Assembly aid for a tap changer

Abstract

This application provides an assembly auxiliary device for tap changers. The device includes an integrated assembly table, a transmission component alignment module, a locking accuracy calibration module, and a base plate positioning module. The integrated assembly table provides the basic support; the transmission component alignment module ensures the alignment accuracy of the drive shaft assembly and transmission gears; the locking accuracy calibration module controls the clearance between the positioning wheel and the locking assembly; and the base plate positioning module securely mounts the base plate. The device provided in this application is a multi-model, high-precision tap changer assembly auxiliary device. It can quickly fix the mounting base plate, accurately align the transmission components, and calibrate the locking assembly accuracy, thereby improving the assembly accuracy and efficiency of the tap changer and reducing the intensity of manual operation.

Description

Technical Field

[0001] This application relates to the field of power equipment assembly tools, and in particular to an assembly auxiliary device for tap changers. Background Technology

[0002] As a core component of transformer voltage regulation, the tap changer's internal structure includes key components such as drive shaft assembly 14, transmission gear 16, positioning wheel 20, locking assembly 21, and mounting base plate 18. Each component needs to be assembled with high precision to ensure the reliability of gear switching.

[0003] Currently, tap changer assembly mainly relies on manual operation, which presents many technical challenges: Firstly, the connection between the drive shaft assembly 14 and the transmission gear 16 relies on manual visual inspection, and the coaxiality deviation often exceeds 0.5mm, resulting in abnormal gear meshing noise and accelerated wear. In later operation, the failure rate exceeds 35%. Secondly, the fit clearance between the positioning wheel 20 and the locking assembly 21 needs to be manually adjusted repeatedly with a feeler gauge, which is inefficient and the clearance error is prone to exceed 0.05mm, causing unstable gear locking. Third, fixing the mounting substrate 18 requires multiple people to work together to align the holes, and fixing a single substrate takes more than 20 minutes. Furthermore, uneven fixing force can easily cause the substrate to deform. Fourth, most existing assembly tools are general-purpose fixtures, lacking dedicated positioning mechanisms for tap changer components. This makes it impossible to meet the assembly needs of different tap changer models, requiring frequent tooling changes and resulting in low assembly efficiency.

[0004] Therefore, developing an assembly auxiliary device that is compatible with multiple models and has high precision is key to improving assembly quality and efficiency. Summary of the Invention

[0005] To address one of the aforementioned technical deficiencies, this application provides an assembly auxiliary device for tap changers.

[0006] The device includes: an integrated assembly table, a transmission component alignment module, a locking accuracy calibration module, and a substrate positioning module; The integrated assembly platform is used to provide basic support. The transmission component alignment module is used to ensure the alignment accuracy of the drive shaft assembly (14) and the transmission gear (16); The locking accuracy calibration module is used to control the mating clearance between the positioning wheel (20) and the locking assembly (21); The substrate positioning module is used to fix the substrate (18).

[0007] Optionally, the integrated assembly table is made of welded steel plate; The surface of the integrated assembly table is chrome-plated with a thickness of 10 mm and a roughness Ra≤1.6 μm. The surface is provided with cross-shaped T-shaped grooves, and the bottom is equipped with universal wheels with braking function. The integrated assembly table has a level bubble embedded on its surface, and the table surface dimensions are 1200mm × 800mm. The groove is 20mm wide and 15mm deep, with PTFE wear-resistant strips attached to the inside. The casters are made of polyurethane, with a diameter of 100mm, and each caster can bear a weight of ≥300 kg after braking.

[0008] Optionally, the integrated assembly station also includes component storage drawers and tool racks; The component storage drawer has built-in cushioning foam, with special grooves cut into the foam according to the component size, and the groove depth is 5mm deeper than the component height. The tool rack is made of cold-rolled steel plate, bent and formed, with powder coating on the surface. It is equipped with multiple dedicated hooks with a hook spacing of 150mm.

[0009] Optionally, the transmission component alignment module includes: a laser coaxial instrument, a gear guide bracket, and a shaft end fixing seat; The laser coaxial instrument uses a 650 nm visible laser, with a transmitter power of 5 mW, a measurement distance of 0.2-2 m, and a measurement accuracy of ±0.05 mm. The laser coaxial instrument includes a transmitter and a receiver. The transmitter is integrated with the shaft end mounting base, and the receiver is fixedly connected to the gear guide bracket. The gear guide bracket is attached to the integrated assembly table by a strong magnetic chuck, and has a built-in guide tooth groove that meshes with the transmission gear (16); the magnetic force of the strong magnetic chuck is ≥200 N, the module of the guide tooth groove can be flexibly changed, the surface of the guide tooth groove is hardened, and the hardness of the guide tooth groove is HRC50-55. The shaft end mounting base is adapted to the drive shaft assembly (14) and clamps the drive shaft assembly (14) with a three-jaw chuck, and can be rotated 360°. The clamping range of the three-jaw chuck is 15-50mm, and the inner side is covered with a copper anti-slip pad.

[0010] Optionally, the laser coaxial instrument also includes an LCD display. The shaft end retainer also includes an angle locking knob; The transmission component alignment module is also equipped with a magnetic base, which is attached to the integrated assembly table or gear guide bracket to fix the dial indicator; the dial indicator has a measuring range of 0-10mm and an accuracy of 0.01mm.

[0011] Optionally, the locking accuracy calibration module includes: a locking gap gauge, an angle positioning instrument, and a pressure sensor; Among them, the locking clearance gauge has an accuracy of 0.01mm and is adapted to detect the mating clearance between the positioning wheel (20) and the locking assembly (21); The angle positioning instrument uses a laser to point to the scale of the positioning wheel (20), with a resolution of 0.01°; The pressure sensor is integrated into the locking assembly (21) mounting fixture, with a detection range of 0-50N.

