Water tunnel corner flow deflector and manufacturing method thereof

Abstract

The invention provides a water tunnel corner flow deflector and a manufacturing method thereof, and relates to the technical field of water tunnel flow deflectors, the water tunnel corner flow deflector comprises a first outer panel and a second outer panel, the first outer panel and the second outer panel are arc-shaped plates, the two ends of the first outer panel are connected with the two ends of the second outer panel respectively, and a gap is formed between the first outer panel and the second outer panel; the at least two reinforcing rib plates are arranged in the gap and connected with the first outer panel and the second outer panel, a cavity is formed between the first outer panel and the second outer panel, and the cavity is filled with force-bearing damping filler; the problems that in the prior art, the size precision of a water tunnel corner flow deflector is difficult to guarantee, machining is more depended in the manufacturing process, the machining cost is high, and the machining period is long are solved.

Description

Technical Field

[0001] The present invention belongs to the technical field of water tunnel guide vanes, and more specifically, relates to a water tunnel corner guide vane and a manufacturing method thereof. Background Art

[0002] Guide vanes are usually installed at the bends of fluid delivery pipelines. The main function of the guide vanes is to optimize the flow direction of the fluid and improve the flow efficiency. The operating principle of low-speed fluid test equipment is similar to that of fluid delivery pipelines. Commonly used fluid test equipment includes recirculation wind tunnels and water tunnels. In low-speed fluid test equipment, due to test requirements, higher requirements are placed on indicators such as the uniformity of fluid flow velocity, so higher requirements are placed on guide vanes at corners. In addition to guiding the fluid, the main function of the corner guide vanes in low-speed fluid test equipment is to prevent airflow separation, break up vortices, and form a uniform velocity field at the corner outlet section.

[0003] The processing accuracy of corner guide vanes is an important factor in ensuring the uniformity of the flow field at the corner outlet. The existing processing techniques for corner guide vanes of water tunnels are mostly the same as those for corner guide vanes of low-speed wind tunnels. The role and function of corner guide vanes of water tunnels are basically the same as those of wind tunnels. However, the working medium of corner guide vanes of water tunnels is water. At the same time, they need to withstand water pressure and prevent the influence of guide vane vibration. Therefore, the structural form and manufacturing process of guide vanes also need to be different.

[0004] With the advancement of technology, the requirements for flow field accuracy and noise indicators in water tunnel tests are constantly increasing, and the requirements for the structure and processing accuracy of the guide vanes are also constantly increasing. The structure and processing technology of the guide vanes of traditional wind tunnels can no longer meet the current high requirements for water tunnel corner guide vanes in terms of comprehensive indicators such as accuracy indicators, processing cycle and production cost.

[0005] Existing corner guide vanes are generally welded together by longitudinal beams, transverse frames and skins. The longitudinal beams and transverse frames constitute a frame, and the skin forms a smooth shape. In order to form the required airfoil profile shape, the transverse frame shape is a machined wing profile shape, and then the skin is pressed and fitted to the frame through a mold to ensure that the skin and the frame fit tightly and then spot welded to fix them. In the water tunnel equipment, the corner guide vane needs to withstand the water pressure and the test pressure. At the same time, the force generated by the internal pressure of the water tunnel shell is transmitted to the water tunnel guide vane. The bearing conditions of the guide vane are essentially different from those of the low-speed wind tunnel. Therefore, the type of the skin on the surface of the guide vane frame in the existing wind tunnel cannot meet the strength index requirements of the water tunnel guide vane, and the deviation between the shape of the guide vane made according to the existing processing and manufacturing process and the theoretical airfoil surface is usually between 3 and 5 mm. In the case of low flow field uniformity requirements of the fluid test equipment, this accuracy can usually meet the use requirements, but in some high-index water tunnel test equipment, the flow field uniformity requirements are high, and this accuracy is difficult to guarantee the flow field index requirements. The accuracy index of the corner guide vane in some water tunnel test equipment requires a deviation of less than 1 mm. In order to achieve the accuracy index, the current solution is usually to perform overall machining after the guide vane is completed to meet the index requirements, but the overall machining cost of the guide vane is very high and the processing cycle is long. Summary of the invention

[0006] The purpose of the present invention is to provide a water tunnel corner guide plate and a method for manufacturing the same in order to address the deficiencies in the prior art, so as to solve the problems in the prior art that the dimensional accuracy of the water tunnel corner guide plates is difficult to ensure, the manufacturing process relies heavily on machining, the processing cost is high, and the processing cycle is long.

