Method for rolling wind power roof flange by adopting core roller double-station mold

Abstract

The invention discloses a method for rolling a wind power top flange through a core roller double-station die, and belongs to the technical field of wind power top flange rolling forming. A rolling device is included and comprises a main roller, the core roller double-station die, a conical roller and a rolling platform, and a stepped circular truncated cone structure is arranged on the core roller double-station die; comprising a thinner first rolling section and a thicker second rolling section; the method comprises the following steps; s1, rolling the blank through a first rolling section of the core roller double-station mold to form a circular ring with a rectangular section; and S2, near-net forming radial rolling is conducted on the blank through the first rolling section and the second rolling section of the core roller double-station mold together. The core roller double-station die is adopted to continuously apply acting force to the main roller in the diameter direction and the conical roller in the height direction, the rectangular section is formed into the special-shaped section, only stations need to be switched, the machining efficiency is improved, the production cost is reduced, raw materials are saved, the first rolling section is independently used for rolling the ring piece with the rectangular section, and universality is good.

Description

Technical Field

[0001] The invention belongs to the technical field of wind turbine top flange rolling forming, in particular to a method for rolling a wind turbine top flange by using a core roller double-station die. Background Art

[0002] Wind turbine flange is an important component that connects wind turbines and towers. It has a fixing and supporting function, and can also reduce damage and wear caused by force. Wind turbine flange manufacturing has a long history of development. With the large-scale wind turbines, the diameter of wind turbine flanges is getting larger and larger, the weight of products is getting larger and larger, and the difficulty of manufacturing is also increasing. In the early manufacturing process, in order to ensure that large-diameter flanges are difficult to process due to large ovality during the production process and to ensure the smooth delivery of wind turbine flanges, the margin of the blank is usually increased, so the production cost is greatly increased.

[0003] Nowadays, the process of wind power flange manufacturing has begun to be improved. By adopting near-net forming methods, the goals of reducing costs, increasing efficiency, saving energy and reducing consumption are achieved, thereby improving market competitiveness.

[0004] Wind power flanges are generally divided into three types according to their shapes: top flanges (higher sub-mouths), L-shaped flanges (middle flanges) and T-shaped flanges (bottom flanges). The traditional production process of wind power flanges is: raw material cutting - heating - forging and blanking - ring rolling machine rolling near net forming - heat treatment - machining. According to the shapes of different cross-sections of wind power flanges, the manufacturing methods are divided into cone roller near net forming and core roller near net forming (main roller and core roller double special shapes are also used). Among them, the wind power top flange is a product with small diameter and high height. The height rolling amount is small during rolling, and the radial rolling amount is large. At the same time, it is affected by factors such as large weight of the cutting material and small rolling height of the ring rolling machine. The traditional selection of rectangular cross-section production will result in low raw material utilization, long processing time, and high production costs. Summary of the invention

[0005] In order to solve the problems of low raw material utilization, long processing time and high production cost caused by traditional selection of rectangular cross-section for production of wind turbine top flanges, the present invention provides a method for rolling wind turbine top flanges using a core roller double-station mold.

[0006] The present invention is achieved through the following technical solutions: A method for rolling a wind turbine top flange using a core roller double-station die, comprising a rolling device, the rolling device comprising a main roller, a core roller double-station die, a cone roller and a rolling platform, the core roller double-station die being provided with a stepped truncated table structure, comprising a thinner first rolling section and a thicker second rolling section; The method comprises the following steps: S1: The first rolling section of the core roller double-station mold rolls the blank into a rectangular ring shape; S2: The first rolling section and the second rolling section of the core roller double-station mold jointly perform radial rolling of the blank to a near-net shape.

[0007] A further improvement of the present invention is that in S1, the height and the edge width of the blank decrease linearly.

[0008] A further improvement of the present invention is that after S1, the following steps are included: S11: The core roller double-station mold position is switched, and the core roller double-station mold is moved downward so that the second rolling section on the core roller double-station mold contacts the upper part of the inner ring of the blank.

[0009] A further improvement of the present invention is that S2 comprises: S21: the second rolling section of the core roller double-station mold radially rolls the blank until the first rolling section of the core roller double-station mold contacts the inner ring of the blank; S22: The second rolling section and the first rolling section of the core roller double-station mold roll the billet.

[0010] A further improvement of the present invention is that in S2, the thickness and edge width of the blank decrease linearly.

[0011] A further improvement of the present invention further comprises S3: the ring is made round.

[0012] A further improvement of the present invention is that the original height and side width of the billet are H and W respectively; the height and side width of the billet after rolling are h and w respectively; H=h+100mm; W=2w.

[0013] A further improvement of the present invention is that in S1, the rolling amount of the billet side width is 50 mm, and the rolling amount of the billet height is 50-70 mm.

[0014] A further improvement of the present invention is that in S2, the edge width rolling amount of the billet is greater than 100 mm.

