A device for machining the grooves of a pumped storage rotor.

Abstract

This utility model relates to the field of yy technology, specifically disclosing a pumped storage rotor wheel groove processing device. Through the cooperation of a movable guide rail and a drive trolley, the frame can be flexibly moved and precisely positioned in the wheel groove repair area at the power station site. The movable frame is connected to the guide rail via a first support rod and fixed to the drive trolley via a second support rod, forming a stable support structure to prevent equipment shaking during processing. Demountable processing components (such as laser cladding equipment) achieve three-dimensional adjustment via a fourth track, a first movable seat, and a second drive component, adapting to different wheel groove repair needs. The accommodating space on top of the drive trolley can be used to install auxiliary components, simplifying on-site pipeline layout. This device can complete processing on-site without disassembling the rotor, solving the problems of poor on-site adaptability and complex installation and commissioning of traditional fixed equipment, providing a modular and mobile technical solution for efficient maintenance of pumped storage rotor wheel grooves.

Description

Technical Field

[0001] This utility model relates to the field of yy technology, and in particular to a device for processing the groove of a pumped storage rotor. Background Technology

[0002] In the operation of pumped storage power stations, the rotor is a key component, and the condition of its wheel grooves directly affects power generation efficiency and stability. Pumped storage rotors are typically enormous, with diameters reaching several meters and weights often reaching hundreds of tons. When problems such as wear and cracks in the rotor wheel grooves require repair, traditional maintenance methods face numerous challenges.

[0003] The existing technology, as represented by patent "CN202010106160.X, a field processing device for the keyway of a generator rotor bracket," attempts to solve the field processing problem to some extent, but still has significant drawbacks. Traditional methods require disassembling the rotor from the power station and transporting it to a factory for processing. This process requires customized large-scale transportation equipment and auxiliary operations such as road modifications and bridge reinforcement, resulting in a single transportation cost of hundreds of thousands of yuan, with a transportation cycle typically lasting 1-2 weeks. This prolonged transportation not only incurs high economic costs but also causes extended power station downtime. Statistics show that a single day of downtime at a large pumped storage power station can result in a power generation loss of several million yuan.

[0004] Moreover, traditional processing equipment is mostly fixed in structure. While the equipment in the aforementioned patent can be installed and adjusted on-site for machining magnetic yoke keyways, it lacks adaptability to the comprehensive maintenance scenarios of pumped storage rotor grooves. Using such equipment in a factory workshop requires high-precision foundation pouring and complex equipment debugging, making it difficult to apply directly to the power plant site. Even if forced on-site deployment, debugging time can take several days or even longer, further extending the maintenance cycle. Furthermore, the rotor is prone to slight deformation during transportation due to vibration and other factors. Upon returning to the factory for machining, the repositioning and calibration process is complex, and secondary clamping errors can severely affect the groove machining accuracy. For example, if the groove depth and width tolerances exceed 0.5mm, the rotor-stator fit will fail, significantly impacting the power plant's operational performance.

[0005] Therefore, a completely new technical solution is urgently needed to address key issues such as equipment portability and on-site adaptability in the field maintenance of pumped storage rotors. Utility Model Content

[0006] In view of this, this utility model provides a pumped storage rotor groove processing device to solve the problem that pumped storage rotors are large and heavy, and traditional maintenance requires disassembling the rotor from the power station and transporting it to the factory for processing, which is costly and time-consuming, resulting in long power station downtime and affecting power generation efficiency.

[0007] This utility model provides a pumped storage rotor groove processing device, comprising: a frame including a movable guide rail disposed on the ground and a movable frame movable based on the movable guide rail; a drive unit including a drive trolley disposed on the movable guide rail and a first drive component for driving the drive trolley to move on the movable guide rail; and a processing assembly detachably disposed on the movable frame; the movable guide rail including a first track, a second track, and a third track, the movable guide rail being disposed on the second track and the third track; a processing area being formed between the first track and the second track; one side of the movable frame being disposed on the first guide rail, and the other side being disposed on the drive trolley, and moving along with the movement of the drive trolley.

[0008] Preferably, the first track, the second track, and the third track are each composed of at least one guide rail base; the guide rail bases are connected by tenon and mortise joints, and the guide rail bases are fixed to the ground by a number of screws or bolts.

[0009] Preferably, the movable frame includes a movable rod and a first support rod and a second support rod disposed at both ends of the movable rod; the first support rod is connected to the first guide rail, and the second support rod is disposed on the drive trolley.

[0010] Preferably, the bottom of the first support rod is further provided with a roller mounting rod; both ends of the roller mounting rod are provided with movable rollers connected to the first guide roller.

