A wind power main shaft heavy forging straightening equipment and method

Abstract

The present application relates to the technical fields of machining and straightening of forgings, and discloses a wind power main shaft heavy forging straightening device and method, which comprises a bottom plate, a straightening mechanism arranged above the bottom plate, a moving assembly arranged below the bottom plate along the axial direction of the workpiece, a clamping mechanism arranged on the top of the moving assembly, and a linkage mechanism connected between the moving assembly and the clamping mechanism. The linkage mechanism comprises a push rod and a latch, and the clamping mechanism comprises a hydraulic valve. The longitudinal displacement of the push rod is used to trigger the pulling out of the latch and the closing of the hydraulic valve. The straightening method uses the longitudinal displacement of the push rod to realize the mechanical linkage of axial unlocking and rigid bearing conversion. The sliding displacement data generated by the compression of the moving assembly is used to update the span, the dynamic down pressure compensation parameters are calculated, and the down pressure stroke target value of the straightening mechanism is superimposed and adjusted. The present application avoids the device jamming and the local damage of the workpiece caused by the axial constraint not being removed, and corrects the down pressure deviation caused by the span change.

Description

Technical Field

[0001] This invention relates to the field of machining and forging straightening technology, specifically to a straightening device and method for heavy forgings for wind turbine main shafts. Background Technology

[0002] Heavy forgings for wind turbine main shafts are prone to bending deformation during manufacturing, requiring straightening using a three-point bending method. This involves placing the workpiece above two support nodes and applying downward pressure via a central hydraulic actuator to induce plastic deformation.

[0003] During actual bending under pressure, the bending deformation of the workpiece is accompanied by axial extension. Existing straightening equipment typically uses a fixed support structure. This fixed support structure hinders the axial extension of the workpiece, causing frictional resistance between the bottom of the workpiece and the support, which in turn leads to mechanical jamming and localized extrusion damage on the workpiece surface.

[0004] If the bottom support mechanism is changed to an unrestricted free-sliding structure, the workpiece's compressive extension will push the support mechanism outward, increasing the support span between the two points. This increased span directly alters the workpiece's bending mechanical state, causing the original deflection parameters to become invalid. Existing straightening methods output the pressing stroke based on a set initial fixed span, without incorporating the dynamic external expansion of the span into the pressing control model. This results in the actual pressing depth failing to reach the theoretically required target deformation, leading to insufficient straightening stroke in a single pass. This forces an increase in the number of repeated pressing operations at the same location, raising the risk of internal stress fatigue in the workpiece. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides a straightening device and method for heavy forgings of wind turbine main shafts, which solves the problems of dynamic outward expansion of support span and sudden changes in radial load state during the three-point bending straightening process of heavy forgings of wind turbine main shafts, which easily lead to equipment jamming and deviation in straightening pressure.

[0006] To achieve the above objectives, the present invention provides the following technical solution: The first aspect of the present invention provides a straightening device for heavy forgings of wind turbine main shafts, including a base plate, a straightening mechanism arranged above the base plate, at least two moving components arranged at intervals along the axial direction of the workpiece below the straightening mechanism, a clamping mechanism arranged on the top of each moving component, and a linkage mechanism connecting the moving component and the corresponding clamping mechanism. The linkage mechanism includes a push rod that contacts and links with the workpiece, and a pin for locking the axial degree of freedom of the moving component; the clamping mechanism includes a hydraulic valve, and the longitudinal displacement of the push rod is used to trigger the pull-out of the pin and the closing of the hydraulic valve. The wind turbine main shaft heavy forging straightening equipment also includes a control system, which comprises a data acquisition module, a control module, a drive module, and a compensation module.

[0007] This solution utilizes a push rod to obtain the downward displacement of the workpiece, converts it into mechanical action, and thus achieves sequential linkage between axial position unlocking and hydraulic rigid support conversion.

[0008] Furthermore, the straightening mechanism specifically includes support plates symmetrically arranged on both sides of the base plate. Guide rails are fixedly connected to the top of each support plate, and a gantry frame spanning above the base plate is slidably connected to the top of the guide rails. A downwardly extending hydraulic cylinder is slidably connected inside the crossbeam of the gantry frame, and a straightening head for pressing against the workpiece is installed at the bottom of the hydraulic cylinder. This facilitates the movement of the straightening head above the workpiece to meet the pressure requirements at different bending points.

[0009] Furthermore, the push rod slides vertically through the inside of the worktable, and a U-shaped block is fixedly connected to the top of the push rod. A roller is rotatably connected inside the U-shaped block. An inclined plate is fixedly connected to the outer wall of the push rod, and a cutting column is slidably inserted into one side of the hydraulic valve. The outer wall of the inclined plate is formed with a three-segment non-linear profile, and the end of the inclined plate and the cutting column away from the hydraulic valve slides against each other. This solution converts the longitudinal displacement of the push rod into the lateral displacement of the cutting column by changing the shape of the inclined plate profile, thereby achieving the delay and pressure holding of the hydraulic valve action.

[0010] Preferably, the worktable has a rotating column internally connected to it, and a lever is fixedly sleeved on the outer wall of the rotating column. The bottom end of the push rod abuts against the top surface of one end of the lever, and the other end of the lever has a clearance groove. A crossbar is fixed to the outer wall of the pin, and the crossbar is movably engaged in the clearance groove. The bottom end of the pin slides into a groove inside the base plate. This design utilizes the lever to convert the downward force of the push rod into the upward pulling force of the pin.

[0011] In one embodiment of the present invention, two support cylinders are symmetrically fixed on the top of the worktable. Each support cylinder is equipped with a clamping head on its top, and the bottoms of the two support cylinders are connected to pipes. The other ends of the two pipes are connected to hydraulic valves. The opening and closing of the hydraulic valves directly changes the internal connection state of the two support cylinders, thereby switching between two states: floating relief and rigid bearing.

[0012] A second aspect of the present invention provides a method for straightening heavy forgings for wind turbine main shafts, applied to the aforementioned straightening equipment for heavy forgings for wind turbine main shafts, comprising the following steps: The control module issues an initial command, the hydraulic valve in the clamping mechanism remains in the conducting state, the fluid flows in the internal circuit of the clamping mechanism, the pin at the end of the linkage mechanism is inserted into the base plate, constraining the displacement of the moving component along the base plate direction, the workpiece is placed above the corresponding moving component, and forms a contact linkage relationship with the push rod through the linkage mechanism; The drive module controls the straightening mechanism to apply pressure to the workpiece. The workpiece sinks and pushes the push rod to generate longitudinal displacement. First, it triggers the pin to pull out and release the axial position restriction of the moving component; then it triggers the hydraulic valve to close, so that the clamping mechanism is converted to a hydraulic rigid support state. The acquisition module obtains the angular displacement data of the linkage mechanism and the fluid pressure data of the clamping mechanism. The control module determines whether the timing setting conditions are met and confirms the completion of axial unlocking and rigid conversion. The straightening mechanism continues to press down to cause the workpiece to bend and extend axially. The extension force pushes the moving component to slide. The acquisition module collects the current sliding displacement data of the moving component. The compensation module updates the bearing span value based on the sliding displacement data, calculates the dynamic compression compensation parameters and generates a compression stroke target value with dynamic compression compensation parameters. The drive module adjusts the output displacement of the straightening mechanism according to the compression stroke target value. The drive module controls the straightening mechanism to lift and reset, the push rod and pin to reset, and relock the axial degree of freedom of the moving component.