[0007] In order to achieve the above object, the present invention provides a water tunnel corner guide vane, comprising:

[0008] A first outer panel and a second outer panel, wherein the first outer panel and the second outer panel are arc-shaped panels, two ends of the first outer panel are respectively connected to two ends of the second outer panel, and a gap is formed between the first outer panel and the second outer panel;

[0009] At least two reinforcing ribs are arranged in the gap and connected to the first outer panel and the second outer panel, a cavity is formed between the first outer panel and the second outer panel, and the cavity is filled with load-bearing and vibration-damping fillers.

[0010] Optionally, two ends of the first outer panel are continuously welded to two ends of the second outer panel respectively.

[0011] Optionally, two sides of the reinforcing rib plate are plug-welded to the first outer panel and the second outer panel respectively.

[0012] Optionally, a plurality of reinforcing rib plates are provided, wherein the two outermost reinforcing rib plates are continuously welded to the first outer panel and the second outer panel.

[0013] Optionally, the reinforcing rib plate is provided with a pouring port and an exhaust port.

[0014] Optionally, a blocking structure is further included, wherein the blocking structure blocks the pouring port and the exhaust port.

[0015] Optionally, the load-bearing and vibration-damping filler is cement or water.

[0016] The present invention also provides a method for manufacturing a water tunnel corner guide vane, which is used to manufacture the water tunnel corner guide vane, comprising:

[0017] Cutting the first outer panel and the second outer panel;

[0018] Press-forming the first outer panel and the second outer panel;

[0019] Providing a mold, wherein a receiving groove is provided inside the mold, and the receiving groove is used to receive and position the first outer panel and the second outer panel;

[0020] Place the first outer panel and the second outer panel into the receiving groove of the mold for positioning, and place the reinforcing rib plate at a set position between the first outer panel and the second outer panel;

[0021] Welding the first outer panel, the second outer panel and the reinforcing rib plate;

[0022] Conduct stress relief treatment;

[0023] Remove the mold;

[0024] Fill the chamber with load-bearing and vibration-damping filler.

[0025] Optionally, the mold includes an upper mold and a lower mold that are detachably connected, and the lower mold and the upper mold are respectively provided with a concave mold and a convex mold on the sides close to each other, and the surface shapes of the concave mold and the convex mold are the theoretical shapes of the back-water surface and the front-water surface of the water tunnel corner guide plate.

[0026] Optionally, before cutting the first outer panel and the second outer panel, the method further includes:

[0027] Polishing the surface of the steel plate;

[0028] Paste parchment paper on the surface of the steel plate.

[0029] The present invention provides a water tunnel corner guide plate and a manufacturing method thereof, which has the beneficial effects that: the water tunnel corner guide plate is formed of a first outer panel and a second outer panel to form a water-facing surface and a water-receiving surface, and at the same time serves as a load-bearing structure; the first outer panel and the second outer panel are both made of thicker steel plates than traditional skins; no load-bearing frame is provided inside the guide plate; at the same time, reinforcing ribs are arranged inside the first outer panel and the second outer panel for reinforcement; the guide plate is filled with incompressible load-bearing and vibration-damping fillers to improve the load-bearing capacity and eliminate cavity resonance; the weight is increased to reduce the resonant frequency of the guide plate, so as to reduce vibration during use; during the manufacturing process of the water tunnel corner guide plate, there is no need to machine the frame shape thereof, nor is there any need to machine the entire skin to meet the appearance index requirements; the shape of the first outer panel and the second outer panel can be formed by bending, and a mold can be used for positioning during the welding forming process, which can reduce the dependence on machining during the manufacturing process and better ensure the dimensional accuracy of the guide plate.

[0030] Other features and advantages of the present invention will be described in detail in the following detailed description. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] The above and other objects, features and advantages of the present invention will become more apparent through a more detailed description of exemplary embodiments of the present invention in conjunction with the accompanying drawings, wherein like reference numerals generally represent like components throughout the exemplary embodiments of the present invention.

[0032] Figure 1 A schematic structural diagram of a water tunnel corner guide vane according to an embodiment of the present invention is shown.

[0033] Figure 2 A flow chart of a method for manufacturing a water tunnel corner guide vane according to an embodiment of the present invention is shown.

