A special-shaped blade flange casting device

Abstract

The invention discloses a special-shaped blade flange casting device, which relates to the technical field of casting devices. The casting device comprises a casting mold, a chill, a pressurized riser, a pressurizing device, a casting device and a support frame. The casting mold and the support frame are tightly connected, the casting mold and the chill are tightly connected, the casting mold and the pressurized riser are tightly connected, the pressurizing device is connected to the support frame, and the casting mold and the casting device are connected. The support frame serves as a main supporting basis for supporting and installing other devices. Casting liquid enters the casting mold through the casting device for casting. The chill accelerates the local heat dissipation rate of the casting mold. The pressurizing device is used to seal the pressurized riser to achieve pressurization inside the casting mold, so that the casting liquid can fill the entire casting mold, thereby achieving a shrinkage compensation effect on the casting mold.

Description

Technical Field

[0001] The invention relates to the technical field of casting devices, in particular to a casting device for a special-shaped blade flange. Background Art

[0002] In recent years, with the rapid growth of demand in the wind power industry, the megawatt level of castings has become larger and larger, and the size and wall thickness of castings have also increased accordingly, resulting in an increase in the risk of shrinkage on thick and large surfaces, and customer requirements have naturally increased accordingly.

[0003] The traditional structure of the blade flange of the wind turbine casting hub is that the blade assembly surface is the machined surface, and the rest of the inner ring is the blank surface. The special-shaped blade flange structure is different from the traditional mixture of machined surface and blank surface. Instead, it adopts a fully machined structure. The wall thickness is about 3 times that of the traditional structure, and the area is about 5 times that of the traditional structure. The risk of shrinkage is also doubled. Shrinkage will cause the last solidified area between the pouring liquid and the casting mold to not receive the shrinkage of the liquid metal or alloy, forming scattered and tiny shrinkage holes, thereby reducing the quality of the casting mold. Summary of the invention

[0004] The object of the present invention is to provide a special-shaped blade flange casting device to solve the problems raised in the prior art.

[0005] To achieve the above object, the present invention provides the following technical solutions: The present invention provides a technical solution for a special-shaped blade flange casting device. The casting device includes a casting mold, a chill, a pressurized riser, a pressurizing device, a pouring device and a support frame. The casting mold and the support frame are fastened together, the casting mold and the chill are fastened together, the casting mold and the pressurized riser are fastened together, the pressurizing device and the support frame are connected, and the casting mold and the pouring device are connected.

[0006] The support frame serves as the main supporting foundation and is used to support and install other devices. The pouring liquid enters the casting mold through the pouring device for pouring. The local heat dissipation rate of the casting mold is accelerated by the cold iron. The pressurized riser is sealed by the pressurizing device to pressurize the inside of the casting mold, so that the pouring liquid can fill the entire casting mold and achieve the shrinkage compensation effect on the casting mold.

[0007] Furthermore, the casting mold includes a main shaft flange and a special-shaped blade flange, the main shaft flange is located below the special-shaped blade flange, the main shaft flange and the special-shaped blade flange are fastened together, the main shaft flange and the support frame are fastened together, the main shaft flange and the casting device are connected, and the special-shaped blade flange and the pressurized riser are connected.

[0008] The support frame supports the main shaft flange. Through the casting process with the main shaft flange at the bottom and the special-shaped blade flange at the top, when the special-shaped blade flange is cast, the air on the top of the special-shaped blade flange exerts a certain pressure on the casting liquid, so that the casting liquid fits the side of the special-shaped blade flange more closely, thereby increasing the self-shrinkage compensation effect of the special-shaped blade flange.

[0009] Furthermore, there are a plurality of chillers, a plurality of which are fastened to the outer side of the main shaft flange, and a plurality of which are fastened to the special-shaped blade flange.

[0010] By arranging a plurality of chillers on the main shaft flange and the special-shaped blade flange, the local cooling speed of the main shaft flange and the special-shaped blade flange is accelerated, so that the casting mold can be cooled and demoulded faster.

[0011] Furthermore, the pouring device includes a pouring cup, a runner and a filter sheet. The pouring cup is connected to the runner, a plurality of filter sheets are arranged on the runner, and one end of the runner away from the pouring cup is connected to the casting mold.

