target plate (201), a spherical reflective target (202), a target magnetic holder (203), and a crosshair laser emitter (204). The target plate (201) is made of a light-transmitting material. The target plate (201) is equipped with a crosshair (2011). A spherical reflective target (202) is installed at one end of the target plate (201). A target magnetic holder (203) is installed on the lower side of the other end of the target plate (201). A crosshair laser emitter (204) is installed on the upper side of the target plate (201).

2. The anti-collision auxiliary system for hoisting and aligning a large hydro-generator rotor according to claim 1, characterized in that: The centering monitoring device (1) includes a tripod (101), a total station base (102) on the top of the tripod (101), a base plate (103) on the total station base (102), a level (106), a point laser emitter (110) and a turntable (104) on the base plate (103), a rotary motor (107) on the turntable (104), the rotary motor (107) is used to drive the rotating frame (105) to rotate, a pitch motor (108) is installed on the rotating frame (105), the pitch motor (108) is connected through a rotating shaft (109) and drives the laser rangefinder (111) to perform pitching action, and an tilt sensor (112) is installed on the laser rangefinder (111).

3. The anti-collision auxiliary system for hoisting and aligning a large hydro-generator rotor according to claim 2, characterized in that: The total station base (102) and the base plate (103) are provided with a through hole in the center. The through hole is used for the laser beam emitted by the point laser emitter (110) to pass through. A foot screw (1021) is provided between the total station base (102) and the base plate (103).

4. The anti-collision auxiliary system for hoisting and aligning a large hydro-generator rotor according to claim 1, characterized in that: The laser beam emitted by the crosshair laser emitter (204) is a visible crosshair laser beam. The crosshair laser beam coincides with the crosshair (2011), and the vertical laser beam is perpendicular to the surface of the target plate and passes through the center of the spherical reflective target (202). The horizontal laser beam of the crosshair laser beam is tangent to the outer edge of the rotor (6).

5. The anti-collision auxiliary system for hoisting and aligning a large hydro-generator rotor according to claim 1, characterized in that: The anti-collision device (3) also includes a base (301), on which a plurality of guide wheels (309) are installed on the vertical plate at the end of the base (301), and anti-collision strip assemblies (312) are inserted between the plurality of guide wheels (309). The anti-collision strip assemblies (312) slide with the guide wheels (309), and the anti-collision strip assemblies (312) are locked to the base (301) by locking members. A pressure sensor (3124) is provided on the anti-collision strip assembly (312). A rotor connection mechanism is provided at the other end of the base (301), which is used to be detachably installed on the top surface of the rotor (6).

6. The anti-collision auxiliary system for hoisting and aligning a large hydro-generator rotor according to claim 5, characterized in that: The rotor connection mechanism includes a universal adjusting foot (302) connected to the base plate (301). The screw head of the universal adjusting foot (302) is equipped with an adjusting handle (303), which is used to adjust the extension amount of the universal adjusting foot (302). The rotor connection mechanism also includes a switchable magnetic base (307), a shank screw (308), a tailstock plate (306), a guide rod (305), and a locking box type slider linear bearing (304). The locking box type slider linear bearing (304) is installed on the base (301). The locking box type slider linear bearing (304) is connected to the tailstock plate (306) through the guide rod (305). The tailstock plate (306) is provided with a shank screw (308), which is connected to the switchable magnetic base (307).

7. The anti-collision auxiliary system for hoisting and aligning a large hydro-generator rotor according to claim 6, characterized in that: The anti-collision strip assembly (312) is composed of several anti-collision strips (3121) spliced ​​together. The two adjacent anti-collision strips (3121) are detachably connected. The anti-collision strips (3121) are provided with guide grooves (31213) on both sides to cooperate with the guide wheel (309). The back of the anti-collision strip (3121) is provided with an adsorption magnet (3123) and a pressure sensor (3124). The adsorption magnet (3123) is used to adsorb onto the outer cylindrical surface of the rotor (6). The contact of the pressure sensor (3124) protrudes from the surface of the anti-collision strip (3121) but is not higher than the adsorption surface of the adsorption magnet (3123).

8. The anti-collision auxiliary system for hoisting and aligning a large hydro-generator rotor according to claim 7, characterized in that: The pressure sensor (3124) is electrically connected to the wireless terminal module (311), which is mounted on the base (301). The wireless terminal module (311) is used to receive the pressure signal from the sensor and transmit the pressure signal wirelessly to the router. The router is electrically connected to the server, and the server displays the pressure value on the screen for use by the crane operator as a reference for adjusting the rotor position and attitude during the hoisting process.

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