Ultrasonic vibration turning device and method for laser repair layer of wind power bearing ring

Abstract

The invention discloses a wind power bearing ring laser repair layer ultrasonic vibration turning device and method, and belongs to the technical field of wind power bearing repair layer machining equipment. The wind power bearing ring laser repair layer ultrasonic vibration turning device specifically comprises a base, a spindle box arranged above the base and an ultrasonic machining platform arranged in parallel with the spindle box; a rotary workbench used for installing a bearing ring to be machined is arranged on the side edge, adjacent to the ultrasonic machining platform, of the spindle box, and the rotary workbench is rotationally arranged on the side edge of the spindle box through a bearing assembly in the spindle box. The ultrasonic machining platform comprises an ultrasonic vibration device used for machining the bearing ring and an X-axis and Y-axis adjusting platform used for adjusting the ultrasonic vibration device. The ultrasonic vibration system is coupled to the high-precision transmission system, damage and residual stress of the laser cladding ceramic reinforced repair layer can be effectively reduced, the heterogeneous material removal effect is good, and stripping of hard particles of the ceramic reinforced repair layer and adhesion stripping of a base body in the machining process are remarkably reduced.

Description

Technical Field

[0001] This invention belongs to the technical field of mechanical processing equipment for wind turbine bearing repair layers, specifically relating to an ultrasonic vibration turning device and method for laser repair layers of wind turbine bearing rings. Background Technology

[0002] In recent years, the global wind power industry has shown a booming development trend, and as an important part of the renewable energy sector, its installed capacity has continued to grow rapidly. Based on the 20-year design life of wind turbine equipment, a large number of wind power devices will subsequently be decommissioned, making the repair and remanufacturing of wind turbine main shaft bearing rings a potentially valuable area. Laser cladding has been widely used in the repair and remanufacturing of key components in recent years; however, the "step effect" and "surface powder adhesion phenomenon" caused by the layer-by-layer deposition characteristic of laser cladding are difficult to eliminate.

[0003] Traditional laser cladding methods result in high surface roughness and low shape accuracy in the laser cladding layer, making it difficult for remanufactured bearing rings to meet usage requirements and limiting the further application of laser cladding repair technology in wind turbine bearing ring repair. Therefore, wind turbine bearing rings repaired using traditional laser cladding still require secondary machining to meet dimensional accuracy and surface roughness requirements. However, current technology lacks secondary machining equipment specifically designed for large wind turbine bearings, making it difficult to achieve secondary machining of wind turbine bearing rings. Summary of the Invention

[0004] In view of the shortcomings of traditional processing methods, such as large surface roughness, low shape accuracy, and difficulty in secondary processing of laser cladding layers, the purpose of this invention is to propose an ultrasonic vibration turning device and method for laser repair layer of wind turbine bearing rings.

[0005] To achieve the aforementioned objectives, the technical solution adopted by this invention is: an ultrasonic vibration turning device for laser repair layer of wind turbine bearing races, comprising a base, a spindle box disposed above the base, and an ultrasonic processing platform disposed parallel to the spindle box. A rotary worktable for mounting the bearing race to be processed is disposed on the side of the spindle box adjacent to the ultrasonic processing platform. The rotary worktable is rotatably disposed on the side of the spindle box via a bearing assembly inside the spindle box. The ultrasonic processing platform includes an ultrasonic vibration device for processing the bearing races and an XY axis adjustment platform for adjusting the ultrasonic vibration device.

[0006] As an improvement to the above technical solution, the ultrasonic vibration device includes an ultrasonic generator for emitting ultrasonic waves and a vibrating cutter controlled by ultrasonic waves. The ultrasonic generator is also provided with a conical amplitude transformer for amplifying ultrasonic waves.

[0007] As a further improvement to the above technical solution, the large end diameter of the amplitude transformer is 225mm, the small end diameter is 50mm, the resonance length is 144.86mm, and the operating frequency is 20kHz.

[0008] As a further improvement to the above technical solution, the ultrasonic vibration device is fixed by a clamping assembly, which includes a clamping cylinder and an arc-shaped claw. The clamping cylinder is fixed on the XY-axis adjustment platform, and the arc-shaped claw is driven by the clamping cylinder to fix the ultrasonic vibration device.

