Rapid and efficient generator carbon brush grinding equipment

Abstract

The invention discloses rapid and efficient generator carbon brush grinding equipment, and relates to the technical field of electrical equipment auxiliary devices, the rapid and efficient generator carbon brush grinding equipment comprises a main support and a carbon brush body, a highlight polishing cutter, a cross-shaped sliding table, a cam groove plate, a cam follower, a carbon brush body, an end point sensor, a servo motor, an original point sensor, a fixing clamp and a high-speed main shaft are arranged above the workbench, the highlight polishing cutter is rotationally connected with the lower end of the high-speed main shaft, and the highlight polishing cutter is a high-speed rotating alloy polishing highlight cutter. The cross-shaped sliding table is installed above the workbench, and the servo motor is fixedly installed on an X-axis lead screw seat of the cross-shaped sliding table. By means of the specific implementation mode, the carbon brush grinding equipment can stably and efficiently achieve high-quality grinding of a carbon brush, the structure and process advantages of the carbon brush grinding equipment are fully played, the carbon brush grinding efficiency is improved, and the carbon brush grinding efficiency is improved. And the strict performance requirement of the hydro-generator on the carbon brush is met.

Description

Technical Field

[0001] The present invention relates to the technical field of auxiliary devices for power equipment, and particularly to a fast and efficient carbon brush grinding device for generators. Background Technique

[0002] During the operation of a hydrogenerator, the carbon brush is one of the key components to ensure the stable transmission of electric energy. It makes close contact with the slip ring to achieve current conduction. Since the carbon brush will wear during long-term operation, when the wear amount exceeds a certain level, it needs to be replaced. The end face of a new carbon brush is usually flat, while the surface of the slip ring is arc-shaped. To ensure good contact between the carbon brush and the slip ring, reduce the generation of electric arcs and wear, the new carbon brush must be ground into an arc surface adapted to the slip ring.

[0003] Traditional grinding methods mostly rely on manual operation. The operator holds the carbon brush and grinds it on the slip ring. This method is extremely inefficient and is strictly limited by the power outage time of the generator, making it difficult to ensure the grinding quality and timeliness. Although some automatic grinding devices have emerged in recent years, they generally have problems such as complex structures, large volumes, insufficient machining accuracy, waste of consumables, and easy blockage of cutting edges, and cannot effectively meet the high-efficiency and high-precision requirements of the power system for carbon brush grinding, affecting the stable operation of the generator and the power production efficiency.

[0004] Therefore, we propose a fast and efficient carbon brush grinding device for generators. Summary of the Invention

[0005] The purpose of the present invention is to provide a fast and efficient carbon brush grinding device for generators to solve the problems raised in the above background technique.

[0006] To achieve the above purpose, the present invention provides the following technical solution: A fast and efficient carbon brush grinding device for generators, including a general support and a carbon brush body. A workbench is slidably installed on the general support. Above the workbench, there are a high-gloss grinding tool, a cross slide, a cam groove plate, a cam follower, a carbon brush body, an end point sensor, a servo motor, an origin sensor, a fixed fixture, and a high-speed spindle.

[0007] The effects achieved by the above components are as follows: The carbon brush grinding device with the above structure can stably and efficiently achieve high-quality grinding of carbon brushes, give full play to its structural and technological advantages, meet the strict performance requirements of carbon brushes for hydrogenerators, and provide strong support for the safe and stable operation of the power system.

[0008] Preferably, the lower ends of the high-gloss grinding tool and the high-speed spindle are rotatably connected, and the high-gloss grinding tool is a high-speed rotating alloy grinding high-gloss tool.

[0009] The effects achieved by the above components are as follows: Abandoning the traditional sandpaper grinding method, a high-speed rotating alloy polishing high-light knife is introduced. This polishing knife is made of special alloy materials and has high hardness, high wear resistance, and good cutting performance. When the equipment is running, the high-light knife rotates at high speed driven by a high-speed spindle. During a single processing operation, by reasonably controlling parameters such as the rotational speed, feed rate, and cutting depth of the tool, the rough machining and finish machining of the carbon brush are integrated.

[0010] Preferably, the cross slide is installed above the workbench, and the servo motor is fixedly installed on the X-axis lead screw seat of the cross slide.

[0011] The effects achieved by the above components are as follows: Installing the drive motor on the X-axis lead screw seat of the cross slide ensures a firm installation and enables the drive motor to operate stably.

[0012] Preferably, a groove with a micro-curved surface structure is provided inside the cam groove plate, and a protrusion with a micro-curved surface structure is provided on the side of the inner side of the cam groove plate opposite to the groove.

