A large rotor automatic laser cleaning device and a cleaning method

Abstract

This invention discloses a large-scale automatic laser cleaning device and method for rotors, including a rotary device and a truss structure connected thereto. The truss structure is connected to a three-degree-of-freedom cleaning system, which includes a laser cleaning head that can be vertically raised and lowered, radially advanced and retreated, and laterally rotated. This invention can meet the requirements for cleaning the outer surface of the rotor and the magnetic pole gap of a water turbine unit.

Description

Technical Field

[0001] This invention relates to the field of maintenance and upkeep technology for hydro-generator sets, and in particular to an automatic laser cleaning device and method for large rotors. Background Technology

[0002] In recent years, my country's hydropower industry has developed rapidly, and the demand for electricity has continued to increase. At the same time, the safety and stability of the operation and maintenance of hydro-generator units have become increasingly important. As an important component of the hydro-turbine, the turbine rotor is also highly valued during maintenance.

[0003] The rotor of a hydro-generator consists of a shaft, support frame, yoke, magnetic poles, and current collecting device, used to generate a magnetic field, convert energy, and transmit torque. After prolonged operation, the unit requires maintenance and cleaning to remove internal oil and dust. Current cleaning methods involve manually spraying cleaning agents on-site to remove oil and wiping surface stains. This method is labor-intensive, inefficient, and the cleaning quality is difficult to guarantee. Furthermore, the cleaning agents used pose certain health risks to operators, and there is a risk of environmental pollution. Gaps between the rotor magnetic poles are difficult to clean completely, and manual operation is inconvenient.

[0004] Laser cleaning is a process that uses a high-energy laser beam to irradiate the surface of a workpiece, causing dirt, rust, or coatings to evaporate or peel off instantly, thus achieving cleanliness. Compared to traditional cleaning processes, laser cleaning is a "dry" cleaning method, requiring no cleaning fluid or other chemical solutions, and its cleanliness is far superior to chemical cleaning. Furthermore, laser cleaning is a "green" process, eliminating waste in the form of small, easily stored solid powder, and causing virtually no environmental pollution. By adjusting the laser process parameters, contaminants can be effectively removed without damaging the substrate surface.

[0005] During rotor maintenance, it is necessary to install a roundness measuring tool for large rotors. This part is proposed by patent CN201020674859.8, which is an inventive improvement based on the roundness measuring tool for large rotors. By improving the existing tooling and adding a laser automatic cleaning device, the automatic cleaning of the runner can be achieved, which can significantly reduce equipment cost investment and reduce on-site manual operation time. However, it can only thoroughly clean the outer surface of the turbine rotor. As for the magnetic pole gap, since the surface of the magnetic pole gap and the outer surface of the rotor are not at the same depth, the cleaning effect is poor. Summary of the Invention

[0006] The purpose of this invention is to overcome the above-mentioned shortcomings and provide a large-scale automatic laser cleaning device and cleaning method for rotors, which can meet the requirements for cleaning the outer surface of turbine rotors and the magnetic pole gaps.

[0007] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is: a large rotor automatic laser cleaning device, including a rotary device and a truss structure connected thereto, wherein the truss structure is connected to a three-degree-of-freedom cleaning system, and the three-degree-of-freedom cleaning system includes a laser cleaning head that can be vertically lifted, radially advanced and retreated, and laterally rotated.

[0008] Preferably, the rotary device includes a heavy-duty rotary motor located at the center of the rotor shaft, the output end of the heavy-duty rotary motor being connected to the center of the truss structure, the truss structure being located above the rotor, and a three-degree-of-freedom cleaning system being provided at both ends of the truss structure.

[0009] Preferably, the truss structure is connected to the three-degree-of-freedom cleaning system via connecting corner pieces.

[0010] Preferably, the three-degree-of-freedom cleaning system includes a vertical lifting system, a radial advance and retreat system installed on the lifting support of the vertical lifting system, a horizontal rotation system installed on the radial advance and retreat system, and a laser cleaning head installed at the output end of the horizontal rotation system.

[0011] Preferably, the vertical lifting system includes a guide rail and a rack fixed on the surface of the aluminum profile. The guide rail is slidably connected to the slider of the lifting support. A Z-axis reduction motor is installed on the lifting support, and the output end of the Z-axis reduction motor is provided with a gear that meshes with the rack.

