A rectifier axial welding tool and welding method

Abstract

A rectifier axial welding tool and a welding method, the welding tool comprising two upper and lower spaced apart plate bodies connected by bolts, welding windows provided on the two plate bodies, arc-shaped clamping grooves provided on the opposite surfaces of the two plate bodies for clamping the two side edges of the outer ring of the rectifier, a second top block and a first top block provided between the two plate bodies, a plurality of jacking screws provided on the second top block for jacking the inner side of the flange plate of the blade to be welded, a screw rod provided on the first top block, a heat dissipation top block slidingly mounted between the two plate bodies and rotationally connected to the end of the screw rod, and an arc-shaped surface provided on the heat dissipation top block for abutting against the outer circumferential surface of the outer ring of the rectifier. The welding method adopts the above welding tool to clamp the outer ring of the rectifier and the blade to be welded. The clamping and mounting are convenient, and the deformation and warping of the outer ring of the rectifier at the welding position can be reduced.

Description

Technical Field

[0001] This invention relates to the field of aircraft engine repair technology, and in particular to a rectifier axial welding fixture and welding method. Background Technology

[0002] Aero-engine blades operate under harsh environments of high temperature, high pressure, and high speed for extended periods, making them highly susceptible to damage. Therefore, blade welding repair is a crucial technology in aero-engine maintenance and repair.

[0003] A certain type of rectifier consists of an outer ring and multiple blades brazed together. The bottom edge plate of the blades has the same shape as the inner wall of the outer ring, and the outer ring wraps around the bottom edge plate of the blades. During operation, blade damage and cracking are prone to occur. To reduce engine repair costs, welding repair of the rectifier is essential.

[0004] like Figure 1 The diagram shows the structure of a rectifier and the welding area of ​​the blades to be welded. The rectifier consists of an outer ring 1 and a pair of blades brazed together. Due to the high requirements for the fit between the outer ring 1 and the blades and the thinness of the welded area, the welding method is end welding. When one of the blades is damaged or cracked, it needs to be replaced. The blade to be welded 2 is welded onto the outer ring 1 of the rectifier. Weld A is located on the side of the blade edge plate, and the joint is end welding. The warpage of the rear end face before and after welding is required to be no more than 0.1 mm.

[0005] Due to the unique structure of the aforementioned rectifier and the fact that weld A is located on the side of the blade rim, clamping the rectifier outer ring 2 and the blade 2 to be welded is inconvenient during welding. Furthermore, the high temperatures generated during welding can easily cause deformation and warping of the rectifier outer ring 2 at the welding point. Summary of the Invention

[0006] The main objective of this invention is to provide an axial welding fixture and welding method for rectifiers, aiming to solve the aforementioned technical problems.

[0007] To achieve the above objectives, the present invention proposes an axial welding fixture for a rectifier, comprising two plates arranged opposite each other at an upper and lower interval, and the two plates being connected by bolts; welding windows are respectively provided on the two plates; arc-shaped grooves are respectively provided on the opposite surfaces of the two plates for engaging the two sides of the outer ring of the rectifier; a second top block and a first top block are provided between the two plates; multiple tightening screws are provided on the second top block for tightening the inner side of the edge plate of the blade to be welded; a screw is provided on the first top block; a heat dissipation top block is slidably installed between the two plates, and the heat dissipation top block is rotatably connected to the end of the screw; an arc-shaped surface is provided on the heat dissipation top block for abutting against the outer circumferential surface of the outer ring of the rectifier.

[0008] Preferably, the heat dissipation top block is made of aluminum alloy.

[0009] Preferably, a groove is provided on the opposing surfaces of the two plates, and the heat dissipation top block is slidably installed in the groove.

[0010] Preferably, a first slot and a second slot are provided on the opposing surfaces of the two plates, with the upper and lower ends of the second top block respectively inserted into the second slot; and the upper and lower ends of the first top block respectively inserted into the first slot.

[0011] Preferably, the length of the second top block is 3mm-5mm smaller on each side than the length of the second slot.

[0012] Preferably, clearance notches are provided at the upper and lower edges of the arc-shaped surface of the heat dissipation top block.