[0012] Optionally, the locking clearance gauge is made of stainless steel and includes multiple thickness specifications. Each clearance gauge is 50mm long, 10mm wide, and has a 0.5mm chamfer on the edge. The angle positioning instrument has a laser wavelength of 635nm, a spot diameter of ≤1mm, a working distance of 0.1-1.5m, an angular resolution of 0.01°, and a data refresh rate of 10Hz. The pressure sensor is a strain gauge type, with a measurement range of 0-50N and an accuracy of ±0.1N. The output signal is transmitted to the display terminal.

[0013] Optionally, the pressure sensor also integrates an audible and visual alarm function.

[0014] Optionally, the substrate positioning module includes: a positioning fixture, a quick-clamping cylinder, and hole positioning pins; The positioning fixture is made of aluminum alloy and weighs ≤2kg. The positioning fixture is slidably connected to the slide groove of the integrated assembly table through a T-shaped slider, with an adjustment range of 0-1000mm. The inner side of the positioning fixture is equipped with a rubber anti-slip pad adapted to the mounting base plate (18), and the edge is engraved with 0.5mm scale. The rubber anti-slip pad is a 5mm thick nitrile rubber anti-slip pad with a friction coefficient ≥0.8. The quick-clamping cylinder is a double-acting type symmetrically arranged on both sides of the positioning fixture. The cylinder diameter is 32mm, the piston rod stroke is 20-50mm, the output pressure is 0.3-0.6 MPa and is adjusted by the pressure regulating valve. The clamping response time is ≤0.5 seconds and the clamping stroke is 20-50mm. The diameter of the hole positioning pin is adapted to the bolt hole of the mounting base (18), and the height is dynamically adjustable; the diameter of the hole positioning pin covers multiple levels, the hardness is HRC30-35, and the height is adjusted by the thread, with an adjustment range of 10-30mm.

[0015] Optionally, the substrate positioning module is also provided with a limiting baffle; The limiting baffle is fixed to the edge of the integrated assembly table by bolts, and its position is adjusted along the slide groove. A 3mm thick rubber buffer pad is attached to the inside of the limit baffle.

[0016] This application provides an assembly auxiliary device for tap changers. The device includes an integrated assembly table, a transmission component alignment module, a locking accuracy calibration module, and a base plate positioning module. The integrated assembly table provides the basic support; the transmission component alignment module ensures the alignment accuracy of the drive shaft assembly and transmission gears; the locking accuracy calibration module controls the clearance between the positioning wheel and the locking assembly; and the base plate positioning module securely mounts the base plate. The device provided in this application is a multi-model, high-precision tap changer assembly auxiliary device. It can quickly fix the mounting base plate, accurately align the transmission components, and calibrate the locking assembly accuracy, thereby improving the assembly accuracy and efficiency of the tap changer and reducing the intensity of manual operation. Attached Figure Description

[0017] The accompanying drawings, which are included to provide a further understanding of this application and form part of this application, illustrate exemplary embodiments and are used to explain this application, but do not constitute an undue limitation of this application. In the drawings: Figure 1 An exploded view of a key internal component of a tap changer provided in an embodiment of this application; Figure 2 A schematic diagram of a tap changer gear transmission mechanism provided in this application embodiment; Figure 3 This is a schematic diagram illustrating the structure and function of an assembly auxiliary device for a tap changer, provided in an embodiment of this application.

[0018] [Attached reference numerals] 14-Drive shaft assembly, 15-Linkage bracket, 16-Transmission gear, 18-Mounting base plate, 20-Positioning wheel, 21-Locking assembly, 22-Support shaft. Detailed Implementation

[0019] To make the technical solutions and advantages of the embodiments of this application clearer, the exemplary embodiments of this application will be described in further detail below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not an exhaustive list of all embodiments. It should be noted that, unless otherwise specified, the embodiments and features in the embodiments of this application can be combined with each other.

[0020] In the process of developing this application, the inventors discovered that the tap changer, as a core component of transformer voltage regulation, contains key components such as a drive shaft assembly 14, transmission gear 16, positioning wheel 20, locking assembly 21, and mounting base plate 18. Each component requires high-precision assembly to ensure reliable tap-shifting. Therefore, the development of a high-precision tap changer assembly auxiliary device adaptable to multiple models is crucial for improving assembly quality and efficiency.

[0021] To address the aforementioned issues, this application provides an assembly auxiliary device for tap changers. This device includes an integrated assembly table, a transmission component alignment module, a locking accuracy calibration module, and a base plate positioning module. The integrated assembly table provides the basic support; the transmission component alignment module ensures the alignment accuracy of the drive shaft assembly and transmission gears; the locking accuracy calibration module controls the clearance between the positioning wheel and the locking component; and the base plate positioning module securely mounts the base plate. The device provided in this application is a multi-model, high-precision tap changer assembly auxiliary device. It can quickly fix the mounting base plate, accurately align the transmission components, and calibrate the locking component accuracy, thereby improving the assembly accuracy and efficiency of tap changers and reducing manual labor intensity, taking into account the assembly characteristics of the core components of the tap changer.

[0022] See Figures 1-3 This embodiment provides an assembly auxiliary device for tap changers, which includes an integrated assembly table, a transmission component alignment module, a locking accuracy calibration module, and a substrate positioning module.

