Waste fan blade cutting equipment

Abstract

The invention provides waste fan blade cutting equipment which comprises a rope saw cutting system, and the rope saw cutting system comprises a feeding device used for controlling the feeding amount, speed and path of a rope saw; the tensioning device is used for adjusting the tension of the wire saw; the driving device is used for driving the rope saw to rotate; the rope saw bypasses the feeding device, the driving device and the tensioning device to form a closed loop; wherein the feeding device is provided with a rotating mechanism, a guide wheel set is arranged on the rotating mechanism, and the guide wheel set is used for changing the path of the rope saw. Through modular design, intelligent control and environmental protection technology integration, efficient and green treatment of the waste fan blades is achieved, and a complete solution is provided for sustainable operation of the wind power industry.

Description

Technical Field

[0001] The present invention belongs to the technical field of fan blades, and particularly relates to a device for cutting waste fan blades. Background Art

[0002] The rapid development of the global wind power industry has led to a surge in the number of wind turbine blade retirements. Blades are primarily composed of glass fiber / carbon fiber reinforced with thermosetting resins (such as epoxy resins), which are difficult to degrade naturally after curing. Existing recycling technologies require material separation through cutting and decomposition, but the irreversible bonding of thermosetting resins with fibers results in reduced performance of the recycled fibers (for example, mechanical shredding can result in a loss of fiber strength of over 50%) and low economic value.

[0003] The existing wind blade cutting technology has the following technical problems: 1. Manual cutting efficiency and safety issues: Traditional cutting relies on manual operation of large saws, which requires the cooperation of multiple people, serious dust pollution, poor cutting consistency, and safety risks such as blade deformation and flying debris, and cannot meet the needs of large-scale processing. 2. Limitations of fixed equipment: Most existing cutting equipment is fixed, and the blades need to be transported to a centralized processing plant. However, wind farms are mostly located in remote areas, with blades exceeding 60 meters in length (some reaching 100 meters). The transportation cost is high, and multiple devices are required for segmented processing, resulting in high overall costs. 3. Insufficient environmental protection: The cutting process generates a large amount of dust and wastewater, and existing technologies lack efficient purification methods. 4. Insufficient adaptability of the cutting process: The blade structure is complex and is divided into three parts: the blade root (hollow cylinder), the blade middle (asymmetric streamlined), and the blade tip (flat solid). Existing cutting methods are difficult to adapt to the structural characteristics of different parts, which can easily lead to problems such as uneven cutting depth, blade deformation, or rope saw tension failure.

[0004] Patent CN119347435A, titled "Wind Turbine Blade Post-Processing Gantry Platform," offers significant advantages in integration, intelligence, and environmental friendliness, making it particularly well-suited for the large-scale post-processing needs of centralized wind farms. However, the system integrates multiple precision machining devices (such as high-pressure water jets and scanning probes), a three-dimensional motion system, and high-precision positioning, resulting in a unit price exceeding one million US dollars, making it unaffordable for small and medium-sized enterprises. Furthermore, the diamond cutting and grinding heads used in the system wear rapidly during composite material processing, resulting in high maintenance costs and low material recovery rates.

[0005] Patent CN114406351B, "Device and Method for Recycling Waste Wind Turbine Blades," significantly improves the safety and efficiency of cutting waste wind turbine blades through dynamic cutting modes, autorotation coordination technology, and modular design. It is particularly innovative in preventing blade deformation. However, core components such as precision guide rails, wire saw mainframes, and autorotation drive systems are expensive, making them difficult for small and medium-sized recycling companies to afford. Precision components such as the circular track, movable guide wheel assembly, and tightening and transverse movement mechanism require regular calibration, resulting in high maintenance costs. The above factors limit its commercial potential and make it unsuitable for the recycling needs of distributed wind farms.

[0006] Patent CN212635901U, "A Mobile Automatic Blade Root Cutter for Wind Turbine Blades," significantly improves the safety and environmental friendliness of blade root cutting through modular design, automated cutting, and source dust collection technology, making it particularly suitable for batch operations in standardized wind farms. However, factors such as the need to pre-place the cutting guide rail on a flat surface or fixed support, the cutting depth of the diamond band saw being limited by the travel of the lead screw module, the diamond band saw being susceptible to wear when cutting fiberglass, requiring frequent replacement, and the need for regular lubrication and calibration of the lead screw module and guide rails, result in high maintenance costs and hinder its widespread applicability.

[0007] Patent CN118649989A, "An Environmentally Friendly Wind Turbine Blade Recycling System," features innovative features such as fully enclosed cutting, multi-station simultaneous operation, and dust control, making it particularly suitable for the efficient recycling of standardized blades. However, the equipment is highly complex, requiring cumbersome replacement of resin inserts during use, regular calibration and lubrication of precision components such as the drive shaft, guide wheels, and vacuum pump, and the easy intrusion of dust into the mechanical structure, increasing failure rates and maintenance costs. These factors have hindered its commercial application.

[0008] Patent CN118595126A "Method and system for cutting waste fan blades" is innovative in terms of process systematization and standardized cutting, but lacks specific cutting tools and technical details, and environmental and safety issues are not fully considered. The fixing, flipping and positioning of large blades face challenges during the cutting process, especially multi-step cutting requires repeated adjustment of the blade position, which increases the difficulty and time cost of operation. Parameter verification is insufficient, and it does not involve system redundancy design or module replacement solutions.

