A large-scale wind turbine rotor core block and intelligent assembly system and assembly method

Abstract

The present invention belongs to the technical field of wind turbine rotor assembly, and specifically relates to a large-scale wind turbine rotor core block and an intelligent assembly system and assembly method. The large-scale wind turbine rotor core block includes a rotor core segment, a non-magnetic carrier block and a permanent magnet pole. The rotor core segment includes an outer rotor sleeve plate, a hub flange connection block, an inner arc yoke plate, a bent yoke plate, an outer arc yoke plate, an axial yoke baffle, a radial yoke baffle and an arc-shaped limit lock block; the intelligent assembly system includes an assembly positioning device and an assembly fastening device. The present invention installs the non-magnetic carrier block by designing a carrier block installation area, and by adding an arc-shaped limit lock block in the inner surrounding area of ​​the carrier block installation area, the permanent magnet pole is inserted into the non-magnetic carrier block and can be locked by the arc-shaped limit lock block to achieve radial limit after being screwed into the carrier block installation area; in this way, the non-magnetic carrier block and the permanent magnet pole can be prevented from slipping, and the service life can be extended.

Description

Technical Field

[0001] The invention belongs to the technical field of wind turbine rotor assembly, and in particular relates to a large-size wind turbine rotor iron core block and an intelligent assembly system and an assembly method. Background Art

[0002] In recent years, high magnetic energy permanent magnet technology has developed rapidly, especially rare earth permanent magnet material neodymium iron boron has been widely used in direct-drive generators. Direct-drive generators using permanent magnet technology have simple structure and high efficiency. For the outer rotor permanent magnet direct-drive wind turbine, the characteristics of the outer rotor motor are that the stator is fixed in the middle position near the shaft and does not move, and the rotor rotates on the periphery of the stator. It also belongs to the radial air gap flux structure. Compared with the inner rotor structure, the rotor and the stator have changed positions. The stator inside the motor is called the inner stator, and the rotor is on the outer periphery of the motor, called the outer rotor. The outer rotor is like a barrel sleeved on the outside of the stator. It is made of iron material with good magnetic conductivity. The inner circumference of the "barrel" is fixed with magnetic poles made of permanent magnets. The "barrel" is the rotor yoke. One of the advantages of this structure is that the magnetic poles are easier to fix and will not fall off due to centrifugal force. The outer rotor yoke is fixed on the rotor sleeve. With the large-scale development of wind turbines, super-large rotor workpieces have also developed rapidly.

[0003] To this end, a Chinese patent document with publication number CN113964986B discloses an oversized wind turbine rotor workpiece and its intelligent assembly system and assembly method. The rotor workpiece is a combined outer rotor structure, including a plurality of rotor module units distributed in a ring array; the rotor module unit includes a mounting block, a non-magnetic heat conductive strip and a permanent magnet block made of a permanent magnet, the mounting block is composed of a yoke plate, an inner arc-shaped shaft sleeve plate, an outer arc-shaped mounting plate, a baffle, a first ear plate and a second ear plate, the yoke plate is a fan-shaped plate structure, the inner end is connected to the inner arc-shaped shaft sleeve plate, the outer end is connected to the baffle via the outer arc-shaped mounting plate, and the two sides of the yoke plate are respectively provided with ear plates. The oversized wind turbine rotor workpiece is a combined outer rotor structure. Compared with the traditional overall transportation, it can realize the transportation of components to the coast before assembly, which reduces the transportation difficulty and also reduces the transportation cost.

[0004] Regarding the above solution, our company found some shortcomings when using it. First, the connection between the large-scale wind turbine rotor core blocks as rotor module units mainly relies on bolts, and there is a lack of connection structure to prevent axial displacement. This leads to greater force on the bolts after assembly, and the bolts are prone to breakage during the long-term operation of the outer rotor; second, the non-magnetic thermal conductive strips and permanent magnets installed on the large-scale wind turbine rotor core blocks are prone to slippage, and the thermal conductivity of the non-magnetic thermal conductive strips needs to be further strengthened; third, the intelligent assembly system cannot realize the rapid assembly of the improved large-scale wind turbine rotor core blocks.

[0005] In view of this, the inventors hope to optimize and improve the existing super-large wind turbine rotor workpiece and its intelligent assembly system and assembly method. Summary of the invention

[0006] The purpose of the present invention is to overcome at least one of the above problems existing in the prior art and to provide a large-scale wind turbine rotor core block and an intelligent assembly system and assembly method.

[0007] In order to achieve the above technical objectives and the above technical effects, the present invention is implemented through the following technical solutions:

[0008] The present invention provides a large-scale wind turbine rotor core block, which includes a rotor core segment, a non-magnetic carrier block and a permanent magnet pole. The rotor core segment includes an outer rotor sleeve plate, a hub flange connection block, an inner arc-shaped yoke plate, a bent yoke plate, an outer arc-shaped yoke plate, an axial yoke baffle, a radial yoke baffle and an arc-shaped limit lock block. The outer side of the outer rotor sleeve plate is connected to the inner end of the inner arc-shaped yoke plate through the hub flange connection block, and the outer end of the inner arc-shaped yoke plate is connected to the inner end of the inner arc-shaped yoke plate through the bent yoke plate. It is connected to the inner end of the outer arc yoke plate, and the outer end of the outer arc yoke plate is connected to the radial yoke baffle via the axial yoke baffle. A flange mounting hole is provided on the hub flange connecting block. The outer arc yoke plate, the axial yoke baffle and the radial yoke baffle together form a carrier mounting area for installing a non-magnetic carrier block. A plurality of permanent magnet poles are evenly clamped and installed on the inner side of the non-magnetic carrier block. The outer arc yoke plate and the radial yoke baffle are relatively provided with arc-shaped limit lock blocks for limiting the radial displacement of the permanent magnet poles.