[0023] The modules work together to achieve a full-process assembly assistance function, including fixing the tap changer mounting base plate 18, docking the drive shaft assembly 14 with the transmission gear 16, and calibrating the positioning wheel 20 with the locking assembly 21. This solves the problems of low precision and poor efficiency in traditional manual assembly and achieves standardized assembly of the core components of the tap changer.

[0024] 1. Integrated assembly table The integrated assembly platform is used to provide basic support.

[0025] The integrated assembly platform is formed by welding steel plates, such as Q235 steel plates.

[0026] The integrated assembly table has a chrome-plated surface with a thickness of 10 mm and a surface roughness Ra ≤ 1.6 μm, making it rust-proof and wear-resistant. The surface features cross-shaped T-slots, and the bottom is equipped with casters with brakes. In addition, the integrated assembly table can also include component storage drawers and tool racks.

[0027] The integrated assembly table has a level bubble embedded on its surface, and the table surface dimensions are 1200mm × 800mm.

[0028] (1) Slide The slide groove is 20mm wide and 15mm deep, with PTFE wear-resistant strips attached to the inside to reduce sliding wear of the slider.

[0029] (2) Casters The casters are made of polyurethane, with a diameter of 100mm. When braked, each caster can bear a load of ≥300kg, ensuring the stability of the assembly table.

[0030] (3) Component storage drawer The component storage drawer has built-in cushioning foam and is suitable for storing components such as support shaft 22 and linkage bracket 15.

[0031] For example, the component storage drawer is equipped with EVA (Ethylene-Vinyl Acetate) cushioning foam. The foam has special grooves cut according to the dimensions of components such as support shaft 22 and linkage bracket 15. The depth of the grooves is 5mm deeper than the height of the components to prevent the components from colliding.

[0032] (4) Tool rack The tool rack is made of cold-rolled steel plate, bent and formed, with powder coating on the surface. It has multiple (e.g., 10) dedicated hooks with a hook spacing of 150mm, making it convenient to access and return tools.

[0033] The tool rack is equipped with special hooks for hanging tools such as laser coaxial instruments, locking gap gauges, and wrenches.

[0034] 2. Alignment module for transmission components The transmission component alignment module is used to ensure the alignment accuracy of the drive shaft assembly (14) and the transmission gear (16).

[0035] The transmission component alignment module includes: a laser coaxial instrument, a gear guide bracket, and a shaft end fixing seat.

[0036] In addition, the alignment module for the transmission components is also equipped with a magnetic base.

[0037] (1) Laser coaxial instrument The laser coaxial instrument uses a 650nm visible laser with an emitter power of 5mW, a measurement distance of 0.2-2m, and a measurement accuracy of ±0.05mm.

[0038] A laser coaxial instrument consists of a transmitter (i.e., a laser emitter) and a receiver, which are respectively mounted on a shaft end mount and a gear guide bracket. For example, the transmitter is integrated with the shaft end mount, and the receiver is fixedly connected to the gear guide bracket.

[0039] In addition, laser coaxial instruments may also include a liquid crystal display (LCD) screen. That is, the laser coaxial instrument has a built-in LCD screen, which can display the deviation value in real time.

[0040] In addition, a laser coaxial instrument may also include a power supply module.

[0041] (2) Gear guide bracket The gear guide bracket is attached to the integrated assembly table by a strong magnetic chuck, and has a built-in guide tooth groove that meshes with the transmission gear (16).

[0042] The magnetic chuck has a suction force of ≥200N (Newtons).

[0043] The guide tooth module can be flexibly changed (e.g., the guide tooth module can be changed to 2mm, 3mm, 4mm, and 5mm).

[0044] The guide tooth groove surface is hardened to HRC50-55.

[0045] (3) Shaft end fixing seat The shaft end mounting bracket is adapted to the drive shaft assembly (14) and clamps the drive shaft assembly (14) by a three-jaw chuck. It can be rotated 360° and has an angle locking knob.

[0046] The three-jaw chuck has a clamping range of 15-50mm and a copper anti-slip pad on the inside.

[0047] In a specific implementation, the shaft end retainer may also include an angle locking knob to avoid damaging the drive shaft surface of the drive shaft assembly 14.

[0048] (4) Magnetic base The magnetic base can be attached to an integrated assembly table or gear guide bracket to fix the dial indicator and assist in detecting the radial runout of the transmission gear 16.

[0049] Among them, the dial indicator has a measurement range of 0-10mm and an accuracy of 0.01mm, which further improves the assembly accuracy of transmission components.

[0050] 3. Locking accuracy calibration module The locking accuracy calibration module is used to control the mating clearance between the positioning wheel (20) and the locking assembly (21).

[0051] The locking accuracy calibration module includes: a locking gap gauge, an angle positioning instrument, and a pressure sensor.

[0052] (1) Locking gap gauge Among them, the locking gap gauge has an accuracy of 0.01mm and is adapted to detect the mating gap between the positioning wheel (20) and the locking assembly (21).

[0053] The locking clearance gauge is made of stainless steel (e.g., the locking clearance gauge is made of 304 stainless steel) and includes multiple thickness specifications (e.g., thickness specifications include 0.01mm, 0.02mm, 0.03mm, 0.04mm, 0.05mm, 0.06mm, 0.07mm, 0.08mm, 0.09mm, and 0.1mm, a total of 10 sets).

[0054] Each set of gap gauges is 50mm long, 10mm wide, and has a 0.5mm chamfer on the edge.

[0055] (2) Angle positioning instrument The angle positioning instrument uses a laser to point to the positioning wheel at 20 degrees, with a resolution of 0.01°.

