Assembly process method of high-pressure diesel generating set

Abstract

The invention discloses an assembly process method of a high-pressure diesel generating set, the high-pressure diesel generating set comprises a set chassis, and a generator and an engine which are mounted on the set chassis, and further comprises a heat dissipation water tank connected with the set chassis, the generator is positioned on one side of the engine, and the heat dissipation water tank is positioned on the other side of the engine; the assembly process method comprises the following steps that the unit chassis is cleaned, protected and leveled; selecting an elastic coupling; a shaft hub of the elastic coupling and an elastic element are mounted on a main shaft of the generator; a flange body of the elastic coupling is installed on a flywheel of an engine; the engine is hoisted to the position close to the unit chassis, it is ensured that supporting legs of the engine are aligned with first mounting bases on the unit chassis, and the engine and the first mounting bases of the unit chassis are aligned and preliminarily fixed through bolt assemblies. The process method provided by the invention can standardize the installation process of the diesel generating set, improve the performance stability of the diesel generating set and improve the product quality.

Description

Technical Field

[0001] The present invention relates to the technical field of diesel generator equipment, and more particularly to an assembly process method for a high-voltage diesel generator set. Background Art

[0002] With the rapid development of industry, the capacity of domestic electrical equipment continues to expand. Diesel generator sets, used as backup power sources, also need to be increasingly powerful, sometimes even requiring multiple high-power diesel generator sets connected in parallel to meet operational requirements. Against this backdrop, high-voltage diesel generator sets have emerged. Compared to traditional low-voltage generators, high-voltage diesel generator sets offer higher output voltages, lower transmission currents, and minimal power losses during power transmission, making them suitable for long-distance transmission. They are widely used in finance, communications, metallurgy, airports, data centers, and other fields.

[0003] In the prior art, there are two common methods for connecting the diesel engine and generator during the assembly of high-voltage diesel generator sets: a disc-shaped spigot connection and a coupling connection. However, when different people install the generator set, different installation techniques can easily lead to unstable performance of the diesel generator set, resulting in poor installation consistency and quality consistency. Summary of the Invention

[0004] In view of this, the purpose of the present invention is to provide a high-voltage diesel generator set assembly process to solve the problems existing in the prior art. The process provided by the present invention can standardize the diesel generator set installation process, improve the performance stability of the diesel generator set, and improve product quality.

[0005] To achieve the above object, the technical solution of the present invention is as follows:

[0006] A method for assembling a high-voltage diesel generator set, comprising a generator chassis, a generator mounted on the generator chassis, and an engine, and further comprising a heat sink connected to the generator chassis, wherein the generator is located on one side of the engine and the heat sink is located on the other side of the engine. The method comprises the following steps:

[0007] S1. Clean, protect and level the chassis of the unit;

[0008] S2. Select an elastic coupling; install the hub and elastic element of the elastic coupling on the main shaft of the generator; install the flange of the elastic coupling on the flywheel of the engine;

[0009] S3. Hoist the engine near the chassis of the unit, ensure that the engine's legs are aligned with the first mounting seat on the chassis for mounting the engine, align the engine with the first mounting seat on the chassis of the unit, and use the bolt assembly to perform preliminary fixation;

[0010] S4. Hoist the generator above one side of the unit chassis, then lower the generator so that the generator legs are close to the second mounting base on the unit chassis for mounting the generator. Simultaneously, move the generator toward the engine so that the elastic element is close to the flange body.

[0011] S5. Rotate the elastic element to align the inner and outer teeth of the flange and the elastic element, then continue to move the generator toward the engine so that the generator fits into the engine housing, and then connect the generator to the engine using the bolt assembly.

[0012] S6. Tighten the generator to the second mounting base on the unit chassis, and the engine to the first mounting base on the unit chassis, respectively, and tighten them in a cross-tightening manner;

[0013] S7. Measure the axial clearance of the engine crankshaft to see if it is between 0.330 and 0.544 mm. If so, the requirement is met. If not, adjust the clearance to between 0.330 and 0.544 mm.

[0014] S8. Connect the radiator tank to the chassis of the unit.

[0015] Furthermore, in step S1, the cleaning and protection are specifically as follows:

[0016] Use cardboard and paper tape to wrap the mounting base on the chassis of the unit for protection;

[0017] Clean the welding slag and perform sandblasting first, spraying both sides;

[0018] Use high-pressure air to clean the dust on the surface of the chassis of the unit, and spray iron red anti-rust primer and black topcoat after drying.

[0019] Furthermore, in step S2, the step of installing the hub and the elastic element of the elastic coupling on the main shaft of the generator specifically includes:

[0020] Remove the flat key on the main shaft of the generator;

[0021] Disassemble the elastic coupling and separate it into the hub, elastic element and flange body;

[0022] Use kerosene or gasoline to clean the main shaft and flat key of the generator, clean the hub, elastic element and flange of the coupling, and dry them;

[0023] Measure the main shaft diameter and key width of the generator, the hub hole diameter and keyway width, and determine the heating temperature and whether to grind the key or main shaft based on the corresponding interference.

