A method of manufacturing a heavy-duty gas turbine transition piece structure

Abstract

This invention relates to a manufacturing method for a transition section structure of a heavy-duty gas turbine. The invention addresses the problem of deformation during welding of transition section structures due to welding temperature variations, which affects product dimensions and subsequent assembly. The invention includes a transition section assembly and first, second, and third tooling. The transition section assembly includes a transition section component and a transition section outer bushing, with the outer bushing coaxially fitted onto the transition section component. The manufacturing method of this invention designs more rational tooling and welding sequences tailored to the characteristics of the transition section structure, solving the problem of welding deformation and facilitating the assembly and welding of the transition section component and outer bushing. This further ensures the overall manufacturing accuracy of the transition section structure and guarantees its performance. This invention belongs to the field of transition section structure manufacturing technology.

Description

Technical Field

[0001] This invention relates to a method for manufacturing a transition section structure, specifically a method for manufacturing a transition section structure for a heavy-duty gas turbine, and belongs to the field of transition section structure manufacturing technology. Background Technology

[0002] The transition section structure is a very important component in a gas turbine. Its main function is to guide the high-temperature gas generated in the combustion chamber to the guide vanes of the turbine, ensuring that the gas can flow smoothly from the combustion chamber to the turbine section.

[0003] The patent with publication number CN117532190A discloses a welding tool and welding method for the overall assembly of the transition section components of a 400MW heavy-duty gas turbine. In the technical solution of this patent, the welding of the transition section components is completed by various tooling. However, with the continuous improvement of unit performance, it is necessary to add bushings to the original transition section components to form an inner and outer double-layer transition section structure in order to improve the cooling effect of the transition section components.

[0004] Currently, this type of transition section structure is a thin-walled welded structure. Due to its complex shape, direct welding would result in welding deformation, making it difficult to guarantee the final dimensions and severely affecting the subsequent assembly of the inner and outer layers. Therefore, there is currently no mature manufacturing technology solution for this type of transition section structure.

[0005] In summary, how to propose a novel manufacturing method for the transition section structure to address the aforementioned technical problems has become a pressing issue for those skilled in the art. Summary of the Invention

[0006] In view of the shortcomings of the prior art, the present invention provides a method for manufacturing a heavy-duty gas turbine transition section structure.

[0007] The technical solution of the present invention is: a method for manufacturing a transition section structure of a heavy-duty gas turbine, comprising a transition section assembly and a first tooling, a second tooling and a third tooling.

[0008] The transition section assembly includes a transition section component and a transition section outer bushing, with the transition section outer bushing coaxially fitted onto the transition section component.

[0009] The transition section assembly includes, from top to bottom, a mounting edge, a connecting section, a spoiler section, a support ring, and a front ring, and several floating rings are installed on both the connecting section and the spoiler section.

[0010] The transition section outer bushing includes, from top to bottom, a mounting flange, a curved connecting cylinder, a turbulence cone, and a transition ring, welded together sequentially.

[0011] Both the curved connecting cylinder and the turbulence cone have several cooling holes and several floating ring connection holes machined on their surfaces. The turbulence cone has the same surface as the turbulence section, and the curved connecting cylinder has the same surface as the connecting section. The curved connecting cylinder includes an inner arc side butt joint and an outer arc side butt joint. The inner arc side butt joint and the outer arc side butt joint are connected by welding. The inner diameter of the transition ring is the same as the outer diameter of the support ring, and the transition ring is fitted onto the support ring.

[0012] The first tooling includes a first base plate, a first central support column, wedges, and a square positioning plate.

[0013] The first base plate is integrally provided with a first positioning boss, the outer diameter of which is the same as the inner diameter of the outlet end of the curved connecting cylinder.

[0014] One end of the first central support column is coaxially inserted into the first base plate, and the other end of the first central support column has a wedge hole.

[0015] The wedge is inserted into the wedge hole, and the square-mouth positioning plate is coaxially mounted on the first central support column. The square-mouth positioning plate is arranged between the first base plate and the wedge. The square-mouth positioning plate is integrally provided with a second positioning boss. The outer diameter of the second positioning boss is the same as the inner diameter of the inlet end of the curved connecting cylinder.

[0016] The second tooling includes a second base plate, a second central support column, wedges and a clamping top plate, a first positioning ring, a second positioning ring, two first step rods and two second step rods.

[0017] The second base plate is integrally provided with a third positioning boss, the outer diameter of which is the same as the inner diameter of the outlet end of the adapter ring; one end of the second central support column is coaxially inserted into the second base plate, and the other end of the second central support column has a wedge hole.

[0018] The wedge is inserted into the wedge hole. The pressing top plate, the first positioning ring and the second positioning ring are coaxially mounted on the second central support column in sequence. The pressing top plate is arranged between the wedge and the first positioning ring. The pressing top plate is integrally provided with a fourth positioning boss. The outer diameter of the fourth positioning boss is the same as the inner diameter of the inlet end of the curved connecting cylinder.

[0019] The inner diameter of the outlet end of the curved connecting cylinder and the inner diameter of the inlet end of the turbulence cone are the same as the outer diameter of the first positioning ring, and the inner diameter of the outlet end of the turbulence cone and the inner diameter of the inlet end of the transition ring are the same as the outer diameter of the second positioning ring.

