(CCTV Finance "Tianxia Finance") customized power equipment to meet a variety of application scenarios in various industries. Today, "Intelligent Manufacturing China Research Line" walked into an intelligent manufacturing factory of energy conversion equipment in Xi'an, Shaanxi Province, to explore the technological breakthrough and intelligent transformation of China's energy conversion equipment.
CCTV Finance "World Finance" column**.
At present, the world's largest axial compressor with a rotor diameter of 14 meters, with a total weight of 400 tons, standing up, equivalent to building a 70-square-meter two-story building on flat ground, is the core power unit of China's aero engine high-altitude simulation test, and is also the "power heart" of metallurgical super-large blast furnace, catalytic cracking, compressed air, energy storage, remote gas transmission and other field equipment.
An axial compressor is composed of three parts: the casing, the bearing steel and the rotor, the rotor looks like a "mace", which is equipped with 868 moving blades, and the bearing steel is equipped with 1074 static vanes, adding up to a total of 1942 blades. The combination of dynamic and static ensures the normal operation of the axial compressor.
After the air enters the axial compressor, the rotor can reach 2500 revolutions per minute, the moving blade will do work on the gas when rotating at high speed, and the gas will flow into the static blade at high speed after being stressed, the role of the static blade is to expand the pressure, convert the kinetic energy into pressure energy, so that the air pressure rises, and the maximum air volume is 20,000 cubic meters per minute, that is, the gas volume per minute is equivalent to the size of a standard football field, the volume of a 3-meter-high plant, and the conversion efficiency reaches more than 92%.
At present, 2,600 sets of axial compressor units have gone out from this intelligent manufacturing factory and become the "single champion product" of China's manufacturing industry. In order to realize the safe, stable and efficient operation of each axial compressor, thousands of blades are the core components to achieve energy conversion. The blade, which is composed of two parts, the root and the blade shape, presents a complex three-dimensional surface, and the contour of the blade shape should be accurate to 01 mm. The tooth shape of the leaf root should be accurate to 001 mm, which is equivalent to a quarter of the diameter of a hair. If there is a deviation in the accuracy of the blade shape, the air output will be smaller and the power consumption will increaseThe production process is very difficult.
The factory can produce 800 blades per day, and all blade shapes here are currently produced by five-axis linkage machining centers. In the fully enclosed CNC machine tool, the blade shape rotates 360 degrees, and the blade works in the opposite direction with the blade shape, spirally processing the blade shape, and forming it at one time. It not only improves efficiency, but also ensures the consistency of quality.
At present, axial compressors are also used in the field of new energy storage. The energy storage equipment model built by the air compressor unit is to store the electric energy in the abandoned salt cavern, and when the electricity consumption is low at night, the air compressor is driven to store the electric energy, and the compressed air is released when it is needed during the day, generating huge kinetic energy and driving the generator to generate electricity. Like a huge "power bank", it has great potential in solving the contradiction between power supply and demand, improving energy efficiency, and reducing environmental pollution. In addition to intelligent production, an intelligent remote monitoring and diagnosis platform for the whole life cycle has also been built here, which is also known as the "smart brain" of the factory. Nearly 7,000 equipment information and operation conditions exported to more than 100 countries and regions are monitored and digitally managed here.
The data on the platform is updated every three seconds, and once the yellow warning information appears, the expert team will remotely give a diagnostic solution, and the maintenance service team will cooperate on site to resolve the risk in advance. At present, the platform has provided customers with thousands of single diagnostic services, which is expected to save 200 million yuan in maintenance costs every year. This is also the deep integration of the equipment manufacturing industry and the modern service industry, reflecting the development of China's new model of service-oriented manufacturing industry, and promoting the latest achievements of the intelligent, high-end and green development of the manufacturing industry.
*Please specify CCTV Finance
Editor: Wang Yifan.