[0009] Furthermore, in the above-mentioned large-size wind turbine rotor core block, the inner sides of the inner arc yoke plate, the bent yoke plate and the outer arc yoke plate are respectively provided with a first arc slide rail, a second arc slide rail and a third arc slide rail, and the first arc slide rail, the second arc slide rail and the third arc slide rail are respectively slidingly restricted by a first arc slide block, a second arc slide block and a third arc slide block, and the first arc slide block, the second arc slide block and the third arc slide block are each installed with two fastening screws.

[0010] Furthermore, in the above-mentioned large-size wind turbine rotor core block, the first arc-shaped slider, the second arc-shaped slider and the third arc-shaped slider all include an arc-shaped slider body, the cross-section of the arc-shaped slider body is a T-shaped anti-slip structure that is wide inside and narrow outside, the first arc-shaped slide rail, the second arc-shaped slide rail and the third arc-shaped slide rail are each provided with a T-shaped anti-slip groove that is wide inside and narrow outside, two fastening through holes that cooperate with fastening screws are provided on the arc-shaped slider body, and two fastening screw holes that cooperate with the fastening screws are provided in the T-shaped anti-slip groove.

[0011] Furthermore, in the above-mentioned large-scale wind turbine rotor core block, the non-magnetic carrier block includes an arc-shaped carrier block body, and a plurality of pole clamping grooves are equidistantly provided on the inner side of the arc-shaped carrier block body; the permanent magnet pole includes a permanent magnet block, and arc-shaped limit locking grooves cooperating with the arc-shaped limit locking block are provided on both sides of the permanent magnet block.

[0012] Furthermore, in the above-mentioned large-scale wind turbine rotor core block, the non-magnetic carrier block is made of non-magnetic high thermal conductivity silicon nitride ceramic material, and the specific preparation steps are as follows:

[0013] 1) Silicon nitride powder, a sintering aid, carbon black, triethyl phosphite and a solvent are mixed for the first time by ball milling; the sintering aid is a mixture of yttrium oxide and aluminum oxide, and the mass ratio of yttrium oxide to aluminum oxide is 1:1-2; the mass ratio of the sintering aid to silicon nitride powder is 1:20-340; after the first mixing, polyethylene glycol is added for a second mixing to obtain a slurry;

[0014] 3) Pour the slurry into an injection molding machine, which injects the slurry into a molding mold to form a ceramic blank of the desired shape in the mold;

[0015] 4) The ceramic green body is placed in a debinding furnace for debinding treatment, and the debinded ceramic green body is placed in a high-temperature sintering furnace. Before high-temperature sintering, it is first heated to 1400-1480°C under vacuum conditions and kept warm for 3-4 hours; then, it is continuously heated to 1850-1900°C under a nitrogen pressure of 2-8 MPa and kept warm for 5-10 hours for high-temperature sintering to obtain a non-magnetic carrier block.

[0016] The present invention also provides an intelligent assembly system, which can assemble a plurality of large-sized wind turbine rotor core blocks as described above into a large-sized wind turbine rotor, and the intelligent assembly system includes an assembly positioning device for pre-assembling the large-sized wind turbine rotor and an assembly fastening device for assembling the large-sized wind turbine rotor;

[0017] The assembly positioning device comprises an open housing, a slewing bearing and a straightening sleeve located at the periphery thereof are installed on the inner side of the bottom plate of the open housing, a movable disk is installed on the upper end of the movable part of the slewing bearing, a positioning sleeve is installed at the center of the movable disk, a plurality of arc-shaped vacuum suction cups are installed along the circumferential direction at the upper side of the periphery of the movable disk, a straightening ring is installed at the lower side of the periphery of the movable disk, the straightening ring is restricted in its movement in the straightening sleeve, a plurality of telescopic push rods are installed along the circumferential direction on the cylindrical side plate of the open housing, and a straightening roller is installed at the movable end of the telescopic push rod;

[0018] The assembly and fastening device includes a horizontal linear guide pair, a mounting frame, a lifting push rod, a smooth ring, a suspension shaft, a turntable, a flip assembly, a first screw tightening machine, a second screw tightening machine and a third screw tightening machine. The mounting frame is fixed on the slider of the horizontal linear guide pair, and the upper frame plate of the mounting frame is fixed with a lifting push rod. The movable end of the lifting push rod is connected to the top end of the suspension shaft via a smooth ring, and a turntable is fixed to the bottom end of the suspension shaft. A flip assembly for driving the suspension shaft to rotate is installed in the mounting frame, and the first screw tightening machine, the second screw tightening machine and the third screw tightening machine are installed in sequence on the lower side of the turntable from the inside to the outside, and the number of the first screw tightening machine, the second screw tightening machine and the third screw tightening machine is equal to the number of fastening screws in the corresponding area.

[0019] Furthermore, in the above-mentioned intelligent assembly system, the flip component includes a servo motor, a driving wheel, a driven wheel and a transmission belt, the output end of the servo motor is equipped with a driving wheel, the driving wheel is connected to the driven wheel through a transmission belt, the driving wheel and the driven wheel are movably supported by the lower frame plate of the mounting frame, the driven wheel is sleeved on the outer side of the suspension shaft, the outer side of the suspension shaft is provided with an axial keyway, and the inner hole wall of the driven wheel is provided with a convex key that cooperates with the axial keyway.

[0020] Furthermore, in the above-mentioned intelligent assembly system, the first screw-tightening machine is composed of a first bracket and a fixed screw-tightening component A installed at its lower end; the second screw-tightening machine is composed of a second bracket and a movable screw-tightening component installed at its lower end; and the third screw-tightening machine is composed of a third bracket and a fixed screw-tightening component B installed at its lower end.

[0021] Furthermore, in the above-mentioned intelligent assembly system, the movable screw-tightening assembly includes a gear roller, a support plate, a screw-tightening motor, a screw nut, an adjusting motor and an adjusting gear, the gear roller is movably supported by a second bracket, the screw-tightening motor is fixed to the outer side of the gear roller via the support plate, the screw nut is installed at the output end of the screw-tightening motor, the adjusting motor is fixed on the second bracket, and the output end of the adjusting motor is installed with an adjusting gear meshing with the gear roller.

