EP2422929B1 - Grinding device for mechanical grinding of rotor blades for wind power systems - Google Patents
Grinding device for mechanical grinding of rotor blades for wind power systems Download PDFInfo
- Publication number
- EP2422929B1 EP2422929B1 EP10174283.1A EP10174283A EP2422929B1 EP 2422929 B1 EP2422929 B1 EP 2422929B1 EP 10174283 A EP10174283 A EP 10174283A EP 2422929 B1 EP2422929 B1 EP 2422929B1
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- EP
- European Patent Office
- Prior art keywords
- grinding
- belt
- dust
- unit
- rotor blade
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- 238000000227 grinding Methods 0.000 title claims description 158
- 239000000428 dust Substances 0.000 claims description 67
- 238000000576 coating method Methods 0.000 claims description 38
- 239000011248 coating agent Substances 0.000 claims description 34
- 238000004140 cleaning Methods 0.000 claims description 24
- 239000007921 spray Substances 0.000 claims description 4
- 238000007664 blowing Methods 0.000 claims description 2
- 230000001680 brushing effect Effects 0.000 claims description 2
- 238000000034 method Methods 0.000 description 5
- 238000007639 printing Methods 0.000 description 5
- 238000000605 extraction Methods 0.000 description 4
- 238000004519 manufacturing process Methods 0.000 description 4
- 239000000463 material Substances 0.000 description 3
- 238000005452 bending Methods 0.000 description 2
- 239000000945 filler Substances 0.000 description 2
- 238000003754 machining Methods 0.000 description 2
- 239000006061 abrasive grain Substances 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 230000003111 delayed effect Effects 0.000 description 1
- 230000003628 erosive effect Effects 0.000 description 1
- 239000004744 fabric Substances 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 238000010422 painting Methods 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 229920002635 polyurethane Polymers 0.000 description 1
- 239000004814 polyurethane Substances 0.000 description 1
- 238000010248 power generation Methods 0.000 description 1
- 230000005855 radiation Effects 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
- 239000004576 sand Substances 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B21/00—Machines or devices using grinding or polishing belts; Accessories therefor
- B24B21/16—Machines or devices using grinding or polishing belts; Accessories therefor for grinding other surfaces of particular shape
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B55/00—Safety devices for grinding or polishing machines; Accessories fitted to grinding or polishing machines for keeping tools or parts of the machine in good working condition
- B24B55/06—Dust extraction equipment on grinding or polishing machines
- B24B55/08—Dust extraction equipment on grinding or polishing machines specially designed for belt grinding machines
Definitions
- the present invention relates to a grinding apparatus for machine grinding rotor blades for wind turbines.
- the grinding device can be used to automate grinding operations during the manufacture and maintenance of rotor blades.
- wind turbines which have a rotor which drives a generator and which is rotatably mounted on a mast.
- stresses to which the components, in particular the rotor blades of the wind turbine are exposed, are enormous.
- the extremely contaminated plastic surfaces of rotor blades are coated several times.
- the coating systems for protecting the surfaces consist of a so-called gelcoat, spatula, edge protection and topcoats.
- the dafiir used products generally consist of solvent-free, two-component polyurethane compounds. After the application of the individual layers, these must be ground in each case.
- the rotor blades to be ground have a length of up to about 80 m and a surface to be ground of up to about 300 m 2. Accordingly, the area to be ground manually is very large.
- a grinding apparatus according to the preamble of claim 1 is known. It has a cylindrical rotatable grinding element, are attached to the radially projecting abrasive sheets.
- the Where 2006/006843 A1 shows such a sanding belt cleaning system for a portable belt sander, wherein the portable belt sander has a revolving sanding belt.
- the viscoelastic coatings of the rotor blades are used because rotor blades move at speeds of up to 300 km / h and they must not be damaged when, for example, hailstones hit them.
- DE 298 05 833 U1 DE 199 29 386 A and DE 297 09 342 U1 describes coating systems for rotor blades.
- the cost of the grinding work can be 30% and more of the manufacturing cost of a rotor blade.
- the grinding process can be automated, eliminating the need for manual grinding. Grinding work, which is currently carried out with hand grinders, can be omitted and carried out by means of the grinding device according to the invention. This is made possible by the use of a belt grinding unit with a revolving sanding belt, which makes it possible to mechanically grind several 100 square meters of tough-elastic coating of a rotor blade for wind turbines.
- revolving abrasive belts has the advantage that only one part of the abrasive belt is engaged with the rotor blade while another part of the abrasive belt is freely accessible and in this area of the tough-elastic sanding dust can be cleaned. This prevents a rapid clogging of the sanding belt with the likewise viscoelastic sanding dust.
- an abrasive belt has the advantage that the grinding speed is infinitely variable and can be exactly adapted to the coating of the rotor blades.
- the grinding device further comprises a drive unit for moving the belt grinding unit in the direction of the longitudinal axis of a rotor blade.
- the belt grinding unit with the preferably transverse to the rotor blade rotating belt is moved by a drive unit in the direction of the longitudinal axis of the rotor blade.
- the continuous grinding process also gives a smoother grinding result than a batch hand grinding.
- By rotating the rotor blade about its longitudinal axis the entire surface of the rotor blade can be mechanically ground in further passages.
- the grinding device further comprises a dust belt unit with a circumferential dust belt, which is guided along at least one surface of a rotor blade in order to free the surface of the rotor blade from dust.
- a dust belt unit with a circumferential dust belt, which is guided along at least one surface of a rotor blade in order to free the surface of the rotor blade from dust.
- the dust band With the aid of the dust band, after sanding, the surface of the Rotor blades are cleaned of Straub so that it is suitable for direct recoating.
- the dust-tape unit By using the dust-tape unit, a quasi-dust-free surface of the rotor blade is obtained.
- the grinding device further comprises at least one belt cleaning device.
- the belt cleaning device By means of the belt cleaning device, the abrasive belt and / or the dust belt are cleaned continuously during the respective use of the belt. This increases in particular the service life of the grinding belt many times over a sanding belt without suction or even a sanding belt, is sucked in the dust.
- the belt cleaning device cleans the abrasive belt and / or the dust belt by means of a nozzle for inflating compressed air and / or a device for extracting sanding dust and / or a brush for brushing the abrasive belt and / or the dust belt.
- the belt grinding unit preferably has pressure elements which press the sanding belt and / or the dust belt against a surface of a rotor blade and which are mounted on the drive unit.
- pressure elements of the grinding pressure of the abrasive belt or the cleaning pressure of the dust belt can be precisely determined and varied, and thus the grinding and cleaning conditions are precisely determined on the surface of the rotor blade.
- the pressure elements in the direction of the transverse axis of a rotor blade on the drive unit movable link pressure bar or pressure rollers.
- Sectional pressure bars or pressure rollers can adhere to the curved surface adjust the rotor blade and thus results in a uniform contact pressure for the abrasive belt or the dust belt.
- the pressure elements can be pneumatically driven against the surface of a rotor blade to set the grinding pressure of the abrasive belt and / or the cleaning pressure of the dust belt on the surface. Due to the pneumatic control, the grinding pressure of the grinding belt can be precisely determined by the air pressure used. In this case, the pressure element adapt automatically to the curved surface of the rotor blade, without the need for a complex control is necessary.
- the individual members of the sectional pressure bar or the pressure rollers are each subjected to the same air pressure, so that their pressure on the surface is always constant even with variable geometries of the surface of the rotor blade.
- the same principle can also be realized via a hydraulic control.
- the pressure elements preferably have a suction hood in order to suck off grinding dust through the abrasive belt and / or the dust belt and through the pressure element.
- a suction hood in order to suck off grinding dust through the abrasive belt and / or the dust belt and through the pressure element.
- the dust belt unit is attached to the drive unit and can therefore also be moved along the rotor blade in the longitudinal direction.