[0020] The second positioning ring is fixedly connected to the second base plate, and one end of the first step rod and the second step rod are both inserted into the second base plate; the other end of the first step rod and the second step rod abuts against the first positioning ring.

[0021] The third tooling includes a third base plate, a first type of line template, a wedge-shaped positioning base, a second type of line template, a positioning upright plate, a third step rod, a third positioning ring, a fourth step rod, and a fourth positioning ring.

[0022] The first type of line template, the wedge-shaped positioning base, the second type of line template, and the positioning upright are all vertically installed on the third base plate.

[0023] The positioning plate is arranged at 90° with the first type of line template. The first type of line template abuts against the surface of the outer arc side connecting petal, and the first type of line template is arranged at 90° with the connecting surface of the curved connecting cylinder.

[0024] The second type of line template abuts against the inner arc side of the mating petal, and the second type of line template is arranged at 180° with the first type of line template.

[0025] The third step rod is arranged perpendicularly to the third base plate, and the third step rod is installed on the wedge-shaped positioning base. The wedge-shaped positioning base is equipped with a positioning base plate, and the outer diameter of the positioning base plate is the same as the inner diameter of the inlet end of the curved connecting cylinder.

[0026] The third positioning ring is fitted onto the third step rod, and the third positioning ring is axially fixed on the third step rod by a nut.

[0027] The fourth step rod is threadedly connected to the third step rod, and the fourth positioning ring is fitted onto the fourth step rod. The fourth positioning ring is axially fixed on the fourth step rod by a nut.

[0028] The manufacturing method is carried out in the following steps:

[0029] Step 1: Manufacturing the curved surface connecting cylinder

[0030] Step 11: Place the sheet metal between the punch and the die, and press out the inner arc side mating piece and the outer arc side mating piece respectively;

[0031] Step 1 and 2: First, insert the first central support column into the first base plate. Then, install the inner arc side mating petals and the outer arc side mating petals into the first base plate. Next, fit the square-mouth positioning plate onto the first central support column, ensuring that the two ends of the inner arc side mating petals and the outer arc side mating petals mate with the first positioning boss and the second positioning boss, respectively. Finally, insert the wedge into the wedge hole of the first central support column, ensuring that the wedge abuts against the square-mouth positioning plate.

[0032] Step 13: Weld the butt joint of the inner arc side butt joint and the outer arc side butt joint to weld the inner arc side butt joint and the outer arc side butt joint into a curved connecting cylinder.

[0033] Step 2: Manufacturing the turbulence cone

[0034] The sheet metal is rolled into a turbulence cone by a tapering machine. Both ends of the turbulence cone have machining allowances. The butt joint of the turbulence cone is welded by argon arc welding. After welding, the allowance is removed by laser cutting.

[0035] Step 3: Manufacturing the adapter ring

[0036] The sheet metal is placed between the punch and the die to form the adapter ring. Both ends of the adapter ring have machining allowances, and the allowances at the entrance end of the adapter ring are removed by laser cutting.

[0037] Step 4: Assemble and weld the curved connecting cylinder, the turbulence cone, and the transition ring onto the second tooling.

[0038] Step 41: Fit the adapter ring onto the third positioning boss of the second base plate;

[0039] Step 42: First, install the second positioning ring and the second central support column on the second base plate. Then, fit the first positioning ring onto the second central support column and position the first positioning ring using the first and second step rods.

[0040] Step 43: Install the turbulence cone onto the second central support column, ensuring that the outlet and inlet ends of the turbulence cone mate with the second positioning ring and the first positioning ring, respectively.

[0041] Step 4: Sequentially mount the curved connecting cylinder and the pressing top plate onto the second central support column, ensuring that the outlet end and inlet end of the curved connecting cylinder mate with the first positioning ring and the fourth positioning boss on the pressing top plate, respectively.

[0042] Steps 4 and 5: Insert the wedge into the wedge hole of the second central support column, ensuring that the wedge abuts against the pressing top plate;

[0043] Step 46: Weld the joint between the inlet end of the transition ring and the outlet end of the turbulence cone, and the joint between the outlet end of the curved connecting cylinder and the inlet end of the turbulence cone.

[0044] Step 47: After welding, the curved connecting cylinder, the turbulence cone, and the transition ring form a welded assembly. The welded assembly and the second tooling are then heat-treated together to eliminate welding stress.

[0045] Step 5: Mark and divide the weldment on the third tooling.

[0046] Step 51: Remove the welded assembly from the second tooling;

[0047] Step 52: First, install the wedge-shaped positioning base on the third base plate, and then install the third step rod on the wedge-shaped positioning base;

[0048] Step 53: Fit the welded assembly onto the third step rod, ensuring that the inlet end of the curved connecting cylinder mates with the positioning base plate;

[0049] Step 54: Install the first type line template, the second type line template, and the positioning plate on the third base plate, ensuring that the first type line template, the second type line template, and the positioning plate all abut against the surface of the welded body;

[0050] Step 55: Fit the third positioning ring onto the third step rod, ensuring that the outer circumferential surface of the third positioning ring abuts against the inner circumferential surface of the welded body;

[0051] Steps 5 and 6: First, screw the fourth step rod onto the third step rod, then put the fourth positioning ring onto the fourth step rod, ensuring that the fourth positioning ring abuts against the outlet end of the adapter ring;

[0052] Step 57: Draw axisymmetric dividing lines on the welded body using the first and second templates, and draw the outlines of two cooling holes on the surface of the welded body.

