Full-automatic production device and method for large turbine blades

Abstract

The invention relates to the technical field of automatic machining of large complex components, in particular to a full-automatic production device and method.The full-automatic production device comprises a platform, a machining machine head, a bearing table and an electromagnetic assembly, and a vertical frame and a transverse sliding table are arranged on the platform and used for driving the machining machine head to move in the space in a positioned mode; the machining machine head is of a parallel structure composed of a plurality of movable arm sets, and a milling cutter main shaft is driven through the Stewart platform driving principle to achieve multi-degree-of-freedom and multi-azimuth posture movement. The surface of the bearing table is provided with an indexing rotary table, and the bearing table is driven by meshing of a fixed gear ring and an outer rotor motor. By means of the structure and the method, multi-surface continuous machining of the large turbine blade under the condition that repeated clamping is not needed is achieved, the limitation of a traditional milling machine on the machine tool size and the posture freedom degree is broken through, and the adaptability, the machining precision and the production efficiency of complex curved surface machining are remarkably improved; and the method is suitable for automatic and large-scale production of the super-large-specification steam turbine blades.

Description

Technical Field

[0001] This invention relates to the field of automated processing technology for large and complex components, specifically to a fully automated production device and method for large steam turbine blades. Background Technology

[0002] Large steam turbine blades, as key load-bearing and aerodynamic components in steam turbines, are typically characterized by their large size, complex structure, high degree of surface distortion, and stringent requirements for machining precision. Their machining quality directly affects the operating efficiency, stability, and service life of the steam turbine. Therefore, high-precision, high-efficiency machining of large steam turbine blades has always been a technical challenge in the field of high-end equipment manufacturing.

[0003] In existing technologies, large steam turbine blades are mostly machined using vertical milling machines, horizontal milling machines, or five-axis machining centers. These machines typically use a fixed worktable or a rotary worktable with a limited stroke as the workpiece support, and their machining space and stroke range are significantly limited by the size of the machine tool itself. When dealing with ultra-large steam turbine blades, it is often necessary to complete all machining processes by segmented machining, repeated clamping, or multiple flipping. This not only makes the machining process complex but also easily introduces cumulative positioning errors, making it difficult to ensure the continuity and consistency of the overall blade profile.

[0004] Meanwhile, traditional milling machines rely heavily on manual labor or independent auxiliary handling equipment to transfer workpieces and connect processes, making it difficult to achieve seamless continuous transport and collaborative processing between multiple processes. This results in long auxiliary times, low production cycle time, and risks such as workpiece collisions and positioning inaccuracies during the transfer process, which is not conducive to the large-scale and automated production of large steam turbine blades.

[0005] Furthermore, while existing five-axis milling machines offer certain advantages in tool orientation adjustment, their motion is primarily based on a serial structure. When machining complex twisted surfaces, deep grooves, or spatially confined areas of large steam turbine blades, issues such as limited tool orientation, high interference risk, and insufficient achievable orientation range persist. Especially given the increasing size and surface complexity of blades, traditional five-axis milling machines can no longer simultaneously meet the dual demands of machining ultra-large workpieces and achieving high-degree-of-freedom orientation adjustment.

[0006] In summary, existing large steam turbine blade processing equipment generally suffers from problems such as limited machine tool size, insufficient workpiece transfer and multi-process collaboration capabilities, and limited adaptability of cutting tools and workpieces to multiple degrees of freedom postures. There is an urgent need for a new type of automated processing device and processing method that can break through the constraints of traditional machine tool size, realize continuous transfer and processing of ultra-large blades, and have higher degree of freedom processing capabilities, so as to meet the needs of high-precision and high-efficiency manufacturing of modern large steam turbine blades. Summary of the Invention

[0007] This invention aims to solve the problems commonly encountered in the processing of large steam turbine blades, such as machine tool size limitations, reliance on manual workpiece transfer, large repeated clamping errors, and limited machining posture for complex curved surfaces. This invention proposes a fully automated production device and method for large steam turbine blades, which aims to break through the structural limitations of traditional milling machine processing space and posture capabilities, and realize highly stable, multi-degree-of-freedom, and continuous automated processing of ultra-large steam turbine blades.