[0013] Preferably, slopes are provided on the outer surfaces of the two plates on both sides of the welding window, and the slopes are located on the opposite back side of the arc-shaped groove, and the slopes are inclined towards the welding window.

[0014] On the other hand, the present invention also proposes an axial welding method for rectifiers, employing the aforementioned welding fixture, comprising the following steps:

[0015] Step S1: Inspect the outer ring of the rectifier that needs to be welded to determine the parts that need to be repaired;

[0016] Step S2: Clean the contact surface between the rectifier outer ring and the blade to be welded, removing oil, rust, dust and other impurities. Use sandpaper and alcohol to polish and clean, ensuring that the welding surface is smooth, flat, dry and free of dirt and oxides.

[0017] Step S3: Place the two plates horizontally and place the rectifier outer ring radially horizontally between the two plates. Insert the two side edges of the rectifier outer ring into the arc-shaped slots on the plates. Rotate the rectifier outer ring to rotate the part to be repaired to the welding window position.

[0018] Step S4: Initially tighten the bolts between the two plates to initially fix the approximate position of the rectifier outer ring. At this time, the bolts should not be fully tightened.

[0019] Step S5: Slide the outer ring of the rectifier along the arc-shaped groove on the plate so that the part to be welded on the outer ring of the rectifier is in the center of the welding window;

[0020] Step S6: Tighten the screws to make the heat sink top block fit against the outer ring of the rectifier, tighten the clamping bolts to make them press against the inner side of the flange of the blade to be welded; then finally tighten the bolts.

[0021] Step S7: Using a laser welding device and setting the welding parameters, weld the part to be repaired through the welding window on the plate and weld the blade to be welded onto the outer ring of the rectifier. When welding, weld one side first, and then weld the other side after the rectifier and the tooling have completely cooled to room temperature. After the rectifier and the tooling have completely cooled to room temperature, remove the rectifier to complete one blade replacement.

[0022] Preferably, the laser welding device includes a JPT 4KW fiber laser with a fiber diameter of 100μm; a KUKA six-axis linkage robot with a positioning accuracy of 0.1mm; a HIGHYAG laser head; and welding parameters of 500W laser power, 10mm defocusing, 600mm / min welding speed, and 0.86 thermal efficiency.

[0023] Preferably, in step S6, the assembly gap between the outer end face of the blade edge plate to be welded and the inner surface of the rectifier outer ring is no greater than 0.05mm. Before welding, the four corners of the blade edge plate to be welded are tack-fixed.

[0024] Due to the adoption of the above technical solution, the beneficial effects of the present invention are as follows:

[0025] (1) In this invention, the rectifier outer ring is fixed by using two plates arranged at an upper and lower interval and an arc-shaped groove on the plates, and the blade to be welded is tightened by a tightening bolt, so that the outer end face of the blade edge plate is tightly attached to the inner surface of the rectifier outer ring. This completes the fixing and clamping of the rectifier outer ring and the blade to be welded. The structure is simple and the clamping and installation are convenient. In addition, by using a screw to drive the heat dissipation top block to be tightened on the outer circumferential surface of the rectifier outer ring, the heat dissipation top block not only dissipates heat but also applies a counter-deformation force to the arc of the rectifier outer ring to reduce the deformation and warping of the rectifier outer ring at the welding part.

[0026] (2) In this invention, a sliding groove is provided on the opposing surfaces of the two plates, and the heat dissipation top block is slidably installed in the sliding groove. Since the heat dissipation top block adopts a sliding installation structure, it is convenient to adjust the clamping force of the heat dissipation top block by screw, so as to better control the deformation during the welding of the outer ring of the rectifier.

[0027] (3) The rectifier is repaired by welding using the welding fixture provided by this invention. During the welding process, after welding one side, the rectifier and the fixture are completely cooled to room temperature before welding the other side. After the rectifier and the fixture are completely cooled to room temperature, the rectifier is removed, and one blade replacement is completed. The fixture does not need to be removed during the entire welding process, which effectively improves the welding efficiency. Attached Figure Description

[0028] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0029] Figure 1 This is a schematic diagram of the structure of a rectifier and the welding area of ​​the blades to be welded.