[0011] Preferably, the bottom of the drive trolley is provided with movable wheels connected by a rotating shaft; the rotating shaft is driven by a first drive component disposed on the drive trolley.

[0012] Preferably, the mobile trolley is provided with a accommodating space for installing the first driving component and the auxiliary components of the processing component, so that the auxiliary components of the processing component move synchronously with the processing component.

[0013] Preferably, the moving rod is provided with a pair of fourth rails and a first moving seat that can move based on the fourth rails; the first moving seat is also provided with a second driving component, and the second driving component is provided with a second moving seat that can move based on the second driving component; the processing component is detachably disposed on the second moving seat.

[0014] Preferably, the bottom of the second movable seat is also provided with a connecting arm.

[0015] Preferably, the working components include at least one of laser cladding equipment, electron beam filament deposition equipment, ultrasonic processing equipment, and electroplating equipment.

[0016] The pumped storage rotor groove processing device provided by this utility model has the following beneficial effects:

[0017] The pumped storage rotor groove processing device provided in this utility model achieves rapid on-site deployment and processing through the coordinated design of movable guide rails and detachable processing components. The movable guide rails, in conjunction with the drive trolley, allow the equipment to move flexibly and be precisely positioned at the power plant site to the groove repair location, avoiding the high costs and prolonged downtime associated with traditional transportation. The processing components are detachable and replaceable, adaptable to various repair processes such as laser cladding equipment. Combined with the trolley's space-adaptive design for auxiliary components, this significantly improves on-site repair efficiency, shortens the repair cycle, and reduces transportation costs, effectively solving the technical challenges of on-site repair of large rotors. Furthermore, the device adopts a modular assembly and disassembly design, allowing the disassembled independent modules to be combined during on-site transportation, reducing transport volume. Upon arrival at the site, it can be quickly assembled using mortise and tenon joints and bolt fixing, achieving "ready to use immediately," completely solving the technical problems of complex on-site installation and inconvenient transportation associated with traditional fixed processing equipment. Attached Figure Description

[0018] To more clearly illustrate the technical solutions of the embodiments of this utility model, the drawings used in the embodiments of this utility model will be briefly introduced below. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort, and these are all within the protection scope of this utility model.

[0019] Figure 1 This is a schematic diagram of a pumped storage rotor groove processing device;

[0020] Figure 2 This is a side structural schematic diagram of a pumped storage rotor wheel groove processing device;

[0021] Figure 3 This is a schematic diagram of a pumped storage rotor groove processing device from another angle;

[0022] Figure 4 This is a partial structural schematic diagram of a pumped storage rotor groove processing device;

[0023] Parts and component numbers in the diagram:

[0024] 100-Moving guide rail, 111-First track, 112-Second track, 113-Third track, 114-Guide rail base, 120-Moving frame, 121-Moving rod, 122-Fourth track, 123-First moving seat, 124-Second driving component, 125-Rack, 126-Second moving seat, 127-Third driving component, 128-Threaded sleeve, 129-Screw, 130-Connecting arm, 141-First support rod, 142-Roller mounting rod, 143-Moving roller, 144-Second support rod;

[0025] 210-Drive trolley, 211-Rotating shaft, 212-Moving wheel, 213-First drive component, 220-Accommodation space, 230-Auxiliary component;

[0026] 300 - Processing components, 310 - Laser cladding equipment. Detailed Implementation

[0027] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. It should be noted that, in this document, relational terms such as "first" and "second" are merely used to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. In the description of this utility model, it should be understood that the terms "center," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings, and are only for the convenience of describing this application and 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, and therefore should not be construed as a limitation of this utility model. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element. Unless otherwise specified, embodiments of the present invention and the various features thereof can be combined with each other, all within the protection scope of the present invention.

[0028] Example 1

[0029] Please see Figure 1This utility model provides a device for machining the grooves of a pumped-storage rotor. When a pumped-storage rotor malfunctions or requires routine maintenance, the usual practice is to disassemble the rotor and transport it to a specialized repair shop for comprehensive inspection and repair. However, due to the large size and complex structure of pumped-storage rotors, their transportation requires not only special transport vehicles and equipment but also consideration of road conditions and traffic restrictions along the way, making the transportation work extremely difficult and time-consuming. Furthermore, long-distance transportation not only increases transportation costs but may also cause secondary damage to the rotor due to bumps and vibrations during the journey, further extending the maintenance cycle. Therefore, considering all factors, on-site machining and repair at the pumped-storage power station is a more reasonable and efficient choice. On-site repair can significantly shorten repair time and reduce transportation costs, effectively avoiding potential risks and damage during transportation, ensuring the rotor can be restored to operation as soon as possible, and guaranteeing the normal power generation and peak-shaving functions of the power station.

