Welding device for fan impeller machining

Abstract

The invention belongs to the technical field of fan impeller machining, and particularly relates to a welding device for fan impeller machining, the welding device comprises a workbench, a PLC console, a control panel and a wheel shaft frame, the PLC console is arranged at the upper end of the workbench, the control panel is arranged at the side end of the PLC console, and the wheel shaft frame is arranged above the workbench. By arranging the self-guiding inclined limiting plate, the limiting groove, the anti-inclination plate, the guiding transmission wheel, the inner ring self-adaptive positioning mechanism, the connecting rod, the large gear ring and the driving gear, when blades need to be welded to the periphery of the wheel shaft frame, the wheel shaft frame is arranged at the upper end of the plastic ring. An operator holds and rotates the grip to enable the threaded rod connected with the lower end of the grip to rotate, and when the threaded rod rotates, the periphery of the threaded rod moves upwards or downwards according to the rotating direction of the grip through the movable end shaft sleeve connected in a threaded mode. In the moving process of the movable end shaft sleeve, the distance between the movable end shaft sleeve and the fixed end sleeve ring is lengthened or shortened, and therefore the angle between the peripheral connecting rods is continuously adjusted.

Description

Technical Field

[0001] The present invention relates to the technical field of fan impeller processing, in particular to a welding device used for fan impeller processing. Background Art

[0002] Wind turbine impeller welding is a critical process in wind turbine manufacturing, primarily used to precisely connect multiple blades to the hub to form an efficient wind-capturing structure. With the surge in global demand for clean energy, welding quality directly impacts the impeller's aerodynamic performance and service life in complex wind conditions. The quality of welding determines the turbine's power generation efficiency and maintenance costs over its 20-year operating cycle. This technology overcomes the precision bottlenecks of traditional manual welding, achieving millimeter-level positioning through automated control. This improves the dynamic balance of the impeller by over 40%, effectively reducing downtime losses caused by impeller failures at wind farms. This technology is of strategic significance for promoting the localization of large offshore wind turbines and reducing the cost of electricity.

[0003] The existing technology has the following deficiencies: the prior art "A welding device for a fan impeller" with publication number CN118218895B "includes a base plate, a placement plate is provided on the top of the base plate, the placement plate is used to support and place the hub, a discharge box is provided on the top of the base plate on one side of the placement plate, the discharge box is used to place the blades, a support is provided at the bottom of the discharge box, the support is used to support the blades, a welding head is provided between the discharge box and the placement plate, the welding head is used to weld the blades and the hub."

[0004] Although the above structure is provided with basic structures such as a placement plate, a material discharge box and an adjusting member, the whole structure relies on mechanical limit and manual adjustment mode, and there is a significant technical generation gap. Its blade positioning is only achieved by the elastic contact between the slide groove and the arc block. Although the compression spring (64) and the return spring (66) in the limiter (6) provide adaptive compression, they lack a dynamic feedback mechanism and cannot compensate for the offset caused by blade deformation in real time, resulting in limited welding positioning accuracy (more than ±0.5mm). In addition, the adjusting member (44) relies on the threaded rod (443) to manually rotate the support rod (445), and it is necessary to repeatedly try and error to match the inclination angle of the L-shaped plate (43). A single change of type takes more than 10 minutes; the internal support mechanism only relies on the spring return structure (return spring 72 / semicircular block 73) of the pusher (7) to provide a unidirectional tightening force, which cannot adapt to different hub inner diameters (applicable range <500mm) and lacks multi-directional synchronous locking capability. Its driving member (8) adopts belt transmission (belt member 83), and the dynamic accuracy is affected by the belt relaxation. Summary of the Invention

[0005] In view of the deficiencies of the prior art, the present invention provides a welding device for processing fan impellers, which solves the current problems of poor automation accuracy and inability to adapt to axle frames with different inner diameters.

[0006] To achieve the above-mentioned objectives, the present invention provides the following technical solutions: a welding device for processing fan impellers, comprising a workbench, a PLC console, a control panel and a wheel axle frame, wherein the PLC console is arranged at the upper end of the workbench, the control panel is arranged at the side end of the PLC console, and the wheel axle frame is arranged above the workbench.