[0013] The effects achieved by the above components are as follows: The cam groove plate is specially designed, and its contour curve precisely fits the requirements of the grinding motion trajectory, achieving efficient power transmission and motion conversion within a relatively small space layout.

[0014] Preferably, the carbon brush body is located inside the fixed fixture, and the fixed fixture includes a slider that is slidably connected to the upper side of the cross slide.

[0015] The effects achieved by the above components are as follows: To ensure the motion accuracy of the carbon brush during the grinding process, the equipment is equipped with a high-precision guiding mechanism, which is mainly composed of a precision guide rail and a slider. The guide rail is manufactured by a high-precision machining process, and the linearity and flatness errors of its surface are controlled within a very small range, ensuring that the carbon brush always maintains a linear motion trajectory during the motion process.

[0016] Preferably, the slider is made of a special self-lubricating material.

[0017] The effects achieved by the above components are as follows: The slider is made of a special self-lubricating material, and the friction coefficient between it and the guide rail is extremely low, effectively reducing the energy loss and wear during the motion process.

[0018] Preferably, the cam follower is installed on the Y-axis of the cross slide.

[0019] The effects achieved by the above components are as follows: Installing the cam follower on the Y-axis ensures its accurate installation position and enables it to move flexibly during subsequent motions. Then, install the cam groove wheel mechanism according to the design requirements to ensure the installation accuracy of the cam groove plate.

[0020] Compared with the prior art, the beneficial effects of the present invention are:

[0021] 1. The compact structure of the present invention makes the equipment small in size, which can be flexibly installed in various generator rooms with limited space, reducing the requirements for the installation site, improving the applicability and versatility of the equipment. At the same time, it reduces the floor area of the equipment, facilitating the layout and management of the equipment, and providing more convenience for the equipment configuration of the power system.

[0022] 2. The present invention uses a high-speed rotating alloy polishing and high-gloss tool to achieve roughing and finishing in one processing, greatly shortening the processing time and improving the production efficiency. Compared with the traditional sandpaper polishing method, it does not require frequent replacement of consumables, reducing the production cost and maintenance workload. Moreover, it effectively avoids the problem of graphite clogging the cutting edge, ensuring the cutting performance of the tool, extending the service life of the tool, and improving the overall operation stability and reliability of the equipment.

[0023] 3. The high-precision guiding mechanism ensures the accuracy and quality of carbon brush grinding, enabling the arc surface of the carbon brush to precisely match the surface of the slip ring, improving the contact performance between the carbon brush and the slip ring, reducing the generation of electric arcs and wear, extending the service life of the carbon brush and the slip ring, thereby ensuring the stable operation of the hydro-generator, reducing the risk of generator failure caused by carbon brush problems, and improving the power supply reliability and safety of the power system. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 is a schematic diagram of the overall structure of the present invention;

[0025] Figure 2 is a schematic diagram of the structure at the workbench of the present invention;

[0026] Figure 3 is a schematic diagram of the structure at the fixed fixture of the present invention;

[0027] Figure 4 is a schematic diagram of the structure at the cam groove plate of the present invention;

[0028] Figure 5 is another perspective schematic diagram of the cam groove plate of the present invention;

[0029] Figure 6 is a schematic diagram of the structure at the high-speed main shaft of the present invention;

[0030] Figure 7 in the present invention Figure 6 is another perspective schematic diagram.

[0031] In the figure: 1, workbench; 2, high-gloss polishing tool; 3, cross slide; 4, cam groove plate; 5, cam follower; 6, carbon brush body; 7, end sensor; 8, servo motor; 9, origin sensor; 10, high-speed main shaft; 11, fixed fixture; 12, groove; 13, protrusion; 14, general support. Detailed implementation manners

[0032] The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0033] Please refer to Figures 1-7 , the present invention provides a technical solution: a fast and efficient carbon brush grinding device for a generator, including a general support 14 and a carbon brush body 6.

[0034] The following specifically describes its overall specific settings and functions.

[0035] In this embodiment: a workbench 1 is slidably installed on the general support 14, and a high-gloss grinding knife 2, a cross slide 3, a cam groove plate 4, a cam follower 5, a carbon brush body 6, an end sensor 7, a servo motor 8, a home sensor 9, a fixed fixture 11 and a high-speed spindle 10 are arranged above the workbench 1. The carbon brush grinding device with the above structure can stably and efficiently achieve high-quality grinding of carbon brushes, give full play to its structural and technological advantages, meet the strict performance requirements of carbon brushes for hydro-generators, and provide strong support for the safe and stable operation of the power system.