[0053] Step 58: First, remove the welded assembly from the third tooling;

[0054] Then, a 3D solid model of the welded assembly is created, and the 3D solid model is programmed; the programmed code is then sent to a five-axis laser cutting machine.

[0055] Then, the cooling holes of the welded body are cut using a five-axis laser cutting machine. When cutting, the outline drawn in step five and seven is cut first. Observe whether the cut cooling holes coincide with the outline. If they do not coincide, adjust the position of the welded body on the five-axis laser cutting machine until the cooling holes coincide with the outline.

[0056] Finally, cut the cooling holes at other locations on the weldment surface;

[0057] Step 59: Use a five-axis laser cutting machine to cut the welded body into two welded body butt joints along the axisymmetric dividing line;

[0058] Step 6: Assemble the transition section components and the transition section outer bushing.

[0059] Step 61: Install the mounting flange of the transition section outer bushing onto the mounting edge of the transition section assembly using screws;

[0060] Step 62: Fit the two welded joint segments onto the transition section assembly, ensuring that the inlet end of the curved connecting cylinder abuts against the mounting flange;

[0061] Step 63: Adjust the position of the two welded joint segments to ensure that the distance between the inner surface of the welded joint segments and the outer surface of the transition section component is consistent.

[0062] Step 64: First, using the front ring outlet end face of the transition section component as a reference, draw the allowance line at the outlet end of the transition ring.

[0063] Then, the mounting flange is spot-welded to the inlet end of the curved connecting cylinder using argon arc welding;

[0064] The screws between the mounting flange and the mounting edge are then removed to separate the transition section outer bushing from the transition section assembly.

[0065] Finally, laser cutting is used to remove the excess material at the outlet end of the adapter ring;

[0066] Step 65: First, weld the connection between the mounting flange and the curved connecting cylinder;

[0067] Then the butt joint of the welded body segments is welded;

[0068] The outer bushing of the transition section is then fitted onto the transition section assembly;

[0069] Finally, the mounting flange and the mounting edge of the transition section assembly are connected by screws;

[0070] Step 66: Observe the position of the floating ring through the cooling holes, draw the outline of the floating ring position on the profile of the outer bushing of the transition section, and machine the floating ring connecting hole according to the outline. This completes the manufacturing of the transition section structure.

[0071] Compared with the prior art, the present invention has the following advantages:

[0072] The manufacturing method of the present invention designs more reasonable tooling and welding sequence for the characteristics of the transition section structure, solves the problem of welding deformation, and provides convenience for the assembly and welding of the transition section component 110 and the transition section outer bushing 120, further ensuring the overall manufacturing accuracy of the transition section structure and ensuring the performance of the transition section structure. Attached Figure Description

[0073] Figure 1 This is a schematic diagram of the structure of the ferry section assembly 100 of the present invention;

[0074] Figure 2 This is a schematic diagram of the structure of the transition section outer bushing 120 of the present invention;

[0075] Figure 3 This is a schematic diagram of the structure of the first tooling 200 of the present invention;

[0076] Figure 4 This is a schematic diagram of the structure of the second tooling 300 of the present invention;

[0077] Figure 5 This is a front view of the third tooling 400 of the present invention;

[0078] Figure 6 This is a side view of the third tooling 400 of the present invention.

[0079] In the picture:

[0080] 100. Transition section assembly; 110. Transition section component; 120. Transition section outer bushing; 121. Mounting flange; 122. Curved connecting cylinder; 123. Baffle cone; 124. Adapter ring;

[0081] 200. First tooling; 11. First base plate; 12. First support seat; 15. Locating pin; 16. First central support column; 17. Wedge block; 18. Square positioning plate;

[0082] 300. Second tooling; 31. Second base plate; 32. Second support seat; 36. Second central support column; 38. Pressing top plate; 310. First positioning ring; 320. Second positioning ring; 330. First step rod; 340. Second step rod;

[0083] 400. Third tooling; 410. Third base plate; 420. First type line template; 430. Wedge-shaped positioning base; 431. Positioning base plate; 470. Second type line template; 480. Positioning upright plate; 490. Third step rod; 491. Third positioning ring; 492. Fourth step rod; 493. Fourth positioning ring. Detailed Implementation

[0084] To make the objectives, features, and advantages of this invention more apparent and understandable, the technical solutions of this invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments.

[0085] Specific implementation method one: Combining Figures 1 to 6 This embodiment describes a method for manufacturing a heavy-duty gas turbine transition section structure, which includes a transition section assembly 100 and a first tooling 200, a second tooling 300, and a third tooling 400.

[0086] The transition section assembly 100 includes a transition section component 110 and a transition section outer bushing 120, with the transition section outer bushing 120 coaxially mounted on the transition section component 110.

[0087] The transition section assembly 110 includes, from top to bottom, a mounting edge, a connecting section, a spoiler section, a support ring, and a front ring, and several floating rings are installed on both the connecting section and the spoiler section.

[0088] The transition section outer bushing 120 includes, from top to bottom, a mounting flange 121, a curved connecting cylinder 122, a turbulence cone 123, and a transition ring 124, which are welded together sequentially.