[0008] To achieve the above objectives, the present invention adopts the following technical solution.

[0009] This invention provides a fully automated production device for large steam turbine blades, comprising a platform, a machining head, a support platform, and an electromagnetic assembly. The platform serves as the base for the entire machine, with a vertical frame and a horizontal slide table mounted on it to drive the machining head for positioning and movement within space. The machining head adopts a parallel multi-degree-of-freedom structure, using multiple sets of motorized arms to collaboratively drive the milling cutter spindle to achieve multi-directional motion. The support platform carries the steam turbine blade workpiece and can transport it between multiple workstations; its surface is equipped with an indexing turntable for indexing rotation of the workpiece. The electromagnetic assembly is used to attract and position the support platform or workpiece during the machining stage to improve machining stability.

[0010] In a preferred embodiment, the present invention is further configured such that: a vertical frame is fixedly installed on the top surface of the platform, a horizontal slide is slidably installed on the surface of the vertical frame, and the machining head is slidably installed on the surface of the horizontal slide. The vertical frame and the horizontal slide drive the machining head to perform planar motion. Through the above structure, the machining head can cover different processing areas of large-sized steam turbine blades. Specifically, it achieves the decoupling of processing space and workpiece size, breaking through the limitations of traditional machine tool stroke on processing specifications.

[0011] In a preferred embodiment, the present invention is further configured such that: the machining head includes a trolley, a fixed-axis table, a milling cutter spindle, a moving sleeve, and a set of motorized arms evenly distributed in a circumferential direction. Each set of motorized arms forms a parallel connection structure with the trolley and the moving sleeve through a main slide and a sliding arm. A lead screw assembly for driving the sliding arm is provided on the surface of the main slide. Through the coordinated movement of multiple sets of motorized arms, the moving sleeve and the milling cutter spindle inside it are driven to achieve multi-degree-of-freedom attitude adjustment in space. Specifically, this enables the milling cutter to act on the complex curved surface of the turbine blade in the optimal attitude, thereby improving machining accuracy and surface quality.

[0012] In a preferred embodiment, the present invention is further configured as follows: a set of movable wheels is provided at the bottom of the support platform, the set of movable wheels is driven independently, enabling the support platform to be moved on the platform; an indexing turntable is provided on the surface of the support platform, the indexing turntable is rotatably mounted on the surface of the support platform through a planar collar, and is driven by an external rotor motor meshing with a fixed gear ring to achieve high load-bearing and high-precision indexing rotation, specifically, enabling the turbine blades to complete continuous processing of multiple angles and surfaces without repeated clamping.

[0013] In a preferred embodiment, the present invention is further configured such that: a tooling assembly for positioning turbine blade workpieces is provided on the indexing turntable, which is used to stably position the workpieces during the processing. Specifically, this improves the positioning reliability of the workpieces during indexing and processing and reduces processing errors.

[0014] In a preferred embodiment, the present invention is further configured such that: an electromagnetic component is provided on the surface of the platform, the electromagnetic component including an electromagnetic adsorption unit and an on / off control unit, which is energized during the processing stage to adsorb and position the workpiece on the support platform or turbine blade, and de-energized during the transfer or indexing stage to release the adsorption. Specifically, this effectively suppresses the vibration and micro-displacement generated during high-speed cutting and heavy-load processing, and improves the overall processing stability.

[0015] This invention also provides a fully automated production method for large steam turbine blades, comprising: placing the steam turbine blade workpiece on the surface of a support platform and positioning it; transporting the workpiece to a machining head via the support platform for single-sided machining; after single-sided machining, transporting it to a flipping station for flipping; transporting it again to the machining head for machining the other side; and after completing all machining steps, transporting the machined workpiece to any subsequent station via the support platform. Specifically, this method achieves a continuous and automated machining process for large steam turbine blades, reducing manual intervention and improving production efficiency and machining consistency.