[0024] Heat the hub of the coupling and place it in a drying oven for heating and insulation treatment. After heating, take out the hub and measure the diameter and keyway width of the hub. Keep the clearance between the diameter of the hub and the diameter of the spindle, and the clearance between the keyway width of the hub and the flat key ≥ 0.08mm;

[0025] Install the hub, lubricate the main shaft and flat key of the generator, then install the flat key on the main shaft of the generator, and then install the heated hub on the main shaft of the generator. After installation, the flat key of the generator is locked in the keyway of the hub;

[0026] After the shaft hub has cooled, rotate the shaft hub to check for any sticking or lag, and then install the elastic element onto the shaft hub.

[0027] Furthermore, the determination of the heating temperature and whether to grind the flat key or the main shaft according to the corresponding interference is specifically as follows:

[0028] When the interference is less than 0.07mm, the heating temperature is 230℃; when the interference is greater than 0.07mm and less than 0.09mm, the heating temperature is 290℃; if the interference exceeds 0.09mm, the spindle and / or flat key must be ground to a range of 0.07-0.09mm.

[0029] Furthermore, in step S7, the step of measuring whether the axial clearance of the engine crankshaft is 0.330-0.544 mm is specifically as follows:

[0030] Open the observation hole cover on the flywheel housing and use a steel chisel to pry the flywheel to move the crankshaft toward the generator end;

[0031] Use a dial indicator to set the position at the engine pulley to zero, with the dial indicator showing a 1-2mm downward pressure.

[0032] Use a steel chisel to pry the flywheel to move the crankshaft toward the generator end, and use a dial indicator to read the crankshaft axial clearance value;

[0033] Use a steel chisel to pry the flywheel to move the crankshaft toward the radiator tank, and use a dial indicator to read the crankshaft axial clearance value;

[0034] Calculate the difference between the dial indicators in the two states, which is the axial clearance value of the engine crankshaft.

[0035] Furthermore, in step S7, after measuring the axial clearance of the engine crankshaft, the method further includes:

[0036] Open the inspection port of the engine flywheel housing and check whether there is any excess material. Use compressed air to blow into the inspection port to ensure that there is no excess material.

[0037] Crank the engine to check for any signs of sticking or increased resistance, and make a mark while cranking to ensure a full rotation.

[0038] Furthermore, the specific operations in step S8 are:

[0039] Weigh the radiator tank and record the weighing data;

[0040] Remove the support beam, belt guard, and transmission belt of the radiator water tank, raise the radiator water tank to 300-500mm from the ground, and place the water tank shock absorber in the corresponding mounting hole at the bottom of the radiator water tank in advance;

[0041] Adjust the position of the radiator water tank so that its center line coincides with the center line of the unit chassis, then place the radiator water tank on the water tank vibration damper, and connect and lock the water tank vibration damper to the radiator water tank;

[0042] Install the support beam of the radiator tank and lock it;

[0043] Then hoist the radiator water tank to the installation position of the unit chassis and adjust the fan blades in the radiator water tank;

[0044] Connect and lock the bottom of the radiator tank to the chassis of the unit;

[0045] Install the removed drive belt between the engine pulley and the radiator pulley, and install the belt guard on the outside of the drive belt.

[0046] Furthermore, when installing the transmission belt, it also includes adjusting the parallelism of the engine pulley and the radiator pulley, controlling the relative parallelism of the two end faces of the engine pulley and the radiator pulley to be within 0.3 degrees; it also includes adjusting the coplanarity of the engine pulley and the radiator pulley, controlling the coplanarity of the two end faces of the engine pulley and the radiator pulley to not exceed 2mm.

[0047] Furthermore, the radial distance between the fan blades and the heat dissipation water tank is not less than 10 mm.

[0048] Compared with the prior art, the present invention has the following advantages:

[0049] The high-voltage diesel generator set assembly process method of the present invention can improve the assembly quality of the diesel generator set and the product quality through scientific and reasonable step design and key parameter control; and ensure the stability of the diesel generator set during operation. BRIEF DESCRIPTION OF THE DRAWINGS

[0050] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other embodiments can also be obtained based on these drawings.

[0051] Figure 1 It is a structural schematic diagram of a high-voltage diesel generator set provided by an embodiment of the present invention.

[0052] Figure 2 It is a structural schematic diagram of the elastic coupling provided by an embodiment of the present invention.

[0053] Description of reference numerals:

[0054] 1. Unit chassis; 11. First mounting base; 12. Second mounting base; 2. Generator; 3. Engine; 4. Radiator; 5. Elastic coupling; 51. Hub; 52. Elastic element; 53. Flange; DETAILED DESCRIPTION

[0055] The structure provided by the present invention is explained and illustrated in detail below with reference to the accompanying drawings.

