A machining tool and clamping method for an intelligent variable-speed high-power double-fed fan brake caliper

Abstract

The application discloses a machining tool and clamping method for an intelligent variable-speed high-power double-fed fan brake caliper, the machining tool comprises a base plate, a pair of vertical plate frames, a backing plate and a top pressing beam, the brake caliper is laid on the backing plate, the backing plate supports the brake caliper through three height-adjustable struts, and the brake caliper is limited in the up-down direction through a pressing head arranged on the top pressing beam; the vertical plate frame is pressed against a protruding jaw on the brake caliper through a pressing block, thereby limiting the brake caliper in the front-back direction; the vertical plate frame is also provided with a top rod which abuts against and fixes the brake caliper from both ends; the clamping method comprises the steps of leveling, up-down limiting, left-right limiting, front-back limiting and table checking, etc.; the application can quickly realize leveling and stable clamping of the brake caliper, and improve machining precision and efficiency.

Description

Technical Field

[0001] This invention relates to the field of wind power equipment manufacturing technology, and more specifically, to a machining fixture and clamping method for an intelligent variable speed high-power doubly fed wind turbine brake caliper. Background Technology

[0002] Doubly fed wind turbines are one of the mainstream wind power generation devices currently available. Their braking systems typically employ brake calipers and brake discs to achieve braking functionality. As a critical safety component, the machining precision of the brake calipers directly affects the reliability and stability of braking performance.

[0003] Brake calipers are typically irregularly shaped structures with multiple surfaces to be machined, requiring high precision. For example, during finishing, high precision requirements must be met, such as flatness ≤0.025mm, parallelism ≤0.05mm, and positional accuracy ≤0.3mm. Traditional machining methods often use general-purpose fixtures with spacers for positioning brake calipers, which presents the following problems:

[0004] 1. Unstable clamping and positioning make it difficult to guarantee machining accuracy;

[0005] 2. The leveling process is cumbersome, time-consuming, and inefficient;

[0006] 3. Poor adaptability to blanks, making it difficult to adapt to changes in blank height;

[0007] 4. Deformation is prone to occur during clamping, affecting the final machining quality.

[0008] Therefore, there is an urgent need to develop a machining fixture and clamping method specifically for brake calipers to solve the above problems. Summary of the Invention

[0009] The present invention aims to provide a machining fixture and clamping method for intelligent variable speed high-power doubly fed wind turbine brake calipers, so as to solve the technical problems of unstable clamping, difficulty in leveling, and difficulty in guaranteeing machining accuracy in the prior art.

[0010] To achieve the above objectives, according to one aspect of the present invention, a machining fixture for a smart variable speed high-power doubly-fed wind turbine brake caliper is provided for clamping the brake caliper, comprising: a base plate; a pair of upright plates disposed on the base plate and located at both ends of the brake caliper; a pad disposed on the base plate and located at the lower part of the brake caliper; a top pressure beam supported at both ends on the top of the pair of upright plates and located above the brake caliper; the brake caliper is provided with protruding claws; the brake caliper lies on the pad, the pad supports the brake caliper by three height-adjustable supports, and is limited in the vertical direction by a pressure head disposed on the top pressure beam; the upright plates press against the protruding claws by pressure blocks to limit the brake caliper in the front-rear direction; the upright plates are also provided with top rods that abut against and fix the brake caliper from both ends.

[0011] Furthermore, the upright frame has windows facing the process holes at both ends of the brake caliper.

[0012] Furthermore, height-adjustable studs are installed on the side wall of the window, with protruding claws on top of the studs, and are fastened by pressure blocks.

[0013] Furthermore, the support includes a threaded rod and an adjusting nut, by rotating the adjusting nut to change the support height of the support.

[0014] Furthermore, the push rod is threaded into the upright plate frame, and the end of the push rod contacts the side of the brake caliper.

[0015] Furthermore, reinforcing ribs are provided between the upright frame and the base plate.

[0016] Furthermore, the upright frame is provided with mounting steps for supporting the protruding claws.