- the drive unit preferably has a drive carriage which can be moved in the longitudinal direction, on which the belt grinding unit and / or the dust belt unit are mounted so as to be movable perpendicular thereto.
- the drive unit serves the belt grinding unit and / or the dust belt unit during the respective processing along the rotor blade and onto the rotor blade to and from it.
- the grinding device preferably also has a control unit which numerically controls at least the movements of the drive unit and / or the movements of the pressure elements in the direction of a rotor blade.
- the movement of the drive unit and / or the movements of the pressure elements in the direction of the rotor blade are preferably numerically controlled (NC) in order to grind the entire surface of the rotor blade with a uniform contact pressure and to the desired degree.
- the control unit causes the contours of the respective rotor blade to be traced by the drive unit.
- the grinding device further comprises a belt tensioner which holds the abrasive belt in a tension necessary for grinding.
- the abrasive belt is a perforated abrasive belt which is provided with perforations substantially over its entire surface.
- a perforated abrasive belt which, in contrast to ordinary abrasive belts, has many small, closely spaced perforations, the sanding dust on the abrasive surface has only a very short distance to travel through the sanding belt to be sucked backwards. Accordingly, the use of perforated abrasive belts reduces the risk of the abrasive belt clogging.
- the grinding apparatus further comprises a coating unit for automatically coating the surface of a rotor blade, which is attached to the drive unit.
- a coating unit for automatically coating the surface of a rotor blade, which is attached to the drive unit.
- the rotor blade can be recoated or repainted after grinding with the same device. This has the advantage that the rotor blade can remain on the system and not to a Painting plant must be moved. Furthermore, an automated coating is much more uniform than a manual job and without dangers for a painter.
- the coating unit has at least one automatically movable coating roller and / or at least one automatically movable spray unit and / or at least one radiant heater.
- the coating of the rotor blade can be carried out by rolling or by spraying, wherein the respective type of coating depends on the material used for the coating. After coating, or even parallel to this, the newly coated surfaces can be dried by means of a radiant heater accelerated. This reduces the total machining time of the rotor blade.
- this relates to a ship for processing rotor blades of wind turbines with a grinding device as described above.
- a ship with a grinding device for mechanical grinding of rotor blades for wind turbines could be used in particular for the revision of rotor blades in offshore wind turbines.
- the possibility of grinding and re-coating the rotor blades directly on the sea reduces the transport times of the rotor blades during the overhaul and the wind turbine can be reused in a very short time.
- Fig. 1 shows a side view of a grinding apparatus 1 for machine grinding of rotor blades 100.
- a belt grinding unit 10 is arranged, which can grind a surface 110 of a rotor blade 100 of a wind turbine with a revolving grinding belt 12.
- the rotating abrasive belt 12 by means of guide rollers 22 out, which are attached to a main body 21 of the belt grinding unit 10.
- the drive of the sanding belt 12 via a controllable electric drive motor 20, which sets the grinding speed. So that the grinding belt 12 is always under the required tension, the belt grinding unit 10 is equipped with a belt tensioner 18, which acts on the belt 12 via a guide roller 22.
- the belt grinding unit 10 has pressure elements 14, 15, which can be driven in the transverse direction Q to the main body 21 numerically controlled up and down and which press in the direction Z pneumatically against the back of the grinding belt 12.
- the pressure elements 14, 15 serve to press the sanding belt 12 with the required sanding pressure to the surface 110 of the rotor blade 100 and to apply this sanding pressure to any desired location of the surface 110 in a targeted manner.
- the pressure elements 14, 15 can be moved pneumatically by means of one or more pneumatic cylinders 26 in the direction Z against the surface of the rotor blade in order to apply the necessary grinding pressure.
- the required grinding pressure can then be adjusted very easily via the pressure in the respective pneumatic cylinders 26. This has the advantage that even with changing geometries of the surface 110, the same defined grinding pressure can always be set for grinding. This happens purely by mechanical means, without the need for elaborate control devices are necessary.
- the printing elements can be designed as movable segmental pressure bars 14 or pressure rollers 15, as described in detail in FIG Fig. 4 are shown. Exemplary is in Fig. 4 shown on the left side of a pressure element 15 with three pressure rollers 23 which press against the back of the grinding belt 12. Both the pressure element 15 as a whole, as well as the individual pressure rollers 23 are with corresponding Pneumatic cylinders 26 provided that are individually adjustable. For a precise and individually adjustable grinding of the surface 110 is possible.
- the pressure rollers 23 are surrounded by a suction hood 17, to which a negative pressure is applied in order to suck the grinding dust through the grinding belt 12 therethrough.
- the pressure elements 14, 15 may be further provided with guide rollers 22, which ensure a low-friction transition of the abrasive belt 12 to the pressure element 14, 15.
- a pressure element 14 in the form of a sectional pressure bar 14 is shown on the right side of the Fig. 4 .
- the segmental pressure beam 14 as a whole is also pressed by a pneumatic cylinder 26 against the back of the abrasive belt 12, wherein the members 25 of the link pressure beam 14 are individually controllably pressed against the grinding belt 12 also via their own pneumatic cylinder 26. Again, an individually adjustable and pinpoint grinding of the surface 110 of the rotor blade 100 is possible.
- the segmented pressure bar 14 is provided with an exhaust (not shown) which acts on a suction hood 16. For effective extraction, the segmented pressure beam 14 is provided with openings that allow extraction of grinding dust through the abrasive belt 12.
- the sanding belt 12 is preferably a perforated sanding belt which is provided with comparatively small perforation openings which have a diameter of preferably 1 mm to 4 mm and a spacing of the perforation openings from one another of preferably 10 mm to 20 mm.
- the abrasive belt may otherwise be constructed of a base fabric having abrasive grains coated thereon and having a width of preferably 100-300 mm.
- the belt grinding unit 10 is further equipped with a belt cleaner 16 for the abrasive belt 12.
- the belt cleaning device 16 preferably comprises, as in Fig. 5 As a result, easily adhering dust particles detach from the grinding surface of the grinding belt 12, which can then be sucked off by a suction unit (not shown) connected to a suction hood 29. Furthermore, the belt cleaning device 16 comprises a brush 27, which are pressed by means of pressure cylinder 26 against the grinding surface of the sanding belt 12.
- the brush 27 also dissolves stuck, tough grinding dust, which is not yet removed by blowing off with the nozzle 28. The thus dissolved grinding dust is then sucked by means of the suction hood 29 and an additional suction 24, which is directed to the grinding side of the grinding belt 12.
- the belt cleaning device 16 With the belt cleaning device 16, it is possible to virtually completely clean the sanding belt 12 of adhering sanding dust of the viscoelastic coatings of the rotor blade 100. In this case, the fact is exploited that only a part of the grinding belt 12 is always in engagement with the surface 110 of the rotor blade 100 and a large part of the grinding belt 10 is freely accessible, in particular for belt cleaning.
- the belt grinding unit 10 by a drive unit 30 along the rotor blade 100 is movable.
- This is preferably done by an electrically driven drive carriage 32, which is guided on rails 33, numerically controlled (NC) along the longitudinal axis L of the rotor blade can be moved.
- the belt grinding unit 10 is numerically total controlled (NC) in the direction Z on the rotor blade 100 to or from the rotor blade 100 movable away.
- the surface 110 of the rotor blade 100 can thus be ground precisely at any point.
- Fig. 1 In order to grind the profile nose or the lower shell of the rotor blade, it is also possible to rotate the rotor blade 100 about the longitudinal axis L and for machining the rotor blade in determine the desired positions 100. However, it is also possible to equip the grinding devices with a plurality of belt grinding units 10 so that the rotor blade 11 can be machined on both sides or on all sides at the same time. It is further advantageous that opposite belt grinding units 10 each exert a counter-pressure on the rotor blade 100, so that a bending of the rotor blade 100 is largely avoided during grinding.
