Wind power main shaft metal mold
By designing the first and second components of the wind turbine main shaft metal mold to work together, real-time cleaning of impurities and automated management of molten metal during the wind turbine main shaft casting process are realized. This solves the problems of incomplete impurity cleaning and low automation in the existing technology, and improves the quality of castings and production efficiency.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- SHANDONG JINLEI NEW ENERGY RELOADING CO LTD
- Filing Date
- 2026-03-06
- Publication Date
- 2026-05-12
AI Technical Summary
In existing technologies, the timeliness of impurity cleaning during the casting process of wind turbine main shaft is poor, and real-time dynamic cleaning cannot be achieved, which increases the risk of slag inclusions in the castings. In addition, the degree of automation is low, safety hazards are prominent, and the feeding channel is prone to blockage, affecting the quality of castings and production efficiency.
A metal mold for wind turbine main shaft was designed. The first and second components work together to target and separate impurities through a toothed plate and a stirring shaft. A buffer spring prevents collisions, and an automated cyclic operation is achieved using a drive motor and an electric telescopic rod to ensure unobstructed feeding channels and uniform distribution of molten metal.
It achieves precise cleaning of impurities and effective utilization of molten metal, avoids slag inclusion defects, improves the density and mechanical properties of castings, reduces production costs and safety risks, and improves production efficiency.
Smart Images
Figure CN122007344A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of wind turbine main shaft mold technology, specifically a wind turbine main shaft metal mold. Background Technology
[0002] As the core load-bearing component of a wind turbine generator set, the casting quality of the wind turbine main shaft directly determines the operational stability and service life of the unit. During the casting process of the wind turbine main shaft, a metal mold casting process is typically used. Molten metal is injected into the mold cavity to form the shaft, and an open riser is used to compensate for the shrinkage of the molten metal during solidification, preventing defects such as shrinkage cavities and porosity. However, during the casting and feeding process, impurities such as oxide slag are inevitably generated. Because of their low density, these impurities easily rise to the surface of the molten metal above the open riser. If not cleaned in time, these impurities may flow back into the casting with the molten metal, causing inclusion defects, severely reducing the density and mechanical properties of the casting, and even leading to safety accidents.
[0003] Currently, the wind turbine main shaft casting industry mainly uses traditional methods to clean impurities from exposed risers. These methods have several shortcomings that urgently need to be addressed, as follows: Impurity removal is not timely and requires interruption of casting operations: Existing technologies mostly adopt an offline cleaning mode, meaning that impurities in the riser can only be cleaned after the casting operation is completed or paused. This method cannot achieve real-time dynamic cleaning during the casting process. Long-term accumulation of impurities can easily lead to some small impurities being re-mixed into the molten metal, increasing the risk of slag inclusions in the casting. At the same time, the interruption of operations significantly prolongs the overall casting cycle and reduces production efficiency.
[0004] Impurities are not completely separated from molten metal, resulting in significant waste of molten metal: Traditional cleaning devices often use simple scooping or adsorption methods to remove impurities, lacking a dedicated separation structure design. During the impurity cleaning process, unsolidified molten metal is easily carried out along with the impurities, causing a large waste of molten metal and increasing production costs. Moreover, the accuracy of scooping or adsorption is low, making it difficult to completely remove the oxide slag above the liquid surface, resulting in poor cleaning effect.
[0005] Low level of automation and prominent safety hazards: Existing cleaning operations mostly rely on manual operation, requiring operators to be in close contact with high-temperature molten metal and molds. This not only results in high labor intensity but also poses serious safety hazards such as molten metal splashes and high-temperature burns. At the same time, the accuracy of manual operation is greatly affected by human factors, which can easily lead to problems such as spillage of impurities and secondary contamination of molds or castings, further affecting the stability of casting quality.
[0006] Feeding channels are prone to blockage, resulting in a high defect rate in castings: During the impurity cleaning interval, the molten metal in the riser is prone to solidify prematurely due to the rapid temperature drop, causing blockage of the feeding channels and preventing continuous feeding; moreover, the molten metal is prone to uneven distribution of composition and temperature during solidification, which further increases the incidence of defects such as shrinkage cavities and porosity, making it difficult to meet the stringent high-quality requirements of wind turbine main shafts for castings.
[0007] Therefore, this invention proposes a metal mold for wind turbine main shafts to solve the above problems. Summary of the Invention
[0008] To address the shortcomings of existing technologies, this invention provides a metal mold for wind turbine main shafts, thereby solving the problems mentioned in the background section.