[0009] As a further improvement to the above technical solution, the clamping cylinder is a finger cylinder, the claw of the arc-shaped claw is driven by the finger cylinder, and the center of the arc-shaped claw is provided with a positioning groove for clamping the ultrasonic vibration device.

[0010] As a further improvement to the above technical solution, the XY-axis adjustment platform includes an X-axis slide and a Y-axis slide. The Y-axis slide includes a Y-axis servo motor, a Y-axis ball screw, and a Y-axis linear guide. The ultrasonic vibration device is slidably mounted on the Y-axis slide via a slider assembly. The X-axis slide includes an X-axis servo motor, an X-axis ball screw, and an X-axis linear guide. The Y-axis slide is slidably mounted on the X-axis slide via a slider assembly. The X-axis slide is mounted on a base.

[0011] As a further improvement to the above technical solution, a shock-absorbing pad is provided between the X-axis slide and the base, and the shock-absorbing pad is made of rubber.

[0012] As a further improvement to the above technical solution, a spindle drive motor is also provided outside the spindle box. The spindle transmission mechanism inside the spindle box is connected to the spindle drive motor outside the spindle box through a belt transmission mechanism. A protective cover is provided on the outside of the belt transmission mechanism. The protective cover is fixed to the side of the spindle box by bolts, and its surface is provided with heat dissipation holes. The spindle drive motor is adjustablely mounted on the base through a motor mounting bracket.

[0013] As a further improvement to the above technical solution, the rotary table includes a chuck and a transition plate, the chuck being connected to the end of the spindle via the transition plate; three adjustable support blocks are evenly arranged along the circumference of the chuck, the support blocks being used to support and clamp the bearing rings, and a pressure sensor and a speed sensor are also provided on the rotary table.

[0014] And a method for ultrasonically vibrating the machining of a wind turbine bearing ring laser repair layer using the aforementioned ultrasonic vibration machining device, comprising the aforementioned ultrasonic vibration machining device for the wind turbine bearing ring laser repair layer, and further comprising the following steps: S1: First, the laser-clad wind turbine bearing rings are hoisted onto the rotating worktable; S2: Start the clamping program. The support block clamps the bearing ring. During the clamping process, the pressure sensor installed inside the support block is activated, and the clamping force is determined by the signal fed back by the pressure sensor. S3: The XY axis adjustment platform moves the ultrasonic vibration device to the processing position and starts the spindle drive motor. At the same time, the rotation speed of the bearing ring is determined by the signal fed back by the speed sensor on the rotary table. S4: Start the ultrasonic vibration device to begin processing; S5: After completing the machining at one station, the spindle drive mechanism drives the rotary table to finely adjust the angle, rotate to the next machining position, and perform the next machining at the next station. S6: Repeat S5 to complete the machining of the entire bearing ring.

[0015] The aforementioned quick-detachable integrated chassis offers the following advantages: (1) The two-stage reduction system of belt drive and gear drive provided by the present invention can improve the stability of large bearing rings during rotation, effectively reduce vibration interference during processing, and significantly improve the stability of processing.

[0016] (2) The rotary worktable of the present invention has good applicability to the processing of laser repair layers of wind turbine bearing rings of different sizes, and can be extended to the post-processing of other laser cladding repair parts, which is conducive to the realization of automation.

[0017] (3) The ultrasonic vibration system of the present invention is coupled to a high-precision transmission system, which can effectively reduce the damage and residual stress of the laser cladding ceramic reinforcement repair layer, and has a good effect on the removal of heterogeneous materials, significantly reducing the peeling of hard particles of ceramic reinforcement repair layer and the peeling of matrix adhesion during the processing.

[0018] (4) Based on the characteristics of the inner arc surface of the wind turbine bearing ring, the device is designed with a clamp that matches the inner arc surface according to the six-point positioning principle. This can effectively ensure the concentricity and constraint of the wind turbine bearing ring clamping and reduce positioning error.

