Irregular blade and vortex plate processing and installation method of a water brake

Abstract

This invention belongs to the field of hydraulic dynamometer processing technology, specifically providing a method for processing and installing irregular blades and vortex plates for hydraulic dynamometers. The method includes: parts preparation: processing of blades, inner vortex plates, and outer vortex plates; assembly: drawing contact lines between the blades and end plates on an assembly platform, assembling the blades at an angle according to the contact lines, and then installing the inner and outer vortex plates between adjacent sets of blades. Both sides of the inner and outer vortex plates are welded and fixed to the blades. This method solves the problems of cutting and unfolding irregular blades and vortex plates, meets the assembly size requirements of stainless steel irregular parts, and improves work efficiency.

Description

Technical Field

[0001] This invention relates to the field of hydraulic dynamometer processing technology, and in particular to a method for processing and installing irregular blades and vortex plates of a hydraulic dynamometer. Background Technology

[0002] The Y60 hydraulic dynamometer features irregularly shaped blades and vortex plates, with left-hand and right-hand spiral layers. The two layers have identical structures, differing only in the blade installation direction. Figure 1 As shown. The blades are tilted at 45° and rotate around the flange at 20° intervals, with the inner and outer spiral plates separated by the blades. Both the blades and spiral plates are made of ferritic stainless steel, with the blades being 30mm thick and the spiral plates 15mm thick. Due to the lack of a 3D model, the machining of the blade and spiral plate shapes and chamfers is quite difficult, and the unfolding and patterning of the irregularly shaped stainless steel spiral plates is challenging, making it difficult to control the forming and assembly dimensions. Summary of the Invention

[0003] This invention proposes a method for processing and installing irregular blades and vortex plates of a hydraulic dynamometer, which solves the problems of cutting and unfolding irregular blades and vortex plates, meets the assembly size requirements of stainless steel irregular parts, and improves work efficiency.

[0004] The technical solution of this invention is implemented as follows:

[0005] A method for processing and installing irregular blades and vortex plates of a hydraulic dynamometer includes the following steps:

[0006] Step 1: Parts preparation: including the machining of blades, inner turbine plates, and outer turbine plates;

[0007] Step 2, Assembly: Draw the contact line between the blade and the end plate on the assembly platform, assemble the blade at an angle according to the contact line, and then install the inner and outer vortex plates between two adjacent sets of blades. The inner and outer vortex plates are welded and fixed to the blades on both sides.

[0008] In the preferred embodiment, the blade processing procedure in step one is as follows:

[0009] 1) Draw the maximum external dimensions of each blade according to the part drawing, and cut the material according to these dimensions to make blade blanks;

[0010] 2) Assemble the blades according to the positioning of the general assembly drawing. Trim the positions where the blades interfere with the inner cylinder, outer cylinder and flange. Draw the model drawing according to the dimensions of the trimmed blade blank. The model drawing needs to draw the holes, chamfers, rounded edges, straight edges and arc edges together to complete the model drawing.

[0011] 3) Machining the blade blanks: Machining all blades according to the completed model drawings to complete the blade machining.

[0012] In the preferred embodiment, the processing procedure for the inner spiral plate in step one is as follows:

[0013] 1) Cut the inner vortex plate to its maximum unfolded size to make an inner vortex plate blank;

[0014] 2) Chamfer the two sides of the inner vortex plate according to the drawn inner vortex plate model drawing;

[0015] 3) The inner spiral plate is processed by using a bending machine to process the arc.

[0016] 4. The method for processing and installing irregular blades and vortex plates of a hydraulic dynamometer according to claim 3, characterized in that, in step 2), the chamfers on both sides of the inner vortex plate need to fit against the surface of the blade.

[0017] In the preferred embodiment, in step 3), after the inner vortex plate is processed by the folding machine, it is necessary to use an inner vortex plate forming template for inspection. The inner vortex plate forming template is designed and formed according to the inner contour of the inner vortex plate.

[0018] In the preferred embodiment, the processing procedure for the outer spiral plate in step one is as follows:

[0019] 1) Cut the material according to the maximum unfolded size of the outer vortex plate to make an outer vortex plate blank;

[0020] 2) According to the drawn external volute model drawing, machine the chamfers of the two circular arc edges of the external volute;

[0021] 3) The outer spiral plate is processed by using a bending machine to process the arc.

