CN111453629A - Single-blade installation robot for offshore wind turbine generator system - Google Patents
Single-blade installation robot for offshore wind turbine generator system Download PDFInfo
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- CN111453629A CN111453629A CN201910060323.2A CN201910060323A CN111453629A CN 111453629 A CN111453629 A CN 111453629A CN 201910060323 A CN201910060323 A CN 201910060323A CN 111453629 A CN111453629 A CN 111453629A
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- 238000009434 installation Methods 0.000 title claims abstract description 116
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- 229910052744 lithium Inorganic materials 0.000 claims description 7
- 230000009467 reduction Effects 0.000 claims description 6
- 238000012544 monitoring process Methods 0.000 claims description 4
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- 230000000712 assembly Effects 0.000 claims 2
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- 238000000034 method Methods 0.000 abstract description 17
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
- B66C23/00—Cranes comprising essentially a beam, boom, or triangular structure acting as a cantilever and mounted for translatory of swinging movements in vertical or horizontal planes or a combination of such movements, e.g. jib-cranes, derricks, tower cranes
- B66C23/06—Cranes comprising essentially a beam, boom, or triangular structure acting as a cantilever and mounted for translatory of swinging movements in vertical or horizontal planes or a combination of such movements, e.g. jib-cranes, derricks, tower cranes with jibs mounted for jibbing or luffing movements
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
- B66C1/00—Load-engaging elements or devices attached to lifting or lowering gear of cranes or adapted for connection therewith for transmitting lifting forces to articles or groups of articles
- B66C1/10—Load-engaging elements or devices attached to lifting or lowering gear of cranes or adapted for connection therewith for transmitting lifting forces to articles or groups of articles by mechanical means
- B66C1/42—Gripping members engaging only the external or internal surfaces of the articles
- B66C1/44—Gripping members engaging only the external or internal surfaces of the articles and applying frictional forces
- B66C1/445—Gripping members engaging only the external or internal surfaces of the articles and applying frictional forces motor actuated
- B66C1/447—Gripping members engaging only the external or internal surfaces of the articles and applying frictional forces motor actuated by hydraulic or pneumatic motors
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
- B66C13/00—Other constructional features or details
- B66C13/04—Auxiliary devices for controlling movements of suspended loads, or preventing cable slack
- B66C13/08—Auxiliary devices for controlling movements of suspended loads, or preventing cable slack for depositing loads in desired attitudes or positions
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
- B66C13/00—Other constructional features or details
- B66C13/16—Applications of indicating, registering, or weighing devices
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
- B66C13/00—Other constructional features or details
- B66C13/18—Control systems or devices
- B66C13/46—Position indicators for suspended loads or for crane elements
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
- B66C23/00—Cranes comprising essentially a beam, boom, or triangular structure acting as a cantilever and mounted for translatory of swinging movements in vertical or horizontal planes or a combination of such movements, e.g. jib-cranes, derricks, tower cranes
- B66C23/62—Constructional features or details
- B66C23/72—Counterweights or supports for balancing lifting couples
- B66C23/74—Counterweights or supports for balancing lifting couples separate from jib
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66D—CAPSTANS; WINCHES; TACKLES, e.g. PULLEY BLOCKS; HOISTS
- B66D1/00—Rope, cable, or chain winding mechanisms; Capstans
- B66D1/02—Driving gear
- B66D1/12—Driving gear incorporating electric motors
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66D—CAPSTANS; WINCHES; TACKLES, e.g. PULLEY BLOCKS; HOISTS
- B66D1/00—Rope, cable, or chain winding mechanisms; Capstans
- B66D1/28—Other constructional details
- B66D1/40—Control devices
- B66D1/42—Control devices non-automatic
- B66D1/46—Control devices non-automatic electric
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66D—CAPSTANS; WINCHES; TACKLES, e.g. PULLEY BLOCKS; HOISTS
- B66D1/00—Rope, cable, or chain winding mechanisms; Capstans
- B66D1/54—Safety gear
- B66D1/56—Adaptations of limit switches
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
- F03D—WIND MOTORS
- F03D13/00—Assembly, mounting or commissioning of wind motors; Arrangements specially adapted for transporting wind motor components
- F03D13/20—Arrangements for mounting or supporting wind motors; Masts or towers for wind motors
- F03D13/25—Arrangements for mounting or supporting wind motors; Masts or towers for wind motors specially adapted for offshore installation
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/70—Wind energy
- Y02E10/72—Wind turbines with rotation axis in wind direction
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/70—Wind energy
- Y02E10/727—Offshore wind turbines
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Automation & Control Theory (AREA)
- Life Sciences & Earth Sciences (AREA)
- Sustainable Development (AREA)
- Sustainable Energy (AREA)
- Chemical & Material Sciences (AREA)
- Combustion & Propulsion (AREA)
- General Engineering & Computer Science (AREA)
- Wind Motors (AREA)
Abstract
The invention relates to an offshore wind turbine single-blade installation robot which comprises a single-blade installation mechanical arm (1) capable of automatically adjusting posture, a hanging bracket (2) with an active compensation function and two sets of intelligent cable wind systems (3) installed at the root of a crane arm support (53), wherein the single-blade installation mechanical arm (1) is connected to the crane arm support (53) through the hanging bracket (2), the intelligent cable wind systems (3) are connected with the single-blade installation mechanical arm (1), and the single-blade installation mechanical arm (1) grabs a fan blade (41) to be installed and is installed on a wind turbine. Compared with the prior art, the invention can complete the full-automatic installation of the single blade of the offshore large-scale wind turbine generator under the conditions that the station position of the wind power installation ship is unchanged and no additional barring gear is needed. The method has the advantages of shortening the installation time, reducing the installation cost, improving the installation safety, realizing the installation of the single blade of the offshore wind turbine generator set and the like.
