Ring forging water immersion ultrasonic automatic detection device and method of wind turbine generator set

Abstract

The application discloses a wind turbine ring forging water immersion ultrasonic automatic detection device and method, which comprises a rack, conveying chains rotatably arranged on both sides of the rack, a plurality of first bearing rods and second bearing rods arranged on the conveying chains in an interval and staggered manner and used for conveying ring forgings, both ends of the first bearing rods and the second bearing rods are detachably connected with the conveying chains through limiting pieces, a water immersion groove is arranged on the inner side of the conveying chain, and an ultrasonic detection device is arranged in the water immersion groove, and both sides of the water immersion groove are arranged on the rack. The application stacks a plurality of ring forgings in a feeding bin, starts the device, conveys the ring forgings to the upper side of the water immersion groove through the conveying chains, sends the ring forgings into the water immersion groove through a lifting assembly, carries out water immersion and ultrasonic detection, lifts and sends out the ring forgings after the detection is completed, and the device realizes batch automatic detection of the ring forgings and improves the detection efficiency of the ring forgings.

Description

Technical Field

[0001] This invention relates to the field of ultrasonic testing technology for ring forgings immersed in water, and in particular to an automatic ultrasonic testing device and method for ring forgings in wind turbine generator sets immersed in water. Background Technology

[0002] Ring forgings are generally used as flange blanks for producing wind turbine generator sets. Ring forgings are produced by processing the ring blanks using a ring rolling mill. The outer edge of the rolls drives the blank to rotate, achieving the rolling process of reducing the blank thickness and increasing the diameter. Water immersion ultrasonic testing of ring forgings is used to evaluate the internal and surface quality defects of the ring forgings to ensure that they meet engineering requirements. It mainly detects internal defects such as cracks, pores, inclusions, and looseness in the ring forgings, avoiding structural failures caused by internal discontinuities in the material.

[0003] Existing methods for ultrasonic testing of ring forgings by immersion in water generally involve clamping a single ring forging with a fixture, placing it in a water immersion tank for monitoring, and then removing the ring forging. This method not only requires fixtures but also has low efficiency and automation, making it unsuitable for batch testing of ring forgings. Therefore, this invention proposes an automatic ultrasonic testing device and method for ring forgings in water immersion in wind turbine generator sets to solve the above problems. Summary of the Invention

[0004] The purpose of this invention is to provide an automatic ultrasonic testing device and method for water immersion of ring forgings of wind turbine generator sets, so as to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: an automatic ultrasonic testing device for ring forgings of wind turbine generator sets, comprising a frame, a conveyor chain rotatably arranged on both sides of the frame, and a plurality of first and second bearing rods arranged at intervals on the conveyor chain for conveying the ring forgings, wherein both ends of the first and second bearing rods are detachably connected to the conveyor chain through limiting members;

[0006] The inner side of the conveyor chain is provided with a water immersion tank, and an ultrasonic testing device is installed in the water immersion tank. The two sides of the water immersion tank are mounted on the frame. A lifting assembly for lifting the ring forging is provided in the water immersion tank. A feeding hopper is also provided on one side above the conveyor chain.

[0007] In a preferred embodiment of the present invention, a rotating shaft is provided at each of the four inner corners of the conveyor chain, and the two ends of the rotating shaft are rotatably mounted on the frame. Two sprockets are provided on the rotating shaft, and the conveyor chain is fitted onto the sprockets. A first motor is installed on one side of the frame, and the output shaft of the first motor is connected to one end of a rotating shaft.

[0008] In a preferred embodiment of the present invention, the limiting member includes a grooved plate sleeved at both ends of the first and second bearing rods and two annular slide rails disposed inside the conveyor chain. The grooved plate is mounted on the conveyor chain. Rollers are provided at the bottom and sides of both ends of the first and second bearing rods. The rollers on both sides are in contact with the inner walls of the two sides of the grooved plate, and the rollers at the bottom roll along the annular slide rails.

[0009] In a preferred embodiment of the present invention, baffles are provided on the top and inner side of the first and second bearing rods, and first supports are provided on both sides of the frame, and the two annular slide rails are connected to the first supports.

[0010] In a preferred embodiment of the present invention, the annular slide rail is provided with two notches above the water immersion tank, and the annular slide rail between the two notches is installed at the bottom of the water immersion tank by a vertical rod. When the first support rod and the second support rod move to the notch of the annular slide rail, the two ends of the first support rod and the second support rod move down and disengage from the tank plate.