[0056] This embodiment specifically discloses a high-voltage diesel generator set assembly process method, such as Figure 1 As shown, the high-voltage diesel generator set includes a chassis 1 and a generator 2 and an engine 3 mounted on the chassis 1. It also includes a heat sink 4 connected to the chassis 1. The generator 2 is located on one side of the engine 3, and the heat sink 4 is located on the other side of the engine 3. The assembly process includes the following steps:

[0057] S1. Clean, protect and level the chassis 1 of the unit;

[0058] It is understood that a plurality of mounting seats are processed on the chassis 1 of the unit, including a first mounting seat 11 for mounting and placing the engine 3 and a second mounting seat 12 for mounting and placing the generator 2. After all the mounting seats are processed on the base plate 1 of the unit (which can be obtained by welding), the mounting seats on the chassis of the unit can be wrapped with cardboard or paper tape for protection.

[0059] Then clean the welding slag and perform sandblasting. Both sides of the unit chassis 1 are sandblasted. When turning over the unit chassis 1, driving assistance can be used. After the sandblasting is completed, use high-pressure air to clean the surface dust of the unit chassis 1. After drying, spray iron red anti-rust primer and black topcoat.

[0060] Among them, sandblasting can effectively remove the surface oxide layer and impurities, improve the adhesion of the paint, and extend the service life of the paint surface. High-pressure air cleaning can further ensure that the surface is free of dust and particulate matter; provide a clean surface for subsequent painting, and avoid paint defects caused by surface impurities. Spraying iron red anti-rust primer can effectively prevent corrosion on the surface of the unit chassis and provide long-term anti-rust protection; and iron red anti-rust primer has good adhesion and anti-corrosion properties, which can significantly extend the service life of the unit chassis. Spraying black topcoat on the basis of anti-rust primer not only improves the appearance quality of the unit chassis, but also provides an additional protective layer to prevent the external environment from eroding the chassis; and the wear resistance and UV resistance of the black topcoat further enhance the durability of the unit chassis.

[0061] It is understandable that in some embodiments, after spraying the iron red anti-rust primer and the black topcoat, the paint surface can be inspected to ensure that the paint surface is uniform and without omissions, and a hardness test can be performed after the paint surface is dry.

[0062] After spraying, the paint surface is inspected to ensure uniformity and complete coverage. This step promptly identifies unevenness during the spraying process, such as areas where the paint is too thick or too thin, or discontinuous spraying. Through timely inspection and correction, the overall uniformity of the paint surface is ensured, improving the product's appearance quality. Thorough paint inspection ensures complete coverage of the product surface, avoiding the risk of corrosion or damage caused by unpainted areas. This is crucial for the product's protective performance, especially when used in harsh environments.

[0063] Optionally, when leveling the unit, the steps include placing the damping spring isolator roughly on the flat ground according to the installation hole position of the unit chassis, lifting the unit chassis with a 5T crane and placing it on the damping spring isolator, tightening the bolts, and leveling the machined surface (i.e., the upper end face); when leveling, place a digital level ruler on the upper surface of the unit chassis, measure the levelness of the upper surface, and if the leveling level is below 0.3 degrees and does not meet the levelness requirement, add a 1mm or 2mm adjustment pad between the damping spring isolator and the ground until the levelness meets the requirement.

[0064] After the chassis processing of the unit is completed, you can proceed to the next step.

[0065] S2, select the elastic coupling 5; the elastic coupling hub 51 and the elastic element 52 are installed on the main shaft of the generator 2; the elastic coupling flange 53 is installed on the flywheel of the engine 3;

[0066] In this embodiment, a high elastic coupling 5 is selected, and its structure is as follows Figure 2As shown, it includes a hub 51, an elastic element 52 and a flange body 53; the outer periphery of the elastic element 52 is formed with external teeth, and the inner wall of the flange body 53 is formed with internal teeth that can match the external teeth; when the engine 3 is subsequently connected to the generator 2, the external teeth of the elastic element 52 and the internal teeth of the flange body 53 are used to achieve positioning connection;

[0067] Installing the hub and elastic element on the main shaft of the generator; installing the flange body of the elastic coupling on the flywheel of the engine can ensure the precise connection between the generator and the engine; the close fit between the hub and the main shaft of the generator, and the stable connection between the flange body and the flywheel of the engine provide a reliable mechanical foundation for power transmission.

[0068] The elastic element of the flexible coupling compensates for minor axial, radial, and angular displacements that may occur between the generator and engine during installation. This compensation capability effectively reduces shaft misalignment caused by factors such as installation errors and thermal expansion during operation, thereby extending the equipment's service life. Furthermore, the elastic element provides excellent shock-absorbing and cushioning properties, effectively absorbing and attenuating vibration and impact energy generated during operation. This not only improves equipment operation stability but also reduces vibration impacts on the foundation and surrounding structures, thereby lowering noise levels.