Description
Technical Field
The invention relates to the technical field of wind power generation, in particular to a single-blade installation manipulator of a wind turbine generator, and particularly relates to a robot capable of automatically installing a single blade of a large-scale offshore wind turbine generator.
Background
Offshore wind power generation is developed as a pollution-free renewable energy source, and has the advantages of good wind energy conditions, no land use problem, no atmospheric pollution, considerable environmental protection value and the like, so that the development is very rapid. The global offshore wind industry, especially europe, is transitioning towards larger scale wind turbines. China has the manufacturing capability of large-scale offshore wind turbines of 8 megawatts or more by 2020. The scale of the offshore wind power start construction reaches 1000 ten thousand kilowatts, and the grid-connected capacity reaches 500 ten thousand kilowatts. Meanwhile, key technologies of offshore wind power construction and grid-connected operation are broken through, and an offshore wind power plant panoramic monitoring and comprehensive control system is built. The method is superior to the European and American advanced level in the aspects of offshore wind farm construction level, operation and maintenance detection and the like. According to measurement, the newly increased capacity of China in 2020 to 2030 years reaches 200 to 300 ten thousand kilowatts. Therefore, the market space of offshore wind power is difficult to estimate. However, the severe offshore environment conditions and the complexity of offshore construction limit the progress of offshore wind power development, and research and breakthrough need to be made on the technical level including unit, construction, power transmission, operation and maintenance.
The blade is one of the most basic and key parts of an offshore wind turbine, and a wind wheel formed by the blade and a hub is an energy capture mechanism and can convert wind energy into mechanical energy. At the same time, the blades are also the main load-bearing members of the wind load. When the blades operate in gust and storm environments, the blades are easy to vibrate, deform and the like, and even are damaged or destroyed. Along with the trend of large-scale wind generating set, the center of gravity of the hub of the main engine is higher and higher, and the length and the weight of the blade are also larger and larger. The installation and operation of the blades is therefore a major problem.
The traditional fan blade is mainly installed in the following three ways:
1. and (6) assembling the single blade. And respectively hoisting the blades by using a hoisting tool. Because the lifting appliance can not adjust the installation angle in the air, the three blades can be installed only in the horizontal position. After a blade is installed, the angle of the hub needs to be adjusted to ensure that the next installed blade can be installed in a horizontal position. In the process, the weight distribution of the blades is unbalanced (as shown in fig. 8), especially for a high-power fan, the blades are long and heavy, and the hub cannot be braked at any angle only by the brake of the hub, so that a barring gear needs to be additionally arranged.
2. And (4) assembling in a three-leaf mode. The three blades and the hub cap are assembled on land to form a wind wheel, but are not connected with the nacelle. When the wind turbine is installed on the sea, the engine room is installed on the tower barrel, and the assembled wind wheel is hoisted on the engine room, so that the operations of positioning, butt joint and the like during blade installation are reduced, and the construction difficulty is reduced. However, during transportation, the blades occupy large deck space, and the requirement on the bearing of a transport ship is high. This problem is more pronounced as the blade length is lengthened and the weight is increased.
3. The whole assembled type. And after the whole fan is assembled on land, the fan is transported to the sea and butted with the foundation. Although the process is relatively simple, the transport difficulty is great. For a large fan, the method cannot be basically realized.
Therefore, the three modes can not meet the requirements of safe and efficient installation of the blades of the high-power offshore wind turbine, and the operation and maintenance requirements of a single blade in use can not be met.
Disclosure of Invention
The invention aims to overcome the defects in the prior art and provide the offshore wind turbine single-blade mounting robot which is safe and efficient to mount, convenient to transport and maintain.
The purpose of the invention can be realized by the following technical scheme: the single-blade installation robot for the offshore wind turbine is characterized by comprising a single-blade installation manipulator capable of automatically adjusting posture, a hanging bracket with an active compensation function and two sets of intelligent cable wind systems arranged at the root of a crane arm frame, wherein the single-blade installation manipulator is connected to the crane arm frame through the hanging bracket, the intelligent cable wind systems are connected with the single-blade installation manipulator, and the single-blade installation manipulator grabs a fan blade to be installed and is installed on the wind turbine.
The single-blade installation manipulator include crossbeam, davit, the hydro-cylinder that verts, computer lab, counter weight, two at least centre gripping subassemblies, davit one end be connected with the crossbeam through hinge point down, the other end is connected the gallows, the hydro-cylinder that verts connect the davit to the drive davit is around its lower hinge point swing, the crossbeam on install counter weight and computer lab, the crossbeam on be equipped with two at least centre gripping subassemblies, every centre gripping subassembly all includes a C type frame, be equipped with in the C type frame that the centre gripping hydro-cylinder is held tightly or release fan blade down with each four of centre gripping hydro-cylinder down, each centre gripping hydro-cylinder is held tightly to reduce and is used for the concentrated power on blade surface, avoid the blade to damage. All the above parts can be disassembled for easy transportation.