[0015] A further improvement of the present invention is that in S3, the height of the billet remains unchanged and the edge width rolling amount is ≤10 mm.

[0016] It can be seen from the above technical solutions that the beneficial effects of the present invention are: A core roller double-station mold (first rolling section and second rolling section) is used to roll the wind turbine top flange, and force is continuously applied to the main roller in the diameter direction and the cone roller in the height direction to gradually form the rectangular cross-section into a special-shaped cross-section. There is no need to replace the core roller, only the workstation needs to be switched, which effectively improves processing efficiency, reduces production costs, and saves raw materials. The first rolling section of the core roller double-station mold is used alone to roll rings with rectangular cross-sections, which does not affect its normal use and has a certain degree of versatility. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] In order to more clearly illustrate the technical solution of the present invention, the accompanying drawings required for use in the description will be briefly introduced below. Obviously, the accompanying drawings in the following description are only some embodiments of the present invention. For ordinary technicians in this field, other accompanying drawings can be obtained based on these accompanying drawings without paying creative work.

[0018] Figure 1 It is a schematic cross-sectional view of a wind turbine top flange according to a specific embodiment of the present invention.

[0019] Figure 2 This is a rolling process curve diagram of a core roller double-station mold according to a specific embodiment of the present invention.

[0020] Figure 3 It is a schematic diagram of a rolling process according to a specific embodiment of the present invention.

[0021] Figure 4 This is a schematic diagram of the second rolling process according to a specific embodiment of the present invention.

[0022] Figure 5 Schematic diagram of the rolling process according to the specific embodiment of the present invention.

[0023] In the attached drawings: 1. main roller, 2. core roller double-station mold, 21. first rolling section, 22. second rolling section, 3. tapered roller, 4. blank, 5. rolling platform. DETAILED DESCRIPTION

[0024] In order to make the purpose, features and advantages of the present invention more obvious and easy to understand, the technical scheme of the present invention will be clearly and completely described below in conjunction with the drawings in this specific embodiment. Obviously, the embodiments described below are only part of the embodiments of the present invention, not all of them. Based on the embodiments in this patent, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of this patent.

[0025] Ring rolling is a process in which the width and height of the billet are reduced simultaneously while the inner and outer diameters are continuously increased.

[0026] The present invention discloses a method for rolling a wind turbine top flange using a core roller double-station die, comprising a rolling device, such as Figure 3-5 As shown, the rolling device includes a main roll 1, a core roll double-station mold 2, a tapered roll 3 and a rolling platform 5. The core roll double-station mold 2 is provided with a stepped truncated cone structure, including a first rolling section 21 with a thinner bottom and a second rolling section 22 with a thicker top; the main roll 1 and the core roll double-station mold 2 are rotated to roll the side width, and the tapered roll 3 is rotated to roll the height; The method comprises the following steps: S1: The first rolling section 21 of the core roller double-station mold 2 rolls the blank 4 into a rectangular ring shape; S2: The first rolling section 21 and the second rolling section 22 of the core roller double-station die 2 jointly perform near-net-shape radial rolling on the blank 4. The core roller double-station die 2 continuously applies force to the main roller 1 in the diameter direction and the tapered roller 3 in the height direction, thereby realizing the manufacturing process in which the rectangular cross section is gradually formed into a special-shaped cross section.

[0027] The wind turbine top flange is rolled using a core roller double-station mold 2 (a first rolling section 21 and a second rolling section 22). Force is continuously applied to the main roller 1 in the diameter direction and to the cone roller 3 in the height direction, so that the rectangular cross-section is gradually formed into a special-shaped cross-section. There is no need to replace the core roller, only the workstation needs to be switched, which effectively improves the processing efficiency, simplifies the process, reduces production costs, and saves raw materials. The first rolling section 21 of the core roller double-station mold 2 is used alone to roll rings with rectangular cross-sections, which does not affect its normal use and has a certain degree of versatility.

[0028] Also includes S3: Ring full circle.

[0029] After S1 , the following further includes: S11 : switching the core roller double-station mold 2 , moving the core roller double-station mold 2 downward, so that the second rolling section 22 on the core roller double-station mold 2 contacts the upper part of the inner ring of the blank 4 .

[0030] Further, S2 includes: S21: the second rolling section 22 of the core roller double-station mold 2 radially rolls the blank 4 until the first rolling section 21 of the core roller double-station mold 2 contacts the inner ring of the blank 4; S22: the second rolling section 22 and the first rolling section 21 of the core roller double-station mold 2 roll the blank 4.

[0031] Among them, Figure 2 As shown, A1-A2 is the S1 rolling process; A2-A3 is the S11 process; A3-A4 is the S2 rolling process. The original height and side width of billet 4 are H and W respectively; the height and side width of billet 4 after rolling are h (h must be greater than or equal to the minimum working height of cone roller 3) and w respectively; the w wing plate is required to be greater than 150mm; Among them, H=h+100mm, ensuring sufficient rolling amount in height; W=2w, so that the billet 4 has a certain radial rolling amount during the rolling process to ensure the final forming.