[0009] To achieve the above objectives, the present invention provides the following technical solution: a metal mold for a wind turbine main shaft, comprising: a metal mold body and a first component mounted thereon, wherein a casting device for rapidly pouring molten metal into the metal mold body is provided on one side of the metal mold body, and an exposed riser is provided above the metal mold body, the exposed riser being cylindrical in shape, and the first component comprising: a positioning frame fixedly connected to the metal mold body, the positioning frame being disposed on one side of the exposed riser; The first component also includes: a drive vertical wheel disposed on the positioning frame, wherein a transmission bevel gear is engaged on the side of the drive vertical wheel near the exposed riser; The first component also includes a screw fixedly connected to the transmission bevel gear. An outer cover is fixedly connected to the positioning frame. Both the transmission bevel gear and the screw are rotatably connected inside the outer cover. An inverted L-shaped guide groove is opened on the outer ring of the outer cover. A transmission body is driven and sleeved on the screw. The end of the transmission body away from the screw is slidably connected to the inverted L-shaped guide groove. A long connecting piece is slidably connected to the outer ring of the outer cover. One end of the long connecting piece is fixedly connected to the transmission body. A vertical connecting rod is fixedly connected to the end of the long connecting piece away from the transmission body. A buffer spring is slidably sleeved on the outer ring of the vertical connecting rod. It also includes a second component for scraping off floating impurities.
[0010] Preferably, the driving vertical wheel consists of a drive motor and a bevel gear. The driving vertical wheel and the transmission bevel gear are arranged perpendicularly, and the transmission bevel gear is parallel to the surface of the metal mold body.
[0011] Preferably, the vertical connecting rod and the long connecting member are arranged perpendicularly, the vertical connecting rod and the outer cover are parallel, the long connecting member and the outer cover are arranged perpendicularly, and one end of the buffer spring is connected to the long connecting member.
[0012] Preferably, the second component includes a semi-circular shell fixedly connected to the bottom of the vertical connecting rod. The inner diameter of the semi-circular shell matches the outer diameter of the exposed riser, and the width of the rectangular groove matches the thickness of the toothed plate, ensuring that the movement trajectory of the toothed plate corresponds to the inner cavity of the exposed riser. A rectangular groove is provided in the inner cavity at the bottom of the semi-circular shell. An inner fixing frame is fixedly connected to the top of the inner cavity of the semi-circular shell. An electric telescopic rod is fixedly connected inside the inner fixing frame. The extension end of the electric telescopic rod extends downward and is fixedly connected to a connecting body. A symmetrical positioning rod is fixedly connected to the side of the connecting body away from the electric telescopic rod. Both ends of the symmetrical positioning rod are rotatably connected to a first connecting rod.
[0013] Preferably, there are two semi-circular shells that are joined together to form a circle. The two sets of semi-circular shells have semi-circular grooves perpendicularly opened on the symmetrical planes near the vertical connecting rod. The vertical connecting rod is set in the semi-circular groove and its bottom end is fixedly connected to the two sets of semi-circular shells respectively. The electric telescopic rod is connected to an external controller. There are two symmetrical positioning rods that are symmetrically arranged with the central axis of the connecting body as the center. The symmetrical positioning rods are parallel to the ground.
[0014] Preferably, the second component further includes a positioning body disposed at the bottom of the symmetrical positioning rod. The positioning body has mounting grooves on both sides and is fixedly connected to the bottom of the inner fixing frame. A second connecting rod is rotatably connected in the mounting grooves on both sides of the positioning body. The end of the first connecting rod away from the symmetrical positioning rod is rotatably connected to the middle of the second connecting rod. A toothed plate is fixedly connected to the end of the second connecting rod away from the positioning body. The toothed plate has two sets of toothed grooves on both symmetrical surfaces. The toothed plate has leakage holes that are equidistantly and intermittently disposed on the toothed plate. A stirring shaft is fixedly connected to the bottom of the toothed plate. The stirring shaft is evenly spaced with multiple sets of leakage holes. A collection tank is disposed directly below the stirring shaft.
[0015] Preferably, the second connecting rod is a V-shaped curved rod with an obtuse angle, and the end of the second connecting rod away from the positioning body extends and bends towards both sides of the positioning body.
[0016] Preferably, the toothed plate has an arc-shaped cross-section, the tooth grooves of the two sets of toothed plates are spaced apart, and they can be spliced into one piece when they intersect.
[0017] Compared with the prior art, the present invention provides a metal mold for wind turbine main shaft, which has the following beneficial effects: Through the coordinated operation of the first and second components, impurities such as oxide slag above the surface of the open riser can be accurately located. The two sets of toothed plates are centered and interlocked to form a sealed structure with a downward groove, achieving targeted capture of impurities. At the same time, the perforations on the toothed plates allow the unsolidified molten metal to be screened back into the open riser to continue participating in feeding, while impurities remain in the groove. This avoids interference from impurities in the feeding process and reduces the waste of molten metal, solving the problem of difficult cleaning of impurities in the open riser and easy failure of feeding in the traditional wind turbine main shaft casting process.