[0012] Preferably, the radial advance and retreat system includes an X-axis linear module mounted on the lifting support. The X-axis linear module includes a stepper motor fixedly connected to the lifting support. The output end of the stepper motor is connected to a lead screw. A lead screw nut is provided on its surface and slidably connected thereto. The lead screw nut is slidably engaged with a linear guide rail. A transverse rotation system is mounted on the lead screw nut.

[0013] Preferably, the transverse rotation system includes a C-axis rotation motor fixedly mounted on the wire nut seat, and a laser cleaning head is provided at the output end of the C-axis rotation motor.

[0014] Preferably, the laser cleaning head is connected to the laser via an optical fiber, the laser cleaning head is connected to the air source via an air tube, the laser cleaning head is connected to the communication line and the electronic control system via a power line, the input end of the electronic control system is connected to the output end of the laser ranging sensor, the laser ranging sensor is mounted on the lifting support, and the output end of the electronic control system is connected to the motor control ends of the vertical lifting system, the radial advance and retreat system and the horizontal rotation system.

[0015] In addition, this invention discloses a cleaning method for the aforementioned large rotor automatic laser cleaning device, which includes the following steps:

[0016] S1. After the device is installed, start the laser and the rotating device at the same time. Wait for the laser cleaning head to emit light, and then clean the outer surface of the rotor in a circumferential manner. During the cleaning process, the distance between the laser cleaning head and the rotor is monitored in real time by the laser range sensor, and the distance between the laser cleaning head and the rotor is compensated in real time by the electronic control system to ensure the cleaning effect and thus realize the cleaning process of the outer surface of the rotor.

[0017] S2. When the laser ranging sensor detects the position of entering the rotor magnetic pole gap, the rotor magnetic pole gap cleaning process is carried out. The laser cleaning head performs the cleaning process in the rotor magnetic pole gap by radial advance and retreat and lateral rotation, thereby realizing the cleaning process of the rotor magnetic pole gap.

[0018] S3: After cleaning one ring of the rotor's outer surface at a certain height in the circumference, the electronic control system controls the z-axis reduction motor of the vertical lifting system to adjust the height of the laser cleaning head off the ground. After the adjustment is completed, the laser and the rotation device are restarted, and the laser cleaning head is allowed to emit light to clean another ring of the rotor's outer surface at a different height in the circumference.

[0019] S4: Repeat the above process to complete the cleaning process of the rotor outer surface circumferential direction and rotor magnetic pole gap at the entire height.

[0020] Further, the specific process of step S2 is as follows: when the laser ranging sensor detects the position of entering the rotor magnetic pole gap, the X-direction linear module of the radial advance and retreat system works, thereby driving the laser cleaning head to move into the magnetic pole gap, and then withdrawing from the magnetic pole gap to the outside; at the same time, the C-direction rotary motor of the transverse rotation system works, causing the laser cleaning head to rotate at a certain angle and sweep across the side and bottom surfaces of the magnetic pole gap, thereby completing the cleaning process of one of the magnetic pole gaps.

[0021] Beneficial effects of this invention:

[0022] 1. This invention reduces environmental pollution by using laser cleaning and achieves stable oil stain cleaning effect through automated control, which can meet the requirements for cleaning the outer surface of the turbine rotor and the magnetic pole gap.

[0023] 2. This invention uses laser cleaning to reduce environmental pollution. The waste eliminated is in the form of solid powder, which is small in volume, easy to store, and basically does not pollute the environment.

[0024] 3. This invention has a large cleaning coverage area and proposes a special cleaning process for the rotor magnetic pole gap, which reduces dead corners and achieves a larger cleaning coverage area;

[0025] 4. The large-scale rotor automatic laser cleaning device provided by the present invention can realize the rapid assembly and disassembly of the equipment on site through the modular structure and quick-disassembly structure design, reducing the difficulty of equipment transportation and storage, and reducing the safety hazards caused by repeated climbing operations.

[0026] 5. This invention is a creative improvement on the existing large rotor roundness measuring fixture. By improving the existing fixture and adding a laser automatic cleaning device, the rotor can be automatically cleaned, which can significantly reduce equipment cost investment and reduce on-site manual operation time. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of a large-scale automatic laser cleaning device for rotors.

[0028] Figure 2 for Figure 1 A magnified schematic diagram of a three-degree-of-freedom cleaning system;

[0029] Figure 3 This is a magnified structural diagram of the area where the X-axis linear module is located from another perspective.