[0013] This method uses the sliding displacement caused by workpiece deformation as feedback, combined with the timing judgment of state transition, to correct the deflection deviation caused by span changes by dynamically compensating the downward stroke.

[0014] Furthermore, the specific process of the push rod generating longitudinal displacement includes: defining the real-time vertical displacement generated by the push rod as the workpiece is pressed down, setting the total downward stroke, and preset a first displacement threshold, wherein the first displacement threshold is greater than zero and less than or equal to the total downward stroke; When the real-time vertical displacement is greater than zero and less than or equal to the first displacement threshold, a transient pin-pulling action is performed, and the pin exits the groove of the base plate; when the real-time vertical displacement is greater than the first displacement threshold and less than or equal to the total downward stroke, the inclined plate on the outer wall of the push rod pushes the cut-off column to slide into the hydraulic valve to block the fluid circuit.

[0015] By dividing the displacement range, the release of axial position restriction takes precedence over the transition to rigid support state, preventing the moving component from jamming when it deforms under pressure.

[0016] Furthermore, the control module determines whether the timing settings are met as follows: the time when the angular displacement data is first greater than or equal to the physical angle threshold is the first determination time; the time when the fluid pressure data is first simultaneously greater than or equal to the preset pressure threshold and the pressure change rate is greater than or equal to the pressure step change rate threshold is the second determination time. The judgment condition is that the second judgment time is later than the first judgment time, and the time difference is less than or equal to the preset timing tolerance judgment window. This scheme combines angular displacement and fluid pressure data for timing judgment to ensure that the state transition of the support component conforms to the action setting sequence.

[0017] In a specific embodiment of the present invention, the specific process of calculating the dynamic pressure compensation parameters includes: the compensation module obtains the outward sliding displacement data generated by the moving components on both sides respectively, adds the outward sliding displacement data on both sides to obtain the total axial outward expansion amount, and adds it with the static reference span to generate the real-time dynamic span parameter; The compensation module calculates the span compensation amount based on a pre-calibrated span and compression correction model. The correction model includes at least a span variation term and an elastic-plastic correction coefficient. The span variation term characterizes the change in compression caused by the increase of the real-time dynamic span relative to the static reference span. The elastic-plastic correction coefficient is determined based on trial calibration data, finite element simulation data, or a combination of both. The span compensation amount is compared with the compensation safety limit, and the smaller value is taken as the dynamic compression compensation parameter.

[0018] This solution calculates compensation parameters based on the mathematical relationship between bending deflection and span, and dynamically adjusts and limits the downward stroke.

[0019] Preferably, after relocking the axial degrees of freedom of the moving component, the method further includes: starting a static delay timer, and after the delay timer ends, the acquisition module drives the laser ranging array to scan along the axial direction of the workpiece to obtain a global relative contour dataset, and calculates and generates the current straightness deviation data. The control module compares the current straightness deviation data with the straightness tolerance threshold. If it is greater than the straightness tolerance threshold, it reads the count of the number of straightening rounds that have been executed and compares it with the maximum number of iterations threshold, and decides whether to return to execute a new round of the process or output an abnormal shutdown command code.

[0020] This solution obtains straightness data by releasing stress through static delay and uses iterative conditions to determine whether the workpiece will be damaged by excessive bending.

[0021] This invention provides a straightening device and method for heavy-duty forgings used in wind turbine main shafts. It offers the following advantages: 1. This invention establishes a linkage mechanism between the moving component and the clamping mechanism, utilizing the longitudinal displacement of the downward-sinking push rod to sequentially trigger the release of the pin and the closure of the hydraulic valve. This ensures that the axial unlocking action of the moving component takes precedence over the rigid load conversion of the clamping component in physical timing. Consequently, when the workpiece is subjected to pressure and bends, resulting in axial extension, the bottom moving component can adapt to the extension force and slide outward with the workpiece, avoiding equipment jamming and localized workpiece damage caused by unresolved axial constraints.

[0022] 2. This invention acquires the actual sliding displacement data of the moving component during the straightening process through a data acquisition module, and calculates and updates the real-time dynamic span parameters accordingly. The system combines the span variation term, elastic-plastic correction coefficient, and compensation safety limit to generate dynamic compression compensation parameters, and then dynamically compensates and superimposes the target value of the compression stroke of the straightening mechanism. This calculation and compensation mechanism corrects the problem of insufficient compression caused by the dynamic expansion of the span during the straightening operation, ensuring the accuracy of the bending deformation depth of the heavy forging.

[0023] 3. This invention incorporates timing judgment conditions based on dual data of angular displacement and fluid pressure, as well as a static delay process after straightening and resetting, into the control logic. The timing judgment is used to confirm that the mechanical unlocking and hydraulic rigidity conversion have been completed in sequence before the equipment outputs heavy load, preventing the equipment from being subjected to force in an incorrect state; the static delay ensures that the residual stress inside the workpiece is released naturally, so that the straightness data obtained by laser ranging reflects the true plastic deformation result, avoiding meaningless repeated bending and workpiece metal fatigue caused by measurement errors. Attached Figure Description

[0024] Figure 1 This is a perspective view of the present invention; Figure 2 This is a schematic diagram of the internal structure of the moving component of the present invention; Figure 3 This is a schematic diagram of the internal structure of the clamping mechanism of the present invention; Figure 4 This is a schematic diagram of the internal structure of the linkage mechanism of the present invention; Figure 5 This is a cross-sectional view of the worktable of the present invention; Figure 6 This is a schematic diagram of the internal structure of the hydraulic valve of the present invention; Figure 7 This is a flowchart of the method of the present invention; Figure 8 This is a flowchart of the dynamic span reconstruction and downpressure compensation control of the present invention.

[0025] The components are as follows: 1. Base plate; 2. Straightening mechanism; 21. Support plate; 22. Guide rail; 23. Gantry frame; 24. Hydraulic cylinder; 25. Straightening head; 3. Moving assembly; 31. Track; 32. Slider; 33. Worktable; 4. Clamping mechanism; 41. Support cylinder; 42. Clamping head; 43. Pipe; 44. Hydraulic valve; 45. Cutting column; 46. Inclined plate; 5. Linkage mechanism; 51. Push rod; 52. U-block; 53. Roller; 54. Follower wheel; 55. Lever; 56. Crossbar; 57. Pin; 58. Rotating column; 6. Workpiece. Detailed Implementation

[0026] The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0027] See attached document Figure 1 -Appendix Figure 3 This invention provides a straightening device for heavy forgings of wind turbine main shafts, which may include: A base plate 1 is provided above the base plate 1. At least two moving components 3 are provided at intervals along the axial direction of the workpiece 6 below the straightening mechanism 2. Each moving component 3 is provided with a clamping mechanism 4 at its top. The at least two moving components 3 respectively form the two end support points of the workpiece 6. The straightening mechanism 2 is located between two adjacent support points to form a three-point bending straightening force structure. A linkage mechanism 5 is connected between the moving components 3 and the corresponding clamping mechanism 4.