[0022] The present invention also provides an intelligent assembly method, which is implemented based on the above-mentioned intelligent assembly system and includes the following steps:

[0023] 1) Use lifting equipment to lift the large-sized wind turbine rotor core blocks to the inside of the assembly positioning device in sequence, so that the side of the large-sized wind turbine rotor core blocks with fastening screws faces upward, the outer rotor shaft sleeve plate of the large-sized wind turbine rotor core blocks is inserted into the positioning sleeve and spliced ​​into a circle, and the first arc-shaped slider, the second arc-shaped slider and the third arc-shaped slider in the large-sized wind turbine rotor core blocks are installed in the corresponding first arc-shaped slide rails, the second arc-shaped slide rails and the third arc-shaped slide rails by fastening screws; during the lifting process, the corresponding rotor core segments are adsorbed and locked by the arc-shaped vacuum suction cup, and the movable disk and the adsorbed and locked rotor core segments are driven to rotate by the slewing bearing, so that the landing point of the lifting equipment does not need to be adjusted, and there is always a space for material dropping below;

[0024] 2) When the pre-assembly of the large-sized wind turbine rotor core block is completed, the horizontal linear guide pair in the assembly and fastening device moves to transfer the installation frame and its upper components to the top of the assembly positioning device; then the lifting push rod moves to drive the first screw tightening machine, the second screw tightening machine and the third screw tightening machine to move down and contact with the corresponding fastening screws, and the first screw tightening machine, the second screw tightening machine and the third screw tightening machine respectively move to loosen the corresponding fastening screws until the arc-shaped slider body can automatically slide in the arc-shaped slide rail; then the flip assembly is used to drive the suspension shaft and the turntable to rotate, and the first screw tightening machine, the second screw tightening machine and the third screw tightening machine also drive each arc-shaped slider body to slide in the arc-shaped slide rail until the two fastening through holes of each arc-shaped slider body are respectively aligned with the fastening screw holes in the two adjacent arc-shaped slide rails; finally, the first screw tightening machine, the second screw tightening machine and the third screw tightening machine respectively move to tighten the corresponding fastening screws, thus completing the assembly operation of the large-sized wind turbine rotor;

[0025] 3) The assembly and fastening device is reset, and the assembled large-sized wind turbine rotor is lifted out and transferred from the assembly and positioning device using lifting equipment.

[0026] The beneficial effects of the present invention are:

[0027] 1. The present invention provides a large-scale wind turbine rotor core block, which is used to install non-magnetic carrier blocks by designing a carrier block installation area. The non-magnetic carrier block is pre-coated with thermal conductive adhesive on the outside before sliding into the carrier block installation area. The thermal conductive adhesive is used to fix the position of the non-magnetic carrier block in the carrier block installation area, and the thermal conductive adhesive can ensure the thermal conductivity effect. By adding an arc-shaped limit lock block to the inner area of ​​the carrier block installation area and adding an arc-shaped limit lock groove to the permanent magnet pole, the permanent magnet pole is inserted into the non-magnetic carrier block and after being screwed into the carrier block installation area, the permanent magnet pole can be locked by the arc-shaped limit lock block to achieve radial limitation. In this way, the problem of non-magnetic carrier blocks and permanent magnet poles slipping can be avoided, and the service life can be extended.

[0028] 2. The present invention adds carbon black in the process of preparing the non-magnetic carrier block, and the sintering is carried out in two steps of heating, so that the carbon black and the oxygen impurities of silicon nitride can fully react chemically under suitable temperature and atmosphere conditions, remove or partially remove the oxygen impurities, and effectively reduce the lattice oxygen content and lattice defects of silicon nitride, so that the prepared non-magnetic carrier block has a higher thermal conductivity, can quickly transfer the heat of the permanent magnet pole to the rotor core segment, and has a better heat dissipation effect. At the same time, the non-magnetic carrier block is conducive to reducing the eddy current loss on the outer rotor.

[0029] 3. The present invention provides a large-size wind turbine rotor core block, by respectively adding a first arc-shaped slide rail, a second arc-shaped slide rail and a third arc-shaped slide rail on the inner side of the inner arc-shaped magnetic yoke plate, the bent magnetic yoke plate and the outer arc-shaped magnetic yoke plate, respectively, and respectively arranging a first arc-shaped slide rail, a second arc-shaped slide rail and a third arc-shaped slide rail, respectively, the first arc-shaped slide rail, the second arc-shaped slide rail and the third arc-shaped slide rail, respectively, the first arc-shaped slide rail, the second arc-shaped slide rail and the third arc-shaped slide rail are each equipped with two fastening screws, and fastening screw holes are added in the corresponding slide grooves of the slide rails, so that the arc-shaped slide rails are hidden in the corresponding arc-shaped slide rails during subpackaging and transportation. In the slide rail, when assembly is required, each arc-shaped slider slides out a part from the corresponding arc-shaped slide rail, and the sliding part is screwed into the T-shaped anti-slip groove of the adjacent slide rail, and then the fastening screws are used to lock each arc-shaped slide rail and the rotor core segment. In this way, the fastening screws only need to complete their own fastening function, and the arc-shaped slider is used to replace the traditional bolt connection method to prevent axial displacement between the rotor core segments. The arc-shaped slider has high shear resistance and will not break during the long-term operation of the outer rotor. It is easy to break during the long-term operation of the outer rotor, thereby ensuring the service life of the outer rotor.

[0030] 4. The present invention provides an intelligent assembly system, including an assembly positioning device and an assembly fastening device. The assembly positioning device uses a slewing bearing to drive the movable disk to rotate horizontally at a fixed angle, uses an arc-shaped vacuum suction cup to lock the position of the received rotor core segment, and uses a telescopic push rod to drive the straightening roller to move radially, so that the straightening roller can provide lateral auxiliary rolling support for the rotor core segment. The assembly fastening device uses a lifting push rod to drive the turntable and the first screw tightening machine, the second screw tightening machine and the third screw tightening machine below it to lift and lower, and uses a flip assembly to drive the suspension shaft and the turntable to rotate at a fixed angle, and the first screw tightening machine, the second screw tightening machine and the third screw tightening machine below the turntable also rotate accordingly, so that the fastening screw is used as a force application point to drive the arc-shaped slider body where the fastening screw is located to rotate and slide, and then the splicing and fixing operation can be performed.

