Hydro-generator rotor bracket center body and welding method thereof

Abstract

The invention discloses a hydro-generator rotor bracket center body and a welding method thereof, and relates to the technical field of production and manufacturing of hydro-generator rotor bracket center bodies, in particular to a hydro-generator rotor bracket center body and a welding method thereof. The rotor center body is a cylindrical barrel, the disc forgings are arranged at the two ends of the rotor center body, welding grooves are formed in the annular connecting faces of the disc forgings and the rotor center body, and the rotor center body is arranged on the roller carrier in a rolling mode. And the section of the welding groove is I-shaped. The welding method has the advantages that a traditional K-shaped groove design is improved into an I-shaped narrow-gap groove, the welding area is effectively reduced, the requirement for welding filling materials is effectively reduced, and therefore the welding workload is reduced. By means of the design, the material cost is reduced, the welding time is shortened, and the overall production efficiency is improved.

Description

Technical Field

[0001] The invention relates to the technical field of manufacturing a central body of a hydro-generator rotor support, and in particular to a central body of a hydro-generator rotor support and a welding method thereof. Background Art

[0002] In the field of hydro-turbine generators, the rotor support center body is one of the core components, and its design and manufacturing quality directly affect the performance and reliability of the entire generator. The traditional rotor support center body is usually composed of upper and lower disc forgings and a cylinder in the middle connected by welding. Although this structural design meets the strength requirements to a certain extent, with the continuous improvement of hydro-turbine generator parameters, higher requirements are placed on the size, thickness and welding quality of the rotor support center body.

[0003] At present, the welding of the upper and lower disc forgings and the cylinder mainly adopts K-type groove and is welded by manual gas shielded welding. However, this traditional method has many shortcomings. First, the design of the K-type groove leads to a large amount of welding filler material, which increases the manufacturing cost and time. Secondly, the welding operation of large structures is complicated and requires extremely high skills of welders. In addition, manual welding cannot ensure that every weld meets high standards, and defects such as pores and slag inclusions are prone to occur, resulting in unstable welding quality. Finally, due to the above problems, the rework rate of finished products is high, which affects production efficiency and economic benefits.

[0004] Therefore, it is particularly important to develop a new rotor support center body and a welding method thereof that can reduce welding amount and ensure welding quality. The present invention is based on this demand and aims to improve the manufacturing quality and efficiency of the rotor support center body by improving the welding groove design and adopting automated welding technology. Summary of the invention

[0005] The present invention aims to overcome the above-mentioned disadvantages of the prior art and provides a central body of a hydro-generator rotor support and a welding method thereof.

[0006] The technical solution adopted by the present invention is as follows:

[0007] A hydro-generator rotor support center body, comprising: a disc forging, a rotor center body and a roller frame, wherein the rotor center body is configured as a cylindrical barrel, the disc forging is disposed at both ends of the rotor center body, a welding groove is disposed on the annular connection surface between the disc forging and the rotor center body, and the rotor center body is rotatably disposed on the roller frame;

[0008] The welding groove section is set to I type.

[0009] Furthermore, the end of the welding groove close to the axis is narrower than the outer end.

[0010] Furthermore, the welding groove of the rotor center body and / or the disc forging is provided with a positioning fulcrum.

[0011] Furthermore, two positioning fulcrums are radially arranged on the same connection surface according to the width of the welding groove.

[0012] Furthermore, the positioning fulcrum is detachably arranged on the welding groove of the rotor center body and / or the disc forging.

[0013] Furthermore, a method for welding a central body of a hydro-generator rotor support comprises the following steps:

[0014] S1: After the rotor center body and disc forgings and the cylinder are manufactured as a single piece, the welding groove is processed to an I-type narrow gap groove;

[0015] S2: Set a positioning fulcrum on the welding groove so that the rotor center body and the disc forging after docking form an I-type welding groove with narrow inside and wide outside, and adjust it;

[0016] S3: Spot welding is performed on the inner welding groove of the rotor center body, and the positioning support is removed after positioning;

[0017] S4: placing the rotor center body and the disc forging assembly on the roller frame, so that the center body and the disc forging assembly can rotate with the axis as the axis;

[0018] S5: Rotate the center body and the disc forging assembly, and weld the welding groove from inside to outside until the I-type welding groove is fully welded;

[0019] S6: After welding is completed, the back side is manually cleaned and welding is performed;

[0020] S7: After welding is completed, enter the furnace for annealing.

