Disc wheel experiment platform

Abstract

The application discloses a turning gear experiment platform, and relates to the technical field of large mechanical equipment testing, comprising a turning gear installation system, a load simulation system, a rotating speed synchronization and disengagement simulation system, the turning gear installation system is used for fixing different types of turning gears; the turning gear output torque is transmitted to a magnetic powder brake through a gear set and a transmission shaft, and the tail end of the magnetic powder brake is connected with a friction clutch.The application achieves universal compatible testing of various types of turning gears through a series of structures.With the aid of three special installation tables and an adjustable meshing mechanism, the testing efficiency is greatly improved.Meanwhile, the starting impact load, the rotor speed-up process and the automatic disengagement whole process under real working conditions are accurately simulated.Adjustable torque is provided by the magnetic powder brake, the rotating speed is synchronized through the friction clutch, the variable frequency motor is used to simulate the speed-up, and the PLC automation control and real-time monitoring of sensors are adopted, so that the verification level of the turning gear reliability and safety is significantly improved.

Description

Technical Field

[0001] This invention relates to the field of testing technology for large-scale mechanical equipment, specifically a rotary testing platform. Background Technology

[0002] The rotor of large machinery such as steam turbines, large generator sets, and large electric motors is one of the core components of the machine, requiring extremely high precision. Therefore, many problems arise during operation. For example, during the startup of a steam turbine unit, due to the large weight of the rotor, direct steam flow into the cylinder can damage blades and other parts. During unit shutdown, the steam turbine cools down due to steam blockage. Uneven cooling of the cylinder and the upper and lower parts of the rotor can cause thermal bending after rotation stops. Restarting the turbine under such conditions can easily lead to rubbing between moving and stationary parts, and excessive rotor coaxiality causing vibrations beyond the allowable range. To avoid these problems, steam turbines are equipped with a turning gear. After shutdown, the turning gear is operated to allow the rotor to rotate continuously or intermittently, avoiding or reducing thermal bending deformation, thus preventing accidents and extending the rotor's service life. The turning gear can be operated manually or automatically.

[0003] The turning gear device needs to undergo rigorous performance testing to ensure its reliability and safety. Traditional turning gear testing methods usually rely on manual operation or simple mechanical auxiliary tools, generally adopt a "dedicated machine for dedicated use" design mode, and cannot simulate automatic disengagement. These methods have problems such as low efficiency, poor accuracy, and inability to simulate impact loads in real working environments. Summary of the Invention

[0004] The purpose of this invention is to provide a rotary testing platform to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a turning gear test platform, comprising a turning gear installation system, a load simulation system, a speed synchronization system, and a platform base. The platform base is located at the bottom of the turning gear installation system, the load simulation system, and the speed synchronization system. The turning gear installation system is located on the top left side of the platform base and is used to fix different types of turning gears. The load simulation system is located at the center of the top of the platform base. One end of the load simulation system is provided with a disengagement simulation system. The load simulation system includes a magnetic powder brake, which is driven by a drive shaft. A gear set is fixedly sleeved on the outer side of the drive shaft surface, and the gear set is located on the right side of the magnetic powder brake. A friction clutch is connected to the tail end of the magnetic powder brake, and the other end of the friction clutch is connected to a variable frequency motor located on the right side of the platform's extension arm structure. A control cabinet is provided on the top right side of the platform base. The control cabinet collects speed signals through a speed sensor installed at the output end of the magnetic powder brake and controls the variable frequency motor to realize load simulation and automatic disengagement function testing.

[0006] Preferably, the turning gear mounting system includes a first mounting platform, a second mounting platform, and a third mounting platform; the first mounting platform is located at the top of the platform base and is adapted to a small electric turning gear, supporting radial and axial engagement; the second mounting platform is located at the top of the first mounting platform and is adapted to an end-face turning gear; the third mounting platform is located at the top of the second mounting platform, and the top of the third mounting platform is equipped with a swing plate; the driving turning gear engages radially with the connecting gear and the swing plate.

[0007] Preferably, the load simulation system is a magnetic powder brake, which applies adjustable torque to simulate the rotor starting impact load and running damping.