[0031] Of course, any product implementing the present invention does not necessarily need to achieve all of the above advantages at the same time. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings required for describing the embodiments are briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0033] Figure 1 This is a structural schematic diagram of a large-scale wind turbine rotor core block at one angle of the present invention;

[0034] Figure 2 It is a structural schematic diagram of another angle of a large-scale wind turbine rotor core block of the present invention;

[0035] Figure 3 It is a schematic diagram of the structure of the rotor core segment in the present invention;

[0036] Figure 4 It is a structural schematic diagram of the non-magnetic carrier block in the present invention;

[0037] Figure 5 It is a schematic diagram of the structure of the permanent magnet pole in the present invention;

[0038] Figure 6 is a schematic structural diagram of a third arc-shaped sliding block in the present invention;

[0039] Figure 7 It is a schematic diagram of the composition of the intelligent assembly system in the present invention;

[0040] Figure 8 It is a structural schematic diagram of the assembly positioning device in the present invention;

[0041] Fig. 9 It is a schematic diagram of the structure of the slewing bearing in the present invention;

[0042] Fig.10 It is a schematic diagram of the structure of the stabilizing sleeve and the stabilizing ring in the present invention;

[0043] Fig.11 It is a structural schematic diagram of the assembly and fastening device in the present invention;

[0044] Fig.12 It is a structural schematic diagram of the second screw tightening machine in the present invention;

[0045] Fig.13 It is a schematic diagram of the effect of assembling and fixing a large-sized wind turbine rotor workpiece at the latter angle in the present invention;

[0046] Fig.14 It is a schematic diagram of another angle effect after the large-sized wind turbine rotor workpiece is assembled and fixed in the present invention;

[0047] In the accompanying drawings, the components represented by the reference numerals are as follows:

[0048] 1-large size wind turbine rotor core block, 101-outer rotor shaft sleeve plate, 102-hub flange connection block, 103-inner arc yoke plate, 104-bent yoke plate, 105-outer arc yoke plate, 106-axial yoke baffle, 107-radial yoke baffle, 108-arc limit lock block, 109-non-magnetic carrier block, 109a-arc carrier block body, 109b-pole clamping groove, 110-permanent magnet Magnetic pole, 110a-permanent magnet block, 110b-arc limit lock groove, 111-flange mounting hole, 112-first arc slide rail, 113-first arc slider, 114-second arc slide rail, 115-second arc slider, 116-third arc slide rail, 117-third arc slider, 117a-arc slider body, 117b-fastening through hole, 118-fastening screw, 119-fastening screw hole;

[0049] 2-assembly positioning device, 201-opening mask, 202-slewing bearing, 203-movable plate, 204-positioning sleeve, 205-arc vacuum suction cup, 206-righting sleeve, 207-righting ring, 208-telescopic push rod, 209-righting roller;

[0050] 3-assembly and fastening device, 301-horizontal linear guide pair, 302-installation frame, 303-lifting push rod, 304-smooth ring, 305-suspension shaft, 306-turntable, 307-servo motor, 308-driving wheel, 309-driven wheel, 310-transmission belt, 311-first screw tightening machine, 312-second screw tightening machine, 312a-second bracket, 312b-tooth roller, 312c-support plate, 312d-screw tightening motor, 312e-screw nut, 312f-adjustment motor, 312g-adjustment gear, 313-third screw tightening machine. DETAILED DESCRIPTION

[0051] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0052] like Figure 1-Figure 3As shown, this embodiment provides a large-scale wind turbine rotor core block, which includes a rotor core segment, a non-magnetic carrier block 109 and a permanent magnet pole 110. The rotor core segment includes an outer rotor sleeve plate 101, a hub flange connecting block 102, an inner arc-shaped yoke plate 103, a bent yoke plate 104, an outer arc-shaped yoke plate 105, an axial yoke baffle 106, a radial yoke baffle 107 and an arc-shaped limit lock block 108. The outer side of the outer rotor sleeve plate 101 is connected to the inner end of the inner arc yoke plate 103 through the hub flange connection block 102, the outer end of the inner arc yoke plate 103 is connected to the inner end of the outer arc yoke plate 105 through the bent yoke plate 104, the outer end of the outer arc yoke plate 105 is connected to the radial yoke baffle 107 through the axial yoke baffle 106, and the hub flange connection block 102 is provided with a flange mounting hole 111. The outer arc yoke plate 105, the axial yoke baffle 106, and the radial yoke baffle 107 together form a carrier block installation area for installing a non-magnetic carrier block 109, and a plurality of permanent magnet poles 110 are evenly clamped and installed on the inner side of the non-magnetic carrier block 109, and the outer arc yoke plate 105 and the radial yoke baffle 107 are relatively provided with arc-shaped limit lock blocks 108 for limiting the radial displacement of the permanent magnet poles 110.

[0053] In this embodiment, the inner sides of the inner arc yoke plate 103, the bent yoke plate 104 and the outer arc yoke plate 105 are respectively provided with a first arc slide rail 112, a second arc slide rail 114 and a third arc slide rail 116, and the first arc slide rail 112, the second arc slide rail 114 and the third arc slide rail 116 are respectively slidingly restricted by a first arc slider 113, a second arc slider 115 and a third arc slider 117, and the first arc slider 113, the second arc slider 115 and the third arc slider 117 are each installed with two fastening screws 118.

[0054] like Figure 6 As shown, the first arc-shaped slider 113, the second arc-shaped slider 115 and the third arc-shaped slider 117 all include an arc-shaped slider body 117a, the cross-section of the arc-shaped slider body 117a is a T-shaped anti-slip structure that is wide inside and narrow outside, the first arc-shaped slide rail 112, the second arc-shaped slide rail 114 and the third arc-shaped slide rail 116 are each provided with a T-shaped anti-slip groove that is wide inside and narrow outside, and two fastening through holes 117b that cooperate with the fastening screws 118 are provided on the arc-shaped slider body 117a, and two fastening screw holes 119 that cooperate with the fastening screws 118 are provided in the T-shaped anti-slip groove.