[0007] A self-guided inclined limit plate is provided at the upper end of the workbench, a first motor is provided at the upper end of the self-guided inclined limit plate, a transmission roller is also provided at the upper end of the workbench, a synchronous belt is provided at the side end of the transmission roller, a second motor is provided on the other side of the transmission roller, an inner ring adaptive positioning mechanism is provided at the middle part of the inner side of the wheel axle frame, a middle shaft column is provided at the bottom of the workbench, and a third motor is provided on the other side of the bottom of the workbench.

[0008] The self-guided inclined limit plate also includes a limit groove, an anti-roll plate and an arched limit block. The limit groove is opened at the side end of the self-guided inclined limit plate, the anti-roll plate is fixedly installed on the upper end surface of the self-guided inclined limit plate, and the arched limit block is welded to the upper end of the self-guided inclined limit plate.

[0009] In some embodiments, a circular sleeve structure is provided at the side end of the anti-roll plate, and the structure is placed horizontally on the side of the anti-roll plate and establishes a fixed connection relationship with each other.

[0010] In some embodiments, the guide transmission wheel also includes a swing arm, a linear push rod and a push plate. The swing arm is inserted into the side end of the guide transmission wheel, the linear push rod is movably connected to the side end of the swing arm, and the other side passes through the sleeve structure at the side end of the anti-roll plate, and the push plate is fixedly connected to the other end of the linear push rod.

[0011] In some embodiments, the inner ring adaptive positioning mechanism also includes a threaded rod, a movable end sleeve, a handle, a fixed end ring, a connecting rod and an inner support block. The threaded rod is movably connected to the top of the inner ring adaptive positioning mechanism, and the movable end sleeve is threadedly connected to the outer periphery of the threaded rod.

[0012] In some embodiments, the handle is fixedly connected to the movable end sleeve, the fixed end ring is fixedly connected to the outer periphery of the bottom of the inner ring adaptive positioning mechanism, and an axis structure is provided at both ends of the connecting rod, and is movably connected to the movable end sleeve and the side end of the inner support block through the axis structure.

[0013] In some embodiments, the connecting rod is arranged in four directions, and a single direction is divided into two groups, the lower group, and the lower group is movably connected between the inner support block and the fixed end ring, and the inner support block unit is designed with an arc surface structure.

[0014] In some embodiments, the middle shaft column also includes a large gear ring, a plastic ring and a driving gear. The large gear ring is movably connected to the outer periphery of the middle shaft column, the plastic ring is adhered to the top of the large gear ring, the tooth grooves of the driving gear are engaged with the large gear ring, and are sleeved on the top of the third motor.

[0015] In some embodiments, the self-guided inclined limit plate provided below the axle frame, its limit groove, anti-roll plate and arched limit block form a three-dimensional constraint structure.

[0016] In some embodiments, the PLC console is programmed to control the start and stop timing of the first motor, the second motor, and the third motor, wherein: the action of the first motor conveying the blades through the transmission roller and the pushing action of the second motor driving the linear push rod are separated by 0.5-1.2 seconds; the third motor is started after the blade welding is completed, and drives the wheel shaft frame to rotate 15°±0.5° through the large ring gear.

[0017] Compared to the prior art, the present invention provides a welding device for fan impeller machining. This device incorporates a self-guided inclined limit plate, a limit groove, an anti-roll plate, a guide drive wheel, an inner ring adaptive positioning mechanism, connecting rods, a large ring gear, and a drive gear. During use, the operator controls the first, second, and third motors via a control panel and a PLC console. When blades need to be welded to the periphery of the axle frame, the axle frame is placed on top of a plastic ring. The operator grips and rotates a handle, causing the threaded rod connected to the lower end of the handle to rotate. As the rod rotates, the outer sleeve, threadedly connected to the fixed end, moves upward or downward depending on the direction of the handle's rotation. As the sleeve moves, the distance between it and the fixed end ring increases or decreases, thereby continuously adjusting the angle between the outer connecting rods, causing the inner support block to approach the inner wall of the axle frame until it is firmly against the inside of the axle frame. The blade to be welded is then placed on the drive roller. The second motor drives the transmission roller to rotate through the synchronous belt, and at the same time transports the blades at the upper end. When the blades are transported to the upper end of the self-guided inclined limit plate, they are sunk into the limit groove through one side, and then the blades tilt. At this time, the first motor starts, and drives the outer swing arm to rotate by driving the guide transmission wheel, and the swing arm drives the linear push rod connected to the side end to reciprocate. When the linear push rod pushes the blades sunk into the limit groove through the push plate, the anti-roll plate and the arched limit block move in a straight line under the limit until they contact the wheel axle frame. At this time, the workers can start welding on both sides. When a group of blades are welded, the third motor drives the large gear ring to rotate through the driving gear, and the large gear ring drives the wheel axle frame placed on the upper end to rotate a fixed angle. Repeat the above steps until the outer blades of the wheel axle frame are welded;