The upper clamping oil cylinder is arranged on the upper clamping arm, the upper clamping arm is connected with the opening and closing arm, the opening and closing arm is connected with the opening and closing oil cylinder, and the opening and closing oil cylinder drives the opening and closing arm to stretch out or retract, so that the upper clamping arm is driven to drive the upper clamping oil cylinder to clamp or loosen the fan blade, and the fan blade can freely enter and exit the C-shaped frame.
The lifting frame comprises an upper support, a lower support and three compensation oil cylinders arranged between the upper support and the lower support, wherein the upper side of the upper support is connected with a lifting hook steel wire rope on a crane arm support through a shackle, and the lower support is provided with a connecting pin shaft connected with a lifting arm of the single-blade installation mechanical arm. The hanger can actively compensate the tension change of the steel wire rope of the lifting hook caused by the vibration of the arm support of the crane, and can also adjust the tiny error of the installation position.
The upper parts of the three compensation oil cylinders are connected with the upper support through an upper connecting shaft, and the lower parts of the three compensation oil cylinders are connected with the lower support through a lower connecting shaft.
The intelligent cable wind system comprises a motor, a reduction gearbox, a cable wind steel wire rope and a winding drum which are arranged on an upper support, wherein the motor is sequentially connected with the reduction gearbox and the winding drum, the cable wind steel wire rope is wound on the winding drum, the free end of the cable wind steel wire rope is connected with the two ends of a cross beam of the single-blade installation manipulator, the upper support is connected with a lower support through a connecting bolt and is fixed on a crane arm support, so that the length of the cable wind steel wire rope is not influenced by the rotation and amplitude variation motion of the crane arm support, and the installation and the disassembly are convenient.
The motor is provided with an encoder and an overspeed switch, the output shaft of the winding drum is provided with the encoder and a limit switch, the crane arm support is provided with a cable wind pulley, and the free end of the cable wind steel wire rope is connected with the two ends of the cross beam after bypassing the cable wind pulley.
The single-blade installation mechanical arm clamps the fan blade to form a whole, and the synthetic gravity center of the single-blade installation mechanical arm is located at the origin of coordinates O in the figure. When the manipulator clamps the blade and rotates around the three coordinate axes X, Y, Z, the adjustment of the attitude of the blade in the air can be realized. Because the single-hook hoisting is adopted, under any posture, the connecting line of the integral synthetic gravity center and the upper hinge point of the suspension arm is a vertical line, and the tilting oil cylinder pushes the suspension arm to rotate around the lower hinge point of the suspension arm, so that the single-blade installation manipulator can clamp the fan blade to rotate around the Y axis; two cable wind steel wire ropes are simultaneously wound and unwound, so that the single-blade installation mechanical arm can clamp the fan blade to rotate around the X axis; two cable wind steel wire ropes are respectively wound and unwound, and the single-blade installation manipulator can clamp the fan blade to rotate around the Z axis.
According to the installation height of the blades, two cable wind pulleys are installed at proper positions of a crane arm frame, cable wind steel wire ropes led out from two driving mechanism drums are connected with a single-blade installation manipulator through pulley steering, and the speed and the position of the single-blade installation manipulator can be accurately controlled.
In order to ensure safety, the whole set of installation robot is provided with two sets of independent power systems, one set of operation is performed, one set of standby operation is performed, each set of power system is provided with an emergency lithium battery, the lithium batteries are located in a machine room of the single-blade installation manipulator, upper cables of the two sets of power systems are respectively led out from the machine room of the crane, the upper cables are connected with two cable drums near a cable wind pulley along the wiring of a crane arm frame, the cables led out from the cable drums are connected with two power supply lines in the single-blade installation manipulator and are transmitted to the machine room, and the rope storage amount of the cable drums ensures that the cables are operated at any height along with the manipulator.
The whole set of installation robot is also provided with a hydraulic system, and the hydraulic system comprises a hydraulic power station, two tilting oil cylinders, four opening and closing oil cylinders, sixteen clamping oil cylinders, three compensation oil cylinders, a hydraulic control valve group, a pipeline, a valve and the like. The hydraulic power station is positioned in the machine room and is provided with an independent circulating filtration system, a cooling system and an oil temperature and liquid level detection and display device. All the oil cylinders are controlled by electro-hydraulic proportion, and are provided with displacement sensors, so that the device has the functions of limiting the speed of movement, preventing explosion and self-locking, and can detect and control the position and the pressure.
The single-blade installation manipulator is provided with three attitude sensors, a height sensor and a GPS (global positioning system) for determining the air position and attitude of the single-blade installation manipulator, and a wind sensor for determining the operating environment of the single-blade installation manipulator; an automatic targeting device and a distance measuring sensor are arranged at a blade hub of a fan main machine to guide the operation of a single-blade installation manipulator, two video cameras with a cloud deck are respectively arranged at two positions where the single-blade installation manipulator clamps a blade, and a video camera with a cloud deck is respectively arranged in the direction of aligning a wind post and a wind tip of the blade; two movable video cameras with cloud platforms are installed at the hub of the fan main unit blade, so that an operator can conveniently monitor on line and adjust the posture of the manipulator at any time.