[0018] During the impurity grabbing process, the high-temperature heating rod of the stirring shaft at the bottom of the toothed plate is activated simultaneously. During the movement, the molten metal in the open riser is heated and stirred. On the one hand, this can effectively prevent the molten metal from solidifying too early and ensure that the feeding channel remains unobstructed. On the other hand, it can make the composition and temperature distribution of the molten metal more uniform, significantly improve the density of the wind turbine main shaft casting, and fundamentally avoid the generation of defects such as shrinkage cavities and porosity, ensuring that the mechanical properties of the casting meet the high-strength use requirements of the wind turbine main shaft.
[0019] The buffer springs prevent the second component from violently colliding with the high-temperature molten metal when it moves downwards towards the surface of the molten metal. This protects the structural integrity of the component and prevents safety hazards and quality impacts caused by splashing molten metal. Under the switching control of the forward and reverse rotation of the first component, the second component moves to the impurity collection area outside the main body of the metal mold. Then, through the transmission of the first connecting rod and other components, the toothed plate disperses and releases impurities, completing the directional discharge of impurities and preventing secondary contamination of the mold or castings.
[0020] The impurity removal and grasping mechanism can be highly adjustable according to the needs of different metal solutions. The impurity removal process is automated and cyclical through the coordinated control of the drive motor, electric telescopic rod, and external controller. No manual intervention is required for impurity grasping, transfer, and release. This not only significantly reduces the labor intensity of operators but also avoids operational errors and safety risks that may be caused by manual cleaning. At the same time, the automated cyclical operation can flexibly adjust the cleaning frequency according to the accumulation of impurities in the riser, improving cleaning efficiency, shortening the casting cycle, and reducing the overall production and manufacturing cost of the wind turbine main shaft. Attached Figure Description
[0021] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 For the present invention Figure 1 Enlarged structural diagram at point A in the middle; Figure 3 This is a partial structural diagram of the present invention; Figure 4 This is a partial side view of the structure of the present invention; Figure 5 This is a disassembled structural diagram of the first component of the present invention; Figure 6 This is a cross-sectional view of the second component of the present invention; Figure 7 This is a disassembled structural diagram of the second component of the present invention; Figure 8 This is a partial structural diagram of the second component of the present invention; Figure 9 This is a partial disassembly diagram of the second component of the present invention.
[0022] In the picture: 11. Metal mold body; 12. Casting equipment; 13. Open riser; 21. Positioning frame; 22. Drive vertical wheel; 23. Transmission bevel gear; 24. Screw; 25. Outer casing; 26. Inverted L-shaped guide groove; 27. Transmission body; 28. Long connecting piece; 29. Vertical connecting rod; 210. Buffer spring; 31. Semi-circular shell; 32. Rectangular trough; 33. Internal fixing frame; 34. Electric telescopic rod; 35. Connector; 36. Symmetrical positioning rod; 37. First connecting rod; 38. Positioning body; 39. Second connecting rod; 310. Toothed plate; 311. Leakage hole; 312. Container tank; 313. Stirring shaft. Detailed Implementation
[0023] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.
[0024] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments.
[0025] Example Please refer to Figures 1 to 5 As shown: To address the problems mentioned in the technical solutions, this application provides a wind turbine main shaft metal mold comprising: a metal mold body 11 and a first component mounted thereon; a casting device 12 for rapidly pouring molten metal into the metal mold body 11 is provided on one side of the metal mold body 11; an exposed riser 13 is provided above the metal mold body 11, the exposed riser 13 being cylindrical; and the first component comprising: a positioning frame 21 fixedly connected to the metal mold body 11, the positioning frame 21 being disposed on one side of the exposed riser 13. The first component also includes: a drive vertical wheel 22 disposed on the positioning frame 21, a transmission bevel gear 23 meshing on the side of the drive vertical wheel 22 near the exposed riser 13, and the drive vertical wheel 22 is used to drive the transmission bevel gear 23 to perform axial forward and reverse rotation. It also includes a second component for scraping off floating impurities.
