A wind power platform lifting frame structure manufacturing process

Abstract

The application relates to a wind power platform lifting frame structure manufacturing process, which comprises the following steps: step 1, positioning and scribing a tire on a middle plate, step 2, assembling small components on the side of a shear block, step 3, assembling small components on the side of a pile leg, step 4, installing a guide pad plate, step 5, installing a bearing seat, a gear shell support and a steel sleeve, and step 6, installing a positioning nut; the manufacturing process takes the middle plate as a bottom plate, after the small components on the side of the shear block are assembled, the middle plate is turned upside down, then the small components on the side of the pile leg are assembled and the guide pad plate is installed, the middle plate is turned upside down again, and finally the bearing seat, the gear shell support, the steel sleeve and the positioning nut are installed; the manufacturing process reduces the difficulty of precision control, can reduce the manufacturing deviation to the minimum, improves the precision requirement, reduces the rework guarantee and shortens the manufacturing period.

Description

Technical Field

[0001] This invention relates to the field of wind power platform lifting frame manufacturing technology, and in particular to a manufacturing process for a wind power platform lifting frame structure. Background Technology

[0002] like Figure 1-3 As shown, the lifting frame structure includes, from top to bottom, a shear block side cover plate, a middle plate, and a pile leg side cover plate. Small components are assembled between the middle plate and each of the two cover plates. The lifting frame structure also includes 21 shear blocks, 12 bearing seats, 12 gear housing supports, 12 steel sleeves, and 48 positioning nuts, among other high-precision components. Each bearing seat, gear housing support, and steel sleeve forms a set of coaxial internal bore assemblies, resulting in 12 sets of coaxial internal bore assemblies evenly arranged in two rows and installed in the middle of the lifting frame structure. The steel sleeve is installed on the shear block side cover plate, the gear housing support is installed on the middle plate, and the bearing housing is installed on the pile leg side cover plate. Twenty-one shear blocks are evenly divided into three rows and installed on the top surface of the shear block side cover plate. The three rows of shear blocks are spaced apart from two rows of inner hole coaxial assemblies, and each inner hole coaxial assembly is surrounded by four shear blocks. Forty-eight positioning nuts are arranged in groups of four, totaling 12 groups, corresponding to the 12 groups of inner hole coaxial assemblies. The four positioning nuts in each group are evenly distributed around the corresponding inner hole coaxial assembly. A wear-resistant guide plate is provided at the opening on the pile leg side of the lifting frame structure. The lifting frame structure plate is at its thickest point (50mm), made of EH550, and the forgings are made of EH690.

[0003] Because the lifting structure will have 12 lifting devices installed in the middle to lift the pile legs, enabling the wind turbine platform to rise and fall, the lifting performance of the wind turbine platform is closely related to the precision of the lifting frame construction. Due to its high precision requirements, large amount of welding work, and high welding quality requirements, the lifting frame is recognized worldwide as one of the most difficult structures to construct for self-elevating wind turbine platforms, and its construction problems have not been well resolved domestically. Currently, the mainstream approach for constructing lifting frames in China is to assemble and weld the structure onto a base plate near the pile legs using a formwork. Because the lifting frame structure has many internal partitions, a large amount of welding, special materials, and high precision requirements, it is prone to deformation and the precision cannot be controlled. Furthermore, this approach requires highly skilled welders and involves significant investment.

[0004] Therefore, this invention proposes a manufacturing process for a wind power platform lifting frame structure to solve the above problems. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to provide a manufacturing process for a wind power platform lifting frame structure that improves the accuracy requirements, reduces rework, and shortens the manufacturing period.

[0006] To solve the above-mentioned technical problems, the technical solution of the present invention is: a manufacturing process for a wind power platform lifting frame structure, the innovation of which lies in: including the following steps:

[0007] Step 1, Tire positioning and marking on the middle plate: Hoist and fix the middle plate on the tire frame and add reverse deformation;

[0008] Step 2: Assembly of the small components on the shear block side: Assemble the small components on the shear block side according to the positioning marking requirements. When welding, add diagonal braces to each partition for fixation. Then install the cover plate on the shear block side and perform fire straightening after installation.