- a dust belt unit 40 In a similar manner as the belt grinding unit 10 is in Fig. 1 mounted on the left side of a dust belt unit 40 with a rotating dust belt 42 on the grinding device 1.
- a base body 41 carries guide rollers 49, which ensure the circulation of a dust belt 42.
- the dust band 42 is guided along the surface 110 of a rotor blade 100 in order to pick up the resulting grinding dust there and to almost completely clear the surface 110 of dust. This can be done with a dust belt unit 40 automatic wiping or dedusting of the rotor blade 100.
- the dust belt unit 40 has a belt tensioner 48 which holds the dust belt 40, which preferably consists of a nonwoven material, in the required tension.
- the dust belt unit preferably has pneumatically controlled pressure elements 44 which press the dust belt 42 against the surface 110.
- the printing elements 44 can be moved up and down on the main body 41 in the transverse direction Q to selectively press the dust belt 42 to the desired location of the surface 110 of the rotor blade 100.
- the pressure elements 44 are constructed similarly to the pressure elements 14, 15 for the abrasive belt 12, which in Fig. 4 are shown.
- the pressure elements 44 furthermore have a suction hood 47 in order to suck the dust absorbed by the dust band 42 out of the dust band 42.
- the dust belt unit 40 is also provided with a belt cleaning device 46, which essentially corresponds to the belt cleaning device 16 of the abrasive belt 12, which in FIG Fig. 5 is shown. By this belt cleaning device 46, the dust belt 42 is continuously cleaned by the recorded grinding dust, so that clogging of the dust belt 42 is avoided.
- the dust belt unit 40 as a whole is similar to the belt grinding unit 10 on the movable drive carriage 32 by means of another in the Z direction numerically controlled (NC) movable and electrically driven carriage 35 stored so that the entire surface 110 of the rotor blade 100 can be cleaned.
- NC numerically controlled
- the grinding apparatus 1 further comprises a coating unit 50 which serves to automatically coat the surface 110 of a rotor blade 100.
- the coating unit 50 may comprise at least one automatically displaceable coating roller 52 and / or at least one automatically movable spray unit and / or at least one radiant heater 54 (cf. Fig. 3 ) exhibit.
- a coating unit 50 By means of such a coating unit 50, the ground and cleaned rotor blade 100 can be coated with the next layer of the layer system to be applied.
- a spray unit (not shown) or an automatically movable coating roller 52 is used.
- the grinding apparatus 1 can also be equipped with at least one electric radiant heater 54, which can likewise be positioned at any point on the surface 110 of the rotor blade 100.
- Rotor blades 100 for wind turbines must be serviced at regular intervals and, if required by damage and stress, also be recoated.
- the surface 110 of the rotor blade 100 is abraded and provided with a new coating. Since many of the wind turbines are installed in the sea (so-called offshore wind turbines) is provided to provide a ship for processing rotor blades of wind turbines, on which an automatic grinder 1, as described above, is installed. Thus, a revision of the rotor blades 100 is possible on site and it reduces the transport routes. Due to the complete automation of grinding, cleaning and recoating, these processes can also be carried out on a constantly moving ship.
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Finish Polishing, Edge Sharpening, And Grinding By Specific Grinding Devices (AREA)
- Polishing Bodies And Polishing Tools (AREA)
Description
Die vorliegende Erfindung betrifft eine Schleifvorrichtung zum maschinellen Schleifen von Rotorblättern für Windkraftanlagen. Mit Hilfe der Schleifvorrichtung können Schleifarbeiten bei der Herstellung und bei der Wartung von Rotorblättern automatisiert werden.The present invention relates to a grinding apparatus for machine grinding rotor blades for wind turbines. The grinding device can be used to automate grinding operations during the manufacture and maintenance of rotor blades.
Als eine der umweltfreundlichsten Formen der Energiegewinnung wird die Verwendung von Windkraft zur Stromerzeugung angesehen. Hierzu werden Windkraftanlagen verwendet, welche einen Rotor aufweisen, der einen Generator antreibt und der an einem Mast drehbar gelagert ist. Die Belastungen, denen die Bauteile, insbesondere die Rotorblätter der Windkraftanlage ausgesetzt sind, sind jedoch enorm.As one of the most environmentally friendly forms of energy production, the use of wind power for power generation is considered. For this purpose, wind turbines are used which have a rotor which drives a generator and which is rotatably mounted on a mast. However, the stresses to which the components, in particular the rotor blades of the wind turbine are exposed, are enormous.
Witterungseinflüsse, wie zum Beispiel Wind, Wasser, Hagel, UV-Strahlung, Erosions- und Biegebelastungen stellen höchste Anforderungen an das Material der Rotorblätter. Die Funktionsfähigkeit und die Oberflächenqualität sind wesentlich für die Effektivität und Wirtschaftlichkeit von Windkraftanlagen. Daher weisen die Rotorblätter eine besondere Beschichtung auf, deren Aufbringung sehr zeitaufwendig ist, da jede einzelne Schicht der Beschichtung in der Regel beschliffen werden muss.Weather influences, such as wind, water, hail, UV radiation, erosion and bending loads place the highest demands on the material of the rotor blades. The functionality and the surface quality are essential for the effectiveness and efficiency of wind turbines. Therefore, the rotor blades have a special coating, the application of which is very time-consuming, since each individual layer of the coating usually has to be ground.
Die extrem belasteten Kunststoffoberflächen von Rotorblättern sind mehrfach beschichtet. Die Beschichtungssysteme zum Schutz der Oberflächen bestehen aus einem sogenannten Gelcoat, Spachtel, Kantenschutz und Decklacken. Die dafiir eingesetzten Produkte bestehen in der Regel aus lösemittelfreien, zweikomponentigen Polyurethanverbindungen. Nach dem Auftrag der einzelnen Schichten müssen diese jeweils beschliffen werden.The extremely contaminated plastic surfaces of rotor blades are coated several times. The coating systems for protecting the surfaces consist of a so-called gelcoat, spatula, edge protection and topcoats. The dafiir used products generally consist of solvent-free, two-component polyurethane compounds. After the application of the individual layers, these must be ground in each case.
Diese Schleifarbeiten sind ein sehr personalintensiver Prozess, da sie manuell mit Handschleifmaschinen durchgeführt werden. Die zu schleifenden Rotorblätter weisen beispielsweise eine Länge von bis zu ca. 80 m und eine zu beschleifende Fläche von bis zu ca. 300 qm auf. Dementsprechend ist die manuell zu beschleifende Fläche sehr groß.These sanding operations are a very labor intensive process as they are done manually with hand grinders. For example, the rotor blades to be ground have a length of up to about 80 m and a surface to be ground of up to about 300 m 2. Accordingly, the area to be ground manually is very large.
Ein weiterer Grund dafiir, dass Schleifarbeiten an Rotorblättern immer noch manuell mithilfe von Handschleifmaschinen, beispielsweise mit Exzenterschleifern mit Staubabsaugung durchgeführt werden, besteht darin, dass die zu beschleifenden Rotorblätterbeschichtungen sehr zähelastisch eingestellt sind und sich daher die Schleifscheiben sehr schnell zusetzen. Mit einer Schleifscheibe kann nur eine kleine Fläche beschliffen werden und dann muss diese Schleifscheibe gegen eine neue Schleifscheibe gewechselt werden, was bei Handschleifmaschinen von Hand sehr schnell möglich ist. Aufgrund der häufigen Wechselraten konnten auch Schleifroboter nicht wirtschaftlich eingesetzt werden. Mit einer Schleifscheibe können trotz Absaugung in der Regel nur ca. 0,5 qm - 1,5 qm der zähelastischen Beschichtung eines Rotorblatts beschliffen werden. Die Fläche eines Windkraftflügels von ca. 60 m bis ca. 80 m Flügellänge beträgt jedoch 160 qm bis 300 qm, so dass pro Rotorblatt und Schleifdurchgang ca. 300 - 600 Schleifscheiben eingesetzt werden müssen. In der Regel gibt es 3 - 4 Schleifdurchgänge pro Rotorblatt.Another reason for the fact that grinding work on rotor blades is still carried out manually using hand grinders, for example with eccentric grinders with dust extraction, is that the rotor blade coatings to be ground are set very viscous and therefore the grinding wheels clog very quickly. With a grinding wheel, only a small area can be ground and then this grinding wheel has to be replaced with a new grinding wheel, which is possible very quickly with hand grinding machines by hand. Due to the frequent change rates, grinding robots could not be used economically. With a grinding wheel, only approx. 0.5 m² - 1.5 m² of the viscoelastic coating of a rotor blade can be sanded despite extraction. However, the area of a wind turbine blade of approx. 60 m to approx. 80 m wing length is 160 m² to 300 m², so that approx. 300 - 600 grinding wheels have to be used per rotor blade and grinding cycle. There are usually 3-4 sanding passes per rotor blade.
