Design And Research Of Automatic Surfacing Repair Device For Guide Vane Of Small Water Turbine

With the gradual exhaustion of fossil energy and the intensification of environmental pollution,the development of clean energy such as hydroelectric power generation has become an unstoppable trend.However,due to the high sediment content of rivers in Xinjiang,the turbine guide vane,the flow-through component of the turbine,is severely abraded during power generation.Manual surfacing repair is used to repair the abraded guide vane,which has low efficiency,heavy workload,and difficult quality.Guarantee.Therefore,it is urgent to design an automatic surfacing repair device for guide vanes of small water turbines,so as to improve the efficiency of surfacing repair of guide vanes and ensure the quality of surfacing repair.This paper takes the turbine guide vanes of Hongshanzui Power Plant in Shihezi City,Xinjiang as the research object.According to the three-dimensional characteristics of small turbine guide vanes,abrasion parts and the quality requirements of surfacing repair,a set of equipment that meets the automatic surfacing repair of small turbine guide vanes is designed.,The main research contents are as follows:(1)Research on surfacing welding technology of guide vane of small water turbine and overall scheme design of automatic surfacing welding device.Through enterprise research,literature review,theoretical analysis and other methods,the difficulties of surfacing welding technology for guide vanes of small hydraulic turbines are analyzed,and the surfacing welding path is planned according to the surfacing welding requirements of different abrasion parts;cold crack sensitivity coefficient method and carbon equivalent method are used Qualification of ZG25 proves that the surfacing performance is good;through the comparative analysis of surfacing welding methods,it is finally determined to use CO2 gas shielded welding to repair the guide vanes,and the relevant process parameters are analyzed and selected;through the automatic surfacing The functional requirements and main technical indicators of the welding repair device design propose an overall design scheme that uses a welding gun's posture adjustment mechanism and cooperates with the planetary wheel rotation mechanism and the end support mechanism,and determines the transmission scheme and driving mode of the device.(2)Design of key components of automatic surfacing repair device for guide vanes of small water turbines.Completed the design of the welding torch pose adjustment mechanism;completed the design of the middle clamping and turning mechanism,the end support mechanism and the frame,and the design and calculation of the corresponding transmission elements of the mechanism and the selection of the motor,and used ANSYS to adjust the frame The static analysis of the whole and the upper movable frame shows that the rigidity of the frame and the upper movable frame is sufficient to ensure that the distance between the arc and the surface of the workpiece to be surfacing is between 0.5 and 1.0 times the wire diameter during the surfacing process.Surfacing requirements.(3)Uniformity test of welding layer of guide vane of small water turbine.The designed automatic surfacing repair device for guide vane of small water turbine was manufactured,assembled and debugged,and on this basis,the uniformity test of the guide vane welding layer was carried out.Select surfacing voltage(18?22V),surfacing welding speed(4?6mm/s),welding bead distance(3?5mm)as the test factors,the welding layer height difference is the evaluation index,and the quadrature orthogonal rotation center is adopted.Combined test design method to conduct welding layer uniformity test.The results show that the significant order of the significant influence on the uniformity of the weld layer after welding is the bead spacing,the surfacing voltage,and the surfacing speed.After parameter optimization,the best combination of parameters is that the surfacing arc voltage is 20 V,the surfacing welding speed is 5mm/s,and the weld bead spacing is 4mm.The height difference of the welding layer is 0.78 mm,and the experimental value is close to the optimized model,which meets the requirements.