[0030] Figure 4 for Figure 2 A schematic diagram of the cross-sectional structure at the location of the Z-axis geared motor;

[0031] Figure 5 Wiring diagram for the electrical control, fiber optic, and pneumatic circuits of an automatic laser cleaning device;

[0032] Figure 6 This is a schematic diagram of the cleaning trajectory for the rotor magnetic pole gap. Detailed Implementation

[0033] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0034] like Figure 1-6 As shown, a large rotor automatic laser cleaning device includes a rotary device 1 and a truss structure 2 connected thereto. The truss structure 2 is connected to a three-degree-of-freedom cleaning system 3, which includes a laser cleaning head 7 that can be vertically lifted, radially advanced and retreated, and laterally rotated.

[0035] Preferably, the rotary device 1 includes a heavy-duty rotary motor located at the center of the rotor 101. The output end of the heavy-duty rotary motor is connected to the center of the truss structure 2, which is located above the rotor 101. Three-degree-of-freedom cleaning systems 3 are installed at both ends of the truss structure 2. More preferably, the rotary device 1 consists of a heavy-duty rotary motor and a rotary support bearing. It is fixed to the rotor 101 via a guide shaft and flange, and bolted to the top of the rotor 101. The guide shaft acts as a positioning pin to ensure accurate installation. Two sections of the truss structure 2 are installed above the rotary device 1. The truss structure 2 is bolted to the rotary device 1, and the rotation of the rotary device drives the truss structure 2 to perform circular motion around the rotor 101. The truss structure is a welded steel component with good rigidity. It can be disassembled into modular components for transport and can be quickly assembled into a whole on-site. Benefiting from the modular installation method, the length of the truss structure 2 can be changed by selecting different modules to meet the cleaning requirements of rotors of different sizes.

[0036] Preferably, the truss structure 2 is connected to the three-degree-of-freedom cleaning system 3 via connecting corner pieces 10.

[0037] Preferably, the three-degree-of-freedom cleaning system 3 includes a vertical lifting system, a radial advance and retreat system is installed on the lifting support 9 of the vertical lifting system, a horizontal rotation system is installed on the radial advance and retreat system, and a laser cleaning head 7 is provided at the output end of the horizontal rotation system.

[0038] Preferably, the vertical lifting system includes a guide rail 4 and a rack 5 fixedly mounted on the surface of the aluminum profile 6. The guide rail 4 is slidably connected to the slider 9.1 of the lifting support 9. A Z-axis reduction motor 8 is mounted on the lifting support 9, and the output end of the Z-axis reduction motor 8 is provided with a gear 8.1 that meshes with the rack 5. With this design, when the Z-axis reduction motor 8 is working, it can drive the gear 8.1 to rotate. Since the gear 8.1 meshes with the rack 5, the Z-axis reduction motor 8 and the lifting support 9 move up and down together. Through the guiding effect of the guide rail 4, the lifting support 9 moves vertically up and down along the guide rail 4.

[0039] Preferably, the radial advance / retreat system includes an X-axis linear module 11 mounted on the lifting support 9. The X-axis linear module 11 includes a stepper motor 11.1 fixedly connected to the lifting support 9. The output end of the stepper motor 11.1 is connected to a lead screw 11.2. The surface of the lead screw 11.2 is provided with a lead screw nut 11.4 slidably connected to it. The lead screw nut 11.4 is slidably engaged with a linear guide rail 11.3. A transverse rotation system is mounted on the lead screw nut 11.4. With this design, when the stepper motor 11.1 works, it drives the lead screw 11.2 to rotate. Since the moving lead screw 11.2 and the lead screw nut 11.4 are threadedly engaged, and the lead screw nut 11.4 is slidably engaged with the linear guide rail 11.3, the lead screw nut 11.4 can move linearly along the linear guide rail 11.3, thus realizing the radial advance / retreat process.

[0040] Preferably, the transverse rotation system includes a c-axis rotary motor 12 fixedly mounted on the wire nut 11.4, and a laser cleaning head 7 is mounted on the output end of the c-axis rotary motor 12. When the c-axis rotary motor 12 is working, its output shaft rotates, thereby driving the laser cleaning head 7 to rotate transversely.