[0056] The angle positioning instrument has a laser wavelength of 635nm, a spot diameter of ≤1mm, a working distance of 0.1-1.5m, an angular resolution of 0.01°, and a data refresh rate of 10Hz.

[0057] (3) Pressure sensor The pressure sensor is integrated into the locking assembly 21 mounting fixture, with a detection range of 0-50N.

[0058] The pressure sensor is a strain gauge type, with a measurement range of 0-50N and an accuracy of ±0.1N. The output signal is transmitted to the display terminal (e.g., the output signal is transmitted to the display terminal via an RS485 interface).

[0059] In addition, the pressure sensor can also integrate an audible and visual alarm function. When the detected clamping force exceeds the set threshold (such as a value between 5-50N) or falls below the lower limit, it will automatically issue a buzzer alarm and a red light prompt to avoid structural deformation and locking failure caused by the locking component 21 being installed too loosely or too tightly.

[0060] 4. Baseboard positioning module The substrate positioning module is used to fix and install the substrate 18.

[0061] The substrate positioning module includes: a positioning fixture, a quick-clamping cylinder, and hole positioning pins.

[0062] In practical implementation, the substrate positioning module may also be equipped with a limiting baffle.

[0063] (1) Positioning fixture The positioning fixture is adjustable.

[0064] The adjustable positioning fixture is made of aluminum alloy and weighs ≤2kg. The positioning fixture is slidably connected to the slide groove of the integrated assembly table via a T-shaped slider, with an adjustment range of 0-1000mm.

[0065] The positioning fixture has a rubber anti-slip pad adapted to the mounting base plate (18) on the inside (such as an adjustable positioning fixture with a rubber anti-slip pad pasted on the inside), and the edge is engraved with a 0.5mm scale.

[0066] The rubber anti-slip mat is a 5mm thick nitrile rubber anti-slip mat with a friction coefficient ≥0.8.

[0067] (2) Quick-pressing cylinder The quick-clamping cylinder is a double-acting type, symmetrically arranged on both sides of the positioning fixture.

[0068] The quick-pressing cylinder has a cylinder diameter of 32mm, a piston rod stroke of 20-50mm, an output pressure of 0.3-0.6MPa (megapascals) which is adjustable by a pressure regulating valve, a pressing response time of ≤0.5 seconds, and a pressing stroke of 20-50mm.

[0069] (3) Hole positioning pin The diameter of the hole positioning pin is adapted to the bolt hole of the mounting base (18), and the height is dynamically adjustable.

[0070] The diameter of the locating pins is available in multiple sizes (e.g., M8, M10, M12, and M16), made of 45 steel with heat treatment and a hardness of HRC30-35. The height is adjusted via thread (e.g., M10 thread), with an adjustment range of 10-30mm.

[0071] (4) Limiting baffle The limit baffle is fixed to the edge of the integrated assembly table by bolts and its position can be adjusted along the slide.

[0072] The limiting baffle is used to limit the lateral limit position of the mounting base plate 18 to prevent over-adjustment.

[0073] A 3mm thick rubber buffer pad is attached to the inside of the limiting baffle to prevent damage caused by hard contact between the mounting base plate 18 and the baffle.

[0074] As is well known, the assembly quality of tap changers directly depends on the fitting accuracy of each component, especially the coaxiality of the drive shaft assembly and transmission gears, and the clearance between the positioning wheel and the locking assembly. If the assembly deviation exceeds the tolerance, it will lead to malfunctions such as gear wear and gear jamming during operation. Traditional manual assembly relies on experience-based judgment, and the coaxiality deviation often exceeds 0.5mm, the clearance control error exceeds 0.1mm, and the assembly time for a single unit exceeds 2 hours. However, the tap changer assembly auxiliary device provided in this embodiment uses specialized mechanisms such as laser coaxiality gauges and locking clearance gauges to control the coaxiality accuracy to ±0.05mm and the clearance error to 0.03-0.05mm. At the same time, with the help of automated structures such as rapid clamping cylinders, the assembly time is greatly shortened, fundamentally solving the pain points of traditional assembly.

[0075] The alignment module of the transmission components of the tap changer assembly auxiliary device provided in this embodiment can adopt the structure of a laser coaxiality meter combined with a shaft end fixing seat. The transmitter of the laser coaxiality meter is integrally installed with the shaft end fixing seat, the receiver is fixedly connected to the gear guiding bracket, the shaft end fixing seat clamps the drive shaft assembly through a three-jaw chuck, and the gear guiding bracket is adsorbed on the integrated assembly table through a strong magnetic chuck. During assembly, after the drive shaft assembly 14 is installed in the three-jaw chuck, start the transmitter of the laser coaxiality meter, and the laser beam projects along the axis of the drive shaft; embed the transmission gear 16 into the guiding tooth groove, adjust the position of the gear guiding bracket, so that the coaxiality deviation shown by the laser signal received by the receiver of the laser coaxiality meter is ≤0.05 mm, and at this time the alignment of the transmission components is completed. As Figure 3 shown, a copper anti-slip pad is pasted on the inner side of the three-jaw chuck of the shaft end fixing seat to avoid scratching the surface of the drive shaft during clamping; the guiding tooth groove of the gear guiding bracket can be replaced according to the gear module to adapt to different specifications of transmission gears. The main components of the laser coaxiality meter include a laser transmitter, a receiver, an LCD display screen, a power supply module, etc. When the power supply module is powered on, the transmitter emits a laser beam, the receiver converts the received signal into coaxiality data, and displays it in real time through the LCD display screen. The operator can fine-tune the position of the components according to the data until the accuracy meets the standard.