[0089] Both the curved connecting cylinder 122 and the turbulence cone 123 have several cooling holes and several floating ring connection holes machined on their surfaces. The turbulence cone 123 has the same surface as the turbulence section, and the curved connecting cylinder 122 has the same surface as the connecting section. The curved connecting cylinder 122 includes an inner arc side butt flap and an outer arc side butt flap. The inner arc side butt flap and the outer arc side butt flap are connected by welding. The inner diameter of the transition ring 124 is the same as the outer diameter of the support ring, and the transition ring 124 is fitted on the support ring.

[0090] The first tooling 200 includes a first base plate 11, a first central support column 16, a wedge block 17, and a square positioning plate 18.

[0091] The first base plate 11 is integrally provided with a first positioning boss, the outer diameter of which is the same as the inner diameter of the outlet end of the curved connecting cylinder 122.

[0092] One end of the first central support column 16 is coaxially inserted into the first base plate 11, and the other end of the first central support column 16 has a wedge hole.

[0093] The wedge block 17 is inserted into the wedge hole, and the square-mouth positioning plate 18 is coaxially mounted on the first central support column 16. The square-mouth positioning plate 18 is arranged between the first base plate 11 and the wedge block 17. The square-mouth positioning plate 18 is integrally provided with a second positioning boss. The outer diameter of the second positioning boss is the same as the inner diameter of the inlet end of the curved connecting cylinder 122.

[0094] The second tooling 300 includes a second base plate 31, a second central support column 36, a wedge block 17, a pressing top plate 38, a first positioning ring 310, a second positioning ring 320, two first step rods 330, and two second step rods 340.

[0095] The second base plate 31 is integrally provided with a third positioning boss, the outer diameter of which is the same as the inner diameter of the outlet end of the adapter ring 124; one end of the second central support column 36 is coaxially inserted into the second base plate 31, and the other end of the second central support column 36 has a wedge hole.

[0096] The wedge block 17 is inserted into the wedge hole. The pressing top plate 38, the first positioning ring 310 and the second positioning ring 320 are coaxially mounted on the second central support column 36 in sequence. The pressing top plate 38 is arranged between the wedge block 17 and the first positioning ring 310. A fourth positioning boss is integrally provided on the pressing top plate 38. The outer diameter of the fourth positioning boss is the same as the inner diameter of the inlet end of the curved connecting cylinder 122.

[0097] The inner diameter of the outlet end of the curved connecting cylinder 122 and the inner diameter of the inlet end of the turbulence cone 123 are the same as the outer diameter of the first positioning ring 310. The inner diameter of the outlet end of the turbulence cone 123 and the inner diameter of the inlet end of the transition ring 124 are the same as the outer diameter of the second positioning ring 320.

[0098] The second positioning ring 320 is fixedly connected to the second base plate 31. One end of the first step rod 330 and the second step rod 340 are both inserted into the second base plate 31; the other end of the first step rod 330 and the second step rod 340 abuts against the first positioning ring 310.

[0099] Furthermore, two first step rods 330 are arranged at 180° in the circumferential direction of the second base plate 31, and the first step rods 330 support the surface of the first positioning ring 310 facing the second base plate 31; two second step rods 340 are arranged at 180° in the circumferential direction of the second base plate 31, and the second step rods 340 pass through the first positioning ring 310 and are connected to the second base plate 31. This arrangement is to enable the second step rods 340 to press the surface of the first positioning ring 310 facing the pressing top plate 38.

[0100] The third tooling 400 includes a third base plate 410, a first profile template 420, a wedge-shaped positioning base 430, a second profile template 470, a positioning upright plate 480, a third step rod 490, a third positioning ring 491, a fourth step rod 492, and a fourth positioning ring 493.

[0101] The first type of line template 420, the wedge-shaped positioning base 430, the second type of line template 470, and the positioning plate 480 are all vertically installed on the third base plate 410.

[0102] The positioning plate 480 is arranged at 90° with the first type line template 420. The first type line template 420 abuts against the surface of the outer arc side docking petal, and the first type line template 420 is arranged at 90° with the docking surface of the curved connecting cylinder 122.

[0103] The second type of line template 470 abuts against the surface of the inner arc side connecting petals, and the second type of line template 470 is arranged at 180° with the first type of line template 420.

[0104] The third step rod 490 is arranged perpendicularly to the third base plate 410, and the third step rod 490 is installed on the wedge-shaped positioning base 430. The wedge-shaped positioning base 430 is equipped with a positioning base plate 431, and the outer diameter of the positioning base plate 431 is the same as the inner diameter of the inlet end of the curved connecting cylinder 122.

[0105] The third positioning ring 491 is fitted onto the third step rod 490, and the third positioning ring 491 is axially fixed on the third step rod 490 by a nut.

[0106] The fourth step rod 492 is threadedly connected to the third step rod 490. The fourth positioning ring 493 is fitted onto the fourth step rod 492, and the fourth positioning ring 493 is axially fixed on the fourth step rod 492 by a nut.