[0009] Step 3: Assembly of small components on the side of the pile leg: Turn over, assemble and adjust the small components on the side of the pile leg according to the positioning and marking requirements, and fix them. When welding, use process supports in the space on the side of the pile leg for fixation. Then install the cover plate on the side of the pile leg and finally straighten it with fire.

[0010] Step 4, Guide Plate Installation: Mark the positions of the upper and lower guide plates and baffles, measure the opening of the guide plates, calculate the thickness of each guide plate, and then process them. After processing, weld the guide plates to ensure the opening accuracy requirements.

[0011] Step 5: Install bearing housing, gear housing support, and steel sleeve: Turn the plate over and first install the gear housing support on the middle plate. Then, install the bearing housing and steel sleeve according to the welding deformation. Ensure the coaxiality of the center of the gear housing support, bearing housing, and steel sleeve, and ensure the machining allowance.

[0012] Step 6: Install the positioning nuts: Position the positioning nuts according to the reference, ensuring that the positioning nuts are on the same horizontal plane.

[0013] Furthermore, the detailed steps for marking the tire positioning lines on the plate in step 1 are as follows:

[0014] Step 1.1: Arrange the jig frame, using the middle plate as the base plate, hoist the jig onto it, and align it with the ground line as the base.

[0015] Step 1.2: Add a 10mm anti-deformation layer in the middle of the middle plate and fix it at both ends. Remove the anti-deformation layer before turning over.

[0016] Step 1.3: Mark the middle plate according to the requirements of the drawing. The deviation of the installation line should be within 1mm. After passing the inspection, fix the middle plate with a clamp.

[0017] Furthermore, in step 1.1, when arranging the jig, the accuracy of the jig is strictly controlled, and the positioning deviation is within 1mm.

[0018] Furthermore, the detailed steps for assembling the small component on the shear block side in step 2 are as follows:

[0019] Step 2.1: Complete the production of all components according to the group's design drawings, and check them according to WPS requirements;

[0020] Step 2.2: Based on the middle plate mounting line, install small components and partitions from the middle to both sides;

[0021] Step 2.3: During installation, use angle steel supports for reinforcement. When positioning the partition, add a 1mm welding compensation. To reduce deformation, use symmetrical welding. For welds of longitudinal parts, use a segmented back-welding method, first weld the vertical fillet weld, then weld the horizontal fillet weld.

[0022] Step 2.4: Install the shear block. Leave a 10mm allowance at both ends of the shear block. Position it around the center and use symmetrical welding and segmented back welding as the welding method.

[0023] Step 2.5: Weld the cover plate on the side of the shear block, and the flatness of the cover plate on the side of the shear block should be less than 2mm;

[0024] Step 2.6: Before turning over, check if any welds have been missed.

[0025] Furthermore, the detailed steps for assembling the small component on the pile leg side in step 3 are as follows:

[0026] Step 3.1: After turning over, check and confirm the components that need to be welded and the side cover plate of the pile leg, and perform local heat treatment on the areas with large deformation;

[0027] Step 3.2: Mark the installation positioning lines for each group and report for inspection;

[0028] Step 3.3: During the installation of small components, use process supports to reinforce them and ensure that the opening size and verticality are within 3mm. When assembling and positioning, add 1mm of welding compensation. To reduce deformation, use symmetrical welding. For the welds of longitudinal parts, use the segmented back welding method, first weld the vertical fillet weld, and then weld the flat fillet weld.

[0029] Step 3.4: Weld the cover plate on the side of the pile leg. The flatness of the cover plate on the side of the pile leg should be less than 2mm.

[0030] Step 3.5: Before turning over, check if any welds have been missed.

[0031] Furthermore, the detailed steps for installing the guide plate in step 4 are as follows:

[0032] Step 4.1: Use the center line of the lifting frame and the center line of the rack as references for marking and positioning;

[0033] Step 4.2: Measure and record the structural opening dimensions of the guide plate on site, and determine the thickness of the guide plate;

[0034] Step 4.3: Based on the measurement data, cut and process the guide pad and baffle;

[0035] Step 4.4: Install the guide plate and baffle. The size at the opening position is only allowed to be smaller than the theoretical size. To ensure a good fit, additional plug welding holes are added.