[0028] Furthermore, in order to meet the straightening requirements of large spindle forgings at multiple points, the straightening mechanism 2 specifically includes support plates 21 symmetrically arranged on both sides of the base plate 1. The top of the support plates 21 on both sides is fixedly connected to guide rails 22, and the top of the guide rails 22 is slidably connected to a gantry frame 23 spanning above the base plate 1.

[0029] A downward-extending hydraulic cylinder 24 is slidably connected inside the crossbeam of the gantry frame 23. A straightening head 25 for pressing against the workpiece 6 is installed at the bottom of the hydraulic cylinder 24. In actual operation, by the horizontal sliding of the gantry frame 23 along the guide rail 22 and the lateral sliding of the hydraulic cylinder 24 within the crossbeam, the straightening head 25 can accurately move above different bending extreme points of the workpiece 6 to perform the pressing operation.

[0030] It should be noted that the clamping mechanism 4 in this invention is used to radially support, position and limit the heavy forging of the wind turbine main shaft. Its clamping meaning includes support clamping and is not limited to active closing clamping.

[0031] The heavy forging straightening equipment for wind turbine main shafts is also equipped with a control system. The control system includes a data acquisition module, a control module, a drive module, and a compensation module.

[0032] The acquisition module is used to acquire angular displacement data of linkage mechanism 5, fluid pressure data of clamping mechanism 4, sliding displacement data of moving component 3, and contour detection data of workpiece 6. The control module is used to determine whether the mechanical-hydraulic state transition is complete based on angular displacement data and fluid pressure data, and outputs down pressure, return, interruption or scan commands to the drive module; The compensation module is used to update the real-time dynamic span based on the slip displacement data and generate dynamic pressure compensation parameters; The drive module is used to drive the straightening mechanism 2 to move according to the target displacement command output by the control module, and to drive the scanning execution mechanism related to contour detection.

[0033] Reference Appendix Figure 7 This invention provides a method for straightening heavy forgings for wind turbine main shafts, comprising the following steps: S10, the control module issues an initial command, the hydraulic valve 44 in the clamping mechanism 4 remains in the conducting state, the fluid flows in the internal circuit of the clamping mechanism 4, the pin 57 at the end of the linkage mechanism 5 is inserted into the base plate 1, constraining the displacement of the moving component 3 along the direction of the base plate 1, and the workpiece 6 is placed on the support structure on top of the linkage mechanism 5. S20, the drive module controls the straightening mechanism 2 to apply pressure to the workpiece 6. The workpiece 6 sinks downward and pushes the push rod 51 in the linkage mechanism 5 to generate longitudinal displacement. The longitudinal displacement of the push rod 51 first triggers the pin 57 to be pulled out, so that the pin 57 is separated from the base plate 1, and the axial position restriction of the moving component 3 is released. Then the push rod 51 continues to move downward and triggers the hydraulic valve 44 to close, so that the clamping mechanism 4 changes from a flexible floating state to a hydraulic rigid support state. S30, the acquisition module acquires the angular displacement data of the linkage mechanism 5 and the fluid pressure data of the clamping mechanism 4 and transmits them to the control module. The control module determines whether the received data meets the timing setting conditions and confirms that the component has completed axial unlocking and rigid conversion when the judgment conditions are met. S40, the straightening mechanism 2 continues to press down, causing the workpiece 6 to bend and extend axially. The extension force pushes the moving component 3 to slide on the base plate 1. The acquisition module collects the current sliding displacement data of the moving component 3 and sends the sliding displacement data to the compensation module. S50, the compensation module updates the bearing span value based on the received sliding displacement data, calculates the dynamic pressure compensation parameters based on the updated bearing span value, and generates a pressure stroke target value with dynamic pressure compensation parameters. The control module sends the pressure stroke target value to the drive module, and the drive module adjusts the output displacement of the straightening mechanism 2 according to the pressure stroke target value. S60, the drive module controls the straightening mechanism 2 to lift and reset, the workpiece 6 is unloaded and springs back, the push rod 51 moves upward under the action of the reset elastic element, or is simultaneously reset when the workpiece 6 springs back and drives the roller 53 and U-shaped block 52 to move upward, thereby relieving the mechanical compression on the hydraulic valve 44; the pin 57 moves downward under its own weight or the action of the elastic reset element, and is inserted into the corresponding groove of the base plate 1 under the action of the guide structure, relocking the axial degree of freedom of the moving component 3.

[0034] To more clearly reveal the working principle and structural features of the present invention, the following will provide a detailed description of each core component and control process in the above technical solution.

[0035] See attached document Figure 3 -Appendix Figure 6 This invention provides an initial operation stage of a method for straightening heavy forgings for wind turbine main shafts, specifically including the following sub-steps: S101, the control module sends a status initialization signal to the clamping mechanism 4. The clamping mechanism 4 is equipped with a hydraulic valve 44, which is a normally open two-position two-way valve. The cutting column 45 is horizontally slidably inserted into the side wall of the hydraulic valve 44, and the central axis of the cutting column 45 is perpendicular to the central axis of the push rod 51. At this time, the cutting column 45 is not subjected to the mechanical thrust of the inclined plate 46 on the outer wall of the push rod 51. Under the action of the return spring configured inside, the cutting column 45 is maintained in the initial extended position outside the hydraulic valve 44, so that the fluid circuit inside the hydraulic valve 44 remains open.

[0036] Specifically, to achieve the conversion of mechanical thrust during the straightening process, the inclined plate 46 has a wedge-shaped structure that is wider at the top and narrower at the bottom. The outer wall of the inclined plate 46 is formed with a three-segment nonlinear profile, consisting of a lower clearance surface, a middle pressing inclined surface, and an upper pressure holding surface from bottom to top. In the initial state, the outer end of the cutting column 45 slides against the lower clearance surface of the inclined plate 46, and the inclined plate 46 does not exert a lateral displacement force on the cutting column 45 on this plane.

[0037] Two support cylinders 41 are symmetrically fixed on the top of the workbench 33. Each support cylinder 41 is equipped with a clamping head 42, and the two clamping heads 42 are arranged symmetrically in a V-shape. The bottom of the support cylinders 41 is connected to pipes 43, and the other end of each pipe 43 is connected to a hydraulic valve 44.

[0038] Hydraulic valve 44 is installed on the connecting oil line between two pipes 43. When hydraulic valve 44 is in the open state, the inner cavities of the two support cylinders 41 are connected to each other through pipes 43, allowing the clamping head 42 to float and retract. When hydraulic valve 44 is in the closed state, the connection between the inner cavities of the two support cylinders 41 is cut off, and the support cylinders 41 form a closed pressure chamber, causing the clamping head 42 to switch to a hydraulic rigid support state.

[0039] With hydraulic valve 44 in operation, fluid flows reciprocally between the inner cavities of the two supporting cylinders 41 via pipe 43, allowing the clamping head 42 to float and retract vertically, resulting in a flexible floating state. The piston sealing structure inside the supporting cylinders 41 and the oil supply circuit configuration of the external basic hydraulic pump station can be selected by those skilled in the art based on conventional hydraulic transmission principles. Their installation and layout are well-known technologies in the field and will not be elaborated upon here.