[0019] The above description is merely an overview of the technical solution of the present invention. In order to better understand the technical means of the present invention and to implement it in accordance with the contents of the specification, and to make the above and other objects, features and advantages of the present invention more apparent and understandable, preferred embodiments are described below in detail with reference to the accompanying drawings. Attached Figure Description

[0020] Figure 1 This is an isometric view of an ultrasonic vibration turning device for laser repair layer of wind turbine bearing rings according to the present invention.

[0021] Figure 2This is a structural schematic diagram of the spindle box part of the present invention.

[0022] Figure 3 This is a schematic diagram of the ultrasonic vibration device and the XY axis adjustment platform of the present invention.

[0023] Figure 4 This is a schematic diagram of the ultrasonic vibration device of the present invention.

[0024] Figure 5 This is a schematic diagram of the structure of the rotary worktable of the present invention.

[0025] Figure 6 This is a schematic diagram of the internal structure of the rotary table of the present invention.

[0026] The components include: 1. XY axis adjustment platform; 11. X-axis ball screw; 12. X-axis linear guide; 13. Y-axis ball screw; 14. Y-axis linear guide; 2. Ultrasonic vibration device; 21. Ultrasonic generator; 22. Vibrating cutter; 23. Amplitude bar; 3. Clamping assembly; 31. Clamping cylinder; 32. Arc-shaped chuck; 33. Positioning slot; 4. Rotary worktable; 41. Chuck; 42. Transition plate; 43. Support block; 5. Spindle box; 51. Spindle transmission mechanism; 6. Spindle drive motor; 7. Belt drive mechanism; 71. Protective cover; 72. Heat dissipation holes; 8. Machine tool base. Detailed Implementation

[0027] The features and exemplary embodiments of various aspects of the present invention will now be described in detail. Numerous specific details are set forth in the following detailed description in order to provide a thorough understanding of the invention. However, it will be apparent to those skilled in the art that the invention may be practiced without requiring some of these specific details. The following description of embodiments is merely intended to provide a better understanding of the invention by illustrating examples of the invention. In the accompanying drawings and the following description, at least some well-known structures and techniques have not been shown in order to avoid unnecessarily obscuring the invention; and, for clarity, the dimensions of some structures may be exaggerated. The features, structures, or characteristics described below may be combined in any suitable manner in one or more embodiments; furthermore, the terms “first or I,” “second or II,” “third or III,” etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0028] The directional terms used in the following description refer to the directions shown in the figures and are not intended to limit the specific structure of the present invention. It should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," and "connect" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0029] Reference Figure 1 An ultrasonic vibration turning device for laser repair layer of wind turbine bearing rings includes a machine tool base 8, a spindle box 5 disposed above the base, and an ultrasonic processing platform disposed parallel to the spindle box 5. Ultrasonic vibration-assisted processing technology, with its unique advantages in improving material removal rate, reducing surface roughness, and improving processing accuracy, combines ultrasonic vibration technology with turning process, which can significantly improve the surface quality and dimensional accuracy of laser cladding layer, provide reliable equipment support for green remanufacturing of wind turbine bearing rings, and help the sustainable development of wind power industry.

[0030] Reference Figure 2 The spindle box 5 is provided with a rotary worktable 4 for mounting the bearing rings to be processed on one side adjacent to the ultrasonic processing platform. The rotary worktable 4 is rotatably mounted on the side of the spindle box 5 through the bearing assembly inside the spindle box 5. The rotary worktable 4 mounted on the side of the spindle box 5 is connected to the spindle transmission mechanism 51 inside the spindle box 5 and is driven by the spindle transmission mechanism 51 to drive the bearing rings to be processed on the rotary worktable 4.

[0031] A spindle drive motor 6 is also installed outside the spindle box 5. The spindle transmission mechanism 51 inside the spindle box 5 is connected to the spindle drive motor 6 outside the spindle box 5 via a belt transmission mechanism 7. The spindle drive motor 6 is adjustablely mounted on the base via a motor mounting bracket. The motor mounting bracket at the bottom of the spindle drive motor 6 is also provided with a slide rail that cooperates with the base to achieve adjustable settings. The motor bracket is also provided with an adjusting bolt. The machine tool base 8 is provided with a slotted hole corresponding to the adjusting bolt. The belt tension in the belt transmission mechanism 7 can be precisely controlled through the cooperation of the slide rail and the adjusting bolt.