[0036] Furthermore, the detailed steps for installing the bearing housing, gear housing support, and steel sleeve in step 5 are as follows:

[0037] Step 5.1: The bearing housing and gear housing support are forged parts. A 10mm allowance is added to the bearing housing, gear housing support and steel sleeve. The holes are marked according to the shape of the forging.

[0038] Step 5.2: Position and weld the gear housing support, and then weld the bearing housing and steel sleeve according to the deformation of the gear housing support;

[0039] Step 5.3: After welding the bearing housing and gear housing support, install the corresponding elbow plate. The welding sequence is two people for one component and eight people for four components simultaneously. The eight people should skip welding to ensure that the concentricity is within 3mm and the centerline deviation is within 2mm.

[0040] Furthermore, the detailed steps for installing the positioning nut in step 6 are as follows:

[0041] Step 6.1: Mark the positioning nut according to the center of each hole;

[0042] Step 6.2: Ensure the perpendicularity of the positioning nut to the side cover plate of the shear block. Considering subsequent processing, leave a 10mm allowance in both the thickness and length of the positioning nut.

[0043] The advantages of this invention are:

[0044] (1) The manufacturing process of the present invention uses the middle plate as the base plate. After the installation of the small components on the anti-shear block side is completed, the middle plate is turned upward by flipping the plate. Then the small components on the pile leg side are assembled and the guide pad is installed. After flipping the plate again, the bearing seat, gear housing support, steel sleeve and positioning nut are finally installed. This manufacturing process reduces the difficulty of manufacturing precision control, minimizes manufacturing deviation, improves precision requirements, reduces rework, and shortens the manufacturing period.

[0045] (2) The manufacturing process of the present invention allows for a 10mm allowance in all machined parts such as bearing housing, gear housing support, steel sleeve, anti-shear block, and positioning nut, which can both compensate for welding shrinkage and ensure machining dimensions. Attached Figure Description

[0046] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0047] Figure 1 This is a schematic diagram of the structure of the wind power platform lifting frame structure of the present invention, on the side near the pile leg.

[0048] Figure 2 This is a schematic diagram of the shear block side of the wind power platform lifting frame structure of the present invention.

[0049] Figure 3 This is a cross-sectional view of the shear block of the wind power platform lifting frame structure of the present invention.

[0050] Figure 4 This is a schematic flowchart illustrating the manufacturing process of the wind power platform lifting frame structure of the present invention. Detailed Implementation

[0051] The following embodiments are intended to enable those skilled in the art to more fully understand the present invention, but do not limit the invention to the scope of the embodiments described.

[0052] like Figure 1-3 As shown, the lifting frame structure includes, from top to bottom, a shear block side cover plate 10, a middle plate 9, and a pile leg side cover plate 1. Small components are assembled between the middle plate 9 and each of the shear block side cover plate 10 and pile leg side cover plate 1. The lifting frame structure also includes 21 shear blocks 7, 12 bearing seats 3, 12 gear housing supports 4, 12 steel sleeves 6, and 48 positioning nuts 8, among other high-precision components. Each bearing seat 3, gear housing support 4, and steel sleeve 6 forms a set of coaxial internal bore assemblies, resulting in 12 sets of coaxial internal bore assemblies evenly arranged in two rows and installed on the lifting frame. In the middle of the frame structure, steel sleeve 6 is installed on the cover plate 10 near the shear block, gear housing support 4 is installed on the middle plate 9, bearing seat 3 is installed on the cover plate 1 near the pile leg, and 21 shear blocks 7 are evenly divided into three rows and installed on the top surface of the cover plate 10 near the shear block. The three rows of shear blocks are spaced apart from the two rows of inner hole coaxial components, and each inner hole coaxial component is surrounded by four shear blocks. 48 positioning nuts 8 are arranged in groups of four, totaling 12 groups of positioning nuts, corresponding to 12 groups of inner hole coaxial components. The four positioning nuts in each group are evenly arranged around the corresponding inner hole coaxial component. Wear-resistant guide pads are provided at the opening of the lifting frame structure near the pile leg. The guide pads have upper guide pads 2 and lower guide pads 5, which are respectively set on both sides of the lifting frame structure.

