[Editor's note] As an efficient, safe and renewable clean energy source, wind power has been widely adopted in China. In high altitude and plain areas, large wind turbine equipment can be seen everywhere. Most of the wind turbines are located in remote areas, the working conditions are bad, and the maintenance is inconvenient. The quality reliability is particularly important. Among them, the parts with the highest frequency of fan failures may be caused . The processing of gears in wind power speed increasers has received widespread attention. In the cooperation with Taiyuan Heavy Industry, Walter proposed the best turning tool solution to help Taiyuan Heavy Industry. Consolidate the absolute leading edge in the industry.
Among the various components of wind turbines, wind turbine speed increaser is one of the most difficult links, and it is also the main bottleneck of China's wind power design level. The speed increaser is an important part of the wind turbine. It is a separate closed transmission installed between the prime mover and the working machine to increase the speed and reduce the torque accordingly. The speed increaser often bears the tasks of speed regulation, changing the form of motion, transmission and distribution of power and motion, and has the characteristics of high carrying capacity, long service life, stable operation and low noise. The core component of the speed increaser is the speed-increasing gearbox, so the gear failure has become the main cause of the failure of the wind turbine speed increaser. Therefore, the production of efficient and reliable gear products has become the key to the development of China's wind power industry.
As the leader in the manufacture of wind turbine gearboxes, Taiyuan Heavy Industry Co., Ltd. Gear Transmission Branch (hereinafter referred to as "Tai Heavy Gear") is a professional manufacturer with sixty years of production of large heavy-duty gearboxes and other mechanical transmissions. Its sales, R&D, processing and manufacturing capabilities are all in the leading position in the domestic gear industry. The main products include a variety of reducers, wind power speed increasers, EMU subway gearboxes, oil offshore drilling platform lifting systems and various standard reducers, etc. Used in metallurgy, lifting, mining, building materials, shipbuilding, aerospace, wind power, railway, general machinery and national defense technology.
Since the early 1980s, Taizhong Gear has continuously strengthened technical exchanges and cooperation with well-known national enterprises. Through research and development of new products and new technologies, it has formed a unique technological advantage. It has a professional gearbox design and manufacturing team capable of Ensure excellent design and the best product quality.
Through the technical cooperation with the German RENK 1.5MW and 5MW wind turbine gearboxes, it is too heavy to have the ability to serially design and manufacture wind turbine speed increasers. The main products are: doubly-fed and semi-direct drive speed increaser, yaw pitch gearbox, main shaft and other transmission parts, specifications are: 1.0MW, 1.5MW, 2.0MW, 2.5MW, 3.0MW, 3.6MW, 5.0MW . At present, Taizhong is developing 6MW, 7MW and 8MW wind turbine speed increasers. The wind power increaser that is too heavy to produce mainly has several structures such as one-stage planetary + two-stage parallel shaft, two-stage planetary + one-stage parallel shaft, and inner ring-ring drive NW-type planetary transmission. The product has the characteristics of advanced structure, reliable performance and light weight.
Development opportunities bring improvement in processing levels
Compared with other large domestic manufacturers, it is too early to step into the road of independent research and development and innovation. In 2007, it was too close to the wind power manufacturing field, and independently developed a 1.5MW wind power gearbox to fill the Focus on the gap in the field of wind power.
At the time of the white-hot development of China's wind power sector, it is too determined to win the top of China's wind power gearbox manufacturing in three years, and invested nearly 300 million yuan in 2008 to build wind power gearbox plant and equipment investment, 2009 Completed the design and manufacturing base of modern wind power gearbox with world advanced level and annual production capacity of 1500 wind turbine gearboxes. At that time, Taihe Gear designed a fully enclosed thermostatic workshop and purchased various advanced precision CNC machining and inspection equipment: such as NILES gear grinding machine, GLEASON gear hobbing machine, gear shaping machine, gear grinding machine, sump UTENSILI high speed gear hobbing machine, high speed forming Gear milling machine, gear tooth end chamfering machine and other gear processing equipment; car grinding compound machining center, gantry boring and milling machining center, Hector machining center, Pittler vertical turning and milling composite machining center, φ180/φ260 floor boring machine, General-purpose processing equipment such as CNC vertical combined grinding machine and top hole grinding machine; precision testing equipment such as Klingberg 3 meter tooth detector; and AICHELIN box type multifunctional furnace heat treatment production line and various heat treatment special testing equipment.
