A wind turbine stator welding die and control system

Abstract

The application discloses a kind of wind-driven generator stator welding mould and adjusting system, and the longitudinal both ends side surface of inner support column is arranged with several connecting ribs in annular array, and inner support ring and outer support ring are arranged coaxially outside inner support column by connecting rib;The outer ring of inner support ring is provided with inner support mechanism, and the stator petal is connected to the outside of inner support ring by inner support mechanism;The inner ring of outer support ring is provided with outer support mechanism;Inner push rod is included in inner support mechanism;End of inner push rod is fixed support spring blade, and support spring blade is connected to the both ends of stator petal;Outer support mechanism, including several adjusting mechanisms, each adjusting mechanism is connected to outer support ring by auxiliary push mechanism;Auxiliary push mechanism includes outer push rod;Adjusting mechanism includes connecting arm, connecting arm both ends are connected to secondary push rod, and stator petal end is connected to secondary push rod, and distance sensor for controlling the work of adjusting mechanism is arranged on inner support ring.

Description

Technical Field

[0001] This invention relates to a stator welding mold and control system for a wind turbine generator, belonging to the field of wind turbine generator manufacturing equipment. Background Technology

[0002] Large wind turbine stators are generally made up of several stator segments welded together. However, because the stator segments themselves are quite large, in existing technologies, the stator segments are usually fixed and welded by placing them on the ground, then fixing a support frame on the outside and making minor adjustments based on the support frame. When placed inside the support frame, the stator segments are prone to local deformation and bending due to their own weight and the deflection caused by their large size. Moreover, the support frame is generally a rigid structure, and the position of the stator segments is usually fine-tuned by floating structures such as connecting bolts. However, due to the deflection of the stator segments themselves, the fine-tuning can only achieve local adjustments to the position of the stator segments, and cannot adjust the overall position. Furthermore, since the stator has multiple stator segments, adjusting one segment affects the entire structure, making the adjustment process lengthy and complex. Summary of the Invention

[0003] The technical problem to be solved by the present invention is to overcome the technical problems in the prior art and provide a wind turbine stator welding mold and control system.

[0004] The technical solution adopted by this invention to solve its technical problem is:

[0005] A welding mold for a wind turbine stator, the wind turbine stator comprising: a plurality of stator segments arranged in a ring array, the stator segments having an arc-shaped structure, and connecting plates for fixing to adjacent stator segments are provided at both lateral ends of the stator segments.

[0006] Stator welding molds include:

[0007] The connecting frame includes an inner support column, which is fixed to the ground. Several connecting ribs are arranged in a circular array on both sides of the longitudinal ends of the inner support column. An inner support ring and an outer support ring are arranged coaxially on the outside of the inner support column through the connecting ribs. The connecting ribs are fixedly connected to the two ends of the inner support ring and the outer support ring.

[0008] The inner support ring has several inner support mechanisms arranged in an outer ring array. The stator lobe is connected to the outside of the inner support ring through the inner support mechanisms.

[0009] The outer support ring has an outer support mechanism on its inner ring, and the outer side of the stator lobe is pressed against the inner support mechanism by the outer support mechanism.

[0010] The inner support mechanism includes at least two sets of inner push rods arranged in an equidistant array along the longitudinal axis of the inner support ring; the inner support mechanism also includes at least two sets of arc-shaped support springs, the ends of the inner push rods being fixed to the transverse middle of the support springs; the inner support mechanism also includes two sets of stator lobe connecting blocks, the stator lobe connecting blocks being fixed to the transverse ends of each support spring, and the stator lobe connecting blocks being fixed to the transverse ends of the stator lobe by bolts;

[0011] An external support mechanism includes an adjustment mechanism arranged in a ring array inside the outer support ring. Each adjustment mechanism is connected to the outer support ring via an auxiliary pushing mechanism. The auxiliary pushing mechanism includes at least two sets of external pushing rods arranged equidistantly along the longitudinal axis of the outer support ring inside the outer support ring. The adjustment mechanism includes a connecting arm fixed to the pushing end of the external pushing rod. The axis of the connecting arm is arranged perpendicular to the longitudinal axis of the outer support ring. A secondary pushing rod is provided at each end of the connecting arm. A pressure block is connected to the pushing end of the secondary pushing rod via a universal mechanism. The pressure block is fixedly connected to the connecting plate at the end of the stator segment.