[0018] Through the above-mentioned configuration and process, the welding device has the following advantages compared with the existing welding devices for fan impeller processing:

[0019] 1. By integrating the automated process, including the transmission roller conveying blades, the self-guided inclined limit plate to achieve automatic inclined positioning of the blades, and the linear actuator to accurately push them to the welding position, combined with the two-way limiting structure of the anti-roll plate and arched limit block, the positioning deviation problem caused by traditional manual placement is effectively solved, the blade welding position accuracy is improved to ±0.1mm, and the degree of automation of the entire process is greatly improved.

[0020] 2. The inner ring's adaptive positioning mechanism uses a threaded rod to drive a movable end sleeve to link multiple connecting rods, allowing the inner support block to adapt to axle carriers with varying inner diameters ranging from 200 to 1200 mm. Rapid positioning is achieved with a simple rotation of the handle, reducing changeover time from the traditional 15 minutes to less than 5 minutes. This device has increased the welding qualification rate from the industry average of 85% to over 98%, shortening the single-piece production cycle by 60%. The combined design of the plastic ring and large gear ring effectively absorbs welding vibrations and increases the rotational friction of the axle carrier, keeping the product's coaxiality error within 0.05 mm, achieving high-precision, high-efficiency, and highly compatible intelligent welding of fan impellers. BRIEF DESCRIPTION OF THE DRAWINGS

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

[0022] Figure 2 This is a schematic diagram of the connection position of the bottom drive gear of the present invention;

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

[0024] Figure 4 This is a schematic diagram of the installation position structure of the transmission roller and the self-guided inclined limit plate of the present invention;

[0025] Figure 5 This is a schematic diagram of the connection position structure of the linear push rod and the swing arm of the present invention;

[0026] Figure 6 This is a schematic diagram of the connection position of the large ring gear and the driving gear of the present invention;

[0027] Figure 7 This is a schematic diagram of the connecting position structure of the connecting rod and the movable end sleeve of the present invention.

[0028] In the figure: 1. Workbench; 2. PLC console; 3. Control panel; 4. Wheel axle frame; 5. Self-guided inclined limit plate; 501. Limit groove; 502. Anti-roll plate; 503. Arch limit block; 6. Guide transmission wheel; 601. Swing arm; 602. Linear push rod; 603. Push plate; 7. First motor; 8. Drive roller; 9. Synchronous belt; 10. Second motor; 11. Inner ring adaptive positioning mechanism; 1101. Threaded rod; 1102. Movable end sleeve; 1103. Handle; 1104. Fixed end collar; 1105. Connecting rod; 1106. Inner support block; 12. Middle shaft column; 1201. Large gear ring; 1202. Plastic ring; 1203. Drive gear; 13. Third motor. DETAILED DESCRIPTION

[0029] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0030] In the description of the present invention, it should be noted that the terms "upper," "lower," "inner," "outer," "front end," "rear end," "both ends," "one end," "the other end," and the like, indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings and are intended solely to facilitate and simplify the description of the present invention. They are not intended to indicate or imply that the devices or components referred to must have, be constructed, or operate in a specific orientation, and therefore should not be construed as limiting the present invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0031] In the description of the present invention, it should be noted that, unless otherwise expressly specified or limited, the terms "installed," "provided with," "connected," etc., should be understood in a broad sense. For example, "connected" may refer to a fixed connection, a detachable connection, or an integral connection; it may refer to a mechanical connection or an electrical connection; it may refer to a direct connection or an indirect connection through an intermediate medium; it may refer to internal communication between two components. Those skilled in the art will be able to understand the specific meanings of the above terms in the present invention based on the specific circumstances.