The whole set of installation robot is also provided with a control system, a complete machine control room is positioned in a machine room of the manipulator and is provided with a monitoring system, an operator can operate on the spot, all signals are transmitted to a remote operation console through Ethernet so as to be convenient for remote operation, and the control system is provided with three operation modes, namely manual operation, semi-automatic operation and automatic operation, can realize effective control on the system by establishing a motion model and applying a P L C control program under the full-automatic mode and adopting a model self-adaptive control method, so that the safety of the blade is ensured.
Compared with the prior art, the invention has the following beneficial effects:
1. the single-blade installation mechanical arm capable of automatically adjusting the posture can complete full-automatic installation and disassembly of a single blade of a large-scale offshore wind turbine generator set under the condition of not additionally adding a barring gear under the cooperation of an intelligent cable wind system.
2. The single-blade installation manipulator realizes the operation of the blades through the clamping oil cylinder, the opening and closing oil cylinder and the tilting oil cylinder. The pressure, position and speed of all oil cylinders can be measured, controlled and visible, so that the intelligent control of the manipulator is realized.
3. The intelligent cable wind system can realize intelligent control on the cable wind steel wire rope, is convenient to install and disassemble, and can be matched with different cranes.
4. The hanger with the active compensation function can actively compensate the tension change of a steel wire rope of the lifting hook caused by the vibration of the arm support of the crane so as to ensure the safety of the blade and the hub; minor errors in the blade mounting positions can also be adjusted.
5. In order to ensure safety, the whole machine adopts two independent power systems, one power system works and the other power system is standby, and a lithium battery is arranged for emergency. The operation demand of manipulator can be guaranteed to the detachable cable reel, also can cooperate different loop wheel machines.
6. The system can realize the full-automatic operation of the manipulator for the installation of the single blade under the assistance of an attitude sensor, a height sensor, a pressure sensor, a distance measuring sensor, a wind sensor, a GPS, an automatic targeting device, an encoder, an overspeed switch, a travel switch and a video camera with a holder and by combining P L C.
7. The action control of the mechanical arm adopts two sets of independent systems, one set of independent systems works and the other set of independent systems is standby, so that the absolute safety of the fan blade is ensured.
8. The single-blade installation robot is combined with a reasonable operation program, can ensure that the wind power installation ship can complete the installation of three blades of the whole fan under the condition of one-time standing, greatly shortens the installation time, saves the installation cost of the fan, and is particularly suitable for the requirement of large-scale current offshore fans. Meanwhile, the required necessary conditions can be provided for the disassembly and the reinstallation of the single blade of the large-scale offshore wind turbine.
Drawings
FIG. 1 is a schematic structural view of a single blade installation robot that is performing blade installation of an offshore wind turbine;
FIG. 2 is a schematic structural view of a single blade mounting robot;
FIG. 3 is a side view of a single blade mounting robot;
FIG. 4 is a top view of a single blade mounting robot;
FIG. 5 is a schematic view of a hanger with active compensation;
FIG. 6 is a side view of a hanger with active compensation;
fig. 7 is a schematic structural diagram of the intelligent cable wind system;
FIG. 8 is a sectional view taken along line A of FIG. 7;
fig. 9 is a top view of the smart cable wind system;
FIG. 10 is a schematic diagram of the operation of the single blade mounting robot;
FIG. 11 is a side view schematic diagram of a single blade mounted robot;
FIG. 12 is a schematic top view of a single blade mounted robot;
FIG. 13 is a pose of the single blade mounted robot at one angle;
FIG. 14 is a pose of the single blade mounted robot at another angle;
FIG. 15 is a crane equipped with a single blade mounted robotic system;
FIG. 16 is a first blade installation step;
fig. 17 is a second blade mounting step;
fig. 18 shows a third blade mounting step.
Detailed Description
The invention is described in detail below with reference to the figures and specific embodiments.
As shown in fig. 1 and 15, a single-blade installation robot for an offshore wind turbine comprises a single-blade installation manipulator 1 capable of automatically adjusting the posture, a hanger 2 with an active compensation function, two sets of intelligent cable wind systems 3 installed at the root of a crane arm support 53, the single-blade installation mechanical arm 1 is connected to a crane arm frame 53 through a hanging bracket 2, a lifting hook 51 is arranged on the crane arm frame 53, the lifting hook 51 is connected with the hanging bracket 2 through a steel wire rope 53, the intelligent cable wind system 3 is connected with the single-blade installation manipulator 1, as shown in fig. 1, a single blade installation manipulator 1 for installing blades of an offshore wind turbine 4 is being performed, the single blade installation manipulator 1 is installed on a crane 5, the crane 5 is installed on a self-elevating wind turbine installation platform 6, and the blade to be installed is installed on the wind turbine 4 through the single blade installation manipulator 1.