[0030] Figure 2 This is a schematic diagram of the welding fixture provided in this invention;

[0031] Figure 3 This is a schematic diagram of the welding fixture provided in this invention after one of the plates has been removed.

[0032] Figure 4 This is a schematic diagram of the welding fixture used in this invention for welding the rectifier after clamping it.

[0033] Explanation of reference numerals in the attached diagram: 1. Rectifier outer ring; 2. Blade to be welded; 3. Plate body; 3a. Welding window; 3b. Arc-shaped slot; 3c. Slide groove; 3d. First slot; 3e. Second slot; 4. Bolt; 5. Nut; 6. Screw; 7. First top block; 8. Heat dissipation top block; 8a. Arc-shaped surface; 8b. Relief notch; 9. Second top block; 10. Tightening bolt; A. Weld seam. Detailed Implementation

[0034] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0035] It should be noted that all directional indications (such as up, down, left, right, front, back, etc.) in the embodiments of the present invention are only used to explain the relative positional relationship and movement of each component in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indication will also change accordingly.

[0036] Furthermore, the use of terms such as "first" and "second" in this invention is for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of that feature. Additionally, the technical solutions of the various embodiments can be combined with each other, but only on the basis of being achievable by those skilled in the art. When the combination of technical solutions is contradictory or impossible to implement, such a combination of technical solutions should be considered non-existent and not within the scope of protection claimed by this invention.

[0037] As a first aspect of this embodiment, a rectifier axial welding fixture is provided, combined with Figures 2 to 3 As shown, the welding fixture includes two plates 3 arranged opposite each other at an upper and lower interval, and the two plates 3 are connected by bolts 4; welding windows 3a are provided on the two plates 3 respectively; arc-shaped grooves 3b are provided on the opposite surfaces of the two plates 3 for engaging the two sides of the outer ring 1 of the rectifier; a second top block 9 and a first top block 7 are provided between the two plates 3; multiple tightening screws 10 are provided on the second top block 9 for tightening the inner side of the edge plate of the blade 2 to be welded; a screw 6 is provided on the first top block 7; a heat dissipation top block 8 is slidably installed between the two plates 3, and the heat dissipation top block 8 is rotatably connected to the end of the screw 6; an arc-shaped surface 8a is provided on the heat dissipation top block 8 for abutting against the outer circumferential surface of the outer ring 1 of the rectifier.

[0038] In this embodiment, the heat dissipation top block 8 is made of aluminum alloy. Aluminum alloy has good heat dissipation performance and can be used to contact and conduct heat and dissipate heat to the rectifier outer ring 1. Moreover, aluminum alloy is softer than the rectifier outer ring 1, so it will not cause indentation to the rectifier outer ring 1 when a counter-deformation force is applied, effectively protecting the rectifier outer ring 1.

[0039] Combination Figure 3 As shown, grooves 3c are provided on the opposing surfaces of the two plates 3, and the heat dissipation top block 8 is slidably installed in the grooves 3c. Since the heat dissipation top block 8 adopts a sliding installation structure, it is easy to adjust the clamping force of the heat dissipation top block 8 by means of the screw 6, so as to better control the deformation of the rectifier outer ring 1 during welding.

[0040] Combination Figure 3As shown, on the opposing surfaces of the two plates 3, there are first slots 3d and second slots 3e. The upper and lower ends of the second top block 9 are respectively inserted into the second slot 3e; the upper and lower ends of the first top block 7 are respectively inserted into the first slot 3d. The first top block 7 and the second top block 9 are movably installed using the first slots 3d and the second slots 3e, primarily to facilitate the clamping of the rectifier outer ring 1. Specifically, during installation, the rectifier outer ring 1 is first snapped into the arc-shaped slot 3b of one of the plates 3, and then the first top block 7 and the second top block 9 are inserted into the corresponding first slots 3d and second slots 3e. Then, the other plate 3 is fastened, and the two plates 3 are tightened by bolts 4 and nuts 5 to form a bolted connection. Therefore, the first top block 7 and the second top block 9 are installed in the first slots 3d and the second slots 3e using a movable insertion method, which facilitates the installation of the rectifier outer ring 1.