[0032] In this embodiment: a welding device for processing fan impellers, including a workbench 1, a PLC console 2, a control panel 3 and a wheel axle frame 4, the PLC console 2 is arranged at the upper end of the workbench 1, the control panel 3 is arranged at the side end of the PLC console 2, and the wheel axle frame 4 is arranged above the workbench 1.

[0033] A self-guided inclined limit plate 5 is provided at the upper end of the workbench 1, and a first motor 7 is provided at the upper end of the self-guided inclined limit plate 5. A transmission roller 8 is also provided at the upper end of the workbench 1, and a synchronous belt 9 is provided at the side end of the transmission roller 8. A second motor 10 is provided on the other side of the transmission roller 8. An inner ring adaptive positioning mechanism 11 is provided at the middle part of the inner side of the wheel axle frame 4, a middle shaft column 12 is provided at the bottom of the workbench 1, and a third motor 13 is provided on the other side of the bottom of the workbench 1.

[0034] The self-guided inclined limit plate 5 also includes a limit groove 501, an anti-roll plate 502 and an arched limit block 503. The limit groove 501 is opened at the side end of the self-guided inclined limit plate 5, the anti-roll plate 502 is fixedly installed on the upper end surface of the self-guided inclined limit plate 5, and the arched limit block 503 is welded to the upper end of the self-guided inclined limit plate 5.

[0035] In this embodiment, a circular sleeve structure is provided at the side end of the anti-roll plate 502, and the structure is placed horizontally on the side of the anti-roll plate 502 and establishes a fixed connection relationship with each other; the guide transmission wheel 6 also includes a swing arm 601, a linear push rod 602 and a push plate 603, the swing arm 601 is inserted into the side end of the guide transmission wheel 6, the linear push rod 602 is movably connected to the side end of the swing arm 601, and the other side passes through the sleeve structure at the side end of the anti-roll plate 502, and the push plate 603 is fixedly connected to the other end of the linear push rod 602.

[0036] Specifically, such as Figure 1 and Figure 5 As shown, the sleeve structure provided at the side end of the anti-roll plate 502 is penetrated by the linear push rod 602 and limits the movement of the linear push rod 602 from the outside, so that the linear push rod 602 performs reciprocating linear motion.

[0037] In this embodiment, the inner ring adaptive positioning mechanism 11 also includes a threaded rod 1101, a movable end sleeve 1102, a handle 1103, a fixed end ring 1104, a connecting rod 1105 and an inner support block 1106. The threaded rod 1101 is movably connected to the top of the inner ring adaptive positioning mechanism 11, and the movable end sleeve 1102 is threadedly connected to the outer periphery of the threaded rod 1101; the handle 1103 is fixedly connected to the movable end sleeve 1102, and the fixed end ring 1104 is fixedly connected to the outer periphery of the bottom of the inner ring adaptive positioning mechanism 11. A shaft structure is provided at both ends of the connecting rod 1105, and is movably connected to the movable end sleeve 1102 and the side end of the inner support block 1106 through the shaft structure.

[0038] Specifically, such as Figure 1 、 Figure 6 as well as Figure 7 Shown, when the movable end shaft sleeve 1102 moves up, the angle between the connecting rod 1105 increases, and the inner support block 1106 closes toward the middle. Now, the wheel shaft frame 4 can be taken away at will.

[0039] In this embodiment, the connecting rod 1105 is arranged in four directions, among which a single direction is divided into two groups, one above and one below, wherein the downward group is movably connected between the inner support block 1106 and the fixed end ring 1104, and the inner support block 1106 is designed as an arc surface structure; the middle shaft column 12 also includes a large gear ring 1201, a plastic ring 1202 and a driving gear 1203, the large gear ring 1201 is movably connected to the outer periphery of the middle shaft column 12, the plastic ring 1202 is adhered to the top of the large gear ring 1201, the tooth grooves of the driving gear 1203 are engaged with the large gear ring 1201, and are sleeved on the top of the third motor 13.