Mr. Chai Xi, Deputy Chief, Technical Section, Gear Transmission Branch, Taiyuan Heavy Industry Co., Ltd.
"But in the early days of use, in terms of the manufacture of large gears, not high-end equipment can solve all problems." Mr. Chai Xi, deputy chief of the technical department of the gear transmission branch of Taiyuan Heavy Industry Co., Ltd. recalled: "The development strategy of the group allows us to The level of processing in the field of wind power has been greatly improved. The high starting point gives us the opportunity to access the world's most advanced manufacturing technology. But as the saying goes, 'good horse with good saddle', high-end CNC equipment must be equipped with the right tool. In order to better play its own advantages and achieve a breakthrough of 1+1>2." Mr. Chai Xi believes that high-quality tools are as important as the top equipment. "Selecting cost-effective tools can not only improve production. Efficiency, and contribute to the realization of the company's target cost. "In this demand, in 2009, too heavy gear to get acquainted with the world's leading tool brand Walter, Walter's products after a relatively obvious processing improvement in the early stage of cooperation It has been widely used in the workshop of the heavy gear. At present, Walter's three-sided milling cutter, rough boring tool, milling cutter, All kinds of car blade products are running efficiently in the production workshop of heavy gears, especially Walter's turning tool products. At present, they have monopolized all the semi-finishing and finishing processes of the heavy gears, and the high precision of their large gears. Efficient processing provides a strong guarantee.
High precision and high efficiency cutting under complex conditions
At present, the specifications of the heavy-duty gears are various, and the 1.5MW-class wind power-increasing gearbox is the mainstream product. These products usually use gears with a diameter of about 1 meter. The processing steps are: roughing - quenching - semi-finishing - hobbing - carburizing and quenching - finishing - grinding.
Walter's turning tool products are used in all semi-finished and finished car processes of heavy gears.
In the semi-finishing process, the heavy-duty gears are Walter CNMG 160612 WPP20 and CNMA 160612 WPP20, which are much more efficient than similar products. According to Mr. Sun Shuming, a Walter energy industry expert, the WPP20 series of blades is the Tiger.tec blade series, which is mainly used for the machining of various steel materials, and also uses a two-color composite coating. This series of inserts has been optimized and upgraded for the machining of steel parts, which has greatly improved the reliability, stability and high efficiency of machining steel parts, ensuring the best machining results even under difficult machining conditions.
According to the woodworking, the blade is mainly used for processing and tempering parts. In the case of the same machining parts and cutting elements, according to the field statistics, the Walter blade has a longer cutting distance; if the cutting distance is the same, the Walter tool can be The cutting process is completed with faster cutting speed, larger feed rate, and larger back-feeding. In the past, it took about two days to process a gear product. After using Walter knives, two to three gear products could be processed in one day, and the processing efficiency increased rapidly.
Good continuous cutting performance can avoid the machining error caused by tool chipping and re-tooling
The annual output of the heavy-duty gear wind power increase gearbox is 500 sets, which has extremely high requirements on the processing efficiency. At the same time, the quality requirements are also very strict, and the surface quality of the machined parts is much higher than that of the general parts. For example, the end face and the end of the ring gear, the roughness requirement Ra3.2, here is the Walter car blade CNMA160608 WAK10 and CNMG160608 WAK10, which can guarantee the processing quality. "The WAK10 series of blades used here also belong to the Tiger.tec blade series. It was the first two-color coated blade developed by Walter in 2001. It is very suitable for cast iron and carburized alloy steel. Machining efficiency and processing quality are very stable. The two-color coating of WAK greatly improves the wear resistance of the tool, which greatly improves the tool life. It can be determined by distinguishing the color change during processing. The degree of wear of the blade maximizes the utilization of the blade," said Mr. Sun Shuming.