[0009] In summary, with the rapid development of the wind power industry, the large-scale treatment of discarded wind turbine blades has become a major challenge in the field of environmental protection. Traditional wind turbine blade cutting equipment generally has problems such as large size, inconvenient transportation, low cutting efficiency, and high risk of secondary pollution, which makes it difficult to meet the needs of rapid on-site disassembly and green treatment. Although existing technologies have made some improvements in intelligence and modularization, the following problems are still common: (1) Low cutting efficiency: a single cut only completes a single-sided operation, which takes a long time. (2) High cost: the maintenance cost of core components such as precision guide rails and self-rotating drive systems is high, which is difficult for small and medium-sized enterprises to afford. (3) Environmental defects: dust and wastewater treatment are not thorough, and the risk of secondary pollution is high. (4) Lack of mobility: the equipment is large and complex, relies on fixed sites, and cannot adapt to the needs of distributed wind farms. Summary of the Invention

[0010] In response to the problems in the background technology, the present invention proposes a waste wind turbine blade cutting device, including a rope saw cutting system, which includes: a feeding device for controlling the feed amount, speed and path of the rope saw; a tensioning device, which is used to adjust the tension of the rope saw in real time, and one end of the rope saw is connected to the tensioning device; a driving device for providing power for the movement of the rope saw, and the other end of the rope saw is connected to the tensioning device; a linear guide rail, on which a guide wheel is installed, the guide wheel can rotate around the linear guide rail, and the direction of the rope saw is controlled by the guide wheel.

[0011] The beneficial effects of the present invention include: The blade cutting equipment improves cutting efficiency through intelligent cutting control, features a modular design, and is mobile. Its dust control meets environmental requirements, fills a technological gap in large-scale recycling, and addresses a pressing industry need. It achieves efficient and green processing of discarded wind turbine blades, providing a complete solution for sustainable operations in the wind power industry. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] In order to make the present invention more easily understood, the present invention will be described in more detail with reference to the specific embodiments shown in the accompanying drawings. These drawings only depict typical embodiments of the present invention and should not be considered as limiting the scope of protection of the present invention.

[0013] Figure 1 This is a schematic diagram of the main structure of the waste fan blade cutting equipment.

[0014] Figure 2 Schematic diagram of the container transportation plan for the wind blade cutting system.

[0015] Figure 3 Schematic diagram of the structure of the guide device and guide wheel of the fan blade cutting system in one embodiment.

[0016] Figure numerals: 1—upper crossbeam; 2—feeding device; 3—middle crossbeam; 4—sheet metal cover; 5—circulating cooling water spray system; 6—tensioning device; 7—rope saw; 8—drive device; 9—left column; 10—right column; 11—anti-slip electric roller; 12—circulating cooling water tank; 13—cutting system base; 14—PLC control cabinet; 15—40-foot container wall; 16—guide device; 17—guide wheel; 18—clamping device. DETAILED DESCRIPTION

[0017] The following describes the embodiments of the present invention with reference to the accompanying drawings so that those skilled in the art can better understand the present invention and implement it. However, the enumerated embodiments are not intended to limit the present invention. Unless there is a conflict, the following embodiments and the technical features in the embodiments can be combined with each other, wherein the same components are represented by the same figure marks.

[0018] It should be noted that the terms "including" and "having" and any variations thereof in the specification and claims of this application and the above-mentioned drawings are intended to cover non-exclusive inclusions. For example, a process, method, system, product or apparatus that includes a series of steps or units is not necessarily limited to those steps or units clearly listed, but may include other steps or units that are not clearly listed or are inherent to these processes, methods, products or apparatuses.

[0019] like Figure 1 As shown, the waste wind turbine blade cutting equipment of the present invention includes: a wire rope saw cutting system, which includes: a feed device 2, a tensioning device 6, a drive device 8, and a wire rope saw 7 (preferably made of diamond beads). One end of the wire rope saw 7 is connected to the tensioning device 6, and the other end of the wire rope saw 7 is connected to the drive device 8. The feed device 2 is used to control the feed amount, speed, and path of the wire rope saw 7. The tensioning device 6 is used to adjust the tension of the wire rope saw 7 in real time to prevent slack (causing cutting deviation) or overtightening (causing wire rope breakage). The drive device 8 is used to provide power for the movement of the wire rope saw 7 and control the main movement speed and direction.

[0020] In one embodiment, the tensioning device 6 is mounted on the left column 9. The driving device 8 is mounted on the right column 10. The left column 9 and the right column 10 are placed vertically. When the wire saw 7 is tightened, it is perpendicular to the left column 9 and the right column 10.

[0021] In one embodiment, the tensioning device 6 includes a cylinder, a tensioning wheel, a spring mechanism, an electric actuator, and a tension sensor (such as a weighing sensor or a piezoelectric sensor).

[0022] The role of the spring mechanism and the electric actuator is to dynamically maintain the tension stability of the wire rope saw 7, ensuring that the wire rope saw 7 is always in the best tension state during the cutting process. In actual operation, the spring provides basic tension buffering and the electric actuator performs dynamic fine adjustment (such as a CNC stone engraving machine).

[0023] The tensioning pulley is mounted on a tensioning pulley bracket. A spring mechanism is connected between the tensioning pulley bracket and the main frame of the tensioning device 6. The rope saw 7 is wound around the tensioning pulley. The spring mechanism achieves coarse adjustment through passive expansion and contraction, making it suitable for low-cost, low-complexity systems.

[0024] The functions of the spring mechanism include: (1) Passive tension maintenance: The spring provides a constant or gradual reaction force through its own elastic deformation, offsetting the tension fluctuations caused by rope saw slack, thermal expansion, or load changes. (2) Vibration and shock absorption: When cutting hard materials (such as stone and metal), the spring can absorb the instantaneous impact force of the rope saw, reduce system vibration, and protect the mechanical structure.