[0012] The pouring liquid is poured into the pouring cup, and then flows through the pouring cup, through the runner and the filter sheet, and finally flows into the casting mold. The pouring liquid is filtered through multiple filter sheets to remove granular impurities in the pouring liquid, thereby improving the molding quality of the mold.

[0013] Furthermore, the pressurizing device includes a movable plate, a manipulator and a pressurizing element, the movable plate is connected to the support frame, the movable plate is firmly connected to the manipulator, and the manipulator is firmly connected to the pressurizing element.

[0014] The moving plate moves on the support frame, driving the manipulator and the pressurizing element to move to the specified position, and then the manipulator sends the pressurizing element to the working position, and the pressurizing element starts to pressurize the pressurized riser.

[0015] Furthermore, the movable plate includes a fixed plate, a fixed motor and a gear. The fixed plate is firmly connected to the manipulator, the fixed plate is slidably connected to the support frame, the fixed motor is placed in the fixed plate, the fixed motor is firmly connected to the fixed plate, the output end of the fixed motor is firmly connected to the gear, and the gear is connected to the support frame.

[0016] The fixed motor outputs a torque to drive the gear to rotate, and the gear rotation is moved by the reaction force of the support frame. The reaction force of the support frame drives the gear to move, and the movement of the gear drives the fixed motor to move. The movement of the fixed motor drives the fixed plate to move. The movement of the fixed plate drives the manipulator to move. The movement of the manipulator drives the pressure element to move. After the pressure element moves to the working position, the fixed motor stops outputting the torque.

[0017] Furthermore, the pressurizing element includes a steering disc, a steering slider, a steering motor, a steering plate, a rotating motor, a pressurizing cylinder and a pressurizing plug. The steering disc and the manipulator are tightly connected, the steering disc and the steering slider are slidingly connected, the steering slider and the steering motor are tightly connected, the output end of the steering motor and the steering plate are tightly connected, the steering plate of the rotating motor is tightly connected, the output end of the rotating motor and the pressurizing cylinder are tightly connected, the output end of the pressurizing cylinder and the pressurizing plug are tightly connected, and a pressure sensor is provided on the end of the pressurizing plug facing the pressurizing riser.

[0018] The steering disc is used as the main installation base for the installation and positioning of other components. The steering motor is driven to move by the movement of the steering slider, the steering plate is driven to move by the movement of the steering motor, the rotating motor is driven to move by the movement of the steering plate, the pressurizing cylinder is driven to move by the movement of the rotating motor, and the pressurizing plug is driven to move by the movement of the pressurizing cylinder until the pressurizing plug moves to the specified position. The steering plate is driven to rotate by the output torque of the steering motor, and the pressurizing cylinder and the pressurizing plug are driven to rotate by the output torque of the rotating motor until the pressurizing plug is aligned with the pressurizing riser. When the pressurized riser is required to pressurize the casting mold, the pressurizing plug is driven to move by the output displacement of the pressurizing cylinder until the pressurizing plug blocks the pressurizing riser, and the pouring liquid is transported to the inside of the casting mold through the pouring device to increase the air pressure above the casting mold. After the air pressure increases, a reaction force is applied to the pouring liquid below, so that the pouring liquid below and the casting mold are more closely fitted. At the same time, the pressure change inside the casting mold is fed back according to the pressure sensor on the pressurizing plug. According to the pressure inside the casting mold, the pressure value of the pressurizing cylinder is adjusted to discharge the excess air inside the casting mold.

[0019] Furthermore, a driving motor and a driving roller are provided on the steering slider, the output end of the driving motor and the driving roller are tightly connected, and the driving roller and the steering disc are rollingly connected.

[0020] The driving motor outputs a rotational torque to drive the driving roller to rotate. The driving roller is moved by the friction of the steering disc. The movement of the driving roller drives the steering slider to move, so that the steering slider moves on the steering disc, allowing the pressure plug to align with the pressure riser.

[0021] Furthermore, a rack is provided on the support frame, and the rack is meshed with the gear.

[0022] The support frame serves as the main mounting device and is used to provide a mounting position for the rack.