[0055] like Figure 4 As shown, the non-magnetic carrier block 109 includes an arc-shaped carrier block body 109a, and a plurality of magnetic pole engaging grooves 109b are equidistantly formed on the inner side of the arc-shaped carrier block body 109a.

[0056] like Figure 5As shown, the permanent magnet pole 110 includes a permanent magnet block 110 a , and arc-shaped limit locking grooves 110 b cooperating with the arc-shaped limit locking block 108 are formed on both sides of the permanent magnet block 110 a .

[0057] In this embodiment, the non-magnetic carrier block 109 is made of non-magnetic high thermal conductivity silicon nitride ceramic material, and the specific preparation steps are as follows:

[0058] 1) Silicon nitride powder, sintering aid, carbon black, triethyl phosphite and solvent are mixed for the first time by ball milling; the sintering aid is a mixture of yttrium oxide and aluminum oxide, and the mass ratio of yttrium oxide to aluminum oxide is 1:1-2; the mass ratio of sintering aid to silicon nitride powder is 1:20-340; after the first mixing, polyethylene glycol is added for the second mixing to obtain slurry;

[0059] 3) Pour the slurry into an injection molding machine, which injects the slurry into a molding mold to form a ceramic blank of the desired shape in the mold;

[0060] 4) The ceramic green body is placed in a debinding furnace for debinding treatment, and the debinded ceramic green body is placed in a high-temperature sintering furnace. Before high-temperature sintering, it is first heated to 1400-1480°C under vacuum conditions and kept warm for 3-4 hours; then, it is continuously heated to 1850-1900°C under a nitrogen pressure of 2-8 MPa and kept warm for 5-10 hours for high-temperature sintering to obtain a non-magnetic carrier block.

[0061] In this embodiment, carbon black is added during the process of preparing the non-magnetic carrier block 109, and the sintering is performed in two steps of heating, so that the carbon black and the oxygen impurities of silicon nitride can fully react chemically under appropriate temperature and atmosphere conditions, remove or partially remove the oxygen impurities, and effectively reduce the lattice oxygen content and lattice defects of silicon nitride, so that the prepared non-magnetic carrier block 109 has a higher thermal conductivity, can quickly transfer the heat of the permanent magnet pole 110 to the rotor core segment, and has a better heat dissipation effect. At the same time, the non-magnetic carrier block 109 is conducive to reducing the eddy current loss on the outer rotor.

[0062] The large-scale wind turbine rotor core block 1 provided in this embodiment is used to install the non-magnetic carrier block 109 by designing the carrier block installation area. The non-magnetic carrier block 109 is pre-coated with thermal conductive adhesive on the outside before sliding into the carrier block installation area. The thermal conductive adhesive is used to fix the position of the non-magnetic carrier block 109 in the carrier block installation area, and the thermal conductive adhesive can ensure the heat conduction effect. By adding an arc-shaped limit lock block 108 to the inner area of ​​the carrier block installation area and adding an arc-shaped limit lock groove 110b to the permanent magnet pole 110, the permanent magnet pole 110 is inserted into the non-magnetic carrier block 109 and after being screwed into the carrier block installation area, the permanent magnet pole 110 can be locked by the arc-shaped limit lock block 108 to achieve radial limitation. In this way, the non-magnetic carrier block 109 and the permanent magnet pole 110 can be prevented from slipping, thereby extending the service life.

[0063] The large-scale wind turbine rotor core block 1 provided in this embodiment is provided with a first arc-shaped slide rail 112, a second arc-shaped slide rail 114 and a third arc-shaped slide rail 116 on the inner side of the inner arc-shaped yoke plate 103, the bent yoke plate 104 and the outer arc-shaped yoke plate 105, respectively, and a first arc-shaped slide block 113, a second arc-shaped slide block 115 and a third arc-shaped slide block 117 are respectively provided in the first arc-shaped slide rail 112, the second arc-shaped slide rail 114 and the third arc-shaped slide rail 116, and the first arc-shaped slide block 113, the second arc-shaped slide block 115 and the third arc-shaped slide block 117 are respectively installed with two fastening screws 118, and fastening screw holes 119 are added in the slide grooves of the corresponding slide rails. In this way, During subpackaging and transportation, the arc-shaped slider is hidden in the corresponding arc-shaped slide rail. When assembly is required, each arc-shaped slider slides out a portion (can be set to half) from the corresponding arc-shaped slide rail, and the slid-out portion is screwed into the T-shaped anti-slip groove of the adjacent slide rail, and then each arc-shaped slide rail is locked to the rotor core segment using the fastening screws. In this way, the fastening screws only need to complete their own fastening function, and the arc-shaped slider is used to replace the traditional bolt connection method to prevent axial displacement between the rotor core segments. The arc-shaped slider has high shear resistance and will not break during the long-term operation of the outer rotor. The outer rotor is prone to breakage during long-term operation, thereby ensuring the service life of the outer rotor.

[0064] like Figure 7 As shown, this embodiment also provides an intelligent assembly system, which can assemble multiple large-scale wind turbine rotor core blocks 1 as described above into a large-scale wind turbine rotor. The intelligent assembly system includes an assembly positioning device 2 for pre-assembling the large-scale wind turbine rotor and an assembly fastening device 3 for assembling the large-scale wind turbine rotor.

[0065] like Figure 8-Figure 10 As shown, the assembly positioning device 2 includes an open housing 201, a slewing bearing 202 and a straightening sleeve 206 located on the periphery thereof are installed on the inner side of the bottom plate of the open housing 201, a movable disk 203 is installed on the upper end of the movable part of the slewing bearing 202, a positioning sleeve 204 is installed at the center of the movable disk 203, and a plurality of arc-shaped vacuum suction cups 205 are installed along the circumferential direction at the upper side of the outer periphery of the movable disk 203, and the number of the arc-shaped vacuum suction cups 205 is equal to the number of the large-sized wind turbine rotor core blocks 1 assembled in a circle. A straightening ring 207 is installed at the lower side of the outer periphery of the movable disk 203, and the movement of the straightening ring 207 is limited in the annular rotation groove opened inward at the upper end of the straightening sleeve 206. A plurality of telescopic push rods 208 are installed along the circumferential direction on the cylindrical side plate of the open housing 201, and a straightening roller 209 is installed at the movable end of the telescopic push rod 208.