[0026] The first component also includes a screw 24 fixedly connected to the transmission bevel gear 23. An outer casing 25 is fixedly connected to the positioning frame 21. The screw 24 rotates forward and backward to control the lifting and lowering movement of the transmission body 27, thereby controlling the offset of the long connecting piece 28. Both the transmission bevel gear 23 and the screw 24 are rotatably connected inside the outer casing 25. The outer casing 25 has an inverted L-shaped guide groove 26 on its outer circumference. The inverted L-shaped guide groove 26 is composed of an arc groove and a vertical groove, enabling the deflection and lifting of the transmission body 27. Combined with the helical transmission of the screw 24, it converts the rotational motion of the motor into the composite motion of the second component, providing power for impurity grabbing and transfer. The inverted L-shaped guide groove 26 is used to limit the linear lifting and lowering movement and deflection of the transmission body 27. The inverted L-shaped guide groove 26 is composed of... The outer casing 25 consists of a one-third circular arc groove and a vertical groove perpendicular to the outer surface of the outer casing 25. A transmission body 27 is connected to the screw 24. The transmission body 27 moves up and down and deflects around the outer casing 25, synchronously driving the long connector 28 and the second component to perform synchronous up and down deflection operations. The end of the transmission body 27 away from the screw 24 is slidably connected to the inverted L-shaped guide groove 26. The outer ring of the outer casing 25 is slidably connected to the long connector 28. One end of the long connector 28 is fixedly connected to the transmission body 27. The end of the long connector 28 away from the transmission body 27 is fixedly connected to the vertical connecting rod 29. The outer ring of the vertical connecting rod 29 is slidably connected to the buffer spring 210, which is used to provide buffer for the long connector 28 and the second component.
[0027] The drive vertical wheel 22 consists of a drive motor and a bevel gear. The drive vertical wheel 22 and the transmission bevel gear 23 are arranged perpendicularly, and the transmission bevel gear 23 is parallel to the surface of the metal mold body 11.
[0028] The vertical connecting rod 29 and the long connecting piece 28 are arranged perpendicularly, the vertical connecting rod 29 and the outer cover 25 are parallel, the long connecting piece 28 and the outer cover 25 are arranged perpendicularly, and one end of the buffer spring 210 is connected to the long connecting piece 28.
[0029] A further embodiment: Please refer to Figures 6 to 9 As shown: The second component includes a semi-circular shell 31 fixedly connected to the bottom of the vertical connecting rod 29. The inner diameter of the semi-circular shell 31 matches the outer diameter of the exposed riser 13, and the width of the rectangular groove 32 matches the thickness of the toothed plate 310, ensuring that the movement trajectory of the toothed plate 310 corresponds to the inner cavity of the exposed riser 13. A rectangular groove 32 is provided in the inner cavity at the bottom of the semi-circular shell 31. An inner fixing frame 33 is fixedly connected to the top of the inner cavity of the semi-circular shell 31. An electric telescopic rod 34 is fixedly connected inside the inner fixing frame 33. The electric telescopic rod 34 is used to extend and retract to adjust the height of the connecting body 35 in the vertical position. In turn, the deflection of the connecting end of the first connecting rod 37 and the symmetrical positioning rod 36 is adjusted by the up and down movement of the connecting body 35. When the first connecting rod 37 moves upward with the connecting body 35, the end of the first connecting rod 37 away from the symmetrical positioning rod 36 is connected to the second connecting rod 39. At the central rotating connection, the first connecting rod 37 and the second connecting rod 39 are rotatably connected. Pulling the connection end of the second connecting rod 39 and the toothed plate 310 opens to both sides, and the two sets of toothed plates 310 are in a dispersed state. Conversely, when the first connecting rod 37 moves downward with the connecting body 35, the connection between the first connecting rod 37 and the second connecting rod 39 drives the two sets of second connecting rods 39 and the toothed plates 310 to move in the center and merge into one. The extension end of the electric telescopic rod 34 extends downward and is fixedly connected to the connecting body 35. One side of the connecting body 35 is slidably connected to the electric telescopic rod 34. The side of the connecting body 35 away from the electric telescopic rod 34 is fixedly connected to a symmetrical positioning rod 36. Both ends of the symmetrical positioning rod 36 are rotatably connected to the first connecting rod 37. The end of the first connecting rod 37 away from the symmetrical positioning rod 36 is rotatably connected to the bend of the second connecting rod 39.
[0030] Two semi-circular shells 31 are provided and spliced into a circle. The two sets of semi-circular shells 31 have semi-circular grooves vertically opened on the symmetrical planes near the vertical connecting rod 29. The vertical connecting rod 29 is set in the semi-circular grooves and its bottom end is fixedly connected to the two sets of semi-circular shells 31 respectively. The electric telescopic rod 34 is connected to an external controller. Two symmetrical positioning rods 36 are provided and symmetrically arranged with the central axis of the connecting body 35 as the center. The symmetrical positioning rods 36 are parallel to the ground.
