Turbine Casing Assembly Simulation for Positional Accuracy
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Solution Overview
Problem
The existing methods for assembling turbines require a lengthy temporary assembly of casings, which affects the operation period and accuracy of positional adjustment, especially due to the need for heating and cooling large bolts and variations in measurement accuracy among workers, making it difficult to apply to small turbines and those under high temperature conditions.
Innovation Solution
The method involves simulating the turbine assembly using numerical analysis and three-dimensional laser measurement to calculate the change in configuration and positional adjustments without temporary assembly, allowing for accurate positional adjustment and reduced assembly time by comparing measurement data with simulation data to determine the necessary adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If temporary assembly of casing is performed to measure positional changes, then measurement accuracy is improved, but assembly period is extended
Solution Approach 1:
The invention creates a virtual copy of the casing assembly state through numerical analysis simulation. The simulation model replicates the deformation characteristics of the actual casing when bolts are tightened, allowing positional changes to be calculated without physical temporary assembly. This virtual copying approach maintains measurement accuracy while eliminating time consumption.
Solution Approach 2:
The invention replaces the mechanical temporary assembly system with a computational simulation system. Instead of physically assembling the casing to measure positional changes, the patent uses numerical analysis to calculate these changes based on bolt tightening forces and casing material properties, substituting physical measurement with computational prediction.
2Ease of manufacture
If heating and cooling of large bolts is performed for temporary assembly, then casing fastening is achieved, but time consumption increases
Solution Approach 1:
The invention creates a virtual copy of the casing assembly state through numerical analysis simulation. The simulation model replicates the deformation characteristics of the actual casing when bolts are tightened, allowing positional changes to be calculated without physical temporary assembly. This virtual copying approach maintains measurement accuracy while eliminating time consumption.
Solution Approach 2:
The invention replaces the mechanical temporary assembly system with a computational simulation system. Instead of physically assembling the casing to measure positional changes, the patent uses numerical analysis to calculate these changes based on bolt tightening forces and casing material properties, substituting physical measurement with computational prediction.
3Ease of operation
If measurement is performed by workers with different skill levels, then flexibility is improved, but measurement accuracy varies
Solution Approach 1:
The invention replaces the mechanical temporary assembly system with a computational simulation system. Instead of physically assembling the casing to measure positional changes, the patent uses numerical analysis to calculate these changes based on bolt tightening forces and casing material properties, substituting physical measurement with computational prediction.
Solution Approach 2:
The invention changes the measurement parameters from physical dimensions requiring human judgment to computational variables based on material properties and applied forces. By using standardized material parameters and bolt tightening parameters in the numerical analysis, the system eliminates variability introduced by different measurement skills while maintaining operational flexibility.
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 approach maintains the accuracy of positional adjustments while significantly reducing the turbine assembly period, eliminating the need for temporary casing assembly and minimizing the impact of measurement variations, and is applicable to turbines under high temperature conditions and small turbines.
Implementation Method 1
three-dimensional laser measurement
Implementation Method 2
change amount of configuration when the casing upper half part is fastened to the casing lower half part by the bolts
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A method of assembling includes the steps of: gaining measurement data on the configuration of a casing upper half part 12, 22 not fastened to a casing lower half part 11, 21; gaining measurement data on the configuration of the casing lower half part 11, 21 in an open state; comparing measurement data on the configuration of the casing upper and lower half part with simulation data on the configuration of the casing to select simulation data closest to the measurement data on the configuration of the casing upper and lower half part; calculating, based on the selected simulation data, a change amount of the configuration when the casing upper half part 12, 22 is fastened to the casing lower half part 11, 21 in the open state; and adjusting the installation position of the stationary part 6 inside the casing taking into account the calculated change amount.