[0032] In this embodiment, four sets of adjusting bolts and oblong holes are provided, with the four adjusting bolts located on the two sides of the motor mounting base respectively.

[0033] In this embodiment, the belt in the belt drive mechanism 7 is an A-type V-belt with a small pulley diameter of 140mm and a large pulley diameter of 420mm, forming a 3:1 reduction ratio. This ensures that the spindle output speed is stable at 600r / min, guaranteeing the stability of the large bearing rings during rotation and ensuring machining accuracy. Furthermore, a protective cover 71 is provided on the outside of the belt drive mechanism 7. The protective cover 71 is bolted to the side of the spindle box 5, and its surface is provided with heat dissipation holes 72. This protects the belt drive mechanism 7 while ensuring its heat dissipation performance, increasing its service life.

[0034] In addition, in this embodiment, the spindle box 5 is supported by a combination of double-row cylindrical roller bearings and thrust ball bearings. A Morse taper interface is provided at the position where the spindle end connects to the rotary table 4. It is locked by an axial locking nut, which can realize the quick replacement of the fixtures on the rotary table 4.

[0035] Reference Figure 5 , Figure 6 The rotary table 4 includes a chuck 41 and a transition plate 42. The chuck 41 is connected to the end of the spindle via the transition plate. The rotary table 4 employs a three-jaw self-centering structure to support the bearing races. Specifically, three adjustable support blocks 43 are evenly distributed circumferentially on the chuck 41. These support blocks 43 support and clamp the bearing races. To protect the bearing races and prevent excessive clamping force during clamping, wear-resistant pads are provided on the top of the support blocks 43, which contact the bearing races. In this embodiment, the three support blocks 43 are evenly distributed 120° circumferentially. The working surface of each support block 43 is inlaid with a carbide block, and its flatness is ensured to be ≤0.01mm after grinding. A pneumatic rotary joint is provided at the rear end of the chuck 41, connected to a clamping cylinder 31 via an air pipe, enabling rapid clamping and releasing of the bearing races. For bearing races of different sizes, the support range can be adjusted by replacing the support blocks 43. In addition, the chuck 41 is also equipped with a dial, and the support block 43, together with the dial, can achieve positioning accuracy of ±0.02mm.

[0036] Reference Figure 3 , Figure 4The ultrasonic machining platform includes an ultrasonic vibration device 2 for machining bearing rings and an XY-axis adjustment platform 1 for adjusting the ultrasonic vibration device 2. The ultrasonic vibration device is located on the side of the rotary table 4 and is used to machine the bearing rings on the rotary table 4. The ultrasonic vibration device 2 includes an ultrasonic generator 21 for emitting ultrasonic waves and a vibrating cutter 22 controlled by ultrasonic waves. The ultrasonic generator 21 is also equipped with a conical amplitude transformer 23 for amplifying ultrasonic waves. In this embodiment, the ultrasonic generator 21 outputs 20kHz vibration, which is amplified by the amplitude transformer 23 and transmitted to the cutter. The amplitude transformer 23 is made of steel, with a large end diameter of 225mm, a small end diameter of 50mm, a resonant length of 144.86mm, and a working frequency of 20kHz. The ultrasonic amplitude transformer 23 is heat-treated to achieve a hardness of 27-39HRC, and its surface is also provided with a chrome-plated wear-resistant layer.

[0037] The ultrasonic vibration device is fixed by a clamping assembly 3, which includes a clamping cylinder 31 and an arc-shaped claw 32. The clamping cylinder 31 is fixed on the XY-axis adjustment platform 1 and is a finger cylinder. The arc-shaped claw 32 is driven by the clamping cylinder to fix the ultrasonic vibration device; that is, the claw of the arc-shaped claw 32 is driven by the finger cylinder. In this embodiment, the arc-shaped claw 32 has two claws, and the joint of the two claws is arc-shaped, forming a positioning groove 33 for clamping the ultrasonic vibration device 2. Two sets of air rods are respectively provided on both sides of the finger cylinder, and the two sets of air rods are respectively connected to the other end of the two claws. The extension and retraction of the air rods realizes the disassembly and replacement of the ultrasonic vibration device 2 at the joint of the two claws. This fixing method can realize the simple replacement of the ultrasonic vibration device 2. Different ultrasonic vibration devices 2 can be used for different processing needs, thus expanding the application range of the ultrasonic vibration device 2.