[0025] The functions of electric actuators include: (1) Active tension control: By driving the tensioning pulley through a motor (servo motor, stepper motor) or a linear electric push rod, the wire saw tension is adjusted in real time to adapt to complex working conditions. (2) Precise closed-loop adjustment: By combining feedback from a tension sensor (such as a weighing sensor), high-precision dynamic tension compensation under the PID control algorithm is achieved. The electric actuator is connected to the tensioning pulley slide or the guide wheel rotating platform, and achieves high-precision closed-loop control through active drive, which is suitable for CNC and high-dynamic scenarios.

[0026] The cylinder of the tensioning device 6 is preferably a servo electric cylinder (0.75 kW, with a maximum tensioning force of 400 kg) to tighten the wire saw 7 .

[0027] The tensioning device 6 has a hydraulic adjustment mechanism connected to the wire rope 7 for dynamically adjusting the tension of the wire rope 7 to compensate for tension fluctuations caused by changes in cutting load or extension and retraction of the wire rope.

[0028] The tensioning device 6 is equipped with a tension sensor (such as a load cell or piezoelectric sensor) that monitors the pressure of the hydraulic adjustment mechanism in real time, indirectly reflecting the tension of the wire rope 7. The pressure monitored by the tension sensor is transmitted to the PLC control system (described in detail below). The PLC control system uses the pressure detected by the tension sensor to control the hydraulic adjustment mechanism to adjust the tension of the wire rope 7. The tension control accuracy is ±0.5 kN, ensuring a flatness deviation of the cut surface of less than 5 mm.

[0029] The tensioning device 6 has a guide wheel and a limit switch. The rope saw 7 is wound around the guide wheel. The limit switch is used to limit the mechanical travel of the guide wheel to prevent excessive movement from causing structural damage.

[0030] The tensioning device 6 has a rope-breaking alarm device, which detects insufficient length of the rope saw 7 due to breakage or excessive wear through the tension of the rope saw 7 .

[0031] The hydraulic adjustment mechanism, pressure sensor, limit switch, and rope-break alarm are controlled by a PLC control system. The PLC controls these mechanisms, ensuring they work together: the pressure sensor provides real-time feedback, the hydraulic adjustment mechanism maintains stable tension, the limit switch ensures safe mechanical travel, and the rope-break alarm rapidly responds to rope-break risks. Upon receiving the alarm signal, the PLC controls the hydraulic adjustment mechanism to trigger an emergency stop. Simultaneously, the PLC issues an audible and visual alarm and locks the entire blade cutting machine. This creates a closed "monitoring-adjustment-protection" loop, ensuring the efficiency and safety of the blade cutting machine during wind turbine blade recovery.

[0032] The driving device 8 is used to provide power for the movement of the rope saw 7 and control the main movement speed and direction of the rope saw 7.

[0033] The driving device 8 includes a servo motor or a variable frequency motor, a speed reducer and a transmission mechanism (such as a gear or a pulley), and the servo motor or the variable frequency motor drives the driving device 8. The speed reducer and the transmission mechanism convert the rotary motion into the linear or rotary motion of the rope saw 7.

[0034] In one embodiment, the drive device 8 comprises a motor (e.g., a Siemens three-phase asynchronous motor with a maximum power of 30 kW, capable of driving a wire saw with a linear speed range of 0-40 m / s) and a frequency converter. This converter utilizes power electronics modulation technology and closed-loop feedback control to precisely regulate the speed of the three-phase asynchronous motor, achieving stepless speed regulation to accommodate the cutting requirements of different materials. Table 1 shows the logic for matching the frequency converter with the cutting process.

[0035] Table 1

[0036]

[0037] The PLC control system coordinates the tensioning device 6 and drive device 8, ensuring stable cutting and extending equipment life. Dynamic tension control and closed-loop power-speed matching achieve precise coordination. This ensures efficient and stable cutting across all operating conditions, from glass fiber to carbon fiber composites, meeting the stringent process requirements of wind turbine blade recycling.

[0038] Feeding device 2 is used to control cutting efficiency and accuracy. Its operating principle and control method are as follows. The core functions of feeding device 2 include: (1) Speed ​​control: Adjusting the feed rate of wire saw 7 to match the hardness, thickness, and cutting requirements of different materials (such as stone, metal, or concrete). (2) Direction control: Ensuring that the wire saw moves stably along a preset path (straight line, curve, or complex geometry). (3) Pressure regulation: Dynamically adjusting the feed pressure based on the cutting resistance to prevent wire saw overload or breakage.

[0039] There are two control mechanisms for the feed device 2: (1) Mechanical transmission control: Power is converted into linear motion through gears, screws, or chain mechanisms to achieve precise displacement control. Suitable for scenarios with low precision requirements or stable loads (such as simple stone cutting). (2) Hydraulic / pneumatic control: The feed device is driven by a hydraulic pump or cylinder to provide high thrust and impact resistance. Commonly used for heavy-duty cutting tasks (such as large-section concrete demolition). (3) Electric servo control: A servo motor is combined with an encoder to adjust the feed speed and position in real time through closed-loop feedback. Advantages: High precision, fast response, suitable for complex paths or automated cutting (such as CNC wire saw systems).

[0040] The feeding device 2 includes a guide device: when the path turns or curves are cut, the feeding device synchronizes with the guide device to adjust the speed to ensure that the rope saw 7 is always close to the guide wheel.

[0041] The feeding device 2 includes sensor feedback: the cutting status is monitored in real time through force sensors and displacement sensors, and the feeding parameters are adjusted (such as reducing the speed when encountering hard materials).

[0042] The feeding device 2 is linked to the tensioning device 6: the feeding speed is dynamically matched with the tension of the cutting rope to avoid slipping or deviation of the cutting rope due to insufficient tension.