[0066] In this embodiment, the slewing bearing 202 adopts a structure in which the outer ring is fixed and the inner ring is rotating. Fig. 9 shown.

[0067] In this embodiment, the structures of the straightening sleeve 206 and the straightening ring 207 are as follows: Fig.10 The design of the stabilizing sleeve 206 and the stabilizing ring 207 is to improve the support reliability of the movable plate 203 and avoid the occurrence of compression deformation at the edge thereof.

[0068] The working principle of the assembly positioning device 2 is: using the slewing bearing 202 to drive the movable disk 203 to rotate horizontally at a fixed angle, using the arc-shaped vacuum suction cup 205 to adsorb and lock the position of the received rotor core segment, and using the telescopic push rod 208 to drive the straightening roller 209 to move radially, so that the straightening roller 209 can provide lateral auxiliary rolling support for the rotor core segment.

[0069] like Fig.11 As shown, the assembly and fastening device 3 includes a horizontal linear guide pair 301, a mounting frame 302, a lifting push rod 303, a smooth ring 304, a suspension shaft 305, a turntable 306, a flip assembly, a first screwing machine 311, a second screwing machine 312, and a third screwing machine 313. The mounting frame 302 is fixed on the slider of the horizontal linear guide pair 301, the lifting push rod 303 is fixed on the upper frame plate of the mounting frame 302, the movable end of the lifting push rod 303 is connected to the top end of the suspension shaft 305 through the smooth ring 304, and the turntable 306 is fixed to the bottom end of the suspension shaft 305. A flip assembly for driving the suspension shaft 305 to rotate is installed in the installation frame 302, and the first screw tightening machine 311, the second screw tightening machine 312 and the third screw tightening machine 313 are installed on the lower side of the turntable 306 from the inside to the outside. The number of the first screw tightening machine 311, the second screw tightening machine 312 and the third screw tightening machine 313 is equal to the number of fastening screws 118 in the corresponding area.

[0070] In this embodiment, the flip assembly includes a servo motor 307, a driving wheel 308, a driven wheel 309 and a transmission belt 310. The output end of the servo motor 307 is equipped with a driving wheel 308, and the driving wheel 308 is connected to the driven wheel 309 through the transmission belt 310. The driving wheel 308 and the driven wheel 309 are movably supported by the lower frame plate of the installation frame 302. The driven wheel 309 is sleeved on the outer side of the suspension shaft 305, and an axial keyway is provided on the outer side of the suspension shaft 305. The inner hole wall of the driven wheel 309 is provided with a convex key that matches the axial keyway.

[0071] like Fig.12As shown, the second screwing machine 312 is composed of a second bracket 312a and a movable screwing assembly installed at the lower end thereof; the movable screwing assembly includes a gear roller 312b, a support plate 312c, a screwing motor 312d, a screw nut 312e, an adjustment motor 312f and an adjustment gear 312g, the gear roller 312b is provided with movable support by the second bracket 312a, and the screwing motor 312d is fixed to the outer side of the gear roller 312b through the support plate 312c. The output end of the screwing motor 312d is installed with a screw nut 312e, the adjustment motor 312f is fixed on the second bracket 312a, and the output end of the adjustment motor 312f is installed with an adjustment gear 312g meshing with the gear roller 312b. The toothed roller 312b, adjusting motor 312f and adjusting gear 312g in the second screw tightening machine 312 constitute a flip adjustment mechanism, which is used to enable the screw tightening mechanism composed of the support plate 312c, screw tightening motor 312d and screw tightening nut 312e to adapt to the inclination angle of the bent yoke plate 104. The screw tightening nut 312e flips accordingly during the descent process to ensure that it can accurately contact the fastening screw 118 pre-loaded on the second arc-shaped slider 115.

[0072] In this embodiment, the first screwing machine 311 is composed of a first bracket and a fixed screwing assembly A installed at the lower end thereof; the third screwing machine 313 is composed of a third bracket and a fixed screwing assembly B installed at the lower end thereof. The first bracket and the third bracket are set with reference to the structure of the second bracket 312a, except that the heights are different. The fixed screwing assembly A and the fixed screwing assembly B are set with reference to the structure of the support plate 312c, the screwing motor 312d, and the screw nut 312e, except that the support plates of the fixed screwing assembly A and the fixed screwing assembly B are directly fixed to the corresponding bracket and cannot be turned over.

[0073] The working principle of the assembly and fastening device 3 is: the lifting push rod 303 is used to drive the turntable 306 and the first screw machine 311, the second screw machine 312 and the third screw machine 313 thereunder to perform lifting actions, and the flip assembly is used to drive the suspension shaft 305 and the turntable 306 to perform a fixed angle rotation action, and the first screw machine 311, the second screw machine 312 and the third screw machine 313 below the turntable 306 also rotate accordingly, so that the fastening screw 118 is used as a force application point to drive the arc-shaped slider body 117a where the fastening screw 118 is located to perform a rotational sliding action, and then the splicing and fixing operation can be performed.

[0074] This embodiment also provides an intelligent assembly method applicable to large-scale wind turbine rotors, comprising the following steps:

[0075] 1) Use the lifting equipment to lift the large-scale wind turbine rotor core block 1 to the inside of the assembly positioning device 2 in sequence, so that the side of the large-scale wind turbine rotor core block 1 with the fastening screw 118 faces upward, the outer rotor shaft sleeve plate 101 of the large-scale wind turbine rotor core block 1 is inserted into the positioning sleeve 204 and spliced ​​into a circle, and the first arc-shaped slider 113, the second arc-shaped slider 115 and the third arc-shaped slider 117 in the large-scale wind turbine rotor core block 1 are installed in the corresponding first arc-shaped slide rail 112, the second arc-shaped slide rail 114 and the third arc-shaped slide rail 116 by fastening screws 118; during the lifting process, the corresponding rotor core segment is adsorbed and locked by the arc-shaped vacuum suction cup 205, and the rotary bearing 202 is used to drive the movable disk 203 and the adsorbed and locked rotor core segment to rotate, so that the landing point of the lifting equipment does not need to be adjusted, and there is always a blanking space at the bottom; the pre-assembly effect of the large-scale wind turbine rotor core block 1 is as follows Fig.13 shown.