[0008] Preferably, the speed synchronization and disengagement simulation system includes a friction clutch and a variable frequency motor; when the turning gear reaches the rated speed, the variable frequency motor synchronizes the speed and direction, the friction clutch engages after the magnetic powder brake is de-energized, and the variable frequency motor continues to simulate rotor speed increase until the turning gear automatically disengages.

[0009] Preferably, the measurement system includes a speed sensor, a speed measuring disk, and a torque sensor; the speed sensor works in conjunction with the speed measuring disk to monitor the rotational speed of the load simulation system in real time, and the torque sensor is mounted on the drive shaft.

[0010] Preferably, the control system includes a control cabinet, a frequency converter, and a PLC controller; the control cabinet automatically controls the variable frequency motor according to the speed sensor signal to realize the automatic verification of speed synchronization and disengagement process.

[0011] Preferably, the control system further includes an AI optimization module, which automatically adjusts the load curve and test parameters based on experimental data.

[0012] Preferably, the first mounting platform of the rotating platform installation system is equipped with a base that can adjust the angle and height, and the swing plate of the third mounting platform is hydraulically driven.

[0013] Compared with the prior art, the beneficial effects of the present invention are:

[0014] 1. This turning wheel test platform enables universal compatibility testing of various types of turning wheels (small electric turning wheels, end-face turning wheels, and large turning wheels). Through three dedicated mounting platforms and adjustable meshing mechanisms, it completely solves the limitations of traditional "dedicated machines for specific purposes", greatly improves testing efficiency, reduces the cost of repeated equipment investment, and supports multiple meshing methods such as radial / axial / end-face.

[0015] 2. This rotary turning test platform accurately simulates the starting impact load, rotor speed-up process, and automatic disengagement process under real working conditions. It utilizes a magnetic powder brake to provide adjustable torque, a friction clutch to achieve speed synchronization, and a variable frequency motor to simulate speed-up. Combined with PLC automatic control and real-time sensor monitoring, it effectively improves the verification accuracy of key parameters such as disengagement timing, torque, and separation distance, significantly enhances the reliability and safety verification level of the rotary turning, and reduces potential accident hazards on site. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0017] Figure 2 This is a side view of the present invention;

[0018] Figure 3 This is a schematic diagram of the internal structure of the present invention.

[0019] In the diagram: 1. First turning gear mounting platform; 2. Second turning gear mounting platform; 3. Third turning gear mounting platform; 4. Swing plate; 5. Turning gear; 6. Connecting gear; 7. Gear set; 8. Drive shaft; 9. Magnetic powder brake; 10. Friction clutch; 11. Variable frequency motor; 12. Control cabinet; 13. Speed ​​sensor; 14. Speed ​​measuring disc. Detailed Implementation

[0020] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0021] In the description of this invention, it should be noted that the terms "upper," "lower," "inner," "outer," "front end," "rear end," "both ends," "one end," and "the other end," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0022] like Figures 1 to 3 As shown, this embodiment is a turning gear test platform, mainly composed of a turning gear mounting system, a load simulation system, and a speed synchronization and disengagement simulation system. The turning gear mounting platform is designed to stably fix various types and specifications of turning gear devices, providing a reliable foundation for subsequent experiments. In the power transmission path, the torque output by the turning gear is first transmitted through a precision gear set 7, and then further transmitted to the magnetic powder brake 9 via the drive shaft 8. The tail end of the magnetic powder brake 9 is connected to a friction clutch 10, and the other end of the friction clutch 10 is linked with a variable frequency motor 11, thus forming a continuous power transmission chain. The control cabinet 12, as the central hub of the entire system, collects speed signals in real time through a high-precision speed sensor 13 and precisely controls the variable frequency motor 11 based on these signals. This control mechanism enables the test platform to effectively simulate actual load conditions and successfully complete the testing and verification of the automatic disengagement function.