[0043] The feed device ensures efficient, precise, and safe wire saw cutting through multi-dimensional control (speed, direction, pressure) and system coordination. The control method should be flexibly configured according to the specific application scenario and the degree of automation.

[0044] The feeding device 2 is mounted on the upper crossbeam 1, and the upper crossbeam is mounted on the upper ends of the left column 9 and the right column 10. The feeding device 2 is used to control the feed amount, speed and path of the rope saw 7 and match complex cutting trajectories (such as spirals and variable cross-section curves). The feeding device 2 includes a servo motor and a ball screw driven by the servo motor, a guide wheel, and an encoder. The ball screw is driven by the servo motor to achieve vertical feeding. The feed speed range of 0-1440mm / min can be adjusted by the servo motor (2.2kW). The displacement accuracy is ±0.1mm, which ensures the stability of the cutting process. The position of the feeding device 2 is fed back to the PLC control system through the encoder, and closed-loop control is achieved by the PLC control system. In one embodiment, the vertical displacement accuracy of the high-precision servo drive device 8 and the ball screw feeding device 2 reaches ±0.1mm, and is combined with the stepless speed regulation function (linear speed 0-40m / s) to adapt to different blade thickness requirements. The high-precision servo drive 8, coupled with the stepless speed regulation function, seamlessly matches precise displacement and speed through the PLC control system's closed-loop control system and dynamic parameter adaptation. This stepless speed regulation achieves the dual goals of continuously adjustable speed and precise displacement control. Even at speeds of 40 m / s, it maintains a vertical positioning accuracy of ±0.1 mm, meeting the demands of complex blade recovery scenarios.

[0045] The waste fan blade cutting equipment of the present invention also includes a cooling water spray system 5, which is mounted on the middle crossbeam 3, located between the left and right columns 9 and 10. The cooling water spray system 5 has multiple nozzles, which are located above the wire rope saw 7. The cooling water spray system 5 includes a nozzle temperature sensor to monitor the water temperature. The cooling water spray system 5 has a flow switch to monitor the flow rate (50-200 L / min). Dynamic regulation is achieved through the temperature sensor to ensure continuous and efficient cutting by the wire rope saw. The cooling water spray system 5 uses the temperature sensor to control the water temperature in real time. The flow switch is triggered only when the water flow is normal, allowing the wire rope saw 7 to start cutting and preventing the equipment from overheating. The cooling water spray system 5 is connected to the water tank 12, and the water in the water tank 12 is supplied to the nozzles. The cooling water spray system 5 also includes a flow switch, piping, a water distribution device, a high-pressure water pump, and a multi-nozzle cooling device. The cooling water flow rate is 50-200 L / min, and a temperature sensor is configured to control the water temperature in real time. Only when water flows through, the flow switch outputs a signal to start the rope saw 7 for cutting.

[0046] During cutting, the PLC control system controls the cooling water spray system 5 to work first, then transmits a signal to the tensioning device 6 and the drive device 8, and then controls the rope saw 7 to start cutting. Specifically, before cutting, the high-pressure water pump (pressure range 0.5-2MPa) is started in advance by the PLC control system to ensure that the water flow covers the rope saw cutting area to form a stable lubricating film and cooling layer. When the cooling water flow and pressure reach the set value (such as flow 30L / min, pressure 1.2MPa), the servo electric cylinder driving the rope saw 7 is started at a preset speed (such as 20-40m / s linear speed) to avoid dry friction damage. After the cutting is completed, the motor driving the rope saw 7 stops running immediately, but the cooling water continues to spray until the temperature of the cutting area drops to a safe value (<50°C) to prevent residual heat from burning back and damaging the diamond beads of the rope saw 7.

[0047] The waste wind turbine blade cutting device of the present invention further includes a motorized roller 11 and a cutting system base 13. The motorized roller 11 is used for feeding and is mounted on the cutting system base 13. The left and right columns 9, 10 are also mounted on the cutting system base 13. The motorized roller 11 is located in front of the left and right columns 9, 10. The motorized roller 11 is preferably coated with a polyurethane / rubber anti-slip layer, has a maximum load capacity of 10 tons, and is driven by a variable frequency motor with a linear speed of 0.16 m / s and a rotational speed range of 0-30 rpm, ensuring smooth feeding of blades onto the cutting system base 13.

[0048] Preferably, the waste fan blade cutting device of the present invention further includes a blade holder. The blade holder has a groove for accommodating the blades. The blade holder utilizes a hydraulic clamping mechanism with a clamping force range of 5-20 tons and is equipped with a laser positioning sensor with a positioning accuracy of ±1mm, ensuring stability during the blade cutting process.

[0049] The waste fan blade cutting device of the present invention also includes: a PLC control system, which is located in the PLC control cabinet 14. The PLC control system integrates wireless remote control and dust concentration monitoring functions, supports remote program upgrades; rope break protection, low pressure alarm and dust exceeding the standard automatic shutdown mechanism (threshold ≤ 10mg / m 3 ) to fully ensure operational safety.

[0050] Specifically, the wireless remote control system of the PLC control system integrates a wireless communication module (5G communication module, signal delay time is 82 milliseconds), which can receive remote control signals and thus control the entire equipment from a distance.

[0051] The dust concentration monitoring system of the PLC control system will alarm if it detects that the dust concentration exceeds the standard (the time from detecting the exceeding standard to the alarm is less than 2.4 seconds).

[0052] The remote program upgrade system of the PLC control system realizes the upgrade of the firmware program and performs program verification through CRC32, with the standard verification rate of 100%.

