Welding method for maintaining flatness of weld seam between cylinder and flange of large wind power generation equipment
Through strict pre-weld preparation, optimized welding process and detailed post-weld inspection and treatment, the problem of difficult to maintain the flatness of the cylinder and flange welds of large wind power generation equipment is solved, and the design requirements for the flatness of the welds are realized, which reduces production costs and improves the stability of the tooling.
Patent Information
- Application Number
- CN202411717058.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-11-27
- Publication Date
- 2025-04-04
AI Technical Summary
The flatness of the cylinder and flange welds of large-scale wind power generation equipment is difficult to maintain, the existing tooling structure is complex, the production cost is high, and the stability is poor.
Through strict pre-weld preparation, optimized welding process and detailed post-weld inspection and treatment, including quality control of flanges and cylinder sections, assurance of assembly gaps, selection of welding materials, optimization of welding sequence, temperature control between preheated layers and layers, assistance of special rigid platforms, and non-destructive detection of weld quality.
It effectively ensures that the planarity of the flange and cylinder weld meets the design requirements, reduces production costs, and improves the stability and welding quality of the tooling.
Abstract
Description
Technical Field
[0001] The invention relates to the technical field of tower and flange welding methods, in particular to a welding method for maintaining the flatness of a weld between a cylinder and a flange of a large wind power generation equipment. Background Art
[0002] With the development of large-diameter onshore wind power towers, the structure of the towers is getting larger and larger, and the transportation requirements for the towers are getting higher and higher. Especially for onshore wind power of 3MW and above, it is difficult to transport the diameter of more than 5m. Solving the transportation problem is the key technology of large-power diameter towers. Therefore, cutting the towers for transportation to meet the requirements of large-piece transportation is the best choice for some models of towers. The diameter of the large-diameter tower flange is generally φ6500-φ5000. After the overall ring forging is completed, it is cut into three pieces and transported to the tower factory. Then the tower factory assembles it. After qualified assembly, it is welded with the tower barrel. The separated flanges are welded with the tower group respectively, which is very difficult and cannot guarantee the accuracy of their size. In order to ensure the dimensional accuracy of the segmented flange assembly connection, a tooling for welding the segmented flange and the tower is required. The existing tooling has a complex structure, which increases the production cost and has poor stability. Summary of the invention
[0003] The technical problem to be solved by the present invention is to overcome the above technical defects and provide a welding method for maintaining the flatness of the weld between the cylinder and the flange of large-scale wind power generation equipment.
[0004] In order to solve the above problems, the technical solution of the present invention is: a welding method for maintaining the flatness of the weld between the cylinder and the flange of a large-scale wind power generation equipment, comprising the following steps: S1 pre-welding preparation, wherein the pre-welding preparation includes quality control of the flange and the cylinder section, guarantee of the assembly gap and preparation of welding materials; The flange in the quality control of the flange and the cylinder section should be a product that is forged as a whole and then machined. When cutting the cylinder section, a standard cutting drawing should be laid out according to the outer dimensions of the cylinder section, and a CNC cutting machine should be used for cutting. The guarantee of the assembly gap requires ensuring that the gap between the flange and the cylinder section is uniform and as small as possible. The preparation of the welding materials requires the selection of appropriate welding materials and flux.
[0005] S2 welding process, the welding process includes optimization of welding sequence, control during welding, temperature control of preheating layer and interlayer, and assistance of special rigid platform; The optimization of the welding sequence requires that the weld groove position be subjected to V-shaped single-sided processing first, and double-sided submerged arc welding technology be used. The inner ring should be welded first and then the outer ring. The control during the welding process requires strict control of welding current, voltage, speed and other parameters. After welding is completed, dehydrogenation treatment is required. The preheating layer and interlayer temperature control preheat the flange and the cylinder to reduce thermal stress during welding. The special rigid platform is assisted by a pre-inclined flange platform. S3 post-weld inspection and treatment, including inspection of flange flatness, inspection of weld quality and treatment of flatness that does not meet requirements; The inspection of the flange flatness requires the use of appropriate measuring tools and methods to inspect the flatness of the flange and ensure a good measuring environment. The inspection of the weld quality requires non-destructive testing of the weld. If the flatness does not meet the requirements, rework is required.