[0022] In the preferred embodiment, in step 3), after the outer vortex plate is processed by the folding machine to form an arc, it is necessary to use an outer vortex plate forming template for inspection. The outer vortex plate forming template is designed and formed according to the inner contour of the outer vortex plate.

[0023] In the preferred embodiment, step two, the assembly operation includes the following steps:

[0024] S201. Installation test: First, install the blades, inner volute and outer volute of the first grade for installation test, including two blades, one inner volute and one outer volute. Draw the contact line between the blade and the end plate on the assembly platform. Assemble the blade at an angle according to the contact line. Adjust the height from the upper end of the blade to the end plate and the assembly gap between the blade and the inner and outer cylinders to conform to the drawing. Then, perform tack welding.

[0025] S202. Draw the assembly lines of the inner and outer spiral plates on the end plate. Place the inner and outer spiral plates between the two sets of blades. The edges of the inner and outer spiral plates should match the assembly lines on the end plate. Check the gaps between the other three sides of the inner and outer spiral plates and the blades, inner flange, and filler plate. If there is installation interference, remove the interfering parts, record the cutting amount, and reprocess the other inner and outer spiral plates according to the cutting amount. The subsequent cutting should be arranged according to the actual size.

[0026] S203. After the first gear is installed, install the blades, inner vortex plate and outer vortex plate of the other gears in sequence, and perform tack welding.

[0027] In the preferred embodiment, in step two, the tilt angle of the blade is 45°.

[0028] In the preferred embodiment, in step two, the blades, inner vortex plate, and outer vortex plate are symmetrically welded using CO2 gas shielded welding.

[0029] The present invention provides a method for processing and installing irregular blades and vortex plates of a hydraulic dynamometer, which has the following beneficial effects:

[0030] The blades and inner and outer vortex plates manufactured using this method not only solve the problem of unfolding and shaping complex irregular parts, but also ensure the assembly dimensions of irregular blades and vortex plates, control the assembly gap, and make the irregular blades and vortex plates welded onto the hydraulic dynamometer conform to the drawing requirements. At the same time, it meets the assembly dimension requirements of stainless steel irregular parts and improves work efficiency. Attached Figure Description

[0031] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0032] Figure 1 Diagram of irregular blades and vortex plate structure;

[0033] Figure 2 This is a schematic diagram of a blade component;

[0034] Figure 3 Layout diagram for cutting blade parts;

[0035] Figure 4 This is a schematic diagram of an internal spiral plate component.

[0036] Figure 5 This is a schematic diagram of an external turbine plate component.

[0037] Figure 6 Layout diagram for cutting out external turbine plate parts;

[0038] Figure 7 Layout diagram for cutting and blanking internal turbine plate parts;

[0039] Figure 8 This is a schematic diagram of the blade assembly.

[0040] Figure 9 This is a schematic diagram of the assembly of the inner and outer spiral plates;

[0041] Figure 10 A schematic diagram of a single-layer blade and turbine plate assembly;

[0042] Figure 11 This is a template for forming an internal vortex plate.

[0043] Figure 12 This is a template for forming an external vortex plate.

[0044] In the diagram: 1. Right-handed spiral layer; 2. Left-handed spiral layer; 3. Blade; 4. Inner spiral plate; 5. Outer spiral plate; 6. End plate; 7. Outer cylinder; 8. Inner cylinder; 9. Gap filler plate. Detailed Implementation

[0045] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0046] This embodiment takes the machining of the Y60 hydraulic dynamometer as an example to provide a method for machining and installing irregular blades and vortex plates of a hydraulic dynamometer, including the following steps:

[0047] Step 1: Parts Preparation: This includes machining the blades, inner turbine plate, and outer turbine plate. The structure of the machined parts is as follows: Figure 2 , Figure 4 and Figure 5 As shown.

[0048] The blade processing procedure is as follows:

[0049] 1) Draw the maximum external dimensions of each blade according to the part drawing, and cut the material according to these dimensions to make blade blanks, such as... Figure 3 As shown.