[0040] Specifically, such as Figure 2 、 Figure 3 as well as Figure 4 As shown, the arc-shaped inner support block 1106 structure can fit the inner wall of the annular wheel axle frame 4 as much as possible, so that the inner pressure is evenly distributed and unnecessary wear of the inner side of the wheel axle frame 4 is avoided.

[0041] In this embodiment, the self-guided inclined limit plate 5 is arranged under the wheel axle frame 4, and its limit groove 501, anti-roll plate 502, and arched limit block 503 form a three-dimensional constraint structure; the PLC console 2 is programmed to control the start and stop timing of the first motor 7, the second motor 10, and the third motor 13, wherein: the action of the first motor 7 conveying the blades through the transmission roller 8 and the pushing action of the second motor 10 driving the linear push rod 602 are spaced 0.5-1.2 seconds apart; the third motor 13 is started after the blade welding is completed, and drives the wheel axle frame 4 to rotate 15°±0.5° through the large ring gear 1201.

[0042] Specifically, such as Figure 1 and Figure 4 As shown, the PLC console 2 sets the three-motor coordinated timing: the first motor 7 drives the transmission roller 8 through the synchronous belt 9 to transport the blade at 0.8 m / s; 1 second later, the second motor 10 starts the linear push rod 602, pushing the blade to the hub with a thrust of 5 kN; after welding is completed, the third motor 13 drives the wheel shaft frame 4 to rotate 15.2°.

[0043] The operating principle and usage process of the present invention are as follows: When using this structure, the operator controls the first motor 7, the second motor 10, and the third motor 13 via the control panel 3 and the PLC console 2. When blades need to be welded to the periphery of the axle frame 4, the axle frame 4 is placed on top of the plastic ring 1202. The operator grasps and rotates the handle 1103, causing the threaded rod 1101 connected to the lower end of the handle 1103 to rotate. As the threaded rod 1101 rotates, the outer threaded sleeve 1102 moves upward or downward depending on the direction of rotation of the handle 1103. As the movable sleeve 1102 moves, the distance between it and the fixed sleeve 1104 increases or decreases, thereby continuously adjusting the angle between the outer connecting rod 1105 and the inner support block 1106, causing it to continuously approach the inner wall of the axle frame 4 until it is firmly against the inner side of the axle frame 4. The blade to be welded is then placed on the transmission roller 8. The second motor 10 drives the transmission roller 8 via the synchronous belt 9, simultaneously conveying the blades at the upper end. When the blades reach the upper end of the self-guided inclined stop plate 5, they slide into the stop groove 501 on one side, causing the blades to tilt. At this point, the first motor 7 is activated, driving the guide transmission wheel 6 to rotate, which in turn drives the outer swing arm 601. The swing arm 601 drives the linear push rod 602 connected to the side end to reciprocate. When the linear push rod 602 pushes the blades trapped in the stop groove 501 via the push plate 603, the anti-tilt plate 502 and the arched stop block 503 move linearly under the limit until they contact the axle frame 4. At this point, workers can begin welding on both sides. Once a set of blades is welded, the third motor 13 drives the large ring gear 1201 via the drive gear 1203, which in turn rotates the axle frame 4 at the upper end by a fixed angle. These steps are repeated until the outer blades of the axle frame 4 are welded.

[0044] Finally, it should be noted that the above descriptions are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art will be able to modify the technical solutions described in the aforementioned embodiments or substitute equivalents for some of the technical features. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention shall be included within the scope of protection of the present invention.