[0053] The present invention provides a manufacturing process for a wind power platform lifting frame structure, comprising the following steps:

[0054] Step 1, Tire positioning and marking on the middle plate: Hoist and fix the middle plate 9 onto the tire frame and add reverse deformation. Detailed steps are as follows:

[0055] Step 1.1: Arrange the jig frame. Use the middle plate 9 as the base plate and hoist the jig frame. Align it with the ground line as the base. When arranging the jig frame, strictly control the accuracy of the jig frame and the positioning deviation should be within 1mm.

[0056] Step 1.2: Add a 10mm anti-deformation in the middle of the middle plate 9 and fix it at both ends. Remove the anti-deformation before turning over.

[0057] Step 1.3: Mark the middle plate according to the requirements of the drawing. The deviation of the installation line should be within 1mm. After the inspection is passed, fix the middle plate 9 with a clamp.

[0058] Step 2: Assembly of the small components on the shear block side: Assemble the small components on the shear block side according to the positioning marking requirements. During welding, add diagonal braces to each partition for fixation. Then install the cover plate 10 on the shear block side. After installation, perform heat straightening. Detailed steps are as follows:

[0059] Step 2.1: Complete the production of all components according to the group's design drawings, and check them according to WPS requirements;

[0060] Step 2.2: Based on the middle plate mounting line, install small components and partitions from the middle to both sides;

[0061] Step 2.3: During installation, angle steel supports are used for reinforcement. When marking and positioning, factors such as multiple structures and large welding volume are considered. When positioning the partition, a 1mm welding compensation is added. To reduce deformation, symmetrical welding is used. For the welds of longitudinal parts, a segmented back welding method is used. First, weld the vertical fillet weld, then weld the horizontal fillet weld. During the welding process, the deformation is monitored and the welding sequence is adjusted reasonably. After the actual structure is completed, the compensation is offset.

[0062] Step 2.4: Install the shear block 7. Leave a 10mm allowance at both ends of the shear block 7. Therefore, center positioning is used, and the welding method adopts symmetrical welding and segmented back welding.

[0063] Step 2.5: Weld the shear block side cover plate 10, the flatness of the shear block side cover plate 10 is less than 2mm;

[0064] Step 2.6: Before turning over, check if any welds have been missed.

[0065] Step 3: Assembly of the small components on the side of the pile leg: Turn the pile over, assemble and adjust the small components on the side of the pile leg according to the positioning and marking requirements, and fix them. During welding, use process supports in the space on the side of the pile leg for fixation. Then install the cover plate 1 on the side of the pile leg, and finally perform heat straightening. The detailed steps are as follows:

[0066] Step 3.1: After turning over, check and confirm the components that need to be welded and the side cover plate 1 of the pile leg, and perform local heat treatment on the areas with large deformation;

[0067] Step 3.2: Mark the installation positioning lines for each group and report for inspection;

[0068] Step 3.3: During the installation of small components, use process supports to reinforce them and ensure that the opening size and verticality are within 3mm. When assembling and positioning, add 1mm of welding compensation. To reduce deformation, use symmetrical welding. For the welds of longitudinal parts, use the segmented back welding method, first weld the vertical fillet weld, and then weld the flat fillet weld.

[0069] Step 3.4: Weld the side cover plate 1 near the pile leg. The flatness of the side cover plate 1 near the pile leg is less than 2mm.

[0070] Step 3.5: Before turning over, check if any welds have been missed.

[0071] Step 4: Guide Plate Installation: Mark and position the upper guide plate 2, lower guide plate 5, and baffle. Measure the opening of the guide plates, calculate the thickness of each guide plate, and then process them. After processing, weld the guide plates to ensure the opening accuracy requirements. Detailed steps are as follows:

[0072] Step 4.1: Use the center line of the lifting frame and the center line of the rack as references for marking and positioning;

[0073] Step 4.2: Measure and record the structural opening dimensions of the guide plate on site, and determine the thickness of the guide plate;

[0074] Step 4.3: Based on the measurement data, cut and process the guide pad and baffle;

[0075] Step 4.4: Install the guide plate and baffle. The size at the opening position is only allowed to be smaller than the theoretical size. To ensure a good fit, additional plug welding holes are added.