[0050] 2) Assemble the blades according to the positioning of the general assembly drawing. Trim the positions where the blades interfere with the inner cylinder, outer cylinder and flange. Draw the model drawing according to the dimensions of the trimmed blade blank. The model drawing needs to draw the holes, chamfers, rounded edges, straight edges and arc edges together to complete the model drawing.

[0051] 3) Machining the blade blanks: Machining all blades according to the completed model drawings to complete the blade machining, ready for assembly.

[0052] The machining process of the internal spiral plate is as follows:

[0053] 1) Cut the inner vortex plate to its maximum unfolded size to form an inner vortex plate blank, such as... Figure 7 As shown.

[0054] 2) Process the chamfers on both sides of the inner vortex plate according to the drawn inner vortex plate model diagram, that is, the chamfers on the side in contact with the blade. The chamfers on both sides of the inner vortex plate need to fit the surface of the blade.

[0055] 3) The inner spiral plate is processed by forming the arc using a bending machine. After the inner spiral plate is processed by the bending machine, it needs to be inspected using an inner spiral plate forming template. The inner spiral plate forming template is designed and formed according to the inner contour of the inner spiral plate. To ensure the accuracy of the template, laser cutting is used. Figure 11 As shown. The structure of the finished inner vortex plate is as follows. Figure 4 As shown.

[0056] The machining process of the external spiral plate is as follows:

[0057] 1) Cut the material according to the maximum unfolded size of the outer vortex plate to make an outer vortex plate blank, such as... Figure 6 As shown.

[0058] 2) According to the drawn model of the outer vortex plate, process the chamfers of the two arc edges of the outer vortex plate. The chamfers at both ends should be close to the end plate and the outer cylinder to facilitate subsequent welding.

[0059] 3) The outer spiral plate is processed by forming the arc using a bending machine. After the outer spiral plate is formed by bending the arc, it needs to be inspected using an outer spiral plate forming template. The outer spiral plate forming template is designed and formed according to the inner contour of the outer spiral plate. To ensure the accuracy of the template, laser cutting is used. Figure 12 As shown. The structure of the finished inner vortex plate is as follows. Figure 5 As shown.

[0060] Step 2, Assembly: Draw the contact line between the blade and the end plate on the assembly platform, assemble the blade at an angle according to the contact line, and then install the inner and outer vortex plates between two adjacent sets of blades. The inner and outer vortex plates are welded and fixed to the blades on both sides.

[0061] Specifically, the assembly operation includes the following steps:

[0062] S201. To ensure accuracy, an installation test is conducted first. First, install one set of blades, inner volute plate, and outer volute plate, and conduct an installation test, including two blades, one inner volute plate, and one outer volute plate. Draw the contact line between the blade and the end plate on the assembly platform, and assemble the blade at an angle of 45° according to the contact line. Adjust the height of the upper end of the blade from the end plate and the assembly clearance between the blade and the inner and outer cylinders to conform to the drawing, and then perform tack welding.

[0063] S202. Draw the assembly lines of the inner and outer spiral plates on the end plate. Place the inner and outer spiral plates between the two sets of blades. The edges of the inner and outer spiral plates should match the assembly lines on the end plate. Check the gaps between the other three sides of the inner and outer spiral plates and the blades, inner flange, and filler plate. If there is installation interference, remove the interfering parts, record the cutting amount, and reprocess the other inner and outer spiral plates according to the cutting amount. The subsequent cutting should be arranged according to the actual dimensions.

[0064] S203. After the first gear is installed, install the blades, inner vortex plate and outer vortex plate of the other gears in sequence, and perform tack welding.

[0065] The blades and inner and outer turbine plates are symmetrically welded using CO2 gas shielded welding. After welding, the weld seams are ground and cleaned, and PT flaw detection is performed. Once qualified, the inner cavity is cleaned according to the product cleanliness requirements.

[0066] The Y60 hydraulic dynamometer blades and vortex plates manufactured using the above method have been inspected and found to fully meet the dimensional requirements of the drawings.

[0067] This method can solve the problems of cutting and unfolding irregular blades and vortex plates, ensure the assembly dimensions of irregular blades and vortex plates, control the assembly gap, and make the irregular blades and vortex plates welded onto the hydraulic dynamometer meet the requirements of the drawings.