[0036] Specifically, the high-gloss polishing tool 2 is rotatably connected to the lower end of the high-speed spindle 10, and the high-gloss polishing tool 2 is a high-speed rotating alloy polishing tool for high-gloss. Abandoning the traditional sandpaper polishing method and introducing a high-speed rotating alloy polishing tool for high-gloss, this polishing tool is made of special alloy materials and has high hardness, high wear resistance and good cutting performance. When the equipment is running, the high-gloss tool rotates at high speed driven by the high-speed spindle 10. In one processing process, by reasonably controlling parameters such as the rotational speed, feed rate and cutting depth of the tool, the rough machining and finish machining of the carbon brush are integrated. The cross slide 3 is installed above the workbench 1, and the servo motor 8 is fixedly installed on the X-axis lead screw seat of the cross slide 3. Installing the driving motor on the X-axis lead screw seat of the cross slide 3 ensures firm installation and enables the driving motor to operate stably. The inner side of the cam groove plate 4 is provided with a groove 12 with a micro-curved surface structure, and a protrusion 13 with a micro-curved surface structure is arranged on the side of the inner side of the cam groove plate 4 opposite to the groove 12. The cam groove plate 4 is specially designed, and its contour curve precisely fits the requirements of the grinding motion trajectory, realizing efficient power transmission and motion conversion within a small space layout. The carbon brush body 6 is located inside the fixed fixture 11, and the fixed fixture 11 includes a slider, and the slider is slidably connected to the upper side of the cross slide 3. To ensure the motion accuracy of the carbon brush during grinding, the equipment is equipped with a high-precision guiding mechanism, which is mainly composed of a precision guide rail and a slider. The guide rail is manufactured by a high-precision processing technology, and the linearity and flatness errors of its surface are controlled within a very small range to ensure that the carbon brush always maintains a linear motion trajectory during motion. The slider is made of special self-lubricating material. The slider is made of special self-lubricating material, and the friction coefficient between it and the guide rail is extremely low, effectively reducing the energy loss and wear during motion. The cam follower 5 is installed on the Y-axis of the cross slide 3. Installing the cam follower 5 on the Y-axis ensures its accurate installation position and enables it to move flexibly in subsequent motions. Then, install the cam groove wheel mechanism according to the design requirements to ensure the installation accuracy of the cam groove plate 4.

[0037] Working principle:

[0038] The core structure of this equipment combines the cam groove plate 4 mechanism with a linear linkage component: The cam groove plate 4 is specially designed, and its contour curve precisely fits the requirements of the grinding motion trajectory, realizing efficient power transmission and motion conversion within a small space layout. Through the close cooperation between the cam follower 5 and the cam groove plate 4, the rotational motion of the servo motor 8 is converted into a linear motion, which directly acts on the carbon brush grinding part. At the same time, the relative positions and connection methods of each component are cleverly designed, making the entire equipment structure compact, capable of completing the grinding process of large-diameter arc-shaped carbon brushes within a limited space, effectively saving the equipment installation space, improving the space utilization rate, and facilitating installation and maintenance in various complex generator room environments.

[0039] Innovative Grinding Tool System: Abandoning the traditional sandpaper grinding method, a high-speed rotating alloy grinding high-gloss tool is introduced. This grinding tool is made of special alloy materials and has high hardness, high wear resistance, and good cutting performance. When the equipment is running, the high-gloss tool rotates at high speed driven by the high-speed spindle 10. During a single machining process, by reasonably controlling parameters such as the rotational speed, feed rate, and cutting depth of the tool, the rough machining and finish machining of the carbon brush are integrated. In the initial stage, the excess material of the carbon brush is quickly removed with a large feed rate and cutting depth to complete the rough machining. As the machining process progresses, the feed rate and cutting depth are gradually reduced to finely grind the arc surface of the carbon brush and achieve finish machining with high surface finish. This method not only greatly improves the machining efficiency but also, due to the characteristics of the alloy grinding tool itself, completely avoids the problem of graphite clogging the cutting edge during sandpaper grinding, ensures the continuous cutting ability of the tool, reduces the tool replacement frequency and consumable costs, and improves the stability and reliability of the equipment.

[0040] High-precision Guidance Mechanism: To ensure the movement accuracy of the carbon brush during grinding, the equipment is equipped with a high-precision guidance mechanism. This mechanism mainly consists of a precision guide rail and a low-friction slider. The guide rail is manufactured by high-precision machining technology, and the linearity and flatness errors of its surface are controlled within an extremely small range to ensure that the carbon brush always maintains a straight movement trajectory during movement. The slider is made of special self-lubricating material, and the friction coefficient between it and the guide rail is extremely low, effectively reducing the energy loss and wear during movement. After the carbon brush is installed on the slider, the guidance mechanism can provide stable support and accurate movement guidance for the carbon brush, enabling it to be evenly stressed during grinding, ensuring the accuracy and consistency of arc surface machining, improving the fit between the carbon brush and the slip ring, and thus reducing the risk of electric arcs and wear caused by poor contact between the carbon brush and the slip ring during the operation of the generator.