[0017] According to another aspect of the present invention, a method for clamping a brake caliper using the above-described machining fixture is provided, comprising the following steps:

[0018] Step 1: Place the brake caliper on its side on the pad, so that the bottom of the brake caliper is in contact with the three supports;

[0019] Step 2: Adjust the height of the three supports to level the brake caliper so that the surface of the brake caliper to be machined meets the flatness requirements;

[0020] Step 3: Install the top pressure beam on the top of a pair of upright plates, tighten the pressure head so that the pressure head presses against the upper part of the brake caliper to achieve vertical limiting;

[0021] Step 4: Tighten the top rods on both sides of the upright plate frame so that the top rods abut against the sides of the brake caliper from both ends to achieve left and right directional limiting;

[0022] Step 5: Install the pressure block to press it against the pawl on the brake caliper, thereby limiting the forward and backward movement.

[0023] Step 6: Use a dial indicator to confirm the flatness, position, and height difference of each reference surface and reference hole. After confirming that they are qualified, tighten all fasteners to complete the clamping.

[0024] Furthermore, in step two, when adjusting the height of the three supports, the blank height difference at the contact point between the brake caliper and the three supports is measured using a dial indicator, so that the blank height difference is controlled within the range of ≤1mm.

[0025] Furthermore, in step six, the gauge is used to confirm the upper part of the convex claw on the side of the brake caliper, and to confirm that its drop is ≤1mm.

[0026] Compared with the prior art, the advantages and beneficial effects of the present invention are as follows:

[0027] 1. By applying the technical solution of this invention, the bottom surface of the brake caliper is supported by three height-adjustable pillars, which can quickly achieve the leveling of the blank, adapt to changes in blank height, and improve clamping efficiency.

[0028] 2. Vertical positioning is achieved through the top pressure beam and pressure head, horizontal positioning is achieved through the top rod, and front-back positioning is achieved through the cooperation of the pressure block and the claw, forming a complete constraint of six-point positioning to ensure stable and reliable clamping;

[0029] 3. Each limiting structure is independently adjustable, which facilitates fine-tuning during clamping and effectively improves machining accuracy;

[0030] 4. The tooling structure is compact and has good rigidity, which can meet the high-precision machining requirements of brake calipers. Attached Figure Description

[0031] The accompanying drawings, which form part of this application, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an improper limitation of the invention.

[0032] Figure 1 This is a three-dimensional structural diagram of the machining tooling according to an embodiment of the present invention;

[0033] Figure 2 This is a front view schematic diagram of the machining tooling according to an embodiment of the present invention;

[0034] Figure 3 This is a top view schematic diagram of the machining tooling according to an embodiment of the present invention;

[0035] Figure 4 This is a side view of the machining fixture according to an embodiment of the present invention;

[0036] Figure 5 This is a rear view schematic diagram of the machining fixture according to an embodiment of the present invention;

[0037] Figure 6 This is a three-dimensional structural schematic diagram of the brake caliper manufactured according to the present invention;

[0038] Figure 7 This is a front view schematic diagram of the brake caliper manufactured according to the present invention;

[0039] Figure 8 This is a top view of the brake caliper manufactured according to the present invention.

[0040] Figure 9 for Figure 8 A schematic diagram of the AA cross-sectional structure;

[0041] Figure 10 for Figure 8Schematic diagram of the BB cross-section structure;

[0042] In the diagram: 1. Brake caliper; 11. Claw; 2. Base plate; 3. Stand plate; 31. Pressure block; 32. Top rod; 33. Window; 34. Reinforcing rib plate; 35. Mounting step; 4. Pad plate; 41. Support column; 5. Top pressure beam; 51. Pressure head. Detailed Implementation

[0043] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0044] like Figures 1 to 5 As shown, this embodiment provides a machining fixture for a smart variable speed high-power doubly fed wind turbine brake caliper, used to clamp the brake caliper 1, including a base plate 2, a pair of upright frames 3, a pad 4 and a top pressure beam 5.

[0045] The substrate 2 is a rectangular flat plate structure, which serves as the mounting base for the entire tooling. Its bottom surface is flat, making it easy to fix to the worktable of the bottom processing equipment.