[0030] Therefore, this embodiment provides a pumped storage rotor groove processing device for repairing and processing rotor grooves on-site at a pumped storage power station.

[0031] Please see Figure 1 The processing device includes a frame, a drive unit, and processing components. The frame includes a movable guide rail 100 mounted on the ground and a movable frame 120 that can move based on the movable guide rail 100. The drive unit includes a drive trolley 210 mounted on the movable guide rail 100 and a first drive component 213 that drives the drive trolley 210 to move on the movable guide rail 100. The processing components 300 are detachably mounted on the movable frame 120. The movable guide rail 100 includes a first track 111, a second track 112, and a third track 113, and the movable guide rail 100 is mounted on the second track 112 and the third track 113. A processing area 115 is formed between the first track 111 and the second track 112. One side of the movable frame 120 is mounted on the first guide rail, and the other side is mounted on the drive trolley 210, and moves with the drive trolley 210.

[0032] In use, the first track 111, the second track 112, and the third track 113 are laid out in the expected positions, with a processing area 115 reserved between the first track 111 and the second track 112. The movable frame 120 is then assembled and installed on the first track 111, the second track 112, and the third track 113. The processing component 300 is then installed on the movable frame 120. The drive unit is then activated, causing the drive trolley 210 to move the movable frame 120 on the first track 111 and the second track 112, thereby causing the movable frame 120 to move smoothly on the third track 113. The processing component 300 moves with the movable frame 120 into the reserved processing area 115, and through manual operation, the rotor wheel groove repair processing begins.

[0033] In addition, the processing component 300 also includes a cooling component, which is mounted on the mobile trolley and can move along with the mobile trolley; the cooling component is used to cool the wheel groove during the processing to avoid changes in material properties or a decrease in processing quality due to high temperature.

[0034] Furthermore, it also includes a base plate 150, on which the first track 111, the second track 112, and the third track 113 can all be laid. Considering that actual ground often has varying degrees of unevenness, in order to effectively solve this problem, the base plate 150 is laid evenly and firmly on the processing site, thereby ensuring that the flatness of the entire ground reaches an ideal state. The base plate 150 is not a single structure, but is composed of one or more base plates. Each pair of base plates is connected by a traditional mortise and tenon joint. This connection method is not only firm and reliable, but also effectively improves the overall stability and service life of the base plate 150.

[0035] Please see Figure 1 During use, the first track 111, the second track 112, and the third track 113 must first be laid smoothly on the floor surface, ensuring that the track installation positions are accurate and secure. Then, the moving frame 120, the processing component 300, and the moving trolley are sequentially installed on the first track 111, the second track 112, and the third track 113, ensuring a tight connection between each component and the track to guarantee the normal operation of the entire system. In this state, both ends of the rotor are firmly fixed by support frames located outside the base plate 150. This is to avoid unnecessary damage to the base plate 150 due to the rotor's own weight, thereby effectively extending the service life of the equipment and ensuring operational safety.

[0036] The base plate 150 not only provides a flat and stable processing platform but also distributes the pressure of the tracks and equipment on the ground to a certain extent, thus preventing ground damage caused by excessive local stress. Furthermore, the modular design of the base plate 150 facilitates transportation and installation, especially in large processing areas. The laying range of the base plate 150 can be flexibly adjusted according to actual needs, adapting to processing tasks of different scales. This approach not only improves construction efficiency but also reduces subsequent maintenance costs, providing a reliable guarantee for the long-term stable operation of the entire processing unit.

[0037] In this embodiment, the device is compact in design and has good adaptability and flexibility, and can be quickly adjusted according to the rotor size, groove specifications and processing methods of different models.

[0038] Further, please see Figure 1 The first track 111, the second track 112 and the third track 113 are each composed of at least one guide rail base 114; the two guide rail bases 114 are connected by tenon and mortise, and the guide rail base 114 is fixed to the ground by a number of screws or bolts.

[0039] In this embodiment, mortise and tenon joints ensure a stable and precise connection between the tracks, while also facilitating disassembly and reassembly. The use of mortise and tenon joints not only enhances the overall integrity of the tracks but also absorbs vibrations to a certain extent, thereby improving stability during processing. Furthermore, fixing the guide rail base 114 with screws or bolts allows for more flexible track installation, enabling quick adjustments to position or replacement of damaged components as needed. This design, while ensuring processing accuracy, significantly reduces maintenance difficulty and costs, further supporting the efficient operation of the device.