[0053] After receiving the alarm signal from the rope-breaking alarm device, the rope-breaking protection system of the PLC control system brakes the movement of the rope saw 7, and the braking distance accuracy reaches 8.5 mm.

[0054] If the low voltage protection system of the PLC control system detects that the equipment working voltage is off or the working voltage is lower than the set value, it will alarm and turn on the supercapacitor for power-off protection (lasting longer than 30 seconds).

[0055] The PLC control system has a multi-mode automatic cutting program that can realize a double-line and double-vertical surface cutting path. The specific operation is as follows: Based on the input blade length, chord length distribution curve and root flange diameter, the PLC control system calls the parametric blade database to generate a three-dimensional topological model, and identifies the spatial distribution of key load-bearing structures such as the main beam, web, and shell. By matching the material parameters (glass fiber / carbon fiber ratio, epoxy resin system, core material density) with the material cutting characteristic library, the cutting power (5-20kW laser or diamond saw blade speed), feed speed (0.5-3m / min) and cooling parameters are dynamically adjusted. A normal plane is established at L1=1.2D (D is the hub diameter) from the blade root as the first vertical plane positioning. According to the preset recovery section length, a parallel plane is generated at L1+ΔL (the specific value is adjusted according to the actual operation) as the second vertical plane. The angle between the two plane normal vectors is ≤0.5° to ensure that the verticality error of the truncation surface is less than 2mm / m.

[0056] If unusual shapes are to be cut, the guide wheel rotates to follow the path of the wire saw 7. The guide wheel is mounted on a rotatable platform supported by high-precision bearings (such as crossed roller bearings) to ensure low-friction, high-rigidity rotational motion. A servo / stepper motor drives the rotating platform and bearings. The guide wheel is driven by a servo or stepper motor, which receives pulse signals from a PLC control system to precisely control the rotation angle and speed.

[0057] The installation location of the rotatable platform is determined by the functional requirements of the equipment and the complexity of the motion control. In one embodiment, the rotatable platform is integrated with the feed mechanism 2 (cutting head / worktable), which is suitable for high-precision, multi-axis coordinated cutting of complex and irregular shapes. In another embodiment, the rotatable platform is mounted independently (either on the main frame or in a linkage mechanism), which is suitable for wide-angle adjustment or heavy-duty cutting scenarios. A comprehensive balance is achieved by combining mechanical design, control algorithms, and cost to achieve precise matching of the wire saw path to the workpiece contour.

[0058] Guide wheels guide the wire saw, maintain tension, and adapt to changes in the wire saw's path. When cutting complex shapes, the number and layout of guide wheels in a wire saw system directly impacts the saw's path flexibility and cutting accuracy. Typically, at least three guide wheels are required for dynamic steering, but the specific number depends on the cutting complexity, machine design, and motion control solution.

[0059] In one embodiment, the guide wheel assembly includes: a driving wheel, a main guide wheel, an adjustable guide wheel, and an auxiliary guide wheel.

[0060] The drive wheel provides power to the wire saw (not usually considered a guide wheel). The main guide wheel is located in a fixed position and determines the basic path of the wire saw. The adjustable guide wheel is mounted on a rotating platform and dynamically adjusts the direction to match the contour. The auxiliary guide wheel is used for fine-tuning the path or for segment control.

[0061] Complex, custom-shaped cutting requires multi-axis motion. If the cutting path includes multi-directional bends or spatial curves, the number of guide wheels must be increased to control the path in sections. For example, for planar custom-shaped (2D) cuts, four to six guide wheels are typically required to form a closed-loop path control system. For custom-shaped (3D) cuts, six or more guide wheels are typically required, combined with a multi-axis rotary platform to achieve three-dimensional path adjustment.

[0062] like Figure 3 In one embodiment shown, four guide wheels 17 are provided to guide the wire saw, maintain tension, and adapt to path changes.

[0063] A motor (typically a hydraulic or electric motor) drives the saw wire 7 through the main wheel (large wheel). This motor (or hydraulic motor) drives the main wheel, driving the entire saw wire. The saw wire 7 is wound around multiple wheels (including a tensioning wheel and a guide wheel) in a specific path, maintaining tension and direction. The wire passes through the guide wheel, tensioning wheel, and feed wheel, and finally, the two ends of the wire are connected to form a closed loop (optionally with a connector). After tensioning, the closed loop is cut.

[0064] The feeding device 2 controls the rope saw to advance slowly toward the workpiece to achieve continuous cutting. The tensioning device 6 adjusts the distance between the wheels or tightens the rope saw through the thrust of the hydraulic cylinder to ensure that it will not slip during cutting.

[0065] The clamping device 18 has the following functions: In a wire saw cutting system, the clamping device 18 ensures a safe, efficient and precise cutting process. Its core functions include:

[0066] 1. Fix the workpiece to prevent displacement.

[0067] Stable positioning: The clamping device firmly fixes the workpiece through mechanical clamps, hydraulic / pneumatic clamps or electromagnetic adsorption to prevent the workpiece from shifting due to vibration, impact or wire rope tension during cutting.

[0068] Adapt to complex shapes: For workpieces of different sizes or shapes (such as special-shaped stones, concrete blocks), the clamping device can be designed as an adjustable fixture or a multi-point clamping structure to ensure uniform and stable clamping.

[0069] 2. Ensure cutting accuracy

[0070] Reduce vibration interference: Suppress workpiece vibration through rigid clamping, avoid cutting path deviation (such as the "saw runaway" problem in stone cutting), and ensure the flatness of the cutting surface (for example, high precision requirements within ±1mm).

[0071] Positioning reference alignment: The clamping device is often used in conjunction with the positioning pin and the reference surface to ensure that the initial position of the workpiece is accurately aligned with the movement trajectory of the wire saw, thereby improving processing consistency.