[0031] The second component also includes a positioning body 38 located at the bottom of the symmetrical positioning rod 36. The positioning body 38 is fixedly connected to the bottom of the inner fixing frame 33. Mounting grooves are provided on both sides of the positioning body 38. A second connecting rod 39 is rotatably connected within the mounting grooves on both sides of the positioning body 38. The end of the first connecting rod 37 away from the symmetrical positioning rod 36 is rotatably connected to the middle of the second connecting rod 39. A toothed plate 310 is fixedly connected to the end of the second connecting rod 39 away from the positioning body 38. During the assembly of the toothed plate 310, impurities floating at the riser 13 are captured and collected, and excess molten metal is drained through the drain hole 311. The impurities, after cooling and solidifying, remain on the toothed plate 310. The toothed plate 310 has two sets, each with toothed grooves on its symmetrical surfaces. A drain hole 311 is provided on the toothed plate 310, used to screen the unsolidified molten metal to the riser 13 for further processing. Continuing to be used, the leak holes 311 are equidistantly and intermittently opened on the toothed plate 310. The bottom of the toothed plate 310 is fixedly connected to the stirring shaft 313. The stirring shaft 313 is evenly spaced with multiple sets of leak holes 311. The diameter of the leak holes 311 can be set to 0.5 to 1 mm. The stirring shaft 313 is a high-temperature resistant ceramic heating rod. The heating temperature can be adjusted to 1200 to 1500 degrees Celsius. It is used to adapt to the heat preservation requirements of molten steel and molten iron for wind turbine main shaft casting. When grabbing floating impurities, the stirring shaft 313 follows the centering movement of the toothed plate 310 to heat and stir the metal solution in the open riser 13. The stirring shaft 313 can be implemented as a high-temperature resistant heating rod. A collection tank 312 is set directly below the stirring shaft 313. The collection tank 312 is fixedly connected to the metal mold body 11. The collection tank 312 is located on one side of the open riser 13.
[0032] The second link 39 is a V-shaped curved rod with an obtuse angle, and the end of the second link 39 away from the positioning body 38 extends and bends towards both sides of the positioning body 38.
[0033] The toothed plate 310 has an arc-shaped cross-section. The tooth grooves of the two sets of toothed plates 310 are spaced apart and can be spliced into one piece when they intersect. Under the action of the arc surface of the toothed plate 310, the middle part after splicing is grooved, which is more conducive to the collection and loading of impurities.
[0034] The preset height of the second component can be adjusted according to actual needs.
[0035] The second component can adjust the size of the semi-circular shell 31, the curvature of the toothed plate 310, and the arrangement density of the leakage holes 311 according to the casting specifications of the wind turbine main shaft, so as to meet the impurity cleaning requirements of the exposed riser 13 of different specifications of wind turbine main shafts. The telescopic stroke of the electric telescopic rod 34 is 50 to 200 mm, and the gripping height of the toothed plate 310 can be adjusted in real time according to the height of the molten metal surface.
[0036] The stirring shaft 313 is set on an inclined plane.
[0037] Miniature high-frequency vibrators are added to both sides of the positioning body 38 of the second component. The vibrators are linked with an external controller, and the vibration frequency range can be adjusted according to actual needs. The vibrators are high-temperature resistant and explosion-proof, suitable for high-temperature casting environments. At the same time, the surface of the toothed plate 310 is treated with a polytetrafluoroethylene high-temperature resistant coating to reduce the adhesion between the oxide slag and the surface of the toothed plate 310.
[0038] A high-temperature resistant purging nozzle is added to the long connector 28. The nozzle is connected to a high-pressure inert gas source through a high-temperature resistant hose. The purging direction of the nozzle is directly facing the surface of the toothed plate 310, and the movement of the nozzle is linked with that of the second component.
[0039] A molten metal return tank is added next to the container tank 312. The return tank is connected to the open riser 13 and is insulated.
[0040] The working principle of all the content in the above embodiments is as follows: Initial state: The transmission body 27 is at the top of the screw 24, and the transmission body 27 is in the arc groove of the inverted L-shaped guide groove 26. The second component is outside the exposed riser 13 through the deflection state of the long connector 28.
