Water turbine runner structure with stress relief triangular blocks and welding and shaping manufacturing method thereof

Abstract

The application relates to the technical field of water turbine runners, in particular to a water turbine runner structure with stress-reducing triangular blocks and a welding and shaping manufacturing method thereof, which comprises a lower fixing ring, a connecting frame, a mounting cone, an upper fixing ring and a connecting flange, and further comprises a blade assembly, wherein the blade assembly comprises a lower butt joint block, a lower mounting frame, an upper butt joint block, an upper mounting frame, a blade, an abutting frame and a fixing member; by disassembling the abutting frame, damaged blades among the multiple blades installed between the upper fixing ring and the lower fixing ring can be slid out and replaced, so that an operator can conveniently individually disassemble and replace the damaged blades, and the maintenance cost of the blades is reduced.

Description

Technical Field

[0001] This invention relates to the field of turbine runner technology, and in particular to a turbine runner structure with stress-reducing triangular blocks and its welding and shaping manufacturing method. Background Technology

[0002] Traditional impeller blades have a smooth surface structure. They rotate when impacted by water flow during operation, converting the potential or kinetic energy of the fluid into mechanical or electrical energy. However, traditional blades will wear out after prolonged use.

[0003] The blade is designed with a uniquely shaped triangular block with drainage grooves at the connection between the blade and the upper crown. The triangular block has honeycomb-shaped weight-reducing holes and a pre-installed stainless steel liner. The stepped bevel design is used during welding, which reduces the residual stress after welding by 30% and increases the fatigue life of the reinforced area to 120,000 hours. It is suitable for the repair of runners of high-head mixed-flow turbines.

[0004] However, when the blades of existing turbine runners are damaged by the impact of debris in the water flow, it is impossible to disassemble and replace the damaged blades. Usually, the entire runner is replaced as a whole, which means that other undamaged parts of the runner are also discarded, resulting in waste of resources and increased maintenance costs. Summary of the Invention

[0005] The purpose of this invention is to provide a turbine runner structure with stress-reducing triangular blocks and its welding and shaping manufacturing method. This solves the problem that when the blades of existing turbine runners are damaged by the impact of debris in the water flow, it is impossible to disassemble and replace the damaged blades. Usually, the entire runner is replaced as a whole, which causes other undamaged parts of the runner to be discarded as well, resulting in waste of resources and increased maintenance costs.

[0006] To achieve the above objectives, the present invention provides a turbine runner structure with a stress-reducing triangular block, comprising a lower fixed ring, a connecting frame, a mounting cone, an upper fixed ring, and a connecting flange. The connecting frame is fixedly connected to the lower fixed ring and is located on one side of the lower fixed ring. The mounting cone is disposed on the connecting frame, the upper fixed ring is disposed on the mounting cone, and the connecting flange is disposed on the mounting cone. It also includes blade assemblies; The blade assembly includes a lower docking block, a lower mounting bracket, an upper docking block, an upper mounting bracket, blades, an abutment bracket, and a fixing member. The lower docking block is disposed in the lower fixing ring. The lower mounting bracket is fixedly connected to the lower docking block and located on one side of the lower docking block. The upper docking block is disposed in the upper fixing ring. The upper mounting bracket is fixedly connected to the upper docking block. The blades are fixedly connected to the lower mounting bracket and the upper mounting bracket, respectively, and are located between the lower mounting bracket and the upper mounting bracket. The abutment bracket is connected to the connecting bracket through the fixing member and is located on the side of the connecting bracket closer to the lower docking block. The fixing member is disposed on the abutment bracket and connected to the connecting bracket.

[0007] The fixing component includes a fixing bracket and a fixing bolt. The fixing bracket is fixedly connected to the abutment frame and is located on one side of the abutment frame. The fixing bolt is disposed on the fixing bracket and connected to the connecting frame.

[0008] The lower fixing ring has an insertion groove located on the side of the lower fixing ring close to the fixing bracket and cooperates with the fixing bracket.