[0076] Alternatively, the alignment module of the transmission components can adopt the structure of a dial indicator combined with a V-block. The V-block is connected to the sliding groove of the integrated assembly table through a T-shaped slider and is used to support the drive shaft assembly 14 and the transmission gear 16. The dial indicator is fixed to the tabletop of the integrated assembly table through a magnetic base, and the measuring heads respectively contact the outer circle of the drive shaft and the end face of the gear. During assembly, rotate the drive shaft, adjust the position of the V-block through the reading of the dial indicator, so that the radial runout of the drive shaft is ≤0.03 mm; move the V-block on the gear side to make the end face of the gear fit with the measuring head of the dial indicator to ensure that the end face of the gear is parallel to the end face of the drive shaft, and finally achieve coaxial docking. This structure does not require electric drive and is suitable for on-site assembly scenarios without power supply conditions. When the reading of the dial indicator is stable within the error range, it is determined that the alignment of the transmission components is qualified.

[0077] In addition, in practical implementation, the locking accuracy calibration module can also use an inductive gap sensor to replace the mechanical locking gap gauge. The probe of the inductive gap sensor is fixedly connected to the locking assembly 21, with the sensing end facing the tooth groove of the positioning wheel. The sensor output end is connected to the digital display terminal, and the indicator light is connected in series with the digital display terminal. When the gap between the positioning wheel and the locking assembly reaches the set value (e.g., 0.04mm), the sensor output signal triggers the digital display terminal, causing the indicator light to illuminate. This structure can realize real-time dynamic monitoring of the gap, avoiding human error when inserting a mechanical gap gauge, and is especially suitable for batch assembly scenarios. Taking an inductive sensor with a resolution of 0.01mm as an example, its detection range is 0-1mm. After calibration, the gap measurement error is ≤0.005mm. When the actual gap equals the set value, the digital display terminal displays "qualified" and illuminates a green light. The ease of operation and accuracy are superior to traditional mechanical measuring tools.

[0078] Taking the installation and commissioning of an on-load tap changer for a 220kV oil-immersed transformer (model ZY1-220 / 5000) as an example, this model of tap changer has a classic combined structure, consisting of a switching switch, a tap selector, and a transmission mechanism. Power transmission is achieved through the drive shaft assembly 14 and the transmission gear 16. The mounting base plate 18 is the core load-bearing component, the positioning wheel 20 is responsible for precise locking of the tap position, the locking assembly 21 ensures stable locking after tap position switching, and the support shaft 22 provides fixed support for the transmission mechanism. Combined with... Figure 1 , Figure 2 The tap changer structure shown in this embodiment, and the specific implementation steps of the assembly auxiliary device for the tap changer provided in this embodiment, are as follows: Step 1: Device deployment and initial calibration.

[0079] 1. Equipment Deployment Process First, clean the assembly station floor to ensure there is no debris. Then, move the integrated assembly table to the center of the station and press the brake pedal on the casters to secure it.

[0080] Observe the level bubble on the table surface and adjust the height of the casters to ensure that the levelness of the integrated assembly table surface reaches 0.08°, meeting the assembly reference requirements.

[0081] Take out the matching 3mm module guide tooth groove, M12 hole positioning pin and calibration standard gauge block from the component storage drawer and tool rack. Install the guide tooth groove onto the gear guide bracket and assemble the hole positioning pin into the positioning fixture reserved hole of the base plate positioning module. Confirm the connection is stable by using the magnetic hole positioning pin.

[0082] 2. Preliminary calibration process The laser coaxiality meter was tested with a 100mm standard gauge block, and the coaxiality deviation was 0.00mm. The pressure sensor was calibrated with a 15N standard weight, and the reading error was ≤0.1N. The locking gap gauge was re-measured with a micrometer, and the error of the 0.04mm gap gauge was ≤0.002mm, ensuring that the accuracy of all testing tools met the standards.

[0083] Step 2: Positioning and fixing the mounting base plate 18.

[0084] according to Figure 2 The hole distribution dimensions of the mounting base plate 18 (hole spacing 180mm×220mm) are determined. The adjustable positioning fixture is slid to the preset position along the cross-shaped T-slot of the integrated assembly table so that the scale line on the edge of the positioning fixture is aligned with the "200mm" mark on the table surface of the integrated assembly table.

[0085] Place the mounting base plate 18 stably on the nitrile rubber anti-slip pad of the positioning fixture, manually fine-tune the position of the mounting base plate 18 so that the four diagonal bolt holes of the mounting base plate 18 are precisely aligned with the M12 hole positioning pins, and insert the hole positioning pins to complete the initial positioning.

[0086] Depress the foot pedal valve of the quick-clamping cylinder. The cylinder piston rod extends with a pressure of 0.4MPa and presses the mounting plate 18 through the rubber pressure head. After holding for 5 seconds, release the foot pedal valve and gently push the mounting plate 18 to confirm that it is not loose.

[0087] Use a level to check the levelness of the mounting base plate 18. The reading is 0.06°, which meets the requirements. If there is a deviation, fine-tune the height adjustment knob at the bottom of the positioning fixture until the levelness is ≤0.1°. Finally, use a wrench to tighten the locking bolts of the positioning fixture to complete the fixing of the mounting base plate 18.

[0088] Step 3: Alignment and assembly of transmission components.

[0089] Insert the shaft end of the drive shaft assembly 14 into the three-jaw chuck of the shaft end fixing seat, manually tighten the chuck wrench to ensure that the three jaws are evenly clamped (the copper pads on the inside of the jaws prevent scratching the shaft surface), start the transmitter of the laser coaxial instrument, adjust the transmitter height to 150mm, and project the laser beam horizontally along the drive shaft axis.