[0069] Specifically, the steps of installing the hub 51 and the elastic element 52 of the elastic coupling 5 on the main shaft of the generator 2 include:

[0070] S21, remove the flat key on the main shaft of generator 2;

[0071] S22, disassembling the elastic coupling 5, separating the elastic coupling 5 into the hub 51, the elastic element 52 and the flange body 53;

[0072] S23. Use kerosene or gasoline to clean the main shaft and flat key of the generator, clean the hub, elastic element and flange of the coupling, and let them dry. This will provide a good foundation for subsequent accurate installation and avoid installation errors caused by surface dirt.

[0073] S24. Measure the main shaft diameter and key width of the flat key of the generator, measure the hole diameter and keyway width of the hub, and determine the heating temperature and whether to grind the flat key or main shaft based on the corresponding interference.

[0074] Among them, the interference is the difference between the spindle diameter and the hub hole diameter, as well as the difference between the key width and the keyway width of the flat key. Appropriate interference can ensure the stability of the connection after installation.

[0075] S25. Heat the hub of the coupling and place it in a drying oven for heating and insulation treatment. After heating, take out the hub and measure the hub's hole diameter and keyway width. Keep the gap between the hub's hole diameter and the spindle's diameter, as well as the gap between the hub's keyway width and the flat key ≥ 0.08mm for easy installation.

[0076] Understandably, a heated hub is easier to install and ensures tightness and stability after installation. In actual operation, the heating temperature will vary depending on the interference fit setting. However, generally, baking at 290°C and holding for 6-8 hours is sufficient.

[0077] When the interference is less than 0.07mm, set the heating temperature to 230℃; when the interference is greater than 0.07mm and less than 0.09mm, set the heating temperature to 290℃; if the interference exceeds 0.09mm, the spindle and / or flat key must be ground to a range of 0.07-0.09mm.

[0078] When removing the hub from the drying oven, due to its heavy weight and high temperature, use heat-insulating gloves (such as asbestos gloves or high-temperature resistant silicone gloves) to avoid burns. At the same time, it is necessary to measure as soon as possible before performing subsequent installation operations to avoid affecting the installation after the temperature drops.

[0079] S26. Install the hub, lubricate the main shaft and flat key of the generator, then install the flat key on the main shaft of the generator. Then, install the heated hub onto the main shaft of the generator. After installation, the flat key of the generator is locked in the keyway of the hub.

[0080] Lubrication can be done by applying a thin layer of grease or oil on the main shaft and flat key to reduce friction during installation and ensure the precise fit of the flat key and keyway. When installing the flat key, use a copper rod to tap it onto the main shaft of the generator. Remove the heated hub and use a wooden board to support it during installation as an auxiliary support. At the same time, align the keyway of the hub with the flat key of the main shaft. Install it while it is hot, quickly and in place in one go. Use heat-insulating cloth for protection after installation.

[0081] S27. After the shaft hub has cooled down, rotate the shaft hub to check if there is any sticking or lag, and then install the elastic element to the shaft hub with bolts.

[0082] Optionally, when tightening, tighten all the bolts in a diagonal cross manner. Considering that the tightening torque is too large, in order to prevent the bolts from loosening and increase the fastening strength, the torque can be applied in two times, and each time it can be tightened at half the torque. After all the bolts have been torqued, re-tighten them one by one to avoid omissions. During actual operation, the bolts can be tightened with the help of a torque wrench. Furthermore, to prevent the bolts from loosening or falling off during operation, thread fasteners such as Loctite 243 can be applied to the bolts or threaded holes. It has high strength, resistance to engine oil, resistance to anti-corrosion oil, resistance to high temperature, etc., and can also effectively prevent thread corrosion; it can also be easily disassembled when maintenance is required later.

[0083] After the flange body, hub and elastic element are installed respectively, you can proceed to the next step.

[0084] S3. Hoist the engine 3 near the chassis 1 of the unit, ensure that the legs of the engine 3 are aligned with the first mounting seat 11 on the chassis 1 for mounting the engine 3, align the engine 3 with the first mounting seat 11 of the chassis, and use a bolt assembly for preliminary fixation; the bolt assembly includes a flat washer, a spring washer, a bolt, etc.

[0085] Optionally, after the initial fixation, the horizontality and alignment of the engine 3 can also be tested to ensure that the engine 3 and the subsequent generator are on the same axis when connected, to avoid excessive wear of the coupling and reduce vibration and noise.

[0086] S4. Hoist the generator 2 above one side of the unit chassis 1, then lower the generator 2 so that the legs of the generator 2 are close to the second mounting base 12 on the unit chassis 1 for mounting the generator 2. Simultaneously, move the generator 2 toward the engine 3 so that the elastic element 52 is close to the flange 53.