[0023] Specifically, the turning gear mounting system consists of three independent mounting platforms: a first mounting platform, a second mounting platform, and a third mounting platform. The first mounting platform is specifically designed for small electric turning gears. This platform supports not only radial meshing between the turning gear 5 and the connecting gear 6 but also axial meshing, providing flexible and stable installation and operating conditions for the small electric turning gear. The second mounting platform is mainly designed for end-face turning gears, and its structure is optimized for the working characteristics of end-face turning gears, ensuring a stable and efficient meshing state during operation. The third mounting platform is equipped with a flexible swing plate 4. This swing plate 4, under the action of the drive mechanism, precisely controls the relative position between the turning gear 5 and the connecting gear 6, thereby achieving stable and reliable radial meshing between them, providing crucial support and assurance for the overall operation of the turning gear system.

[0024] Furthermore, the load simulation system employs a magnetic powder brake 9, which can apply adjustable torque to effectively simulate the impact loads experienced by the rotor during startup, as well as various damping effects of the rotor during operation.

[0025] Furthermore, the speed synchronization and disengagement simulation system mainly consists of a core component, a friction clutch 10, and a variable frequency motor 11 as the power source. The two work together to achieve specific functions. The specific operation process is as follows: When the turning gear successfully reaches the preset rated operating speed, the system immediately initiates a synchronization control program, ensuring that the output speed and rotation direction of the variable frequency motor 11 are completely consistent with the turning gear state. Immediately afterwards, after the magnetic powder brake 9 receives a power-off command and releases the brake, the friction clutch 10, which is in a standby state, smoothly enters the engagement stage, thus achieving reliable engagement with the motor shaft. Afterward, based on the engagement of the friction clutch 10, the variable frequency motor 11 continues to take over the driving task and simulates the actual rotor's acceleration process in subsequent stages according to a preset control curve. This simulated acceleration process continues until the system meets the preset disengagement conditions, at which point the turning gear automatically and reliably disengages from the drive connection, thus completing the entire speed synchronization and disengagement simulation process.

[0026] Furthermore, the measurement system mainly consists of three core components: a speed sensor 13, a speed measuring disk 14, and a torque sensor 15. The speed sensor 13 and the speed measuring disk 14 work together to monitor the current rotational speed of the load simulation system in real time and accurately, while the torque sensor 15 is mounted on the drive shaft 8 to measure the torque changes during the transmission process in real time.

[0027] Furthermore, the control system mainly consists of three parts: the control cabinet 12, the frequency converter, and the PLC controller. The control cabinet 12, as the core control unit, receives real-time signals from the speed sensor 13 and automatically and precisely regulates the variable frequency motor 11 based on these signals. Through this automated control process, the system not only achieves high-precision synchronization of speeds between various devices but also automatically verifies the disengagement process, thereby ensuring the reliability, efficiency, and automation level of the entire control process.

[0028] Furthermore, the control system integrates an AI optimization module, which can intelligently and automatically adjust the load curve and various key test parameters based on multiple experimental data collected during system operation, in order to achieve more precise control and performance optimization.

[0029] Furthermore, the first mounting platform of the rotary car installation system is equipped with a specially designed adjustable base, which allows for flexible position adjustment through a precision mechanical structure or an advanced hydraulic system to adapt to the installation requirements of different workpieces. Simultaneously, the third mounting platform of the system is equipped with a movable swing plate 4. This swing plate 4 can be driven by either a highly efficient and stable hydraulic system or a fast-responding and energy-saving pneumatic system, ensuring precise and stable completion of various complex swinging movements during operation, greatly improving the adaptability and work efficiency of the entire rotary car installation system.