[0041] The following is the working process of the first component: When in use, the system is started and molten metal liquid, which is special for wind turbine main shaft, is injected into the cavity of the metal mold body 11 through the casting equipment 12. As the metal liquid is injected, some of the metal liquid flows into the open riser 13 at the same time. The open riser 13 plays a feeding role. During this process, the metal liquid, mainly oxide slag and other impurities, gradually float to the surface of the liquid in the open riser 13 because of their low density, in preparation for subsequent impurity cleaning. When a certain amount of impurities accumulate in the riser 13, the drive motor of the vertical drive wheel 22 is started. The drive motor drives the bevel gear at its output end to rotate, and through the bevel gear meshing, it drives the transmission bevel gear 23 to rotate axially in both forward and reverse directions. In the initial stage, it rotates forward first. The transmission bevel gear 23 drives the screw 24, which is fixedly connected to it, to rotate synchronously. Since the transmission body 27 is sleeved on the screw 24 and the transmission body 27 is embedded in the inverted L-shaped guide groove 26, it is limited by the arc groove and vertical groove of the inverted L-shaped guide groove 26 and can only perform linear lifting and circumferential deflection movements. The rotational movement of the screw 24 is converted into the transmission body 27 rotating in the opposite direction along the arc groove of the inverted L-shaped guide groove 26, adjusting the position of the second component to be directly above the riser 13, and then moving downward in the vertical groove to get closer to the liquid surface in the riser 13. When the transmission body 27 moves downward, it drives the long connecting piece 28, which is fixedly connected to it, to move downward synchronously. The long connecting piece 28 drives the entire second component to move downward through the vertical connecting rod 29. During the process, the buffer spring 210 plays a buffering role to prevent the second component from violently colliding with the molten metal in the open riser 13 due to gravity impact. When the second component moves to a preset height above the liquid surface of the open riser 13, the drive vertical wheel 22 stops driving, and the transmission body 27 stops descending. The transmission mechanism, consisting of a vertical drive wheel 22, a transmission bevel gear 23, and a screw 24, converts the rotational motion of the motor into the linear lifting and circumferential deflection motion of the transmission body 27. This provides a stable power output for the impurity grabbing, transfer, and resetting of the second component. Impurities in the exposed riser 13 can be dynamically cleaned in real time during the casting process without interrupting the casting operation. Moreover, the impurity cleaning, transfer, and discharge process is highly automated and requires no manual intervention. This not only avoids the safety hazards of manual cleaning but also significantly shortens the overall casting cycle and improves production efficiency.
[0042] The arc-shaped groove and vertical groove structure of the inverted L-shaped guide groove 26 limits the movement trajectory of the transmission body 27, so that the second component can be aligned with the top of the open riser 13 to complete the impurity grabbing, and deflected to the top of the container tank 312 to complete the impurity release, avoiding impurity spillage or grabbing failure caused by movement deviation. The buffer spring 210 buffers the second component as it moves downward toward the molten metal surface, preventing a violent collision between the second component and the high-temperature molten metal due to gravity. This protects the structural integrity of the component and prevents safety hazards and quality impacts caused by molten metal splashing. Under the switching control of the forward and reverse rotation of the first component, after the second component moves to the impurity collection area outside the metal mold body 11, the toothed plate 310 disperses and releases impurities through the transmission of the first connecting rod 37, thus completing the directional discharge of impurities and preventing secondary contamination of the mold or castings by impurities.
[0043] Please refer to the above work process. Figures 1 to 5 .
[0044] The following is the working process of the second component: In use, an external controller sends a telescopic signal to the electric telescopic rod 34, controlling the extension end of the electric telescopic rod 34 to move downward. The electric telescopic rod 34 drives the connecting body 35 to move downward synchronously. The connecting body 35 drives the two sets of first connecting rods 37 to deflect downward through the symmetrical positioning rod 36. During the deflection process, the first connecting rod 37 drives the two sets of second connecting rods 39 to move towards the center through the rotational connection at the bend of the second connecting rod 39. The second connecting rod 39 drives the two sets of toothed plates 310 fixedly connected to it to move synchronously towards the center. The tooth grooves of the two sets of toothed plates 310 interlock and splice into a sealed state. During this process, the arc surface structure of the toothed plate 310 forms a lower groove in the middle after splicing, which accurately captures impurities such as oxide slag above the liquid surface of the open riser 13. At the same time, the unsolidified molten metal flows back into the open riser 13 through the leakage hole 311 on the toothed plate 310 to continue to participate in the feeding, while the impurities are left in the lower groove of the toothed plate 310 due to cooling and solidification, thus achieving effective separation of impurities and molten metal. During the process of the toothed plate 310 centering and grabbing impurities, the high-temperature heating rod of the stirring shaft 313 at the bottom of the toothed plate 310 is activated simultaneously. While the stirring shaft 313 moves downwards and obliquely following the toothed plate 310 in centering, it heats and stirs the molten metal in the open riser 13. On the one hand, it can prevent the molten metal from solidifying too early and ensure that the feeding channel is unobstructed. On the other hand, it can make the composition and temperature distribution of the molten metal more uniform, improve the density of the casting, and avoid shrinkage