The structure of the single-blade installation manipulator 1 is shown in fig. 2-4 and comprises a cross beam 101, a suspension arm 102, an inclined oil cylinder 103, a machine room 104, a counterweight 107 and at least two clamping components, wherein one end of the suspension arm 102 is connected with the cross beam 101 through a lower hinge point, the other end of the suspension arm is connected with the suspension arm 2, the inclined oil cylinder 103 is connected with the suspension arm 102 and drives the suspension arm 102 to swing around the lower hinge point, the cross beam 101 is provided with the counterweight 107 and the machine room 104, the cross beam 101 is provided with at least two clamping components, each clamping component comprises a C-shaped frame 112, an upper clamping oil cylinder 109 and a lower clamping oil cylinder 110 are arranged in the C-shaped frame 112, and each clamping oil cylinder tightly holds or releases the fan blade 41 so as to reduce the concentrated force acting on the surface of the blade and avoid the blade from being damaged. All the above parts can be disassembled for easy transportation. The upper clamping cylinder 109 is arranged on the upper clamping arm 108, the upper clamping arm 108 is connected with the opening and closing arm 106, the opening and closing arm 106 is connected with the opening and closing cylinder 105, and the opening and closing cylinder 105 drives the opening and closing arm 106 to extend or retract, so that the upper clamping cylinder 109 is driven by the upper clamping cylinder 108 to clamp or loosen the fan blade 41, and the fan blade 41 can freely enter and exit the C-shaped frame 112.
As shown in fig. 5-6, the lifting frame 2 includes an upper bracket 202 and a lower bracket 204, and three compensating cylinders 203 installed between the upper bracket 202 and the lower bracket 204, the upper side of the upper bracket 202 is connected to a hook wire rope on the crane arm 53 through a shackle 201, and the lower bracket 204 is provided with a connecting pin 205 connected to the lifting arm 102 of the single-blade installation manipulator 1. The hanger can actively compensate the change of the tension of the steel wire rope of the hanger caused by the vibration of the arm support of the crane, and can also adjust the tiny error of the installation position. The upper parts of the three compensation oil cylinders 203 are connected with the upper bracket 202 through an upper connecting shaft 206, and the lower parts are connected with the lower bracket 204 through a lower connecting shaft 207.
As shown in fig. 7-9, the intelligent cable wind system 3 includes a motor 301, a reduction box 302, a cable wind steel wire rope 303 and a winding drum 304, which are mounted on an upper support 306, the motor 301 is sequentially connected with the reduction box 302 and the winding drum 304, the cable wind steel wire rope 303 is wound on the winding drum 304, the free end of the cable wind steel wire rope 303 is connected with two ends of the beam 101 of the single-blade mounting manipulator 1, the upper support 306 is connected with a lower support 307 through a connecting bolt 308 and is fixed on the crane boom 53, so that the length of the cable wind steel wire rope 303 is not affected by the rotation and amplitude variation motion of the crane boom 53, and the mounting and dismounting are also facilitated. The motor 301 is provided with an encoder and an overspeed switch, the output shaft of the winding drum 304 is provided with the encoder and a limit switch 305, the crane arm support 53 is provided with a cable wind pulley 310, and the free end of the cable wind steel wire rope 303 is connected with the two ends of the cross beam 101 after bypassing the cable wind pulley 310.
The single-blade installation manipulator 1 clamps the fan blade 41 to form a whole, the synthetic gravity center I of the single-blade installation manipulator is located at the origin of coordinates O shown in the drawing, as shown in figures 10-12, when the manipulator clamping blade rotates around three coordinate axes X, Y, Z, the adjustment of the aerial posture of the blade can be realized, as the single-hook hoisting is adopted, the connecting line of the synthetic gravity center of the whole and a hinge point G on the suspension arm 102 is a vertical line L in any posture, as shown in figures 13-14, the tilting oil cylinder 103 pushes the suspension arm 102 to rotate around the lower hinge point, the single-blade installation manipulator 1 can clamp the fan blade 41 to rotate around the Y axis, two cable wind steel ropes 303 are simultaneously wound and unwound, the single-blade installation manipulator 1 can clamp the fan blade 41 to rotate around the X axis, and the two cable wind steel ropes 303 are respectively wound and unwound, so that the single-blade installation manipulator 1 can clamp the fan.
According to the blade installation height, two cable wind pulleys 310 are installed at proper positions of a crane arm support 53, and cable wind steel wires 303 led out from two driving mechanism winding drums 304 are connected with a single blade installation mechanical arm through pulley turning, so that the speed and the position of the single blade installation mechanical arm can be accurately controlled.
In order to ensure safety, the whole set of installation robot is provided with two independent power systems, one set of operation and one set of standby power system, each power system is provided with an emergency lithium battery, the lithium batteries are located in the machine room 104 of the single-blade installation manipulator 1, the upper cables 703 of the two power systems are respectively led out from the machine room of the crane, the cables are connected with two cable drums 702 near the cable pulley 310 along the wiring of the crane arm support 53, the cables 701 led out from the cable drums 702 are connected with two power supply lines in the single-blade installation manipulator 1 and are transmitted to the machine room 104, and the rope storage capacity of the cable drums 702 ensures that the cables 701 can be operated at any height along with the manipulator. As shown in fig. 15.
