展 望 解 説. Introduction Over the past 10 years, with computer aided techniques (CAD/CID/CAE/CAM/MPS/ CNC) and some advanced manufacturing technology

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1 Design in China (1) 193 展 望 解 説 Design in China Cichang With development application Cichang CHEN Xide advanced design manufacturing progress techniques in industry R&D manufacturing is presented hydro turbine in this paper. Keywords: ; 1. Water ; Design; Introduction Over past 10 years, with computer aided techniques (CAD/CID/CAE/CAM/MPS/ CNC) some advanced manufacturing technology 2. General equipment manufacturers have been trying to capacity intensify cooperation with major Chinese is 1.25 power-generating equipment manufacturers in design manufacturing hydro turbines, which According accelerates progress hydro turbine industry. Dongfang Electrical Machinery Co., Ltd. (DFEM, capacity There x 平 成14年10月21日 a great 33 %) till (about national Chinese on Power Hydro Station Xiaowan, hydro that Stations Longtan, will turbine have industry but so far have been year it has 2010w. R&D units 10 years. (such will with been was Qiluodu, Pubugou) runner's before started from a series turbine built be unit Apart as Laxiwa installed is in constructing, MW 6-9m total hydroelectric in future Power capacity planning, power in China, will MW unit exploited units to huge hydroelectric hydroelectric 108kW hydro- China 16 % Hydro diameters be only emphasis Sanxia with can developed in 3.78 ~108kW that placed units are Shuibuya, 原稿受付 日 development electric been *2 it has made latest progress R&D manufacturing. equipment, a lot foreign power-generating Sichuan University Science & Technology Chenci@mail.sc.cninto.net Sichuan University Science & Technology in China, hydroelectric equipment manufacturers. They have reached international advanced level in both resources *1 techniques A brief introduction Works (HEM, hereinafter) are two major Chinese Because China has abundant hydraulic power resources huge market in hydroelectric Harbin Electrical Machinery LAI*2 Machinery (AMT), being developed graduallyused in hydro turbine industry, a great progress techniquesin R&D manufacturing has been made in China. hereinafter) Xide LAI in past 10 years. Hydroelectric CHEN* in タ ー ボ機 械 第31巻 第4号 1927, 1

2 Table 1 Scope hydro turbines made by major Chinese manufacturers (Included co-produced) re are more than 20 manufacturers up to now in China, two biggest m are DFEM HEM. According to statistics, output marketing shares DFEM HEM is each 1/3 in China, total or manufacturers is about 1/3. China had successfully developed made unit capacity 200MW hydroelectric units in 1970s, 300MW in 1980s, 550MW in 1990s. The major manufacturers researchers also devoted to develop unit capacity 700MW hydroelectric units in 1990s. In beginning 1980s, DFEM had successfully developed made Kaplan turbine with runner diameter 11.3m that is largest in world so far. In 1987, DFEM successfully developed made 320MW Francis turbine with runner diameter 6m, HEM made Francis turbine with runner diameter 8m in It should be mentioned that some Chinese hydro turbine manufacturers co-manufactured turbines for power stations in China with GE Hydro, Voith Hydro Inc., Kvarner, Neyerpic, Toshiba, Fuji Voith Hydro, Hitachi etc. in past 10 years. DFEM HEM are manufacturing Sanxia hydroelectric unit that is largest Francis turbine with unit capacity 710MW runner diameter 10m(2) in cooperation with GE Hydro, Voith Hydro Inc., Kvarner, Alsthom. It is shown in Table 1 that scope hydro turbines has been made by major Chinese manufacturers. After reconstruction reorganization in recent years, DFEM HEM have enhanced ir manufacturing ability to produce Sanxia hydro turbines. They have reached international advanced level in manufacturing ability techniques in a majority types in hydro turbine, but y are still weak in types pump /turbine tubular turbines. 3. Hydraulic R&D for hydro turbines The major hydro turbine researchers manufacturers began to develop special CAD stware in hydraulic design turbine in 1980s(3). During ending 1980s beginning 1990s, more than four universal high accuracy hydraulic test sts with maximum testing head 100m were set up in China. The test st met requirements for international commercial test in accuracy automation. In ending 1990s, several large discharge high accuracy hydraulic test sts with testing head between 10-25m were established for Kaplan Tubular turbines. All test sts found good conditions for developing high performance turbines. The major hydro turbine researchers manufacturers had also done a lot works in methods quasi-3d flow computing analysis, cavitations wear in hydro turbines during same period, which are applied in practical engineering get satisfied solutions. In recent years, CFD has been gradually used in R&D hydro turbines, commercial stware such as Fluent(R) TascFlow(R)