[0090] The gear guide bracket with a 3mm module guide tooth groove is attached to the surface of the integrated assembly table using a strong magnetic chuck, so that the center of the guide tooth groove is aligned with the height of the laser beam; the transmission gear 16 is embedded into the guide tooth groove, ensuring that the end face of the gear is perpendicular to the surface of the integrated assembly table without tilting or offset.

[0091] Turn on the receiver of the laser coaxial instrument and observe that the coaxiality deviation value displayed on the LCD screen is 0.07mm. Adjust the lateral position of the gear guide bracket by fine-tuning (adjusting the step distance by 0.01mm) until the deviation drops to 0.03mm.

[0092] Keep the guide bracket fixed, manually rotate the drive shaft assembly 14 to confirm that the transmission gear 16 meshes smoothly with the drive shaft without jamming or abnormal noise; then use M10 socket head cap screws to fix the transmission gear 16 to the drive shaft flange face, and tighten the bolts to a torque standard of 15 N·m (where N·m is Newton-meter, a unit of torque).

[0093] Remove the laser emitter and use a dial indicator to check the radial runout of transmission gear 16. The reading is 0.02 mm, which meets the accuracy requirements.

[0094] Step 4: Calibration and installation of locking component 21.

[0095] The positioning wheel 20 is fitted onto the end journal of the drive shaft assembly 14, and circumferential positioning is achieved by a flat key. It is then fixed with an M6 set screw to ensure that the end face of the positioning wheel is perpendicular to the axis of the drive shaft.

[0096] Fix the angle locator to the right side of the integrated assembly table using the magnetic base. Adjust the height and angle of the angle locator so that the laser beam is accurately pointed at the "0" scale line of the positioning wheel 20. Rotate the positioning wheel 20 and observe that the deviation between the laser spot and the scale line is 0.012°. Loosen the set screw and fine-tune the position of the positioning wheel until the deviation drops to 0.005°. Tighten the set screw again.

[0097] Place the locking assembly 21 in the preset installation position on the mounting base plate 18. Take a 0.04mm locking gap gauge and insert it into the 20 slots of the positioning wheel 20 between the locking assembly 21 and the locking tongue. Feel that the insertion resistance of the gap gauge is uniform and there is no looseness or tightness. If the resistance of a certain slot is too large, fine-tune the lateral position of the locking assembly 21 (adjustment step distance 0.01mm) until all slot gap gauges are inserted smoothly.

[0098] Place the pressure sensor's detection probe against the side of the locking assembly 21, slowly tighten the fixing bolts of the locking assembly 21, observe the pressure sensor display terminal, stop tightening when the pressure reaches 15N, and mark the bolt position; maintain the pressure for 10 seconds, if the reading is stable and does not drop, confirm that the locking assembly 21 is not deformed, and the installation is complete.

[0099] Step 5: Assemble the support shaft 22 and the linkage bracket 15.

[0100] according to Figure 2 The installation position of the middle support shaft 22 requires that special grease be applied to the preset bearing seat hole position on the mounting base plate 18, and the support shaft 22 be installed into the bearing seat, ensuring that the axis of the support shaft is parallel to the axis of the drive shaft assembly 14 (pitch deviation ≤ 0.02mm).

[0101] Take the linkage bracket 15, connect one end to the drive shaft assembly 14 through a coupling, and connect the other end to the reserved hole of the positioning wheel 20 through a pin. Manually rotate the linkage bracket to check that the drive shaft, transmission gear 16 and positioning wheel 20 are linked smoothly without jamming or abnormal noise.

[0102] Use a dial indicator to check the radial runout of the support shaft 22. The reading should be ≤0.03mm. If there is a deviation, fine-tune the bearing housing position until the runout meets the requirements. Finally, use M8 bolts to fix the bearing housing to the mounting base plate 18.

[0103] Step 6: Overall assembly verification and testing.

[0104] Start the laser coaxiality tester and recheck the coaxiality of the transmission gear 16 and the drive shaft assembly 14. The deviation is still 0.03mm. Use a 0.04mm locking clearance gauge to randomly check the fit clearance between the five tooth grooves of the positioning wheel 20 and the locking assembly 21. All of them are within the range of 0.03-0.05mm.

[0105] Simulated tap changer position switching: Manually rotate the drive shaft assembly 14 to switch from position 0 to position 5, pausing for 3 seconds at each position. The angle positioning instrument shows that the angle error of each position is ≤0.01°. During the switching process, the transmission gear 16 engages without abnormal noise, the locking assembly 21 operates sensitively, and the pressure sensor does not trigger an overpressure alarm. After completing 3 round trip position switching tests, all components are stably linked without any jamming or loosening, indicating that the core components of the tap changer are assembled successfully.

[0106] Step 7: Device storage and data recording.

[0107] Release the quick-clamping cylinder, remove the mounting base plate 18 and the assembled tap changer components, and place them in a special turnover box (with built-in EVA cushioning foam).

[0108] Clean the surface of the integrated assembly table, wiping away metal shavings and oil stains with a cloth; slide the adjustable positioning clamp to the edge of the integrated assembly table surface and retract the piston rod of the quick-clamping cylinder; classify and store tools such as laser coaxial instruments, locking gap gauges, and pressure sensors in the component storage drawers and tool racks respectively.