The whole set of installation robot is also provided with a hydraulic system, and the hydraulic system comprises a hydraulic power station, two tilting oil cylinders, four opening and closing oil cylinders, sixteen clamping oil cylinders, three compensation oil cylinders, a hydraulic control valve group, a pipeline, a valve and the like. The hydraulic power station is positioned in the machine room and is provided with an independent circulating filter, a cooling system air cooling device, an oil temperature device, a liquid level detection device and a display device. All the oil cylinders are controlled by electro-hydraulic proportion, are provided with displacement sensors, have the functions of limiting speed of movement, preventing explosion and locking by self, and can detect and control the position and the pressure.
The single-blade installation mechanical arm 1 is provided with three attitude sensors, a height sensor and a GPS (global positioning system) for determining the air position and attitude of the single-blade installation mechanical arm, and a wind sensor for determining the operating environment of the single-blade installation mechanical arm; an automatic targeting device and a distance measuring sensor are arranged at a blade hub of a fan main machine to guide the operation of a single-blade installation mechanical arm 1, two video cameras with a cloud deck are respectively arranged at two positions where the single-blade installation mechanical arm 1 clamps a blade, and a video camera with a cloud deck is respectively arranged in the direction of aiming at a wind post and a wind tip of the blade; two movable video cameras with cloud platforms are installed at the hub of the fan main machine blade, so that an operator can conveniently monitor on line and adjust the posture of the manipulator at any time.
The whole set of installation robot is also provided with a control system, a complete machine control room is positioned in a machine room of the manipulator and is provided with a monitoring system, an operator can operate on the spot, all signals are transmitted to a remote operation console through Ethernet so as to be convenient for remote operation, and the control system is provided with three operation modes, namely manual operation, semi-automatic operation and automatic operation, can realize effective control on the system by establishing a motion model and applying a P L C control program under the full-automatic mode and adopting a model self-adaptive control method, so that the safety of the blade is ensured.
The specific process of installing the blades of the offshore wind turbine generator by using the single-blade installation robot is as follows:
1. the first blades being mounted horizontally
1.1, a single-blade installation mechanical arm 1 clamps and holds a first blade horizontally placed on a deck at a 0-degree horizontal position, a crane lifts the mechanical arm and the blade to a hub installation height through an active compensation hanging bracket 2, and the single-blade installation mechanical arm is installed in place at the 0-degree position. In the hoisting process, the compensation oil cylinder is locked, namely, the active compensation hanger does not work. When the blade is installed, the height positions of the blades and the hub are staggered due to the vibration of the arm support. At this time, the compensation function can be started, and the compensation oil cylinder is used for enabling the compensation oil cylinder and the compensation oil cylinder to be located at the same height. When the alignment is carried out, the manipulator can automatically sense and adjust the relative position between the blade and the hub through the tilting oil cylinder 103 and the cable wind steel wire rope 303 by utilizing the automatic alignment target device and the distance measuring sensor.
1.2, rotating the first blade from 0 degrees to a-60 degrees clockwise by the single-blade installation mechanical arm 1. When the blade is at 0 degree, the eccentricity of the gravity center to the hub is the largest, and the braking torque of the host brake is insufficient. As the angle is changed from 0 degrees to-60 degrees, the eccentricity is reduced, and the main brake can brake. Therefore, in this process, the single blade mounting robot 1 adjusts the blade angle to-60 ° by the tilt cylinder 103 and descends along with the lifting point. In order to protect the safety of the main engine brake, the active compensation oil cylinder works to ensure that the force for lifting the steel wire rope is constant, namely the weight of the manipulator and the blade is born by the lifting steel wire rope. At the position of 60 degrees below zero, the manipulator clamps the oil cylinder to release pressure and release, the opening and closing oil cylinder is recovered, the opening and closing arm is opened, and the blade is withdrawn.
1.3, the unit is electrified to yaw, and the first blade rotates clockwise from-60 degrees to-120 degrees. In this process, the eccentricity of the center of gravity of the blade is greatest at both extreme positions-60 ° and-120 °, and is equal in value.
2. The second blade is horizontally arranged
2.1, clamping and holding a second support blade horizontally placed on a deck at a horizontal position of 0 degree by the single-blade installation mechanical arm 1, lifting the mechanical arm and the blade to a hub installation height by the crane through the active compensation hanging bracket, and installing the blade in place at the position of 0 degree. In the hoisting process, the compensation oil cylinder is locked, namely, the active compensation hanger does not work. When the blade is installed, the height positions of the blades and the hub are staggered due to the vibration of the arm support. At this time, the compensation function can be started, and the compensation oil cylinder is used for enabling the compensation oil cylinder and the compensation oil cylinder to be located at the same height. When the alignment is carried out, the manipulator can automatically sense and adjust the relative position between the blade and the hub through the tilting oil cylinder 103 and the cable wind steel wire rope 303 by utilizing the automatic alignment target device and the distance measuring sensor.