[0009] The blade assembly further includes an upper cover plate and connecting bolts. The upper cover plate is connected to the upper fixing ring by the connecting bolts and is located on the side of the upper fixing ring near the upper mating block. The connecting bolts are disposed on the upper cover plate and connected to the upper fixing ring.

[0010] The lower fixing ring has an upper docking groove, which is located on the side of the lower fixing ring near the lower docking block and engages with the lower docking block.

[0011] The upper fixing ring has an upper docking groove, which is located on the side of the upper fixing ring close to the upper docking block and engages with the upper docking block.

[0012] The blade assembly further includes a fastening component, which includes a rubber ring and a moving block. The rubber ring is sleeved on the abutment frame and located on one side of the abutment frame; the moving block is fixedly connected to the rubber ring and located on one side of the rubber ring.

[0013] The abutment frame has a rubber ring groove, which is located on the side of the abutment frame near the rubber ring and engages with the rubber ring.

[0014] A welding and shaping manufacturing method for a turbine runner structure with stress-reducing triangular blocks, applicable to the aforementioned turbine runner structure with stress-reducing triangular blocks, includes the following steps: Pre-process the rotor; The upper fixing ring, the blade assembly, and the lower fixing ring component are positioned and assembled on the tooling. Welding is performed on the runner assembly and the stress-reducing triangular blocks on its blades; After the turbine assembly is welded, post-weld heat treatment is performed according to the material and welding process requirements; After heat treatment, non-destructive testing is performed on the weld. The weld seam was manually ground. Static balance testing is performed after processing is completed.

[0015] This invention discloses a turbine runner structure with stress-reducing triangular blocks. When multiple blades need to be installed, the blades are welded between the lower mounting bracket and the upper mounting bracket. A lower connecting block is welded to the lower mounting bracket, and the upper mounting bracket is welded to the upper connecting block. The upper connecting block slides into the upper fixing ring, and the lower connecting block slides into the lower fixing ring. Two abutment brackets are connected to the connecting bracket via a fixing member. After the abutment brackets are fixed, they can splice into a circular ring and abut against the outside of the lower fixing ring. This abutment bracket action restricts and locks the sliding of the multiple lower connecting blocks in the lower fixing ring, thereby enabling... The lower mating block in the lower fixing ring is slid in and locked by the abutment ring, allowing the blade to be installed and fixed in the lower fixing ring and the upper fixing ring. When a damaged blade needs to be replaced, the fixing component and its abutment frame are disassembled, and the upper and lower mating blocks on the corresponding damaged blade are slid out from the upper and lower fixing rings. By disassembling the abutment frame, the damaged blade among the multiple blades installed between the upper and lower fixing rings can be slid out and replaced, which facilitates the operator to disassemble and replace the damaged blade individually, thereby reducing the maintenance cost of the blade. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the accompanying drawings used in the description of the embodiments or the prior art will be briefly introduced below.

[0017] Figure 1 This is a schematic diagram of the turbine runner structure with stress-reducing triangular blocks according to the first embodiment of the present invention.

[0018] Figure 2 This is a schematic diagram of the blade structure according to the first embodiment of the present invention.

[0019] Figure 3 This is a structural schematic diagram of the fixing component according to the first embodiment of the present invention.

[0020] Figure 4This is a schematic diagram of the upper and lower fixing rings according to the first embodiment of the present invention.

[0021] Figure 5 This is a schematic diagram of the turbine runner structure with stress-reducing triangular blocks according to the second embodiment of the present invention.

[0022] Figure 6 This is a step diagram of the welding and shaping manufacturing method of the turbine runner structure with stress-reducing triangular blocks according to the third embodiment of the present invention.

[0023] In the diagram: 101-Lower fixing ring, 102-Connecting bracket, 103-Mounting cone, 104-Upper fixing ring, 105-Connecting flange, 106-Lower mating block, 107-Lower mounting bracket, 108-Upper mating block, 109-Upper mounting bracket, 110-Blade, 111-Abutting bracket, 112-Upper cover plate, 113-Connecting bolt, 114-Fixed bracket, 115-Fixed bolt, 116-Insertion groove, 117-Lower mating groove, 118-Upper mating groove, 201-Rubber ring, 202-Moving block, 203-Rubber ring groove. Detailed Implementation

[0024] The embodiments of the present invention are described in detail below. Examples of the embodiments are shown in the accompanying drawings. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the present invention, but should not be construed as limiting the present invention.

