Laser Quenching equipment
Perform phase transformation hardening treatment on the metal surface to improve the hardness, wear ...
Perform phase transformation hardening treatment on the metal surface to improve the hardness, wear ...
Used for surface strengthening, repair, and remanufacturing of components, the coating has high adhe...
Flexible processing of complex curved sheet metal parts, with high cutting accuracy, fast speed, and...
Specially designed for seamless welding of precision plastic components, with a small heat affected ...
The rotor journal of the generator is the core rotating component of the generator, which operates in conjunction with the bearing. Its surface accuracy and wear state directly affect the air gap uniformity and power generation efficiency of the generator. In the process of long-term high-speed rotation, the rotor journal is easy to be worn due to insufficient lubrication, assembly deviation and other reasons, resulting in uneven air gap, which further leads to increased vibration of the generator, reduced power generation efficiency, and even bearing burnout and other failures. Traditional repair methods (such as scraping and polishing, electroplating) cannot guarantee the repair accuracy, and the service life after repair is short; The replacement of a new rotor is very expensive, and the replacement cycle is long, which will lead to a long shutdown of the power plant and cause huge economic losses. Aiming at the repair requirements of generator rotor journal, Dow Laser Cladding Equipment adopts local accurate cladding technology to cladding a layer of anti-fatigue and wear-resistant alloy coating on the journal wear parts, accurately restoring the dimensional accuracy and surface quality of the journal.
Low-temperature cladding process is adopted for the equipment to strictly control the heat affected zone within 0.3mm, effectively avoid the deformation of the rotor caused by high temperature heating, and ensure that the dynamic balance accuracy of the rotor after repair reaches G2.5, meeting the operation requirements of the generator. The rotor journals of two 300MW generators were repaired in a power plant. The generating efficiency of the two generators was reduced by 3% compared with the new one due to the wear of the journals and uneven air gap, and the operating vibration value reached 0.15m/s. The surface roughness of journal Ra ≤ 0.4 μ m, roundness error ≤ 0.008mm, air gap uniformity returns to the new machine level, power generation efficiency is increased by 1.8%, and the annual increase of power generation of a single unit is over 1.6 million kwh, calculated as 0.5 yuan per kwh, the annual increase of revenue is over 800000 yuan. The repair cost is only 22% of the replacement cost of new rotor. The total cost saved by the two units is over 6 million yuan, and the repair cycle only requires 10 days, which is much shorter than the 45 day cycle of replacement of new rotor, greatly reducing the shutdown loss.