[0041] In this embodiment, the length of the second top block 9 is 3mm-5mm smaller on one side than the length of the second slot 3e, ensuring that the second top block 9 can be adjusted along the length direction of the second slot 3e for fine adjustment, so that the subsequent tightening bolt 10 can be tightened at the appropriate position of the blade 2 to be welded.

[0042] Combination Figure 3 As shown, clearance notches 8b are respectively provided at the upper and lower edges of the arc-shaped surface 8a of the heat dissipation top block 8. In use, combined with... Figure 4 As shown, by utilizing the clearance notch 8b, interference between the heat dissipation top block 8 and the welding head can be avoided.

[0043] Furthermore, in this embodiment, slopes are provided on both sides of the welding window 3a on the outer surfaces of the two plates 3, and the slopes are located on the opposite back side of the arc-shaped groove 3b, with the slopes inclined towards the welding window 3a. By providing the slope structure, when welding with a laser welding device, the laser head can be gradually moved into the welding window 3a along the slope direction. Therefore, providing slopes facilitates the movement of the laser head.

[0044] As a second aspect of this embodiment, a rectifier axial welding method is provided, employing the aforementioned welding fixture, combined with... Figure 4 As shown, the welding method includes the following steps:

[0045] Step S1: Inspect the outer ring 1 of the rectifier that needs to be welded to determine the parts that need to be repaired;

[0046] Step S2: Clean the contact surface between the rectifier outer ring 1 and the blade 2 to be welded, removing oil, rust, dust and other impurities. Use sandpaper and alcohol to polish and clean, ensuring that the welding surface is smooth, flat, dry and free of dirt and oxides.

[0047] Step S3: Place the two plates 3 horizontally, and place the rectifier outer ring 1 radially horizontally between the two plates. Insert the two side edges of the rectifier outer ring 1 into the arc-shaped slots 3b on the plate 3. Rotate the rectifier outer ring 1 to rotate the part to be repaired to the position of the welding window 3a.

[0048] Step S4: Initially tighten the bolts 4 between the two plates 3 to initially fix the approximate position of the rectifier outer ring 1. At this time, the bolts 4 should not be fully tightened.

[0049] Step S5: Slide the rectifier outer ring 1 along the arc-shaped slot 3b on the plate 3 so that the part to be welded on the rectifier outer ring 1 is in the center of the welding window 3a;

[0050] Step S6: Tighten screw 6 so that heat sink 8 fits against rectifier outer ring 1, tighten top bolt 10 so that it presses against the inner side of the flange of blade 2 to be welded; then finally tighten bolt 4.

[0051] Step S7: Using a laser welding device and setting the welding parameters, weld the part to be repaired through the welding window 3a on the plate 3, and weld the blade 2 to be welded onto the outer ring 1 of the rectifier. When welding, weld either side first, and then weld the other side after the rectifier and the tooling have completely cooled to room temperature. After the rectifier and the tooling have completely cooled to room temperature, remove the rectifier to complete one blade replacement.

[0052] In this embodiment, the laser welding device includes a JPT 4KW fiber laser with a fiber diameter of 100μm; a KUKA six-axis linkage robot with a positioning accuracy of 0.1mm; and a HIGHYAG laser head. The welding parameters are: laser power 500W, defocusing amount 10mm, welding speed 600mm / min, and thermal efficiency 0.86.

[0053] In this embodiment, in step S6, the assembly gap between the outer end face of the blade 2 to be welded and the inner surface of the outer ring 1 of the rectifier is no greater than 0.05mm. Before welding, the four corners of the blade 2 to be welded are tack-fixed.

[0054] The above description is merely a preferred embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural transformations made using the contents of the present invention's specification and drawings under the inventive concept of the present invention, or direct / indirect applications in other related technical fields, are included within the patent protection scope of the present invention.

