Sand mold casting device of fan main shaft, fan main shaft and wind generating set

Abstract

The utility model provides a sand mold casting device of a fan main shaft, the fan main shaft and a wind generating set. The sand mold casting device comprises a sand mold, the sand mold comprises an outer sand mold, an inner sand core and a mold cavity defined by the outer sand mold and the inner sand core, the sand mold further comprises an external chilling block and / or an internal chilling block, the external chilling block is arranged around the mold cavity in the outer sand mold and exposed out of the mold cavity, and the internal chilling block is arranged in the outer sand mold and exposed out of the mold cavity. And the internal chilling block is arranged around the cavity in the inner sand core and is exposed from the cavity. According to the sand mold casting device for the fan main shaft, the comprehensive mechanical property of the fan main shaft can be improved.

Description

Technical Field

[0001] The utility model relates to the technical field of sand casting, in particular to a sand casting device for a fan main shaft, the fan main shaft and a wind turbine generator set. Background Art

[0002] The main shaft of a wind turbine is used to connect the impeller and the gearbox and bear complex axial and radial loads. As the power of wind turbines increases, it is necessary to improve the performance of the main shaft of the wind turbine.

[0003] The existing fan main shaft cannot guarantee that the low-temperature impact work meets the index while greatly improving the strength. From the research results of existing technologies, it is a contradiction to improve the strength and ensure the low-temperature impact work at the same time. Improving the strength will inevitably affect the low-temperature impact work. How to solve this problem has become the current research direction. Utility Model Content

[0004] One purpose of the utility model is to provide a sand casting device which can improve the comprehensive mechanical properties of a fan main shaft.

[0005] Another object of the utility model is to provide a sand casting device which can improve the structural density of the fan main shaft and reduce the number of shrinkage cavities.

[0006] Another object of the utility model is to provide a wind turbine main shaft with improved comprehensive mechanical properties and a wind turbine generator set including the wind turbine main shaft.

[0007] According to one aspect of the utility model, a sand casting device for a fan main shaft is provided, the sand casting device comprising a sand mold, the sand mold comprising an outer sand mold and an inner sand core and a mold cavity surrounded by the outer sand mold and the inner sand core, the sand mold further comprising an external chiller and / or an internal chiller, the external chiller being arranged around the mold cavity in the outer sand mold and exposed from the mold cavity, the internal chiller being arranged around the mold cavity in the inner sand core and exposed from the mold cavity.

[0008] Optionally, the ratio of the thickness of the external chiller and / or the internal chiller to the thickness of the portion of the fan main shaft covering the external chiller and / or the internal chiller is 0.5-1.5.

[0009] Optionally, the fan main shaft includes a shaft body, a large flange arranged at one axial end of the shaft body, a trumpet-shaped connecting piece connecting the shaft body and the large flange, and a small flange arranged at the other axial end of the shaft body.

[0010] Optionally, the external chill includes a first molded chill and a second molded chill, the first molded chill is arranged at a position corresponding to the upper end surface of the large flange and the outer peripheral surface of the trumpet-shaped connecting piece, and the second molded chill is arranged at a position corresponding to the lower end surface of the large flange.

[0011] Optionally, each of the first forming chill and the second forming chill is formed in at least two sections around the cavity.

[0012] Optionally, a thickness of each of the first forming chill and the second forming chill is greater than or equal to 200 mm.

[0013] Optionally, the coverage rate of the first formed chill is greater than or equal to 90%, and / or the coverage rate of the second formed chill is greater than or equal to 80%.

[0014] Optionally, the external chiller is also arranged at a position corresponding to the outer peripheral surface of the shaft body and the outer peripheral surface and / or the upper end surface of the small flange.

[0015] Optionally, the internal chiller is arranged at a position corresponding to the inner circumference of the trumpet-shaped connecting piece.

[0016] Optionally, the internal chiller is also arranged at a position corresponding to the inner end surface of the small flange.

[0017] Optionally, the sand casting device further comprises a pouring system, and the pouring system is a bottom pouring system.

