Patent Application
20150292475
1. Technical Field
This invention relates to a method for producing a rotor blade of a wind power installation, as well as to a production facility for producing a rotor blade of a wind power installation.
2. Description of the Related Art
It is known that rotor blades of a wind power installation comprise various elements, or, respectively, semifinished products. These elements may comprise struts or bridges, for example. These are inserted into the rotor blades at various times during the producing process. In addition, a process for producing a rotor blade of a wind power installation comprises various work steps such as filling the rotor blade mold, infusion with resins, tempering, equipping with bridges and the bonding together of two half shells. The surface of the rotor blade is subsequently treated. This treatment comprises deburring of the outside of the rotor blade, or, respectively, the semifinished products, chamfering of the rotor blade finally coating with a coat of paint.
One or more embodiments of the invention improves rotor blade production as a whole, to reduce the costs of such production, to facilitate speedier and safer blade production, thereby enabling a faster overall rotor blade production and at the same time, also improving the safety of blade production.
In the priority application for the present application, the German Patent and Trademark Office researched the following prior art: DE 42 26 397 A1, DE 102 08 850 A1, DE 10 2007 033 414 A1, EP 2 226 186 A1, Journal: Windblatt 03/12 of ENERCON, pages 1-20, Prospectus: MDS Raumsysteme 06/2012, pg. 1-28.
According to the method according to one embodiment of the invention, the semifinished product is produced in parallel to the rotor blade and indeed, is produced in the same building, however on levels of that building, so that, for example, the rotor blades are produced on the ground floor, while the semifinished product is produced on the top floor, and the semifinished product on the top floor can be lowered to the ground floor through an opening between the upper floor and the ground floor.
The advantage to this method is that the production can be set up in a very compact manner, and thus the production building can have a much smaller footprint than has previously been the case.
The parts that are produced on the on the upper floor level are preferably transported from the upper floor level to the ground floor level by means of a crane or a cable winch, etc., and thus, can be consolidated with the parts produced on the ground floor level. Thus a load lifting device such as a crane, cable hoist, cable winches in general, a chain hoist, a lifting frame and/or lifting portal is disposed on the two-story production building.
In a preferred embodiment, a first crane, for example a gantry crane is formed on the first upper floor level, for lifting and/or transporting the parts produced there, and in that a second crane, for example a gantry crane, is formed on the ground floor level, for lifting and/or transporting the parts of the rotor blade produced there. In so doing, the load capacity of the first crane (cable) is less than the load capacity of the second crane. The first crane or, respectively the first cable, thus the crane on the upper floor level, has a lower bearing load, since the parts, which are produced on the upper floor level weigh less than the rotor blade itself. In the case of one or more embodiments of the present invention, a semifinished product is understood to be a subcomponent which can be installed in the rotor blade, or in other words, laminated therein. This may be the strut or bridge of the rotor blade, for example. The first or second crane may be a gantry crane, for example. Said crane spans the work area like a portal and can thereby lift or transport very high loads.
In a particularly preferred embodiment, the maximum crane load or, respectively, bearing load of the crane on the ground floor level falls in the range of 30 metric tons (t) to 40 t, while the maximum crane load of the crane on the upper floor level falls in a range between 1 t and 10 t, preferably 5 t. As a result, the half shells of the rotor blade can be transported on the ground floor level, either without, or with the semifinished products already laminated therein. In so doing, the crane load corresponds to the load, which the crane is able to bear or, respectively, transport, thus the bearing load of the crane.
In a further embodiment, an opening is provided between the upper floor level and the ground floor level, in the floor of the upper floor or, respectively, in the ceiling of the ground floor, through which opening the parts, which are produced on the upper floor level, can be lowered to the ground floor level. In so doing, this opening can be closed, for example by means of a plate, which is embedded in the floor of the upper floor level and/or in the ceiling of the ground floor level, which plate can be moved by a motor. In this way, semifinished products, which are produced on the upper floor level can be transported to the ground floor level in an easy and, in particular, direct manner. In so doing, in the case of a corresponding arrangement of the opening, the semifinished product, which is provided for a specific rotor blade, can be lowered directly to the rotor blade at the correct location. In this way, it is possible to avoid long and time consuming transport routes within the production building.