[0041] Install the drive motor on the X-axis lead screw seat of the cross slide 3 to ensure a firm installation so that the drive motor can operate stably. Install the cam follower 5 on the Y-axis to ensure its accurate installation position and its flexible movement in subsequent movements. Then, install the cam groove wheel mechanism according to the design requirements to ensure the installation accuracy of the cam groove plate 4 and provide an accurate movement trajectory for the movement of the cam follower 5. When installing the high-precision guidance mechanism, carefully adjust the levelness and perpendicularity of the guide rail, install the low-friction slider on the guide rail, and apply an appropriate amount of lubricant. Then, install the high-speed rotating spindle on the spindle seat of the equipment and connect it to the motor through a coupling to ensure the rotational accuracy of the spindle. Finally, install the alloy grinding high-gloss tool at the front end of the spindle and perform dynamic balance debugging to ensure that there is no obvious vibration when the tool rotates at high speed. After the equipment assembly is completed, conduct a comprehensive inspection and debugging of each component to ensure correct electrical connection and flexible mechanical movement without jamming.

[0042] Grinding process operation: Install the new carbon brush to be ground on the carbon brush fixing fixture 11. By adjusting the fastening device on the bracket, ensure that the carbon brush is firmly fixed and in the accurate position. Start the driving motor, which drives the lead screw shaft to rotate, and then drives the cam mechanism to move, so that the carbon brush is ground into the required geometric shape along the predetermined curve trajectory under the guidance of high-precision guidance and the cam mechanism. When the carbon brush contacts the grinding tool, according to the material of the carbon brush and the required arc surface accuracy, set appropriate machining parameters such as the tool rotation speed, feed rate, and cutting depth in the servo control system. During the grinding process, the control system real-time monitors the position and machining status of the carbon brush grinding, and timely adjusts the motor rotation speed and movement direction through the information fed back by the sensor to ensure that the carbon brush is accurately ground within the specified range. During the whole grinding process, the dust suction device operates synchronously to timely suck out the graphite dust generated by grinding, keep the working environment clean, and avoid the adverse effects of dust on the equipment and operators.

[0043] Through the above specific implementation manners, the carbon brush grinding equipment of the present invention can stably and efficiently achieve the high-quality grinding of carbon brushes, give full play to its structural and technological advantages, meet the strict performance requirements of carbon brushes for hydro-generators, and provide strong support for the safe and stable operation of the power system.

[0044] It should be noted that in this article, relational terms such as first and second are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the term "comprising", "including" or any other variant thereof is intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements not only includes those elements, but also includes other elements not expressly listed, or further includes elements inherent to such process, method, article or device.

[0045] Although the embodiments of the present invention have been shown and described, for those of ordinary skill in the art, it can be understood that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principle and spirit of the present invention, and the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A fast and efficient generator carbon brush grinding device, comprising a main bracket (14) and a carbon brush body (6), characterized in that: A workbench (1) is slidably mounted on the main bracket (14), and a high-gloss grinding knife (2), a cross slide (3), a cam slot plate (4), a cam follower (5), a carbon brush body (6), an end point sensor (7), a servo motor (8), an origin sensor (9), a fixing fixture (11) and a high-speed spindle (10) are arranged above the workbench (1).

2. A fast and efficient generator carbon brush grinding device according to claim 1, characterized in that: The highlight grinding knife (2) is rotatably connected to the lower end of the high-speed main shaft (10), and the highlight grinding knife (2) is a high-speed rotating alloy grinding highlight knife.

3. A fast and efficient generator carbon brush grinding device according to claim 1, characterized in that: The cross slide (3) is installed above the workbench (1), and the servo motor (8) is fixedly installed on the X-axis screw seat of the cross slide (3).

4. A fast and efficient generator carbon brush grinding device according to claim 1, characterized in that: A groove (12) with a micro-curved surface structure is provided on the inner side of the cam groove plate (4), and a protrusion (13) with a micro-curved surface structure is provided on the inner side of the cam groove plate (4) opposite to the groove (12).

5. A fast and efficient generator carbon brush grinding device according to claim 1, characterized in that: The carbon brush body (6) is located on the inner side of the fixing fixture (11), and the fixing fixture (11) comprises a sliding block, which is slidably connected to the upper side of the cross slide (3).

6. A fast and efficient generator carbon brush grinding device according to claim 1, characterized in that: The slider is made of special self-lubricating material.

7. A fast and efficient generator carbon brush grinding device according to claim 1, characterized in that: The cam follower (5) is mounted on the Y-axis of the cross slide (3).

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