[0087] It should be noted that the lifting process should be carried out slowly and smoothly, and at the same time, ensure that the generator mounting surface of the unit chassis (i.e., the second mounting seat) is slightly lower than the outer contour of the generator. Then, move the crane to the top of the unit chassis, and then move the generator legs to the upper part of the unit chassis by moving the crane. Then, move the generator legs to the mounting surface of the unit chassis legs by moving the crane. At the same time, move the generator to the side of the engine by moving the elastic element close to the flange body.

[0088] S5. Rotate the elastic element to align the inner and outer teeth of the flange body and the elastic element to ensure accurate meshing between the outer and inner teeth and to ensure that the coupling can effectively transmit torque. Then, move the generator further toward the engine so that the generator fits into the engine housing and then connect the generator to the engine with the bolt assembly, thereby achieving power transmission between the engine and the generator.

[0089] Among them, the bolt assembly also includes flat washers, spring washers, bolts, etc. The flat washers are mainly used to increase the contact area between the bolts and the connected parts, disperse the pressure, and prevent damage when the bolts are tightened; the spring washers use their own elastic deformation to play a role in preventing loosening.

[0090] Furthermore, applying thread fastener to the bolts can fill the tiny gaps between the threads, increase the friction and sealing of the threaded connection, and further prevent the bolts from loosening. At the same time, it can also play a certain role in rust prevention and extend the service life of the bolts.

[0091] During the tightening process, cross-tighten the bolts. By tightening the bolts diagonally and alternately in a certain order, the force applied to each bolt is evenly distributed, preventing deformation of the generator and engine casing or a loose connection due to excessive or insufficient local force. The tightening torque is 120±3N.m. If the torque is too low, the bolts may loosen during operation. If the torque is too high, the bolts may stretch, deform, or even break, or damage the threads. Therefore, setting it to 120±3N.m is sufficient. In some other embodiments, the torque can also be adjusted according to different bolt sizes.

[0092] S6. Tighten the generator to the second mounting base on the unit chassis, and the engine to the first mounting base on the unit chassis, respectively, and tighten them in a cross-tightening manner;

[0093] If necessary, the inspector can use an oil pen to mark the tightening after tightening.

[0094] S7. Measure the axial clearance of the engine crankshaft to see if it is between 0.330 and 0.544 mm. If so, the requirement is met. If not, adjust the clearance to between 0.330 and 0.544 mm.

[0095] The axial clearance of an engine crankshaft is crucial to its proper operation. Proper clearance prevents the crankshaft from jamming and wearing during operation due to insufficient clearance, while also preventing axial movement due to excessive clearance, which could affect engine performance and service life. By measuring and adjusting clearance, you can ensure that the engine is in optimal working condition.

[0096] Specifically, in some embodiments, the step of measuring whether the axial clearance of the engine crankshaft is 0.330-0.544 mm is specifically as follows:

[0097] S71. Open the inspection hole cover on the flywheel housing and use a steel chisel to pry the flywheel to move the crankshaft toward the generator end.

[0098] When using a steel chisel to pry the flywheel, you need to control the force to avoid excessive force that may damage the machine parts. At the same time, you must ensure that the steel chisel is in good contact with the flywheel to effectively transmit force to move the crankshaft.

[0099] S72. Use a dial indicator to set the current position at the engine pulley to zero, with a downward pressure of 1-2 mm. This allows the dial indicator to operate normally and accurately measure the axial displacement of the crankshaft. The downward pressure ensures that the measuring contacts of the dial indicator always maintain contact with the measuring surface, avoiding measurement errors caused by gaps.

[0100] S73. Use a steel chisel to pry the flywheel to move the crankshaft toward the generator end, and use a dial indicator to read the crankshaft axial clearance value. Similarly, the process of prying the flywheel should be smooth and slow to ensure that the crankshaft moves evenly so that the dial indicator can read the value accurately. When reading the dial indicator value, make sure your line of sight is perpendicular to the dial to avoid reading errors.

[0101] S74. Use a steel chisel to pry the flywheel to move the crankshaft toward the radiator tank, and use a dial indicator to read the crankshaft axial clearance value; obtain the displacement data of the crankshaft in the other direction; combine it with the value read in the previous step, and you can calculate the movement range of the crankshaft in the entire axial direction, that is, the axial clearance; similarly, when prying the flywheel, you must control the force and speed to ensure the accuracy of the measurement; when reading the value, make sure that the dial indicator is working properly and the recorded data is accurate.

[0102] S75. Calculate the difference between the dial indicator values under the two conditions to obtain the engine crankshaft axial clearance value. This axial clearance value reflects the actual clearance size of the crankshaft in the axial direction and is used to determine whether the crankshaft axial clearance meets the requirements.

[0103] Optionally, after measuring the engine crankshaft axial clearance, the following steps may also be performed:

[0104] Open the inspection port of the engine flywheel housing and check whether there is any excess material (such as metal debris, tool parts, dust, etc.). Use compressed air to blow into the inspection port to ensure that there is no excess material.