Further details and advantages of the invention are disclosed in the
exemplary embodiments according to the drawings.
Shown are:
After the rotor blades have been formed, they are assembled. Subsumed under this term, for example, is the machining of the flange, testing the lightning protection, etc. In the finishing area, the rotor blade is painted and all of the necessary preparatory steps therefor are carried out.
Once the rotor blade has been painted and all of the necessary preparatory steps have been carried out, the rotor blade is fastened, for example onto a truck, for delivery directly in the production building. In this way, the entire production of the rotor blade all the way to preparation for delivery takes place within the production building.
After the half shells have been filled, the multi-ply weave is impregnated with resins. This is process step 2 of the infusion. A vacuum infusion process is used for this impregnation. As soon as the fiber reinforced material has been impregnated with resins, said material must be heat treated so that the resins react. This process is referred to as tempering. Tempering 3 is performed at a separate station. When changing stations from station 2 to station 3, the mold must be kept in a vacuum. To this end, each rotor blade mold has an energy unit and a vacuum unit, which maintain a vacuum on the mold while moving.
After tempering 3, the mobile carriage is moved to an empty space 4. The carriage is moved transversely from the empty space to the next station. To this end, the rails 14 are mounted transversely to the direction of producing at a 90° angle. In order that the mobile carriage can move transversely, the drive units are rotated 90°.
The bridges are mounted on the half shells and bonded at the station 5. The two half shells are subsequently brought together and bonded in process step 6. This is done with the aid of a bonding portal. After bonding, the half shells, which have been laid one on the other, are again tempered. Upon the completion of the tempering, the rotor blade can be removed from the shell in process step 7. To this end, the upper shell is removed from the lower shell by means of a lever device. The rotor blade is then moved to the empty space 4, from which space it is then brought into the assembly. Upon doing so, the empty mold is again available for the next rotor blade.
When the molds are filled, the belt is placed on the mold of station 1 by means of the gantry crane of station 23. This is done by lowering the corresponding semifinished product, thus the belt, through an opening between the upper floor 23 and the ground floor 26. This opening is depicted in
There are wheels or rollers on the underside of the mobile carriage 25, and some of the rollers or wheels have drives, so that the mobile carriage 25 can also be moved using an active drive, e.g., on the ground floor level or, in the event that the mobile carriage is located on the upper floor level, on that upper floor.
Through at least one embodiment of the invention, it is not only possible to reduce the property area of the production facility by a substantial degree (up to 20% or more), so that overall, a smaller footprint need also be sealed, but it is also possible to significantly increase the length of the production cycle, for example by more than 30%, and at the same time, the entire production sequence is made safer and the production quality is significantly improved because large and heavy parts no longer need to be constantly transported during ongoing operations by means of a gantry crane over people's heads, so that, so that workplace safety is also significantly increased. At the same time, the entire production sequence can be made substantially more fluid by adapting the production steps between the ground floor level and the upper floor level, thus by means of a corresponding production timing.
In the case of the production facility depicted in
At the same time, it is also possible for a separate gantry crane to be provided on the upper floor, which has a lower maximum bearing load, for example up to approximately 5 t, than a gantry crane on the ground floor level. As a result, the overall energy requirement for the entire production is again reduced, and the flexibility in the production and the adaption of the individual production steps to one another are increased.
By separating the production steps and production parts onto at least two levels, specifically the ground floor level and the upper floor level (additional upper floor levels would likewise be possible), the production period is substantially shortened, for example by more than 30% as compared to standard production, in which all of the essential production steps take place on one level, thus in a single, large hall.
In
Several transverse drives 126 are provided in order to drive the pair of wheels 122, said drives having available a transmission 128. The coupling to the respective pair of wheels 122 is not shown in the overview depiction in
The power supply units 55 are supplied with electric power via the power bus-bars. In addition, the power bus-bars are used to transfer data between the power supply unit 55 and the central control unit 56. A separate power bus-bar and a separate data bus-bar may also be provided. The power supply unit 55 and the central control unit 56 are disposed within the grid structures 52, 53.
| Number | Date | Country | Kind |
|---|---|---|---|
| 10 2012 220 937.9 | Nov 2012 | DE | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2013/073993 | 11/15/2013 | WO | 00 |
