Wind power hub pouring system and using method thereof
By designing a wind turbine hub casting system, the flexibility of the integrated molding and casting sequence of the upper web core and the first sand box is achieved, and the problem of large sand and iron ratio and high cost in traditional casting processes is solved, and the effect of reducing production costs is achieved.
Patent Information
- Application Number
- CN202411811969.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-12-10
- Publication Date
- 2025-02-28
AI Technical Summary
In the traditional wind turbine hub casting process, the sand and iron ratio is large, the sand is used more, the cost is high, and the casting process is single, making it difficult to achieve cost optimization.
A wind turbine hub casting system is designed, including the first sand box, the second sand box and the main core. The upper web core and the first sand box are formed integrally, reducing the steps of making web cores separately, and changing the pouring order by replacing the die blocks, realizing two casting processes.
The use of sand is reduced, production costs are reduced, and the lowest cost scheme is selected through process optimization, further reducing the casting cost of wind turbine hubs.
Smart Images
Figure CN119525440A_ABST
Abstract
Description
Technical Field
[0001] The invention belongs to the technical field of wind turbine hub production, and in particular relates to a wind turbine hub casting system and a use method thereof. Background Art
[0002] Wind turbine hub is a key component of wind power equipment. The wind power industry is developing rapidly in my country and the demand is huge. While ensuring the quality of castings, reducing production costs as much as possible is one of the effective means for enterprises to increase production profits.
[0003] When using traditional technology to cast a wind turbine hub, two main sand cores and six web sand cores need to be made. The six web sand cores are fixed on the two main sand cores respectively. The six web sand cores need to have separate molds designed. The web sand cores need to be made separately, which results in a large sand-to-iron ratio, a large amount of sand, a high cost, and the size is not easy to control.
[0004] In addition, traditional process design only designs one casting process, or the wind turbine hub main shaft flange faces upward during casting, or the wind turbine hub main shaft flange faces downward during casting, that is, a set of molds is only suitable for one casting sequence. In this way, once the mold is completed, qualified products can only be cast through process optimization, such as using a large number of heating risers and a large amount of chilled iron. Process optimization may bring higher costs. Summary of the invention
[0005] In view of the defects or shortcomings in the prior art, the present invention provides a wind turbine hub casting system and a method for using the same, which can reduce the amount of sand used and reduce the casting cost of the wind turbine hub.
[0006] To achieve the above object, the present invention adopts the following technical solution: In the first aspect, an embodiment of the present invention provides a wind turbine hub casting system, comprising a first sand box, a second sand box and a main clay core, wherein the first sand box and the second sand box are respectively provided with a cavity, the main clay core comprises an upper main clay core and a lower main clay core, wherein the upper main clay core is arranged in the cavity of the first sand box, and the lower main clay core is arranged in the cavity of the second sand box, an upper belly plate clay core is arranged on the cavity of the first sand box, and a lower belly plate clay core is arranged on the main clay core.
[0007] Furthermore, the mold cavity of the first sand box cooperates with the upper main clay core to form the upper part of the wind turbine hub and the upper part of the pitch flange surface.
[0008] Furthermore, three upper belly plate clay cores are provided and located on the inner wall of the mold cavity of the first sand box, and the three upper belly plate clay cores are integrally formed with the first sand box.
[0009] Furthermore, the three upper web mud cores correspond to the upper parts of the three pitch flange surfaces of the wind turbine hub and are used to shape the upper parts of the three pitch flange surfaces.
[0010] Furthermore, the mold cavity of the second sand box cooperates with the lower main clay core to form the lower part of the wind turbine hub and the flange surface of the wind turbine hub main shaft.
[0011] Furthermore, there are three lower belly plate mud cores, which are respectively arranged on the sides of the lower main mud core and are detachably connected to the lower main mud core. The three lower belly plate mud cores correspond to the lower parts of the three pitch flange surfaces and are used to form the lower parts of the three pitch flange surfaces.
[0012] Furthermore, the first sand box is an upper sand box, the second sand box is a lower sand box, and the first sand box is placed above the second sand box. At this time, after the wind turbine hub is formed, the main shaft flange is arranged downward.
[0013] Furthermore, the lower main clay core is provided with a plurality of mold movable blocks, which are respectively located at the bottom of the lower main clay core, the bottom of the lower belly plate clay core, both sides of the lower belly plate clay core and the through holes between two adjacent lower belly plate clay cores, and the plurality of mold movable blocks are detachably connected to the lower main clay core.