[0018] Optionally, the sand mold includes a riser, and the riser includes at least one of a top riser, a middle section riser and a heat-generating riser, the top riser is arranged at a position corresponding to the outer end of the small flange, the middle section riser is arranged at a position corresponding to the outer wall of the shaft body, and the heat-generating riser is arranged at a position corresponding to the inner cavity of the trumpet-shaped connector.

[0019] According to another aspect of the present invention, a main shaft of a fan is provided, wherein the main shaft of the fan is formed by using the sand casting device as described above.

[0020] Optionally, the outer diameter of the shaft of the fan main shaft is greater than or equal to 1.0 m.

[0021] According to another aspect of the present invention, a wind turbine generator set is provided, wherein the wind turbine generator set comprises the wind turbine main shaft as described above.

[0022] According to the sand casting device for the fan main shaft of the utility model, the comprehensive mechanical properties of the fan main shaft can be improved. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] The above and other purposes, features and advantages of the present invention will become more apparent through the following detailed description in conjunction with the accompanying drawings, in which:

[0024] Figure 1 A wind turbine main shaft of a wind turbine generator set according to an embodiment of the utility model;

[0025] Figure 2 yes Figure 1 Axial cross-section of

[0026] Figure 3 is a schematic diagram of a sand mold according to an embodiment of the utility model;

[0027] Figure 4 It is a three-dimensional diagram of a sand casting device for a fan main shaft according to an embodiment of the utility model;

[0028] Figure 5 yes Figure 4 Axial cross-section of

[0029] Figure 6 is a three-dimensional diagram of a sand casting device for a fan main shaft according to another embodiment of the utility model;

[0030] Figure 7 yes Figure 6 Axial cross-section of . DETAILED DESCRIPTION

[0031] The following will be combined with the drawings in the embodiments of the utility model to clearly and completely describe the technical solutions in the embodiments of the utility model. Obviously, the described embodiments are only part of the embodiments of the utility model, not all of the embodiments. Based on the embodiments in the utility model, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the utility model.

[0032] Unless otherwise defined, all technical and scientific terms used herein have the same meanings as those commonly understood by those skilled in the art. The terms used in the specification of the present invention are only for the purpose of describing specific embodiments and are not intended to limit the present invention.

[0033] In addition, unless there are contradictory descriptions, the various embodiments described below can also be combined with each other. In addition, unless otherwise specified, the devices with the same reference numerals in various embodiments have the same structure, and no redundant description is provided.

[0034] Below, we will refer to Figures 1 to 7 The invention describes a sand casting device, a wind turbine main shaft and a wind turbine generator set according to the embodiments of the invention. Figure 1The main shaft of the wind turbine generator set according to the embodiment of the utility model, Figure 2 yes Figure 1 Axial cross-section of Figure 3 is a schematic diagram of a sand mold according to an embodiment of the utility model, Figure 4 This is a three-dimensional diagram of a sand casting device for a fan main shaft according to an embodiment of the utility model. Figure 5 yes Figure 4 Axial cross-section of Figure 6 is a three-dimensional diagram of a sand casting device for a fan main shaft according to another embodiment of the utility model. Figure 7 yes Figure 6 Axial cross-section of .

[0035] According to an embodiment of the present invention, a sand casting device for a fan main shaft may include a sand mold 100 , wherein the sand mold 100 includes an outer sand mold 110 , an inner sand core 120 , and a mold cavity 130 surrounded by the outer sand mold 110 and the inner sand core 120 .

[0036] like Figure 1 and Figure 2 As shown, one end of the fan main shaft 20 ( Figure 1 The left end of the fan shaft 20 is used to connect with the impeller of the wind turbine generator set, and the other end of the fan main shaft 20 ( Figure 1 The right end in FIG. 2 is used to connect with the gear box of the wind turbine generator set. The wind turbine main shaft 20 may include a shaft body 21, a large flange 22 disposed at one end of the wind turbine main shaft 20, and a trumpet-shaped connecting member 23 connecting the shaft body 21 and the large flange 22. In addition, the wind turbine main shaft 20 may also include a small flange 24 disposed at the other end of the wind turbine main shaft 20.