[0076] Step 5: Install bearing housing 3, gear housing support 4, and steel sleeve 6: Turn the plate over and first install the gear housing support 4 on the middle plate 9. Then, install the bearing housing 3 and steel sleeve 6 according to the welding deformation. Ensure the coaxiality of the gear housing support 4, bearing housing 3, and steel sleeve 6, and ensure sufficient machining allowance. Detailed steps are as follows:

[0077] Step 5.1: Bearing housing 3 and gear housing support 4 are forged parts. A 10mm allowance is added to bearing housing 3, gear housing support 4 and steel sleeve 6. Drill lines and make holes according to the shape of the forging.

[0078] Step 5.2: Position and weld the gear housing support 4, and then weld the bearing housing 3 and the steel sleeve 6 according to the deformation of the gear housing support 4.

[0079] Step 5.3: After welding the bearing housing 3 and gear housing support 4, install the corresponding elbow plate. The welding sequence is two people for one component and eight people for four components simultaneously. The eight people should skip welding to ensure that the concentricity is within 3mm and the centerline deviation is within 2mm.

[0080] Step 6: Install the positioning nuts: Position the positioning nuts according to the reference, ensuring that the positioning nuts are on the same horizontal plane. Detailed steps are as follows:

[0081] Step 6.1: Mark the positioning nut according to the center of each hole;

[0082] Step 6.2: Ensure the perpendicularity of the positioning nut to the side cover plate of the shear block. Considering subsequent processing, leave a 10mm allowance in both the thickness and length of the positioning nut.

[0083] The manufacturing process of this invention uses a middle plate as the base plate. After the installation of the small components on the side against the shear block is completed, the middle plate is turned upwards by flipping it over. Then, the small components on the side against the pile leg are assembled and the guide pad is installed. After another flipping operation, the bearing seat, gear housing support, steel sleeve and positioning nut are finally installed. This manufacturing process reduces the difficulty of controlling manufacturing precision, can minimize manufacturing deviation, improve the precision requirements, reduce rework, and shorten the manufacturing period.

[0084] Those skilled in the art should understand that this invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to this invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the invention as claimed. The scope of protection of this invention is defined by the appended claims and their equivalents.

Claims

1. A manufacturing process for a wind power platform lifting frame structure, characterized in that: Includes the following steps: Step 1, Tire positioning and marking on the middle plate: Hoist and fix the middle plate on the tire frame and add reverse deformation; Step 2: Assembly of the small components on the shear block side: Assemble the small components on the shear block side according to the positioning marking requirements. When welding, add diagonal braces to each partition for fixation. Then install the cover plate on the shear block side and perform fire straightening after installation. Step 3: Assembly of small components on the side of the pile leg: Turn over, assemble and adjust the small components on the side of the pile leg according to the positioning and marking requirements, and fix them. When welding, use process supports in the space on the side of the pile leg for fixation. Then install the cover plate on the side of the pile leg, and finally straighten it with fire. Step 4, Guide Plate Installation: Mark the positions of the upper and lower guide plates and baffles, measure the opening of the guide plates, calculate the thickness of each guide plate, and then process them. After processing, weld the guide plates to ensure the opening accuracy requirements. Step 5: Install bearing housing, gear housing support, and steel sleeve: Turn the plate over and first install the gear housing support on the middle plate. Then, install the bearing housing and steel sleeve according to the welding deformation. Ensure the coaxiality of the center of the gear housing support, bearing housing, and steel sleeve, and ensure the machining allowance. Step 6: Install the positioning nuts: Position the positioning nuts according to the reference, ensuring that the positioning nuts are on the same horizontal plane.

2. The manufacturing process of the wind power platform lifting frame structure according to claim 1, characterized in that: The detailed steps for tire positioning and marking on the plate in step 1 are as follows: Step 1.1: Arrange the jig frame, using the middle plate as the base plate, hoist the jig onto it, and align it with the ground line as the base. Step 1.2: Add a 10mm anti-deformation layer in the middle of the middle plate and fix it at both ends. Remove the anti-deformation layer before turning over. Step 1.3: Mark the middle plate according to the requirements of the drawing. The deviation of the installation line should be within 1mm. After passing the inspection, fix the middle plate with a clamp.