[0014] Furthermore, the second sand box is an upper sand box, the first sand box is a lower sand box, and the second sand box is placed above the first sand box. At this time, after the wind turbine hub is formed, the main shaft flange is arranged upward.
[0015] In a second aspect, an embodiment of the present invention further provides a method for using a wind turbine hub casting system, using the wind turbine hub casting system as described above, comprising the following steps: When the first process scheme is adopted, that is, the hub main shaft flange faces downward, the first sand box is the upper sand box, and the second sand box is the lower sand box. First, the corresponding mold live block is selected according to the process, and fixed on the lower main clay core and the three web clay cores. Then the lower main clay core is placed in the second sand box, and the three web clay cores are placed on the sides of the lower main clay core respectively, so that the three web clay cores correspond to the three pitch flange surfaces, and the upper main clay core is placed above the lower main clay core. Finally, the first sand box is placed above the second sand box to complete the box closing; When the second process is adopted, that is, the hub main shaft flange faces upward, the first sand box is the lower sand box, and the second sand box is the upper sand box. First, the upper main clay core is placed in the first sand box, the lower main clay core is placed above the upper main clay core, and the three web clay cores are fixed on the sides of the lower main clay core respectively. Finally, the second sand box is placed above the first sand box to complete the box assembly. The costs of the two process solutions during process optimization are calculated, and the one with the lowest cost is selected as the optimal process through comparison, thereby further reducing the production cost of the wind turbine hub.
[0016] Compared with the prior art, the present invention has the following beneficial effects: 1. The present invention forms the upper belly plate mud core and the first sand box as one body, that is, the shape of the upper belly plate mud core is brought out in the outer mold of the first sand box, thereby eliminating the process of separately making the upper belly plate mud core, reducing the sand-iron ratio, and reducing the amount of sand used, which can save sand and ensure the shape and size of the product.
[0017] 2. The present invention changes the pouring sequence by replacing the mold movable block, thereby realizing two pouring processes, that is, two pouring processes with one mold. By comparing the costs generated by the two pouring processes during process optimization, the one with the lowest cost is selected as the optimal process, thereby further reducing the production cost of the wind turbine hub. BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Figure 1 It is a schematic diagram of the structure of the pouring system in the first pouring scheme in an embodiment of the present invention; Figure 2 Schematic diagram of the structure of the pouring system in the second pouring scheme in the embodiment of the present invention; Figure 3 Schematic diagram of the main clay core structure in the first casting scheme in an embodiment of the present invention; Figure 4 This is a position relationship diagram of the main clay core and the mold movable block in the first casting scheme in the embodiment of the present invention; Figure 5 Schematic diagram of the main clay core structure in the second casting scheme in an embodiment of the present invention; Among them, 1. The first sand box; 2. The second sand box; 3. The main clay core; 4. The lower belly plate clay core; 5. The mold live block. DETAILED DESCRIPTION
[0019] The present invention is further described below in conjunction with the accompanying drawings and embodiments.
[0020] Embodiment 1 A typical implementation of the present invention is as follows Figure 1 As shown, a wind turbine hub casting system includes a first sand box 1, a second sand box 2 and a main clay core 3. The first sand box 1 and the second sand box 2 are respectively provided with a cavity, the main clay core 3 is arranged in the cavity, and a wind turbine hub molding cavity for casting and molding the wind turbine hub is formed between the main clay core 3 and the cavity.
[0021] The main clay core 3 includes an upper main clay core and a lower main clay core. The cavity of the first sand box 1 cooperates with the upper main clay core to form the upper part of the wind turbine hub and the upper parts of the three pitch flange surfaces. Three upper belly plate clay cores are arranged on the inner wall of the cavity of the first sand box 1. The three upper belly plate clay cores correspond to the upper parts of the three pitch flange surfaces of the wind turbine hub and are used to form the upper parts of the three pitch flange surfaces. The three upper belly plate clay cores are integrally formed with the first sand box 1, that is, when the first sand box 1 is manufactured, the upper belly plate clay cores are manufactured together, eliminating the process of separately manufacturing the upper belly plate clay cores, which can save sand and ensure the shape and size of the product.
