Large-diameter impact type rotating wheel water bucket rotating welding method

Abstract

The invention discloses a large-diameter impact type rotating wheel water bucket rotating welding method which is suitable for the welding process of large-diameter and large-tonnage impact type rotating wheel water buckets, the unbalance loading torque of a single water bucket or multiple water buckets in the welding process of the rotating wheel water buckets can be effectively overcome, and the safety of the welding process of the rotating wheel water buckets is improved. In the welding process, after the impact type rotating wheel body and the fixed rotating disc are combined and fixed, the electric rolling frame can be used for rotating, self-locking can be achieved at any position, and the 360-degree welding requirement of the rotating wheel water bucket is met; and meanwhile, after the runner bucket is welded, the runner relief grinding procedure can be completed on the operation platform. By means of the mode that the fixed disc and the impact type water bucket rotating wheel body are fixed, the problem that the safety is low due to the fact that the unbalance loading torque of water bucket welding is too large can be solved, and the rotating wheel welding efficiency can be effectively improved and the labor intensity of workers can be effectively reduced by means of the electric rolling frame rotating welding mode.

Description

Technical Field

[0001] The invention relates to a large-diameter impact-type runner bucket rotation welding method, belonging to the field of large-diameter impact-type runner bucket welding. Background Art

[0002] The impeller, the core component of a turbine's energy conversion system, typically consists of 18 to 25 identical buckets. Its working principle is to convert water energy into mechanical energy by driving the impeller's buckets into rotation through the impact of high-speed jets.

[0003] Conventional small-diameter impact runners typically use a horizontal monolithic machining process, where all the buckets are milled directly from a single block of stock. However, applying this process to large-diameter runners results in extremely low material utilization, significantly increasing manufacturing costs.

[0004] If a vertical welding solution is used, a single bucket on a large-diameter runner can weigh up to 1 ton, requiring the runner body to be rotated during the welding process to complete the bucket installation. This solution requires special attention to the eccentric load torque generated during the welding process to avoid safety hazards caused by torque imbalance.

[0005] In summary, the current manufacturing of large-diameter impulse turbine generator runners faces a dilemma: the use of horizontal integral processing will lead to excessively high costs, and although the horizontal welding solution can achieve rotating mounting of the runner, it poses a major safety risk. Summary of the Invention

[0006] The present invention aims to solve the problem of runner rotation during vertical welding of large-diameter impact runner buckets, the problem of low efficiency of post-weld processing and the problem of high manufacturing cost, and proposes a large-diameter impact runner bucket rotation welding method.

[0007] The technical solution of the present invention:

[0008] A large-diameter impact-type runner bucket rotation welding method comprises the following steps: S1: Finish turning each machining surface of the impact wheel body, machining the lifting holes and controlling the outer circle deviation of the impact wheel body within 1mm; S2: Place the fixed disc vertically, place the impact wheel body flat on the fixed disc support plate, and fix it with bolts; S3: Fix the left auxiliary support frame, right operating frame and operating platform by ground welding; S4: Adjust the horizontal distance between the left auxiliary support frame and the right operating frame so that the axial distance between the active roller frame and the driven roller frame matches the axial distance between the disc body and the right axial positioning section of the fixed disc, and the horizontal distance error is ≤1mm; S5: Flip the fixed disc and the impact wheel body 90 degrees and place them flat on the driving roller frame and the driven roller frame, so that the disc body in the fixed disc is aligned with the driving roller frame, and the right axial positioning section in the fixed disc is vertically aligned with the driven roller frame; S6: Install the C-type walkway of the operating platform, tighten the pressure plate and top seat of the left auxiliary support frame, and weld the lower plane of the driven roller frame and the upper plane of the right operating frame; S7: Fix the impact wheel bucket on the impact wheel body, and power on to rotate the active roller frame to complete welding.

[0009] Specifically, step S2 includes: S21: installing the wheel body positioning flat keys at the middle shaft end of the fixed disc in eight equal parts, checking the fitting tolerance of the wheel body positioning flat keys, and fixing them with bolts; S22: using the right axial positioning section at the right end of the fixed disc to contact and position with the driven roller frame.

[0010] Specifically, step S3 includes: S31: the deviation of the central axis of the left auxiliary support frame and the right operating frame is ≤1mm; S32: the active roller frame is installed on the plane of the left auxiliary support frame and fixed with bolts, wherein the pressure plate and the top seat do not need to be completely tightened; S33: the driven roller frame is installed on the plane of the right operating frame; S34: the operating platform is arranged in the vertical direction along the axis of the fixed disc, and is divided into a front operating platform and a rear operating platform, both of which are truss welded structures, and C-type walkways are installed on both sides above the operating platform, and the middle span of the C-type walkways on both sides does not interfere with the impact wheel water bucket.

[0011] Specifically, in step S4, the top seat is adjusted so that the disc body and the right axial positioning section are in effective contact with the driving roller frame and the driven roller frame respectively.

[0012] Specifically, in step S5, two ends of the fixed disc are provided with double lifting ears for hanging with the hooks.