[0034] Description of the reference numerals in the figures:

[0035] 1. First outer panel; 2. Second outer panel; 3. Reinforcement rib plate; 4. Continuous weld; 5. Plug weld point; 6. Pouring port; 7. Exhaust port; 8. Upper mold; 9. Lower mold; 10. Connecting bolts. DETAILED DESCRIPTION

[0036] The preferred embodiments of the present invention will be described in more detail below. Although the preferred embodiments of the present invention are described below, it should be understood that the present invention can be implemented in various forms and should not be limited by the embodiments set forth herein. On the contrary, these embodiments are provided to make the present invention more thorough and complete, and to fully convey the scope of the present invention to those skilled in the art.

[0037] like Figure 1As shown, the present invention provides a water tunnel corner guide vane, comprising:

[0038] A first outer panel 1 and a second outer panel 2, wherein the first outer panel 1 and the second outer panel 2 are arc-shaped panels, and two ends of the first outer panel 1 are respectively connected to two ends of the second outer panel 2, forming a gap between the first outer panel 1 and the second outer panel 2;

[0039] At least two reinforcing ribs 3 are arranged in the gap and connected to the first outer panel 1 and the second outer panel 2. A cavity is formed between the first outer panel 1 and the second outer panel 2, and the cavity is filled with load-bearing and vibration-damping fillers.

[0040] Specifically, in order to solve the problem that the dimensional accuracy of the water tunnel corner guide vane in the prior art is difficult to ensure, and the manufacturing process relies heavily on machining, the processing cost is high, and the processing cycle is long; the water tunnel corner guide vane provided by the present invention is formed by the first outer panel 1 and the second outer panel 2 to form the water-facing surface and the water-receiving surface, and at the same time serves as a load-bearing structure, the first outer panel 1 and the second outer panel 2 are both made of thicker steel plates than the traditional skin, and there is no load-bearing frame inside the guide vane. At the same time, the first outer panel 1 and the second outer panel 2 are provided with reinforcing ribs 3 for reinforcement, and the guide vane is filled with incompressible load-bearing and vibration-damping fillers to improve the load-bearing capacity, eliminate the cavity resonance, and increase the weight to reduce the resonant frequency of the guide vane to reduce the vibration during use. During the manufacturing process of the water tunnel corner guide vane, there is no need to machine the frame shape, nor is there any need to machine the skin as a whole to meet the appearance index requirements. The shape of the first outer panel 1 and the second outer panel 2 can be formed by bending, and a mold can be used for positioning during the welding forming process, which can not only reduce the dependence on machining during the manufacturing process, but also better ensure the dimensional accuracy of the guide vane.

[0041] In this embodiment, the thickness of the first outer panel 1 and the second outer panel 2 is greater than 20 mm.

[0042] Optionally, two ends of the first outer panel 1 are continuously welded to two ends of the second outer panel 2 respectively.

[0043] Specifically, the two ends of the first outer panel 1 and the second outer panel 2 are connected by a continuous weld 4 so that the two ends of the gap are closed.

[0044] Optionally, two sides of the reinforcing rib plate 3 are plug-welded to the first outer panel 1 and the second outer panel 2 respectively.

[0045] Specifically, the shape of the reinforcing rib plate 3 is the same as the cross-sectional shape of the gap, and the plug welding point 5 can be used to achieve a fixed connection with the first outer panel 1 and the second outer panel 2 to strengthen the guide vane.

[0046] Optionally, a plurality of reinforcing rib plates 3 are provided, wherein the two outermost reinforcing rib plates 3 are continuously welded to the first outer panel 1 and the second outer panel 2 .

[0047] Specifically, the two outermost reinforcing ribs 3 are fixed to the first outer panel 1 and the second outer panel 2 by plug welding, and continuous welding is also used to seal the cavity inside the guide vane so as to fill the interior of the guide vane with load-bearing and vibration-damping fillers.

[0048] Optionally, the reinforcing rib plate 3 is provided with a pouring port 6 and an exhaust port 7 .

[0049] Specifically, the pouring port 6 is used to pour the load-bearing and vibration-damping filler into the guide plate, and the exhaust port 7 can exhaust gas during the pouring process of the load-bearing and vibration-damping filler to ensure that the load-bearing and vibration-damping filler is fully filled.

[0050] Optionally, a blocking structure is also included, and the blocking structure blocks the pouring port 6 and the exhaust port 7 .