[0046] like Figure 1 , Figure 2 , Figure 5 As shown, a pair of upright frames 3 are vertically mounted on the base plate 2 and are located at both ends of the brake caliper 1. A reinforcing rib 34 is provided between the upright frame 3 and the base plate 2 to improve the structural rigidity of the upright frame 3 and prevent deformation during processing. The upright frame 3 is also provided with mounting steps 35 for supporting the protruding claw 11.

[0047] like Figure 1 , Figure 2 , Figure 5 As shown, the pad 4 is disposed on the base plate 2 and located at the lower part of the brake caliper 1. Three height-adjustable supports 41 are disposed on the pad 4. In this embodiment, each support 41 includes a threaded rod and an adjusting nut; the support height of the support 41 can be changed by rotating the adjusting nut. The three supports 41 are arranged in a triangle, with two at the back and one at the front, forming a three-point support structure. This structure can stably support the bottom surface of the brake caliper 1, and by adjusting the height of each support 41, the brake caliper 1 can be quickly leveled to adapt to changes in the height of the blank.

[0048] like Figures 1-5 As shown, the top pressure beam 5 is supported at both ends by a pair of upright plates 3 and is located above the brake caliper 1. A pressure head 51 is provided on the top pressure beam 5, the lower end of which corresponds to the support column 41, pressing against the upper part of the brake caliper 1 to achieve vertical limiting. Preferably, the pressure head 51 is threaded into the top pressure beam 5, and the clamping force can be adjusted by rotating the pressure head 51.

[0049] like Figure 1 , Figure 4 As shown, the brake caliper 1 is provided with a protruding claw 11. The upright plate frame 3 has a window 33 facing the process holes at both ends of the brake caliper 1. The side wall of the window 33 is provided with a height-adjustable stud. The stud supports the protruding claw 11 and is fastened by the pressure block 31, thereby realizing the front and rear direction limit of the brake caliper 1.

[0050] like Figures 1-5 As shown, a top rod 32 is also provided on the upright plate 3. The top rod 32 is threaded with the upright plate 3 and abuts against the side of the brake caliper 1 from both ends to achieve left and right direction limiting.

[0051] The machining fixture in this embodiment adopts a side-mounted clamping method. The brake caliper 1 lies on the pad 4, and the bottom surface is supported and leveled by three pillars 41. The upper and lower limits are achieved by the top pressure beam 5 and the pressure head 51, the left and right limits are achieved by the top rod 32, and the front and rear limits are achieved by the cooperation of the pressure block 31 and the claw 11, forming a complete six-point positioning constraint to ensure stable and reliable clamping.

[0052] like Figures 1-5 As shown, this embodiment also provides a brake caliper clamping method using the above-mentioned machining fixture, including the following steps:

[0053] Step 1: Place the brake caliper 1 on its side on the pad 4, so that the bottom surface of the brake caliper 1 contacts the three supports 41.

[0054] Step 2: Adjust the height of the three supports 41 to level the brake caliper 1 so that the surface to be machined on the brake caliper 1 meets the flatness requirements; specifically, measure the blank height difference at the contact point between the brake caliper 1 and the three supports 41 using a dial indicator, and control the blank height difference within the range of ≤1mm.

[0055] Step 3: Install the top pressure beam 5 on the top of a pair of upright plates 3, tighten the pressure head 51, so that the pressure head 51 presses against the upper part of the brake caliper 1 to achieve vertical limiting.

[0056] Step 4: Tighten the top rods 32 on both sides of the upright frame 3 so that the top rods 32 abut against the sides of the brake caliper 1 from both ends to achieve left and right direction limiting;

[0057] Step 5: Install the pressure block 31 so that the pressure block 31 presses against the protrusion 11 on the brake caliper 1 to achieve front and rear direction limiting;

[0058] Step Six: Use a dial indicator to confirm the flatness, position, and height difference of each reference surface and reference hole. After confirming that they are qualified, tighten all fasteners and complete the clamping. Specifically, use a dial indicator to confirm the upper part of the convex claw 11 on one side of the brake caliper 1, and confirm that its height difference is ≤1mm. After the machining is completed, the dial indicator also confirms the flatness ≤0.025mm, parallelism ≤0.05mm, position ≤0.3mm, and diameter 24 (0 / 0.021) accuracy requirements.