[0021] Furthermore, in step S5, the position of the welding gun on the axis remains unchanged.

[0022] Furthermore, in step S5, the welding gun is depth-adjusted after one round of welding, and the weld is cleaned to prepare for the next layer of welding.

[0023] Furthermore, in step S5, a welding robot is used for welding, the weld data is input into the robot computer in advance, and the motor is used to control the roller frame to rotate at a constant speed.

[0024] Furthermore, in steps S1-S7, the disc forgings at both ends are assembled and welded simultaneously.

[0025] In summary, due to the adoption of the above technical solution, the beneficial effects of the present invention are:

[0026] The traditional K-type groove design is improved to an I-type narrow gap groove, which effectively reduces the welding area and the demand for welding filler materials, thereby reducing the welding workload. This design not only reduces material costs, but also shortens welding time and improves overall production efficiency.

[0027] Using automatic submerged arc welding or gas shielded welding to replace traditional manual welding can achieve more uniform and stable welding quality. Automated welding technology ensures the consistency and high quality of the weld by precisely controlling welding parameters such as current, voltage, welding speed, etc., and reduces welding defects caused by human factors.

[0028] The application of automated welding technology has greatly improved production efficiency and shortened production cycles. Compared with manual welding, automated welding can be performed continuously without rest and at a faster speed, thus meeting the needs of modern efficient manufacturing.

[0029] The high strength and good mechanical properties of the rotor support center body are ensured through the precisely controlled welding process. The combination of I-type narrow gap groove design and automated welding technology makes the weld more uniform and dense, enhancing the stability and durability of the overall structure.

[0030] The optimized welding method and structural design make future maintenance and overhaul work easier and faster. Due to the high quality and good consistency of the welds, the uncertainty and complexity of the maintenance process are reduced, and the maintainability and reliability of the equipment are improved. Due to the high precision and stability of the automated welding technology, the rework rate of the finished product is significantly reduced. This not only improves production efficiency and economic benefits, but also reduces resource waste and environmental pollution.

[0031] The invention is applicable to the manufacture of the central body of the rotor support of a hydro-turbine generator of various specifications and models. By adjusting the welding parameters and process, the welding requirements of the central body of the rotor support of different sizes, thicknesses and materials can be easily met.

[0032] In summary, the present invention achieves efficient and high-quality manufacturing of the central body of the rotor support of a hydro-generator by improving the design of the welding groove and adopting the automated welding technology. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 It is a schematic diagram of the structure of the present invention;

[0034] Figure 2 It is a schematic diagram of the welding groove of the present invention;

[0035] Figure 3 It is a schematic diagram of the K-type groove structure in the prior art.

[0036] Markings in the figure:

[0037] 1-disc forging, 2-rotor center body, 3-roller frame, 4-welding groove, 5-positioning fulcrum. DETAILED DESCRIPTION

[0039] The present invention will be described in detail below in conjunction with the accompanying drawings.

[0040] In order to make the purpose, technical solution and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0041] In this embodiment, if Figure 1 , 2 As shown, a central body of a rotor support of a hydro-turbine generator comprises: a disc forging 1, a rotor central body 2 and a roller frame 3, wherein the rotor central body 2 is configured as a cylindrical barrel, the disc forging 1 is disposed at both ends of the rotor central body 2, a welding groove 4 is disposed on the annular connection surface between the disc forging 1 and the rotor central body 2, and the rotor central body 2 is rotatably disposed on the roller frame 3;

[0042] The welding groove 4 section is set to I type.

[0043] Setting the welding groove 4 section to I-type can effectively combine the two grooves into one, reduce the welding steps, and reduce the welding amount.

[0044] Furthermore, the end of the welding groove 4 close to the axis is narrower than the outer end.

[0045] Since welding is performed from the inside out, the I-type groove needs to be specially processed. In this embodiment, the groove root width is H1, the groove upper width is H2, the size of H1 is 12-20mm, and H2 is 2-5mm larger than H1. This setting can stabilize the welding quality and improve the welding efficiency.

[0046] Furthermore, the welding groove 4 of the rotor center body 2 and / or the disc forging 1 is provided with a positioning fulcrum 5 .

[0047] Furthermore, two positioning support points 5 are provided in the radial direction of the same connection surface according to the width of the welding groove 4 .

[0048] Furthermore, the positioning support point 5 is detachably arranged on the rotor center body 2 and / or the welding groove 4 of the disc forging 1 .