[0023] Compared with the prior art, the present invention has the following beneficial effects: 1. Abandon the traditional molding process of the main shaft flange at the top, and adopt the casting process of the main shaft flange at the bottom and the special-shaped blade flange at the top, so that the top of the casting mold has a certain self-compensation effect on the special-shaped blade flange, thereby improving the casting quality.

[0024] 2. By arranging multiple chillers on the casting mold, the local cooling rate of the casting mold is accelerated and the demoulding time is shortened.

[0025] 3. A pressure element is provided to pressurize the casting liquid inside the casting mold, so that the casting liquid and the inside of the casting mold fit better and improve the casting quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 It is a schematic diagram of the overall structure of the present invention; Figure 2 It is a schematic diagram of the casting mold structure of the present invention; Figure 3 for Figure 2 A magnified view of a part A; Figure 4 It is a schematic diagram of the support frame structure of the present invention; Figure 5 for Figure 4 BB section view; Figure 6 for Figure 5 A magnified view of a local area C.

[0027] In the figure: 1. casting mold; 11. spindle flange; 12. special-shaped blade flange; 2. chill; 3. pressurized riser; 4. pressurizing device; 41. moving plate; 411. fixed plate; 412. fixed motor; 413. gear; 42. manipulator; 43. pressurizing element; 431. steering disc; 432. steering slider; 433. steering motor; 434. steering plate; 435. rotating motor; 436. pressurized cylinder; 437. pressurized plug; 438. driving motor; 439. driving roller; 5. pouring device; 51. pouring cup; 52. runner; 53. filter; 6. support frame; 61. rack. DETAILED DESCRIPTION

[0028] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0029] Example: Figure 1-Figure 6As shown, the present invention provides a technical solution for a special-shaped blade flange casting device, the casting device comprising a casting mold 1, a chill 2, a pressurized riser 3, a pressurizing device 4, a pouring device 5 and a support frame 6, the casting mold 1 and the support frame 6 are fastened together, the casting mold 1 and the chill 2 are fastened together, the casting mold 1 and the pressurized riser 3 are fastened together, the pressurizing device 4 is connected to the support frame 6, and the casting mold 1 and the pouring device 5 are connected.

[0030] The support frame 6 serves as the main supporting foundation and is used to support and install other devices. The pouring liquid enters the casting mold 1 through the pouring device 5 for pouring. The local heat dissipation rate of the casting mold 1 is accelerated by the cold iron 2. The pressurized riser 3 is sealed by the pressurizing device 4 to pressurize the inside of the casting mold 1, so that the pouring liquid can fill the entire casting mold 1, thereby achieving the shrinkage compensation effect on the casting mold.

[0031] like Figure 1 , Figure 2 and Figure 5 As shown, the casting mold 1 includes a main shaft flange 11 and a special-shaped blade flange 12, the main shaft flange 11 is located below the special-shaped blade flange 12, the main shaft flange 11 and the special-shaped blade flange 12 are fastened together, the main shaft flange 11 and the support frame 6 are fastened together, the main shaft flange 11 and the casting device 5 are connected, and the special-shaped blade flange 12 and the pressurized riser 3 are connected.

[0032] The support frame 6 supports the main shaft flange 11. Through the casting process with the main shaft flange 11 at the bottom and the special-shaped blade flange 12 at the top, when the special-shaped blade flange 12 is cast, the air at the top of the special-shaped blade flange 12 exerts a certain pressure on the casting liquid, allowing the casting liquid to fit the side of the special-shaped blade flange 12 more closely, thereby increasing the self-shrinkage compensation effect of the special-shaped blade flange 12.

[0033] like Figure 1 and Figure 2 As shown, there are several chillers 2 , several of which are fastened to the outer side of the main shaft flange 11 , and several of which are fastened to the special-shaped blade flange 12 .

[0034] By arranging a plurality of chillers 2 on the main shaft flange 11 and the special-shaped blade flange 12, the local cooling speed of the main shaft flange 11 and the special-shaped blade flange 12 is accelerated, so that the casting mold 1 can be cooled and demoulded more quickly.