[0025] The first embodiment of this application is as follows: Please see Figures 1-4 ,in Figure 1 This is a schematic diagram of the turbine runner structure with stress-reducing triangular blocks according to the first embodiment of the present invention. Figure 2 This is a schematic diagram of the blade structure according to the first embodiment of the present invention. Figure 3 This is a structural schematic diagram of the fixing component according to the first embodiment of the present invention. Figure 4 This is a schematic diagram of the upper and lower fixing rings according to the first embodiment of the present invention.

[0026] This invention provides a turbine runner structure with stress-reducing triangular blocks, including a lower fixing ring 101, a connecting frame 102, a mounting cone 103, an upper fixing ring 104, a connecting flange 105, and a blade assembly. The blade assembly includes a lower connecting block 106, a lower mounting frame 107, an upper connecting block 108, an upper mounting frame 109, blades 110, an abutment frame 111, a fixing component, an upper cover plate 112, and connecting bolts 113. The fixing component includes a fixing bracket 114 and fixing bolts 115. The lower fixing ring 101 has an insertion groove 116 and a lower connecting groove 117, and the upper fixing ring 104 has an upper connecting groove 118. The aforementioned solution addresses the problem that when the blades 110 of an existing turbine runner are damaged by debris in the water flow, it is impossible to disassemble and replace the damaged blades 110. Usually, the entire runner is replaced as a whole, which results in the discarding of other undamaged parts of the runner, leading to waste of resources and increased maintenance costs. Understandably, the aforementioned solution can be used when it is necessary to replace the damaged blades 110 individually.

[0027] In this embodiment, the connecting frame 102 is fixedly connected to the lower fixing ring 101, the mounting cone 103 is disposed on the connecting frame 102, the upper fixing ring 104 is disposed on the mounting cone 103, and the connecting flange 105 is disposed on the mounting cone 103. The upper fixing ring 104 is used to support the blade 110 and forms a flow channel with the lower fixing ring 101. The middle part of its upper end is the connecting flange 105, which is provided with a screw hole for connection with the main shaft.