[0076] 2) After the pre-assembly of the large-sized wind turbine rotor core block 1 is completed, the horizontal linear guide pair 301 in the assembly and fastening device 3 is actuated to transfer the installation frame 302 and the components thereon to the top of the assembly and positioning device 2; then the lifting push rod 303 is actuated to drive the first screw tightening machine 311, the second screw tightening machine 312 and the third screw tightening machine 313 to move downward and contact the corresponding fastening screws 118, and the first screw tightening machine 311, the second screw tightening machine 312 and the third screw tightening machine 313 are actuated respectively to loosen the corresponding fastening screws 118 until the arc-shaped slide body 117a where it is located can automatically slide in the arc-shaped slide rail; then The hanging shaft 305 and the turntable 306 are driven to rotate by the flip assembly, and the first screw tightening machine 311, the second screw tightening machine 312 and the third screw tightening machine 313 also drive each arc-shaped slider body 117a to slide in the arc-shaped slide rail until the two fastening through holes 117b of each arc-shaped slider body 117a are respectively aligned with the fastening screw holes 119 in the two adjacent arc-shaped slide rails; finally, the first screw tightening machine 311, the second screw tightening machine 312 and the third screw tightening machine 313 act respectively to tighten the corresponding fastening screws 118, thus completing the assembly operation of the large-sized wind turbine rotor; the effect after the large-sized wind turbine rotor is assembled is as follows: Fig.13 and Fig.14 shown.

[0077] 3) The assembly and fastening device 3 is reset, and the assembled large-sized wind turbine rotor is lifted out of the assembly and positioning device 2 by using a lifting device.

[0078] The preferred embodiments of the present invention disclosed above are only useful to help explain the present invention. The preferred embodiments do not describe all the details in detail, nor do they limit the invention to specific implementation methods. Obviously, many modifications and changes can be made according to the content of this specification. This specification selects and specifically describes these embodiments in order to better explain the principles and practical applications of the present invention, so that those skilled in the art can understand and use the present invention well. The present invention is limited only by the claims and their full scope and equivalents.

Claims

1. An intelligent assembly system, which can assemble a plurality of large-sized wind turbine rotor core blocks into a large-sized wind turbine rotor, characterized in that: The large-scale wind turbine rotor core block includes a rotor core segment, a non-magnetic carrier block and a permanent magnet pole. The rotor core segment includes an outer rotor sleeve plate, a hub flange connection block, an inner arc yoke plate, a bent yoke plate, an outer arc yoke plate, an axial yoke baffle, a radial yoke baffle and an arc-shaped limit lock block. The outer side of the outer rotor sleeve plate is connected to the inner end of the inner arc yoke plate through the hub flange connection block. The outer end of the inner arc yoke plate is connected to the outer arc yoke plate through the bent yoke plate. The inner end is connected, the outer end of the outer arc-shaped magnetic yoke plate is connected to the radial magnetic yoke baffle via the axial magnetic yoke baffle, a flange mounting hole is provided on the hub flange connecting block, the outer arc-shaped magnetic yoke plate, the axial magnetic yoke baffle and the radial magnetic yoke baffle together form a carrier mounting area for mounting a non-magnetic carrier block, a plurality of permanent magnet poles are evenly clamped and mounted on the inner side of the non-magnetic carrier block, and the outer arc-shaped magnetic yoke plate and the radial magnetic yoke baffle are relatively provided with arc-shaped limit lock blocks for limiting the radial displacement of the permanent magnet poles; The intelligent assembly system includes an assembly positioning device for pre-assembling large-sized wind turbine rotors and an assembly fastening device for assembling large-sized wind turbine rotors; The assembly positioning device comprises an open housing, a slewing bearing and a straightening sleeve located at the periphery thereof are installed on the inner side of the bottom plate of the open housing, a movable disk is installed on the upper end of the movable part of the slewing bearing, a positioning sleeve is installed at the center of the movable disk, a plurality of arc-shaped vacuum suction cups are installed along the circumferential direction at the upper side of the periphery of the movable disk, a straightening ring is installed at the lower side of the periphery of the movable disk, the straightening ring is restricted in its movement in the straightening sleeve, a plurality of telescopic push rods are installed along the circumferential direction on the cylindrical side plate of the open housing, and a straightening roller is installed at the movable end of the telescopic push rod; The assembly and fastening device includes a horizontal linear guide pair, a mounting frame, a lifting push rod, a smooth ring, a suspension shaft, a turntable, a flip assembly, a first screw tightening machine, a second screw tightening machine and a third screw tightening machine. The mounting frame is fixed on the slider of the horizontal linear guide pair, and the upper frame plate of the mounting frame is fixed with a lifting push rod. The movable end of the lifting push rod is connected to the top end of the suspension shaft via a smooth ring, and a turntable is fixed to the bottom end of the suspension shaft. A flip assembly for driving the suspension shaft to rotate is installed in the mounting frame, and the first screw tightening machine, the second screw tightening machine and the third screw tightening machine are installed in sequence on the lower side of the turntable from the inside to the outside, and the number of the first screw tightening machine, the second screw tightening machine and the third screw tightening machine is equal to the number of fastening screws in the corresponding area.

2. The intelligent assembly system according to claim 1, characterized in that: The inner sides of the inner arc yoke plate, the bent yoke plate and the outer arc yoke plate are respectively provided with a first arc slide rail, a second arc slide rail and a third arc slide rail, and the first arc slide rail, the second arc slide rail and the third arc slide rail are respectively slidingly restricted with a first arc slider, a second arc slider and a third arc slider, and the first arc slider, the second arc slider and the third arc slider are each installed with two fastening screws.