Claims

1. A welding device for processing a fan impeller, comprising a workbench (1), a PLC console (2), a control panel (3) and a wheel axle frame (4), wherein the PLC console (2) is arranged at the upper end of the workbench (1), the control panel (3) is arranged at the side end of the PLC console (2), and the wheel axle frame (4) is arranged above the workbench (1), characterized in that: The upper end of the workbench (1) is provided with a self-guided inclined limit plate (5), the upper end of the self-guided inclined limit plate (5) is provided with a first motor (7), the upper end of the workbench (1) is also provided with a transmission roller (8), the side end of the transmission roller (8) is provided with a synchronous belt (9), the other side of the transmission roller (8) is provided with a second motor (10), the middle part of the inner side of the wheel shaft frame (4) is provided with an inner ring adaptive positioning mechanism (11), the bottom of the workbench (1) is provided with a middle shaft column (12), and the other side of the bottom of the workbench (1) is provided with a third motor (13); The self-guided inclined limiting plate (5) further comprises a limiting groove (501), an anti-roll plate (502) and an arched limiting block (503); the limiting groove (501) is provided at a side end of the self-guided inclined limiting plate (5); the anti-roll plate (502) is fixedly mounted on an upper end surface of the self-guided inclined limiting plate (5); and the arched limiting block (503) is welded to the upper end of the self-guided inclined limiting plate (5).

2. The welding device for fan impeller processing according to claim 1, characterized in that: A circular sleeve structure is provided at the side end of the anti-roll plate (502), and the structure is placed horizontally on the side of the anti-roll plate (502) and establishes a fixed connection relationship with each other.

3. The welding device for fan impeller processing according to claim 1, characterized in that: The guide transmission wheel (6) further comprises a swing arm (601), a linear push rod (602) and a push plate (603); the swing arm (601) is plugged into the side end of the guide transmission wheel (6); the linear push rod (602) is movably connected to the side end of the swing arm (601), and the other side thereof passes through the sleeve structure at the side end of the anti-roll plate (502); and the push plate (603) is fixedly connected to the other end of the linear push rod (602).

4. The welding device for fan impeller processing according to claim 1, characterized in that: The inner ring adaptive positioning mechanism (11) further comprises a threaded rod (1101), a movable end sleeve (1102), a handle (1103), a fixed end collar (1104), a connecting rod (1105) and an inner support block (1106); the threaded rod (1101) is movably connected to the top of the inner ring adaptive positioning mechanism (11); and the movable end sleeve (1102) is threadedly connected to the outer periphery of the threaded rod (1101).

5. The welding device for fan impeller processing according to claim 4, characterized in that: The handle (1103) is fixedly connected to the movable end sleeve (1102), the fixed end ring (1104) is fixedly connected to the outer periphery of the bottom of the inner ring adaptive positioning mechanism (11), and the connecting rod (1105) is provided with an axis structure at both ends, and is movably connected to the movable end sleeve (1102) and the side end of the inner support block (1106) through the axis structure.

6. The welding device for fan impeller processing according to claim 5, characterized in that: The connecting rods (1105) are arranged in four directions, wherein a single direction is divided into two groups, the lower group, wherein the lower group is movably connected between the inner support block (1106) and the fixed end ring (1104), and the inner support block (1106) is designed as a curved surface structure.

7. The welding device for fan impeller processing according to claim 1, characterized in that: The middle shaft column (12) also includes a large gear ring (1201), a plastic ring (1202) and a driving gear (1203). The large gear ring (1201) is movably connected to the periphery of the middle shaft column (12). The plastic ring (1202) is adhered to the top of the large gear ring (1201). The tooth grooves of the driving gear (1203) are engaged with the large gear ring (1201) and are sleeved on the top of the third motor (13).

8. The welding device for fan impeller processing according to claim 1, characterized in that: The self-guided inclined limiting plate (5) arranged below the wheel axle frame (4) comprises a limiting groove (501), an anti-tilt plate (502) and an arched limiting block (503) forming a three-dimensional constraint structure.

9. The welding device for fan impeller processing according to claim 1, characterized in that: The PLC console (2) is programmed to control the start and stop timing of the first motor (7), the second motor (10), and the third motor (13), wherein: the interval between the action of the first motor (7) conveying the blades through the transmission roller (8) and the pushing action of the second motor (10) driving the linear push rod (602) is 0.5-1.2 seconds; the third motor (13) is started after the blade welding is completed, and drives the wheel shaft frame (4) to rotate 15°±0.5° through the large gear ring (1201).

Images