Aus der
Um die Lebensdauer von Schleifbändern zu erhöhen, werden mitunter Schleitbandreinigungssysteme eingesetzt. Die
Die zähelastischen Beschichtungen der Rotorblätter werden deshalb verwendet, weil Rotorblätter sich mit Geschwindigkeiten von bis zu 300 km/h bewegen und sie nicht beschädigt werden dürfen, wenn beispielsweise Hagelkörner auf sie aufschlagen. In den Druckschriften
Die gewaltigen Dimensionen der Rotorblätter und die Probleme, die beim Beschleifen der zähelastischen Beschichtung auftreten, haben bisher noch keine Automatisierung der Schleifarbeiten zugelassen. Die Kosten der Schleifarbeiten können 30 % und mehr der Herstellungskosten eines Rotorblatts betragen.The enormous dimensions of the rotor blades and the problems that occur when grinding the viscoelastic coating, have not yet allowed automation of the grinding work. The cost of the grinding work can be 30% and more of the manufacturing cost of a rotor blade.
Es ist daher die Aufgabe der vorliegenden Erfindung, die oben genannten Probleme zu lösen und den Schleifprozess bei Rotorblättern für Windkraftanlagen zu verbessern und kostengünstiger zu gestalten.It is therefore the object of the present invention to solve the above-mentioned problems and to improve the grinding process in rotor blades for wind turbines and to make them cheaper.
Die oben genannte Aufgabe wird gelöst durch eine Schleifvorrichtung zum maschinellen Schleifen von Rotorblättern für Windkraftanlagen gemäß Patentanspruch 1.The above-mentioned object is achieved by a grinding device for the mechanical grinding of rotor blades for wind power plants according to
Dadurch dass eine Schleifvorrichtung zum maschinellen Schleifen von Rotorblättern verwendet wird, kann der Schleifvorgang automatisiert werden, sodass keine manuellen Schleifarbeiten mehr notwendig sind. Schleifarbeiten, die derzeit mit Handschleifmaschinen durchgeführt werden, können entfallen und mittels der erfindungsgemäßen Schleifvorrichtung durchgeführt werden. Möglich ist dies durch die Verwendung einer Bandschleifeinheit mit einem umlaufenden Schleifband, welches es erlaubt, auch mehrere 100 qm von zähelastischer Beschichtung eines Rotorblatts für Windkraftanlagen maschinell zu beschleifen.By using a grinder to mechanically grind rotor blades, the grinding process can be automated, eliminating the need for manual grinding. Grinding work, which is currently carried out with hand grinders, can be omitted and carried out by means of the grinding device according to the invention. This is made possible by the use of a belt grinding unit with a revolving sanding belt, which makes it possible to mechanically grind several 100 square meters of tough-elastic coating of a rotor blade for wind turbines.
Die Verwendung von umlaufenden Schleifbändern hat den Vorteil, dass immer nur ein Teil des Schleifbands im Eingriff mit dem Rotorblatt steht, während ein anderer Teil des Schleifbands frei zugänglich ist und in diesem Bereich von dem zähelastischen Schleifstaub gereinigt werden kann. Dies verhindert ein schnelles Zusetzen des Schleifbandes mit dem ebenfalls zähelastischen Schleifstaub.The use of revolving abrasive belts has the advantage that only one part of the abrasive belt is engaged with the rotor blade while another part of the abrasive belt is freely accessible and in this area of the tough-elastic sanding dust can be cleaned. This prevents a rapid clogging of the sanding belt with the likewise viscoelastic sanding dust.
Weiterhin ist die effektiv nutzbare Fläche eines Schleifbandes wesentlich größer als bei Schleifscheiben für handgeführte Schleifmaschinen. Damit kann die Schleiffläche des Schleifbandes entsprechend der Größe der Oberfläche eines Rotorblatts ausgelegt werden, sodass ein Schleifbandwechsel erst nach dem Beschleifen zumindest einer Seite eines Rotorblatts oder des gesamten Rotorblatts notwendig ist. Weiterhin hat ein Schleifband den Vorteil, dass die Schleifgeschwindigkeit stufenlos regelbar ist und auf die Beschichtung der Rotorblätter exakt anpassbar ist. Bei rotierenden oder oszillierenden Schleifscheiben ergibt sich immer das Problem, dass im Inneren der Schleifscheibe prinzipbedingt geringere Geschwindigkeiten vorherrschen als in den äußeren Bereichen, was zu einem schlechteren Schleifergebnis und zu einem schnellen Zusetzen der verwendeten Schleifscheiben führt.Furthermore, the effective usable surface of an abrasive belt is much larger than in grinding wheels for hand-held grinding machines. Thus, the grinding surface of the grinding belt can be designed according to the size of the surface of a rotor blade, so that a grinding belt change is necessary only after grinding at least one side of a rotor blade or the entire rotor blade. Furthermore, an abrasive belt has the advantage that the grinding speed is infinitely variable and can be exactly adapted to the coating of the rotor blades. With rotating or oscillating grinding wheels, there is always the problem that in principle lower speeds prevail inside the grinding wheel than in the outer areas, which leads to a poorer grinding result and to a rapid clogging of the grinding wheels used.
Bevorzugt weist die Schleifvorrichtung weiterhin eine Antriebseinheit zum Verfahren der Bandschleifeinheit in Richtung der Längsachse eines Rotorblatts auf. Die Bandschleifeinheit mit dem bevorzugt quer zum Rotorblatt umlaufenden Schleifband wird durch eine Antriebseinheit in Richtung der Längsachse des Rotorblatts verschoben. Damit ist es möglich, in einem Schleifdurchgang eine Seite eines Rotorblatts kontinuierlich zu beschleifen. Der kontinuierliche Schleifvorgang ergibt auch ein gleichmäßigeres Schleifergebnis als ein diskontinuierliches Schleifen von Hand. Durch ein Drehen des Rotorblatts um seine Längsachse kann in weiteren Durchgängen die gesamte Oberfläche des Rotorblatts maschinell beschliffen werden.Preferably, the grinding device further comprises a drive unit for moving the belt grinding unit in the direction of the longitudinal axis of a rotor blade. The belt grinding unit with the preferably transverse to the rotor blade rotating belt is moved by a drive unit in the direction of the longitudinal axis of the rotor blade. This makes it possible to continuously grind one side of a rotor blade in a grinding pass. The continuous grinding process also gives a smoother grinding result than a batch hand grinding. By rotating the rotor blade about its longitudinal axis, the entire surface of the rotor blade can be mechanically ground in further passages.