[0006] Furthermore, in the quality control of the flange and the cylinder joint, the opening of the cylinder joint groove must be accurate, without defects such as missing edges. When rolling, a standard rolling inspection template must be used for roundness control to ensure the roundness of the cylinder joint and the flatness of the port. The preparation of the welding materials requires submerged arc welding wire H10Mn2 and flux SJ101, etc.
[0007] Furthermore, in the optimization of the welding sequence, it is necessary to perform inner welding first, and then perform outer carbon arc air gouging to clean the root after completing the inner welding, and then complete the outer welding. In addition, when performing girth weld welding, the inner and outer girth welds need to be welded alternately to avoid the influence of stress generated during welding on the flatness of the flange.
[0008] Furthermore, the outwardly inclined flange platform is locked by high-strength bolts and then assembled and welded with the cylinder section to prevent deformation during the welding process.
[0009] Furthermore, the weld quality is tested by ultrasonic testing, X-ray testing, etc. to ensure the quality of the weld. If the weld is deformed, flame shaping, mechanical correction, etc. should be used to correct it in time.
[0010] Compared with the existing technology, the advantages of the present invention are: comprehensive consideration of pre-welding preparation, welding process and post-welding inspection and treatment, etc. By strictly controlling the quality and technical requirements of each link, the flatness of the flange and cylinder weld can be effectively guaranteed to meet the design requirements. DETAILED DESCRIPTION
[0011] The specific implementation of the present invention is further described below in conjunction with the embodiments, wherein the same components are represented by the same embodiment numbers.
[0012] It should be noted that the words "front", "rear", "left", "right", "up" and "down" used in the following description refer to directions in the embodiment, and the words "inside" and "outside" refer to directions toward or away from the geometric center of a specific component, respectively.
[0013] In order to make the contents of the present invention more clearly understood, the technical solutions in the embodiments of the present invention will be clearly and completely described below in combination with the embodiments in the embodiments of the present invention.
[0014] Embodiment 1: A welding method for maintaining the flatness of the weld between the cylinder and flange of a large-scale wind power generation equipment, characterized in that it comprises the following steps: S1 pre-welding preparation, the pre-welding preparation includes quality control of the flange and the cylinder section, guarantee of the assembly gap and preparation of welding materials; The flanges in the quality control of flanges and cylinders should be products that are forged as a whole and then machined. When cutting the cylinder, a standard cutting drawing should be laid out according to the outer dimensions of the cylinder, and a CNC cutting machine should be used for cutting. The guarantee of the assembly gap requires that the gap between the flange and the cylinder be uniform and as small as possible. For the preparation of welding materials, appropriate welding materials and flux should be selected; The flange and the cylinder joint quality control requires that the groove of the cylinder joint be opened accurately without defects such as missing edges. When rolling, a standard rolling inspection sample should be used for roundness control to ensure the roundness of the cylinder joint and the flatness of the port. The preparation of welding materials requires submerged arc welding wire H10Mn2 and flux SJ101, etc. S2 welding process, welding process includes optimization of welding sequence, control during welding, temperature control of preheating layer and interlayer, and assistance of special rigid platform; The optimization of welding sequence requires V-shaped single-sided treatment of the weld groove position first, and the double-sided submerged arc welding technology is used. The inner ring should be welded first and then the outer ring. The control during the welding process requires strict control of welding current, voltage, speed and other parameters. After welding, hydrogen removal treatment is required. The preheating layer and interlayer temperature control are used to preheat the flange and the cylinder to reduce the thermal stress during welding. With the assistance of a special rigid platform, a pre-inclined flange platform is used; In the optimization of welding sequence, the inner side welding needs to be carried out first, and then the outer side carbon arc air gouging root cleaning is carried out after the inner side welding is completed, and then the outer side welding is completed. In addition, when the girth weld is carried out, the inner and outer girth welds need to be welded alternately to avoid the influence of the stress generated during the welding process on the flange flatness; S3 Post-weld inspection and treatment, including flange flatness inspection, weld quality inspection and treatment of flatness that does not meet requirements; The inspection of flange flatness requires the use of appropriate measuring tools and methods to inspect the flatness of the flange and ensure a good measuring environment. The inspection of weld quality requires non-destructive testing of the weld. If the flatness does not meet the requirements, rework is required. The outward-inclined flange platform is locked with high-strength bolts before being assembled and welded with the cylinder section to prevent deformation during the welding process. The quality of the weld is tested by ultrasonic testing, X-ray testing, etc. to ensure the quality of the weld. If the weld is deformed, flame shaping, mechanical correction and other methods should be adopted in time to correct it.