[0107] The manufacturing method is carried out in the following steps:

[0108] Step 1: Manufacturing the curved surface connecting cylinder 122

[0109] Step 11: Place the sheet metal between the punch and the die, and press out the inner arc side mating piece and the outer arc side mating piece respectively;

[0110] Step 12: First, insert the first central support column 16 into the first base plate 11. Then, install the inner arc side mating petals and the outer arc side mating petals into the first base plate 11. Next, fit the square-mouth positioning plate 18 onto the first central support column 16, ensuring that the two ends of the inner arc side mating petals and the outer arc side mating petals mate with the first positioning boss and the second positioning boss respectively. Finally, insert the wedge block 17 into the wedge hole of the first central support column 16, ensuring that the wedge block 17 abuts against the square-mouth positioning plate 18.

[0111] Step 13: Weld the butt joint of the inner arc side butt joint and the outer arc side butt joint to weld the inner arc side butt joint and the outer arc side butt joint into a curved connecting cylinder 122.

[0112] Step 2: Manufacturing the turbulence cone 123

[0113] The sheet metal is rolled into a turbulence cone 123 by a tapering machine. Both ends of the turbulence cone 123 have machining allowances. The butt joint of the turbulence cone 123 is welded by argon arc welding. After welding, the allowance is removed by laser cutting.

[0114] Step 3: Manufacturing the adapter ring 124

[0115] The sheet metal is placed between the punch and the die to form the adapter ring 124. Both ends of the adapter ring 124 have machining allowances. The allowances at the inlet end of the adapter ring 124 are removed by laser cutting.

[0116] Step 4: Assemble and weld the curved connecting cylinder 122, the turbulence cone 123, and the transition ring 124 onto the second tooling 300.

[0117] Step 41: Install the adapter ring 124 onto the third positioning boss of the second base plate 31;

[0118] Step 4. First, install the second positioning ring 320 and the second central support column 36 on the second base plate 31. Then, fit the first positioning ring 310 onto the second central support column 36 and position the first positioning ring 310 using the first step rod 330 and the second step rod 340.

[0119] Step 4.3: Install the turbulence cone 123 onto the second central support column 36, and ensure that the outlet end and inlet end of the turbulence cone 123 are respectively engaged with the second positioning ring 320 and the first positioning ring 310.

[0120] Step 4: Sequentially mount the curved connecting cylinder 122 and the pressing top plate 38 onto the second central support column 36, ensuring that the outlet end and inlet end of the curved connecting cylinder 122 mate with the first positioning ring 310 and the fourth positioning boss on the pressing top plate 38, respectively.

[0121] Steps 4 and 5: Insert the wedge block 17 into the wedge hole of the second central support column 36, and ensure that the wedge block 17 abuts against the pressing top plate 38;

[0122] Step 46: Weld the joint between the inlet end of the transition ring 124 and the outlet end of the turbulence cone 123, and the joint between the outlet end of the curved connecting cylinder 122 and the inlet end of the turbulence cone 123 respectively.

[0123] Step 47: After welding, the curved connecting cylinder 122, the turbulence cone cylinder 123 and the transition ring 124 form a welded body. The welded body and the second tooling 300 are heat-treated together to eliminate welding stress.

[0124] Step 5: Mark and divide the weldment on the third tooling 400.

[0125] Step 51: Remove the welded assembly from the second tooling 300;

[0126] Step 52: First, install the wedge-shaped positioning base 430 on the third base plate 410, and then install the third step rod 490 on the wedge-shaped positioning base 430.

[0127] Step 53: Fit the welded assembly onto the third step rod 490, ensuring that the inlet end of the curved connecting cylinder 122 mates with the positioning base plate 431;

[0128] Step 54: Install the first type line template 420, the second type line template 470 and the positioning plate 480 on the third base plate 410, and ensure that the first type line template 420, the second type line template 470 and the positioning plate 480 all abut against the surface of the welded body.

[0129] Step 55: Fit the third positioning ring 491 onto the third step rod 490, ensuring that the outer circumferential surface of the third positioning ring 491 abuts against the inner circumferential surface of the welded body;

[0130] Steps 5 and 6: First, screw the fourth step rod 492 onto the third step rod 490, and then fit the fourth positioning ring 493 onto the fourth step rod 492, ensuring that the fourth positioning ring 493 abuts against the outlet end of the adapter ring 124.

[0131] Step 57: Draw axisymmetric dividing lines on the welded body using the first template 420 and the second template 470, and draw the outlines of two cooling holes on the surface of the welded body.

[0132] Step 58: First, remove the welded assembly from the third tooling 400;

[0133] Then, a 3D solid model of the welded assembly is created, and the 3D solid model is programmed; the programmed code is then sent to a five-axis laser cutting machine.

[0134] Then, the cooling holes of the welded body are cut using a five-axis laser cutting machine. When cutting, the outline drawn in step five and seven is cut first. Observe whether the cut cooling holes coincide with the outline. If they do not coincide, adjust the position of the welded body on the five-axis laser cutting machine until the cooling holes coincide with the outline.

[0135] Finally, cut the cooling holes at other locations on the weldment surface;

[0136] Step 59: Use a five-axis laser cutting machine to cut the welded body into two welded body butt joints along the axisymmetric dividing line;

[0137] Step 6: Assemble the transition section assembly 110 and the transition section outer bushing 120.