[0028] The lower docking block 106 is disposed in the lower fixing ring 101. The lower mounting bracket 107 is fixedly connected to the lower docking block 106 and located on one side of the lower docking block 106. The upper docking block 108 is disposed in the upper fixing ring 104. The upper mounting bracket 109 is fixedly connected to the upper docking block 108. The blade 110 is fixedly connected to both the lower mounting bracket 107 and the upper mounting bracket 109, and is located between the lower mounting bracket 107 and the upper mounting bracket 109. The abutment bracket 111 is connected to the connecting bracket 102 through the fixing member and is located on the side of the connecting bracket 102 near the lower docking block 106. The fixing member is disposed in the lower fixing ring 101. The abutment frame 111 is connected to the connecting frame 102. Multiple lower abutment blocks 106 can slide into the lower fixing ring 101. Multiple lower mounting frames 107 are welded to the corresponding lower abutment blocks 106. Multiple upper abutment blocks 108 can slide into the upper fixing ring 104. Multiple upper mounting frames 109 are welded to the corresponding upper abutment blocks 108. The two ends of multiple blades 110 are welded and fixed between the corresponding lower mounting frames 107 and upper mounting frames 109. Two abutment frames 111 are connected to the connecting frame 102 via the fixing member. After the abutment frame 111 is fixed, it can splice a circular ring and abut against the outer side of the lower fixing ring 101. The abutment frame 111 abuts against the lower fixing ring 101, thereby restricting and locking the sliding of the plurality of lower connecting blocks 106 in the lower fixing ring 101. The fixing member is disposed on the abutment frame 111 and connected to the connecting frame 102. The fixing member can connect and fix the abutment frame 111 to the connecting frame 102, thereby realizing that when multiple blades 110 need to be installed, the blades 110 are welded between the lower mounting frame 107 and the upper mounting frame 109, and the lower connecting blocks 106 are welded to the lower mounting frame 107, and the upper connecting blocks 108 are welded to the upper mounting frame 109. The upper connecting blocks slide into the upper fixing ring 104, and the lower connecting blocks 106 are welded to the upper mounting frame 107. The connecting block slides into the lower fixing ring 101. Two abutting brackets 111 are connected to the connecting bracket 102 via the fixing member. After being fixed, the abutting brackets 111 can splice into a circular ring and abut against the outside of the lower fixing ring 101. This abutting action of the abutting brackets 111 restricts and locks the sliding of multiple lower abutting blocks 106 in the lower fixing ring 101. The abutting ring also restricts and locks the sliding of the lower abutting blocks 106 in the lower fixing ring 101, allowing the blade 110 to be installed and fixed in the lower fixing ring 101 and the upper fixing ring 104. When a damaged blade 110 needs to be replaced, the fixing member and its abutting brackets 111 are disassembled.By sliding the upper mating block 108 and the lower mating block 106 on the corresponding damaged blade 110 out of the upper fixing ring 104 and the lower fixing ring 101, and by disassembling the abutment frame 111, the damaged blade 110 among the multiple blades 110 installed between the upper fixing ring 104 and the lower fixing ring 101 can be slid out and replaced. This facilitates the operator to individually disassemble and replace the damaged blade 110, thereby reducing the maintenance cost of the blade 110.

[0029] Secondly, the fixed bracket 114 is fixedly connected to the abutment frame 111 and is located on one side of the abutment frame 111; the fixing bolt 115 is disposed on the fixed bracket 114 and connected to the connecting frame 102; the four fixed brackets 114 are welded to the two abutment frames 111; the four fixed brackets 114 can be inserted through into the lower fixing ring 101 and are located on both sides of the connecting frame 102; and the four fixed brackets 114 are connected and fixed to the connecting frame 102 by multiple fixing bolts 115, thereby connecting and fixing the two abutment frames 111 to the connecting frame 102, while restricting the movement of the lower abutment block 106.

[0030] Meanwhile, the insertion slot 116 is located on the side of the lower fixing ring 101 close to the fixing bracket 114 and cooperates with the fixing bracket 114. The lower fixing ring 101 has four insertion slots 116, and the fixing bracket 114 can be inserted through the insertion slots 116 to achieve the purpose of inserting the fixing bracket 114 through the lower fixing ring 101.

[0031] In addition, the upper cover plate 112 is connected to the upper fixing ring 104 by the connecting bolt 113 and is located on the side of the upper fixing ring 104 near the upper docking block 108. The connecting bolt 113 is disposed on the upper cover plate 112 and connected to the upper fixing ring 104. The upper cover plate 112 is connected and fixed to the upper fixing ring 104 by multiple connecting bolts 113. The upper cover plate 112 can restrict the movement of the upper docking block 108 in the upper fixing ring 104, thereby making the connection on the blade 110 more stable.

[0032] Finally, the lower docking groove 117 is located on the side of the lower fixing ring 101 near the lower docking block 106 and engages with the lower docking block 106; the upper docking groove 118 is located on the side of the upper fixing ring 104 near the upper docking block 108 and engages with the upper docking block 108. The lower fixing ring 101 has a plurality of lower docking grooves 117, through which the lower docking block 106 can be positioned and slid into the lower fixing ring 101. The upper fixing ring 104 has a plurality of upper docking grooves 118, through which the upper docking block 108 can be positioned and slid into the upper fixing ring 104.

