| During the overhaul of large generator,if the stator copper bar is to be replaced,the remaining attachment in the stator core copper bar installation groove shall be removed before installing the new copper bar.This work is mainly carried out by the workers who are drilling into the stator core with grinding tools,which is characterized by narrow space,bad environment and low efficiency.In view of this situation,this paper develops a cleaning robot which is easy to install,easy to carry and has complete functions.The optimization analysis of the machine and human is carried out to carry out the lightweight design of the robot.Firstly,according to the structure of stator core and the physicochemical properties of the residue,two technical schemes of the residue in the cleaning tank are proposed: dry ice cleaning technology and laser cleaning technology.The feasibility of cleaning is verified through experiments.Compared with the advantages and disadvantages of the two,the laser cleaning technology has a good cleaning effect and is more in line with the needs of this project.Through the investigation of related fields,the paper designs a variety of feasible cleaning robot schemes.Through the analysis and comparison of the installation convenience,portability and operation efficiency of the scheme,the electromagnetic adsorption scheme has the advantages of transportation,installation and universality,which is more in line with the project requirements.The electrical scheme of robot is designed.Secondly,the detailed analysis and design of each function component is carried out according to the selected robot structure scheme: the selection of laser is completed,the steering gear driving mirror structure of reflector module is designed to solve the problem of cleaning the dead angle of stator slot;The design of vacuum pipe is improved to solve the problem of poor vacuum effect;According to the structure parameters of stator core,the selection of linear module and electric turntable which constitute three degrees of freedom of robot body is completed;The design of the main load plate and the main beam installation plate of the laser is completed;Through the analysis of force and calculation of selection,it is confirmed that the layout of guide module is double row adsorption single row guide rail,and the electromagnetic suction cup,guide rail slider,gear rack and servo motor are selected to complete the structural design of cleaning robot.Then,structural optimization of the cleaning robot is carried out based on FEM(Finite Element Method)and RSM(Response Surface Method).FEM is used to analyze the static characteristics of the cleaning robot.The maximum deformation and stress are within the allowable range of design requirements and rigidity.RSM is used to optimize the structure of cleaning robot.Sampling method is OSF(Optimal Space-Filling Design).Response surface is obtained by fitting the results of static analysis calculated by FEM with Genetic Aggregation and optimized by MOGA(Multi-Objective Genetic Algorithm).After optimization with RSM,the robot can reduce weight by 10.65% and deformation by 10.30%Finally,the process parameters of the cleaning robot in the stator core groove are measured.Through a series of experiments,the best technological parameters are obtained.The overall time of cleaning single slot is about 6 hours,and the design goal of the robot is achieved.Compared with manual,the cleaning robot has good cleaning effect,good uniformity,short cleaning time and less labor required.It realizes the automation of cleaning in stator core groove and reduces the loss of generator maintenance. |
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