[0016] The beneficial effects achieved by this invention are as follows: 1. In this invention, by decoupling the functions of the machining head and the support table, and replacing the traditional fixed worktable with a transport-type support structure, the machining space is no longer limited by the size of the machine tool body, and can adapt to the overall machining needs of ultra-large steam turbine blades, effectively breaking through the structural limitations of traditional milling machines in terms of stroke, load-bearing capacity and workpiece size.

[0017] 2. In this invention, by setting up a movable carrier platform, turbine blades can be continuously transported and transferred without gaps between multiple processing steps, reducing manual handling and repetitive clamping operations, reducing positioning errors in the process of process connection, and significantly improving the continuity and production efficiency of large blade processing.

[0018] 3. In this invention, the machining head adopts a parallel multi-degree-of-freedom structure with multiple motor arms driving electric spindles, and is combined with an indexing turntable on the bearing table surface, so that the tool and the workpiece have the ability to adjust their postures in multiple degrees of freedom at the same time. Its overall posture freedom is significantly higher than that of traditional five-axis milling machines, and it is more adaptable to the machining of complex twisted surfaces, deep grooves and space-constrained areas of turbine blades, thereby improving the overall machining accuracy and machining quality. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the overall structure of one embodiment of the present invention; Figure 2 This is a schematic diagram of the platform surface structure according to an embodiment of the present invention; Figure 3 This is a schematic diagram of a machining head structure according to an embodiment of the present invention; Figure 4 This is an exploded view of the machining head according to an embodiment of the present invention; Figure 5 This is a schematic diagram of the surface structure of the support platform according to an embodiment of the present invention; Figure 6 This is an exploded view of the internal structure of the support platform according to an embodiment of the present invention; Figure 7 This is a schematic diagram of a stator ring and external rotor motor structure according to an embodiment of the present invention.

[0020] Figure label: 100. Platform; 110. Frame; 120. Horizontal slide table; 200. Machining head; 210. Pulley; 211. Fixed axis table; 220. Milling cutter spindle; 230. Movable boom assembly; 231. Main slide; 232. Slide arm; 240. Moving sleeve seat; 300, bearing platform; 310, indexing turntable; 320, moving wheel set; 330, fixed gear ring; 340, external rotor motor; 311, planar shaft collar.

[0021] 400. Electromagnetic components. Detailed Implementation

[0022] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to specific embodiments and accompanying drawings. It should be noted that, unless otherwise specified, the embodiments and features described herein can be combined with each other.

[0023] It should be understood that these descriptions are merely exemplary and are not intended to limit the scope of the invention.

[0024] The following describes, with reference to the accompanying drawings, some embodiments of a fully automated production apparatus and method for large steam turbine blades provided by the present invention.

[0025] Combination Figures 1-7 As shown, the present invention provides a fully automated production device for large steam turbine blades, including a platform 100, a processing head 200, a support platform 300, and an electromagnetic component 400.

[0026] Platform 100 serves as the mounting base for the entire machine, with a support frame 110 fixedly mounted on its top surface. The support frame 110 provides vertical guidance and support for the machining head 200, and a horizontal slide table 120 is slidably mounted on its surface. The horizontal slide table 120 supports the machining head 200 and, under the guidance of the support frame 110, allows for positional adjustment within a planar range.

[0027] The machining head 200 is slidably mounted on the surface of the horizontal slide table 120. Under the joint drive of the vertical frame 110 and the horizontal slide table 120, the machining head 200 can achieve compound movement in the vertical and horizontal directions, thereby covering different processing areas of large steam turbine blades.

[0028] The electromagnetic component 400 is fixedly mounted on the surface of the platform 100 and is arranged directly below the horizontal slide table 120 to adsorb and position the carrier table 300 during the processing stage.