[0068] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for processing and installing irregular blades and vortex plates of a hydraulic dynamometer, characterized in that, Includes the following steps: Step 1: Parts preparation: including the machining of blades, inner turbine plates, and outer turbine plates; The blade processing procedure is as follows: 1) Draw the maximum external dimensions of each blade according to the part drawing, and cut the material according to these dimensions to make blade blanks; 2) Assemble the blades according to the positioning of the general assembly drawing. Trim the positions where the blades interfere with the inner cylinder, outer cylinder and flange. Draw the model drawing according to the dimensions of the trimmed blade blank. The model drawing needs to draw the holes, chamfers, rounded edges, straight edges and arc edges together to complete the model drawing. 3) Machining the blade blanks: Machining all blades according to the completed model drawings to complete the blade machining; The machining process of the internal spiral plate is as follows: 1) Cut the inner vortex plate to its maximum unfolded size to make an inner vortex plate blank; 2) Chamfer the two sides of the inner vortex plate according to the drawn inner vortex plate model drawing; 3) The inner spiral plate is processed by forming the arc using a bending machine; Step 2, Assembly: Draw the contact line between the blade and the end plate on the assembly platform, assemble the blade at an angle according to the contact line, and then install the inner and outer volute plates between two adjacent sets of blades. The inner and outer volute plates are welded and fixed to the blades on both sides. The assembly operation includes the following steps: S201. Installation test: First, install the blades, inner volute and outer volute of the first grade for installation test, including two blades, one inner volute and one outer volute. Draw the contact line between the blade and the end plate on the assembly platform. Assemble the blade at an angle according to the contact line. Adjust the height from the upper end of the blade to the end plate and the assembly gap between the blade and the inner and outer cylinders to conform to the drawing. Then, perform tack welding. S202. Draw the assembly lines of the inner and outer spiral plates on the end plate. Place the inner and outer spiral plates between the two sets of blades. The edges of the inner and outer spiral plates should match the assembly lines on the end plate. Check the gaps between the other three sides of the inner and outer spiral plates and the blades, inner flange, and filler plate. If there is installation interference, remove the interfering parts, record the cutting amount, and reprocess the other inner and outer spiral plates according to the cutting amount. The subsequent cutting should be arranged according to the actual size. S203. After the first gear is installed, install the blades, inner vortex plate and outer vortex plate of the other gears in sequence, and perform tack welding.

2. The method for processing and installing irregular blades and vortex plates of a hydraulic dynamometer according to claim 1, characterized in that, In step 2) of the inner vortex plate machining, the chamfers on both sides of the inner vortex plate need to fit against the surface of the blade.

3. The method for processing and installing irregular blades and vortex plates of a hydraulic dynamometer according to claim 1, characterized in that, In step 3) of the inner vortex plate processing, after the inner vortex plate is processed by the folding machine, it is necessary to use the inner vortex plate forming template for inspection. The inner vortex plate forming template is designed and formed according to the inner contour of the inner vortex plate.

4. The method for processing and installing irregular blades and vortex plates of a hydraulic dynamometer according to claim 1, characterized in that, In step one, the processing procedure for the external spiral plate is as follows: 1) Cut the material according to the maximum unfolded size of the outer vortex plate to make an outer vortex plate blank; 2) According to the drawn external volute model drawing, machine the chamfers of the two circular arc edges of the external volute; 3) The outer spiral plate is processed by using a bending machine to process the arc.

5. The method for processing and installing irregular blades and vortex plates of a hydraulic dynamometer according to claim 4, characterized in that, In step 3) of the outer vortex plate processing, after the outer vortex plate is processed by the folding machine to form an arc, it is necessary to use the outer vortex plate forming template for inspection. The outer vortex plate forming template is designed and formed according to the inner contour of the outer vortex plate.

6. The method for processing and installing irregular blades and vortex plates of a hydraulic dynamometer according to claim 1, characterized in that, In step two, the blade tilt angle is 45°.

7. The method for processing and installing irregular blades and vortex plates of a hydraulic dynamometer according to claim 1, characterized in that, In step two, the blades, inner vortex plate, and outer vortex plate are symmetrically welded using CO2 gas shielded welding.

Images