[0011] In a preferred embodiment of the present invention, the lifting assembly includes a lift, a second bracket, and guide rails on both sides of the inside of the water immersion tank. The lift is installed on the inner wall of the water immersion tank, and the guide rails are installed on the inner wall of the water immersion tank by means of crossbars. The top of the guide rails is located directly below the notch of the annular slide rail.

[0012] In a preferred embodiment of the present invention, the lifting platform includes a rotating rod, mounting seats at both ends of the rotating rod, a second motor mounted on the mounting seats, and a slide on one side of the rotating rod. The lifting platform is installed in a water immersion tank via the mounting seats. The output shaft of the second motor is connected to one end of the rotating rod. Two guide rods are also provided on one side of the mounting seats. The slide is inserted through the guide rods. The rotating rod has intersecting spiral grooves. The slide slides along the spiral grooves of the rotating rod. The bottom of the second bracket is mounted on the slide of the two lifting platforms, and the top of the second bracket is supported by the bottom of the first and second support rods.

[0013] In a preferred embodiment of the present invention, a third support is provided on both sides of the feeding hopper, the feeding hopper is mounted on the third support, the bottom end of the third support is mounted on the frame, the feeding hopper has a square frame structure, the bottom of the feeding hopper is bent inward to form a discharge port, the width of the discharge port is adapted to the width of the ring forging, the top of the baffle of the first bearing rod is flush with the top of the discharge port, and the top of the baffle of the second bearing rod is flush with the bottom of the discharge port.

[0014] The testing method for the water-immersion ultrasonic automatic testing device of ring forgings for wind turbine generator sets includes the following steps:

[0015] S1. Stack multiple ring forgings in the feeding hopper, control the first motor to make it rotate intermittently, drive a rotating shaft to rotate through the first motor, drive the sprocket and the conveyor chain to rotate through the rotating shaft, and the first bearing rod and the second bearing rod follow the rotation of the conveyor chain;

[0016] S2. The second support rod passes through the bottom of the feeding bin and pushes a ring forging out of the feeding bin through the stop bar at the top of the first support rod, so that the ring forging falls on the first support rod and the second support rod.

[0017] S3. When the first and second bearing rods move to the notch of the annular slide rail, the first motor stops and the second motor starts, causing the second motor to drive the rotating rod to rotate. The slide table moves up and down along the spiral groove of the rotating rod. When the slide table moves down, it drives the second support to move down. The first and second bearing rods follow the second support to move down and detach from the groove plate, pass through the notch and enter the guide rail until the ring forging is completely immersed in the water immersion tank for water immersion and ultrasonic testing.

[0018] S4. After the ring forging is inspected, control the second motor to move the slide up and reset the first and second bearing rods. Start the first motor to send out the inspected ring forging.

[0019] Compared with the prior art, the beneficial effects of the present invention are:

[0020] This invention stacks multiple ring forgings in a loading hopper, then starts the device to transport the ring forgings to the top of a water immersion tank via a conveyor chain. The ring forgings are then sent into the water immersion tank by a lifting assembly for water immersion and ultrasonic testing. After the testing is completed, the ring forgings are lifted and sent out. This device realizes automated batch testing of ring forgings and improves the testing efficiency of ring forgings. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0022] Figure 2 For the present invention Figure 1 Enlarged structural diagram at point A;

[0023] Figure 3 This is a schematic diagram of the structure of the limiting component of the present invention;

[0024] Figure 4 For the present invention Figure 3 Enlarged structural diagram at point B;

[0025] Figure 5 This is a schematic diagram of the internal structure of the water immersion tank of the present invention;

[0026] Figure 6 For the present invention Figure 5 Enlarged structural diagram at point C;

[0027] In the diagram: 1. Frame; 2. Conveyor chain; 3. First bearing rod; 4. Second bearing rod; 5. Limiting component; 51. Groove plate; 52. Circular slide rail; 521. Notch; 53. Roller; 6. Water immersion tank; 7. Lifting assembly; 71. Lifting machine; 711. Rotating rod; 7111. Spiral groove; 712. Mounting base; 713. Second motor; 714. Slide table; 715. Guide rod; 72. Second bracket; 73. Guide rail; 8. Feeding bin; 81. Discharge port; 9. Rotating shaft; 10. Sprocket; 11. First motor; 12. First bracket; 13. Third bracket; 14. Baffle. Detailed Implementation

[0028] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0029] Please see Figures 1-6 The automatic ultrasonic testing device for ring forgings of wind turbine generator sets includes a frame 1, a conveyor chain 2 rotatably arranged on both sides of the frame 1, and multiple first bearing rods 3 and second bearing rods 4 arranged at intervals on the conveyor chain 2 for conveying ring forgings. Specifically, the number of first bearing rods 3 and second bearing rods 4 is 4-8 each, and both ends of the first bearing rods 3 and second bearing rods 4 are detachably connected to the conveyor chain 2 through limiting members 5.