[0033] When using the turbine runner structure with stress-reducing triangular blocks according to this embodiment, when multiple blades 110 need to be installed, the blades 110 are welded between the lower mounting bracket 107 and the upper mounting bracket 109, and the lower connecting block 106 is welded to the lower mounting bracket 107. The upper mounting bracket 109 is welded with the upper connecting block 108. The upper connecting block slides into the upper fixing ring 104, and the lower connecting block slides into the lower fixing ring 101. The two abutting brackets 111 are connected to the connecting bracket 102 through the fixing member. After the abutting brackets 111 are fixed, they can splice the ring and abut against the outside of the lower fixing ring 101. Thus, the sliding of multiple lower connecting blocks 106 in the lower fixing ring 101 is restricted and locked by the abutting of the abutting brackets 111. The abutment ring restricts and locks the lower abutment block 106 in the lower fixing ring 101, allowing the blade 110 to be installed and fixed in the lower fixing ring 101 and the upper fixing ring 104. When a damaged blade 110 needs to be replaced, the fixing component and its abutment frame 111 are disassembled, and the upper abutment block 108 and the lower abutment block 106 on the corresponding damaged blade 110 are slid out from the upper fixing ring 104 and the lower fixing ring 101. By disassembling the abutment frame 111, the damaged blade 110 among the multiple blades 110 installed between the upper fixing ring 104 and the lower fixing ring 101 can be slid out and replaced, thus facilitating the operator to disassemble and replace the damaged blade 110 individually, thereby reducing the maintenance cost of the blade 110.

[0034] The second embodiment of this application is as follows: Please see Figure 5 ,in Figure 5 This is a schematic diagram of the turbine runner structure with stress-reducing triangular blocks according to the second embodiment of the present invention.

[0035] Based on the first embodiment, the turbine runner structure with stress-reducing triangular blocks in this embodiment includes a fastening component, which includes a rubber ring 201 and a moving block 202, and the abutment frame 111 has a rubber ring groove 203.

[0036] The rubber ring 201 is sleeved on the abutment frame 111 and located on one side of the abutment frame 111; the moving block 202 is fixedly connected to the rubber ring 201 and located on one side of the rubber ring 201; the rubber ring groove 203 is located on the side of the abutment frame 111 close to the rubber ring 201 and cooperates with the rubber ring 201. The rubber ring 201 is sleeved in the rubber ring groove 203 of the abutment frame 111. Through the sleeve of the rubber ring 201 and the elastic deformation ability of the rubber ring 201, the two abutment frames 111 can be better clamped together. The moving block 202 is integrally connected and fixed on the rubber ring 201. Through the force point provided by the moving block 202, it is easy to remove the sleeved rubber ring 201 from the abutment frame 111.

[0037] The third embodiment of this application is as follows: Please see Figure 6 ,in Figure 6 This is a step diagram of the welding and shaping manufacturing method of the turbine runner structure with stress-reducing triangular blocks according to the third embodiment of the present invention.

[0038] Based on the second embodiment, the welding and shaping manufacturing method of the turbine runner structure with stress-reducing triangular blocks in this embodiment includes the following steps: S301: Pre-treat the rotor; S302: Position and assemble the upper fixing ring 104, the blade assembly, and the lower fixing ring 101 on the tooling; S303: Weld the stress-reducing triangular blocks on the runner assembly and its blades 110; S304: After the turbine assembly is welded, post-weld heat treatment shall be performed according to the material and welding process requirements; S305: Non-destructive testing of welds after heat treatment; S306: Manual grinding of the weld seam; S307: Static balance test shall be performed after processing.

[0039] The upper fixing ring 104 supports the blade 110 and forms a flow channel with the lower fixing ring 101. Its upper middle portion is the connecting flange 105, which has a threaded hole for connection to the main shaft. Each component requires appropriate normalizing and tempering treatment to improve material properties. The upper fixing ring 104, the blade 110, and the lower fixing ring 101 are assembled on a tooling to ensure accurate positioning and tight fit. In both vertical and horizontal positions of the impeller, a mandrel tool is used to connect the stress-reducing triangular block to the impeller blade 110 at the water outlet. The upper mounting bracket 109, which is connected to the upper fixed ring 104, is welded together. After the wheel assembly is completed, post-weld heat treatment is performed according to the material and welding process requirements. After heat treatment, the weld is subjected to MT (magnetic particle testing) non-destructive testing to check for defects inside and on the surface of the weld. The weld is then manually ground to make its surface meet the requirements of a smooth transition in the drawing. After grinding, UT and PT testing are performed again to ensure the quality of the weld. Finally, after the processing is completed, a static balance test is performed to ensure that the wheel rotates smoothly and to reduce vibration and stress concentration during operation.