Bevorzugt weist die Schleifvorrichtung weiterhin eine Staubbandeinheit mit einem umlaufenden Staubband auf, welches an zumindest einer Oberfläche eines Rotorblatts entlang geführt wird, um die Oberfläche des Rotorblatts von Staub zu befreien. Mithilfe des Staubbandes kann nach dem Schleifen die Oberfläche des Rotorblatts vom Straub gereinigt werden, so dass sie sich für eine direkte Neubeschichtung eignet. Durch den Einsatz der Staubbandeinheit wird eine quasi staubfreie Oberfläche des Rotorblatts erhalten.Preferably, the grinding device further comprises a dust belt unit with a circumferential dust belt, which is guided along at least one surface of a rotor blade in order to free the surface of the rotor blade from dust. With the aid of the dust band, after sanding, the surface of the Rotor blades are cleaned of Straub so that it is suitable for direct recoating. By using the dust-tape unit, a quasi-dust-free surface of the rotor blade is obtained.
Bevorzugt weist die Schleifvorrichtung weiterhin mindestens eine Bandreinigungsvorrichtung auf. Mithilfe der Bandreinigungsvorrichtung werden das Schleifband und/oder das Staubband kontinuierlich während des jeweiligen Einsatzes des Bandes gereinigt. Dadurch erhöht sich insbesondere die Standzeit des Schleifbandes um ein Vielfaches gegenüber einem Schleifband ohne Absaugung oder sogar einem Schleifband, bei dem Staub abgesaugt wird.Preferably, the grinding device further comprises at least one belt cleaning device. By means of the belt cleaning device, the abrasive belt and / or the dust belt are cleaned continuously during the respective use of the belt. This increases in particular the service life of the grinding belt many times over a sanding belt without suction or even a sanding belt, is sucked in the dust.
Bevorzugt reinigt die Bandreinigungsvorrichtung das Schleifband und/oder das Staubband mittels einer Düse zum Aufblasen von Druckluft und/oder einer Vorrichtung zum Absaugen von Schleifstaub und/oder einer Bürste zum Abbürsten des Schleifbands und/oder des Staubbands. Durch diese drei Maßnahmen, die einzeln oder in Kombination eingesetzt werden können, kann eine nahezu vollständige Reinigung des Schleifbands und des Staubbands erfolgen, sodass die Standzeit der beiden Bänder jeweils nur durch mechanische Abnutzung begrenzt ist. Ein Zusetzen der Bänder wird damit wirkungsvoll verzögert und der Schleifstaub wird effektiv entfernt ohne in die Umwelt zu gelangen.Preferably, the belt cleaning device cleans the abrasive belt and / or the dust belt by means of a nozzle for inflating compressed air and / or a device for extracting sanding dust and / or a brush for brushing the abrasive belt and / or the dust belt. These three measures, which can be used singly or in combination, allow almost complete cleaning of the sanding belt and the dust belt so that the service life of both belts is limited only by mechanical wear. Clogging of the tapes is thus effectively delayed and the grinding dust is effectively removed without getting into the environment.
Bevorzugt weist die Bandschleifeinheit Druckelemente auf, die das Schleifband und/oder das Staubband gegen eine Oberfläche eines Rotorblatts drücken, und welche an der Antriebseinheit gelagert sind. Durch die Druckelemente kann der Schleifdruck des Schleifbandes oder der Reinigungsdruck des Staubbandes genau festgelegt und variiert werden und somit die Schleif und Reinigungsbedingungen an der Oberfläche des Rotorblatts genau festgelegt werden.The belt grinding unit preferably has pressure elements which press the sanding belt and / or the dust belt against a surface of a rotor blade and which are mounted on the drive unit. By the pressure elements of the grinding pressure of the abrasive belt or the cleaning pressure of the dust belt can be precisely determined and varied, and thus the grinding and cleaning conditions are precisely determined on the surface of the rotor blade.
Bevorzugt weisen die Druckelemente in Richtung der Querachse eines Rotorblatts an der Antriebseinheit verfahrbare Gliederdruckbalken oder Druckrollen auf. Gliederdruckbalken oder Druckrollen können sich an die gekrümmte Oberfläche des Rotorblatts anpassen und somit ergibt sich ein gleichmäßiger Anpressdruck für das Schleifband oder das Staubband. Durch das Verfahren der Druckelemente wird sichergestellt, dass jeder Oberflächenbereich ausreichend lange und mit dem jeweils gewünschten Anpressdruck beschliffen oder gereinigt wird.Preferably, the pressure elements in the direction of the transverse axis of a rotor blade on the drive unit movable link pressure bar or pressure rollers. Sectional pressure bars or pressure rollers can adhere to the curved surface adjust the rotor blade and thus results in a uniform contact pressure for the abrasive belt or the dust belt. By moving the printing elements, it is ensured that each surface area is ground or cleaned for a sufficiently long time and with the required contact pressure.
Bevorzugt können die Druckelemente pneumatisch gegen die Oberfläche eines Rotorblatts gefahren werden, um den Schleifdruck des Schleifbandes und/oder den Reinigungsdruck des Staubbandes auf der Oberfläche festzulegen. Aufgrund der pneumatischen Steuerung kann durch den verwendeten Luftdruck der Schleifdruck des Schleifbands exakt festgelegt werden. Dabei passen sich die Druckelement automatisch an die gewölbte Oberfläche des Rotorblatts an, ohne dass hierfür eine aufwendige Steuerung notwendig ist. Die einzelnen Glieder des Gliederdruckbalkens oder die Druckrollen werden mit jeweils dem gleichen Luftdruck beaufschlagt, sodass ihr Druck auf die Oberfläche auch bei veränderlichen Geometrien der Oberfläche des Rotorblatts stets konstant ist. Selbstverständlich kann das gleiche Prinzip auch über eine hydraulische Steuerung verwirklicht werden.Preferably, the pressure elements can be pneumatically driven against the surface of a rotor blade to set the grinding pressure of the abrasive belt and / or the cleaning pressure of the dust belt on the surface. Due to the pneumatic control, the grinding pressure of the grinding belt can be precisely determined by the air pressure used. In this case, the pressure element adapt automatically to the curved surface of the rotor blade, without the need for a complex control is necessary. The individual members of the sectional pressure bar or the pressure rollers are each subjected to the same air pressure, so that their pressure on the surface is always constant even with variable geometries of the surface of the rotor blade. Of course, the same principle can also be realized via a hydraulic control.
Bevorzugt weisen die Druckelemente eine Absaughaube auf, um Schleifstaub durch das Schleifband und/oder das Staubband und durch das Druckelement hindurch abzusaugen. Damit wird der Schleifstaub, zum Teil schon dort abgesaugt, wo er entsteht oder aufgenommen wird und so ein Zusetzen des Schleifbandes und des Staubbandes vermieden.The pressure elements preferably have a suction hood in order to suck off grinding dust through the abrasive belt and / or the dust belt and through the pressure element. Thus, the sanding dust, already partially sucked out where it is created or absorbed, thus avoiding clogging of the sanding belt and the dust band.
Bevorzugt ist die Staubbandeinheit an der Antriebseinheit befestigt und kann daher ebenfalls in Längsrichtung am Rotorblatt entlang gefahren werden.Preferably, the dust belt unit is attached to the drive unit and can therefore also be moved along the rotor blade in the longitudinal direction.
Bevorzugt weist die Antriebseinheit einen in Längsrichtung verfahrbaren Antriebswagen auf, auf dem senkrecht dazu verfahrbar die Bandschleifeinheit und/oder die Staubbandeinheit gelagert sind. Die Antriebseinheit dient dazu, die Bandschleifeinheit und/oder die Staubbandeinheit während der jeweiligen Bearbeitung am Rotorblatt entlang und auf das Rotorblatt zu und von ihm weg zu führen.The drive unit preferably has a drive carriage which can be moved in the longitudinal direction, on which the belt grinding unit and / or the dust belt unit are mounted so as to be movable perpendicular thereto. The drive unit serves the belt grinding unit and / or the dust belt unit during the respective processing along the rotor blade and onto the rotor blade to and from it.