[0138] Step 61: Install the mounting flange 121 of the transition section outer bushing 120 onto the mounting edge of the transition section assembly 110 using screws;

[0139] Step 62: Fit the two welded joint segments onto the transition section assembly 110, ensuring that the inlet end of the curved connecting cylinder 122 abuts against the mounting flange 121;

[0140] Step 63: Adjust the position of the two welded joint segments to ensure that the distance between the inner surface of the welded joint segment and the outer surface of the transition section component 110 is consistent.

[0141] Step 64: First, using the front ring outlet end face of the transition section component 110 as a reference, draw the allowance line at the outlet end of the transition ring 124.

[0142] Then, the mounting flange 121 is spot-welded to the inlet end of the curved connecting cylinder 122 by argon arc welding;

[0143] The screws between the mounting flange 121 and the mounting edge are then removed to separate the transition section outer bushing 120 from the transition section assembly 110.

[0144] Finally, laser cutting was used to remove the excess material at the outlet end of the adapter ring 124;

[0145] Step 65: First, weld the connection between the mounting flange 121 and the curved connecting cylinder 122;

[0146] Then the butt joint of the welded body segments is welded;

[0147] The transition section outer bushing 120 is then fitted onto the transition section assembly 110;

[0148] Finally, the mounting flange 121 is connected to the mounting edge of the transition section assembly 110 by screws;

[0149] Step 66: Observe the position of the floating ring through the cooling holes, draw the outline of the floating ring position on the profile of the outer bushing 120 of the transition section, and machine the floating ring connection hole according to the outline. This completes the manufacturing of the transition section structure.

[0150] In this embodiment, the outlet end face of the curved connecting cylinder 122 is parallel to the horizontal plane, and the angle between the inlet end face of the curved connecting cylinder 122 and the horizontal plane is β.

[0151] Furthermore, the first central support column 16 includes a first column body and a second column body, which are integrally formed. The first column body is inserted into the first support base 12, and the second column body has a wedge hole. A wedge block 17 is inserted into the wedge hole, and a square positioning plate 18 is coaxially fitted onto the second column body. The angle between the second column body and the first column body is (180°-β).

[0152] Furthermore, the second central support column 36 includes a third column body and a fourth column body, which are integrally formed. The third column body is inserted into the second support base 32, and the fourth column body has a wedge hole. A wedge block 17 is inserted into the wedge hole, and the pressing top plate 38 is coaxially fitted onto the fourth column body. The angle between the fourth column body and the third column body is (180°-β).

[0153] Furthermore, the wedge angle of the wedge-shaped positioning base 430 is β. This setting ensures that the welded assembly is perpendicular to the horizontal plane when it is installed on the third tooling 400.

[0154] Specific Implementation Method Two: Combining Figure 3 To illustrate this embodiment, the first tooling 200 of this embodiment also includes a first support base 12, which is mounted on a first base plate 11, and a first central support column 16 is inserted into the first support base 12.

[0155] Furthermore, the first central support column 16 is axially fixed on the first support seat 12 by a positioning pin 15.

[0156] Other components and connection methods are the same as in Specific Implementation Method 1.

[0157] Specific implementation method three: Combining Figure 4 In this embodiment, the second tooling 300 further includes a second support base 32, which is mounted on the second base plate 31, and the second central support column 36 is inserted into the second support base 32.

[0158] The second central support column 36 is axially fixed on the second support seat 32 by a positioning pin 15.

[0159] Other components and connection methods are the same as in specific implementation method one or two.

[0160] The present invention has been disclosed above with reference to preferred embodiments, but it is not intended to limit the present invention. Any simple modifications, equivalent changes and alterations made by those skilled in the art to the above embodiments without departing from the technical solution of the present invention shall still fall within the scope of the technical solution of the present invention.