[0059] The above clamping method can quickly and stably clamp and fix the brake caliper 1, ensuring the positioning accuracy and rigidity during the machining process, thereby meeting the requirements of high-precision machining.

[0060] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A machining fixture for a smart, variable-speed, high-power, doubly-fed wind turbine brake caliper, used for clamping the brake caliper (1), characterized in that, include: substrate(2); A pair of upright plates (3) are disposed on the base plate (2) and located at both ends of the brake caliper (1); A pad (4) is disposed on the base plate (2) and located below the brake caliper (1). The top pressure beam (5) is supported at both ends on the top of the pair of upright plates (3) and is located above the brake caliper (1); The brake caliper (1) is provided with a claw (11); The brake caliper (1) lies on the pad (4), which is supported by three height-adjustable pillars (41) and is limited in the vertical direction by the pressure head (51) set on the top pressure beam (5). The upright frame (3) presses against the protruding claw (11) by the pressure block (31) to limit the front and rear directions of the brake caliper (1); The upright frame (3) is also provided with top rods (32) that abut against and fix the brake calipers (1) from both ends.

2. The machining tooling for the intelligent variable speed high-power doubly-fed wind turbine brake caliper according to claim 1, characterized in that, The upright frame (3) has a window (33) facing the process holes at both ends of the brake caliper (1).

3. The machining tooling for the intelligent variable speed high-power doubly-fed wind turbine brake caliper according to claim 2, characterized in that, The window (33) is provided with a height-adjustable stud on its side wall. The stud supports the claw (11) and is fastened by a pressure block (31).

4. The machining tooling for the intelligent variable speed high-power doubly-fed wind turbine brake caliper according to claim 1, characterized in that, The support column (41) includes a threaded rod and an adjusting nut, and the support height of the support column (41) can be changed by rotating the adjusting nut.

5. The machining fixture for the intelligent variable speed high-power doubly-fed wind turbine brake caliper according to claim 1, characterized in that, The push rod (32) is threadedly engaged with the upright frame (3), and the end of the push rod (32) contacts the side of the brake caliper (1).

6. The machining fixture for the intelligent variable speed high-power doubly-fed wind turbine brake caliper according to claim 1, characterized in that, A reinforcing rib (34) is provided between the upright frame (3) and the base plate (2).

7. The machining tooling for the intelligent variable speed high-power doubly-fed wind turbine brake caliper according to claim 1, characterized in that, The upright frame (3) is provided with an installation step (35) for supporting the protruding claw 11.

8. A method for clamping a brake caliper using the machining fixture described in any one of claims 1 to 7, characterized in that, Includes the following steps: Step 1: Place the brake caliper (1) on its side on the pad (4) so ​​that the bottom surface of the brake caliper (1) contacts the three supports (41); Step 2: Adjust the height of the three supports (41) to level the brake caliper (1) so that the surface to be machined on the brake caliper (1) meets the flatness requirements; Step 3: Install the top pressure beam (5) on the top of a pair of upright plates (3), tighten the pressure head (51) so that the pressure head (51) presses against the upper part of the brake caliper (1) to achieve vertical and horizontal limiting; Step 4: Tighten the top rods (32) on both sides of the upright frame (3) so that the top rods (32) abut against the sides of the brake calipers (1) from both ends to achieve left and right direction limiting; Step 5: Install the pressure block (31) to press the pressure block (31) against the pawl (11) on the brake caliper (1) to achieve front and rear direction limiting; Step 6: Use a dial indicator to confirm the flatness, position, and height difference of each reference surface and reference hole. After confirming that they are qualified, tighten all fasteners to complete the clamping.

9. The brake caliper clamping method according to claim 8, characterized in that, In step two, when adjusting the height of the three supports (41), the blank drop difference at the contact point between the brake caliper (1) and the three supports (41) is measured by dial gauge, so that the blank drop difference is controlled within the range of ≤1mm.

10. The brake caliper clamping method according to claim 9, characterized in that, In step six, the gauge is used to confirm the upper part of the convex claw (11) at one end of the brake caliper (1) lying on its side, and to confirm that its drop is ≤1mm.

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