[0041] Preferably, the laser cleaning head 7 is connected to the laser 15 via an optical fiber, and to the air source 16 via an air pipe. The laser cleaning head 7 is also connected to the electronic control system 14 via a power cord, a communication line, and a power control system 14. The input terminal of the electronic control system 14 is connected to the output terminal of the laser rangefinder 13, which is mounted on the lifting support 9. The output terminal of the electronic control system 14 is connected to the motor control terminals of the vertical lifting system, the radial forward / backward system, and the horizontal rotation system. The electronic control system 14 is connected to the laser 15 via a power cord and a communication line, providing power and communication signals to the laser 15 to control its light output. The laser 15 is connected to the laser cleaning head 7 via an optical fiber, providing laser enablement. The air source 16 is connected to the laser cleaning head 7 via an air pipe, providing air cooling for the laser cleaning head 7. In addition, during the cleaning process, the distance between the laser cleaning head and the rotor is monitored in real time by the laser range sensor 13, and the vertical lifting system, radial advance and retreat system and horizontal rotation system are controlled by the electronic control system to make corresponding actions, so as to realize real-time compensation of the distance between the laser cleaning head 7 and the rotor and ensure the cleaning effect.

[0042] In addition, this invention discloses a cleaning method for the aforementioned large rotor automatic laser cleaning device, which includes the following steps:

[0043] S1. After the device is installed, start the laser 15 and start the rotary device 1 at the same time. Wait for the laser cleaning head 7 to emit light, and then clean the outer surface of the rotor 101 in a circumferential manner. During the cleaning process, the distance between the laser cleaning head 7 and the rotor 101 is monitored in real time by the laser range sensor 13, and the distance between the laser cleaning head 7 and the rotor 101 is compensated in real time by the electronic control system 14 to ensure the cleaning effect, thereby realizing the cleaning process of the outer surface of the rotor 101.

[0044] S2. When the laser ranging sensor 13 detects the position of entering the magnetic pole gap of the rotor 101, the magnetic pole gap cleaning process of the rotor 101 is carried out. The laser cleaning head 7 performs the cleaning process in the magnetic pole gap of the rotor by radial advance and retreat and transverse rotation, thereby realizing the cleaning process of the magnetic pole gap of the rotor 101.

[0045] S3: After cleaning one circle of the outer surface of rotor 101 at a certain height in the circumference, the electronic control system controls the z-axis reduction motor 8 of the vertical lifting system to adjust the height of the laser cleaning head 7 above the ground. After the adjustment is completed, the laser 15 and the rotary device 1 are restarted, and the laser cleaning head 7 is allowed to emit light to clean another circle of the outer surface of rotor at another height in the circumference.

[0046] S4: Repeat the above process to complete the cleaning process of the outer circumference of the rotor 101 and the magnetic pole gap of the rotor 101 at the entire height.

[0047] Furthermore, the specific process of step S2 is as follows: Figure 6 As shown, when the laser rangefinder 13 detects the position of entering the magnetic pole gap of the rotor 101, the X-direction linear module 11 of the radial advance and retreat system works, thereby driving the laser cleaning head 7 to move into the magnetic pole gap and then exit from the magnetic pole gap to the outside; at the same time, the C-direction rotary motor 12 of the transverse rotation system works, causing the laser cleaning head 7 to rotate at a certain angle and sweep across the side and bottom surfaces of the magnetic pole gap, thereby completing the cleaning process of one of the magnetic pole gaps.