Bevorzugt weist die Schleifvorrichtung weiterhin eine Steuereinheit auf, welche zumindest die Bewegungen der Antriebseinheit und/oder die Bewegungen der Druckelemente in Richtung eines Rotorblatts numerisch steuert. Die Bewegung der Antriebseinheit und/oder die Bewegungen der Druckelemente in Richtung des Rotorblatts werden bevorzugt numerisch gesteuert (NC), um die gesamte Oberfläche des Rotorblatts mit einem gleichmäßigen Anpressdruck und zum gewünschten Grad zu beschleifen. Die Steuereinheit bewirkt, dass von der Antriebseinheit die Konturen des jeweiligen Rotorblatts nachgefahren werden.The grinding device preferably also has a control unit which numerically controls at least the movements of the drive unit and / or the movements of the pressure elements in the direction of a rotor blade. The movement of the drive unit and / or the movements of the pressure elements in the direction of the rotor blade are preferably numerically controlled (NC) in order to grind the entire surface of the rotor blade with a uniform contact pressure and to the desired degree. The control unit causes the contours of the respective rotor blade to be traced by the drive unit.
Bevorzugt weist die Schleifvorrichtung weiterhin einen Bandspanner auf, der das Schleifband in einer zum Schleifen notwendigen Spannung hält.Preferably, the grinding device further comprises a belt tensioner which holds the abrasive belt in a tension necessary for grinding.
Bevorzugt ist das Schleifband ein perforiertes Schleifband, welches im Wesentlichen über seine gesamte Oberfläche mit Perforationsöffnungen versehen ist. Durch die Verwendung eines perforierten Schleifbands, das im Gegensatz zu gewöhnlichen Schleifbändern viele kleine, nah beieinander beabstandete Perforationsöffnungen aufweist, muss der Schleifstaub an der Schleifoberfläche nur einen sehr kurzen Weg zurücklegen, um durch das Schleifband hindurch nach hinten abgesaugt werden zu können. Dementsprechend wird durch die Verwendung von perforierten Schleifbändern die Gefahr des Zusetzens des Schleifbands vermindert.Preferably, the abrasive belt is a perforated abrasive belt which is provided with perforations substantially over its entire surface. By using a perforated abrasive belt which, in contrast to ordinary abrasive belts, has many small, closely spaced perforations, the sanding dust on the abrasive surface has only a very short distance to travel through the sanding belt to be sucked backwards. Accordingly, the use of perforated abrasive belts reduces the risk of the abrasive belt clogging.
In einer bevorzugten Ausfiihrungsform weist die Schleifvorrichtung weiterhin eine Beschichtungseinheit zum automatisierten Beschichten der Oberfläche eines Rotorblatts auf, welche an der Antriebseinheit befestigt ist. Mithilfe einer Beschichtungseinheit kann das Rotorblatt nach dem Beschleifen mit der gleichen Vorrichtung neu beschichtet bzw. neu lackiert werden. Dadurch ergibt sich der Vorteil, dass das Rotorblatt auf der Anlage verbleiben kann und nicht zu einer Lackieranlage bewegt werden muss. Weiterhin ist eine automatisierte Beschichtung wesentlich gleichmäßiger als ein manueller Auftrag und ohne Gefahren für einen Lackierer.In a preferred embodiment, the grinding apparatus further comprises a coating unit for automatically coating the surface of a rotor blade, which is attached to the drive unit. Using a coating unit, the rotor blade can be recoated or repainted after grinding with the same device. This has the advantage that the rotor blade can remain on the system and not to a Painting plant must be moved. Furthermore, an automated coating is much more uniform than a manual job and without dangers for a painter.
Bevorzugt weist die Beschichtungseinheit mindestens eine automatisch verfahrbare Beschichtungswalze und/oder mindestens eine automatisch verfahrbare Sprüheinheit und/oder mindestens einen Heizstrahler auf. Die Beschichtung des Rotorblatts kann durch Aufwalzen oder durch Aufsprühen erfolgen, wobei die jeweilige Beschichtungsart von dem zur Beschichtung verwendeten Material abhängig ist. Nach dem Beschichten, oder auch schon parallel hierzu, können die neu beschichteten Flächen mittels eines Heizstrahlers beschleunigt getrocknet werden. Damit verringert sich die Gesamtbearbeitungszeit des Rotorblatts.Preferably, the coating unit has at least one automatically movable coating roller and / or at least one automatically movable spray unit and / or at least one radiant heater. The coating of the rotor blade can be carried out by rolling or by spraying, wherein the respective type of coating depends on the material used for the coating. After coating, or even parallel to this, the newly coated surfaces can be dried by means of a radiant heater accelerated. This reduces the total machining time of the rotor blade.
In einer weiteren Ausgestaltung der Erfindung betrifft diese ein Schiff zur Bearbeitung von Rotorblättern von Windkraftanlagen mit einer Schleifvorrichtung wie sie oben beschrieben wurde. Ein derartiges Schiff mit einer Schleifvorrichtung zum maschinellen Schleifen von Rotorblättern für Windkraftanlagen könnte insbesondere zur Revision von Rotorblättern bei Offshore-Windanlagen eingesetzt werden. Durch die Möglichkeit, die Rotorblätter direkt auf dem Meer zu beschleifen und neu zu beschichten, verringern sich die Transportzeiten der Rotorblätter bei der Revision und die Windkraftanlage ist in kürzester Zeit wieder verwendbar.In a further embodiment of the invention, this relates to a ship for processing rotor blades of wind turbines with a grinding device as described above. Such a ship with a grinding device for mechanical grinding of rotor blades for wind turbines could be used in particular for the revision of rotor blades in offshore wind turbines. The possibility of grinding and re-coating the rotor blades directly on the sea reduces the transport times of the rotor blades during the overhaul and the wind turbine can be reused in a very short time.
Im Folgenden werden bevorzugte Ausführungsformen der Erfindung mit Bezug auf die Zeichnungen beschrieben. In denen zeigt:
- Fig. 1:
- eine Querschnittsansicht durch eine erste Ausführungsform einer erfindungsgemäßen Schleifvorrichtung zum maschinellen Schleifen von Rotorblättern für Windkraftanlagen;
- Fig. 2:
- eine Seitenansicht der Schleifvorrichtung gemäß
Fig. 1 ; - Fig. 3:
- eine Ansicht von oben einer weiteren Ausführungsform einer Schleifvorrichtung zum maschinellen Schleifen von Rotorblättern für Windkraftanlagen;
- Fig. 4:
- eine Querschnittsansicht einer Bandschleifeinheit im Eingriff mit einem Rotorblatt; und
- Fig. 5:
- eine Querschnittsansicht einer Bandreinigungsvorrichtung beim Reinigen eines Schleifbandes.
- Fig. 1:
- a cross-sectional view through a first embodiment of a grinding device according to the invention for machine grinding rotor blades for wind turbines;
- Fig. 2:
- a side view of the grinding device according to
Fig. 1 ; - 3:
- a top view of another embodiment of a grinding device for machine grinding rotor blades for wind turbines;
- 4:
- a cross-sectional view of a belt grinding unit in engagement with a rotor blade; and
- Fig. 5:
- a cross-sectional view of a belt cleaning device when cleaning a sanding belt.
Im Folgenden werden bevorzugte Ausführungsformen der Erfindung mit Bezug auf die Figuren beschrieben. Einzelne Merkmale der hier beschriebenen Ausführungsformen können mit anderen Ausführungsformen der Erfindung kombiniert werden.Hereinafter, preferred embodiments of the invention will be described with reference to the figures. Individual features of the embodiments described herein may be combined with other embodiments of the invention.