[0037] As an example, the outer diameter of the shaft body 21 may be greater than or equal to 1 m. The large flange 22 may be provided at the radial large end of the fan main shaft 20 for connecting to the impeller of the wind turbine generator set, and the small flange 24 may be provided at the radial small end of the fan main shaft 20 for connecting to the gearbox of the wind turbine generator set. The large flange 22, the trumpet-shaped connector 23 and the small flange 24 are used to connect other rotating parts, and the loads they bear are large and complex, and their comprehensive mechanical properties need to be guaranteed.

[0038] like Figure 3As shown, the sand mold 100 may include an outer sand mold 110 and an inner sand core 120, and the outer sand mold 110 and the inner sand core 120 surround a molding cavity 130. The outer shape of the outer sand mold 110 is determined by the inner cavity shape of the sand box and is not specifically limited. The inner shape of the outer sand mold 110 can be determined by the outer mold and is consistent with the outer shape of the fan main shaft 20. The outer shape of the inner sand core 120 is consistent with the inner cavity shape of the fan main shaft 20. As needed, the outer sand mold 110 and the inner sand core 120 can be divided into multiple sections in the axial direction. As an example, the outer sand mold 110 can be divided into at least three sections in the axial direction, and the inner sand core 120 can be divided into at least two sections in the axial direction to facilitate production and manufacturing.

[0039] According to an embodiment of the present invention, the mold cavity 130 may include an axial cavity 131 for forming the shaft body 21, a large flange cavity 132 for forming the large flange 22, a trumpet cavity 133 for forming the trumpet-shaped connector 23, and a small flange cavity 134 for forming the small flange 24. The above division of the mold cavity 130 is a functional division and does not represent a physical division of the structure.

[0040] According to an embodiment of the present invention, the sand mold 100 may further include an external chill 141 and / or an internal chill 142, wherein the external chill 141 is disposed around the mold cavity 130 in the outer sand mold 110 and exposed from the mold cavity 130, and the internal chill 142 is disposed around the mold cavity 130 in the inner sand core 120 and exposed from the mold cavity 130. According to an embodiment of the present invention, by disposing the external chill 141 and / or the internal chill 142 at a key position, the structural density of the fan main shaft 20 can be improved by strong quenching to improve the comprehensive mechanical properties.

[0041] According to an embodiment of the utility model, the chilling effect can be improved by controlling the ratio of the thickness of the chill and the thickness of the corresponding part of the fan main shaft 20. As an example, the ratio of the thickness of the outer chill 141 and / or the inner chill 142 to the thickness of the part of the fan main shaft on which the outer chill 141 and / or the inner chill 142 are covered is 0.5-1.5. As an example, the ratio is 0.5-1.0.

[0042] According to the embodiments of the present utility model, Figure 4 and Figure 5 As shown, the external chill 141 may include a first formed chill 141a and a second formed chill 141b. The first formed chill 141a is disposed at a position corresponding to the upper end surface of the large flange 22 and the outer peripheral surface of the trumpet-shaped connector 23, and the second formed chill 141b may be disposed at a position corresponding to the lower end surface of the large flange 22.

[0043] like Figure 4As shown, each of the first formed chill 141a and the second formed chill 141b forms at least two sections around the cavity 130, for example, three sections, four sections or more sections. The upper limit of the number of sections of each of the first formed chill 141a and the second formed chill 141b is not specifically limited, and as an example, it can be less than or equal to 10 sections. By arranging the first formed chill 141a and the second formed chill 141b in sections, the versatility of the two can be improved. That is, when producing fan main shafts of different sizes, the number of formed chills can be adjusted to achieve surrounding the entire cavity 130.

[0044] A predetermined interval may be formed between adjacent first formed chills 141a, and a predetermined interval may also be formed between adjacent second formed chills 141b. The coverage of the first formed chill 141a may be increased by reducing the interval between adjacent first formed chills 141a and reducing the number of segments of the first formed chill 141a, thereby improving the chilling effect. Similarly, the coverage of the second formed chill 141b may be increased by reducing the interval between adjacent second formed chills 141b and reducing the number of segments of the second formed chill 141b, thereby improving the chilling effect. That is, compared with the case where a small piece of chill is used to cover the trumpet-shaped connector 23 and the large flange 22, by forming the first formed chill 141a and the second formed chill 141b, it is easy to adjust the coverage, thereby improving the chilling effect.