[0040] Furthermore, the movable frame 120 includes a movable rod 121 and a first support rod 141 and a second support rod 144 disposed at both ends of the movable rod 121; the first support rod 141 is connected to the first guide rail, and the second support rod 144 is disposed on the drive trolley 210.

[0041] The bottom of the first support rod 141 is also provided with a roller mounting rod 142; both ends of the roller mounting rod 142 are provided with movable rollers 143 connected to the first guide roller.

[0042] Please see Figure 2 and Figure 3 The bottom of the driving trolley 210 is provided with movable wheels 212 connected by a rotating shaft 211; the rotating shaft 211 is driven by a first driving component 213 disposed on the driving trolley 210.

[0043] Furthermore, the mobile trolley is provided with a accommodating space 220, which is used to install the first driving component 213 and the auxiliary component 230 of the processing component 300, and to enable the auxiliary component 230 of the processing component 300 to move synchronously with the processing component 300.

[0044] Further, please see Figure 4 The moving rod 121 is provided with a pair of fourth rails 122 and a first moving seat 123 that can move based on the fourth rails 122; the first moving seat 123 is also provided with a second driving component 124, and the second driving component 124 is provided with a second moving seat 126 that can move based on the second driving component 124; the processing component 300 is detachably disposed on the second moving seat 126.

[0045] The bottom of the second movable base 126 is also provided with a connecting arm 130. The connecting arm 130 can extend the installation range of the processing assembly 300, and the connecting arm 130 can rotate based on the second movable base 126 to achieve multi-angle processing.

[0046] Furthermore, the first and second drive components are precisely coupled and driven by gears on the drive shaft of the motor and racks 125 located at the top of the moving rod 121, thereby effectively realizing the lateral movement of the processing assembly 300 in the horizontal direction. This transmission method not only ensures the smoothness of movement but also improves the transmission efficiency of the entire system.

[0047] The second movable seat 126 is precisely driven by a third driving component 127. This third driving component specifically includes a threaded sleeve 128 mounted on the first movable seat 123, and a slide rail and a screw 129 mounted on the second movable seat 126. The screw 129 and the threaded sleeve 128 are precisely connected via a transmission mechanism, ensuring the stability and reliability of the transmission. The screw 129 is efficiently driven by a motor mounted on the top of the third movable seat. The power provided by the motor is transmitted through the screw 129, causing the threaded sleeve 128 to rotate, thereby achieving precise movement of the second movable seat 126.

[0048] Furthermore, the second movable seat 126 slides smoothly along the guide rail, a design that enables the machining assembly 300 to achieve precise longitudinal movement in the vertical direction. The presence of the guide rail not only reduces friction but also improves the stability and accuracy of movement, thereby ensuring the smooth progress of the entire machining process. Through this composite transmission and sliding mechanism, the movement of the machining assembly 300 in both the lateral and longitudinal dimensions is effectively guaranteed, greatly improving machining efficiency and accuracy. This configuration allows the machining assembly to cover the machining range of the rotor.

[0049] Furthermore, the working components include at least one of laser cladding equipment 310, electron beam filament deposition equipment, ultrasonic processing equipment, and electroplating equipment. The detachable configuration allows for various repair operation modes.

[0050] The laser cladding equipment 310 described above is used for additive manufacturing laser cladding. It typically consists of a laser, a powder feeder, a cladding head, and a worktable. The laser provides a high-energy-density laser beam. The powder feeder delivers alloy powder to the cladding head, where the powder melts under the laser's action and deposits on the worn areas of the wheel groove. The worktable supports the rotor and can be moved and rotated as needed. If the rotor wheel grooves experience deep wear, localized cracking, or dimensional deviations (such as thinning of the groove walls or deformation of the contour) due to long-term heavy loads, friction, or corrosion, laser cladding can rapidly melt the alloy powder (such as nickel-based, cobalt-based, or iron-based alloys) using a high-energy laser beam and deposit it onto the damaged areas, precisely restoring dimensions at the millimeter or even micrometer scale. For example, when the wear depth at the bottom of the wheel groove reaches 0.5 mm, multiple layers of cladding material can be deposited, followed by subsequent grinding to the designed dimensions.

[0051] In electron beam wire deposition equipment, key components include the electron gun, vacuum system, wire feeding mechanism, and worktable. The electron gun generates a high-energy electron beam, which melts the welding wire in a vacuum environment and deposits it layer by layer on the rotor grooves. The wire feeding mechanism precisely controls the delivery of the welding wire, and the worktable drives the rotor to achieve precise motion control.