3 Lalest Preliminary Fig. 1 design Optimization estimation Design Fig. 2 Final design in China (3) 195 Efficiency hill diagram by estimating design runner based on performance turbine with optimized runner As to manufacturing is appliedin 3D viscous flowanalysis performance model, estimation in hydraulic R&D, so it decreases model machines testing dramatically.for optimizationhydraulicdesign, whole flow passage that includes spiral case, The series stay vanes, wicket gates, runner draft tube is been developed numerically simulated carefully designed with CFD CAD(2)(3).After hydraulic design, efficiency commercial stware such as UG(R), I-Deas(R), Francis ANSYS(R),NASTRANO, Adams(R)is widely used in 3D geometric design, mechanical design, most shown in Fig. 1. techniques parts testing are machined with self-developed excellent on CNC CAM techniques. hydraulic models turbine, head that is in range from 2 to 400m, have Francis in past model 92.5% blade called 10 yearsw. turbines is up to 94.8% for Kaplan. "X shape" The maximum A kind for new was developed in 4 years ago(2)after GE Hydro KE. mechanism dynamics analysis(4)(5)(6). CIMS virtual manufacturing are gradually applied in 4. major manufacturers, so it has been speeding up 4-1 R &D manufacturing hydro turbines(6. In order to investigate internal flow hydro equipments major manufacturers The CNC controlled equipment is more than 20% turbines, some universities institutes introduce ir total amounts in major manufacturers. advanced instruments such as PIV PDA/ The main equipments in major manufacturers include : 5-axis simultaneous CNC controlled large LDA, which can be used to verify numerical simulation improve hydraulic design. Fig. 1 techniques large hydro turbines Machining capabilities for main size gantry machine (4 sets, made in Germany),5- shows a runner that it was primarily designed with axis 3-axis simultaneous CNC controlled heavy special developed CAD stware duty Horizontal Milling & Boring Machine with spindle diameter mm (5 sets, made on left) (3) furr optimized with CFD analysis (on right)(2. Fig. 2 shows an efficiency hill diagram that is estimated with developed stware CFD for in Germany Italy), CNC controlled Vertical La with maximum machining diameter 12.5m, タ ー ボ機 械 第31巻 第4号 3

4 196 Design Fig. 3 in China (4) Typical blade manufacturing flow chart for large size hydro turbines 15m, 16m, 18m 22m (7 sets, made in Germany China), CNC controlled Horizontal La with maximum machining length 16m maximum machining diameter 2.5m (4 sets), CNC controlled large size Gas cutting machine (4 sets, made in Germany, Japan China). The Machining capabilities can meet requirements for hydroelectric capacity 850MW. 4-2 unit with unit techniques large size runners for Fig. 4 Blade casting measured with odolites The manufacturing techniques runners are most important in manufacturing hydro turbine. 5-axis simultaneous CNC machine is widely used in The progress manufacturing techniques is synchronization for major manufacturers. They major manufacturers. For high head Francis blade, a kind technology called heat press forming have similar techniques experience with moulds is also gradually used. The typical blade different type runners. For large size Francis runner, manufacturers mainly apply a kind manufacturing flow chart is shown in Fig. 3. There are a lot key techniques in CNC fabricated technique called combination welding, machining large blades. One example is that how because y have very strong ability at welding. The b, crown blade can be in same kind or to set up correctly for each blade casting on machine in a very short time, an efficient method for different kind steel by welding. They have computing right spatial setup position is applied design manufacturing experience Kaplan runner with Di =11.3m Francis runner with Di =10m. with measuring each blade casting by odolites. Fig. 4 shows that a blade casting is being measured with It was 10 years before that all blades were manually grinded in China. In recent 10 years, 5- Anor example is that how to correctly compute high accuracy odolites (Made by Leica)(5)(6). axis simultaneous CNC controlled large size gantry tool path for 5-axis machining large blade's sculptured surfaces with large size face milling machine CAM were introduced developed cutters, tool path simulation machine to mill blades, blade machining technology with simulation techniques have been developed to verify 年4月