[0035] like Figure 1 , Figure 2 , Figure 4 and Figure 5 As shown, the pouring device 5 includes a pouring cup 51, a pouring channel 52 and a filter plate 53. The pouring cup 51 is connected to the pouring channel 52. A plurality of filter plates 53 are provided on the pouring channel 52. The pouring channel 52 is connected to the casting mold 1 at one end away from the pouring cup 51.

[0036] The pouring liquid is poured into the pouring cup 51, and then flows through the pouring cup 51, through the runner 52 and the filter plate 53, and finally flows into the casting mold 1. The pouring liquid is filtered through multiple filter plates 53 to remove granular impurities in the pouring liquid, thereby improving the molding quality of the mold.

[0037] like Figure 1 and Figure 2 As shown, the pressurizing device 4 includes a moving plate 41, a manipulator 42 and a pressurizing element 43, the moving plate 41 is connected to the support frame 6, the moving plate 41 and the manipulator 42 are tightly connected, and the manipulator 42 and the pressurizing element 43 are tightly connected.

[0038] The movable plate 41 moves on the support frame 6 to drive the manipulator 42 and the pressurizing element 43 to move to the designated position, and then the manipulator 42 sends the pressurizing element 43 to the working position, and the pressurizing element 43 starts to pressurize the pressurized riser 3.

[0039] like Figure 4 and Figure 5 As shown, the movable plate 41 includes a fixed plate 411, a fixed motor 412 and a gear 413. The fixed plate 411 and the manipulator 42 are fastened together, the fixed plate 411 and the support frame 6 are slidably connected, the fixed motor 412 is placed in the fixed plate 411, the fixed motor 412 and the fixed plate 411 are fastened together, the output end of the fixed motor 412 and the gear 413 are fastened together, and the gear 413 and the support frame 6 are connected.

[0040] The fixed motor 412 outputs a torque to drive the gear 413 to rotate, and the gear 413 moves due to the reaction force of the support frame 6. The reaction force of the support frame 6 drives the gear 413 to move, and the movement of the gear 413 drives the fixed motor 412 to move. The movement of the fixed motor 412 drives the fixed plate 411 to move. The movement of the fixed plate 411 drives the manipulator 42 to move. The movement of the manipulator 42 drives the pressure element 43 to move, until the pressure element 43 moves to the working position, and the fixed motor 412 stops outputting the torque.

[0041] like Figure 2 and Figure 3As shown, the pressurizing element 43 includes a steering disc 431, a steering slider 432, a steering motor 433, a steering plate 434, a rotating motor 435, a pressurizing cylinder 436 and a pressurizing plug 437. The steering disc 431 is firmly connected to the manipulator 42, the steering disc 431 is slidably connected to the steering slider 432, the steering slider 432 is firmly connected to the steering motor 433, the output end of the steering motor 433 is firmly connected to the steering plate 434, the steering plate 434 of the rotating motor 435 is firmly connected, the output end of the rotating motor 435 is firmly connected to the pressurizing cylinder 436, the output end of the pressurizing cylinder 436 is firmly connected to the pressurizing plug 437, and a pressure sensor is provided on the end of the pressurizing plug 437 facing the pressurized riser 3.

[0042] The steering disc 431 is used as the main installation base for the installation and positioning of other components. The steering slider 432 moves to drive the steering motor 433 to move, the steering motor 433 moves to drive the steering plate 434 to move, the steering plate 434 moves to drive the rotating motor 435 to move, the rotating motor 435 moves to drive the pressurizing cylinder 436 to move, the pressurizing cylinder 436 moves to drive the pressurizing plug 437 to move, until the pressurizing plug 437 moves to the specified position, and then the steering motor 433 outputs a rotational torque to drive the steering plate 434 to rotate, and at the same time, the rotating motor 435 outputs a rotational torque to drive the pressurizing cylinder 436 and the pressurizing plug 437 to rotate, until the pressurizing plug 437 is moved to the specified position. Aim at the pressurized riser 3. When the pressurized riser 3 is needed to pressurize the casting mold 1, the pressurized cylinder 436 outputs displacement to drive the pressurized plug 437 to move until the pressurized plug 437 blocks the pressurized riser 3. The pouring liquid is transported to the inside of the casting mold 1 through the pouring device 5 to increase the air pressure above the casting mold 1. After the air pressure increases, a reaction force begins to be applied to the pouring liquid below, so that the pouring liquid below and the casting mold 1 are more closely fitted. At the same time, the pressure sensor on the pressurized plug 437 feeds back the pressure changes inside the casting mold 1. According to the pressure inside the casting mold 1, the pressure value of the pressurized cylinder 436 is adjusted to discharge excess air inside the casting mold 1.