[0029] The bearing platform 300 is mounted on the platform 100, and its surface is provided with an indexing turntable 310. A fixed gear ring 330 is fixedly installed on the inner side of the bearing platform 300, and an external rotor motor 340 is provided on the bottom surface of the indexing turntable 310. The external rotor motor 340 meshes with the surface of the fixed gear ring 330 for transmission, and is used to drive the indexing turntable 310 to perform indexing rotation.

[0030] like Figure 3 and Figure 4 As shown, the machining head 200 includes a trolley 210, a fixed-axis table 211, a milling cutter spindle 220, a motorized arm assembly 230, and a moving sleeve seat 240.

[0031] The trolley 210 is slidably mounted on the surface of the horizontal slide table 120, and a fixed-axis platform 211 is fixedly mounted on its bottom surface, which serves as the mounting and rotation base for the motorized boom assembly 230. Several motorized boom assemblies 230 are evenly distributed in a circumferential direction on the outer periphery of the trolley 210.

[0032] In this embodiment, the mobile boom assembly 230 includes a main slide 231 and a sliding arm 232 slidably mounted on the surface of the main slide 231. The main slide 231 is rotatably mounted on the surface of the trolley 210, and one end of the sliding arm 232 is rotatably connected to the surface of the moving sleeve seat 240. The surface of the main slide 231 is provided with a lead screw assembly for driving the sliding arm 232 to slide, thereby realizing the adjustability of the length and posture of the mobile boom assembly 230.

[0033] The milling cutter spindle 220 is fixedly sleeved inside the movable sleeve 240. The milling cutter spindle 220 includes an electric spindle and a milling cutter assembly detachably fixed to the end of the electric spindle. Through the coordinated movement of multiple sets of motorized arm assemblies 230, the movable sleeve 240 and the milling cutter spindle 220 inside it can achieve multi-degree-of-freedom attitude adjustment in space, thereby adapting to the machining requirements of complex curved surfaces of large steam turbine blades. Its attitude freedom is significantly higher than that of traditional five-axis linkage milling machines.

[0034] A lead screw assembly mounted on the surface of the main slide block 231 drives the sliding arm 232 to slide relative to the surface of the main slide block 231, thereby achieving continuous adjustment of the effective length of the motorized boom assembly 230. When the lead screw assembly drives the sliding arm 232 to extend or retract, the changes in length and installation angle of the motorized boom assembly 230 act together on the movable sleeve 240, causing the movable sleeve 240 to produce corresponding displacement or oscillation.

[0035] Since several mobile boom assemblies 230 are evenly distributed in a circumferential direction and act simultaneously on the movable sleeve base 240, the extension, retraction, and swinging movements of each mobile boom assembly 230 form a complex constraint relationship in space. When each mobile boom assembly 230 moves in coordination according to a preset control strategy, the movable sleeve base 240 can achieve multi-directional displacement and attitude adjustment in three-dimensional space.

[0036] The milling cutter spindle 220 is fixedly sleeved inside the movable sleeve 240. The spatial movement of the movable sleeve 240 directly drives the synchronous movement of the milling cutter spindle 220, thereby enabling the milling cutter spindle 220 to achieve omnidirectional and multi-angle attitude changes relative to the workpiece. The above parallel drive method constitutes a typical Stuart platform drive principle, giving the machining head 200 high rigidity, high response speed, and multi-degree-of-freedom linkage capability, which can meet the high-precision machining requirements of complex curved surfaces of large steam turbine blades.

[0037] like Figures 5 to 7 As shown, the support platform 300 is used to support turbine blade workpieces, and movable wheel sets 320 are fixedly installed at the four corners of its bottom surface. In this embodiment, the movable wheel sets 320 adopt a tracked wheel set structure, and each movable wheel set 320 is equipped with an independent motor drive, so that the support platform 300 can move stably on the platform 100 to realize continuous transfer between multiple workstations.