Die Bandschleifeinheit 10 weist Druckelemente 14, 15 auf, welche in Querrichtung Q an den Grundkörper 21 numerisch gesteuert auf und ab gefahren werden können und welche in Richtung Z pneumatisch gegen die Rückseite des Schleifbands 12 drücken. Die Druckelemente 14, 15 dienen dazu, das Schleifband 12 mit dem erforderlichen Schleifdruck an die Oberfläche 110 des Rotorblatts 100 zu drücken und diesen Schleifdruck an jede gewünschte Stelle der Oberfläche 110 gezielt aufzubringen. Durch die Verfahrbarkeit der Druckelemente 14, 15 an dem Grundkörper 21 kann so gezielt jeder Oberflächenbereich der Oberfläche 110 mit dem gewünschten Druck und der gewünschten Dauer geschliffen werden.The
Die Druckelemente 14, 15 können pneumatisch mittels eines oder mehrerer Pneumatikzylinder 26 in Richtung Z gegen die Oberfläche des Rotorblatts gefahren werden, um den notwendigen Schleifdruck aufzubringen. Der benötigte Schleifdruck kann dann sehr leicht über den Druck in den jeweiligen Pneumatikzylindern 26 eingestellt werden. Dies hat den Vorteil, dass auch bei wechselnden Geometrien der Oberfläche 110 stets der gleiche definierte Schleifdruck zum Schleifen eingestellt werden kann. Dies geschieht rein auf mechanischem Wege, ohne dass hierfür aufwendige Regelungseinrichtungen notwendig sind.The
Die Druckelemente können als verfahrbare Gliederdruckbalken 14 oder Druckrollen 15 ausgestaltet sein, wie sie im Detail in
Auf der rechten Seite der
Das Schleifband 12 ist bevorzugt ein perforiertes Schleifband, welches mit vergleichsweise kleinen Perforationsöffnungen versehen ist, welche einen Durchmesser von bevorzugt 1 mm bis 4 mm aufweisen und einen Abstand der Perforationsöffnungen zueinander von bevorzugt 10 mm bis 20 mm. Durch diese Perforation ist es möglich, den Schleifstaub quasi vollflächig von der Schleifoberfläche abzuführen und durch das Schleifband 12 hindurch abzusaugen. Dementsprechend wird schon durch diese Absaugungsart ein Zusetzen des Schleifbands verringert. Das Schleifband kann ansonsten üblich aus einem Trägergewebe mit darauf beschichteten Schleifkörnern aufgebaut sein und eine Breite von bevorzugt 100 - 300 mm aufweisen.The sanding
Da jedoch die zu schleifenden Beschichtungen bei der Herstellung und Revision von Rotorblättern 100, nämlich Gelcoat, Spachtel, Füller und Deckschichten eher zähelastisch eingestellt sind, kann durch eine bloße Absaugung allein ein Zusetzen des Schleifbands 12 nicht verhindert werden. Daher ist die Bandschleifeinheit 10 weiterhin mit einer Bandreinigungsvorrichtung 16 für das Schleifband 12 ausgerüstet. Die Bandreinigungsvorrichtung 16 umfasst bevorzugt, wie in
Mit der Bandreinigungsvorrichtung 16 ist es möglich, das Schleifband 12 quasi vollständig von anhaftendem Schleifstaub der zähelastischen Beschichtungen des Rotorblatts 100 zu reinigen. Dabei wird die Tatsache ausgenutzt, dass sich immer nur ein Teil des Schleifbands 12 im Eingriff mit der Oberfläche 110 des Rotorblatts 100 befindet und ein großer Teil des Schleifbands 10 frei zugänglich ist, insbesondere für die Bandreinigung.With the
Wie in den
Zusammen mit der individuellen Verfahrbarkeit der Druckelemente 14, 15 innerhalb der Bandschleifeinheit 10 in Querrichtung Q und Richtung Z und der Verfahrbarkeit der Bandschleifeinheit 10 insgesamt in Längsrichtung L, kann somit an jeder Stelle der Oberfläche 110 des Rotorblatts 100 punktgenau geschliffen werden.Together with the individual mobility of the
Wie in
Auf ähnliche Weise wie die Bandschleifeinheit 10 ist in
Bevorzugt weist die Staubbandeinheit pneumatisch gesteuerte Druckelemente 44 auf, die das Staubband 42 gegen die Oberfläche 110 drücken. Die Druckelemente 44 können an dem Grundkörper 41 in Querrichtung Q auf und ab bewegt werden, um selektiv das Staubband 42 an die gewünschte Stelle der Oberfläche 110 des Rotorblatts 100 anzudrücken. Die Druckelemente 44 sind ähnlich aufgebaut wie die Druckelemente 14, 15 für das Schleifband 12, die in
Die Druckelemente 44 weisen weiterhin eine Absaughaube 47 auf, um den vom Staubband 42 aufgenommenen Staub aus dem Staubband 42 abzusaugen. Zusätzlich ist auch die Staubbandeinheit 40 mit einer Bandreinigungsvorrichtung 46 ausgestattet, die im Wesentlichen der Bandreinigungseinrichtung 16 des Schleifbands 12 entspricht, die in
Die Staubbandeinheit 40 als Ganzes ist ähnlich zur Bandschleifeinheit 10 auf dem verfahrbaren Antriebswagen 32 mittels eines weiteren in Z-Richtung numerisch gesteuert (NC) verfahrbaren und elektrisch angetriebenen Wagens 35 gelagert, so dass die komplette Oberfläche 110 des Rotorblatts 100 gereinigt werden kann.The
Wie in
Damit die neu aufgebrachte Beschichtung schneller trocknet und das Rotorblatt 100 schneller weiterbearbeitet werden kann, kann die Schleifvorrichtung 1 auch mit mindestens einem elektrischen Heizstrahler 54 ausgerüstet sein, der ebenfalls auf jeden Punkt der Oberfläche 110 des Rotorblatts 100 positioniert werden kann.So that the newly applied coating dries faster and the
Rotorblätter 100 für Windkraftanlagen müssen in regelmäßigen Abständen gewartet und, wenn durch Beschädigung und Beanspruchung erforderlich, auch neu beschichtet werden. Zu diesem Zweck wird die Oberfläche 110 des Rotorblatts 100 abgeschliffen und mit einer neuen Beschichtung versehen. Da viele der Windkraftanlagen im Meer aufgestellt sind (sog. Offshore-Windkraftanlagen) ist vorgesehen, ein Schiff zur Bearbeitung von Rotorblättern von Windkraftanlagen bereitzustellen, auf dem eine automatische Schleifvorrichtung 1, wie sie vorstehend beschrieben wurde, installiert ist. Damit ist eine Revision der Rotorblätter 100 vor Ort möglich und es verringern sich die Transportwege. Aufgrund der kompletten Automatisierung des Abschleifens, Reinigens und Neubeschichtens können diese Vorgänge auch auf einem sich dauernd bewegenden Schiff durchgeführt werden.