[0015] The present invention and its embodiments are described above, and such description is not restrictive. What is shown in the embodiment is only one of the embodiments of the present invention, and the actual structure is not limited thereto. In short, if ordinary technicians in the field are inspired by it, without departing from the purpose of the invention, they can design a structure and embodiment similar to the technical solution without creativity, which should belong to the protection scope of the present invention.
Claims
1. A welding method for maintaining the flatness of the weld between the cylinder and flange of a large wind power generation equipment, characterized in that: The following steps are involved: S1 Pre-welding preparation, which includes quality control of flanges and sleeves, guarantee of assembly clearance and preparation of welding materials; The flange in the quality control of the flange and the barrel section should be a product that is forged as a whole and then machined. When cutting the barrel section, a standard cutting drawing should be laid out according to the outer dimensions of the barrel section, and a CNC cutting machine should be used for cutting. The guarantee of the assembly gap needs to ensure that the gap between the flange and the barrel section is uniform and as small as possible. For the preparation of the welding materials, suitable welding materials and flux should be selected; S2 welding process, the welding process includes optimization of welding sequence, control during welding, temperature control of preheating layer and interlayer, and assistance of special rigid platform; The optimization of the welding sequence requires that the weld groove position be subjected to V-shaped single-sided processing first, and double-sided submerged arc welding technology be used. The inner ring should be welded first and then the outer ring. The control during the welding process requires strict control of welding current, voltage, speed and other parameters. After welding is completed, dehydrogenation treatment is required. The preheating layer and interlayer temperature control preheat the flange and the cylinder to reduce thermal stress during welding. The special rigid platform is assisted by a pre-inclined flange platform. S3 post-weld inspection and treatment, including inspection of flange flatness, inspection of weld quality and treatment of flatness that does not meet requirements; The inspection of the flange flatness requires the use of appropriate measuring tools and methods to inspect the flatness of the flange and ensure a good measuring environment. The inspection of the weld quality requires non-destructive testing of the weld. If the flatness does not meet the requirements, rework is required.
2. The welding method for maintaining the flatness of the weld seam between the cylinder and flange of large-scale wind power generation equipment according to claim 1 is characterized in that: In the quality control of the flange and the cylinder joint, the opening of the cylinder joint groove must be accurate, without defects such as missing edges. When rolling, a standard rolling inspection template must be used for roundness control to ensure the roundness of the cylinder joint and the flatness of the port. The preparation of the welding materials requires submerged arc welding wire H10Mn2 and flux SJ101, etc.
3. The welding method for maintaining the flatness of the weld seam between the cylinder and flange of large-scale wind power generation equipment according to claim 1 is characterized in that: In the optimization of the welding sequence, the inner side welding needs to be performed first, and after the inner side welding is completed, the outer side carbon arc air gouging root cleaning is performed, and then the outer side welding is completed. In addition, when performing the girth weld, the inner and outer girth welds need to be welded alternately to avoid the influence of the stress generated during the welding process on the flange flatness.
4. The welding method for maintaining the flatness of the weld seam between the cylinder and flange of large-scale wind power generation equipment according to claim 1 is characterized in that: The outwardly inclined flange platform is locked by high-strength bolts and then assembled and welded with the cylinder section to prevent deformation during the welding process.
5. The welding method for maintaining the flatness of the weld seam between the cylinder and flange of large-scale wind power generation equipment according to claim 1 is characterized in that: The weld quality is tested by ultrasonic testing, X-ray testing, etc. to ensure the quality of the weld. If the weld is found to be deformed, flame shaping, mechanical correction, etc. should be adopted in time to correct it.