[0105] Crank the engine to check for any signs of sticking or increased resistance, and make a mark while cranking to ensure a full rotation.

[0106] During engine operation, various foreign objects, such as metal shavings, tool parts, and dust, may enter the flywheel housing. These debris can affect normal engine operation. For example, metal shavings can enter the clearance between the crankshaft and bearings, increasing wear and even causing seizure. Foreign objects can also affect the flywheel's dynamic balance, causing vibration and noise. Opening the inspection port to inspect and remove any debris can effectively eliminate these potential hazards, ensure a clean internal engine environment, and guarantee stable engine operation.

[0107] Cranking is an important method for verifying the proper functioning of the engine's internal mechanical components. This allows you to check for binding or increased resistance in components like the crankshaft, connecting rod, and piston. If binding is present, it could indicate component damage or improper assembly. Increased resistance could indicate a component mismatch, such as insufficient lubrication or insufficient clearance. Marking the crankshaft and ensuring a full rotation allows you to accurately assess the engine's rotational condition and identify potential problems.

[0108] It's important to note that cranking should be done slowly and evenly, typically using specialized tools. Observe the movement of all engine components and listen carefully for any unusual sounds. If you notice a significant increase in resistance or signs of sticking, stop cranking immediately, analyze the cause, and address it. This cranking inspection can identify potential problems before the engine is started, preventing serious malfunctions after startup. Promptly identifying and resolving these issues can reduce maintenance costs, improve engine reliability and safety, and ensure proper operation after the engine is commissioned.

[0109] S8. Connect the radiator tank to the chassis of the unit.

[0110] In high-voltage diesel generator sets, the weight of the radiator water tank is generally more than 2 tons. Therefore, when using a crane for lifting, the crane load capacity should not be less than 5 tons.

[0111] Specifically, the steps for installing the heat dissipation water tank include:

[0112] S81. Weigh the heat dissipation water tank and record the weighing data;

[0113] Weighing the radiator water tank can, on the one hand, check whether the radiator water tank meets the design specifications. Different models of radiator water tanks have specific weight ranges. If the weight deviation is too large, there may be quality problems with the water tank, such as internal structural defects, improper material use, etc.; on the other hand, recording the weighing data can provide a reference for subsequent lifting operations, facilitate the selection of lifting equipment with appropriate load capacity, ensure the safety and reliability of the lifting process, and avoid safety accidents caused by overweight.

[0114] It can be understood that the upper end of the radiator water tank is provided with a lifting hole and the bottom is provided with a forklift hole.

[0115] S82. Remove the radiator's support beams, belt guards, and drive belts. Raise the radiator to 300-500 mm above the ground. Place the radiator shock absorber in the corresponding mounting hole on the bottom of the radiator.

[0116] Removing the support beam, belt guard, and drive belt of the radiator water tank will facilitate the subsequent adjustment of the fan blades inside the radiator water tank; raising it to 300-500mm from the ground can ensure that there is enough space to place the water tank shock absorber without making it too high.

[0117] S83. Adjust the position of the radiator tank so that its centerline coincides with the centerline of the unit chassis. Simultaneously, slowly move it toward the engine, aligning the radiator tank base with the mounting holes on the unit chassis. (At this point, simply align them; do not connect them yet. The unit chassis and radiator tank base will be connected later using bolts, nuts, and spring washers.) Then, use a crane to gently lift the radiator tank, place it on the radiator damper, and tighten the radiator damper to the radiator tank.

[0118] Placing the water tank on the shock absorber and connecting and locking it can basically fix the position of the radiator water tank. At the same time, the water tank shock absorber is used to reduce the transmission of engine vibration to the radiator water tank, thereby improving the stability and reliability of the radiator water tank's operation.

[0119] S84. Install the support beam of the radiator tank and tighten it;

[0120] The support beams include left and right support beams, which are also fastened with bolts, nuts, and spring washers, and the nuts are locked. When installing the left and right support beams, if there is interference between the support beams and the water tank diagonal brace, you can first remove the fastening bolts at the lower end of the water tank diagonal brace, and then restore the diagonal brace bolts after the support beams are installed.

[0121] S85. Then hoist the radiator to its mounting position on the unit chassis. Adjust the fan blades within the radiator. Ensure that the fan blades extend 1 / 3 to 1 / 2 of the way into the radiator frame. Ensure that the fan blades maintain a uniform distance of at least 10 mm from the circumference of the radiator and at least 15 mm from the protective screen (for special requirements, refer to the special process requirements). Avoid any scratching. This prevents contact between the fan blades and the radiator, which could cause wear, deformation, or even damage to the radiator and fan blades. Sufficient radial distance also facilitates smooth air flow between the fan blades and the inner wall of the radiator, improving heat dissipation efficiency and ensuring the cooling system effectively dissipates engine heat.

[0122] S86. Connect and lock the bottom of the heat sink, i.e., the base, to the chassis of the unit, so that the heat sink and the chassis are connected as a whole.