[0109] The assembly process data (including coaxiality, pressure, angle and other test records) is exported via USB interface and uploaded synchronously to the tap changer assembly database. The equipment model, assembly time and operator information are marked. Finally, the integrated assembly table is pushed to the designated storage area to complete the entire assembly process.

[0110] As can be seen from the above process, the assembly auxiliary device for tap changers provided in this embodiment can accurately adapt to the gear transmission and multi-component linkage structure of the ZY1 type tap changer. The assembly accuracy (coaxiality ±0.05mm, locking gap 0.03-0.05mm) and efficiency (assembly time of 45 minutes per unit) are superior to traditional manual assembly. It can cover the core component assembly requirements of on-load / off-load tap changers with voltage levels of 10kV to 500kV, and significantly reduce the risk of later operation failures caused by assembly deviations.

[0111] The tap changer assembly auxiliary device provided in this embodiment can solve problems such as poor coaxiality between the drive shaft assembly and the transmission gear, low precision of the positioning wheel and the locking assembly, and low efficiency of fixing the mounting base during tap changer assembly. This assembly auxiliary device uses a laser coaxial gauge to ensure precise alignment of the drive shaft assembly 14 and the transmission gear 16, uses a locking clearance gauge to calibrate the clearance between the positioning wheel 20 and the locking assembly 21, and uses an adjustable positioning fixture to quickly fix the mounting base 18. This assembly auxiliary device is compatible with on-load / off-load tap changers with voltage levels from 10kV to 500kV, reducing the assembly time of core components by more than 60%, improving assembly accuracy to ±0.1mm, significantly reducing human error, and ensuring the assembly quality of the tap changer.

[0112] The assembly auxiliary device for tap changers provided in this embodiment is designed for the assembly characteristics of the core components of tap changers. It enables rapid fixing of the mounting base plate, precise docking of transmission components, and precision calibration of locking components, thereby improving the assembly accuracy and efficiency of tap changers and reducing the intensity of manual operation.

[0113] The assembly auxiliary device for tap changers provided in this embodiment can achieve the following effects: Firstly, assembly efficiency is significantly improved. The integrated assembly table enables centralized storage of parts and tools. Combined with a fast-clamping cylinder and a laser coaxial device, the total assembly time of a single tap changer core component is reduced from the traditional 2-3 hours to 40-60 minutes, improving overall efficiency by more than 60% and greatly reducing manual operation time. Secondly, the assembly accuracy is greatly improved. The laser coaxiality instrument ensures that the coaxiality of the drive shaft assembly 14 and the transmission gear 16 is ±0.05mm. The locking clearance gauge controls the mating clearance between the positioning wheel 20 and the locking assembly 21 to be 0.03-0.05mm. The angle positioning instrument achieves a gear position accuracy of ±0.01°, which is far superior to the accuracy level of manual assembly. This effectively reduces the risk of later failures such as gear wear and gear jamming caused by component mismatch. The failure rate can be reduced by more than 40%. Third, it is highly versatile and has a wide range of applications. The base plate positioning module is adapted to the mounting base plate 18 of tap changers with voltage levels of 10kV-500kV through adjustable clamps and hole positioning pins; the transmission component alignment module can replace guide tooth grooves of different modules and is compatible with various types of transmission gears 16; one set of equipment can meet the assembly requirements of on-load / off-load tap changers, reduce the repeated investment in special tooling, and reduce equipment costs by more than 30%. Fourth, it is highly convenient and safe to operate. It adopts designs such as magnetic fixation, foot pedal control, and laser visual calibration, allowing a single person to complete the entire assembly process without the need for multiple people to work together, thus reducing reliance on manual labor. The pressure sensor audible and visual alarm and the clamp rubber anti-slip pads can avoid problems such as overpressure damage to components and substrate sliding scratches, ensuring the safety of the assembly process and the integrity of the components.

[0114] It should be noted that this embodiment is only a preferred embodiment of the assembly auxiliary device for tap changers provided in this embodiment. In specific implementation, the guide tooth module of the gear guide bracket and the clamp spacing of the base plate positioning module can be changed according to the model difference of the tap changer (such as V-type split structure); functional modules can also be added or removed according to actual needs, such as adding a temperature sensor to monitor the component temperature during the assembly process, all without departing from the protection scope of this invention.

[0115] This embodiment provides an assembly auxiliary device for tap changers. The device includes an integrated assembly table, a transmission component alignment module, a locking accuracy calibration module, and a base plate positioning module. The integrated assembly table provides the basic support; the transmission component alignment module ensures the alignment accuracy of the drive shaft assembly and transmission gears; the locking accuracy calibration module controls the clearance between the positioning wheel and the locking component; and the base plate positioning module securely mounts the base plate. This embodiment provides a multi-model, high-precision tap changer assembly auxiliary device. It can quickly fix the mounting base plate, accurately align the transmission components, and calibrate the locking component accuracy, thereby improving the assembly accuracy and efficiency of the tap changer and reducing manual labor intensity, taking into account the assembly characteristics of the core components of the tap changer.

[0116] Although preferred embodiments of this application have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments as well as all changes and modifications falling within the scope of this application.

[0117] Obviously, those skilled in the art can make various modifications and variations to this application without departing from the spirit and scope of this application. Therefore, if such modifications and variations fall within the scope of the claims of this application and their equivalents, this application also intends to include such modifications and variations.

Claims

1. An assembly auxiliary device for a tap changer, characterized in that, The device includes: an integrated assembly table, a transmission component alignment module, a locking accuracy calibration module, and a substrate positioning module; The integrated assembly platform is used to provide basic support. The transmission component alignment module is used to ensure the docking accuracy of the drive shaft assembly (14) and the transmission gear (16); The locking accuracy calibration module is used to control the mating clearance between the positioning wheel (20) and the locking assembly (21); The substrate positioning module is used to fix and install the substrate (18).