[0012] As a further improvement of the present invention, a clamping block is sleeved on the connecting rib, and the clamping block is fixed to the connecting rib by bolts. A clamping groove is provided in the clamping block, and the end sidewalls of the inner support ring and the outer support ring are fixed to the clamping groove. A clamping bolt is symmetrically arranged on the clamping block, penetrating the clamping groove, and the end of the clamping bolt is pressed against the inner support ring and the outer support ring. Compared with welding fixation, the clamping block fixing structure can periodically fine-tune the fixing position of the connecting rib, the inner support ring, and the outer support ring, eliminating the error caused by local deformation after long-term use.

[0013] As a further improvement of the present invention, the inner support ring includes a first inner ring and a second inner ring, which are fixedly connected to each other by a first support rib arranged in a ring array; the outer support ring includes a first outer ring and a second outer ring, which are fixedly connected to each other by a second support rib arranged in a ring array; both the inner support ring and the outer support ring adopt a double frame structure, so that the inner support ring and the outer support ring are not easily deformed by the reaction force of the pushing mechanism.

[0014] As a further improvement of the present invention, the outer push rod includes a housing portion and a telescopic portion that moves telescopically relative to the housing, wherein the housing portion passes through the first outer ring and is fixedly connected to the second support rib.

[0015] As a further improvement of the present invention, a contact groove is provided in the pressure block, and the side of the connecting plate facing the arc-shaped middle of the stator lobe is embedded in the contact groove. A permanent magnet block for fixing with the connecting plate is provided on the inner wall of the contact groove. The fixing method of the contact groove makes it less likely for the pressure block to slide relative to the connecting plate, resulting in better fixing strength. The permanent magnet block reduces the difficulty of pre-fixing between the pressure block and the connecting plate.

[0016] As a further improvement of the present invention, the universal mechanism is a universal ball joint mechanism.

[0017] An adjustment system for a stator welding mold of a wind turbine generator includes a distance sensing mechanism arranged in a ring array outside an inner support ring. The distance sensing mechanism is positioned at the connection points between stator segments. Each set of distance sensing mechanisms includes two distance sensors, with the sensing ends of the sensors facing the lateral ends of the stator segments. The adjustment system also includes a fine-tuning module, a coarse-tuning module, and an active adjustment module. The active adjustment module is connected to the control ends of each outer and inner push rod, and is also connected to an active controller. The active controller adjusts the extension amount of each outer and inner push rod through the active adjustment module. The data input sides of the fine-tuning and coarse-tuning modules are connected to the distance sensors, and the output end of the coarse-tuning module is connected to each inner push rod. The second control end of the rod and the outer push rod, and the output end of the fine-tuning module are connected to the control ends of each auxiliary push rod; the adjustment method is as follows: the distance from the center of the inner support column to the 0 position of the distance sensor is L, the distance from the 0 position of the distance sensor to the lateral end of the stator lobe is I, and the inner diameter of the stator is R; after the stator lobe is installed, the coarse adjustment position of the stator lobe is first adjusted by the active adjustment module. When I-(RL)≤10%I, the coarse adjustment module intervenes and drives each inner push rod to retract and the outer push rod to extend; until I-(RL)<5%I, the extension amount of each auxiliary push rod is finely adjusted by the fine-tuning module, thereby fine-tuning the precise position of the stator lobe, until I=RL, and the connecting plates that are in contact with each other are welded.

[0018] As a further improvement of the present invention, the distance sensor is fixed to the surface of the inner support ring by a connecting post, and the connecting post passes through the first inner ring on the outside of the inner support ring and is fixedly connected to the first support rib; the connecting post passes through and is fixed to the first support rib. Compared with fixing to the inner ring surface of the inner support ring, this fixing method has a higher bonding strength and is less likely to affect the accuracy due to local twisting of the inner ring of the inner support.

[0019] The beneficial effects of this invention are:

[0020] This invention supports the stator segments through a set of interconnected support mechanisms arranged in a ring array. The inner side of the stator segments is supported by floating springs. During the adjustment of the stator segment ends, the stator segments can float as a whole, which can reduce the local compression of the stator segments during the adjustment process and reduce the deformation of the stator segments.

[0021] This invention uses a control system to synchronously adjust the position of the stator segments, which is more efficient than the single local adjustment in the prior art. Moreover, by estimating the stator size, it can ensure the consistency of the fixed position of each stator segment relative to the stator center distance, thus ensuring the roundness of the stator. Attached Figure Description

[0022] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0023] Figure 1 This is a schematic diagram of the structure of the present invention;

[0024] Figure 2 yes Figure 1 A magnified view of a portion of point A in the middle;

[0025] Figure 3 This is a schematic diagram of the clamping block being fixed.