[0038] When machining bearing rings, the ultrasonic vibration device needs to be adjusted in position. Therefore, refer to... Figure 3 The XY-axis adjustment platform 1 includes an X-axis slide and a Y-axis slide. The Y-axis slide includes a Y-axis servo motor, a Y-axis ball screw 13, and a Y-axis linear guide 14. The ultrasonic vibration device is slidably mounted on the Y-axis slide via a slider assembly. The X-axis slide includes an X-axis servo motor, an X-axis ball screw 11, and an X-axis linear guide 12. The Y-axis slide is slidably mounted on the X-axis slide via a slider assembly. The X-axis slide is mounted on a base. Additionally, protective covers 71 are provided at the bottom of the X-axis and Y-axis slides to cover the exposed portions of the screw and guide rail, preventing cutting debris from entering the transmission mechanism.

[0039] To increase the stability of the ultrasonic vibration device during the adjustment process, a shock-absorbing pad is provided between the X-axis slide and the base. The shock-absorbing pad is made of rubber.

[0040] The clamping device is equipped with a pressure sensor on the inner side of the jaws to ensure that the workpiece is securely clamped by detecting the clamping force and to prevent displacement during processing.

[0041] In this embodiment, the wind turbine bearing ring after laser cladding is hoisted onto the rotary worktable 4. The foot switch is pressed to start the clamping program, and the support block 43 on the rotary worktable 4 automatically tightens. During the tightening process, the pressure sensor detects whether the clamping force meets the standard.

[0042] Then, the turning parameters are set via the touchscreen, and the drive motor rotates the bearing rings via belt drive. At the same time, the ultrasonic generator 21 moves to the machining position for cutting under the drive of the XY axis adjustment platform 1. During the cutting process, the ultrasonic generator 21 outputs 20kHz vibration, which is amplified by the amplitude transformer 23 and transmitted to the tool to achieve precision turning of the cladding layer. After completing the machining of one station, the spindle drive mechanism 51 drives the rotary table 4 to adjust the angle and move to the next machining position for the next machining.

[0043] Repeat the above turning operations until the entire circumference of the bearing ring is machined, ultimately achieving a surface roughness Ra≤0.8μm and roundness≤0.03mm machining accuracy.

[0044] The spindle box 5 of the aforementioned turning device is horizontally mounted on one side of the base via shock-absorbing pads, while the XY axis adjustment platform 1 is fixed to the other side of the base via a motor bracket, forming a symmetrical layout of "left drive, right adjustment". At the same time, the machine tool as a whole adopts a closed protective cover 71, and a tempered glass observation window is set at the front end of the protective cover 71, which not only ensures the safety of processing but also facilitates real-time monitoring of the turning status of the cladding layer.

[0045] The above description is merely a preferred embodiment of the present invention. Any simple modifications, equivalent changes, and alterations made by those skilled in the art to the above embodiments without departing from the scope of the present invention and based on the technical essence of the present invention shall still fall within the scope of the present invention.

Claims

1. An ultrasonic vibration turning device for laser repair layer of wind turbine bearing rings, characterized in that: The device includes a base, a spindle box disposed above the base, and an ultrasonic machining platform disposed parallel to the spindle box. A rotary worktable for mounting bearing rings to be processed is disposed on the side of the spindle box adjacent to the ultrasonic machining platform. The rotary worktable is rotatably disposed on the side of the spindle box via a bearing assembly inside the spindle box. The ultrasonic machining platform includes an ultrasonic vibration device for processing the bearing rings and an XY axis adjustment platform for adjusting the ultrasonic vibration device.

