Opening-and-Closing Heater for Wind Shaft Forging Temperature Hold
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Solution Overview
Problem
The forging process of large wind generator shafts faces challenges due to temperature drops during the prolonged process, leading to internal defects, increased energy consumption, and poor dimensional accuracy, as existing heating methods are inefficient in maintaining consistent heat and requiring repeated heating.
Innovation Solution
An opening-and-closing type heater with a base, arc-shaped tube bodies, and a moving mechanism that allows for precise heating and temperature control using a refractory material layer, infrared thermometer, and a gas fire pipe injector, enabling targeted heating and real-time temperature measurement to maintain optimal forging temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the forging process is stopped to heat the forgings in the heating furnace when temperature drops below limit value, then internal defects are avoided, but energy consumption increases and productivity decreases
Solution Approach 1:
The heating device is activated before the forging temperature drops below the critical limit, maintaining temperature proactively rather than reactively. This prevents the need to stop the forging process for reheating, thereby avoiding internal defects while maintaining continuous production and productivity.
Solution Approach 2:
The heating device operates continuously or periodically during the forging process to maintain optimal temperature, ensuring the forging action can proceed without interruption. This continuous temperature maintenance eliminates the need to stop the process for reheating, resolving the contradiction between quality and productivity.
2Productivity
If the forging process is completed within specified time to avoid repeated heating, then productivity is maintained, but dimensional accuracy deteriorates
Solution Approach 1:
The heating device prepares and maintains optimal temperature conditions in advance during the forging process, ensuring that sufficient time is available for fine forging operations without causing temperature drop. This allows the process to proceed at normal pace while achieving good dimensional accuracy.
3Temperature
If traditional heating furnace is used to maintain temperature, then temperature control is achieved, but energy consumption increases
Solution Approach 1:
Instead of heating the entire forging piece uniformly in a furnace, the heating device applies heat locally to specific areas that require temperature maintenance. This localized heating approach achieves effective temperature control while consuming significantly less energy compared to full-furnace heating.
Solution Approach 2:
The heating function is extracted from the traditional furnace system and integrated directly into the forging press system. This allows heating to be applied only when and where needed during the forging process, eliminating the energy waste associated with maintaining temperature in a complete furnace.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution effectively maintains heat during the forging process, reduces energy consumption, enhances mechanical properties, and improves dimensional accuracy by allowing for fine forging without the need for repeated heating, thus preventing internal defects and increasing the efficiency of the forging process.
Implementation Method 1
Usually, a refractory fireproof material layer is arranged on the inner wall of the fixed tube body and the movable tube body
Implementation Method 2
the tube body is provided with a gas fire pipe injector and the nozzle thereof is provided with an igniter
Implementation Method 3
the tube body may be provided with a measuring element for measuring temperature of internal forgings thereof
Data Source
AI summary
A heating/heat-retaining device, particularly to a heating/heat-retaining device used in the forging process, and more particularly to an opening-and-closing type heater and a wind generator shaft forging process using the same. The opening-and-closing type heater comprises a base, a tube body mounted on the base and a tube body opening-and-closing mechanism; the tube body comprises a fixed tube body and a movable tube body, the fixed tube body and the movable tube body are arc-shaped shells, and form a hollow shape when the openings thereof match with each other; the tube body opening-and-closing mechanism is connected to the movable tube body for realizing the opening-and-closing of the movable tube body and the fixed tube body. The invention solves heat retaining and heating problems during the forging process of the main shaft forgings and avoids internal defects due to rapid temperature drop of the main shaft forgings.