- 11
- Schleifvorrichtunggrinder
- 1010
- BandschleifeinheitBelt grinding unit
- 1212
- Schleifbandsanding belt
- 1414
- Druckelement als GliederdruckbalkenPressure element as a sectional pressure bar
- 1515
- Druckelement mit DruckrollenPressure element with pressure rollers
- 1616
- BandreinigungsvorrichtungBelt cleaning device
- 1717
- Absaughaubeexhaust hood
- 1818
- Bandspannerbelt tensioner
- 2020
- Antriebsmotordrive motor
- 2121
- Grundkörperbody
- 2222
- Führungsrollenguide rollers
- 2323
- Druckrollenpressure rollers
- 2424
- Absaugungsuction
- 2525
- Glieder des GliederdruckbalkensLimbs of the limb pressure bar
- 2626
- Druckzylinderpressure cylinder
- 2727
- Bürstebrush
- 2828
- Düsejet
- 2929
- Absaughaubeexhaust hood
- 3030
- Antriebseinheitdrive unit
- 3232
- Antriebswagendrive car
- 3333
- Schienenrails
- 3434
- Wagendare
- 3535
- Wagendare
- 4040
- StaubbandeinheitDust belt unit
- 4141
- Grundkörperbody
- 4242
- Staubbanddust lane
- 4444
- Druckelementeprint elements
- 4646
- BandreinigungsvorrichtungBelt cleaning device
- 4747
- Absaughaubeexhaust hood
- 4848
- Bandspannerbelt tensioner
- 4949
- Führungsrollenguide rollers
- 5050
- Beschichtungseinheitcoating unit
- 5252
- Beschichtungswalzecoating roll
- 5454
- Heizstrahlerheater
- 100100
- Rotorblattrotor blade
- 110110
- Oberfläche des RotorblattsSurface of the rotor blade
Claims (15)
- Grinding device (1) for machine-based, automated grinding of rotor blades (100) for wind energy systems,
characterized in that
the grinding device (1) comprises a belt grinding unit (10) with a circulating grinding belt (12). - Grinding device according to claim 1, further comprising a drive unit (30) for moving the belt grinding unit (10) in the direction (L) of the longitudinal axis of a rotor blade (100).
- Grinding device according to one of the claims 1 or 2, further comprising a dust belt unit (40) with a circulating dust belt (42) that is guided along at at least one surface (110) of a rotor blade (100), in order to remove dust from the surface (110) of the rotor blade (100).
- Grinding device according to one of the claims 1 - 3, further comprising at least one belt cleaning device (16, 46).
- Grinding device according to claim 4, wherein the belt cleaning device (16, 46) cleans the grinding belt (12) and/or the dust belt (42) by means of:a) a nozzle (28) for blowing on of pressurized air; and/orb) a device (24) for suctioning grinding dust; and/orc) a brush (27) for brushing the grinding belt (12) and/or the dust belt (42).
- Grinding device according to claim 2, wherein the belt grinding unit (10) comprises pressure members (14, 15, 44) that press the grinding belt (12) and/or the dust belt (42) against a surface (110) of a rotor blade (100) and that are supported at the drive unit (30).
- Grinding device according to claim 6, wherein the pressure members (14, 15, 44) comprise in direction (Q) of the transverse axis of a rotor blade (100) moveable element pressure bars (14) or pressure rollers (15) at the drive unit (30) that can be moved preferably pneumatically to the surface (110) of a rotor blade (100) in order to define the grinding pressure of the grinding belt (12) and/or the cleaning pressure of the dust belt (42) onto the surface (110).
- Grinding device according to one of the claims 6 or 7, wherein the pressure members (14, 15, 44) comprise a suction hood (17, 47), in order to suck grinding dust through the grinding belt (12) and/or the dust belt (42) and through the pressure member (14, 15, 44).
- Grinding device according to one of the claims 3 - 8, wherein the dust belt unit (40) is mounted at the drive unit (30).
- Grinding device according to one of the claims 2 - 9, wherein the drive unit (30) comprises a drive wagon (32) moveable in longitudinal direction (L) on which perpendicular thereto (Z) the belt grinding unit (10) and/or the dust belt unit (40) are moveably supported.
- Grinding device according to one of the claims 2- 10, further comprising a control unit that controls numerically at least the movements of the drive unit (30) and/or the movements of the pressure members (14, 15) in direction (Z) of the rotor blade (100).
- Grinding device according to one of the claims 1 - 11, further comprising a belt tensioner (18) that provides the grinding belt (12) with the tension that is necessary for grinding.
- Grinding device according to one of the claims 1 - 12, wherein the grinding belt (12) is a perforated grinding belt, which is provided essentially over its entire surface with perforation openings.
- Grinding device according to one of the claims 1 - 13, further comprising a coating unit (50) for automated coating of the surface (110) of a rotor blade (100), wherein the coating unit (50) is mounted to the drive unit (30).
- Grinding device (1) according to claim 14, wherein the coating unit (50) comprises:a) at least one automatically moveable coating roller (52); and/orb) at least one automatically moveable spray unit; and/orc) at least one radiant heater (54).
Priority Applications (8)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DK10174283.1T DK2422929T4 (en) | 2010-08-27 | 2010-08-27 | Grinding machine for machine grinding of rotor blades for wind turbines |
ES10174283.1T ES2420992T5 (en) | 2010-08-27 | 2010-08-27 | Sanding device for machine sanding of rotor blades for wind turbine installations |
EP10174283.1A EP2422929B2 (en) | 2010-08-27 | 2010-08-27 | Grinding device for mechanical grinding of rotor blades for wind power systems |
PT101742831T PT2422929E (en) | 2010-08-27 | 2010-08-27 | Grinding device for mechanical grinding of rotor blades for wind power systems |
PL10174283T PL2422929T5 (en) | 2010-08-27 | 2010-08-27 | Grinding device for mechanical grinding of rotor blades for wind power systems |
CN2011800416257A CN103079760A (en) | 2010-08-27 | 2011-08-25 | Grinding device for mechanically grinding rotor blades of wind power plants |
US13/582,041 US8900037B2 (en) | 2010-08-27 | 2011-08-25 | Grinding device for machine based grinding of rotor blades for wind energy systems |
PCT/EP2011/064645 WO2012025598A1 (en) | 2010-08-27 | 2011-08-25 | Grinding device for mechanically grinding rotor blades of wind power plants |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP10174283.1A EP2422929B2 (en) | 2010-08-27 | 2010-08-27 | Grinding device for mechanical grinding of rotor blades for wind power systems |
Publications (3)
Publication Number | Publication Date |
---|---|
EP2422929A1 EP2422929A1 (en) | 2012-02-29 |
EP2422929B1 true EP2422929B1 (en) | 2013-04-17 |
EP2422929B2 EP2422929B2 (en) | 2017-03-01 |
Family
ID=43432245
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP10174283.1A Active EP2422929B2 (en) | 2010-08-27 | 2010-08-27 | Grinding device for mechanical grinding of rotor blades for wind power systems |
Country Status (8)
Country | Link |
---|---|
US (1) | US8900037B2 (en) |
EP (1) | EP2422929B2 (en) |
CN (1) | CN103079760A (en) |
DK (1) | DK2422929T4 (en) |
ES (1) | ES2420992T5 (en) |
PL (1) | PL2422929T5 (en) |
PT (1) | PT2422929E (en) |
WO (1) | WO2012025598A1 (en) |
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-
2010
- 2010-08-27 DK DK10174283.1T patent/DK2422929T4/en active
- 2010-08-27 ES ES10174283.1T patent/ES2420992T5/en active Active
- 2010-08-27 PT PT101742831T patent/PT2422929E/en unknown
- 2010-08-27 EP EP10174283.1A patent/EP2422929B2/en active Active
- 2010-08-27 PL PL10174283T patent/PL2422929T5/en unknown
-
2011
- 2011-08-25 CN CN2011800416257A patent/CN103079760A/en active Pending
- 2011-08-25 WO PCT/EP2011/064645 patent/WO2012025598A1/en active Application Filing
- 2011-08-25 US US13/582,041 patent/US8900037B2/en active Active
Also Published As
Publication number | Publication date |
---|---|
WO2012025598A1 (en) | 2012-03-01 |
DK2422929T3 (en) | 2013-07-15 |
EP2422929A1 (en) | 2012-02-29 |
PL2422929T5 (en) | 2017-10-31 |
US20120318190A1 (en) | 2012-12-20 |
EP2422929B2 (en) | 2017-03-01 |
ES2420992T5 (en) | 2017-07-24 |
PT2422929E (en) | 2013-07-11 |
PL2422929T3 (en) | 2013-09-30 |
CN103079760A (en) | 2013-05-01 |
US8900037B2 (en) | 2014-12-02 |
DK2422929T4 (en) | 2017-06-06 |
ES2420992T3 (en) | 2013-08-28 |
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