Dongfang Turbine Factory, affiliated with Dongfang Electric Group, is a large core state-owned enterprise in my country engaged in the development and manufacturing of power plant and new energy electrical equipment. The company’s product categories cover thermal power, nuclear power, gas power, new energy and other fields. It has become an advanced generator equipment manufacturing center in China and even the world, and one of the three major steam turbine manufacturing bases in the country.
The robust steam turbine is the basic equipment in the field of power generation and drive. It is known as the pearl of the equipment manufacturing industry. It is a symbol of a country’s scientific and technological level and its overall national strength. Equipment allowing my country to break the technological blockade of developed countries. The success of this project has a great influence on the domestic heavy equipment manufacturing industry and is of great strategic importance.
We’ll then show you how 3D scanners can facilitate large-scale three-dimensional data collection, analysis of machining allowances, and precise marking of large steam turbine castings, helping energy companies control costs and to improve the quality and efficiency of equipment manufacturing.
User needs
The workpiece in the housing is a steam turbine exhaust cylinder. As an important component connecting the final blades of the steam turbine and the condenser, the exhaust cylinder directly affects the thermal efficiency of the steam turbine unit. Therefore, strictly controlling the casting precision of the exhaust cylinder and improving the casting process can greatly improve the manufacturing efficiency of steam turbines and enhance the core competitiveness of the enterprise.
The customer needs to make a full-scale measurement of the exhaust cylinder with a diameter of 6m to obtain the casting model, carry out comparative analysis with the processing model, determine whether the tolerance at each angle is sufficient, and formulate a program allocation-based processing.
If there is no margin, you need to confirm whether the base loan amount is sufficient. If the loan amount is insufficient, you must further confirm the location of the missing equipment and the quantity of additional equipment required.
At the same time, virtual tracing is also needed for auxiliary tracing to confirm the processing reference cutting position and 20 window positions.
Traditional measurement method
The customer’s previous inspection method was to manually mark the lines on the cast iron platform, check whether the margin is enough, and find the reference position. The traditional tracing measurement method has many disadvantages:
1. The measurement efficiency is low. Each time the measurement position is adjusted, the baseline must be found again, which is time-consuming and labor-intensive.
2. It is difficult to find the best basic position and highly depends on the experience of workers.
3. Failure to carry out virtual marking will result in the inability to accurately assist the marking position, resulting in some qualified products being judged as unqualified products or defective products, resulting in increased manufacturing costs. treatment.
solution
Equipment used: TrackScan-P, T-Probe measuring light pen
Measurement process:
1. Scan (1 hour)
TrackScan-P series intelligent optical tracking 3D scanner is used to quickly scan the casting mold and obtain the overall model of the casting part.
2. Comparative analysis (10 minutes)
Compare and analyze the three-dimensional scanning data and digital model to see if there is any margin, find the best basic state to ensure that each processing surface has a machining margin in the subsequent processing process to reduce the risk of further processing. Transformation cost; when the margin is insufficient, find the part that requires additives and indicate the quantity of additives.
3. Light pen drawing (duration approximately 2 hours)
Use the T-Probe portable CMM measuring light pen to draw a reference line based on the analysis and draw a line in the window of the required processing location.
4. Mark the line to get the precise processing reference and window position.
Advantages of the solutions
Simple and effective, saving time and effort
TrackScan-P adopts intelligent optical tracking measurement technology, which does not require any patching. The maximum frequency can reach 2,600,000 measurements/second, and the maximum scanning area can reach 500mm × 600mm. It only takes an hour to complete a complete data collection.
In addition, the tracker with dynamic tracking function ensures that the equipment can be moved at any time during scanning and marking, eliminating the need for frequent manual transfers, greatly improving work efficiency.
Portable, stable and highly adaptable
The scanning head is an integrated spherical design and the main frame is made of carbon fiber. It is durable, lightweight and portable. The device is not easily affected by vibration, temperature and other on-site conditions, and has excellent stability and operability. .
The marking points are evenly distributed on the sphere frame, whether the scanning head moves to any angle or position, the tracker can accurately capture the position of the scanning head, thus completing the scanning task easily and efficiently.
Intelligent software analysis to guarantee margin
1. Scan to obtain three-dimensional data and use software to compare and analyze it with the original digital model to form an intuitive chromatographic gap map.
2. The software adjusts the processing reference according to the processing technology, ensuring that each processing surface has processing allowance and reducing the scrap rate.
Auxiliary marking, precise processing
In the plan, a portable CMM measuring light pen T-Probe is used for auxiliary marking. The light pen is suitable for a variety of styluses of different lengths, with a single point repeatability of 0.03mm. Combined with a dynamic tracker, it can. quickly perform marking and reference processing if necessary. Mark the position of the window and check if the marking is accurate.
You can also use software to perform virtual tracing, detect in advance whether the tracing position is accurate, and accurately guide the subsequent tracing and processing processes to maximize tracing efficiency and shorten the processing cycle. manufacturing.
Source: Antarctic Bear
Daguang focuses on providing solutions such as precision CNC machining services (3-axis, 4-axis, 5-axis machining), CNC milling, 3D printing and rapid prototyping services.