[0032] Among them, S1 rounds the blank 4, and the height and side width of the blank 4 in S1 decrease linearly. The rolling amount of the side width of the blank 4 is 50mm (W-W1), and the rolling amount of the height of the blank 4 is 50-70mm (H-H1), that is, H1=h+(30~50)mm. The rolling amount of the height is as large as possible to ensure the reliability of the roundness of the blank 4, prevent the cross-sectional deformation caused by the large height reduction during the subsequent special-shaped rolling, and ensure sufficient radial rolling amount to ensure forming.

[0033] Among them, in S11, the thickness of blank 4 remains unchanged and the change in edge width can be ignored ( Figure 2 W1 to W2 are only for reference of process principle, i.e. W1 is approximately equal to W2).

[0034] In S2, the thickness and side width of the blank 4 decrease linearly. In S2, the side width rolling amount of the blank 4 is greater than 100mm, that is, W2 -W3>100mm; the thickness rolling amount (H1-h) is determined according to the required plate thickness to ensure that the first rolling section 21 and the second rolling section 22 can fully contact the inner diameter of the blank 4, and finally roll to form a heterogeneous cross-section ring (wind turbine top flange).

[0035] In S3, the height of the billet 4 remains unchanged, and the edge width rolling amount (W3-w) is ≤10mm, ensuring rolling accuracy.

[0036] The method for rolling the wind turbine top flange using a core roller double-station mold adopts a core roller double-station mold 2 (a first rolling section 21 and a second rolling section 22) to roll the wind turbine top flange, and continuously applies force to the main roller 1 in the diameter direction and the cone roller 3 in the height direction, so that the rectangular cross-section is gradually formed into a special-shaped cross-section. There is no need to replace the core roller, and only the workstation needs to be switched, which effectively improves the processing efficiency, reduces the production cost, and saves raw materials. The first rolling section 21 of the core roller double-station mold 2 is used alone to roll a ring with a rectangular cross-section, which does not affect its normal use and has certain versatility.

[0037] The above description of the disclosed embodiments enables one skilled in the art to implement or use the present invention. Various modifications to these embodiments will be apparent to one skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention will not be limited to the embodiments shown herein, but rather to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A method for rolling a wind turbine top flange using a core roller double-station die, characterized in that: The rolling device comprises a main roller (1), a core roller double-station mold (2), a tapered roller (3) and a rolling platform (5); the core roller double-station mold (2) is provided with a stepped truncated cone structure, comprising a thinner first rolling section (21) and a thicker second rolling section (22); The method comprises the following steps: S1: rolling the blank (4) into a rectangular ring shape through the first rolling section (21) of the core roller double-station mold (2); S2: The first rolling section (21) and the second rolling section (22) of the core roller double-station mold (2) are used together to radially roll the blank (4) to a near-net shape.

2. The method for rolling a wind turbine top flange using a core roller double-station mold according to claim 1 is characterized in that: In S1, the height and side width of the blank (4) decrease linearly.

3. The method for rolling a wind turbine top flange using a core roller double-station mold according to claim 1 is characterized in that: After S1, it also includes: S11: The core roller double-station mold (2) is switched to a different station, and the core roller double-station mold (2) is moved downward so that the second rolling section (22) on the core roller double-station mold (2) contacts the upper portion of the inner ring of the blank (4).

4. The method for rolling a wind turbine top flange using a core roller double-station mold according to claim 3, characterized in that S2 include: S21: the second rolling section (22) of the core roller double-station mold (2) radially rolls the blank (4) until the first rolling section (21) of the core roller double-station mold (2) contacts the inner ring of the blank (4); S22: The second rolling section (22) and the first rolling section (21) of the core roller double-station mold (2) roll the blank (4).

5. The method for rolling a wind turbine top flange using a core roller double-station mold according to claim 4 is characterized in that: In S2, the thickness and edge width of the blank (4) decrease linearly.

6. The method for rolling a wind turbine top flange using a core roller double-station mold according to claim 1, characterized in that: Also includes S3: Ring full circle.

7. The method for rolling a wind turbine top flange using a core roller double-station mold according to claim 1 is characterized in that: The original height and side width of the billet (4) are H and W respectively; the height and side width of the billet (4) after rolling are h and w respectively; H=h+100mm; W=2w.

8. The method for rolling a wind turbine top flange using a core roller double-station mold according to claim 2 is characterized in that: In S1, the rolling amount of the side width of the billet (4) is 50 mm, and the rolling amount of the height of the billet (4) is 50-70 mm.

9. The method for rolling a wind turbine top flange using a core roller double-station mold according to claim 5, characterized in that: In S2, the edge width rolling amount of the billet (4) is greater than 100 mm.

10. The method for rolling a wind turbine top flange using a core roller double-station mold according to claim 6, characterized in that: In S3, the height of the billet (4) remains unchanged and the edge width rolling amount is ≤10 mm.

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