[0026] In the diagram: 1. Inner support ring; 1-1. Second inner ring; 1-2. First inner ring; 1-3. First support rib; 2. Outer support ring; 2-1. Second outer ring; 2-2. First outer ring; 2-3. Second support rib; 3. Inner support column; 4. Connecting rib; 5. Connecting column; 6. Distance sensor; 7. Inner push rod; 8. Clamping column; 9. Support spring; 10. Outer push rod; 11. Connecting arm; 12. Stator lobe; 13. Secondary push rod; 14. Pressure block; 15. Permanent magnet block; 16. Stator lobe connecting block; 17. Threaded seat; 18. Fixing bolt; 19. Clamping block; 20. Clamping groove; 21. Clamping bolt; 22. Connecting platform; 23. Connecting plate. Detailed Implementation

[0027] The present invention will now be described in further detail with reference to the accompanying drawings. These drawings are simplified schematic diagrams, illustrating only the basic structure of the invention, and therefore only show the components relevant to the invention.

[0028] like Figure 1 The stator of a wind turbine includes several stator segments arranged in a ring array. The stator segments are arc-shaped, and connecting plates for fixing to adjacent stator segments are provided at both ends of the stator segments in the lateral direction. The connecting plates are fixed to each other by welding.

[0029] like Figure 1 This wind turbine stator welding mold includes:

[0030] The connecting frame includes an inner support column, which is fixed to the ground. Several connecting ribs are arranged in a circular array on both sides of the longitudinal ends of the inner support column. An inner support ring and an outer support ring are arranged coaxially on the outside of the inner support column through the connecting ribs. The connecting ribs are fixedly connected to the two ends of the inner support ring and the outer support ring.

[0031] The inner support ring has several inner support mechanisms arranged in an outer ring array. The stator petals are connected to the outside of the inner support ring through the inner support mechanisms. The inner support ring includes a first inner ring and a second inner ring. The first inner ring and the second inner ring are fixedly connected to each other by a first support rib arranged in an annular array.

[0032] The outer support ring has an outer support mechanism on its inner ring. The outer side of the stator lobe is pressed against the inner support mechanism by the outer support mechanism. The outer support ring includes a first outer ring and a second outer ring. The first outer ring and the second outer ring are fixedly connected to each other by a second support rib arranged in a ring array.

[0033] like Figure 3 Four sets of clamping blocks are fitted onto the connecting ribs. The clamping blocks are fixed to the connecting ribs by bolts. A clamping groove is provided in the clamping block. The end sidewalls of the first inner ring, the second inner ring, the first outer ring, and the second outer ring are fixed to the clamping groove. A clamping bolt is symmetrically arranged on the clamping block, penetrating the clamping groove. The end of the clamping bolt is pressed against the end of the first inner ring, the second inner ring, the first outer ring, and the second outer ring.

[0034] like Figure 1 and Figure 2 The inner support mechanism includes at least two sets of inner push rods arranged in an equidistant array along the longitudinal axis of the inner support ring; the inner support mechanism also includes at least two sets of arc-shaped support springs, the ends of the inner push rods are fixed to the transverse middle of the support springs, a threaded clamping post is provided at the end of the inner push rod, and a clamping nut is fixed in an array on the clamping post, the support springs are clamped by the clamping nuts and fixed relative to the clamping post; the inner support mechanism also includes two sets of stator segment connecting blocks, the stator segment connecting blocks are fixed to the transverse ends of each support spring, a threaded seat is fixed on the stator segment connecting block, the stator segment connecting block is pressed against the inner side of the arc surface of the stator segment, and fixed relative to the stator segment connecting block by fixing bolts fixed to the outer side of the arc surface of the stator segment;

[0035] like Figure 1 and Figure 2The outer support mechanism includes several adjustment mechanisms arranged in a ring array inside the outer support ring. Each adjustment mechanism is connected to the outer support ring through an auxiliary pushing mechanism. The auxiliary pushing mechanism includes at least two sets of outer pushing rods arranged in an equidistant array along the longitudinal axis of the outer support ring inside the outer support ring. Each outer pushing rod includes a housing part and a telescopic part that moves telescopically relative to the housing part. The housing part passes through the first outer ring and is fixedly connected to the second support rib. The adjustment mechanism includes a connecting arm fixed to the pushing end of the outer pushing rod. The axis of the connecting arm is arranged perpendicular to the longitudinal axis of the outer support ring. A secondary pushing rod is provided at each end of the connecting arm. A pressure block is connected to the pushing end of the secondary pushing rod through a universal ball joint mechanism. The pressure block is fixedly connected to the connecting plate at the end of the stator lobe. A contact groove is provided in the pressure block. The side of the connecting plate facing the arc-shaped middle of the stator lobe is embedded in the contact groove. A permanent magnet block for fixing with the connecting plate is provided on the inner wall of the contact groove.