[0040] S102, the linkage mechanism 5 is in its initial reset position when unloaded. The push rod 51 slides vertically through the inside of the worktable 33. The rotating column 58 is rotatably connected inside the worktable 33, and the lever 55 is fixedly sleeved on the outer wall of the rotating column 58. The lever 55 is set at an inclined angle to the horizontal plane. The bottom end of the push rod 51 abuts against the top surface of one end of the lever 55.

[0041] To decouple the downward pressing action in the following steps, the bottom end of the push rod 51 is machined with a two-section cam surface, including a steep initial driving surface and a subsequent gentle holding surface.

[0042] The force-bearing end of lever 55 is set as an arc contact end or a rolling contact end, and the smooth retaining surface is configured as a retaining surface that matches the movement trajectory of the force-bearing end of lever 55, so that when push rod 51 continues to move downward, it only maintains the deflection angle of lever 55, without continuing to increase the rotation stroke of lever 55.

[0043] When the device is in its initial state, the force-bearing end of lever 55 is against the starting position of the bottom cam surface of push rod 51, and has not yet undergone forced rotation.

[0044] A clearance groove is provided at the end of lever 55 away from push rod 51. A crossbar 56 is fixed to the outer wall of pin 57, and the crossbar 56 is movably engaged in the clearance groove. In the initial state, the horizontal plane where one end of lever 55 abuts against push rod 51 is lower than the horizontal plane where the end of lever 55 is engaged with crossbar 56. A sliding groove is provided at the top of base plate 1, and rail 31 is fixedly installed inside the sliding groove for sliding of slider 32 at the bottom of worktable 33.

[0045] Multiple grooves are equidistantly spaced along the center line on the top of the base plate 1. The pin 57 slides vertically through the bottom of the worktable 33 under its own weight or the action of an additional elastic reset member, and is inserted into the groove of the base plate 1.

[0046] The lower end of the pin 57 is provided with a tapered guide surface or an arc-shaped guide surface, and the groove entrance of the base plate 1 is provided with a chamfered guide surface, so that when the moving component 3 is reset and locked after sliding, the pin 57 can enter the adjacent groove along the guide surface under the action of elastic reset force or its own weight.

[0047] The physical engagement of the pin 57 with the groove is used to limit the axial sliding freedom of the worktable 33 and the moving component 3 along the direction of the track 31.

[0048] S103, the external lifting equipment moves the workpiece 6 directly above the clamping mechanism 4 and lowers it smoothly. A U-shaped block 52 is fixedly connected to the top of the push rod 51, and a roller 53 is rotatably connected inside the U-shaped block 52. A follower wheel 54 is rotatably mounted on the top of the worktable 33. The roller 53 and the follower wheel 54 are respectively located on the front and rear sides of the two clamping heads 42.

[0049] After the workpiece 6 is lowered, its bottom outer wall overlaps the outer ring surface of the roller 53 and the follower wheel 54. Since the horizontal plane where the highest point of the roller 53 and the follower wheel 54 is located is above the intersection line of the bottom ends of the two clamping heads 42, the bottom surface of the main body of the workpiece 6 is configured not to directly contact the clamping head 42, and a structural clearance is reserved between the two.

[0050] The initial self-weight load of workpiece 6 is borne by roller 53 and follower wheel 54, which avoids the support cylinder 41 from being subjected to gravity impact under non-straightening conditions at the moment of loading, thereby ensuring that the clamping head 42 can maintain the preset position reference before the straightening action is officially started.

[0051] When the straightening mechanism 2 begins to press down and causes the workpiece 6 to continue to sink, the bottom outer wall of the workpiece 6 gradually approaches and contacts the V-shaped support surface formed by the two clamping heads 42; after the hydraulic valve 44 is closed, the clamping head 42 changes from a flexible floating state to a hydraulic rigid support state to bear the subsequent straightening load.

[0052] The method for straightening heavy forgings for wind turbine main shafts provided by this invention specifically includes the following sub-steps in the servo pressing and mechanical-hydraulic decoupling stage: S201, the drive module controls the actuator of the straightening mechanism 2 to start moving downward, contacting the surface of the workpiece 6 and applying initial downward pressure.

[0053] Workpiece 6 sinks downwards under force, and its bottom presses against roller 53 and follower wheel 54, forcing U-shaped block 52 to drive push rod 51 to synchronously generate downward longitudinal displacement inside worktable 33. In order to reduce the probability of physical interference between hydraulic locking action and mechanical pin pulling action in the same sequence, linkage mechanism 5 divides the subsequent action into two mechanical decoupling stages based on the longitudinal displacement of push rod 51.

[0054] S202, define the real-time vertical displacement of push rod 51 as it is pressed down by workpiece 6 as... The total downward stroke of the push rod 51 is set as follows: And preset the first displacement threshold. As a timing switching node.

[0055] in, The value is determined by conversion based on the vertical upward displacement required for the pin 57 to disengage from the groove of the base plate 1 and the lever arm transmission ratio of the lever 55. In this embodiment, The value range is configured as follows 15% to 25%.

[0056] When the real-time vertical displacement satisfies At this time, the equipment performs the first stage of transient pin pulling action. The steep driving surface at the bottom of the push rod 51 presses against the force-bearing end of the lever 55, forcing the lever 55 to rotate around the rotating column 58.

[0057] The lever 55, with its clearance groove at the other end, lifts the crossbar 56 upwards, causing the pin 57 to slide vertically out of the groove in the base plate 1, thereby releasing the sliding freedom of the moving assembly 3 along the axial direction of the base plate 1. In principle, this stage sacrifices a small initial downward displacement of the push rod in exchange for increased physical movement space of the workbench base.

[0058] Within this displacement range, the inclined plate 46 on the outer wall of the push rod 51 moves downward synchronously, and one end of the cutting column 45 slides relative to the clearance surface reserved at the bottom of the inclined plate 46. This clearance surface does not generate lateral displacement thrust on the cutting column 45, so that the hydraulic valve 44 remains internally open. The fluid inside the support cylinder 41 flows freely through the pipe 43, and the clamping head 42 remains in a flexible retracted state, providing physical space for the sinking of the workpiece 6 and the removal of the pin 57.

[0059] To avoid a logic dead zone where pin 57 cannot be easily pulled out due to mechanical wear or foreign object jamming, the control module... arrive Status verification will be performed at times.

[0060] The status verification includes determining whether the angular displacement of the rotating column 58 has reached the physical angle threshold, or whether the position detection element configured on the pin 57 has output a signal indicating that it has been pulled out to the correct position.

[0061] If the angular displacement does not reach the physical angle threshold, or if the pin 57 does not output a signal indicating that it has been pulled out, the control module determines that the pin pulling action has not been completed, generates an interrupt command, and controls the straightening mechanism 2 to return and unload.

[0062] S203, as the straightening mechanism 2 continues to press down, when the real-time vertical displacement of the push rod 51 increases and satisfies... At this time, the equipment transitions to the second stage of smooth locking action.