[0072] 3. Improved security

[0073] Prevent workpiece from falling off: Under high-speed cutting (wire saw linear speed can reach 20-40m / s) or heavy load conditions, the clamping device can resist the severe tension of the wire rope, preventing the workpiece from suddenly loosening and causing equipment damage or personal injury.

[0074] Emergency locking: Some systems are equipped with a sensor-linked clamping device, which automatically locks in the event of abnormal vibration or power failure, providing double safety protection.

[0075] 4. Optimize cutting efficiency

[0076] Multi-station collaboration: In the automated wire saw system, the clamping device can be integrated with the conveyor belt and rotary table to achieve rapid clamping and continuous cutting of the workpiece, reducing downtime.

[0077] Stress dispersion: By rationally designing the distribution of clamping points (such as symmetrical clamping or wrap-around clamping), the stress concentration generated during the cutting process is dispersed, reducing the risk of workpiece breakage (especially for brittle materials).

[0078] 5. Adapt to special working conditions

[0079] Dynamic adjustment: When cutting large or flexible workpieces (such as concrete beams for bridges), the intelligent clamping device can monitor the clamping force in real time and adjust it dynamically to avoid deformation caused by over-clamping.

[0080] Environmental adaptability: In humid, dusty or high temperature environments, the clamping device uses rust-proof materials (such as stainless steel) or sealed design to ensure long-term reliable operation. The PLC control system calculates the spatial trajectory of the cutting rope in real time based on the three-dimensional model of the fan blade (such as spiral line, contour curve, etc.) and generates cutting path parameters (angle, speed).

[0081] The PLC then calculates the required rotation angle of the guide wheel and sends a pulse signal to the guide wheel motor, driving it to the target angle. Based on the encoder's feedback of the actual angle, the PLC control system compares it with preset values ​​and dynamically adjusts the motor output and the guide wheel using a PID algorithm, thereby driving the wire saw's travel path. If tension exceeds the limit, the PLC triggers an emergency stop or reverse rotation compensation to prevent equipment damage.

[0082] When cutting spiral wires, the PLC controls the continuous rotation of the guide wheel, which rotates at a constant speed according to the rope's spiral angle. When performing contour-following cutting, the PLC control system adjusts the rotation angle in sections (e.g., intermittent corrections of ±15°) based on the blade's curvature. When performing adaptive curve cutting, rotational deviations are dynamically compensated through real-time sensor feedback (e.g., laser ranging and tension detection).

[0083] The system adapts to complex curved surfaces with high precision: the guide wheel rotation accuracy can reach 0.01mm, matching the aerodynamic profile of the fan blade. It also features fast dynamic response: the servo motor response time is less than 10ms, meeting high-speed cutting requirements (e.g., 5m / min). It also boasts strong anti-interference capabilities: closed-loop control can offset mechanical deformation caused by vibration and temperature differences.

[0084] In summary, the PLC control system can automatically adjust the cutting path according to the shape of the wind turbine blade, including: straight vertical cutting, spiral cutting, contour following cutting, and adaptive curve cutting. In one embodiment, the applicable part of straight vertical cutting is the straight section of the blade root, and the preferred cutting rate is 5 meters / minute. The applicable part of spiral cutting is the tapered blade tip, and the preferred cutting rate is 2.5 meters / minute. The applicable part of contour following cutting is the S-shaped leading edge or trailing edge of the blade, and the preferred cutting rate is 1.8 meters / minute. The applicable part of adaptive curve cutting is the variable cross-section transition zone of the blade, and the preferred cutting rate is 3.2 meters / minute. An example of the blade cutting path parameters of the present invention is shown in Table 2.

[0085] Table 2 Automatic generation parameters of blade cutting path

[0086]

[0087] The cutting system is linked by three axes (X, Y, Z) to achieve precise control of complex paths.

[0088] Contour-following cutting (X+Y+Z linkage): The X / Y axes horizontally position the blade contour, the Z axis controls the cutting depth, and the three axes move proportionally and collaboratively to complete high-precision cutting (±0.2mm) of the S-shaped leading edge.

[0089] Spiral wire cutting (A+Z axis extended linkage) adds a rotation axis (A axis) to the X / Y / Z system to control the guide wheel angle and realize the spiral trajectory of the tapered blade tip (the number of linkage axes is expanded to four axes).

[0090] Linear guides include X / Y / Z-axis guides: Each axis uses a high-rigidity linear guide to ensure motion direction accuracy (e.g., ±0.01mm). Guide wheels are installed on the XYZ-axis guides, and the guide wheels can rotate 360 ​​degrees around the XYZ-axis linear guides.

[0091] 1. The first embodiment of the rotating mechanism

[0092] The rotation mechanism consists of a guide wheel, bearings, a linear guide, and a rotary drive unit. The guide wheel is mounted on the linear guide's slider using precision bearings (such as crossed roller bearings or ball bearings). The bearings allow the guide wheel to rotate freely about the linear guide's axis (such as the longitudinal axis of an X-axis guide) while maintaining linear motion accuracy.

[0093] Rotation drive unit: If active rotation control is required, a servo motor and harmonic reducer are integrated to drive the guide wheel through gears or synchronous belts, and an encoder is used to achieve closed-loop control (with an accuracy of up to ±0.01mm).

[0094] 2. Second Implementation Method of Rotating Mechanism

[0095] The rotation mechanism includes guide wheels, universal joints or ball joints, linear guides, and a rotary drive unit. Universal joints or ball joints: In scenarios requiring multi-directional adjustment (such as at the end of a robotic arm), guide wheels are connected via universal joints or ball joints, allowing rotation around multiple axes. For example, a guide wheel at the end of a Z-axis guide rail can simultaneously tilt around the X and Y axes, combining this with its own rotation to achieve omnidirectional motion.