2. The ultrasonic vibration turning device for laser repair layer of wind turbine bearing rings according to claim 1, characterized in that: The ultrasonic vibration device includes an ultrasonic generator for emitting ultrasonic waves and a vibrating cutter controlled by ultrasonic waves. The ultrasonic generator is also equipped with a conical amplitude transformer for amplifying ultrasonic waves.

3. The ultrasonic vibration turning device for laser repair layer of wind turbine bearing rings according to claim 2, characterized in that: The large end diameter of the amplitude transformer is 225mm, the small end diameter is 50mm, the resonant length is 144.86mm, and the operating frequency is 20kHz.

4. The ultrasonic vibration turning device for laser repair layer of wind turbine bearing rings according to claim 1, characterized in that: The ultrasonic vibration device is fixed by a clamping assembly, which includes a clamping cylinder and an arc-shaped claw. The clamping cylinder is fixed on the XY axis adjustment platform, and the arc-shaped claw is driven by the clamping cylinder to fix the ultrasonic vibration device.

5. The ultrasonic vibration turning device for laser repair layer of wind turbine bearing rings according to claim 4, characterized in that: The clamping cylinder is a finger cylinder, the claw of the arc-shaped claw is driven by the finger cylinder, and the center of the arc-shaped claw is provided with a positioning groove for clamping the ultrasonic vibration device.

6. The ultrasonic vibration turning device for laser repair layer of wind turbine bearing rings according to claim 1, characterized in that: The XY-axis adjustment platform includes an X-axis slide and a Y-axis slide. The Y-axis slide includes a Y-axis servo motor, a Y-axis ball screw, and a Y-axis linear guide. The ultrasonic vibration device is slidably mounted on the Y-axis slide via a slider assembly. The X-axis slide includes an X-axis servo motor, an X-axis ball screw, and an X-axis linear guide. The Y-axis slide is slidably mounted on the X-axis slide via a slider assembly. The X-axis slide is mounted on a base.

7. The ultrasonic vibration turning device for laser repair layer of wind turbine bearing rings according to claim 6, characterized in that: A shock-absorbing pad, made of rubber, is also provided between the X-axis slide and the base.

8. The ultrasonic vibration turning device for laser repair layer of wind turbine bearing rings according to claim 1, characterized in that: A spindle drive motor is also provided outside the spindle box. The spindle transmission mechanism inside the spindle box is connected to the spindle drive motor outside the spindle box through a belt transmission mechanism. A protective cover is provided on the outside of the belt transmission mechanism. The protective cover is fixed to the side of the spindle box by bolts, and its surface is provided with heat dissipation holes. The spindle drive motor is adjustablely mounted on the base through a motor mounting bracket.

9. The ultrasonic vibration turning device for laser repair layer of wind turbine bearing rings according to claim 1, characterized in that: The rotary table includes a chuck and an intermediate plate. The chuck is connected to the end of the spindle through the intermediate plate. Three adjustable support blocks are evenly arranged along the circumference of the chuck. The support blocks are used to support and clamp the bearing rings. The rotary table is also equipped with a pressure sensor and a speed sensor.

10. A method for ultrasonic vibration turning of a laser repair layer on a wind turbine bearing race, comprising the ultrasonic vibration turning apparatus for laser repair of a wind turbine bearing race as described in any one of claims 1-9, characterized in that: Includes the following steps: S1: First, the laser-clad wind turbine bearing rings are hoisted onto the rotating worktable; S2: Start the clamping program. The support block clamps the bearing ring. During the clamping process, the pressure sensor installed inside the support block is activated, and the clamping force is determined by the signal fed back by the pressure sensor. S3: The XY axis adjustment platform moves the ultrasonic vibration device to the processing position and starts the spindle drive motor. At the same time, the rotation speed of the bearing ring is determined by the signal fed back by the speed sensor on the rotary table. S4: Start the ultrasonic vibration device to begin processing; S5: After completing the machining at one station, the spindle drive mechanism drives the rotary table to finely adjust the angle, rotate to the next machining position, and perform the next machining at the next station. S6: Repeat S5 to complete the machining of the entire bearing ring.

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