[0063] The contact area between the bottom end of push rod 51 and lever 55 shifts from a steep driving surface to a gentle holding surface. The gentle holding surface and the steep driving surface are smoothly transitioned by a rounded chamfer. This gentle holding surface is an equal-angle holding surface or an approximately equidistant relief surface. Its contour is used to counteract the relative motion increment of the force-bearing end of lever 55 when push rod 51 continues to move downward, so that lever 55 is maintained within the deflection angle range after the pin is pulled out, reducing the risk of overload under pressure, while pin 57 remains stably in the pulled-out state.

[0064] Simultaneously, the pushing ramp in the middle of the ramp 46 descends to the height of the corresponding cutting column 45. The pushing ramp uses its geometric slope to generate a lateral force, pushing the cutting column 45 to slide into the hydraulic valve 44. The lateral horizontal width of the pushing ramp is configured to be greater than or equal to the valve core stroke required for the hydraulic valve 44 to move from open to closed.

[0065] S204, the sliding of the cutting column 45 gradually blocks the fluid circuit within the hydraulic valve 44. When the circuit is fully cut off, the cavity formed by the support cylinder 41 and the pipe 43 is sealed. The support cylinder 41 loses its flexible yielding property, and the state of the clamping head 42 changes from flexible floating to rigid support, used to support the bending load generated by the workpiece 6 under subsequent pressure. During the process of the push rod 51 reaching the end of its total downward stroke, the cutting column 45 slides into the pressure-holding straight surface area above the inclined plate 46.

[0066] This pressure-holding mechanism effectively reduces the interference of minute displacement fluctuations caused by heavy-load deformation on the lateral position of the cut-off column 45, maintaining the stability of the hydraulic valve 44 in its closed state. It is understood that those skilled in the art can solve and analyze the micro-compression characteristics of the fluid inside the sealed cylinder under pressure and the equivalent stiffness calculation under heavy-load conditions using conventional fluid volumetric elastic modulus models. The principle of fluid stiffness conversion is a well-known technique in this field and will not be elaborated upon here.

[0067] The method for straightening heavy forgings for wind turbine main shafts provided by this invention specifically includes the following sub-steps in the multi-dimensional state determination and timing handshake stage: S301, the acquisition module is equipped with an angle sensor and a fluid pressure sensor. The angle sensor is directly mounted on the shaft end of the rotating column 58 and is used to continuously acquire the instantaneous angular displacement data generated by the lever 55 as the push rod 51 is pressed down.

[0068] A fluid pressure sensor is installed in the sealed inner cavity of the support cylinder 41 or on the side of the pipe wall of the pipe 43 to capture instantaneous pressure step data generated when the hydraulic oil circuit inside the clamping mechanism 4 is physically cut off in real time.

[0069] The inner cavity of the support cylinder 41 is initially configured with pre-charge pressure. When the workpiece 6 continues to sink and contacts the clamping head 42, the inner cavity of the closed support cylinder 41 is subjected to compressive load, thereby causing an increase in the absolute value of pressure and a sudden change in the rate of pressure change. The acquisition module obtains the hydraulic rigidity transition state based on this. The acquisition module synchronously acquires the above mechanical and fluid state data at a set sampling frequency and transmits the timing signals to the control module.

[0070] For the specific selection of angle sensors and fluid pressure sensors, and the design of signal filtering and conditioning circuits, those skilled in the art can adapt them according to the electromagnetic interference environment on site. The signal front-end acquisition and processing are well-known technologies in this field and will not be elaborated here.

[0071] S302, the control module is pre-programmed with the physical angle threshold required for the pin 57 to disengage from the base plate 1, the preset pressure threshold required for the support cylinder 41 to enter the pressure-bearing state, and the pressure step change rate threshold required for the support cylinder 41 to change from a flexible connected state to a rigid closed state. The calibration of the above threshold parameters is based on the no-load calibration test data and the loading calibration test data of the equipment in the early stage.

[0072] S303, after receiving a continuous data stream, the control module monitors the abrupt changes in angular displacement data and fluid pressure data. The time when the angular displacement data first exceeds or equals the physical angle threshold is recorded as the first determination time, which represents that the axial mechanical degree of freedom of the moving component 3 has been released.

[0073] The time when the fluid pressure data first simultaneously meets the conditions that the absolute pressure value is greater than or equal to the preset pressure threshold and the pressure change rate is greater than or equal to the pressure step change rate threshold is the second determination time. This time indicates that the clamping base at the top of the worktable 33 has completed the rigidification transformation.

[0074] S304, the condition for the control module to determine that the equipment has entered the heavy-load straightening preparation state is: The second determination time is later than the first determination time, and the time difference between the second determination time and the first determination time is less than or equal to the preset timing tolerance determination window. At the same time, the real-time angular displacement data is greater than or equal to the physical angle threshold, and the fluid pressure data is maintained above the preset pressure threshold for a duration greater than or equal to the preset pressure holding time.

[0075] The value of the timing tolerance judgment window is determined based on the ratio of the remaining stroke of the push rod 51 in the second stage to the set pressing speed of the straightening mechanism 2. The specific calculation method is to divide the remaining stroke by the pressing speed and then multiply it by the safety margin coefficient. The value range of the safety margin coefficient is configured to be 1.1 to 1.5.

[0076] S305, when the above judgment conditions are met, the control module confirms that the mechanical pin puller and hydraulic rigid locking have been successfully executed in the predetermined order, the physical axial unlocking and rigid conversion action closed loop is established, and the subsequent dynamic reconstruction calculation process is triggered.

[0077] If the downward execution end of the straightening mechanism 2 has reached the warning and anti-collision position, but the above judgment conditions are still not met, the control module determines that the underlying mechanical mechanism has failed. The control module is configured to interrupt the activation path of the subsequent compensation algorithm and sends a forced pressure relief return command to the drive module.

[0078] The method for straightening heavy forgings for wind turbine main shafts provided by this invention specifically includes the following sub-steps in the workpiece deformation and axial slip data acquisition stage: S401, after the control module confirms that the mechanical and hydraulic systems are ready, the drive module controls the straightening mechanism 2 to apply a working load to the workpiece 6 at a set loading rate. The clamping mechanism 4 is in a hydraulically rigid locked state, and the workpiece 6 forms a three-point bending force model between the straightening mechanism 2 and the bottom clamping head 42.

[0079] When workpiece 6 is under compression, it undergoes bending deflection, and its cross-section extends axially on the tension side, causing a change in the actual support span at both ends of workpiece 6. For the elastoplastic deformation mechanical model of metal forgings and the three-point bending deflection theory, those skilled in the art can refer to conventional materials mechanics literature, which will not be elaborated here.

[0080] S402, the axial extension of workpiece 6 due to bending applies an axial thrust to the clamping mechanism 4 at the bottom. At this time, pin 57 has disengaged from the groove of base plate 1, and the sliding constraint of moving assembly 3 along the direction of base plate 1 is released. Under the action of axial thrust, the slider 32 at the bottom of moving assembly 3 passively slides outward along the track 31 of base plate 1. This passive sliding amount adapts to the axial elongation of workpiece 6, keeping the support surface of workpiece 6 relatively stationary with respect to clamping head 42, reducing the risk of scratches on the surface of workpiece 6, and weakening the rigid impact of axial internal force on worktable 33 and hydraulic components.

