Accumulated domestic equipment experience to reduce the direct loss of 100 million yuan
Recently, Shenyang Blower Group Gear Compressor Co., Ltd. for the Henan Longyu Coal Chemical Co., Ltd. 52,000-class air separation plant supporting large turbo turbocharger implementation of 'change the core' to achieve a success. Success, the performance indicators have reached the factory equipment, which not only for Longyu Coal Chemical Company to reduce the direct economic losses of 100 million yuan, but also for the same type of imported equipment localization has accumulated experience.
Lu Yujun, deputy general manager of Henan Longyu Coal Chemical Co., Ltd. told reporters that Longyu coal chemical industry 52,000-class air separation plant supporting key equipment - turbocharger, the Department of Germany's Man Turbo imports of gear growth five Press, import pressure 0.64MPa, outlet pressure 7.09MPa, intake flow 15600Nm3 / h, put into use in 2007. In July 2017, Longyu Coal Chemical Company in the unit overhaul found that the input shaft gear teeth 7 Department, the crew had to be forced to shut down.
Lu Shijun said that if the use of a set of input shaft spare parts provided by Germany's Man Turbo, the cycle of at least 8 months, the price of 200 million yuan, while the device every day for 1 day of production, will cause direct economic losses up to 100 million. Yu Coal Chemical Company to the domestic major gear research, processing unit issued help information, many units have indicated that inability to carry out surveying and mapping of this unit, repair. Drum Group Gear with many years of high-speed gear manufacturing strength and compressor manufacturing advantages and experience, Resolutely took over the difficult mapping 'change' transformation task.
Shen drum Group Gear Compressor Co., Ltd. Department of Manufacturing, Yan Feng, minister of manufacturing told reporters that the gear company received maintenance 'change the core' mission, the first time sent technicians went to the site for mapping work. Because of the turbocharger input Shaft and gear for the up and down structure, and the center distance is large, combined with severe gear tooth distortion, measurement is extremely difficult, due to serious damage to the unit, gearbox, gear and rotor there are signs of deformation, resulting in The measurement data or is not the original design data, resulting in the measurement data can not be directly determined by the gear displacement coefficient.To solve this problem, the gear company a lot of simulation and analysis, and based on past experience in mapping analysis, and ultimately determine The optimal solution of the displacement coefficient by using advanced technical means to detect the helical angle of the broken tooth gear and other parameters of their sophisticated calculation and verification and sending technical personnel to measure the final determination of the design parameters.As the original gear on the research The situation is poor, only about 50% of the teeth in the broken tooth contact, the company technical team analysis of the broken tooth may be the load concentration at the site, Use of fatigue cause broken teeth.
Gear company with many years of high-speed gear tooth profile, tooth shape modification experience, the mapping of the second gear optimization design to ensure that the gear research to reach 85% of the contact. The unit from September 2017 mapping to processing and manufacturing, On-site installation, commissioning to formally put into operation, only 3 months, and the price is much lower than foreign spare parts to ensure the repair speed and quality of large turbocharger. 'Drum gear company repaired the device, due to localization gear Field operation is good, vibration, temperature and other major parameters can reach the factory state (vibration value of 37um, temperature 80 ℃), and completed in 5 months in advance to repair, for enterprises to reduce the economic loss of 100 million yuan.
Li Peng, general manager of Shenyang Bearing Group Gear Compressor Co., Ltd., told the reporter that Shenyang Shengu Group Gear Compressor Co., Ltd. is a major supporting manufacturer of Shengu and also a major gear manufacturer in China. Its main products are gear box, gear assembly compression Machine, of which gearbox power up to 30000kW, single-stage speed ratio up to 8.9615. Gear line speed up to 200m / s (China's first.) Gear unit compressor maximum single-stage ratio of 23.867, the highest number of revolutions 52035rpm, the maximum total power of 32020kW, gear diameter of nearly 3300mm. The company produced a maximum of 48,000 air compressor level, the final gear all precision grinding, manufacturing precision up to 3. In 2017 the introduction of a German ELB End machine, the rotor has been changed to suppress the tooth structure, with EDM closed impeller ability.
Li Peng said that the successful implementation of the 'core change' for Germany Turbine giant turbocharger has proved successful that the gear company is fully equipped with the capacity of a large compressor unit to replace imports.At present, 50,000 to 100,000 air splits Installation of about 80. In the future, the gear company will strive to perfect its technology, quality service for the domestic import of compressor core components localization and upgrading make new contributions.