[0096] 3. The third embodiment of the rotating mechanism

[0097] Rotary mechanisms include a composite motion module: a linear guideway is superimposed with a rotary module (such as a rotary table) to form a "linear + rotary" compound axis. For example, the slider of the X-axis guideway is mounted on a rotary table, and the guide wheels are fixed to the rotary table, achieving simultaneous movement along the X-axis and rotation around it.

[0098] The wire saw feeding of the present invention has a precision guarantee measure.

[0099] Preload and eliminate backlash: Use preloaded bearings or double-nut ball screws to eliminate backlash during rotation and ensure repeat positioning accuracy.

[0100] Rigid structure design: The guide rail and rotating mechanism are made of high-rigidity materials (such as hardened steel or aluminum alloy), and the structure is optimized through finite element analysis to reduce the impact of deformation on accuracy.

[0101] The guide wheel's 360° rotation is achieved through the coordinated design of precision bearings, a multi-degree-of-freedom mechanism, and a high-rigidity guideway. This ensures linear motion accuracy (±0.01mm) while also expanding system flexibility. In actual design, the appropriate rotation mechanism and materials must be selected based on the specific application scenario (such as load, speed, and environment).

[0102] Ball screw drive: converts the rotary motion of the servo motor into linear motion, providing high-precision positioning (such as the Z axis is responsible for cutting depth control).

[0103] Frame support: Aluminum alloy or steel structure frame carries the three-axis system to resist vibration and load during cutting.

[0104] The drive system utilizes servo motors and drivers. Each axis (X, Y, and Z) is equipped with a separate servo motor, which receives pulse / analog signals from the PLC to control speed and position. The driver interprets the commands in real time, driving the motor to follow the set trajectory (for example, contour-following cutting requires synchronized acceleration and deceleration along all three axes).

[0105] Reducer (optional): Improves torque output and adapts to heavy-load cutting (such as high-speed cutting of the straight section of the blade root).

[0106] Motion control is achieved by a PLC control system. It generates path instructions (such as G-code) based on the three-dimensional blade model and decomposes them into three-axis linkage coordinates (X+Y+Z). The PLC control system integrates interpolation algorithms (linear and circular interpolation) to ensure smooth three-axis coordinated motion trajectories (such as the continuous curve of the S-shaped leading edge). The PLC control system also integrates an AI prediction module (adaptive cutting): This optimizes path parameters through machine learning and dynamically adjusts the speed and acceleration of the three axes.

[0107] Feedback and closed-loop control of the cutting system are achieved by the encoder and optical scale of feed mechanism 2. Each axis motor has a built-in encoder that provides real-time feedback on rotation angle, which is converted into linear displacement. A high-precision optical scale directly measures the guide rail position, creating a fully closed-loop control system (with an accuracy of ±0.005mm). The encoder, servo motor, and ball screw together form a closed-loop drive-feedback system, responsible for real-time monitoring and adjustment of motor motion.

[0108] PID adjustment of the cutting system: Compare the target and actual positions, dynamically correct the motor output, and eliminate cumulative errors (such as the influence of temperature drift during long-term cutting).

[0109] The various components of the cutting system have a collaborative linkage mechanism, and its synchronous control protocol uses EtherCAT or Profinet bus communication to ensure real-time synchronization of three-axis instructions (response time <1ms).

[0110] The cutting system has a dynamic load distribution mechanism: the torque of each axis is adjusted according to the cutting resistance (for example, the transition area of ​​the variable cross-section requires rapid compensation of the Z axis).

[0111] The cutting system has an anti-collision function, which is realized by limit switches and soft limits to prevent overtravel. The cutting system has an emergency brake function: the three axes will stop synchronously in case of abnormality (such as rope break sensor triggering).

[0112] Through mechatronic design, the system deeply integrates three-axis mechanical structure, servo drive, and intelligent control, becoming the core technology for automated cutting of large wind turbine blades.

[0113] Through the above-mentioned path planning and multi-axis collaboration, the wire saw system can still efficiently complete the full-profile cutting of wind turbine blades even if it is limited by vertical movement, meeting the precision and flexible production requirements of composite material recycling.

[0114] The waste fan blade cutting equipment of the present invention also includes: a sewage treatment system, which is movable and has a cyclone separator and a centrifugal pump, with a solid particle separation efficiency of ≥95% and a filtered water recycling rate of ≥90%, effectively solving the problem of cutting wastewater pollution.

[0115] The following is an example of a wire saw cutting system for stone cutting. Through structural analysis and workflow description, the connection method and coordination of various components (linear guide rails, feed device, tensioning device, and drive device) are demonstrated.

[0116] The linear guides are made of high-precision carbide rails, fixed parallel to the frame on both sides. They are bolted to the frame and coated with a wear-resistant coating. The linear guides engage the slider of the feed mechanism, which uses a ball screw to achieve linear motion on the linear guides. The feed mechanism's hydraulic cylinder (or servo motor) drives the ball screw, moving the slider along the guide rails. The feed mechanism's pressure sensor is embedded in the hydraulic cylinder, providing real-time feedback on the propulsion resistance. The slider is rigidly connected to the drive mechanism and tensioning mechanism, allowing the drive mechanism and tensioning mechanism to be propelled along the guide rails as a whole.

[0117] The output shaft of the variable frequency motor in the drive unit is mounted on a driving pulley (with a rope saw groove). The driving pulley is located at one end of a linear guide rail, and the rope saw passes around the driving pulley and the guide pulley of the tensioning device to form a closed loop. The variable frequency motor is directly connected to the reducer via a coupling, and the reducer flange is fixed to the frame.