[0081] S403, the acquisition module is equipped with a linear displacement sensor. The stator of the linear displacement sensor is fixed to the reference side of the base plate 1, and the mover is connected to the outer wall of the moving component 3, used to measure the axial position change of the moving component 3 relative to the base plate 1.

[0082] In actual straightening operations, workpiece 6 is supported by the moving components 3 on both the left and right sides. To eliminate the rigid body translation error of workpiece 6 caused by uneven force distribution, the acquisition module synchronously acquires the outward sliding amount of the moving components 3 on both sides through two sets of linear displacement sensors.

[0083] The positive directions of both sets of linear displacement sensors are defined as the outward expansion direction away from the center of workpiece 6. The acquisition module adds the outward expansion displacement on the left and the outward expansion displacement on the right to obtain the total axial outward expansion of workpiece 6. Alternatively, the acquisition module can directly calculate the real-time support span between the current positions of the two moving components 3 in a unified coordinate system, and then subtract the real-time support span from the static reference span to obtain the total axial outward expansion of the workpiece 6.

[0084] The acquisition module sends the left outward displacement, the right outward displacement, and the total axial outward displacement obtained by adding the two to the compensation module in real time as position feedback parameters for subsequent compensation calculations.

[0085] See attached document Figure 8 The method for straightening heavy forgings for wind turbine main shafts provided by this invention specifically includes the following sub-steps in the dynamic compensation and straightening closed-loop execution stage: S501, the compensation module receives the outward sliding displacement data on both sides and the total axial outward expansion amount sent by the acquisition module. In the three-point bending stress condition, the actual span between the support points at both ends of workpiece 6 increases with axial extension. If the control system performs a constant depth pressing operation according to the initial span of the workpiece, the outward expansion of the span will cause the actual deformation amount in the middle of workpiece 6 to deviate from the target value, resulting in insufficient straightening.

[0086] S502, the compensation module performs dynamic reconstruction calculations of the support span. The compensation module pre-stores the static reference span of workpiece 6 in its initial loading state. The compensation module adds the outward sliding displacement data on both sides to obtain the total axial outward expansion of workpiece 6 under the current stress state.

[0087] The compensation module adds the total axial outward expansion to the static reference span to generate a real-time dynamic span parameter that characterizes the current actual physical span boundary. The real-time dynamic span parameter is used to replace the static reference span in subsequent downward pressure compensation calculations, so that the output displacement of the straightening mechanism 2 is dynamically updated according to the actual axial extension state of the workpiece 6.

[0088] S503, the compensation module performs span compensation calculations based on real-time dynamic span parameters. The compensation module pre-stores a span and downward pressure correction model, which includes at least a span variation term and an elastic-plastic correction coefficient. The elastic-plastic correction coefficient is determined by trial calibration data, finite element simulation data, or a combination of both, and is used to correct the deviation between the elastic-plastic stage of the heavy forging and the ideal elastic beam model.

[0089] When workpiece 6 is in a stage of small deflection, three-point support and approximate elasticity, the span change term is calculated according to the relationship between the real-time dynamic span and the static reference span; in the elastoplastic straightening stage, the compensation module multiplies the span change term by the elastoplastic correction coefficient to obtain the span compensation amount.

[0090] To avoid exceeding compensation limits due to sudden changes in sensor data or unexpected material deformation, the compensation module has a preset compensation safety limit. The compensation module compares the acquired span compensation amount with the compensation safety limit and takes the smaller value as the dynamic pressure compensation parameter. The compensation safety limit is determined based on the maximum stroke of the straightening mechanism 2 and the allowable stress of the workpiece 6.

[0091] S504, the compensation module also calculates the frictional energy consumption of the moving component 3 during the sliding process based on the sliding displacement of the moving component 3, the equivalent friction coefficient between the slider 32 and the track 31, and the equivalent normal load borne by the moving component 3. The compensation module converts the frictional energy consumption into an equivalent downward pressure compensation amount for the straightening mechanism 2, and then superimposes this equivalent downward pressure compensation amount with the dynamic downward pressure compensation parameters caused by the span expansion to generate the final downward pressure compensation parameters. These parameters are then superimposed with the theoretical downward pressure target value to generate the final target displacement command. The control module sends the final target displacement command to the drive module.

[0092] According to the final target displacement command, the drive module drives the execution end of the straightening mechanism 2 to descend to the corresponding depth, completing the straightening action of the workpiece 6. For the position closed-loop tracking control of the servo hydraulic actuator, those skilled in the art can tune the parameters based on the system hardware response characteristics. Its position servo feedback control is a well-known technology in the field and will not be elaborated further here.

[0093] S505, after the straightening action is completed, the control module issues an unloading command, and the drive module controls the straightening mechanism 2 to return upward to unload.

[0094] When workpiece 6 is released from the loading force, it undergoes geometric springback. The push rod 51 of the linkage mechanism 5 moves upward to reset under the action of the reset elastic element, or it resets synchronously when the workpiece 6 springs back and drives the roller 53 and U-shaped block 52 to move upward. The pin 57 moves downward under its own weight or the action of the elastic reset element, and through the guide surface at the lower end of the pin 57 engaging with the chamfered guide surface at the groove entrance of the base plate 1, it inserts into the corresponding groove of the base plate 1, thus relocking the axial degree of freedom of the moving component 3.

[0095] Simultaneously, the cutting column 45 returns to its initial position under the action of the return spring, the hydraulic valve 44 resumes fluid conduction, the support cylinder 41 is released from its sealed state, and the clamping head 42 returns to its flexible floating state, completing the closed-loop restoration of the mechanical and hydraulic state for a single straightening cycle.

[0096] The method for straightening heavy forgings for wind turbine main shafts provided by this invention specifically includes the following sub-steps in the global detection and task stoppage stage: S601, after a single straightening cycle is completed, the control module initiates a static delay timer. The duration of the static delay timer is configured based on the yield strength and volume equivalent of the workpiece 6 material, with a value range of 10 to 30 seconds. This delay operation is used to release transient residual stress inside the workpiece 6, preventing drift in the contour detection data due to material elastic aftereffects. For the springback hysteresis effect and residual stress attenuation characteristics of metal materials after unloading, those skilled in the art can refer to conventional metal mechanics specifications, which will not be elaborated upon here.

[0097] S602, after the delay timer ends, the control module sends a scanning command to the drive module. The drive module drives the integrated laser ranging array or the ranging array moving mechanism to scan along the axis of the workpiece 6. The acquisition module receives the data output by the laser ranging array.

[0098] In order to obtain the true deformation extreme points of the rotating workpiece in three-dimensional space and avoid omissions caused by single generatrix scanning, a rotary drive mechanism is provided on the worktable 33 or the base plate 1. The rotary drive mechanism includes an active friction wheel and a rotary drive motor. The active friction wheel is in contact with the outer circular surface of the workpiece 6. The control module controls the rotary drive motor to drive the active friction wheel to rotate, causing the workpiece 6 to rotate circumferentially under the support of the clamping mechanism 4. The laser ranging array synchronously performs multi-angle axial generatrix scanning on the workpiece 6 to obtain a global relative contour dataset of the workpiece 6 surface.

[0099] The acquisition module extracts the position information of the highest and lowest points in the global relative contour dataset, calculates the absolute height difference between them, generates the current straightness deviation data of workpiece 6, and sends the data to the control module.