[0030] Among them, the four inner corners of the conveyor chain 2 are provided with rotating shafts 9, and the two ends of the rotating shafts 9 are rotatably mounted on the frame 1. Two sprockets 10 are provided on the rotating shafts 9, and the conveyor chain 2 is fitted on the sprockets 10. A first motor 11 is installed on one side of the frame 1, and the output shaft of the first motor 11 is connected to one end of a rotating shaft 9.

[0031] A water immersion tank 6 is provided inside the conveyor chain 2, and an ultrasonic testing device is installed inside the water immersion tank 6. The two sides of the water immersion tank 6 are installed on the frame 1. A lifting assembly 7 for lifting the ring forging is provided inside the water immersion tank 6. A feeding bin 8 is also provided on one side above the conveyor chain 2.

[0032] It should be noted that the ultrasonic testing equipment is existing technology and can be installed in the water immersion tank 6 to generate ultrasonic waves to detect internal defects such as cracks, pores, inclusions, and looseness in the ring forging.

[0033] In this embodiment, the limiting member 5 includes a groove plate 51 sleeved on both ends of the first bearing rod 3 and the second bearing rod 4, and two annular slide rails 52 disposed on the inner side of the conveyor chain 2. Specifically, the annular slide rail 52 is provided with two notches 521 above the water immersion tank 6. The annular slide rail 52 between the two notches 521 is installed at the bottom of the water immersion tank 6 by a vertical rod. When the first bearing rod 3 and the second bearing rod 4 move to the notch 521 of the annular slide rail 52, the two ends of the first bearing rod 3 and the second bearing rod 4 move down and disengage from the groove plate 51. The groove plate 51 is installed on the conveyor chain 2. Rollers 53 are provided at the bottom and sides of both ends of the first bearing rod 3 and the second bearing rod 4. The rollers 53 on both sides are in contact with the inner walls of both sides of the groove plate 51, and the rollers 53 at the bottom roll along the annular slide rail 52.

[0034] It should be noted that the width of the notch 521 of the annular slide rail 52 is greater than the width of the first support rod 3 and the second support rod 4. Two rollers 53 are provided at the bottom of both ends of the first support rod 3 and the second support rod 4. The two rollers 53 roll along the annular slide rail 52. A roller 53 is provided on each side of both ends of the first support rod 3 and the second support rod 4, so that the first support rod 3 and the second support rod 4 can slide down along the groove plate 51 and the guide rail 73.

[0035] Furthermore, baffles 14 are provided on the top and inner side of the first bearing rod 3 and the second bearing rod 4. First supports 12 are also provided on both sides of the frame 1. Both annular slide rails 52 are connected to the first supports 12. Specifically, the first supports 12 are composed of four sets of vertical and horizontal bars connected together. The two ends of the horizontal bars are installed on the frame 1, and the two ends of the vertical bars are connected to the annular slide rails 52.

[0036] In this embodiment, the lifting assembly 7 includes a lifting machine 71, a second bracket 72, and guide rails 73 disposed on both sides of the water immersion tank 6. The lifting machine 71 is installed on the inner wall of the water immersion tank 6, and the guide rails 73 are installed on the inner wall of the water immersion tank 6 by means of a crossbar. The top of the guide rail 73 is located directly below the notch 521 of the annular slide rail 52, so that the first support rod 3 and the second support rod 4 can slide through the notch 521 into the annular slide rail 52.

[0037] Furthermore, the lifting platform 71 includes a rotating rod 711, mounting seats 712 disposed at both ends of the rotating rod 711, a second motor 713 disposed on the mounting seats 712, and a slide 714 disposed on one side of the rotating rod 711. The lifting platform 71 is installed in the water immersion tank 6 via the mounting seats 712. The output shaft of the second motor 713 is connected to one end of the rotating rod 711. Two guide rods 715 are also disposed on one side of the mounting seat 712. The slide 714 is inserted into the guide rods 715. The rotating rod 711 is provided with intersecting spiral grooves 7111. The slide 714 is disposed on the guide rods 715. 4. Slide along the spiral groove 7111 of the rotating rod 711, so that the slide table 714 can move up and down reciprocally. The bottom of the second bracket 72 is installed on the slide table 714 of the two lifting machines 71. The top of the second bracket 72 is supported by the bottom of the first bearing rod 3 and the second bearing rod 4. Specifically, the upper layer of the second bracket 72 is provided with two horizontal bars, and the lower layer is provided with two horizontal bars. The two are perpendicular to each other and connected by a vertical rod. The upper horizontal bars are supported by the bottom of the first bearing rod 3 and the second bearing rod 4, and the two ends of the lower horizontal bars are installed on the slide table 714 of the lifting machine 71.