[0049] By setting the positioning fulcrum 5, the width of the welding groove 4 can be effectively determined during assembly, ensuring that the width of the welding groove 4 remains consistent within the circumference, and ensuring that the subsequent welding process proceeds smoothly.

[0050] Embodiment 1:

[0051] First, the rotor center body 2 and the disc forging 1 at one end are manufactured, and an I-shaped narrow gap groove is machined on the annular connection surface of the two. Figure 3 As shown, this step utilizes the technical feature of the present invention that the conventional K-type groove is designed as an I-type narrow gap groove, which effectively reduces the welding area and the demand for welding filler materials, thereby reducing the welding workload.

[0052] A detachable positioning fulcrum 5 is installed on the welding groove 4 to ensure accurate docking. This step corresponds to the structural features of the present invention that the cross section of the welding groove 4 close to the axis is an I-type narrow gap groove, the cross section of the other side is narrow close to the axis and wide on the outside, and a positioning fulcrum 5 for welding the rotor center body 2 is provided on the welding groove 4, and the positioning fulcrum 5 is detachably provided on the welding groove 4. Through precise positioning, stability and accuracy in the welding process are guaranteed.

[0053] The spot welding method is used to perform preliminary fixing at the inner groove. This step is a key step of the present invention, which ensures that the relative positions of the components will not change in the subsequent welding process, thereby improving the welding quality.

[0054] The assembly is placed on the roller frame 3, and the roller frame 3 is controlled to rotate at a constant speed by a robot, while the welding gun is kept in the same position, and welding is completed layer by layer from the inside to the outside. This step corresponds to the technical feature of the present invention that automatic submerged arc welding or gas shielded welding is used to replace traditional manual welding, and the position of the welding gun remains unchanged, and the position of the welding gun axis remains unchanged. Through the automated welding technology, a more uniform and stable welding quality is achieved, and the production efficiency is greatly improved.

[0055] After welding is completed, the back surface is cleaned and necessary annealing is performed to eliminate stress. This step is a subsequent processing step of the present invention, which ensures that the rotor support center body after welding has good mechanical properties and stability.

[0056] Furthermore, a method for welding a central body of a hydro-generator rotor support comprises the following steps:

[0057] S1: After the rotor center body 2, the disc forging 1 and the cylinder are manufactured as a single piece, the welding groove 4 is processed into an I-type narrow gap groove;

[0058] S2: Setting a positioning support point 5 on the welding groove 4 so that the rotor center body 2 and the disc forging 1 after docking form an I-shaped welding groove 4 that is narrow inside and wide outside, and adjusting it;

[0059] S3: Spot welding is performed on the welding groove 4 on the inner side of the rotor center body 2, and after positioning, the positioning support 5 is removed;

[0060] S4: placing the rotor center body 2 and the disc forging 1 assembly onto the roller frame 3, so that the center body and the disc forging 1 assembly can rotate with the axis as the axis;

[0061] S5: rotating the center body and the disc forging 1 assembly, welding the welding groove 4 from the inside to the outside, until the I-type welding groove 4 is fully welded;

[0062] S6: After welding is completed, the back side is manually cleaned and welding is performed;

[0063] S7: After welding is completed, enter the furnace for annealing.

[0064] Furthermore, in step S5, the position of the welding gun on the axis remains unchanged.

[0065] Furthermore, in step S5, the welding gun is depth-adjusted after one round of welding, and the weld is cleaned to prepare for the next layer of welding.

[0066] Furthermore, in step S5, a welding robot is used for welding, the weld data is input into the robot computer in advance, and the motor is used to control the roller frame 3 to rotate at a constant speed.

[0067] Furthermore, in steps S1 to S7, the disc forgings 1 at both ends are assembled and welded simultaneously.

[0068] Embodiment 2:

[0069] At the same time, the disc forgings 1 at both ends and the rotor center body 2 in the middle are prepared, and all parts are pre-processed with I-type narrow gap grooves. This step utilizes the technical feature of the present invention that the conventional K-type groove is designed as an I-type narrow gap groove, and the cross section of the welding groove 4 close to the axis is an I-type narrow gap groove, and the cross section of the other side is narrow on the side close to the axis and wide on the outside. Through this design, the welding area and the demand for welding filler materials are effectively reduced, thereby reducing the welding workload.