[0051] Specifically, the sealing structure may adopt a welding sealing structure and a mechanical sealing component, which is used to seal the cavity behind the cavity inside the guide plate of the load-bearing and vibration-damping filler.

[0052] Optionally, the load-bearing and vibration-damping filler is cement or water.

[0053] Specifically, the load-bearing and vibration-damping filler is made of cement or water, which significantly increases the weight to improve the load-bearing capacity and prevent cavity resonance, while being able to reduce the resonance frequency of the guide vane.

[0054] like Figure 2 As shown, the present invention also provides a method for manufacturing a water tunnel corner guide vane, which is used to manufacture the water tunnel corner guide vane, comprising:

[0055] Cutting the first outer panel 1 and the second outer panel 2;

[0056] Press-forming the first outer panel 1 and the second outer panel 2;

[0057] Providing a mold, wherein a receiving groove is provided inside the mold, and the receiving groove is used to receive and position the first outer panel 1 and the second outer panel 2;

[0058] Place the first outer panel 1 and the second outer panel 2 into the receiving groove of the mold for positioning, and place the reinforcing rib plate 3 at a set position between the first outer panel 1 and the second outer panel 2;

[0059] Welding the first outer panel 1, the second outer panel 2 and the reinforcing rib plate 3;

[0060] Conduct stress relief treatment;

[0061] Remove the mold;

[0062] Fill the chamber with load-bearing and vibration-damping filler.

[0063] Specifically, when the above-mentioned water tunnel corner guide plate is manufactured, after the first outer panel 1 and the second outer panel 2 are cut and pressed into shape, the first outer panel 1, the second outer panel 2 and the reinforcing rib plate 3 therebetween are positioned by a mold, and welding is performed after positioning. After welding, the mold is subjected to stress relief treatment to improve dimensional accuracy. Thereafter, the mold is removed and load-bearing and vibration-damping fillers are filled inside the guide plate to improve its load-bearing capacity and reduce vibrations generated during use.

[0064] In this embodiment, a polishing machine is used to polish the outer surfaces of the raw materials of the first outer panel and the second outer panel steel plates; the first outer panel and the second outer panel are cut by laser; and parchment paper is pasted on the surfaces of the first outer panel and the second outer panel steel plates for protection before press molding.

[0065] Optionally, the mold includes an upper mold 8 and a lower mold 9 that are detachably connected, and the lower mold 9 and the upper mold 8 are respectively provided with a concave mold and a convex mold on the sides close to each other, and the surface shapes of the concave mold and the convex mold are the theoretical shapes of the back-water surface and the front-water surface of the water tunnel corner guide plate.

[0066] Specifically, the concave and convex parts of the upper mold 8 and the lower mold 9 need to be precisely machined to ensure that the shapes of the concave and convex molds and the mold cavity therebetween exactly match the theoretical shape of the guide vane when the molds are closed, thereby ensuring the shape accuracy of the guide vane.

[0067] In this embodiment, the upper mold 8 and the lower mold 9 are both plate-like structures. The lower mold 9 and the upper mold 8 are fixedly connected by connecting ears and connecting bolts 10 to achieve mold closing. The lower mold 9 and the upper mold 8 are made by welding steel sections. After the mold is made, machining is performed to ensure the shape accuracy of the die and the punch.

[0068] Optionally, before cutting the first outer panel 1 and the second outer panel 2, the method further includes:

[0069] Polishing the surface of the steel plate;

[0070] Paste parchment paper on the surface of the steel plate.

[0071] Specifically, the surface finish of the steel plate is made higher than Ra1.6 by polishing to reduce the friction between the high-speed water flow and the guide vane and the vibration caused by the uneven surface. Parchment paper is pasted on the surface of the steel plate to protect the surface from damage during the manufacturing process.