[0038] The indexing rotary table 310 is disposed on the surface of the support platform 300. A flat collar 311 is provided on its bottom surface, and the rotary table 310 is rotatably mounted on the surface of the support platform 300 through the flat collar 311, so that the indexing rotary table 310 and the support platform 300 form a coaxial rotation structure. The indexing rotary table 310 is provided with tooling components for positioning turbine blade workpieces, which are used to reliably fix the workpieces during the processing.

[0039] The external rotor motor 340 is mounted on the bottom surface of the indexing turntable 310 and meshes with the fixed gear ring 330 on the inner side of the bearing platform 300 to achieve high load capacity and high precision indexing rotation of the indexing turntable 310.

[0040] like Figure 1 As shown, the electromagnetic component 400 includes an electromagnetic adsorption unit and an on / off control unit. The electromagnetic component 400 is fixedly mounted on the surface of the platform 100 and operates when energized during the processing stage. It generates an adsorption force on the support platform 300 through the electromagnetic adsorption unit, creating a stable constraint between the support platform 300 or the workpiece and the platform 100. Furthermore, to avoid magnetic interference from the electromagnetic component 400, the support platform 300 can be equipped with a shielding layer for magnetic pole protection, and a ferromagnetic disk opposite to the electromagnetic component 400 is fixed to the bottom surface of the support platform 300, improving the positioning capability between the electromagnetic component 400 and the support platform 300.

[0041] The electromagnetic adsorption method described above can effectively suppress the vibration and micro-displacement generated under high-speed cutting or heavy-load cutting conditions, thereby improving machining stability and machining accuracy. During the transport or indexing rotation of the carrier table 300, the electromagnetic component 400 can be de-energized to release the adsorption, ensuring the normal movement of the carrier table 300.

[0042] In actual production, the turbine blade workpiece to be processed is first placed on the surface of the bearing platform 300 and positioned and fixed by the tooling assembly on the indexing turntable 310. Subsequently, the bearing platform 300 is transported to the processing station where the processing head 200 is located under the drive of the moving wheel set 320.

[0043] During the processing stage, the electromagnetic component 400 is energized to attract and position the support platform 300. The processing head 200 is adjusted in position under the drive of the upright frame 110 and the horizontal slide table 120, and the milling cutter spindle 220 is driven by the motorized arm assembly 230 to perform multi-degree-of-freedom posture movement to process the first side of the turbine blade workpiece.

[0044] After the first side is machined, the support platform 300 is released from its electromagnetic adsorption constraint and transported to the flipping station. The turbine blade workpiece is flipped and then placed back on the surface of the support platform 300. Subsequently, the support platform 300 is transported again to the machining station where the machining head 200 is located to machine the other side of the turbine blade workpiece.

[0045] After all processing steps are completed, the carrier platform 300 transports the processed turbine blade workpiece to any subsequent workstation, achieving continuous connection with processes such as inspection, grinding, or assembly.

[0046] In the description of this specification, the terms "one embodiment," "some embodiments," "specific embodiment," etc., refer to a specific feature, structure, material, or characteristic described in connection with that embodiment or example, which is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0047] Although embodiments of the invention have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and their equivalents.

Claims

1. A fully automated production device for large steam turbine blades, characterized in that, Including platform (100), processing machine head (200), bearing table (300) and electromagnetic assembly (400), the top surface of the platform (100) is fixedly installed with a stand (110), and the surface of the stand (110) is slidably installed with a horizontal sliding table (120), the processing machine head (200) is slidably installed on the surface of the horizontal sliding table (120), and the processing machine head (200) is driven by the stand (110) and the horizontal sliding table (120) to move in plane; The electromagnetic assembly (400) is fixed on the surface of the platform (100), and is arranged opposite to the horizontal sliding table (120) below; the surface of the bearing table (300) is provided with a indexing turntable (310), and the inner side of the bearing table (300) is fixedly installed with a toothed ring (330), the bottom surface of the indexing turntable (310) is provided with an outer rotor motor (340) which is in meshing transmission with the surface of the toothed ring (330).