[0038] In this embodiment, a third support 13 is provided on both sides of the feeding bin 8. The feeding bin 8 is mounted on the third support 13, and the bottom of the third support 13 is mounted on the frame 1. The feeding bin 8 has a square frame structure. The bottom of the feeding bin 8 is bent inward to form a discharge port 81. The width of the discharge port 81 is adapted to the width of the ring forging. The top of the baffle 14 at the top of the first bearing rod 3 is flush with the top of the discharge port 81. The top of the baffle 14 at the top of the second bearing rod 4 is flush with the bottom of the discharge port 81, so that the second bearing rod 4 can pass through the bottom of the feeding bin 8 and then push the ring forging in the feeding bin 8 out of the discharge port 81 through the baffle 14 at the top of the first bearing rod 3.

[0039] The method of using the automatic ultrasonic testing device for water immersion of ring forgings in wind turbine generator sets according to the present invention includes the following steps:

[0040] S1. Stack multiple ring forgings in the feeding hopper 8, control the first motor 11 to make it rotate intermittently, drive a rotating shaft 9 to rotate through the first motor 11, drive the sprocket 10 and the conveyor chain 2 to rotate through the rotating shaft 9, and the first bearing rod 3 and the second bearing rod 4 follow the rotation of the conveyor chain 2.

[0041] S2. The second bearing rod 4 passes through the bottom of the feeding bin 8 and pushes a ring forging out of the discharge port 81 of the feeding bin 8 through the stop bar at the top of the first bearing rod 3, so that the ring forging falls on the first bearing rod 3 and the second bearing rod 4.

[0042] S3. When the first bearing rod 3 and the second bearing rod 4 move to the notch 521 of the annular slide rail 52, the first motor 11 stops and the second motor 713 is started, so that the second motor 713 drives the rotating rod 711 to rotate. The slide table 714 moves up and down along the spiral groove 7111 of the rotating rod 711. When the slide table 714 moves down, it drives the second support 72 to move down. The first bearing rod 3 and the second bearing rod 4 follow the second support 72 to move down and get off the groove plate 51, pass through the notch 521 and enter the guide rail 73 until the ring forging completely falls into the water immersion tank 6 for water immersion and ultrasonic testing.

[0043] S4. After the ring forging is inspected, control the second motor 713 to move the slide table 714 upward, reset the first bearing rod 3 and the second bearing rod 4, start the first motor 11, and send out the inspected ring forging.

[0044] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. An automatic ultrasonic testing device for ring forgings of wind turbine generator sets, characterized in that: It includes a frame (1), a conveyor chain (2) rotatably arranged on both sides of the frame (1), and multiple first bearing rods (3) and second bearing rods (4) arranged at intervals on the conveyor chain (2) for conveying ring forgings. The two ends of the first bearing rods (3) and the second bearing rods (4) are detachably connected to the conveyor chain (2) through limiting members (5). The inner side of the conveyor chain (2) is provided with a water immersion tank (6), and an ultrasonic testing device is installed in the water immersion tank (6). The two sides of the water immersion tank (6) are installed on the frame (1). The water immersion tank (6) is provided with a lifting assembly (7) for lifting the ring forging. A feeding bin (8) is also provided on one side above the conveyor chain (2). The limiting member (5) includes a groove plate (51) sleeved on both ends of the first bearing rod (3) and the second bearing rod (4) and two annular slide rails (52) set on the inner side of the conveyor chain (2). The groove plate (51) is installed on the conveyor chain (2). Rollers (53) are provided at the bottom and sides of both ends of the first bearing rod (3) and the second bearing rod (4). The rollers (53) on both sides are in contact with the inner walls of both sides of the groove plate (51), and the rollers (53) at the bottom roll along the annular slide rails (52). The annular slide rail (52) is located above the water immersion tank (6) and has two notches (521). The annular slide rail (52) between the two notches (521) is installed at the bottom of the water immersion tank (6) by a vertical rod. When the first support rod (3) and the second support rod (4) move to the notch (521) of the annular slide rail (52), the two ends of the first support rod (3) and the second support rod (4) move down and disengage from the tank plate (51).