[0040] The above-disclosed embodiments are merely one or more preferred embodiments of this application and should not be construed as limiting the scope of this application. Those skilled in the art can understand that all or part of the processes for implementing the above embodiments and equivalent changes made in accordance with the claims of this application still fall within the scope of this application.

Claims

1. A turbine runner structure with a stress-reducing triangular block, comprising a lower fixed ring, a connecting frame, a mounting cone, an upper fixed ring, and a connecting flange, wherein the connecting frame is fixedly connected to the lower fixed ring and located on one side of the lower fixed ring, the mounting cone is disposed on the connecting frame, the upper fixed ring is disposed on the mounting cone, and the connecting flange is disposed on the mounting cone, characterized in that, It also includes blade assemblies; The blade assembly includes a lower docking block, a lower mounting bracket, an upper docking block, an upper mounting bracket, blades, an abutment bracket, and a fixing member. The lower docking block is disposed in the lower fixing ring. The lower mounting bracket is fixedly connected to the lower docking block and located on one side of the lower docking block. The upper docking block is disposed in the upper fixing ring. The upper mounting bracket is fixedly connected to the upper docking block. The blades are fixedly connected to the lower mounting bracket and the upper mounting bracket, respectively, and are located between the lower mounting bracket and the upper mounting bracket. The abutment bracket is connected to the connecting bracket through the fixing member and is located on the side of the connecting bracket closer to the lower docking block. The fixing member is disposed on the abutment bracket and connected to the connecting bracket.

2. The turbine runner structure with stress-reducing triangular blocks as described in claim 1, characterized in that, The fixing component includes a fixing bracket and a fixing bolt. The fixing bracket is fixedly connected to the abutment frame and is located on one side of the abutment frame. The fixing bolt is disposed on the fixing bracket and connected to the connecting frame.

3. The turbine runner structure with stress-reducing triangular blocks as described in claim 2, characterized in that, The lower fixing ring has an insertion groove located on the side of the lower fixing ring close to the fixing bracket and cooperates with the fixing bracket.

4. The turbine runner structure with stress-reducing triangular blocks as described in claim 1, characterized in that, The blade assembly also includes an upper cover plate and connecting bolts. The upper cover plate is connected to the upper fixing ring by the connecting bolts and is located on the side of the upper fixing ring near the upper mating block. The connecting bolts are disposed on the upper cover plate and connected to the upper fixing ring.

5. The turbine runner structure with stress-reducing triangular blocks as described in claim 1, characterized in that, The blade assembly further includes a fastening component, which includes a rubber ring and a movable block. The rubber ring is sleeved on the abutment frame and located on one side of the abutment frame; the movable block is fixedly connected to the rubber ring and located on one side of the rubber ring.

6. The turbine runner structure with stress-reducing triangular blocks as described in claim 5, characterized in that, The abutment frame has a rubber ring groove, which is located on the side of the abutment frame close to the rubber ring and engages with the rubber ring.

7. A welding and shaping manufacturing method for a turbine runner structure with stress-reducing triangular blocks, applicable to the turbine runner structure with stress-reducing triangular blocks as described in any one of claims 1 to 6, characterized in that, Includes the following steps: Pre-process the rotor; The upper fixing ring, the blade assembly, and the lower fixing ring component are positioned and assembled on the tooling. Welding is performed on the runner assembly and the stress-reducing triangular blocks on its blades; After the turbine assembly is welded, post-weld heat treatment is performed according to the material and welding process requirements. After heat treatment, non-destructive testing is performed on the weld. The weld seam was manually ground. Static balance testing is performed after processing is completed.

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