Claims

1. A method for manufacturing a transition section structure for a heavy-duty gas turbine, comprising a transition section assembly (100) and a first tooling (200), a second tooling (300) and a third tooling (400); The transition section assembly (100) includes a transition section component (110) and a transition section outer bushing (120), with the transition section outer bushing (120) coaxially fitted onto the transition section component (110); The transition section assembly (110) includes, from top to bottom, a mounting edge, a connecting section, a spoiler section, a support ring, and a front ring, and several floating rings are installed on both the connecting section and the spoiler section; The transition section outer bushing (120) includes, from top to bottom, a mounting flange (121), a curved connecting cylinder (122), a turbulence cone (123), and a transition ring (124); Both the curved connecting cylinder (122) and the turbulence cone (123) have several cooling holes and several floating ring connection holes machined on their surfaces. The turbulence cone (123) has the same surface as the turbulence section, and the curved connecting cylinder (122) has the same surface as the connecting section. The curved connecting cylinder (122) includes an inner arc side butt flap and an outer arc side butt flap. The inner arc side butt flap and the outer arc side butt flap are connected by welding. The inner diameter of the transition ring (124) is the same as the outer diameter of the support ring, and the transition ring (124) is fitted on the support ring. The first tooling (200) includes a first base plate (11), a first central support column (16), a wedge block (17), and a square positioning plate (18); The first base plate (11) is integrally provided with a first positioning boss, the outer diameter of which is the same as the inner diameter of the outlet end of the curved connecting cylinder (122); One end of the first central support column (16) is coaxially inserted into the first base plate (11), and the other end of the first central support column (16) has a wedge hole. The wedge (17) is inserted into the wedge hole, and the square positioning plate (18) is coaxially mounted on the first central support column (16). The square positioning plate (18) is arranged between the first base plate (11) and the wedge (17). The square positioning plate (18) is integrally provided with a second positioning boss. The outer diameter of the second positioning boss is the same as the inner diameter of the inlet end of the curved connecting cylinder (122). The second tooling (300) includes a second base plate (31), a second central support column (36), a wedge block (17), a pressing top plate (38), a first positioning ring (310), a second positioning ring (320), two first step rods (330) and two second step rods (340); The second base plate (31) is integrally provided with a third positioning boss, the outer diameter of which is the same as the inner diameter of the outlet end of the adapter ring (124); one end of the second central support column (36) is coaxially inserted into the second base plate (31), and the other end of the second central support column (36) has a wedge hole. The wedge (17) is inserted into the wedge hole. The pressing top plate (38), the first positioning ring (310) and the second positioning ring (320) are coaxially mounted on the second central support column (36) in sequence. The pressing top plate (38) is arranged between the wedge (17) and the first positioning ring (310). The pressing top plate (38) is integrally provided with a fourth positioning boss. The outer diameter of the fourth positioning boss is the same as the inner diameter of the inlet end of the curved connecting cylinder (122). The inner diameter of the outlet end of the curved connecting tube (122) and the inner diameter of the inlet end of the turbulence cone (123) are the same as the outer diameter of the first positioning ring (310), and the inner diameter of the outlet end of the turbulence cone (123) and the inner diameter of the inlet end of the transition ring (124) are the same as the outer diameter of the second positioning ring (320). The second positioning ring (320) is fixedly connected to the second base plate (31), and one end of the first step rod (330) and the second step rod (340) are both inserted into the second base plate (31); the other end of the first step rod (330) and the second step rod (340) abut against the first positioning ring (310); The third tooling (400) includes a third base plate (410), a first type line template (420), a wedge-shaped positioning base (430), a second type line template (470), a positioning upright plate (480), a third step rod (490), a third positioning ring (491), a fourth step rod (492), and a fourth positioning ring (493); The first type of line template (420), the wedge-shaped positioning base (430), the second type of line template (470) and the positioning upright plate (480) are all vertically installed on the third base plate (410); The positioning plate (480) is arranged at 90° with the first type line template (420), the first type line template (420) abuts against the surface of the outer arc side docking petal, and the first type line template (420) is arranged at 90° with the docking surface of the curved connecting cylinder (122). The second type of line template (470) abuts against the surface of the inner arc side butt petal, and the second type of line template (470) is arranged at 180° with the first type of line template (420). The third step rod (490) is arranged perpendicularly to the third base plate (410), and the third step rod (490) is installed on the wedge-shaped positioning base (430). The wedge-shaped positioning base (430) is equipped with a positioning base plate (431), and the outer diameter of the positioning base plate (431) is the same as the inner diameter of the inlet end of the curved connecting cylinder (122). The third positioning ring (491) is fitted onto the third step rod (490), and the third positioning ring (491) is axially fixed on the third step rod (490) by a nut; The fourth step rod (492) is threadedly connected to the third step rod (490), and the fourth positioning ring (493) is fitted on the fourth step rod (492), and the fourth positioning ring (493) is axially fixed on the fourth step rod (492) by a nut; Its features are, The manufacturing method is carried out in the following steps: Step 1: Manufacturing the curved surface connecting cylinder (122) Step 11: Place the sheet metal between the punch and the die, and press out the inner arc side mating piece and the outer arc side mating piece respectively; Step 1 and 2: First, insert the first central support column (16) into the first base plate (11), then install the inner arc side docking petal and the outer arc side docking petal into the first base plate (11), then fit the square mouth positioning plate (18) onto the first central support column (16), and ensure that the two ends of the inner arc side docking petal and the outer arc side docking petal are respectively engaged with the first positioning boss and the second positioning boss, and finally insert the wedge block (17) into the wedge hole of the first central support column (16), and ensure that the wedge block (17) abuts against the square mouth positioning plate (18); Step 13: Weld the butt joint of the inner arc side butt joint and the outer arc side butt joint to weld the inner arc side butt joint and the outer arc side butt joint into a curved connecting cylinder (122); Step 2: Manufacturing the turbulence cone (123) The sheet metal is rolled into a turbulence cone (123) by a cone rolling machine. Both ends of the turbulence cone (123) have machining allowances. The butt joint