2. The automatic ultrasonic testing device for ring forgings of wind turbine generator sets under water immersion as described in claim 1, characterized in that: The conveyor chain (2) has four rotating shafts (9) at its inner corners. The two ends of the rotating shafts (9) are rotatably mounted on the frame (1). Two sprockets (10) are mounted on the rotating shafts (9). The conveyor chain (2) is fitted onto the sprockets (10). A first motor (11) is mounted on one side of the frame (1). The output shaft of the first motor (11) is connected to one end of a rotating shaft (9).

3. The automatic ultrasonic testing device for ring forgings of wind turbine generator sets under water immersion as described in claim 2, characterized in that: The top and inner side of the first support rod (3) and the second support rod (4) are provided with baffles (14), and the two sides of the frame (1) are also provided with first brackets (12). The two annular slide rails (52) are connected to the first brackets (12).

4. The automatic ultrasonic testing device for ring forgings of wind turbine generator sets under water immersion as described in claim 3, characterized in that: The lifting assembly (7) includes a lift (71) disposed on both sides inside the water immersion tank (6), a second bracket (72), and guide rails (73) disposed on both sides of the lift (71). The lift (71) is installed on the inner wall of the water immersion tank (6), and the guide rails (73) are installed on the inner wall of the water immersion tank (6) by means of a crossbar. The top of the guide rails (73) is located directly below the notch (521) of the annular slide rail (52).

5. The automatic ultrasonic testing device for ring forgings of wind turbine generator sets under water immersion as described in claim 4, characterized in that: The elevator (71) includes a rotating rod (711), mounting seats (712) at both ends of the rotating rod (711), a second motor (713) mounted on the mounting seats (712), and a slide (714) on one side of the rotating rod (711). The elevator (71) is installed in the water immersion tank (6) via the mounting seats (712). The output shaft of the second motor (713) is connected to one end of the rotating rod (711). A slide (714) is also provided on one side of the mounting seats (712). There are two guide rods (715), and the slide (714) is interspersed on the guide rods (715). The rotating rod (711) is provided with intersecting spiral grooves (7111). The slide (714) slides along the spiral grooves (7111) of the rotating rod (711). The bottom of the second bracket (72) is installed on the slide (714) of the two elevators (71). The top of the second bracket (72) is supported on the bottom of the first support rod (3) and the second support rod (4).

6. The automatic ultrasonic testing device for ring forgings of wind turbine generator sets under water immersion as described in claim 5, characterized in that: The feeding bin (8) is provided with a third support (13) on both sides. The feeding bin (8) is installed on the third support (13). The bottom of the third support (13) is installed on the frame (1). The feeding bin (8) is a square frame structure. The bottom of the feeding bin (8) is bent inward to form a discharge port (81). The width of the discharge port (81) is adapted to the width of the ring forging. The top of the baffle (14) at the top of the first bearing rod (3) is flush with the top of the discharge port (81). The top of the baffle (14) at the top of the second bearing rod (4) is flush with the bottom of the discharge port (81).

7. The detection method based on the water immersion ultrasonic automatic detection device for wind turbine generator ring forgings according to claim 6, characterized in that: Includes the following steps: S1. Stack multiple ring forgings in the loading bin (8), control the first motor (11) to make it rotate intermittently, drive a rotating shaft (9) to rotate through the first motor (11), drive the sprocket (10) and the conveyor chain (2) to rotate through the rotating shaft (9), and the first bearing rod (3) and the second bearing rod (4) follow the conveyor chain (2) to rotate. S2. The second bearing rod (4) passes through the bottom of the feeding bin (8) and pushes a ring forging out of the discharge port (81) of the feeding bin (8) through the stop bar at the top of the first bearing rod (3), so that the ring forging falls on the first bearing rod (3) and the second bearing rod (4); S3. When the first bearing rod (3) and the second bearing rod (4) move to the notch (521) of the annular slide rail (52), the first motor (11) stops and the second motor (713) is started, so that the second motor (713) drives the rotating rod (711) to rotate. The slide table (714) moves up and down along the spiral groove (7111) of the rotating rod (711). When the slide table (714) moves down, the second support (72) moves down through the slide table (714). The first bearing rod (3) and the second bearing rod (4) follow the second support (72) to move down and get off the groove plate (51), pass through the notch (521) and enter the guide rail (73) until the ring forging is completely dropped into the water immersion tank (6) for water immersion and ultrasonic testing. S4. After the ring forging is inspected, control the second motor (713) to move the slide (714) upward, reset the first bearing rod (3) and the second bearing rod (4), start the first motor (11), and send out the ring forging after inspection.

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