2. The full-automatic production device for large steam turbine blades according to claim 1, characterized in that, The inner side of the stand (110) and the horizontal sliding table (120) is provided with a servo lead screw structure, respectively used for driving the horizontal sliding table (120) to move up and down and driving the processing machine head (200) to move horizontally on the surface of the horizontal sliding table (120).

3. The full-automatic production device for large steam turbine blades according to claim 1, characterized in that, The processing machine head (200) includes a trolley (210), a milling cutter spindle (220), a motorized arm group (230) and a movable sleeve (240), the bottom surface of the trolley (210) is fixedly installed with a fixed shaft table (211), a plurality of motorized arm groups (230) are uniformly distributed in the circumferential direction of the outer periphery of the fixed shaft table (211), the milling cutter spindle (220) is fixedly sleeved on the inner side of the movable sleeve (240), the motorized arm group (230) includes a main slide (231) and a sliding arm (232) slidably installed on the surface of the main slide (231), the main slide (231) is rotatably installed on the surface of the trolley (210), and one end of the sliding arm (232) is rotatably connected with the surface of the movable sleeve (240).

4. The full-automatic production device for large steam turbine blades according to claim 3, characterized in that, The milling cutter spindle (220) includes an electric spindle and a milling cutter assembly detachably fixed on the shaft end of the electric spindle, and the motorized arm group (230) is uniformly distributed in the circumferential direction of the outer periphery of the movable sleeve (240).

5. The full-automatic production device for large steam turbine blades according to claim 3, characterized in that, The surface of the main slide (231) is provided with a lead screw assembly for driving the sliding arm (232) to slide.

6. The full-automatic production device for large steam turbine blades according to claim 1, characterized in that, The bottom surface of the bearing table (300) is fixedly installed with a mobile wheel set (320) at four corners, the mobile wheel set (320) is a track wheel set structure, and each mobile wheel set (320) is driven by an independent motor.

7. The full-automatic production device for large steam turbine blades according to claim 1, characterized in that, The bottom surface of the indexing turntable (310) is provided with a plane shaft ring (311), and the indexing turntable (310) is rotatably installed on the surface of the bearing table (300) through the plane shaft ring (311), so that a coaxial rotation structure is formed between the indexing turntable (310) and the bearing table (300), and a tool assembly for positioning a steam turbine blade workpiece is arranged on the indexing turntable (310).

8. The full-automatic production device for large steam turbine blades according to claim 1, characterized in that, The electromagnetic assembly (400) comprises an electromagnetic adsorption unit and an on-off control unit, the electromagnetic adsorption unit is powered to generate adsorption force in the processing stage, so that a stable constraint is formed between the bearing table (300) and the platform (100).

9. The production method of the full-automatic production device for large-scale turbine blades according to claim 1, characterized in that, It comprises the following steps: Place the turbine blade workpiece to be processed on the surface of the bearing table (300) and position it; Transport the turbine blade workpiece to the processing station where the processing head (200) is located by the bearing table (300), and process the first side of the turbine blade workpiece by the processing head (200); After the first side processing is completed, transport the turbine blade workpiece with the bearing table (300) to the turnover station, place the turbine blade workpiece on the surface of the bearing table (300) again after the turbine blade workpiece is turned over; Transport the turned-over turbine blade workpiece with the bearing table (300) to the processing station where the processing head (200) is located again, and process the other side of the turbine blade workpiece by the processing head (200); After all the processing procedures are completed, transport the processed turbine blade workpiece to any subsequent station by the bearing table (300).

10. A production method of a full-automatic production apparatus for a large-scale turbine blade according to claim 9, characterized in that, When the turbine blade workpiece is processed, the bearing table (300) is electromagnetically adsorbed and positioned by the electromagnetic assembly (400); During the processing, the milling cutter spindle (220) is driven by the motorized arm group (230) to perform multi-degree-of-freedom posture motion to adapt to the complex curved surface processing of the turbine blade.

Images