[0013] Specifically, in step S6, the C-shaped walkway is welded and fixed to the front and rear operating platforms.

[0014] Specifically, the step S7 includes: S71: preheating the impact wheel bucket during welding and welding in symmetrical positions; S72: grinding the root of the impact wheel bucket on the C-shaped walkway after welding is completed.

[0015] Beneficial effects of the present invention:

[0016] 1. Realize the separate welding of the Pelton turbine bucket and the runner body, greatly reducing the manufacturing cost of the runner.

[0017] 2. Overcome the eccentric load moment caused by welding a single bucket, achieve simultaneous and synchronous welding of multiple buckets, and greatly improve the welding efficiency of the impact wheel and bucket.

[0018] 3. The electric roller is used to rotate to achieve 360-degree rotation of the impact wheel bucket during welding and self-lock at any position. The positioning flat key is used in conjunction with the impact wheel bucket to ensure the accuracy of welding and improve the safety of impact wheel bucket welding. It greatly reduces the labor intensity of workers and has certain promotion significance.

[0019] 4. The use of an external operating platform can adapt to the requirements of multiple impact wheel bucket grinding, ensuring the quality of the wheel grinding.

[0020] 5. The present invention is easy to install, reduces the labor intensity of workers, and greatly improves the efficiency of installation and adjustment. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 A three-dimensional view of a large-diameter impact wheel bucket rotation welding method;

[0022] Figure 2 A three-dimensional view of a large-diameter impact wheel bucket rotation welding method for fixing the disc and the impact wheel handle;

[0023] Figure 3 A three-dimensional view of a large-diameter impact bucket rotating welding method for fixing the disc;

[0024] Figure 4 A three-dimensional view of a large-diameter impact runner bucket rotation welding method;

[0025] In the figure, 1-impact runner body, 2-impact runner water bucket, 3-fixed disc, 301-disc body, 302-right axial positioning section, 303-positioning flat key, 4-bolt, 5-left auxiliary support frame, 6-right operating frame, 7-operating platform, 701-front operating platform, 702-rear operating platform, 703-C-type walkway, 8-driving roller frame, 9-driven roller frame, 10-pressure plate, 11-top seat. DETAILED DESCRIPTION

[0026] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the drawings in the examples of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all embodiments obtained by ordinary technicians in this field without making any creative work shall fall within the scope of protection of the present invention.

[0027] like Figure 1 、 Figure 2 、 Figure 3 、 Figure 4 As shown, the present invention is achieved by the following steps:

[0028] S1. Perform full finish turning on all machined surfaces of the impact wheel body 1 and machine the lifting holes. During marking, care should be taken to control the outer diameter deviation of the impact wheel body 1 to within 1mm to reduce the welding deviation of the impact wheel bucket 2.

[0029] S2. Pre-assemble the fixed disc 3 and the impact wheel bucket body 1. Place the fixed disc 3 vertically and place the impact wheel body 1 flat on the support plate of the fixed disc 3. Use bolts 4 to fix them together as a whole.

[0030] S21, the middle shaft end of the fixed disc 3 is divided into eight equal parts and installed with the positioning flat key 303 of the runner body. Before the impact runner body 1 and the fixed disc 3 are fixed together, it is necessary to ensure the matching tolerance of the positioning flat key (303). After the requirement is met, the bolts 4 are used to fix them together.

[0031] S22. A right axial positioning section 302 is processed on the shaft section at the right end of the fixed disc 3. This area contacts and positions the roller of the driven roller frame 9 to avoid rotation and separation.

[0032] S3. Mark, recheck, and correct the placement of the impact wheel bucket welding device, and weld the left auxiliary support frame 5, the right operating frame 6, and the bottom surface of the operating platform 7 to the ground;

[0033] S31, the left auxiliary support frame 5 is divided into two groups, front and rear, and the ground before welding to ensure that the center axis and the center axis of the right operating frame 6 deviation is not greater than 1mm;

[0034] S32. Install the active roller frame 8 on the left auxiliary support frame 5 and secure it with bolts. The pressure plate 10 and the top seat 11 do not need to be completely tightened.

[0035] S33, the auxiliary driven roller frame 9 is installed on the right operating frame 6 and fixed with bolts;

[0036] S34. The operating platform 7 is placed in a direction perpendicular to the axis of the fixed disc 3 and is divided into a front operating platform 701 and a rear operating platform 702. Both are truss welded structures. C-shaped walkways 703 are installed on both sides above the operating platform. During installation, it is necessary to ensure that the middle span of the C-shaped walkways 703 on both sides does not interfere with the impact wheel water bucket 2.

[0037] S4. Fine-tune the horizontal distance between the left auxiliary support frame 5 and the right operating frame 6 by adjusting the top seat 11 on the upper plane of the left auxiliary support frame 5 to ensure that the axial distance between the active roller frame 8 above the left support frame 5 and the driven roller frame 9 above the right operating frame 6 matches the axial distance between the disc body 301 and the right axial positioning section 302 in the fixed disc 3, and adjust the horizontal distance error to no more than 1 mm.