[0036] like Figure 2 An adjustment system for a stator welding mold of a wind turbine generator includes a distance sensing mechanism arranged in a ring array outside an inner support ring. The distance sensing mechanism is positioned at the connection points between stator segments. A connecting column is fixed on the inner support ring, passing through a first inner ring outside the inner support ring and fixedly connected to a first support rib. The distance sensing mechanism is fixed to the end of the connecting column. Each set of distance sensing mechanisms includes two distance sensors, with the sensing ends of the sensors facing the lateral ends of the stator segments. The adjustment system also includes a fine-tuning module, a coarse-tuning module, and an active adjustment module. The active adjustment module is connected to the control ends of each outer and inner push rod, and is also connected to an active controller. The active controller adjusts the extension amount of each outer and inner push rod through the active adjustment module. The fine-tuning module and coarse-tuning module... The data input side is connected to a distance sensor. The output of the coarse adjustment module is connected to the second control end of each inner push rod and outer push rod. The output of the fine adjustment module is connected to the control end of each auxiliary push rod. The adjustment method is as follows: the distance from the 0 position of the distance sensor to the center of the inner support column is L; the distance detected by the distance sensor 0 position relative to the lateral end of the stator lobe is I; and the inner diameter of the stator is R. After the stator lobe is installed, the coarse adjustment position of the stator lobe is first adjusted by the active adjustment module. When I-(RL)≤10%I, the coarse adjustment module intervenes, driving each inner push rod to retract and the outer push rod to extend. Until I-(RL)<5%I, the extension amount of each auxiliary push rod is finely adjusted by the fine adjustment module, thereby finely adjusting the precise position of the stator lobe, until I=RL, and the connecting plates that are in contact with each other are welded.

[0037] During construction, the active adjustment module first extends the inner push rod fully and retracts the outer push rod fully. Then, the stator segments are hoisted into the fixed area through the gap between the inner and outer support rings. Next, the stator segments are fixed to the stator segment connecting blocks at both ends of the support spring using fixing bolts. Then, the active adjustment module extends the outer push rod, causing the connecting plates at both ends of the stator segments to embed into the contact grooves of the pressure blocks, thus fixing the inner and outer sides of the stator segment's arc surface. Subsequently, the adjustment system is activated, using the active adjustment module to bring the stator segments closer together until the distance sensor detects that I-(RL) = 10%I, at which point the adjustment stops. At this point, the spacing between the stator segments enters the fine-tuning range, which can be further adjusted using both the coarse and fine-tuning modules. Fine-tuning begins with the coarse-tuning module continuing to control the retraction of the inner push rod and the extension of the outer push rod, reducing the distance between the stator segments and causing partial contact between the two ends of the stator segments until the distance sensor detects I-(RL)=5%I. At this point, the fine-tuning module intervenes, controlling the extension of the auxiliary push rod to bring the stator segments closer together until they make contact. Simultaneously, the fine-tuning module fine-tunes the extension and retraction of each auxiliary push rod to ensure that the distance between each stator segment and the center of the mechanism is the same. After this is completed, the connecting plates at the ends of the stator segments can be welded together. After welding, the connecting rib at one end is removed, and the coarse-tuning module is used to fully retract both the outer and inner push rods, thus separating the stator segment clamping mechanism. Finally, the entire stator can be hoisted and separated.

[0038] Based on the above-described preferred embodiments of the present invention, and through the foregoing description, those skilled in the art can make various changes and modifications without departing from the inventive concept. The technical scope of this invention is not limited to the contents of the specification, but must be determined according to the scope of the claims.