[0045] like Figure 4 and Figure 5 As shown, along the axial direction of the fan main shaft 20, each section of the first molded cold iron 141a is integrally formed on the outer peripheral surface of the trumpet-shaped connecting piece 23 and the upper end surface of the large flange 22, thereby facilitating the improvement of its quenching effect.

[0046] According to an embodiment of the present invention, the thickness of each of the first and second formed chills 141a and 141b is greater than or equal to 200 mm. According to an embodiment of the present invention, preferably, the thickness of each of the first and second formed chills 141a and 141b is greater than or equal to 230 mm.

[0047] like Figure 5 As shown, the wall thickness of the large flange 22 and the trumpet-shaped connector 23 of the fan main shaft 20 is relatively thick, and the large flange 22 and the trumpet-shaped connector 23 are the locations connected to the impeller, and the loads they are subjected to are large and complex, so it is necessary to ensure a high organizational density to improve the comprehensive mechanical properties. According to the embodiment of the utility model, by making the thickness of each of the first formed chill 141a and the second formed chill 141b greater than or equal to 200mm, the cooling rate of the molten iron can be effectively increased, the grains can be refined, and the organizational density can be improved.

[0048] According to an embodiment of the utility model, the coverage rate of the first forming chill 141a can be greater than or equal to 90%, and the coverage rate of the second forming chill 141b can be greater than or equal to 80%. Coverage rate refers to the area ratio covered by the first forming chill 141a or the second forming chill 141b around the cavity 130. According to the utility model, by making the coverage rate of the first forming chill 141a greater than or equal to 90% or the coverage rate of the second forming chill 141b greater than or equal to 80%, the cooling rate of the molten iron can be effectively increased, the grains can be refined, and the density of the structure can be improved.

[0049] like Figure 4 and Figure 5 As shown, the external chill 141 may also be arranged at a position corresponding to the outer peripheral surface of the shaft body 21 and the outer peripheral surface of the small flange 24. The external chill 141 arranged at this position may be a small piece of chill, and is arranged around the outer peripheral surface of the shaft body 21 and the small flange 24. However, the utility model is not limited thereto, and at least a portion of the external chill 141 surrounding the shaft body 21 and the small flange 24 may also form a large piece of shaped chill. As an example, the thickness of the external chill 141 surrounding the shaft body 21 and the small flange 24 may be less than the thickness of the first shaped chill 141a and the second shaped chill 141b, for example, greater than or equal to 70 mm, or greater than or equal to 100 mm.

[0050] Although not shown, according to an embodiment of the present invention, the external chill 141 may also be disposed at a position corresponding to the upper end surface of the small flange 24 to improve the chilling effect of the small flange 24. The thickness of the external chill 141 disposed at a position corresponding to the upper end surface of the small flange 24 may be less than the thickness of the first molded chill 141a and the second molded chill 141b, for example, greater than or equal to 100 mm.

[0051] According to the embodiments of the present utility model, Figure 5 As shown, the internal chiller 142 may be disposed at a position corresponding to the inner circumference of the trumpet-shaped connection member 23. In addition, although not shown, the internal chiller 142 may also be disposed at a position corresponding to the inner end surface of the small flange 24.

[0052] According to an embodiment of the present invention, the sand mold 100 may further include a riser. Figures 4 to 7 As shown, the riser may include at least one of a top riser 151 , a middle section riser 152 , and a heat generating riser 153 .

[0053] The top riser 151 can be a clear riser, which is set at a position corresponding to the outer end of the small flange 24 for heat preservation, slag removal and exhaust. The specific structure and number of the top riser 151 are not limited, but the riser form known in the art can be applied. As an example, an outlet 161 can also be set on the top riser 151 for exhaust.