[0100] S603, the control module has a pre-stored straightness tolerance threshold for the process requirements. The control module compares the current straightness deviation data with the straightness tolerance threshold. If the current straightness deviation data is less than or equal to the straightness tolerance threshold, the control module determines that the form and position accuracy of workpiece 6 meets the standard, terminates the straightening task flow, generates a work completion record, and controls the equipment to enter the standby unloading state.

[0101] S604, if the current straightness deviation data is greater than the straightness tolerance threshold, the control module determines that workpiece 6 has not reached the target accuracy and needs to initiate compensation iteration. To prevent the equipment from getting stuck in an infinite iteration loop, the control module has a preset maximum iteration threshold. The control module reads the count value of the currently executed straightening rounds in memory and compares this count value with the maximum iteration threshold. The maximum iteration threshold is determined based on the allowable fatigue bending number of workpiece 6 under the room temperature work hardening limit, and its value range is configured to be 3 to 5 times.

[0102] S605, if the current straightening cycle count is less than the maximum iteration count threshold, the control module increments the straightening cycle count in memory and updates it, uses the current straightness deviation data as the new initial deviation, and controls the drive module to return to execute a new round of servo pressing and dynamic span compensation process.

[0103] If the current count of straightening cycles performed is greater than or equal to the maximum iteration threshold, the control module determines that workpiece 6 has material yielding abnormalities or stiffness exceeding the equipment's load-bearing capacity. The control module blocks the closed-loop pressing trigger path, activates the system protection lock, outputs an abnormal shutdown command code to prevent equipment overload damage, and generates an abnormal operation record containing the current straightness deviation data, the number of straightening cycles performed, the final pressing stroke target value, and the abnormality cause code for subsequent manual review.

[0104] Working principle: At the start of the operation, the workpiece 6 to be straightened is hoisted and placed above the clamping mechanism 4 on top of the moving assembly 3. The bottom of the workpiece 6 rests on the roller 53 rotatably connected inside the U-shaped block 52 and the follower wheel 54 rotatably mounted on the top of the worktable 33. Since the highest horizontal plane of the roller 53 and the follower wheel 54 is higher than the intersection line of the bottom ends of the two clamping heads 42 mounted on the top of the support cylinder 41, the bottom surface of the workpiece 6 remains suspended from the clamping heads 42.

[0105] At this time, the cutting column 45, which is slidably inserted into the side of the hydraulic valve 44, is not compressed, the hydraulic valve 44 remains open, and the pipes 43 connected to the bottom of the two support cylinders 41 are interconnected through the hydraulic valve 44, allowing the internal hydraulic oil to flow freely. The clamping head 42 at the top of the support cylinder 41 is in a flexible floating state. At the same time, the pin 57, which is vertically slidably inserted into the worktable 33, has its bottom end inserted into the groove opened at the top of the base plate 1, keeping the worktable 33 and the base plate 1 locked in position.

[0106] When straightening is performed, the hydraulic cylinder 24, which is slidably connected inside the gantry 23, is activated, driving the straightening head 25 installed at the bottom to press down on the workpiece 6. The workpiece 6 sinks downward as a whole under the force and presses down on the roller 53. The roller 53 drives the U-shaped block 52, which is fixedly connected to its outside, and the push rod 51, which is fixedly connected to the bottom of the U-shaped block 52, to slide downward vertically within the worktable 33.

[0107] As the push rod 51 slides downward, the inclined plate 46, fixedly connected to the outer wall of the push rod 51, moves downward synchronously. Because the inclined plate 46 has a wedge-shaped structure that is wider at the top and narrower at the bottom, and its inclined surface slides against the end of the cutting column 45 away from the hydraulic valve 44, the downward-moving inclined plate 46 squeezes and pushes the cutting column 45, which is horizontally slidably inserted into the side wall of the hydraulic valve 44, causing it to slide into the hydraulic valve 44, thereby closing the oil passage inside the hydraulic valve 44. The pipe 43 connected to the hydraulic valve 44 is sealed, the hydraulic oil in the two support cylinders 41 stops flowing, and the support cylinders 41 and the top clamping head 42 change from a flexible state to a rigid state, firmly supporting the workpiece 6 as it continues to sink.

[0108] Meanwhile, as the bottom end of the push rod 51 abuts against the top surface of one end of the lever 55, the push rod 51 simultaneously presses down on the lever 55 as it slides downward. Since the lever 55 is fixedly sleeved on the rotating column 58 rotatably connected inside the worktable 33, the lever 55 rotates around the rotating column 58 after being pressed, causing the other end of the lever 55 away from the push rod 51 to tilt upward. Since the outer wall of the pin 57 is fixedly connected to the crossbar 56, and the crossbar 56 is movably engaged in the clearance groove opened at the end of the lever 55, the tilted end of the lever 55 lifts the crossbar 56 upward, causing the pin 57 to slide upward in the vertical direction, pulling the bottom end of the pin 57 out of the groove in the base plate 1, thus releasing the lock between the worktable 33 and the base plate 1.

[0109] As the straightening head 25 continues to apply pressure to the workpiece 6, the workpiece 6 generates axial extension stress during bending deformation. Since the pin 57 has detached from the base plate 1, the slider 32, which is fixedly connected to the bottom of the worktable 33, slides relative to the track 31, which is fixedly installed in the slide groove of the base plate 1. The moving assembly 3 as a whole generates axial displacement along the track 31, releasing the axial deformation internal stress generated by the workpiece 6 during the straightening process.

[0110] After the straightening action is completed, the hydraulic cylinder 24 drives the straightening head 25 to lift upward. The workpiece 6 loses downward pressure, and the push rod 51 slides upward in the vertical direction within the worktable 33 to reset. The inclined plate 46, which is fixedly connected to the outside of the push rod 51, rises synchronously and releases the pressure on the cutting column 45. The cutting column 45 slides outward to reset, the hydraulic valve 44 is reopened, and the clamping mechanism 4 returns to its flexible floating state.

[0111] Simultaneously, the bottom end of push rod 51 releases pressure on lever 55, lever 55 rotates in the opposite direction around rotating column 58 to reset, and crossbar 56, which is engaged in the clearance groove, descends accordingly, causing pin 57 to slide downward and re-engage in the groove of base plate 1. Moving component 3 is locked back to base plate 1, and the equipment returns to its initial state.

Claims

1. A straightening device for heavy forgings of wind turbine main shafts, comprising a base plate (1), characterized in that, A straightening mechanism (2) is provided above the base plate (1). At least two moving components (3) are provided at intervals along the axial direction of the workpiece (6) below the straightening mechanism (2). A clamping mechanism (4) is provided on the top of each moving component (3). A linkage mechanism (5) is connected between the moving component (3) and the corresponding clamping mechanism (4). The linkage mechanism (5) includes a push rod (51) that is in contact with the workpiece (6) and a pin (57) for locking the axial degree of freedom of the moving component (3). The clamping mechanism (4) includes a hydraulic valve (44), and the longitudinal displacement of the push rod (51) is used to trigger the pull-out of the pin (57) and the closing of the hydraulic valve (44); The wind turbine main shaft heavy forging straightening equipment also includes a control system, which comprises a data acquisition module, a control module, a drive module, and a compensation module.