Claims

1. A welding mold for a wind turbine stator, wherein the wind turbine stator includes several stator segments arranged in a ring array, the stator segments having an arc-shaped structure, and connecting plates for fixing to adjacent stator segments are provided at both transverse ends of the stator segments. Its characteristics are, include: The connecting frame includes an inner support column, which is fixed to the ground. Several connecting ribs are arranged in a circular array on both sides of the longitudinal ends of the inner support column. An inner support ring and an outer support ring are arranged coaxially on the outside of the inner support column through the connecting ribs. The connecting ribs are fixedly connected to the two ends of the inner support ring and the outer support ring. The inner support ring has several inner support mechanisms arranged in an outer ring array. The stator lobe is connected to the outside of the inner support ring through the inner support mechanisms. The outer support ring has an outer support mechanism on its inner ring, and the outer side of the stator lobe is pressed against the inner support mechanism by the outer support mechanism. The inner support mechanism includes at least two sets of inner push rods arranged in an equidistant array along the longitudinal axis of the inner support ring; the inner support mechanism also includes at least two sets of arc-shaped support springs, the ends of the inner push rods being fixed to the transverse middle of the support springs; the inner support mechanism also includes two sets of stator lobe connecting blocks, the stator lobe connecting blocks being fixed to the transverse ends of each support spring, and the stator lobe connecting blocks being fixed to the transverse ends of the stator lobe by bolts; An external support mechanism includes several adjustment mechanisms arranged in a ring array inside the outer support ring. Each adjustment mechanism is connected to the outer support ring via an auxiliary pushing mechanism. The auxiliary pushing mechanism includes at least two sets of external pushing rods arranged equidistantly along the longitudinal axis of the outer support ring inside the outer support ring. The adjustment mechanism includes a connecting arm fixed to the pushing end of the external pushing rod. The axis of the connecting arm is arranged perpendicular to the longitudinal axis of the outer support ring. A secondary pushing rod is provided at each end of the connecting arm. A pressure block is connected to the pushing end of the secondary pushing rod via a universal mechanism. The pressure block is fixedly connected to the connecting plate at the end of the stator segment.

2. The wind turbine stator welding mold as described in claim 1, characterized in that: A clamping block is sleeved on the connecting rib, and the clamping block is fixed to the connecting rib by bolts. A clamping groove is provided in the clamping block. The end sidewalls of the inner support ring and the outer support ring are fixed to the clamping groove. A clamping bolt is symmetrically arranged on the clamping block, penetrating the clamping groove. The end of the clamping bolt is pressed against the inner support ring and the outer support ring.

3. The wind turbine stator welding mold as described in claim 1, characterized in that, The inner support ring includes a first inner ring and a second inner ring, which are fixedly connected to each other by a first support rib arranged in a ring array; the outer support ring includes a first outer ring and a second outer ring, which are fixedly connected to each other by a second support rib arranged in a ring array.

4. The wind turbine stator welding mold as described in claim 1, characterized in that: The outer push rod includes an outer shell and a telescopic part that moves telescopically relative to the outer shell, wherein the outer shell passes through the first outer ring and is fixedly connected to the second support rib.

5. A wind turbine stator welding mold as described in claim 1, characterized in that: in The pressure block is provided with a contact groove. The connecting plate is embedded in the contact groove on one side facing the middle of the stator lobe arc. A permanent magnet block for fixing with the connecting plate is provided on the inner wall of the contact groove.

6. The stator welding mold for a wind turbine generator as described in claim 1, characterized in that: The universal joint mechanism is a universal ball joint mechanism.

7. The adjustment system for a wind turbine stator welding mold as described in claim 1, characterized in that: The adjustment system includes a distance sensing mechanism arranged in a ring array outside the inner support ring. The distance sensing mechanism is positioned at the connection points between the stator segments. Each group of distance sensing mechanisms includes two distance sensors, with the sensing ends of the sensors facing the lateral ends of the stator segments. The adjustment system also includes a fine-tuning module, a coarse-tuning module, and an active adjustment module. The active adjustment module is connected to the control ends of each outer and inner push rod. The active adjustment module is also connected to an active controller, which adjusts the extension amount of each outer and inner push rod through the active adjustment module. The data input sides of the fine-tuning and coarse-tuning modules are connected to the distance sensors, and the output end of the coarse-tuning module is connected to the second... The control end, the output end of the fine-tuning module is connected to the control end of each auxiliary push rod; the adjustment method is as follows: the distance from the center of the inner support column to the 0 position of the distance sensor is L, the distance detected by the distance sensor from the 0 position of the distance sensor to the lateral end of the stator lobe is I, and the inner diameter of the stator is R; after the stator lobe is installed, the coarse adjustment position of the stator lobe is first adjusted by the active adjustment module. When I-(RL)≤10%I, the coarse adjustment module intervenes, and the coarse adjustment module drives each inner push rod to retract and the outer push rod to extend; until I-(RL)<5%I, the extension amount of each auxiliary push rod is finely adjusted by the fine-tuning module, thereby finely adjusting the precise position of the stator lobe, until I=RL, and the connecting plates that are in contact with each other are welded.

8. The adjustment system for a wind turbine stator welding mold as described in claim 7, characterized in that: The distance sensor is fixed to the surface of the inner support ring by a connecting post, which passes through the first inner ring on the outside of the inner support ring and is fixedly connected to the first support rib.

Images