[0048] 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 cleaning method for a large-scale automatic laser cleaning device for rotors, the large-scale automatic laser cleaning device for rotors comprising a rotary device (1) and a truss structure (2) connected thereto, the truss structure (2) being connected to a three-degree-of-freedom cleaning system (3), the three-degree-of-freedom cleaning system (3) comprising a laser cleaning head (7) capable of vertical lifting, radial advance and retreat, and horizontal rotation; characterized in that: It includes the following steps: S1. After the device is installed, start the laser (15) and start the rotary device (1) at the same time. Wait for the laser cleaning head (7) to emit light, and then clean the outer surface of the rotor (101) in a circumferential manner. During the cleaning process, the distance between the laser cleaning head (7) and the rotor (101) is monitored in real time by the laser distance sensor (13), and the distance between the laser cleaning head (7) and the rotor (101) is compensated in real time by the electronic control system (14) to ensure the cleaning effect and thus realize the cleaning process of the outer surface of the rotor (101). S2. When the laser rangefinder (13) detects the position of entering the magnetic pole gap of the rotor (101), the magnetic pole gap of the rotor (101) is cleaned. The laser cleaning head (7) performs the cleaning process in the magnetic pole gap of the rotor by radial advance and retreat and transverse rotation, thereby realizing the cleaning process of the magnetic pole gap of the rotor (101). S3: After cleaning one circle of the outer surface of the rotor (101) at a certain height in the circumference, the electrical control system controls the z-direction reduction motor (8) of the vertical lifting system to adjust the height of the laser cleaning head (7) above the ground. After the adjustment is completed, the laser (15) and the rotary device (1) are restarted again, and the laser cleaning head (7) is waited to emit light to clean another circle of the outer surface of the rotor at another height in the circumference. S4: Repeat the above process to complete the cleaning process of the outer circumference of the rotor (101) and the magnetic pole gap of the rotor (101) at the entire height; The three-degree-of-freedom cleaning system (3) includes a vertical lifting system, a radial advance and retreat system is installed on the lifting support (9) on the vertical lifting system, a horizontal rotation system is installed on the radial advance and retreat system, and a laser cleaning head (7) is set at the output end of the horizontal rotation system. The specific process of step S2 is as follows: when the laser ranging sensor (13) detects the position of entering the magnetic pole gap of the rotor (101), the X-direction linear module (11) of the radial advance and retreat system works, thereby driving the laser cleaning head (7) to move into the magnetic pole gap, and then exiting from the inside of the magnetic pole gap to the outside; at the same time, the c-direction rotary motor (12) of the transverse rotation system works, causing the laser cleaning head (7) to rotate at a certain angle and sweep across the side and bottom of the magnetic pole gap, thereby completing the cleaning process of one of the magnetic pole gaps.

2. The cleaning method of a large rotor automatic laser cleaning device according to claim 1, characterized in that: The rotary device (1) includes a heavy-duty rotary motor located at the center of the rotor (101). The output end of the heavy-duty rotary motor is connected to the center of the truss structure (2). The truss structure (2) is located above the rotor (101). A three-degree-of-freedom cleaning system (3) is provided at both ends of the truss structure (2).

3. The cleaning method of a large rotor automatic laser cleaning device according to claim 2, characterized in that: The truss structure (2) is connected to the three-degree-of-freedom cleaning system (3) via connecting corner pieces (10).

4. The cleaning method of a large rotor automatic laser cleaning device according to claim 1, characterized in that: The vertical lifting system includes a guide rail (4) and a rack (5) fixed on the surface of the aluminum profile (6). The guide rail (4) is slidably connected to the slider (9.1) of the lifting support (9). A z-axis reduction motor (8) is installed on the lifting support (9). The output end of the z-axis reduction motor (8) is provided with a gear (8.1) that meshes with the rack (5).

5. The cleaning method of a large rotor automatic laser cleaning device according to claim 1, characterized in that: The radial advance and retreat system includes an X-direction linear module (11) mounted on the lifting support (9). The X-direction linear module (11) includes a stepper motor (11.1) fixedly connected to the lifting support (9). The output end of the stepper motor (11.1) is connected to a lead screw (11.2). The surface of the lead screw (11.2) is provided with a lead screw nut (11.4) slidably connected to it. The lead screw nut (11.4) is slidably engaged with a linear guide rail (11.3). A transverse rotation system is mounted on the lead screw nut (11.4).

6. The cleaning method of a large rotor automatic laser cleaning device according to claim 5, characterized in that: The transverse rotation system includes a C-axis rotation motor (12) fixed on the wire nut seat (11.4), and a laser cleaning head (7) is provided at the output end of the C-axis rotation motor (12).

7. The cleaning method of a large rotor automatic laser cleaning device according to claim 1, characterized in that: The laser cleaning head (7) is connected to the laser (15) via an optical fiber. The laser cleaning head (7) is connected to the air source (16) via an air pipe. The laser cleaning head (7) is connected to the communication line and the electronic control system (14) via a power line. The input end of the electronic control system (14) is connected to the output end of the laser ranging sensor (13). The laser ranging sensor (13) is installed on the lifting support (9). The output end of the electronic control system (14) is connected to the motor control end of the vertical lifting system, the radial advance and retreat system and the horizontal rotation system.

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