"Our product has a very narrow tolerance range, but even so, Walter inserts can still perform high-quality machining tasks. Its good continuous cutting performance can avoid the machining error caused by tool chipping. "The firewood explained that the gears after the semi-finished car should be processed by hobbing, then quenched, and then the next fine car. At present, the gearboxes produced by the heavy gears mainly adopt the hard tooth surface technology. After the carburizing or nitriding treatment, the tooth surface hardness is up to HRC60. In addition, during the finishing process, the tooth end face may be interrupted by the processing.
"For example, the gear shaft of the material is 17CrNiMo6, after carburizing and quenching, the hardness of the tooth surface is about HRC60, and the other surface hardness is about HRC40. The processing conditions are more complicated, and it is interrupted cutting, so the impact resistance to the blade, Durability requirements are particularly high. Previously, many brands of tools have been used, and there have been cases of blade cutting in the middle. "In cooperation with Walter, the heavy gear used Walter CNMG160612 WAK10 for continuous cutting of the outer surface. The CNM160612 WAK10 performs a slight interrupted cut of the end face.
In order to ensure the machining accuracy of the large gears, it is often necessary for the tool to complete the turning of the gears in one pass. Therefore, the accuracy and efficiency, as well as the service life of the tools are indispensable, which jointly determine the gears and even the wind turbine gearboxes and fans. quality. At this point, Walter provides all-round support to the heavy gear, providing a guarantee for winning a thousand miles.
Tool selection success or failure
In the Chinese machining market, there is no shortage of good tooling products, but in the face of various processing environments, not all good tooling products can come in handy. Therefore, the selection of tools is particularly important. How to select the tool model according to the actual processing needs of the user and let them complete the machining task with higher quality and lower processing cost has become another challenge for the tool manufacturers.
Accuracy and efficiency, as well as the service life of the tool, are indispensable to determine the quality of gearboxes and even wind turbine gearboxes and fans.
"Walter first impressed us with its high-tech coatings and high-quality tool substrates," said Wood. "But it allows us to achieve extensive and in-depth cooperation thanks to Walter's recognition of tools and processing applications. Knowing, thus providing us with the most suitable tool products." Chaigong believes that choosing the right blade model in the process is the most critical issue besides the product itself. The appropriate tool is selected according to the material of the machined part and the heat treatment state. In addition, the rational selection of blade shape and tool parameters, such as tool angle, blade shape and cutting elements, is critical to the quality of the part's surface. "The right blade selection can do more with less, greatly improving processing efficiency," said the firewood.
At present, in addition to self-sufficiency, the wind power gearbox of Taizhong Group is used for external suppliers.
As far as the selection of the Walter WAK10 series of blades is concerned, this product was not originally used for machining steel materials, but for machining castings. However, after analyzing the actual processing of the heavy gears, Walter's staff recommended this product for them and carried out trial processing. As a result, the effect was better than that of traditional steel products. This type of selection is actually risky because the steel parts are machined with the inserts of the castings, and the material to be processed is harder and more difficult to cut, which is highly likely to cause a series of problems such as tool damage and reduced tool life. However, Walter's determination has strengthened the confidence of the heavy gear. It turns out that the selection of the blade is very suitable for the processing of the heavy gear, which is the main reason why the heavy gear has selected Walter tool products in all turning processes. .
In the face of increasingly fierce competition in the wind power market, the quality requirements and delivery requirements of wind turbine products will be more stringent. Whoever can turn the quality off will stand in the market's commanding heights. At present, Taizhong Group has become one of the forefront in the manufacture of wind power gearboxes. Except for self-sufficiency, 50% of the products are used for export. For the heavy gears, there is still more room for development in the future, such as semi-automated production to meet the beat control, etc., and this requires more support from excellent basic equipment manufacturers like Walter. .
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