China's wind power industry has continued to improve in recent years. The annual new and cumulative installed capacity has doubled for four consecutive years. In 2010, the installed capacity of wind power ranked second in the world. The rapid development of China's wind power industry has led to a rapid increase in the domestic level of domestic wind power equipment, and has also driven the rapid development of relevant domestic industries. The processing of the main components of wind turbines requires a large number of sophisticated and efficient CNC machine tools and high-end tools. The advancement of wind power equipment processing technology depends largely on the advancement and precision of machine tools and tools. In addition, most of the wind power equipment working environment is relatively harsh, which also puts high requirements on the processing of related equipment. It can be said that advanced equipment manufacturing processes, especially advanced machine tools and tools, are the fundamental guarantee for upgrading the wind power equipment manufacturing industry.
Among the related wind power equipment manufacturing enterprises visited, both managers and technicians expressed strong dependence on wind power equipment for advanced processing equipment such as machine tools. At the Beijing Wind Energy Exhibition held in October 2010, Huarui Wind Power's technical staff explained to the reporter some of the process requirements for wind power equipment processing. Taking the gearbox of wind power equipment as an example, it is mainly composed of a box body, a planetary gear train and a shifting mechanism. The gearbox body belongs to a large box body, and its structure is complicated. The processing of various components requires different machine tools and tools to complete. Most of the MW-class wind power equipment gearboxes are split-structured. CNC machining, floor milling and boring machines, large horizontal machining centers and gantry machining centers are required for machining. Large-size, large-modulus gears and ring gears need to be machined using CNC forming and milling machines and CNC forming gear grinding machines. Among them, CNC forming and milling machine requires large depth of cut, large feed and high rolling speed. The precision of CNC forming gear grinding machine is more than 5 grades, and it requires high degree of automation such as automatic centering, automatic measurement and automatic shaping. High stability.
In the case of gearbox processing of wind power equipment, CNC floor milling and boring machine, large horizontal machining center, gantry machining center, CNC forming and milling machine and CNC forming gear grinding machine are all high-end equipment with high technical content in the current machine tool industry. The technicians of wind power equipment manufacturers have clearly stated that the machine tools used by their company are technologically advanced high-end products imported from abroad. This shows that the wind power equipment processing process is extremely high. In an interview with wind power equipment manufacturing companies, the reporter recorded the requirements for machine tools and related processes when processing multiple wind power equipment parts.
Case 1: The processing of large blades requires CNC milling machines. These machines are large-scale light non-metal five-axis machining machines. Although the machining accuracy is not high, the power and torque are small, but the cutting speed of the machine is very high. The cutting speed is generally required to be above 30 m/min. The machining of the rotor shaft of the motor requires a large-scale horizontal milling and milling machine. It is necessary to increase the milling and grinding functions on the basis of the traditional horizontal lathe to realize the machining of one clamping. Motor stator manufacturing requires vertical turning and milling machine tools, especially the machining of the stator under-slot. To increase the milling and grinding functions on the basis of the traditional vertical lathe, it is also necessary to realize the one-time clamping process. The main components of the yaw mechanism, such as large bearings with internal and external teeth, and the manufacture of pinion gears and shifting devices, also require some special machine tools. The main shaft, the wind wheel and the tower are large components, which are difficult to process and require high precision. Specially designed special processing equipment is required, and it has high speed, high efficiency, intelligence, flexibility, automatic conversion of CAD/CAM, automatic A number of advanced features such as detection, error compensation and automatic fault diagnosis.
Case 2: The machining part of the hub machining can be divided into two parts: the main shaft system and the blade hole system. In order to obtain the optimal input-output ratio, it is an ideal choice to use vertical and planer boring and milling. The use of vertical car processing rotary hole system has always been the most economical and efficient processing method. Since there are some pin holes or threaded holes at the end face of the spindle hole, in order to avoid re-clamping, the selected vertical car should have a drilling and milling function, and the drilling and milling head usually needs to be equipped with an internal cooling device to ensure the drilling efficiency. . For hubs that machine the angle between the blade and the main shaft, the planer boring and milling machine needs to be equipped with a special clamp. The angle of the clamp is the same as the angle between the blade and the hub, and the blade position is rotated automatically or manually. Here, the boring and milling machine is also required to have internal cooling, the coolant pressure is above 1Mpa, and the machine speed is above 2000r/min, mainly considering the efficient processing of a part of the smaller diameter holes.
Case 3: The spindle is a long-axis rotary part, and most of the machining is done on the sleeper. There are many options for the sleeper tool interface, such as a square turret and a double blade. The condition of the rough car is generally very demanding, requiring both the impact resistance of the tool tip and the high metal removal rate. In this case, a circular blade can be used for processing. In addition to sleeping cars, deep hole drilling machines and floor boring and milling machines are also important for spindle machining. The biggest difficulty of the generator spindle lies in the efficient milling of the lower slot. The machining is divided into two steps: straight slot milling and lower slot milling. Both are in the form of indexable end mills, which can reduce the power and torque of the equipment. Claim.
Case 4: The inner hole, end face, outer circle, raceway, etc. of the turning slewing ring are all completed on the vertical car. For efficient tooth machining, it is done on a gear milling machine. Bolt vias are completed on the vertical drilling center. Since wind power does not have strict requirements on the accuracy of the slewing bearing teeth, it is usually able to meet the requirements of use in the 9 to 10 stages, so the tooth processing can be simplified into two steps of rough and fine milling. For roughing, in the case of machine rigidity and fixture rigidity, it can be processed with a feed of more than 400 mm/min, and fine milling can use a larger feed. The base is a typical structural part that is machined twice with a gantry milling machine. The connecting flange processing equipment is similar to the slewing bearing, but the material of the connecting flange is mostly low carbon steel, and it is not easy to break the chip when drilling.
It can be seen from these processing cases that the requirements for machine tools, tools and processes for the processing of wind power equipment parts can be described as harsh. As the saying goes, "Workers want to do their best, they first benefit their tools." In the wind power equipment manufacturing industry, in order to produce qualified and durable wind power equipment, software and hardware facilities such as machine tools, tools and processes must be very powerful. How to best balance the various factors involved in the processing of wind power equipment, and further propose the best processing technology for the processing of wind power equipment parts, will undoubtedly become the eternal pursuit of wind power equipment manufacturing.
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