[0038] S5. Use a crane to flip the fixed disc 3 and the impact runner body 1 90° from an upright position to a horizontal position. When placing them on the active roller frame 8 and the driven roller frame 9, recheck the placement of the fixed disc 3. That is, after the disc body 301 of the fixed disc 3 is aligned with the active roller frame 8 and the right axial positioning section 302 of the fixed disc 3 is aligned with the driven roller frame 9, place the fixed disc 3, the impact runner bucket body 1, the active roller frame 8, and the driven roller frame 9. The fixed disc 3 is then placed on the impact runner bucket body 1, the active roller frame 8, and the driven roller frame 9. The fixed disc 3 has double lifting ears 304 at both ends for hanging with hooks.

[0039] S6. Place the C-shaped platform 703 of the operating platform, weld the C-shaped platform 703 to the upper surfaces of the front operating platform 701 and the rear operating platform 702, tighten the pressure plate 10 and the top seat 11 above the left auxiliary support frame 5, and weld the lower surface of the driven electric roller frame 9 to the upper surface of the right operating frame 6;

[0040] S7, fix the impact runner bucket 2 to the impact runner body 1, power on and rotate the active roller frame 8, and weld the buckets in sequence.

[0041] S71. During the welding process of the impact wheel bucket 2, it is necessary to preheat and weld in a symmetrical position of the impact wheel bucket 2;

[0042] S72. After the impact wheel bucket 2 is connected, the scraping and grinding work on the root of the impact wheel bucket 2 is completed on the C-shaped walkways 703 on both sides of the operating platform 7.

Claims

1. A large diameter impact wheel bucket rotation welding method, characterized in that: The following steps are involved: S1: Finish turning each machining surface of the impact wheel body (1), machining the lifting holes and controlling the outer circle deviation of the impact wheel body (1) to be within 1 mm; S2: Place the fixed disc (3) vertically, place the impact wheel body (1) flat on the support plate of the fixed disc (3), and fix it with bolts (4); S3: Weld and fix the left auxiliary support frame (5), the right operating frame (6) and the operating platform (7) to the ground; S4: Adjust the horizontal distance between the left auxiliary support frame (5) and the right operating frame (6) so that the axial distance between the active roller frame (8) and the driven roller frame (9) matches the axial distance between the disc body (301) and the right axial positioning section (302) of the fixed disc (3), and the horizontal distance error is ≤1mm; S5: Turn the fixed disc (3) and the impact wheel body (1) 90 degrees and place them flat on the active roller frame (8) and the driven roller frame (9), so that the disc body (301) in the fixed disc (3) is aligned with the active roller frame (8), and the right axial positioning section (302) in the fixed disc (3) is vertically aligned with the driven roller frame (9); S6: Install the operating platform C-type walkway (703), tighten the pressure plate (10) and the top seat (11) of the left auxiliary support frame (5), and weld the lower plane of the driven roller frame (9) and the upper plane of the right operating frame (6); S7: Fix the impact wheel bucket (2) on the impact wheel body (1), and energize and rotate the active roller frame (8) to complete the welding.

2. The method according to claim 1, characterized in that The step S2 comprises: S21: installing the wheel body positioning flat keys (303) at the middle shaft end of the fixed disc (3) in eight equal parts, checking the matching tolerance of the wheel body positioning flat keys (303), and fixing them together with bolts (4); S22: utilizing the right axial positioning section (302) at the right end of the fixed disc (3) to contact and position the driven roller frame (9).

3. The method according to claim 1, characterized in that Step S3 The invention comprises: S31: the deviation of the central axis of the left auxiliary support frame (5) and the right operating frame (6) is ≤1mm; S32: the active roller frame (8) is installed on the upper plane of the left auxiliary support frame (5), and is fixed by bolts, wherein the pressure plate (10) and the top seat (11) do not need to be completely tightened; S33: the driven roller frame (9) is installed on the upper plane of the right operating frame (6); S34: the operating platform (7) is arranged in a vertical direction along the axis of the fixed disc (3), and is divided into a front operating platform (701) and a rear operating platform (702), both of which are truss welded structures, and C-type walkways (703) are installed on both sides above the operating platform, and the middle span of the C-type walkways (703) on both sides does not interfere with the impact wheel bucket (2).

4. The method according to claim 1, wherein In step S4, the top seat (11) is adjusted so that the disc body (301) and the right axial positioning section (302) are in effective contact with the driving roller frame (8) and the driven roller frame (9), respectively.

5. The method according to claim 1, wherein In step S5, two ends of the fixed disc (3) are provided with double hanging ears (304) for hanging with the hooks.

6. The method according to claim 1, characterized in that In step S6, the C-shaped platform (703) is welded and fixed to the front operating platform (701) and the rear operating platform (702).

7. The method according to claim 1, characterized in that The step S7 comprises: S71: preheating the impact wheel bucket (2) during welding and welding in symmetrical positions; S72: grinding the root of the impact wheel bucket (2) on the C-shaped platform (703) after welding is completed.

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