[0052] Ultrasonic machining equipment mainly consists of an ultrasonic transducer, an amplitude transformer, a tool head, and an abrasive suspension supply system. The ultrasonic transducer converts electrical energy into ultrasonic vibrations, which are amplified by the amplitude transformer and transmitted to the tool head. The tool head causes abrasive particles in the abrasive suspension to impact the workpiece surface, removing the micro-damage layer. Ion beam machining: Ion beam machining equipment includes an ion source, accelerating electrodes, a focusing system, and a worktable. The ion source generates an argon ion beam, the accelerating electrodes provide sufficient energy to the ions, the focusing system focuses the ion beam onto the workpiece surface, and the worktable is used to fix and move the rotor for precise machining.

[0053] After long-term operation, rotor grooves may experience dimensional shrinkage (e.g., narrowing of groove width, shallowing of depth) or surface damage such as pits and scratches due to friction, corrosion, or fatigue. Electroplating, by depositing metal ions (such as nickel, copper, chromium alloy plating) on ​​the workpiece surface, can precisely thicken the surface, restoring the groove dimensions (e.g., width, depth, contour accuracy) to design standards. For example, if the groove has excessive clearance due to wear, brush plating with a nickel-based alloy followed by grinding to the tolerance range can restore a tight fit with the rotor groove components (e.g., windings, permanent magnets). The electroplating equipment generally includes components such as a plating pen, power supply, and plating solution. The plating pen acts as the cathode, depositing metal ions from the plating solution onto the workpiece surface, which acts as the anode, under the influence of the power supply.

[0054] The auxiliary components 230 of these components can all be installed on the mobile trolley.

[0055] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model, and are not intended to limit it. Although the utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this utility model.

Claims

1. A device for machining grooves in a pumped storage rotor, characterized in that, include: The frame includes a movable guide rail (100) disposed on the ground and a movable frame (120) movable based on the movable guide rail (100); The drive unit includes a drive trolley (210) disposed on the moving guide rail (100) and a first drive component (213) that drives the drive trolley (210) to move on the moving guide rail (100); The processing component (300) is detachably mounted on the movable frame (120); The movable guide rail (100) includes a first rail (111), a second rail (112) and a third rail (113), and the movable frame (120) is disposed on the second rail (112) and the third rail (113); a processing area (115) is formed between the first rail (111) and the second rail (112); One side of the mobile frame (120) is disposed on the first track (111), and the other side is disposed on the drive trolley (210), and moves along with the drive trolley (210).

2. The pumped storage rotor groove processing device according to claim 1, characterized in that, The first track (111), the second track (112), and the third track (113) are each composed of at least one guide rail base (114); The two guide rail bases (114) are connected by tenon and mortise joints, and the guide rail bases (114) are fixed to the ground by a number of screws or bolts.

3. The pumped storage rotor groove processing device according to claim 1, characterized in that, The movable frame (120) includes a movable rod (121) and a first support rod (141) and a second support rod (144) disposed at both ends of the movable rod (121); The first support rod (141) is connected to the first track (111), and the second support rod (144) is disposed on the drive trolley (210).

4. The pumped storage rotor groove processing device according to claim 3, characterized in that, The bottom of the first support rod (141) is also provided with a roller mounting rod (142); both ends of the roller mounting rod (142) are provided with movable rollers (143) connected to the first track (111).

5. The pumped storage rotor groove processing device according to claim 1, characterized in that, The bottom of the drive trolley (210) is provided with movable wheels (212) connected by a rotating shaft (211); The rotating shaft (211) is driven by a first driving component (213) disposed on the driving trolley (210).

6. The pumped storage rotor groove processing device according to claim 1, characterized in that, The drive trolley (210) is provided with a accommodating space (220), which is used to install the first drive component (213) and the auxiliary component (230) of the processing component (300), and to enable the auxiliary component (230) of the processing component (300) to move synchronously with the processing component (300).

7. The pumped storage rotor groove processing device according to claim 3, characterized in that, The movable rod (121) is provided with a pair of fourth rails (122) and a first movable seat (123) that can move based on the fourth rails (122); The first movable seat (123) is further provided with a second driving component (124), and the second driving component (124) is provided with a second movable seat (126) that can move based on the second driving component (124); The processing component (300) is detachably mounted on the second movable seat (126).

8. The pumped storage rotor groove processing device according to claim 7, characterized in that, The bottom of the second movable seat (126) is also provided with a connecting arm (130).

9. The pumped storage rotor groove processing device according to claim 1, characterized in that, The processing component (300) includes at least one of a laser cladding device (310), an electron beam filament deposition device, an ultrasonic processing device, and an electroplating device.

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