of the turbulence cone (123) is welded by argon arc welding. After welding, the allowance is removed by laser cutting. Step 3: Manufacture the adapter ring (124) The sheet metal is placed between the punch and the die to form the adapter ring (124). Both ends of the adapter ring (124) have machining allowances. The allowances at the entrance end of the adapter ring (124) are removed by laser cutting. Step 4: Assemble and weld the curved connecting cylinder (122), the turbulence cone (123), and the transition ring (124) onto the second tooling (300). Step 41: Fit the adapter ring (124) onto the third positioning boss of the second base plate (31); Step 4. First, install the second positioning ring (320) and the second central support column (36) on the second base plate (31). Then, fit the first positioning ring (310) onto the second central support column (36) and position the first positioning ring (310) using the first step rod (330) and the second step rod (340). Step 43: Fit the turbulence cone (123) onto the second central support column (36), and ensure that the outlet end and inlet end of the turbulence cone (123) are respectively matched with the second positioning ring (320) and the first positioning ring (310); Step 4: Install the curved connecting cylinder (122) and the pressing top plate (38) onto the second central support column (36) in sequence, and ensure that the outlet end and inlet end of the curved connecting cylinder (122) are respectively engaged with the fourth positioning boss on the first positioning ring (310) and the pressing top plate (38); Steps 4 and 5: Insert the wedge (17) into the wedge hole of the second central support column (36), and ensure that the wedge (17) abuts against the pressing top plate (38); Step 46: Weld the butt joint between the inlet end of the transition ring (124) and the outlet end of the turbulence cone (123), and the butt joint between the outlet end of the curved connecting cylinder (122) and the inlet end of the turbulence cone (123) respectively; Step 47: After welding, the curved connecting cylinder (122), the turbulence cone (123) and the transition ring (124) form a welded body. The welded body and the second tooling (300) are heat-treated together to eliminate welding stress. Step 5: Mark and divide the weldment on the third tooling (400). Step 51: Remove the welded assembly from the second tooling (300); Step 52: First, install the wedge-shaped positioning base (430) on the third base plate (410), and then install the third step rod (490) on the wedge-shaped positioning base (430); Step 53: Fit the welded assembly onto the third step rod (490), and ensure that the inlet end of the curved connecting tube (122) matches the positioning base plate (431); Step 54: Install the first type line template (420), the second type line template (470), and the positioning plate (480) on the third base plate (410), and ensure that the first type line template (420), the second type line template (470), and the positioning plate (480) all abut against the surface of the welded body; Step 55: Fit the third positioning ring (491) onto the third step rod (490), and ensure that the outer circumferential surface of the third positioning ring (491) abuts against the inner circumferential surface of the welded body; Steps 5 and 6: First, screw the fourth step rod (492) onto the third step rod (490), and then put the fourth positioning ring (493) onto the fourth step rod (492) to ensure that the fourth positioning ring (493) abuts against the outlet end of the adapter ring (124); Step 57: Draw axisymmetric dividing lines on the welded body using the first template (420) and the second template (470), and draw the outlines of two cooling holes on the surface of the welded body. Step 58: First, remove the welded assembly from the third tooling (400); Then, a 3D solid model of the welded assembly is created, and the 3D solid model is programmed; the programmed code is then sent to a five-axis laser cutting machine. Then, the cooling holes of the welded body are cut using a five-axis laser cutting machine. When cutting, the outline drawn in step five and seven is cut first. Observe whether the cut cooling holes coincide with the outline. If they do not coincide, adjust the position of the welded body on the five-axis laser cutting machine until the cooling holes coincide with the outline. Finally, cut the cooling holes at other locations on the weldment surface; Step 59: Use a five-axis laser cutting machine to cut the welded body into two welded body butt joints along the axisymmetric dividing line; Step 6: Assemble the transition section assembly (110) and the transition section outer bushing (120). Step 61: Install the mounting flange (121) of the transition section outer bushing (120) onto the mounting edge of the transition section assembly (110) using screws; Step 62: Fit the two welded joint segments onto the transition section assembly (110), and ensure that the inlet end of the curved connecting cylinder (122) abuts against the mounting flange (121); Step 63: Adjust the position of the two welded joint segments to ensure that the distance between the inner surface of the welded joint segments and the outer surface of the transition section assembly (110) is consistent. Step 64: First, using the front ring outlet end face of the transition section component (110) as a reference, draw the allowance line at the outlet end of the transition ring (124); Then, the mounting flange (121) is spot-welded to the inlet end of the curved connecting cylinder (122) by argon arc welding; The screws between the mounting flange (121) and the mounting edge are then removed to separate the transition section outer bushing (120) from the transition section assembly (110); Finally, laser cutting was used to remove the excess material at the outlet end of the adapter ring (124); Step 65: First, weld the connection between the mounting flange (121) and the curved connecting cylinder (122); Then the butt joint of the welded body segments is welded; The transition section outer bushing (120) is then fitted onto the transition section assembly (110); Finally, the mounting flange (121) and the mounting edge of the transition section assembly (110) are connected by screws; Step 66: Observe the position of the floating ring through the cooling hole, draw the outline of the floating ring position on the profile of the outer bushing (120) of the transition section, and process the floating ring connecting hole according to the outline. This completes the manufacturing of the transition section structure.

2. The manufacturing method of a heavy-duty gas turbine transition section structure according to claim 1, characterized in that: The first tooling (200) also includes a first support base (12), which is mounted on the first base plate (11), and a first central support column (16) is inserted into the first support base (12).

3. The manufacturing method of a heavy-duty gas turbine transition section structure according to claim 2, characterized in that: The first central support column (16) is axially fixed on the first support seat (12) by a positioning pin (15).

4. The manufacturing method of a heavy-duty gas turbine transition section structure according to claim 3, characterized in that: The second tooling (300) also includes a second support base (32), which is mounted on the second base plate (31), and a second central support column (36) is inserted into the second support base (32).

5. The manufacturing method of a heavy-duty gas turbine transition section structure according to claim 4, characterized in that: The second central support column (36) is axially fixed on the second support base (32) by a positioning pin (15).

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