3. The manufacturing process of the wind power platform lifting frame structure according to claim 2, characterized in that: In step 1.1, when arranging the jig, the accuracy of the jig is strictly controlled, and the positioning deviation is within 1mm.

4. The manufacturing process of the wind power platform lifting frame structure according to claim 1, characterized in that: The detailed steps for assembling the small component on the shear block side in step 2 are as follows: Step 2.1: Complete the production of all components according to the group's design drawings, and check them according to WPS requirements; Step 2.2: Based on the middle plate mounting line, install small components and partitions from the middle to both sides; Step 2.3: During installation, use angle steel supports for reinforcement. When positioning the partition, add a 1mm welding compensation. To reduce deformation, use symmetrical welding. For welds of longitudinal parts, use a segmented back-welding method, first weld the vertical fillet weld, then weld the horizontal fillet weld. Step 2.4: Install the shear block. Leave a 10mm allowance at both ends of the shear block. Position it around the center and use symmetrical welding and segmented back welding as the welding method. Step 2.5: Weld the cover plate on the side of the shear block, and the flatness of the cover plate on the side of the shear block should be less than 2mm; Step 2.6: Before turning over, check if any welds have been missed.

5. The manufacturing process of the wind power platform lifting frame structure according to claim 1, characterized in that: The detailed steps for assembling the small component on the pile leg side in step 3 are as follows: Step 3.1: After turning over, check and confirm the components that need to be welded and the side cover plate of the pile leg, and perform local heat treatment on the areas with large deformation; Step 3.2: Mark the installation positioning lines for each group and report for inspection; Step 3.3: During the installation of small components, use process supports to reinforce them and ensure that the opening size and verticality are within 3mm. When assembling and positioning, add 1mm of welding compensation. To reduce deformation, use symmetrical welding. For the welds of longitudinal parts, use the segmented back welding method, first weld the vertical fillet weld, and then weld the flat fillet weld. Step 3.4: Weld the cover plate on the side of the pile leg. The flatness of the cover plate on the side of the pile leg should be less than 2mm. Step 3.5: Before turning over, check if any welds have been missed.

6. The manufacturing process of the wind power platform lifting frame structure according to claim 1, characterized in that: The detailed steps for installing the guide plate in step 4 are as follows: Step 4.1: Use the center line of the lifting frame and the center line of the rack as references for marking and positioning; Step 4.2: Measure and record the structural opening dimensions of the guide plate on site, and determine the thickness of the guide plate; Step 4.3: Based on the measurement data, cut and process the guide pad and baffle; Step 4.4: Install the guide plate and baffle. The size at the opening position is only allowed to be smaller than the theoretical size. To ensure a good fit, additional plug welding holes are added.

7. The manufacturing process of the wind power platform lifting frame structure according to claim 1, characterized in that: The detailed steps for installing the bearing housing, gear housing support, and steel sleeve in step 5 are as follows: Step 5.1: The bearing housing and gear housing support are forged parts. A 10mm allowance is added to the bearing housing, gear housing support and steel sleeve. Drill lines and make holes according to the shape of the forging. Step 5.2: Position and weld the gear housing support, and then weld the bearing housing and steel sleeve according to the deformation of the gear housing support; Step 5.3: After welding the bearing housing and gear housing support, install the corresponding elbow plate. The welding sequence is two people for one component and eight people for four components simultaneously. The eight people should skip welding to ensure that the concentricity is within 3mm and the centerline deviation is within 2mm.

8. The manufacturing process of the wind power platform lifting frame structure according to claim 1, characterized in that: The detailed steps for installing the positioning nut in step 6 are as follows: Step 6.1: Mark the positioning nut according to the center of each hole; Step 6.2: Ensure the perpendicularity of the positioning nut to the side cover plate of the shear block. Considering subsequent processing, leave a 10mm allowance in both the thickness and length of the positioning nut.

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