Claims

1. A rectifier axial welding method, characterized in that, The welding fixture used includes two plates (3) arranged opposite each other at an upper and lower interval, and the two plates (3) are connected by bolts (4); welding windows (3a) are provided on the two plates (3); arc-shaped slots (3b) are provided on the opposite surfaces of the two plates (3) to clamp the two sides of the outer ring (1) of the rectifier; a second top block (9) and a first top block (7) are provided between the two plates (3); multiple tightening bolts (10) are provided on the second top block (9) to tighten the inner side of the flange of the blade (2) to be welded; a screw (6) is provided on the first top block (7); a heat dissipation top block (8) is slidably installed between the two plates (3), and the heat dissipation top block (8) is rotatably connected to the end of the screw (6); an arc-shaped surface (8a) is provided on the heat dissipation top block (8) to abut against the outer circumferential surface of the outer ring (1) of the rectifier; The welding method includes the following steps: Step S1: Inspect the outer ring (1) of the rectifier that needs to be welded to determine the parts that need to be repaired; Step S2: Clean the contact surface between the outer ring (1) of the rectifier and the blade (2) to be welded, remove oil, rust, dust and other impurities, and polish and clean with sandpaper and alcohol to ensure that the welding surface is smooth, flat and dry and free of dirt and oxides. Step S3: Place the two plates (3) horizontally and place the rectifier outer ring (1) radially horizontally between the two plates. Insert the two sides of the rectifier outer ring (1) into the arc-shaped slots (3b) on the plate (3). Rotate the rectifier outer ring (1) to rotate the part to be repaired to the position of the welding window (3a). Step S4: Initially tighten the bolts (4) between the two plates (3) to initially fix the approximate position of the rectifier outer ring (1). At this time, the bolts (4) should not be fully tightened. Step S5: Slide the rectifier outer ring (1) along the arc-shaped groove (3b) on the plate (3) so that the part to be welded on the rectifier outer ring (1) is in the center of the welding window (3a); Step S6: Tighten the screw (6) so that the heat dissipation top block (8) fits against the outer ring (1) of the rectifier, tighten the top bolt (10) so that it presses against the inner side of the flange of the blade (2) to be welded; then finally tighten the bolt (4). Step S7: Using a laser welding device and setting the welding parameters, weld the part to be repaired from the welding window (3a) on the plate (3), and weld the blade (2) to be welded onto the outer ring (1) of the rectifier. When welding, weld either side first, and then weld the other side after the rectifier and tooling have completely cooled to room temperature. After the rectifier and tooling have completely cooled to room temperature, remove the rectifier and complete one blade replacement.

2. The axial welding method for a rectifier as described in claim 1, characterized in that, The heat dissipation top block (8) is made of aluminum alloy.

3. The axial welding method for a rectifier as described in claim 1, characterized in that, A groove (3c) is provided on the opposite surfaces of the two plates (3), and the heat dissipation top block (8) is slidably installed in the groove (3c).

4. The axial welding method for a rectifier as described in claim 1, characterized in that, On the opposing surfaces of the two plates (3), there is a first slot (3d) and a second slot (3e). The upper and lower ends of the second top block (9) are respectively inserted into the second slot (3e); the upper and lower ends of the first top block (7) are respectively inserted into the first slot (3d).

5. The axial welding method for a rectifier as described in claim 4, characterized in that, The length of the second top block (9) is 3mm-5mm shorter on one side than the length of the second slot (3e).

6. The axial welding method for a rectifier as described in claim 1, characterized in that, Clearance notches (8b) are provided at the upper and lower edges of the arc-shaped surface (8a) of the heat dissipation top block (8).

7. The axial welding method for a rectifier as described in claim 1, characterized in that, Slopes are provided on the outer surfaces of the two plates (3) on both sides of the welding window (3a), and the slopes are located on the opposite back side of the arc-shaped slot (3b), and the slopes are inclined to the welding window (3a).

8. The axial welding method for a rectifier as described in claim 1, characterized in that, The laser welding device includes a JPT 4KW fiber laser with a fiber diameter of 100µm; a KUKA six-axis linkage robot with a positioning accuracy of 0.1mm; and a HIGHYAG laser head. The welding parameters are: laser power 500W, defocusing amount 10mm, welding speed 600mm / min, and thermal efficiency 0.

86.

9. The axial welding method for a rectifier as described in claim 1, characterized in that, In step S6, the assembly gap between the outer end face of the blade (2) to be welded and the inner surface of the outer ring (1) of the rectifier is no greater than 0.05 mm. Before welding, the four corners of the blade (2) to be welded are tack-fixed.

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