[0022] The mold cavity of the second sand box 2 cooperates with the lower main clay core 3 to form the upper part of the wind turbine hub, the flange surface of the wind turbine hub main shaft and three pitch flange surfaces. Three lower belly plate clay cores 4 are arranged on the lower main clay core 3. The three lower belly plate clay cores 4 are respectively arranged on the sides of the lower main clay core 3 and are detachably connected to the lower main clay core 3. The three lower belly plate clay cores 4 correspond to the lower parts of the three pitch flange surfaces and are used to form the lower parts of the three pitch flange surfaces.
[0023] The casting system provided by the present invention can produce two casting processes. The first is to place the first sand box 1 above the second sand box 2, the first sand box 1 is the upper sand box, and the second sand box 2 is the lower sand box. At this time, the main shaft flange is placed downward after the wind turbine hub is formed. The second is to place the second sand box 2 above the first sand box 1, the second sand box 2 is the upper sand box, and the first sand box 1 is the lower sand box. At this time, the main shaft flange is placed upward after the wind turbine hub is formed.
[0024] When the first casting process is adopted, that is, the first sand box 1 is the upper sand box and the second sand box 2 is the lower sand box, a pouring port and an air outlet are arranged on the upper part of the first sand box 1, and a straight runner connected to the pouring port and an air outlet pipe connected to the air outlet are arranged inside the first sand box 1, and the air outlet pipe provides a smooth outlet for the air (or other fluid) remaining in the casting system. The air outlet pipe can be arranged in multiples, and the specific design is based on the structure of the actual casting system. An inner runner and a horizontal runner are arranged inside the second sand box 2, and a filter is arranged at the bottom of the second sand box 2, and the filter is arranged between the inner runner and the horizontal runner, and connects the horizontal runner and the inner runner.
[0025] This process solution requires setting mold blocks 5 at the bottom of the lower main clay core 3, the bottom of the lower belly plate clay core 4, both sides of the lower belly plate clay core 4 and the through holes between two adjacent lower belly plate clay cores 4. The mold blocks 5 are detachably connected to the lower main clay core 3 to facilitate subsequent demolding.
[0026] This process reduces the number of web cores in the upper sand box, shortens the molding time, and also reduces the number of web cores in the mold, increases the mold matching speed, and thus improves the casting efficiency of the wind turbine hub.
[0027] When the second casting process is adopted, that is, the second sand box 2 is the upper sand box and the first sand box 1 is the lower sand box, a pouring port and an air outlet are arranged on the upper part of the second sand box 2, and a straight runner connected to the pouring port and an air outlet pipe connected to the air outlet are arranged inside the second sand box 2. An inner runner and a horizontal runner are arranged inside the first sand box 1, and a filter is arranged at the bottom of the first sand box 1. The filter is made separately and embedded in advance during molding. The filter is arranged between the horizontal runner and the inner runner, and connects the horizontal runner and the inner runner. By adopting this process scheme, the lower sand box has three less belly plate clay cores, which reduces the modeling and mold matching time. In addition, the lower sand box has only one upper main clay core 3 and an outer mold, and the relative size of the casting is easy to control.
[0028] The pouring sequence is changed by replacing the mold blocks, thereby realizing two pouring processes, that is, two pouring processes with one mold. By comparing the costs generated by the two pouring processes during process optimization, the one with the lowest cost is selected as the optimal process, thereby further reducing the casting cost of the wind turbine hub.
[0029] Embodiment 2 This embodiment provides a method for using a wind turbine hub casting system, using a wind turbine hub casting system as described in Embodiment 1, including the following steps: When the first process scheme is adopted, that is, the hub main shaft flange faces downward, the first sand box is the upper sand box, and the second sand box is the lower sand box. First, the corresponding mold live block is selected according to the process as the lower core positioning core head of the lower main clay core and the web clay core, and fixed on the lower main clay core and the three web clay cores. Then, the lower main clay core is placed in the second sand box, and the three web clay cores are placed on the sides of the lower main clay core respectively, so that the three web clay cores correspond to the three pitch flange surfaces, and the upper main clay core is placed above the lower main clay core. Finally, the first sand box is placed above the second sand box to complete the box closing; When the second process is adopted, that is, the hub main shaft flange faces upward, the first sand box is the lower sand box, and the second sand box is the upper sand box. First, the upper main clay core is placed in the first sand box, the lower main clay core is placed above the upper main clay core, and the three web clay cores are fixed on the sides of the lower main clay core respectively. Finally, the second sand box is placed above the first sand box to complete the box assembly. The costs of the two process solutions during process optimization are calculated, and the one with the lowest cost is selected as the optimal process through comparison, thereby further reducing the production cost of the wind turbine hub.