cavities and porosity defects. After the impurities are collected, the drive motor of the vertical drive wheel 22 is restarted and controlled to rotate in the opposite direction. Through the reverse transmission of the transmission bevel gear 23 and the screw 24, the transmission body 27 is driven to move upward along the vertical groove of the inverted L-shaped guide groove 26, and then the second component is driven to rise as a whole through the long connector 28 and the vertical connecting rod 29. When the second component rises to the preset height, the drive vertical drive wheel 22 continues to rotate in the opposite direction. At this time, the transmission body 27 is deflected around the outer shell 25 under the limiting action of the arc groove of the inverted L-shaped guide groove 26, and the second component is moved to the impurity collection area outside the metal mold body 11. Then, the extension end of the electric telescopic rod 34 is controlled to move upward through the external controller, which drives the connecting body 35 and the symmetrical positioning rod 36 to rise. Through the transmission of the first connecting rod 37 and the second connecting rod 39, the two sets of toothed plates 310 are dispersed to both sides. Furthermore, when the second component moves directly above the container tank 312 and the toothed plate 310 disperses to both sides, the external controller simultaneously starts the micro high-frequency vibrator. Through vibration, the oxide residue adhering to the surface and grooves of the toothed plate 310 is detached from the toothed plate 310 and falls into the container tank 312. The polytetrafluoroethylene coating can significantly reduce the contact adhesion between the oxide residue and the toothed plate 310. Combined with the vibration, the detachment rate of the oxide residue is increased, solving the adhesion problem. Then, the impurities collected on it are released into the container tank 312, completing one impurity cleaning cycle. Furthermore, after the toothed plate 310 releases the oxide slag, the purging nozzle simultaneously sprays high-pressure argon gas to purge the unsolidified molten metal remaining on the surface of the toothed plate 310 and in the leak hole 311 into the return tank. The molten metal flows back to the open riser 13 through the return tank to continue to participate in feeding, and there is no molten metal retention. If a very small amount of molten metal is not completely swept away, the toothed plate 310 will be in a normal temperature environment outside the open riser 13 after resetting. However, since the amount of molten metal remaining after sweeping is very small, and the high temperature of the stirring shaft 313 will remelt the molten metal when the impurities are grabbed next time, the molten metal will flow back to the open riser 13 with the new molten metal, thus avoiding solidification and forming solid impurities, and better avoiding the introduction of new impurities.
[0045] The second component is centered and spliced through toothed plates 310 to form a sealed lower groove to grab impurities above the liquid surface of the open riser 13. At the same time, the leakage holes 311 on the toothed plates 310 are used to screen and return the unsolidified molten metal. This not only avoids the slag inclusion defects caused by impurities mixing into the casting, but also reduces the waste of molten metal and improves the utilization rate of molten metal. The synchronous heating and stirring action of the stirring shaft 313 prevents the molten metal from solidifying too early and blocking the feeding channel, ensuring continuous and effective feeding. At the same time, the rotation and stirring of the stirring shaft 313 can quickly float the micron-sized oxide slag suspended in the molten metal to the surface, making it easier to capture the next impurity and preventing it from spreading in the molten metal, thus further solving the problem of micron-sized oxide slag. On the other hand, it makes the composition and temperature distribution of the molten metal more uniform, improves the density of the casting, effectively reduces the incidence of defects such as shrinkage cavities and porosity, and significantly improves the density and mechanical properties of the wind turbine main shaft casting.
[0046] Please refer to the above work process. Figures 6 to 9 .
[0047] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.
[0048] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art 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 appended claims and their equivalents.
Claims
1. A metal mold for a wind turbine main shaft, comprising: The metal mold body (11) and a first component mounted thereon, wherein a casting device (12) for rapidly casting molten metal into the metal mold body (11) is provided on one side of the metal mold body (11), and an open riser (13) is provided above the metal mold body (11), the open riser (13) being cylindrical in shape, characterized in that: the first component includes: a positioning frame (21) fixedly connected to the metal mold body (11), the positioning frame (21) being provided on one side of the open riser (13); The first component also includes: a drive vertical wheel (22) disposed on the positioning frame (21), wherein a transmission bevel gear (23) is engaged on the side of the drive vertical wheel (22) near the exposed riser (13). The first component also includes a screw (24) fixedly connected to the transmission bevel gear (23), an outer cover (25) fixedly connected to the positioning frame (21), the transmission bevel gear (23) and the screw (24) are both rotatably connected inside the outer cover (25), the outer ring of the outer cover (25) is provided with an inverted L-shaped guide groove (26), a transmission body (27) is driven and sleeved on the screw (24), the end of the transmission body (27) away from the screw (24) is slidably connected to the inverted L-shaped guide groove (26), a long connecting piece (28) is slidably connected to the outer ring of the outer cover (25), one end of the long connecting piece (28) is fixedly connected to the transmission body (27), the end of the long connecting piece (28) away from the transmission body (27) is fixedly connected to a vertical connecting rod (29), and a buffer spring (210) is slidably sleeved on the outer ring of the vertical connecting rod (29). It also includes a second component fixed to the bottom of the vertical connecting rod (29) for scraping and grabbing oxide slag impurities floating in the open riser (13) and for separating impurities from molten metal.