2. The apparatus according to claim 1, characterized in that, The integrated assembly platform is formed by welding steel plates. The surface of the integrated assembly table is chrome-plated with a thickness of 10 mm and a roughness Ra≤1.6 μm. The surface is provided with cross-shaped T-shaped grooves, and the bottom is provided with universal wheels with braking function. The integrated assembly table has a level bubble embedded on its surface, and the table surface dimensions are 1200mm × 800mm. The groove is 20mm wide and 15mm deep, with a polytetrafluoroethylene wear-resistant strip attached to the inner side. The casters are made of polyurethane, with a diameter of 100mm, and each caster can bear a load of ≥300 kg after braking.

3. The apparatus according to claim 1 or 2, characterized in that, The integrated assembly table is also equipped with component storage drawers and tool racks; The component storage drawer has built-in cushioning foam, and the foam has special grooves cut according to the component size, with the groove depth being 5mm deeper than the component height; The tool rack is made of cold-rolled steel plate, bent and formed, with powder coating on the surface, and is equipped with multiple dedicated hooks with a hook spacing of 150mm.

4. The apparatus according to claim 1, characterized in that, The transmission component alignment module includes: a laser coaxial instrument, a gear guide bracket, and a shaft end fixing seat; The laser coaxial instrument uses a 650 nm visible laser, with a transmitter power of 5 mW, a measurement distance of 0.2-2 m, and a measurement accuracy of ±0.05 mm. The laser coaxial instrument includes a transmitter and a receiver. The transmitter is integrated with the shaft end fixing seat, and the receiver is fixedly connected to the gear guide bracket. The gear guide bracket is attached to the integrated assembly table by a strong magnetic chuck, and has a built-in guide tooth groove that meshes with the transmission gear (16); the strong magnetic chuck has a suction force of ≥200 N, the module of the guide tooth groove can be flexibly changed, the surface of the guide tooth groove is hardened, and the hardness of the guide tooth groove is HRC50-55. The shaft end fixing seat is adapted to the drive shaft assembly (14) and clamps the drive shaft assembly (14) by a three-jaw chuck, and can be rotated 360° for adjustment; the clamping range of the three-jaw chuck is 15-50mm, and the inner side is covered with a copper anti-slip pad.

5. The apparatus according to claim 4, characterized in that, The laser coaxial instrument also includes an LCD screen; The shaft end fixing seat also includes an angle locking knob; The alignment module of the transmission component is also equipped with a magnetic base, which is attached to the integrated assembly table or the gear guide bracket to fix the dial indicator; wherein, the dial indicator has a measuring range of 0-10mm and an accuracy of 0.01mm.

6. The apparatus according to claim 1, characterized in that, The locking accuracy calibration module includes: a locking gap gauge, an angle positioning instrument, and a pressure sensor; The locking gap gauge has an accuracy of 0.01mm and is adapted to detect the mating gap between the positioning wheel (20) and the locking assembly (21). The angle positioning instrument uses a laser to point to the scale of the positioning wheel (20), with a resolution of 0.01°; The pressure sensor is integrated into the locking assembly (21) mounting fixture and has a detection range of 0-50N.

7. The apparatus according to claim 6, characterized in that, The locking gap gauge is made of stainless steel and includes multiple thickness specifications. Each gap gauge is 50mm long, 10mm wide, and has a 0.5mm chamfer on the edge. The angle positioning instrument has a laser wavelength of 635nm, a spot diameter of ≤1mm, a working distance of 0.1-1.5m, an angular resolution of 0.01°, and a data refresh rate of 10Hz. The pressure sensor is a strain gauge type, with a measurement range of 0-50N and an accuracy of ±0.1N. The output signal is transmitted to the display terminal.

8. The apparatus according to claim 6 or 7, characterized in that, The pressure sensor also integrates an audible and visual alarm function.

9. The apparatus according to claim 1, characterized in that, The substrate positioning module includes: a positioning fixture, a quick-clamping cylinder, and hole positioning pins; The positioning fixture is made of aluminum alloy and weighs ≤2kg; the positioning fixture is slidably connected to the slide groove of the integrated assembly table through a T-shaped slider, with an adjustment range of 0-1000mm; the inner side of the positioning fixture is provided with a rubber anti-slip pad adapted to the mounting base plate (18), and the edge is engraved with 0.5mm scale; the rubber anti-slip pad is a 5mm thick nitrile rubber anti-slip pad with a friction coefficient ≥0.8; The quick-clamping cylinder is a double-acting type symmetrically arranged on both sides of the positioning fixture. The cylinder diameter is 32mm, the piston rod stroke is 20-50mm, the output pressure is 0.3-0.6 MPa and is adjusted by the pressure regulating valve, the clamping response time is ≤0.5 seconds, and the clamping stroke is 20-50mm. The diameter of the hole positioning pin is adapted to the bolt hole of the mounting base plate (18), and the height is dynamically adjustable; the diameter of the hole positioning pin covers multiple levels, the hardness is HRC30-35, and the height is adjusted by the thread, with an adjustment range of 10-30mm.

10. The apparatus according to claim 1 or 9, characterized in that, The substrate positioning module is also provided with a limiting baffle; The limiting baffle is fixed to the edge of the integrated assembly table by bolts, and its position is adjusted along the slide groove direction; The inner side of the limiting baffle is fitted with a rubber buffer pad with a thickness of 3mm.

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