[0030] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. For those skilled in the art, the present invention may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.
Claims
1. A wind turbine hub casting system, characterized in that: It includes a first sand box, a second sand box and a main clay core, wherein the first sand box and the second sand box are respectively provided with a cavity, and the main clay core includes an upper main clay core and a lower main clay core, wherein the upper main clay core is arranged in the cavity of the first sand box, and the lower main clay core is arranged in the cavity of the second sand box, an upper belly plate clay core is arranged on the cavity of the first sand box, and a lower belly plate clay core is arranged on the main clay core.
2. A wind turbine hub casting system according to claim 1, characterized in that: The mold cavity of the first sand box cooperates with the upper main clay core to form the upper part of the wind turbine hub and the upper part of the pitch flange surface.
3. A wind turbine hub casting system according to claim 1, characterized in that: The upper belly plate clay cores are provided with three and are located on the inner wall of the mold cavity of the first sand box. The three upper belly plate clay cores are integrally formed with the first sand box.
4. A wind turbine hub casting system as claimed in claim 3, characterized in that: The three upper belly plate mud cores correspond to the upper parts of the three variable pitch flange surfaces of the wind turbine hub and are used for forming the upper parts of the three variable pitch flange surfaces.
5. A wind turbine hub casting system as claimed in claim 1, characterized in that: The mold cavity of the second sand box cooperates with the lower main clay core to form the lower part of the wind turbine hub and the flange surface of the wind turbine hub main shaft.
6. A wind turbine hub casting system as claimed in claim 1, characterized in that: There are three lower belly plate mud cores, which are respectively arranged on the sides of the lower main mud core and are detachably connected to the lower main mud core. The three lower belly plate mud cores correspond to the lower parts of the three pitch flange surfaces and are used to form the lower parts of the three pitch flange surfaces.
7. A wind turbine hub casting system according to claim 1, characterized in that: The first sand box is an upper sand box, the second sand box is a lower sand box, the first sand box is placed above the second sand box, and at this time, the main shaft flange is arranged downward after the wind turbine hub is formed.
8. A wind turbine hub casting system as claimed in claim 7, characterized in that: The lower main clay core is provided with a plurality of mold movable blocks, which are respectively located at the bottom of the lower main clay core, the bottom of the lower belly plate clay core, both sides of the lower belly plate clay core and the through holes between two adjacent lower belly plate clay cores. The plurality of mold movable blocks are detachably connected to the lower main clay core.
9. A wind turbine hub casting system as claimed in claim 1, characterized in that: The second sand box is an upper sand box, the first sand box is a lower sand box, and the second sand box is placed above the first sand box. At this time, the main shaft flange is arranged upward after the wind turbine hub is formed.
10. A method for using a wind turbine hub casting system, using a wind turbine hub casting system as claimed in any one of claims 1 to 9, characterized in that: The following steps are involved: When the first process scheme is adopted, that is, the hub main shaft flange faces downward, the first sand box is the upper sand box, and the second sand box is the lower sand box. First, the corresponding mold live block is selected according to the process, and fixed on the lower main clay core and the three web clay cores. Then the lower main clay core is placed in the second sand box, and the three web clay cores are placed on the sides of the lower main clay core respectively, so that the three web clay cores correspond to the three pitch flange surfaces, and the upper main clay core is placed above the lower main clay core. Finally, the first sand box is placed above the second sand box to complete the box closing; When the second process is adopted, that is, the hub main shaft flange faces upward, the first sand box is the lower sand box, and the second sand box is the upper sand box. First, the upper main clay core is placed in the first sand box, the lower main clay core is placed above the upper main clay core, and the three web clay cores are fixed on the sides of the lower main clay core respectively. Finally, the second sand box is placed above the first sand box to complete the box assembly. The costs of the above two process solutions during process optimization are calculated, and the one with the lowest cost is selected as the optimal process through comparison, thereby further reducing the production cost of the wind turbine hub.