Practical application of converter valve automatic detection technology
The State Grid production base has the world's leading converter valve research and development strength, testing methods and production capacity. It is the world's largest production base for DC transmission equipment, and is equipped with a world-class UHV/HVDC converter valve laboratory. In such high-end equipment-concentrated enterprises, the precision converter valve products are carried out in the traditional way for manual handling, assembly, testing and other processes, affecting the production efficiency and quality of the converter valve products. The quality of the flow valve and the key aspects of ensuring that the qualified product is put into operation.
Converter valve automatic inspection production line feasibility study
Since the introduction of China Manufacturing 2025 , major central enterprises have invested in the tide of automation and transformation, and the issue of changing the backward production situation of converter valve products has been submitted to the Ministry of Science and Technology and has become a new topic. The engineering application of the converter valve product is the primary task. The construction opinions are widely collected from the whole society. After the declaration-project-bidding and bidding, the development task of the converter production line of the national UHV experimental base is finally undertaken by Beigang. .
Figure 1 3D simulation of the converter valve test workshop
Overcoming the difficulties of automatic detection technology for converter valve
Automated testing of converter valve products is a world-class problem. The core technology of batch testing has been monopolized by ABB, Siemens and Alstom for 40 years. The existing testing process is to manually push the converter valve products to each. At the test station, the weight of the converter valve is about 1-2 tons. When manually pushing, several workers need to install 4 special caster legs at the bottom of the product, and manually push the product to the test station for corresponding detection. Prior to this, any research on automated detection of converter valves was still in the theoretical stage.
A series of problems such as insulation coordination, seismic analysis and pressure-resistant design are in front of the mountain. To this end, the North Steel Group has set up a project team, which is divided into two groups of people to conduct research and visits. The main line is mainly domestic production enterprises and institutes, and the experts of the Institute of Electric Power Research of the Chinese Academy of Sciences have talked extensively; the other is the existing production line abroad. Research and study mainly, visiting ABB, Siemens and other foreign manufacturers. The domestic expert team went deep into the user unit to understand the manual production process, listened to the opinions of the frontline employees, and worked hard to develop an automation plan. However, the foreign team’s intention to learn from the peers was directly rejected by the other party, and even the production line workshops and laboratories did not allow a glance. It is extremely confidential to the Chinese. Since the North Steel Group is the governing unit of the Sino-German Intelligent Manufacturing Alliance, the expert team has opened a breakthrough.
Successful application of converter valve automatic detection technology
After the sum of the two teams, it was found that there are many restrictions on the foreign converter valve production line, and there is no place that is not in line with China's national conditions. It is not the optimal solution. After 55 research reports, more than 40 questions and answers, 677 drawings were drawn and finally determined. The implementation plan:
1, walking in the air, breaking the conventional thinking
Due to the particularity of the test of the converter valve product, the test process must maintain a certain insulation height with the ground, thus breaking the conventional ground running flow mode and adopting the air walking mode. The air-supporting track is built by the column supporting the steel structure, and the ferry car runs under the track. The trolley is equipped with a lifting mechanism to lift the product from the ground to a certain height, which not only meets the test conditions of the converter valve, but also saves the floor space.
2, distributed DCS control, stable and reliable
DCS control based on wireless control mode, compared with traditional wired control, it is not necessary to connect intricate cables between various mechanisms to avoid interference between lines in the wired transmission process, and the control is more stable and reliable; wireless control also makes the equipment operate. The space is not limited and the flexibility is high. The characteristics of distributed control, each car has its own independent control system , the failure of a single car will not affect the entire production line, ensuring more stable control.
Figure 2 Distributed dcs control
3, sliding line + UPS, providing lasting stability
Since the ferry car needs continuous power supply during the operation, the R&D team conducts a comparative study on various power supply schemes, and finally selects “slide line + UPS†dual power supply; at the same time, conduct field inspection to ensure the highest quality sliding line is applied to the production line. .
Figure 3 The sliding line provides stable power
4. Triple protection to ensure zero accidents
In order to prevent the running car from entering the test station during the test, affecting the product test data, the production line has a triple protection system to effectively ensure that the car runs zero "accidents".
5, flexible design, adapt to different test content
The design of the spreader adopts an electric cylinder to adjust the height of the insulating rod, which can adapt to the test height of different specifications. The four-point folding type retracting rod avoids the interference problem between the vertical retracting rod and the equipment while ensuring the smooth running of the lifting, and is suitable for Flexible transfer of large workpieces.
Figure 4 The spreader is compatible with various products
6, effective isolation, improve the safety factor of the test process
The original converter valve routine test workshop did not effectively separate the test area from the non-test area, and there were hidden dangers caused by personnel mistakenly causing personal injury in the test area. In view of the existing safety hazards, a fence door and a safety light curtain are installed between the test area and the non-test area to prevent personnel from being mistaken.
Figure 5 Human-friendly layout design
From project start-up to successful delivery, it took only 112 days and completely changed the traditional manual production method, which increased efficiency by 150% and labor cost by 35%. The automatic test production line of the converter valve has been highly evaluated by experts at home and abroad, and the automatic detection technology of the converter valve is increasingly applied in practical engineering. The project results further consolidate China's technological leadership in the field of international direct current transmission, laying a technical foundation for the implementation and promotion of ultra-large transmission capacity DC project, which will promote the lean management of power energy and the development of smart grid in China, and provide a global energy Internet. Strong technical support.
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