2. The wind turbine main shaft heavy forging straightening equipment according to claim 1, characterized in that, The straightening mechanism (2) specifically includes support plates (21) symmetrically arranged on both sides of the base plate (1). The top of the support plates (21) on both sides is fixedly connected to guide rails (22), and the top of the guide rails (22) is slidably connected to a gantry frame (23) spanning above the base plate (1). The gantry (23) has a downwardly extending hydraulic cylinder (24) slidably connected inside the crossbeam, and the bottom of the hydraulic cylinder (24) is equipped with a straightening head (25) for pressing against the workpiece (6).

3. The wind turbine main shaft heavy forging straightening equipment according to claim 1, characterized in that, The moving component (3) includes a worktable (33), the push rod (51) slides through the worktable (33) in the vertical direction, a U-shaped block (52) is fixedly connected to the top of the push rod (51), a roller (53) is rotatably connected inside the U-shaped block (52), and a follower wheel (54) is rotatably installed on the top of the worktable (33). An inclined plate (46) is fixedly connected to the outer wall of the push rod (51), and a cutting column (45) is slidably inserted into one side of the hydraulic valve (44). The outer wall of the inclined plate (46) is formed with a three-segment nonlinear profile, and the inclined plate (46) and the cutting column (45) slide against each other at the end away from the hydraulic valve (44).

4. The wind turbine main shaft heavy forging straightening equipment according to claim 3, characterized in that, The workbench (33) is rotatably connected to a rotating column (58). A lever (55) is fixedly sleeved on the outer wall of the rotating column (58). The bottom end of the push rod (51) abuts against the top surface of one end of the lever (55). A clearance groove is provided at the other end of the lever (55). A crossbar (56) is fixed on the outer wall of the pin (57). The crossbar (56) is movably engaged in the clearance groove. The bottom end of the pin (57) is slidably inserted into the groove inside the base plate (1).

5. A wind turbine main shaft heavy forging straightening device according to claim 3, characterized in that, The workbench (33) has two symmetrically fixed support cylinders (41) on its top. Each support cylinder (41) is equipped with a clamping head (42) on its top. The bottom of the two support cylinders (41) is connected to a pipe (43), and the other end of each pipe (43) is connected to a hydraulic valve (44).

6. A method for straightening heavy forgings for wind turbine main shafts, applied to the straightening equipment for heavy forgings for wind turbine main shafts as described in any one of claims 1 to 5, characterized in that, Includes the following steps: The control module issues an initial command, the hydraulic valve (44) in the clamping mechanism (4) remains in the conducting state, the fluid flows in the internal circuit of the clamping mechanism (4), the pin (57) at the end of the linkage mechanism (5) is inserted into the base plate (1), constraining the displacement of the moving component (3) along the direction of the base plate (1), and the workpiece (6) is placed on top of the roller (53) and follower wheel (54) in the linkage mechanism (5); The drive module controls the straightening mechanism (2) to apply pressure to the workpiece (6). The workpiece (6) sinks and pushes the push rod (51) to generate longitudinal displacement, first triggering the pin (57) to pull out and release the axial position restriction of the moving component (3); Then the hydraulic valve (44) is triggered to close, causing the clamping mechanism (4) to switch to a hydraulic rigid support state; The acquisition module obtains the angular displacement data of the linkage mechanism (5) and the fluid pressure data of the clamping mechanism (4). The control module determines whether the timing setting conditions are met and confirms the completion of axial unlocking and rigid conversion. The straightening mechanism (2) continues to press down, causing the workpiece (6) to bend and extend axially. The extension force pushes the moving component (3) to slide. The acquisition module collects the current sliding displacement data of the moving component (3). The compensation module updates the bearing span value based on the sliding displacement data, calculates the dynamic compression compensation parameters and generates a compression stroke target value with dynamic compression compensation parameters. The drive module adjusts the output displacement of the straightening mechanism (2) according to the compression stroke target value. The drive module controls the straightening mechanism (2) to lift and reset, the push rod (51) and the pin (57) to reset, and relock the axial degree of freedom of the moving component (3).

7. The method for straightening heavy forgings for wind turbine main shafts according to claim 6, characterized in that, When applied to the wind turbine main shaft heavy forging straightening equipment as described in claim 4, the specific process by which the push rod (51) generates longitudinal displacement includes: Define the real-time vertical displacement of the push rod (51) as the workpiece (6) is pressed down, set the total downward stroke, and preset a first displacement threshold, wherein the first displacement threshold is greater than zero and less than or equal to the total downward stroke; When the real-time vertical displacement is greater than zero and less than or equal to the first displacement threshold, a transient pin-pulling action is performed, and the pin (57) is removed from the groove of the base plate (1). When the real-time vertical displacement is greater than the first displacement threshold and less than or equal to the total downward stroke, the inclined plate (46) on the outer wall of the push rod (51) pushes the cut-off column (45) to slide into the hydraulic valve (44) to block the fluid circuit.

8. The method for straightening heavy forgings for wind turbine main shafts according to claim 6, characterized in that, The control module determines whether the timing setting conditions are met in the following ways: The time when the angular displacement data first exceeds or equals the physical angle threshold is recorded as the first determination time; The time when the fluid pressure data first simultaneously satisfies that the absolute pressure value is greater than or equal to a preset pressure threshold and the pressure change rate is greater than or equal to a pressure step change rate threshold is recorded as the second determination time. The determination condition is that the second determination time is later than the first determination time, and the time difference is less than or equal to the preset timing tolerance determination window.

9. A method for straightening heavy forgings for wind turbine main shafts according to claim 6, characterized in that, The specific process for calculating the dynamic downpressure compensation parameters includes: The compensation module acquires the outward sliding displacement data generated by the moving components (3) located on both sides of the workpiece, adds the outward sliding displacement data on both sides to obtain the total axial outward expansion amount, and adds it to the static reference span to generate real-time dynamic span parameters. The compensation module calculates the span compensation based on a pre-calibrated span and pressure correction model. The span and pressure correction model includes at least a span variation term and an elastic-plastic correction coefficient. The span variation term is used to characterize the change in pressure caused by the increase of the real-time dynamic span relative to the static reference span. The elastic-plastic correction coefficient is determined based on trial calibration data, finite element simulation data, or a combination of both. The span compensation amount is compared with the compensation safety limit, and the smaller value is taken as the dynamic downpressure compensation parameter.

10. A method for straightening heavy forgings for wind turbine main shafts according to claim 6, characterized in that, After the axial degrees of freedom of the relocking moving component (3) are re-locked, the following is also included: Start the static delay timer. After the timer ends, the control module sends a scanning command to the drive module. The drive module drives the laser ranging array or the ranging array moving mechanism to scan along the axis of the workpiece (6). The acquisition module receives the global relative contour dataset output by the laser ranging array and calculates and generates the current straightness deviation data. The control module compares the current straightness deviation data with the straightness tolerance threshold. If it is greater than the straightness tolerance threshold, it reads the count of the number of straightening rounds that have been executed and compares it with the maximum number of iterations threshold, and decides to return to execute a new round of the process or output an abnormal shutdown instruction code.

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