5 Fig. 5 Machining Design Fig. 7 simulation for Francis blade Machining 197 in China (5) simulation for Kaplan blade fabricated weld m into a runner, a series combined templates is used to control ensure inlet outlet angles blades openings runner. After finished welding, 100 % UT MT are carried out for checking welding seams. Then, runner is machined on large size NC controlled vertical la with boring functions for all operations at one set-up, a method called stress bar is used to balance Fig. 6 Sanxia's blade is being machining controlled gantry machine on a large CNC runner. Generally speaking, major manufacturers have kept in step with international advanced level in manu- facturing technology runners. modify tion tool path. Fig. 5 shows for machining a Francis shows that this blade 5-axis CNC shows simulation blade is machining controlled simula- gantry Fig. 6 machine(5). for machining Fig. 7 a Kaplan Typical hydro manufactured on large size In consideration transportation large Francis runner into 2 or 4 pieces. vertical la ir on NC controlled weld preparation axis simultaneous is ten split The crown b are machined on NC controlled face machined from boring blade milled CNC controlled split turbines recently in China During past 3 years, annual output DFEM HEM is over 24000MW With progress blade manufacturers, 5. technology, turbine capabilities in each year. manufacturing manufacturing are greatly improved quality products is also up to international advanced whole process from stards. R&D The products, machine, purchasing on 5- products, inspection finished products to after- machine. When raw materials, sale services, has also reached manufacturing international ター ボ機 械 第31巻 第4号 5

6 Table 2 Typical hydro turbines manufactured by major manufacturers in China stards. Their hydro turbines not only install in domestic, but also export to abroad. The typical hydro turbines manufactured in China over past 15 years is shown in Table Conclusions During past 10 years, Chinese hydro turbines industry had made a gigantic development in both R&D manufacturing technology. They not only pay more attention to research develop by mselves, but also import advanced foreign technology enhance to make cooperation with well-known foreign companies. The manufacturing technology major manufacturers has reached international advanced level in most types hydro turbines, ir products not only service in China, but also export to foreign countries. They are trying every effort to keep in step with international advanced technology in whole hydro turbines industry. (1) Zhang Fuqin," The developments hydro turbines in domestic abroad", J. Dongfang Electrical Machinery, 25 (1), pp.1-12, 1998.(in Chinese). (2) Shi Qinghua, Sutart Coulson," Hydraulic design hydro turbine for Sanxia power station" J. Dongfang Electrical Machinery, 25 (1), pp.19-31, 2001.(in Chinese). (3) Lai Xide," An integrated hydraulic CAD system for Francis hydro turbine", J. Dongfang Electrical Machinery, 20 (1), pp.1-12, 1993.(in Chinese). (4) Lai Xide," Technology for 5-axis simultaneous CNC machining large Kaplan hydro turbine blades", CAD/ CAM, 66 (5), pp.71-75, (in Chinese). (5) Lai Xide," Technology for 5-axis simultaneous CNC machining large Francis hydro turbine blades", Ordnance Industry Automation, 20 (3), pp.40-43, 2001.(in Chinese). (6) Lai Xide, Zhou yunfei, Yan sijie," Application virtual manufacturing technology in design manufacturing in hydro turbine runners", Machinery, 29 (3), pp.21-24, (in Chinese).