[0072] In summary, during the actual production of the water tunnel corner guide vane provided by the present invention, a single production is taken as an example: (1) the surface of the steel plate is polished to ensure that its surface finish is higher than Ra1.6; (2) parchment paper is pasted on the surface of the steel plate to protect its surface from damage during the manufacturing process; (3) the first outer panel 1 and the second outer panel 2 are cut according to the theoretical size, and a margin is left during the cutting process so that their lengths can be controlled later; (4) the first outer panel 1 and the second outer panel 2 are pressed and formed according to the theoretical contour; (5) the first outer panel 1 and the second outer panel 2 and the reinforcing rib plate 3 therebetween are positioned in the mold; (6) the upper mold 8 and the lower mold 9 are tightened by bolts, and the first outer panel 1 and the second outer panel 2 are fine-tuned before tightening. The positions of the outer panel 1 and the second outer panel 2 and the reinforcing rib plate 3 between them are such that the second outer panel 2 and the first outer panel 1 are fitted with the concave mold and the convex mold respectively as much as possible, and the bolts are tightened in place to ensure the outer contour size and accuracy of the guide plate; (7) The first outer panel 1 and the second outer panel 2 are fixed with the reinforcing rib plates 3 inside them by the welding points 5 to ensure the molding accuracy of the guide plate; (8) The guide plate continuous weld 4 is welded with a small current; (9) The guide plate and the mold are placed in a vibration stress relief device for vibration stress relief treatment; (10) The weld surface is polished; (11) Stress relief heat treatment; (12) The mold is removed; (13) The guide plate is filled with cement or water; (14) The pouring port 6 and the exhaust port 7 are sealed. Through the above process links, the influence of welding stress factors is reduced, and the accuracy of the guide plate after production is ensured to meet the design index requirements; at the same time, the mold accuracy is designed to ensure that the deviation between the outer contour of the guide plate and the theoretical contour is less than 1mm with as little machining as possible.

[0073] The embodiments of the present invention have been described above, and the above description is exemplary, not exhaustive, and is not limited to the disclosed embodiments. Many modifications and changes will be apparent to those skilled in the art without departing from the scope and spirit of the described embodiments.

Claims

1. A water tunnel corner guide vane, characterized in that: include: A first outer panel and a second outer panel, wherein the first outer panel and the second outer panel are arc-shaped panels, two ends of the first outer panel are respectively connected to two ends of the second outer panel, and a gap is formed between the first outer panel and the second outer panel; At least two reinforcing ribs are arranged in the gap and connected to the first outer panel and the second outer panel, a cavity is formed between the first outer panel and the second outer panel, and the cavity is filled with load-bearing and vibration-damping fillers.

2. The water tunnel corner guide vane according to claim 1, characterized in that: Two ends of the first outer panel are respectively continuously welded to two ends of the second outer panel.

3. The water tunnel corner guide vane according to claim 1, characterized in that: Two sides of the reinforcing rib plate are plug-welded to the first outer panel and the second outer panel respectively.

4. The water tunnel corner guide vane according to claim 3, characterized in that: A plurality of reinforcing rib plates are provided, wherein two outermost reinforcing rib plates are continuously welded to the first outer panel and the second outer panel.

5. The water tunnel corner guide vane according to claim 1, characterized in that: The reinforcing rib plate is provided with a pouring port and an exhaust port.

6. The water tunnel corner guide vane according to claim 5, characterized in that: It also includes a blocking structure, which blocks the pouring port and the exhaust port.

7. The water tunnel corner guide vane according to claim 1, characterized in that: The load-bearing and vibration-damping filler is cement or water.

8. A method for manufacturing a water tunnel corner guide vane, used for manufacturing the water tunnel corner guide vane according to any one of claims 1 to 7, characterized in that: include: Cutting the first outer panel and the second outer panel; Press-forming the first outer panel and the second outer panel; Providing a mold, wherein a receiving groove is provided inside the mold, and the receiving groove is used to receive and position the first outer panel and the second outer panel; Place the first outer panel and the second outer panel into the receiving groove of the mold for positioning, and place the reinforcing rib plate at a set position between the first outer panel and the second outer panel; Welding the first outer panel, the second outer panel and the reinforcing rib plate; Conduct stress relief treatment; Remove the mold; Fill the chamber with load-bearing and vibration-damping filler.

9. The method for manufacturing a water tunnel corner guide vane according to claim 8, characterized in that: The mold comprises an upper mold and a lower mold that are detachably connected, and the lower mold and the upper mold are respectively provided with a concave mold and a convex mold on the sides close to each other, and the surface shapes of the concave mold and the convex mold are the theoretical shapes of the back-water surface and the front-water surface of the water tunnel corner guide plate.

10. The method for manufacturing a water tunnel corner guide vane according to claim 8, characterized in that: Before cutting the first outer panel and the second outer panel, the method further includes: Polishing the surface of the steel plate; Paste parchment paper on the surface of the steel plate.

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