[0043] like Figure 5 and Figure 6 As shown, a driving motor 438 and a driving roller 439 are provided on the steering slider 432 , the output end of the driving motor 438 and the driving roller 439 are tightly connected, and the driving roller 439 and the steering disc 431 are rollingly connected.

[0044] The driving motor 438 outputs a rotational torque to drive the driving roller 439 to rotate. The driving roller 439 is moved by the friction force of the steering disc 431. The movement of the driving roller 439 drives the steering slider 432 to move, so that the steering slider 432 moves on the steering disc 431, allowing the pressurizing plug 437 to align with the pressurizing riser 3.

[0045] like Figure 4 and Figure 5 As shown, a rack 61 is provided on the support frame 6 , and the rack 61 is meshed with the gear 413 .

[0046] The support frame 6 serves as a main installation device, and is used to provide an installation position for the rack 61 .

[0047] The working principle of the present invention is as follows: the spindle flange 11 in the traditional casting process is located above the special-shaped blade flange 12, and the spindle flange 11 is located below the special-shaped blade flange 12, so that when the special-shaped blade flange 12 is cast, the air existing at the top of the special-shaped blade flange 12 exerts a certain pressure on the casting liquid, so that the casting liquid fits the side of the special-shaped blade flange 12 more closely, and the self-shrinkage effect of the special-shaped blade flange 12 is increased. Before pouring, the moving plate 41 moves on the support frame 6 to drive the manipulator 42 and the pressurizing element 43 to move to the specified position, and then the manipulator 42 sends the pressurizing element 43 to the working position, and then the steering slider 432 moves to drive the steering motor 433 to move, the steering motor 433 moves to drive the steering plate 434 to move, the steering plate 434 moves to drive the rotating motor 435 to move, the rotating motor 435 moves to drive the pressurizing cylinder 436 to move, and the pressurizing cylinder 436 moves to drive the pressurizing plug 437 to move, until the pressurizing plug 437 moves to the specified position, and then the steering The motor 433 outputs a rotational torque to drive the steering plate 434 to rotate, and at the same time, the rotating motor 435 outputs a rotational torque to drive the pressurizing cylinder 436 to rotate and the pressurizing plug 437 to rotate, until the pressurizing plug 437 is aligned with the pressurizing riser 3. When the pressurizing riser 3 is needed to pressurize the casting mold 1, the pressurizing cylinder 436 outputs a displacement to drive the pressurizing plug 437 to move, until the pressurizing plug 437 blocks the pressurizing riser 3, and then the pouring liquid is transported to the inside of the casting mold 1 through the pouring device 5 to increase the air pressure above the casting mold 1. After the air pressure increases, a reaction force is applied to the pouring liquid below, so that the pouring liquid below and the casting mold 1 are more closely fitted. At the same time, according to the pressure sensor on the pressurizing plug 437, the pressure change inside the casting mold 1 is fed back, and according to the pressure size inside the casting mold 1, the pressure size value of the pressurizing cylinder 436 is adjusted to discharge the excess air inside the casting mold 1, and the local cooling speed of the spindle flange 11 and the special-shaped blade flange 12 is accelerated through the cold iron 2, so that the casting mold 1 can be cooled and demolded faster.

[0048] It will be apparent to those skilled in the art that the invention is not limited to the details of the exemplary embodiments described above and that the invention can be implemented in other specific forms without departing from the spirit or essential features of the invention. Therefore, the embodiments should be considered exemplary and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description, and it is intended that all variations falling within the meaning and scope of the equivalent elements of the claims be included in the invention. Any reference numeral in a claim should not be considered as limiting the claim to which it relates.