2.2, the second blade is rotated anticlockwise to the position of +30 degrees from 0 degrees by the aid of the single-blade mounting mechanical arm 1, and meanwhile, the first blade is also rotated anticlockwise to the position of-90 degrees from-120 degrees along with the hub. In this process, the robot adjusts the blade angle to +30 ° by tilting the cylinder 103, and the lifting point is raised. In order to protect the safety of the main brake, the active compensation oil cylinder works to ensure that the force for lifting the steel wire rope is constant, namely the weight of the manipulator and the second blade is born by the lifting steel wire rope. The main machine hub only bears the moment caused by the weight of the first blade. The center of gravity of the first blade is the largest at the position of-120 degrees, and when the first blade rotates anticlockwise to-90 degrees, the center of gravity is on a vertical line with the center of the hub, so that the gravity moment is 0. When the second blade is located at the position of +30 degrees, the manipulator clamping oil cylinder releases pressure and releases, the opening and closing oil cylinder is recovered, the opening and closing arm is opened, and the second blade is withdrawn. At this time, the main engine hub receives only the moment caused by the gravity of the second branch blade.
2.3, the unit is electrified to yaw 180 degrees, namely the host drives the first and second blades to horizontally rotate 180 degrees, so as to ensure that the mounting holes of the third blade return to the right side, and the third blade is still mounted from the right side to the left side after being lifted by the crane. Therefore, the wind power installation ship can complete the installation of one fan at one time without displacement. Especially, at present, offshore wind power generation sets are usually installed by adopting self-elevating installation platforms, and once the offshore wind power generation sets are displaced, pile legs are required to be folded and piles are inserted again by the platforms, so that the process is complicated and a large amount of time is consumed. In the process, since the first blade is always perpendicular to the host hub, the gravitational moment is 0; the angle of the second partial blade with respect to the hub is not changed, i.e. the angle with respect to the horizontal is always 30 °, so that the moment of gravity remains unchanged.
3. The third blade is horizontally arranged
3.1, clamping and holding a third blade horizontally placed on a deck at a horizontal position of 0 degree by the single-blade installation mechanical arm 1, and lifting the mechanical arm and the blade to the hub installation height by the crane through the active compensation hanging bracket. In the hoisting process, the compensation oil cylinder is locked, namely, the active compensation hoisting frame does not work.
And 3.2, rotating the third blade from 0 degrees to a position of +30 degrees anticlockwise by the aid of the single-blade mounting manipulator 1, and mounting. In the process, the manipulator adjusts the blade angle to +30 degrees through the tilting oil cylinder, and the lifting point is increased. In order to protect the host machine from being braked and installed, the height positions of the blades and the hub are staggered due to the vibration of the arm support. At this time, the compensation function can be started, and the compensation oil cylinder is used for enabling the compensation oil cylinder and the compensation oil cylinder to be located at the same height. When the alignment is carried out, the mechanical arm can automatically sense and adjust the relative position between the blade and the hub through the tilting oil cylinder and the cable wind steel wire rope by utilizing the automatic alignment target device and the distance measuring sensor.
3.3, after the third blade is installed, releasing the pressure of the manipulator clamping oil cylinder, releasing the pressure, recovering the opening and closing oil cylinder, opening the opening and closing arm and withdrawing the third blade. And finishing the installation of all the blades.
When blades of an offshore wind turbine need to be detached in operation and maintenance, the blades needing to be repaired and replaced need to be detached according to the reverse operation of the installation sequence.
Claims (10)
1. The single-blade installation robot for the offshore wind turbine is characterized by comprising a single-blade installation mechanical arm (1) capable of automatically adjusting posture, a hanging bracket (2) with an active compensation function and two sets of intelligent cable wind systems (3) installed at the root of a crane arm support (53), wherein the single-blade installation mechanical arm (1) is connected to the crane arm support (53) through the hanging bracket (2), the intelligent cable wind systems (3) are connected with the single-blade installation mechanical arm (1), and the single-blade installation mechanical arm (1) grabs a fan blade (41) to be installed and is installed on the wind turbine.
2. The offshore wind turbine single-blade mounting robot of claim 1, wherein the single-blade mounting robot (1) comprises a cross beam (101), a boom (102), a tilting cylinder (103), a machine room (104), a counterweight (107) and at least two clamping assemblies, one end of the boom (102) is connected with the cross beam (101) through a lower hinge point, the other end of the boom is connected with the hanger (2), the tilting cylinder (103) is connected with the boom (102) and drives the boom (102) to swing around the lower hinge point, the cross beam (101) is provided with the counterweight (107) and the machine room (104), the cross beam (101) is provided with at least two clamping assemblies, each clamping assembly comprises a C-shaped frame (112), four upper clamping cylinders (109) and four lower clamping cylinders (110) are arranged in the C-shaped frame (112), and each clamping cylinder holds or releases a fan blade (41), to reduce the concentrated forces acting on the blade surface and avoid damage to the blade.
3. The offshore wind turbine single-blade mounting robot is characterized in that the upper clamping cylinder (109) is arranged on the upper clamping arm (108), the upper clamping arm (108) is connected with the opening and closing arm (106), the opening and closing arm (106) is connected with the opening and closing cylinder (105), the opening and closing cylinder (105) drives the opening and closing arm (106) to extend or retract, and therefore the upper clamping arm (108) is driven to drive the upper clamping cylinder (109) to clamp or loosen the fan blade (41), and the fan blade (41) can freely enter and exit the C-shaped frame (112).