[0070] A positioning support 5 is installed on the groove at each end, and spot welding is performed for positioning. This step corresponds to the technical feature of the present invention that a positioning support 5 for welding the rotor center body 2 is provided on the welding groove 4, and the positioning support 5 is detachably provided on the welding groove 4, and the beneficial effect of preliminary fixing on the inner groove by spot welding. Through precise positioning and spot welding, it is ensured that the relative positions of the components will not change during the subsequent welding process.

[0071] The whole structure is supported by a special roller frame 3, so that the disc forgings 1 at both ends can rotate simultaneously. Two welding robots are used to correspond to the two ends respectively, and the welding tasks are performed synchronously to ensure the consistency and efficiency of welding. This step corresponds to the technical characteristics of the present invention that automatic submerged arc welding or gas shielded welding replaces traditional manual welding, and the technical characteristics that the position of the welding gun remains unchanged and the position of the welding gun axis remains unchanged. Through automated welding technology and synchronous welding methods, a more efficient and high-quality welding process is achieved.

[0072] After welding is completed, the weld is cleaned and inspected, and finally the entire body is annealed. This step is a subsequent processing step of the present invention, which ensures that the welded rotor support center body has good mechanical properties and stability.

[0073] The above description is only a preferred embodiment of the invention and is not intended to limit the invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the invention should be included in the protection scope of the invention.

Claims

1. A central body of a hydro-generator rotor support, characterized in that: include: A disc forging (1), a rotor center body (2) and a roller frame (3), wherein the rotor center body (2) is configured as a cylindrical barrel, the disc forging (1) is arranged at both ends of the rotor center body (2), a welding groove (4) is arranged on the annular connection surface between the disc forging (1) and the rotor center body (2), and the rotor center body (2) is rotatably arranged on the roller frame (3); The cross section of the welding groove (4) is set to be I-shaped.

2. According to the central body of the rotor support of a hydro-generator as claimed in claim 1, it is characterized in that: The welding groove (4) is narrower at one end close to the axis than at the outer end.

3. According to the central body of the rotor support of a hydro-generator as claimed in claim 1, it is characterized in that: The welding groove (4) of the rotor center body (2) and / or the disc forging (1) is provided with a positioning fulcrum (5).

4. A hydro-generator rotor support center body according to claim 3, characterized in that: The positioning support points (5) are arranged at two radial directions on the same connection surface according to the width of the welding groove (4).

5. According to the central body of the rotor support of a hydro-generator as claimed in claim 3, it is characterized in that: The positioning fulcrum (5) is detachably arranged on the rotor center body (2) and / or the welding groove (4) of the disc forging (1).

6. A method for welding a central body of a hydro-turbine generator rotor support, applied to a central body of a hydro-turbine generator rotor support according to any one of claims 1 to 5, characterized in that: The following steps are involved: S1: After the rotor center body (2), the disc forging (1) and the cylinder are manufactured as a single piece, the welding groove (4) is processed into an I-type narrow gap groove; S2: setting a positioning support point (5) on the welding groove (4) so ​​that the rotor center body (2) and the disc forging (1) after butt joint form an I-shaped welding groove (4) that is narrow inside and wide outside, and adjusting the same; S3: Spot welding is performed on the welding groove (4) on the inner side of the rotor center body (2) and after positioning, the positioning support (5) is removed; S4: placing the rotor center body (2) and the disc forging (1) assembly onto the roller frame (3), so that the center body and the disc forging (1) assembly can rotate with the axis as the axis; S5: rotating the center body and the disc forging (1) assembly, welding the welding groove (4) from the inside to the outside, until the I-shaped welding groove (4) is fully welded; S6: After welding is completed, the back side is manually cleaned and welding is performed; S7: After welding is completed, enter the furnace for annealing.

7. A method for welding a central body of a hydro-generator rotor support according to claim 6, characterized in that: In step S5, the position of the welding gun on the axis remains unchanged.

8. A method for welding a central body of a hydro-generator rotor support according to claim 6, characterized in that: In step S5, the welding gun is depth-adjusted after one round of welding, and the weld is cleaned to prepare for the next layer of welding.

9. A method for welding a central body of a hydro-generator rotor support according to claim 6, characterized in that: In step S5, welding is performed using a welding robot, the weld data is input into the robot computer in advance, and the motor controls the roller frame (3) to rotate at a constant speed.

10. The method for welding the central body of a hydro-generator rotor support according to claim 6, characterized in that: In the steps S1 to S7, the disc forgings (1) at both ends are assembled and welded simultaneously.

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