3. The intelligent assembly system according to claim 2, characterized in that: The first arc-shaped slider, the second arc-shaped slider and the third arc-shaped slider include an arc-shaped slider body, the cross-section of the arc-shaped slider body is a T-shaped anti-slip structure that is wide inside and narrow outside, the first arc-shaped slide rail, the second arc-shaped slide rail and the third arc-shaped slide rail are each provided with a T-shaped anti-slip groove that is wide inside and narrow outside, the arc-shaped slider body is provided with two fastening through holes that cooperate with the fastening screws, and the T-shaped anti-slip groove is provided with two fastening screw holes that cooperate with the fastening screws.

4. The intelligent assembly system according to claim 3, characterized in that: The non-magnetic carrier block includes an arc-shaped carrier block body, and a plurality of pole clamping grooves are equidistantly provided on the inner side of the arc-shaped carrier block body; the permanent magnet pole includes a permanent magnet block, and arc-shaped limit locking grooves cooperating with the arc-shaped limit locking block are provided on both sides of the permanent magnet block.

5. The intelligent assembly system according to claim 4, characterized in that: The non-magnetic carrier block is made of non-magnetic high thermal conductivity silicon nitride ceramic material, and the specific preparation steps are as follows: 1) Silicon nitride powder, a sintering aid, carbon black, triethyl phosphite and a solvent are mixed for the first time by ball milling; the sintering aid is a mixture of yttrium oxide and aluminum oxide, and the mass ratio of yttrium oxide to aluminum oxide is 1:1-2; the mass ratio of the sintering aid to silicon nitride powder is 1:20-340; after the first mixing, polyethylene glycol is added for a second mixing to obtain a slurry; 2) Pour the slurry into an injection molding machine, which injects the slurry into a molding mold to form a ceramic blank of the desired shape in the mold; 3) The ceramic green body is placed in a debinding furnace for debinding treatment, and the debinded ceramic green body is placed in a high-temperature sintering furnace. Before high-temperature sintering, it is first heated to 1400-1480°C under vacuum conditions and kept warm for 3-4 hours; then, it is continuously heated to 1850-1900°C under a nitrogen pressure of 2-8 MPa and kept warm for 5-10 hours for high-temperature sintering to obtain a non-magnetic carrier block.

6. The intelligent assembly system according to claim 5, characterized in that: The flip assembly includes a servo motor, a driving wheel, a driven wheel and a transmission belt. The output end of the servo motor is equipped with a driving wheel. The driving wheel is connected to the driven wheel through a transmission belt. The driving wheel and the driven wheel are movably supported by the lower frame plate of the mounting frame. The driven wheel is sleeved on the outer side of the suspension shaft. An axial keyway is provided on the outer side of the suspension shaft. The inner hole wall of the driven wheel is provided with a convex key that cooperates with the axial keyway.

7. The intelligent assembly system according to claim 6, characterized in that: The first screwing machine is composed of a first bracket and a fixed screwing assembly A installed at its lower end; the second screwing machine is composed of a second bracket and a movable screwing assembly installed at its lower end; the third screwing machine is composed of a third bracket and a fixed screwing assembly B installed at its lower end.

8. The intelligent assembly system according to claim 7, characterized in that: The movable screw-tightening assembly includes a gear roller, a support plate, a screw-tightening motor, a screw-tightening nut, an adjusting motor and an adjusting gear. The gear roller is movably supported by a second bracket. The screw-tightening motor is fixed to the outer side of the gear roller via the support plate. The screw-tightening nut is installed at the output end of the screw-tightening motor. The adjusting motor is fixed on the second bracket. The adjusting gear meshing with the gear roller is installed at the output end of the adjusting motor.

9. An intelligent assembly method, implemented based on the intelligent assembly system according to claim 8, characterized in that: The steps include: 1) Use lifting equipment to lift the large-sized wind turbine rotor core blocks to the inside of the assembly positioning device in sequence, so that the side of the large-sized wind turbine rotor core blocks with fastening screws faces upward, the outer rotor shaft sleeve plate of the large-sized wind turbine rotor core blocks is inserted into the positioning sleeve and spliced ​​into a circle, and the first arc-shaped slider, the second arc-shaped slider and the third arc-shaped slider in the large-sized wind turbine rotor core blocks are installed in the corresponding first arc-shaped slide rails, the second arc-shaped slide rails and the third arc-shaped slide rails by fastening screws; during the lifting process, the corresponding rotor core segments are adsorbed and locked by the arc-shaped vacuum suction cup, and the movable disk and the adsorbed and locked rotor core segments are driven to rotate by the slewing bearing, so that the landing point of the lifting equipment does not need to be adjusted, and there is always a space for material dropping below; 2) When the pre-assembly of the large-sized wind turbine rotor core block is completed, the horizontal linear guide pair in the assembly and fastening device moves to transfer the installation frame and its upper components to the top of the assembly positioning device; then the lifting push rod moves to drive the first screw tightening machine, the second screw tightening machine and the third screw tightening machine to move down and contact with the corresponding fastening screws, and the first screw tightening machine, the second screw tightening machine and the third screw tightening machine respectively move to loosen the corresponding fastening screws until the arc-shaped slider body can automatically slide in the arc-shaped slide rail; then the flip assembly is used to drive the suspension shaft and the turntable to rotate, and the first screw tightening machine, the second screw tightening machine and the third screw tightening machine also drive each arc-shaped slider body to slide in the arc-shaped slide rail until the two fastening through holes of each arc-shaped slider body are respectively aligned with the fastening screw holes in the two adjacent arc-shaped slide rails; finally, the first screw tightening machine, the second screw tightening machine and the third screw tightening machine respectively move to tighten the corresponding fastening screws, thus completing the assembly operation of the large-sized wind turbine rotor; 3) The assembly and fastening device is reset, and the assembled large-sized wind turbine rotor is lifted out and transferred from the assembly and positioning device using lifting equipment.

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