[0123] S87. Install the removed drive belt between the engine pulley and the radiator pulley, and install the belt guard on the outside of the drive belt.

[0124] The drive belt is installed between the engine pulley and the radiator pulley to achieve power transmission between the engine and the radiator, allowing the radiator's fan blades to operate normally and dissipate heat. The belt guard ensures personnel safety by preventing contact with the high-speed drive belt and the danger of injury. It also protects the drive belt from interference and damage caused by external debris.

[0125] Optionally, when installing the transmission belt, the parallelism of the engine pulley and the radiator pulley must be adjusted to within 0.3 degrees. If the requirements are not met, the radiator body and the radiator base bolts can be removed and adjustment pads can be placed between them for adjustment. Controlling the relative parallelism of the engine pulley and the radiator pulley to within 0.3 degrees ensures that the transmission belt is evenly stressed during operation, preventing the pulleys (engine pulley and radiator pulley) from being non-parallel, causing the belt to deviate, wear more severely, or even fall off. Pulleys with good parallelism can evenly distribute the tension of the transmission belt, improve transmission efficiency, extend the service life of the transmission belt and pulleys, and ensure stable operation of the cooling system.

[0126] Furthermore, it also includes adjusting the coplanarity of the engine pulley and the radiator pulley, controlling the coplanarity of the two end faces of the engine pulley and the radiator pulley to not exceed 2mm; if the requirements are not met, adjustments should be made by loosening the fastening bolts of the radiator pulley, adjusting its position, aligning the pulley on the radiator pulley and the driving pulley (engine pulley) on the engine, and re-measuring the coplanarity of the end faces to not exceed 2mm.

[0127] Controlling the coplanarity of the two end faces of the engine pulley and the radiator pulley to no more than 2mm can ensure that the transmission belt can engage and transmit correctly between the two pulleys, and prevent the transmission belt from twisting and uneven force due to the non-coplanarity of the pulley end faces, which will affect the transmission effect and accelerate the damage of the transmission belt; appropriate coplanarity can ensure that the transmission belt maintains a good working condition during operation and reduce energy loss and vibration.

[0128] In summary, the embodiment of the present invention provides a high-voltage diesel generator set assembly process method, which can improve the assembly quality of the diesel generator set and improve product quality; and ensure the stability of the diesel generator set during operation.

[0129] In addition, by connecting the base of the radiator water tank to the side end surface of the unit chassis, the stability of the water tank can be ensured, and the radiator water tank and the unit chassis body can be easily lifted separately and assembled on site.

[0130] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise", "axial", "radial", "circumferential" and the like to indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as limiting the present invention.

[0131] In the present invention, unless otherwise specified or limited, the terms "installed," "connected," "connect," "fixed," etc. should be understood in a broad sense. For example, they can refer to fixed connection, detachable connection, or integration; mechanical connection, electrical connection; direct connection, or indirect connection through an intermediate medium; internal communication between two components, or interaction between two components, unless otherwise specified. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on specific circumstances.

[0132] In the description of this specification, the reference terms "this embodiment", "one embodiment", "some embodiments", "example", "specific example", or "some examples" mean that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic expressions of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in an appropriate manner in any at least one embodiment or example. In addition, those skilled in the art can combine and combine different embodiments or examples described in this specification and the features of different embodiments or examples, unless they are contradictory.

[0133] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of the technical features being referred to. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one such feature. In the description of the present invention, "plurality" means at least two, such as two, three, etc., unless otherwise specifically defined.

[0134] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent replacements and simple improvements made to the essential contents of the present invention should be included in the scope of protection of the present invention.

Claims

1. A high-voltage diesel generator assembly process, characterized in that: The high-voltage diesel generator set includes a chassis, a generator and an engine mounted on the chassis, and a heat sink connected to the chassis. The generator is located on one side of the engine, and the heat sink is located on the other side of the engine. The assembly process includes the following steps: S1. Clean, protect and level the chassis of the unit; S2. Select an elastic coupling; install the hub and elastic element of the elastic coupling on the main shaft of the generator; install the flange of the elastic coupling on the flywheel of the engine; S3. Hoist the engine near the chassis of the unit, ensure that the engine's legs are aligned with the first mounting seat on the chassis for mounting the engine, align the engine with the first mounting seat on the chassis of the unit, and use the bolt assembly to perform preliminary fixation; S4. Hoist the generator above one side of the unit chassis, then lower the generator so that the generator legs are close to the second mounting base on the unit chassis for mounting the generator. Simultaneously, move the generator toward the engine so that the elastic element is close to the flange body. S5. Rotate the elastic element to align the inner and outer teeth of the flange and the elastic element, then continue to move the generator toward the engine so that the generator fits into the engine housing, and then connect the generator to the engine using the bolt assembly. S6. Tighten the generator to the second mounting base on the unit chassis, and the engine to the first mounting base on the unit chassis, respectively, and tighten them in a cross-tightening manner; S7. Measure the axial clearance of the engine crankshaft to see if it is between 0.330 and 0.544 mm. If so, the requirement is met. If not, adjust the clearance to between 0.330 and 0.544 mm. S8. Connect the radiator tank to the chassis of the unit.