[0054] like Figure 4 As shown, the middle section riser 152 can be arranged at a position corresponding to the outer wall of the shaft body 21. The middle section riser 152 is a blind riser. Figure 4 As shown, the blind riser is set at the position of the shaft body 21 where the external chiller 141 is not set. At the position where the external chiller 141 is set, the molten iron is rapidly cooled, but there is a tendency of shrinkage at the position where the external chiller 141 is not set. Therefore, the middle section riser 152 is set at the position where the external chiller 141 is not set to compensate for shrinkage, thereby improving the structural density of the fan main shaft 20. However, the utility model is not limited to this. Figure 6 As shown, the intermediate riser 152 may not be provided, but the external chiller 141 may be completely covered at the position corresponding to the shaft body 21. The specific structure and number of the intermediate riser 152 are not limited.

[0055] like Figure 5 and Figure 7 As shown, the heat-generating riser 153 can be arranged at a position corresponding to the inner cavity of the trumpet-shaped connector 23. The specific structure and number of the heat-generating riser 153 are not limited. The material of the heat-generating riser 153 can be ignited when casting molten iron, and the heat released increases the temperature of the molten iron in the riser, prolongs the solidification time of the molten iron in the riser, prolongs the shrinkage feeding time, and improves the shrinkage feeding efficiency of the riser on the casting.

[0056] According to an embodiment of the utility model, the sand casting device may further include a pouring system, and the pouring system may be a bottom pouring pouring system. The structure of the bottom pouring pouring system is not limited. As an example, Figure 4 and Figure 5 As shown, the pouring system may include a sprue 171, a disc cavity 172 communicating with the sprue 171, a runner 173 communicating with the disc cavity 172, and an entrapment 174 communicating with the runner 173 and the cavity 130. The sprue 171 may be external, that is, disposed outside the sand mold 100 and extending to communicate with the disc cavity 172. As an example, Figure 6 and Figure 7 As shown, the sprue 171 may be an internal type, that is, it is disposed through the sand core 120 and extends to communicate with the disc cavity 172 .

[0057] According to the utility model, by using a sand casting device including an external chiller 141 and / or an internal chiller 142 to manufacture the fan main shaft, the structural density of the fan main shaft can be improved through strong quenching, and the comprehensive mechanical properties of various key parts of the fan main shaft can be improved.

[0058] Example

[0059] Pour molten iron into Figure 4 and Figure 5In the sand casting device of the embodiment including the external chiller 141 and the internal chiller 142, a fan main shaft is formed after solidification, and the composition of the fan main shaft is: C 3.71wt%, Si 2.48wt%, Mn 0.125wt%, P0.025wt%, S 0.02wt%, Ni 0.46wt%, Cr 0.011wt%, Mg0.05wt%, and the rest is iron and unavoidable impurities.

[0060] Comparative Example

[0061] The same molten iron as in the embodiment is poured into a common sand casting device without a chiller, and the fan main shaft is formed after solidification.

[0062] Performance Testing

[0063] According to the following testing method, samples were taken from the shaft body, large flange and small flange of the cast fan main shaft, and the tensile strength, yield strength and low-temperature impact energy were tested, and the results are listed in Table 1.

[0064] (1) Tensile strength: tested according to the method specified in GB / T 228.1;

[0065] (2) Yield strength: tested according to the method specified in GB / T 228.1;

[0066] (3) Low-temperature impact toughness at -20℃: tested according to the method specified in GB / T 229.

[0067] Table 1

[0068]

[0069] As shown in Table 1, compared with a main shaft cast by a common sand casting device without a chiller, the comprehensive mechanical properties of various parts of the main shaft cast by the sand casting device according to the utility model are significantly improved.

[0070] According to an embodiment of the utility model, a fan main shaft formed by the above-mentioned sand casting device can also be provided. The fan main shaft can be the fan main shaft 20 as described above, and no repeated description is given here.

[0071] According to another embodiment of the present invention, a wind turbine generator set including a wind turbine main shaft 20 may also be provided.

[0072] According to the sand casting device for the fan main shaft of the utility model, the comprehensive mechanical properties of the fan main shaft can be improved.