[0030] The usage method of this embodiment is as follows: First, according to the type of turning gear to be tested, install it on the corresponding first turning gear mounting platform 1 (small electric turning gear, supporting radial / axial meshing), second turning gear mounting platform 2 (end face turning gear), or third turning gear mounting platform 3 (large turning gear). The turning gear 5 is reliably meshed with the connecting gear 6 by the swing plate 4, and the gear 6 group and the drive shaft 8 are connected. Next, set the starting torque of the magnetic powder brake 9 on the control cabinet 12, start the turning gear. At this time, the friction clutch 10 is in the disengaged state. Observe the turning gear's load operation status (vibration, temperature rise, meshing stability), and monitor the torque in real time through the torque sensor 15. When the turning gear reaches the rated speed, the speed sensor transmits the torque signal. Sensor 13 and speed measuring disc 14 collect the speed signal of magnetic powder brake 9 and transmit it to control cabinet 12. The variable frequency motor 11 is automatically started and controlled by the frequency converter to make its speed and direction completely synchronized with magnetic powder brake 9. After synchronization is completed, the power supply of magnetic powder brake 9 is cut off, the friction clutch 10 automatically engages, and the variable frequency motor 11 simulates the rotor speed-up process until the rated speed is reached. Finally, the entire process of automatic disengagement of the disc brake is observed and recorded (disengagement speed, disengagement torque, separation distance, time, etc.). Control cabinet 12 automatically generates curves and calculates the pass rate (repeated 10-20 times). The entire operation is automatically controlled by PLC and supports real-time display and data export on touch screen to ensure safe, efficient and accurate testing.

[0031] Finally, it should be noted that the above descriptions are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A turning gear test platform, comprising a turning gear installation system, a load simulation system, a speed synchronization system, and a platform base, characterized in that: The platform base is located at the bottom of the turning gear installation system, the load simulation system and the speed synchronization system. The turning gear installation system is located on the top left of the platform base and is used to fix different types of turning gears. The load simulation system is located at the center of the top of the platform base. One end of the load simulation system is equipped with a disengagement simulation system. The load simulation system includes a magnetic powder brake (9). The magnetic powder brake (9) is connected to a drive shaft (8). A gear set (7) is fixedly sleeved on the outer side of the shaft surface of the drive shaft (8). The gear set (7) is located on the right side of the magnetic powder brake (9). The tail end of the magnetic powder brake (9) is connected to a friction clutch (10). The other end of the friction clutch (10) is connected to a variable frequency motor (11) located on the right side of the platform extension arm structure. A control cabinet (12) is set on the top right side of the platform base. The control cabinet (12) collects the speed signal through a speed sensor (13) installed at the output end of the magnetic powder brake (9) and controls the variable frequency motor (11) to realize the load simulation and automatic disengagement function test.

2. The rotary testing platform according to claim 1, characterized in that: The turning wheel installation system includes a first mounting platform, a second mounting platform, and a third mounting platform; the first mounting platform is located at the top of the platform base and is adapted to a small electric turning wheel, supporting radial and axial meshing; the second mounting platform is located at the top of the first mounting platform and is adapted to an end face turning wheel; the third mounting platform is located at the top of the second mounting platform, and the top of the third mounting platform is equipped with a swing plate (4), and the driving turning wheel gear (5) meshes radially with the connecting gear (6) and the swing plate (4).

3. The rotary testing platform according to claim 2, characterized in that: The load simulation system is a magnetic powder brake (9), which applies adjustable torque to simulate rotor starting impact load and running damping.

4. The rotary testing platform according to claim 3, characterized in that: The speed synchronization and disengagement simulation system includes a friction clutch (10) and a variable frequency motor (11). When the turning gear reaches the rated speed, the variable frequency motor (11) synchronizes the speed and direction. After the magnetic powder brake (9) is de-energized, the friction clutch (10) engages, and the variable frequency motor (11) continues to simulate the rotor speed increase until the turning gear automatically disengages.

5. The rotary testing platform according to claim 4, characterized in that: The measurement system includes a speed sensor (13), a speed measuring disk (14), and a torque sensor; the speed sensor (13) and the speed measuring disk (14) work together to monitor the rotational speed of the load simulation system in real time, and the torque sensor is installed on the drive shaft (8).

6. The rotary testing platform according to claim 5, characterized in that: The control system includes a control cabinet (12), a frequency converter and a PLC controller; the control cabinet (12) automatically controls the variable frequency motor (11) according to the signal of the speed sensor (13) to realize the automatic verification of speed synchronization and disengagement process.

7. The rotary testing platform according to claim 6, characterized in that: The control system also includes an AI optimization module, which automatically adjusts the load curve and test parameters based on experimental data.

8. The rotary test platform according to claim 7, characterized in that: The first mounting platform of the rotating carriage installation system is equipped with a base that can adjust the angle and height, and the swing plate (4) of the third mounting platform is hydraulically driven.

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