Claims

1. A special-shaped blade flange casting device, characterized in that: The casting device comprises a casting mold (1), a chill (2), a pressurized riser (3), a pressurizing device (4), a pouring device (5) and a support frame (6); the casting mold (1) and the support frame (6) are tightly connected, the casting mold (1) and the chill (2) are tightly connected, the casting mold (1) and the pressurized riser (3) are tightly connected, the pressurizing device (4) and the support frame (6) are connected, and the casting mold (1) and the pouring device (5) are connected.

2. A special-shaped blade flange casting device according to claim 1, characterized in that: The casting mold (1) comprises a main shaft flange (11) and a special-shaped blade flange (12), the main shaft flange (11) is located below the special-shaped blade flange (12), the main shaft flange (11) and the special-shaped blade flange (12) are fastened together, the main shaft flange (11) and the support frame (6) are fastened together, the main shaft flange (11) and the casting device (5) are connected, and the special-shaped blade flange (12) and the pressurized riser (3) are in communication.

3. A special-shaped blade flange casting device according to claim 2, characterized in that: There are a plurality of the cold irons (2), a plurality of the cold irons (2) are fastened to the outer side of the main shaft flange (11), and a plurality of the cold irons (2) are fastened to the special-shaped blade flange (12).

4. The special-shaped blade flange casting device according to claim 1, characterized in that: The pouring device (5) comprises a pouring cup (51), a pouring channel (52) and a filter sheet (53); the pouring cup (51) and the pouring channel (52) are connected; a plurality of filter sheets (53) are provided on the pouring channel (52); and an end of the pouring channel (52) away from the pouring cup (51) is connected to the casting mould (1).

5. The special-shaped blade flange casting device according to claim 1, characterized in that: The pressurizing device (4) comprises a movable plate (41), a manipulator (42) and a pressurizing element (43); the movable plate (41) is connected to a support frame (6); the movable plate (41) is firmly connected to the manipulator (42); and the manipulator (42) is firmly connected to the pressurizing element (43).

6. A special-shaped blade flange casting device according to claim 5, characterized in that: The movable plate (41) comprises a fixed plate (411), a fixed motor (412) and a gear (413); the fixed plate (411) and the manipulator (42) are tightly connected; the fixed plate (411) and the support frame (6) are slidably connected; the fixed motor (412) is disposed in the fixed plate (411); the fixed motor (412) and the fixed plate (411) are tightly connected; an output end of the fixed motor (412) and the gear (413) are tightly connected; and the gear (413) and the support frame (6) are connected.

7. A special-shaped blade flange casting device according to claim 6, characterized in that: The pressurizing element (43) comprises a steering disc (431), a steering slider (432), a steering motor (433), a steering plate (434), a rotating motor (435), a pressurizing cylinder (436) and a pressurizing plug (437); the steering disc (431) and the manipulator (42) are tightly connected; the steering disc (431) and the steering slider (432) are connected; the steering slider (432) and the steering motor (433) are tightly connected; the output end of the steering motor (433) and the steering plate (434) are tightly connected; the steering plate (434) of the rotating motor (435) is tightly connected; the output end of the rotating motor (435) and the pressurizing cylinder (436) are tightly connected; the output end of the pressurizing cylinder (436) and the pressurizing plug (437) are tightly connected; and a pressure sensor is provided on one end of the pressurizing plug (437) facing the pressurizing riser (3).

8. The special-shaped blade flange casting device according to claim 7, characterized in that: The steering slider (432) is provided with a driving motor (438) and a driving roller (439); the output end of the driving motor (438) and the driving roller (439) are tightly connected; and the driving roller (439) and the steering disc (431) are rollingly linked.

9. The special-shaped blade flange casting device according to claim 1, characterized in that: The pouring device (5) comprises a pouring cup (51), a pouring channel (52) and a filter sheet (53); the pouring cup (51) and the pouring channel (52) are connected; a plurality of filter sheets (53) are provided on the pouring channel (52); and an end of the pouring channel (52) away from the pouring cup (51) is connected to the casting mould (1).

10. The special-shaped blade flange casting device according to claim 5, characterized in that: The support frame (6) is provided with a rack (61), and the rack (61) is meshed with the gear (413).

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