4. The offshore wind turbine single-blade mounting robot as claimed in claim 2, wherein the lifting frame (2) comprises an upper support (202) and a lower support (204), and three compensating cylinders (203) mounted between the upper support (202) and the lower support (204), the upper part of the upper support (202) is connected with a lifting hook steel wire rope on a crane arm support (53) through a shackle (201), and the lower support (204) is provided with a connecting pin shaft (205) connected with the lifting arm (102) of the single-blade mounting manipulator (1).
5. The offshore wind turbine single-blade mounting robot as claimed in claim 4, wherein the three compensation oil cylinders (203) are connected with the upper bracket (202) through upper connecting shafts (206) at the upper part and connected with the lower bracket (204) through lower connecting shafts (207) at the lower part.
6. The offshore wind turbine single-blade installation robot as claimed in claim 2, wherein the intelligent cable wind system (3) comprises a motor (301), a reduction gearbox (302), a cable wind steel wire rope (303) and a winding drum (304) which are installed on an upper support (306), the motor (301) is sequentially connected with the reduction gearbox (302) and the winding drum (304), the cable wind steel wire rope (303) is wound on the winding drum (304), the free end of the cable wind steel wire rope (303) is connected with two ends of a cross beam (101) of the single-blade installation manipulator (1), and the upper support (306) is connected with a lower support (307) and fixed on a crane arm support (53).
7. The offshore wind turbine single-blade mounting robot as claimed in claim 6, wherein the motor (301) is provided with an encoder and an overspeed switch, the output shaft of the winding drum (304) is provided with the encoder and a limit switch (305), the crane arm support (53) is provided with a cable wind pulley (310), and the free end of the cable wind steel wire rope (303) bypasses the cable wind pulley (310) and then is connected with two ends of the cross beam (101).
8. The offshore wind turbine single-blade mounting robot as claimed in claim 7, wherein the single-blade mounting manipulator (1) clamps the fan blade (41) as a whole, the connection line of the synthetic center of gravity of the whole and the pivot point on the boom (102) is a vertical line, and the tilting cylinder (103) pushes the boom (102) to rotate around the lower pivot point thereof, so that the single-blade mounting manipulator (1) can clamp the fan blade (41) to rotate around the Y axis; two cable wind steel wire ropes (303) are simultaneously wound and unwound, so that the single-blade installation manipulator (1) can clamp the fan blade (41) to rotate around the X axis; two cable wind steel wire ropes (303) are respectively wound and unwound, and the single-blade installation manipulator (1) can clamp the fan blade (41) to rotate around the Z axis.
9. The offshore wind turbine single-blade installation robot is characterized in that the whole set of installation robot is provided with two independent power systems, one set of power system works and the other set of power system is standby, each set of power system is provided with an emergency lithium battery, the lithium batteries are located in a machine room (104) of a single-blade installation manipulator (1), upper cables (703) of the two sets of power systems are respectively led out from a crane machine room and are connected with two cable drums (702) located near a cable wind pulley (310) along the wiring of a crane arm frame (53), cables (701) led out of the cable drums (702) are connected with two power supply lines in the single-blade installation manipulator (1) and are transmitted to the machine room (104), and the rope storage amount of the cable drums (702) ensures that the cables (701) operate at any height along with the manipulator;
and a monitoring system is also arranged in the machine room (104), and all signals are transmitted to a remote operation console through Ethernet so as to facilitate remote operation.
10. The offshore wind turbine single-blade mounting robot according to claim 1, characterized in that the single-blade mounting robot (1) is equipped with three attitude sensors, one altitude sensor, one GPS to determine its aerial position and attitude, one wind sensor to determine its operating environment; an automatic targeting device and a distance measuring sensor are arranged at a hub of a fan main machine blade to guide the operation of a single-blade installation manipulator (1), two positions where the single-blade installation manipulator (1) clamps the blade are respectively provided with a video camera with a holder, and a video camera with a holder is respectively arranged in the direction of aligning the wind column and the wind tip of the blade; two movable video cameras with cloud platforms are installed at the hub of the fan main unit blade, so that an operator can conveniently monitor on line and adjust the posture of the manipulator at any time.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201910060323.2A CN111453629B (en) | 2019-01-22 | Marine wind turbine unit single blade installation robot |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201910060323.2A CN111453629B (en) | 2019-01-22 | Marine wind turbine unit single blade installation robot |
Publications (2)
| Publication Number | Publication Date |
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| CN111453629A true CN111453629A (en) | 2020-07-28 |
| CN111453629B CN111453629B (en) | 2024-07-05 |
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| CN112283018A (en) * | 2020-10-22 | 2021-01-29 | 中交第一航务工程局有限公司 | Three-dimensional adjustable hub blade assembling platform and blade mounting method thereof |
| CN113982848A (en) * | 2021-10-20 | 2022-01-28 | 广东精铟海洋工程股份有限公司 | Installation method of single blade of offshore wind driven generator |
| CN116201693A (en) * | 2023-04-23 | 2023-06-02 | 上海海事大学 | Self-propelled self-elevating fan mounting ship and mounting method |
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