2. The assembly process according to claim 1, characterized in that: In step S1, the cleaning and protection are specifically as follows: Use cardboard and paper tape to wrap the mounting base on the chassis of the unit for protection; Clean the welding slag and perform sandblasting first, spraying both sides; Use high-pressure air to clean the dust on the surface of the chassis of the unit, and spray iron red anti-rust primer and black topcoat after drying.

3. The assembly process according to claim 1, characterized in that: In step S2, the step of installing the hub and the elastic element of the elastic coupling on the main shaft of the generator specifically includes: Remove the flat key on the main shaft of the generator; Disassemble the elastic coupling and separate it into the hub, elastic element and flange body; Use kerosene or gasoline to clean the main shaft and flat key of the generator, clean the hub, elastic element and flange of the coupling, and dry them; Measure the main shaft diameter and key width of the generator, the hub hole diameter and keyway width, and determine the heating temperature and whether to grind the key or main shaft based on the corresponding interference. Heat the hub of the coupling and place it in a drying oven for heating and insulation treatment. After heating, take out the hub and measure the diameter and keyway width of the hub. Keep the clearance between the diameter of the hub and the diameter of the spindle, and the clearance between the keyway width of the hub and the flat key ≥ 0.08mm; Install the hub, lubricate the main shaft and flat key of the generator, then install the flat key on the main shaft of the generator, and then install the heated hub on the main shaft of the generator. After installation, the flat key of the generator is locked in the keyway of the hub; After the shaft hub has cooled, rotate the shaft hub to check for any sticking or lag, and then install the elastic element onto the shaft hub.

4. The assembly process according to claim 3, characterized in that: The specific steps of determining the heating temperature and whether to grind the flat key or the spindle according to the corresponding interference are as follows: When the interference is less than 0.07mm, the heating temperature is 230℃; when the interference is greater than 0.07mm and less than 0.09mm, the heating temperature is 290℃; if the interference exceeds 0.09mm, the spindle and / or flat key must be ground to a range of 0.07-0.09mm.

5. The assembly process according to claim 1, characterized in that: In step S7, the step of measuring whether the axial clearance of the engine crankshaft is 0.330-0.544 mm is specifically as follows: Open the observation hole cover on the flywheel housing and use a steel chisel to pry the flywheel to move the crankshaft toward the generator end; Use a dial indicator to set the position at the engine pulley to zero, with the dial indicator showing a 1-2mm downward pressure. Use a steel chisel to pry the flywheel to move the crankshaft toward the generator end, and use a dial indicator to read the crankshaft axial clearance value; Use a steel chisel to pry the flywheel to move the crankshaft toward the radiator tank, and use a dial indicator to read the crankshaft axial clearance value; Calculate the difference between the dial indicators in the two states, which is the axial clearance value of the engine crankshaft.

6. The assembly process according to claim 1, characterized in that: In step S7, after measuring the axial clearance of the engine crankshaft, the following steps are further included: Open the inspection port of the engine flywheel housing and check whether there is any excess material. Use compressed air to blow into the inspection port to ensure that there is no excess material. Crank the engine to check for any signs of sticking or increased resistance, and make a mark while cranking to ensure a full rotation.

7. The assembly process according to claim 1, characterized in that: The specific operations in step S8 are: Weigh the radiator tank and record the weighing data; Remove the support beam, belt guard, and transmission belt of the radiator water tank, raise the radiator water tank to 300-500mm from the ground, and place the water tank shock absorber in the corresponding mounting hole at the bottom of the radiator water tank in advance; Adjust the position of the radiator water tank so that its center line coincides with the center line of the unit chassis, then place the radiator water tank on the water tank vibration damper, and connect and lock the water tank vibration damper to the radiator water tank; Install the support beam of the radiator tank and lock it; Then hoist the radiator water tank to the installation position of the unit chassis and adjust the fan blades in the radiator water tank; Connect and lock the bottom of the radiator tank to the chassis of the unit; Install the removed drive belt between the engine pulley and the radiator pulley, and install the belt guard on the outside of the drive belt.

8. The assembly process according to claim 7, characterized in that: When installing the transmission belt, it also includes adjusting the parallelism of the engine pulley and the radiator pulley, controlling the relative parallelism of the two end faces of the engine pulley and the radiator pulley to be within 0.3 degrees; it also includes adjusting the coplanarity of the engine pulley and the radiator pulley, controlling the coplanarity of the two end faces of the engine pulley and the radiator pulley to not exceed 2mm.

9. The assembly process according to claim 7, characterized in that: The radial distance between the fan blades and the heat dissipation water tank is not less than 10 mm.

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