发电机护环胀形新工艺及其自动控制系统的设计  

Design of new technology for generator guard ring expansion and its automatic control system

作　　者：倪洪启[1] 吴宝胜 杨兵 邵敏刚 NI Hongqi;WU Baosheng;YANG Bing;SHAO Mingang(School of Mechanical and Power Engineering,Shenyang University of Chemical Technology,Shenyang 110142,Liaoning,China;Changzhou Sunshine General Petrochemical Fittings Co.,Ltd.,Changzhou 213169,Jiangsu,China)

机构地区：[1]沈阳化工大学机械与动力工程学院,辽宁沈阳110142 [2]江苏圣贤锻造有限责任公司,江苏常州213169

出　　处：《沈阳工业大学学报》2025年第2期223-230,共8页Journal of Shenyang University of Technology

基　　金：辽宁省自然科学基金面上项目(JKMZ20220774)。

摘　　要：【目的】为生产母线平直、加工余量少、残余应力低的高质量发电机护环,提出了一种基于水压机与超高压泵联动强化护环的新工艺。【方法】利用水压机压下模具,通过模具向下挤压护环,同时使用超高压泵向护环内部注入超高压液体,促使护环产生塑性变形。通过精确控制水压机的压力与超高压泵注液压力,调节护环的变形形状。当护环变形达到一定程度后,由于变形阻力增大,需更换模具继续胀形,直至护环达到预期成形尺寸。相比传统液压胀形工艺,该新工艺设备成本更低且效率更高。以50Mn18Cr5材料作为发电机护环制造基材,采用ANSYS Workbench对胀形过程中的护环外径尺寸变化及受力情况进行有限元分析。同时,根据自动控制系统的要求完成自动控制程序及HMI组态界面的设计,利用PLC控制发动机护环的生产过程,并通过HMI组态界面显示胀形过程中护环的直径变化、变形速度、系统压力及温度等参数。通过监测护环直径变化,精准调控水压机与超高压泵的压力,确保液压胀形顺利进行。若水压机和超高压泵发生故障,控制系统会自动报警,既保护操作人员安全,又避免重大安全事故。【结果】有限元分析显示,护环液压胀形过程中护环外径变化与实际生产结果的最大误差仅为2.312 mm,验证了新工艺的可行性。通过HMI组态界面直观呈现设备工作状态和参数,不仅保证了发电机护环的生产质量和效率,也使操作更加便捷。【结论】水压机与超高压泵联动的新工艺可有效生产母线平直、加工余量少、残余应力低的高质量发电机护环,为护环制造提供了一种高效、低成本的技术方案。[Objective]To produce high-quality generator guard rings with straight busbars,minimal machining allowance,and low residual stress,a new process was proposed to reinforce the guard rings through the linkage of a hydraulic press and an ultra-high-pressure pump.[Methods]The mold was pressed down on the guard ring by a hydraulic press.An ultra-high-pressure liquid was injected into the interior of the guard ring by using an ultra-high-pressure pump to cause plastic deformation.The deformation shape of the guard ring was controlled by precisely controlling the pressure of the hydraulic press and the ultra-high-pressure liquid injected by the ultra-high-pressure pump.When the guard ring deformed to a certain extent,due to the increase in deformation resistance,the mold needed to be replaced to continue expansion until the expected forming size was reached.Compared to the traditional hydraulic expansion process for generator guard rings,the new process used equipment with a lower cost and a higher efficiency.The material used in the manufacturing of the generator guard ring was 50Mn18Cr5.Using the analysis function of ANSYS Workbench,a finite element analysis was conducted on the changes of the outer diameter and stress of the guard ring during the expansion process.At the same time,according to the requirements of the automatic control system,the automatic control program and human-machine interface(HMI)configuration interface were designed,with a programmable logic controller(PLC)used to control the production process of the generator guard ring.Various parameters such as the diameter change,deformation speed,system pressure,and temperature of the guard ring during the expansion process were displayed on the HMI configuration interface.By detecting the diameter changes of the guard ring during the expansion process,the pressure of the hydraulic press and the ultra-high-pressure pump was precisely controlled to ensure the smooth progress of hydraulic expansion.At the same time,if both the hydraulic press and the ultra

关 键 词：发电机护环 水压机与超高压泵联动 护环强化装置 自动控制系统 有限元分析 组态界面 冷变形强化 

分 类 号：TH122[机械工程—机械设计及理论]