2. The metal mold for a wind turbine main shaft according to claim 1, characterized in that: The driving vertical wheel (22) is composed of a driving motor and a bevel gear. The driving vertical wheel (22) and the transmission bevel gear (23) are arranged perpendicularly, and the transmission bevel gear (23) is parallel to the surface of the metal mold body (11).
3. The metal mold for a wind turbine main shaft according to claim 1, characterized in that: The vertical connecting rod (29) is perpendicular to the long connecting piece (28), the vertical connecting rod (29) is parallel to the outer shell (25), the long connecting piece (28) is perpendicular to the outer shell (25), and one end of the buffer spring (210) is connected to the long connecting piece (28).
4. A metal mold for a wind turbine main shaft according to claim 1, characterized in that: The second component includes a semi-circular shell (31) fixedly connected to the bottom of the vertical connecting rod (29). The inner diameter of the semi-circular shell (31) is adapted to the outer diameter of the riser (13), and the width of the rectangular groove (32) matches the thickness of the toothed plate (310) to ensure that the movement trajectory of the toothed plate (310) corresponds to the inner cavity of the riser (13). The bottom inner cavity of the semi-circular shell (31) is provided with a rectangular groove (32). The top of the inner cavity of the semi-circular shell (31) is fixedly connected to an inner fixing frame (33). An electric telescopic rod (34) is fixedly connected inside the inner fixing frame (33). The extension end of the electric telescopic rod (34) extends downward and is fixedly connected to a connecting body (35). A symmetrical positioning rod (36) is fixedly connected to the side of the connecting body (35) away from the electric telescopic rod (34). Both ends of the symmetrical positioning rod (36) are rotatably connected to a first connecting rod (37).
5. A metal mold for a wind turbine main shaft according to claim 4, characterized in that: Two semicircular shells (31) are provided and spliced into a circle. The two sets of semicircular shells (31) have semicircular grooves vertically opened on the symmetrical planes near the vertical connecting rod (29). The vertical connecting rod (29) is set in the semicircular groove and its bottom end is fixedly connected to the two sets of semicircular shells (31) respectively. The electric telescopic rod (34) is connected to an external controller. Two symmetrical positioning rods (36) are provided and symmetrically arranged with the central axis of the connecting body (35) as the center. The symmetrical positioning rods (36) are parallel to the ground.
6. A metal mold for a wind turbine main shaft according to claim 4, characterized in that: The second component also includes a positioning body (38) disposed at the bottom of the symmetrical positioning rod (36). The positioning body (38) is fixedly connected to the bottom of the inner fixing frame (33). Mounting grooves are provided on both sides of the positioning body (38). A second connecting rod (39) is rotatably connected within the mounting grooves on both sides of the positioning body (38). The end of the first connecting rod (37) away from the symmetrical positioning rod (36) is rotatably connected to the middle of the second connecting rod (39). The second connecting rod (39) away from the positioning body (38)... A toothed plate (310) is fixedly connected to one end. The toothed plate (310) is provided with two sets of toothed grooves on symmetrical surfaces. The toothed plate (310) is provided with leakage holes (311). The leakage holes (311) are intermittently and equidistantly opened on the toothed plate (310). A stirring shaft (313) is fixedly connected to the bottom of the toothed plate (310). The stirring shaft (313) is provided with multiple sets of leakage holes (311) evenly spaced. A container tank (312) is provided directly below the stirring shaft (313).
7. A metal mold for a wind turbine main shaft according to claim 6, characterized in that: The second link (39) is a V-shaped curved bar with an obtuse angle. The end of the second link (39) away from the positioning body (38) extends and bends towards both sides of the positioning body (38).
8. A metal mold for a wind turbine main shaft according to claim 6, characterized in that: The toothed plate (310) has an arc-shaped cross-section. The tooth grooves of the two sets of toothed plates (310) are spaced apart and can be spliced into one piece when they intersect.