[0073] Although the exemplary embodiments of the present invention have been described in detail with reference to exemplary embodiments thereof, those skilled in the art will understand that various changes in form and details may be made thereto without departing from the spirit and scope of the present invention as defined by the claims.

Claims

1. A sand casting device for a fan main shaft, the sand casting device comprising a sand mold (100), the sand mold (100) comprising an outer sand mold (110) and an inner sand core (120), and a mold cavity (130) surrounded by the outer sand mold (110) and the inner sand core (120), It is characterized in that The sand mold (100) further comprises an external chill (141) and / or an internal chill (142), wherein the external chill (141) is arranged around the mold cavity (130) in the outer sand mold (110) and is exposed from the mold cavity (130), and the internal chill (142) is arranged around the mold cavity (130) in the inner sand core (120) and is exposed from the mold cavity (130).

2. The sand casting device for the fan main shaft according to claim 1, characterized in that: The ratio of the thickness of the external chiller (141) and / or the internal chiller (142) to the thickness of the portion of the fan main shaft (20) covering the external chiller (141) and / or the internal chiller (142) is 0.5-1.

5.

3. The sand casting device for the fan main shaft according to claim 1 or 2, characterized in that: The fan main shaft (20) comprises a shaft body (21), a large flange (22) arranged at one axial end of the shaft body (21), a trumpet-shaped connecting piece (23) connecting the shaft body (21) and the large flange (22), and a small flange (24) arranged at the other axial end of the shaft body (21).

4. The sand casting device for the fan main shaft according to claim 3 is characterized in that: The external chill (141) includes a first molded chill (141a) and a second molded chill (141b), wherein the first molded chill (141a) is arranged at a position corresponding to the upper end surface of the large flange (22) and the outer peripheral surface of the trumpet-shaped connecting piece (23), and the second molded chill (141b) is arranged at a position corresponding to the lower end surface of the large flange (22).

5. The sand casting device for the fan main shaft according to claim 4, characterized in that: Each of the first forming chill (141a) and the second forming chill (141b) forms at least two sections around the mold cavity (130).

6. The sand casting device for the fan main shaft according to claim 4, characterized in that: The thickness of each of the first formed chill (141a) and the second formed chill (141b) is greater than or equal to 200 mm.

7. The sand casting device for the fan main shaft according to claim 4, characterized in that: The coverage rate of the first formed chill (141a) is greater than or equal to 90%, and / or the coverage rate of the second formed chill (141b) is greater than or equal to 80%.

8. The sand casting device for the fan main shaft according to claim 3, characterized in that: The external cold iron (141) is also arranged at a position corresponding to the outer peripheral surface of the shaft body (21) and the outer peripheral surface and / or the upper end surface of the small flange (24).

9. The sand casting device for the fan main shaft according to claim 3, characterized in that: The internal cold iron (142) is arranged at a position corresponding to the inner circumference of the trumpet-shaped connecting piece (23).

10. The sand casting device for the fan main shaft according to claim 9, characterized in that: The internal chiller (142) is also arranged at a position corresponding to the inner end surface of the small flange (24).

11. The sand casting device for a fan main shaft according to claim 1, characterized in that: The sand casting device also includes a pouring system, and the pouring system is a bottom pouring system.

12. The sand casting device for the fan main shaft according to claim 4, characterized in that: The sand mold (100) comprises a riser, wherein the riser comprises at least one of a top riser (151), a middle section riser (152) and a heat-generating riser (153); the top riser (151) is arranged at a position corresponding to an outer end of the small flange (24); the middle section riser (152) is arranged at a position corresponding to an outer wall of the shaft body (21); and the heat-generating riser (153) is arranged at a position corresponding to an inner cavity of the trumpet-shaped connecting piece (23).

13. A fan main shaft, characterized in that: The fan main shaft is formed by using the sand casting device according to any one of claims 1 to 12.

14. The fan main shaft according to claim 13, characterized in that: The outer diameter of the shaft body (21) of the fan main shaft (20) is greater than or equal to 1.0 m.

15. A wind turbine generator set, characterized in that: The wind turbine generator set comprises a wind turbine main shaft (20) according to claim 13 or 14.

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