[0118] The tensioning device consists of a hydraulic cylinder and a guide wheel assembly that slides laterally along a linear guide rail. The hydraulic cylinder's piston rod is hinged to the guide wheel bracket, allowing adjustment of the rope saw's tension by adjusting the piston's stroke. A tension sensor, mounted on the guide wheel bearing housing, monitors the real-time tension.

[0119] When cutting granite slabs, the workflow of each module is as follows.

[0120] Step 1: System startup. The drive unit's variable frequency motor starts, rotating the driving wheel at a linear speed of 15 m / s. The tensioner's hydraulic cylinder applies an initial tension of 2.5 kN to eliminate slack in the diamond wire rope. The feed unit's hydraulic cylinder preloads the slide, locking it in the guide rail's starting position.

[0121] Step 2: Cut into the stone. The feed mechanism's hydraulic cylinder pushes the slide along the guide rails, slowly feeding the stone (at a speed of 5 cm / min). The linear guide ensures the slide's linear trajectory, with an offset of less than 0.05 mm. The drive detects that the load torque has risen to 80% of the rated value and automatically reduces the speed to 12 m / s to prevent overload. The tension in the tensioning mechanism drops to 2.3 kN due to the wire saw's stretching. The hydraulic cylinder compensates by 0.2 kN to restore the set value.

[0122] Step 3: Dynamic Adjustment. When resistance suddenly changes, as when cutting into cracks within the stone, resistance drops dramatically. The drive detects the drop in torque and increases the speed to 18 m / s to accelerate cutting. Due to the increased centrifugal force on the wire saw, the tensioner increases the pressure in the hydraulic cylinder to 2.8 kN to prevent the wire saw from whipping. Closed-loop feedback: The PLC automatically optimizes parameters based on signals from the pressure sensor (feed resistance), tension sensor, and speed.

[0123] Step 4: Emergency Stop. If the wire saw breaks unexpectedly, the tension sensor detects that the tension has returned to zero, and the drive unit immediately shuts off and brakes. The feed unit hydraulic cylinder quickly retracts, and the slide returns to a safe position.

[0124] The coordinated mechanism of these devices is as follows. The guide rail and slide provide rigid support. When the feed mechanism advances, the drive and tensioning mechanisms move integrally with the slide, ensuring that the wire rope is perpendicular to the cutting surface. The closed-loop path of the wire rope is: drive pulley (drive end) → stone cutting surface → guide pulley (tensioning end) → return drive pulley.

[0125] The control logic of the device is to match speed and tension. Based on a tension reference, adjustments are made according to wire speed and centrifugal force.

[0126] In one embodiment, the feed adaptation rule is as follows: if the pressure sensor value is greater than the threshold, then the feed speed is multiplied by 0.8 and the tension is multiplied by 1.2. If the pressure sensor value is less than the threshold, then the feed speed is multiplied by 1.5 and the tension is multiplied by 0.9.

[0127] In one embodiment, the linear guide rail has a length of 3m and a repeatability of ±0.02mm. The feed mechanism has a maximum thrust of 10kN and a speed of 1-50cm / min. The drive motor has a power of 22kW and a rotational speed of 0-40m / s. The tensioning mechanism has a tension range of 1-5kN and a response time of 0.1s. The wire saw has a diameter of 11mm and a diamond bead spacing of 40mm.

[0128] In this implementation, a linear guide serves as the motion reference, ensuring accurate feed trajectory. The drive and tensioner dynamically balance the wire saw's centrifugal force and cutting resistance. The rigid connection between the feeder and guide rails ensures stable propulsion. Closed-loop control coordinates the parameters of the feeder, drive, and tensioner in real time, adapting to complex working conditions. This structural design is widely used in applications such as stone mining and bridge demolition, balancing efficiency and safety.

[0129] The present invention is described below by means of an example.

[0130] Core components such as wire saw cutting system, circulating cooling water tank 12, sewage treatment system, PLC control cabinet 14 are standardized modules. Figure 2 The pre-set layout shown is loaded into a 40-foot standard container. Anti-slip straps are used to secure the components inside the container to prevent displacement during transport. Bolt locking devices and shock-absorbing washers further enhance stability.

[0131] After arriving at the wind farm, open the side door of the container, take out the cutting system components one by one using a forklift or crane, and assemble them according to the following steps: install the cutting system base 13 and the circulating cooling water tank 12, and adjust the horizontal error to ≤0.5mm / m; install the left column 9 and the right column 10; install the tensioning device 6 and the drive device 8; connect the rope saw 7 between the tensioning device 6 and the drive device 8, and calibrate the rope saw tension to 400kg through the PLC control cabinet 14 after power is turned on; install the middle beam 3 and the circulating cooling water spray system 5; then install the upper beam 1; the feeding device 2 and multiple sheet metal covers 4; connect the pipeline of the circulating cooling water system 5, start the high-pressure water pump after filling the water tank 12 with water, and verify the linkage function of the flow switch (flow ≥50L / min) and the temperature sensor (set threshold ≤40℃).

[0132] The blade cutting operation process is as follows.

[0133] 1. Blade Fixing and Positioning: Once the discarded wind turbine blades are brought to the cutting system, the anti-slip motorized roller 11 is activated to transport the blades to the blade holder. A hydraulic clamping mechanism locks the blades at the root and tip to ensure a stable cut section. The PLC control cabinet 14 is operated to select a preset cutting program (e.g., blade length, material parameters), generating a dual-vertical cutting path. The specific operations are as follows: S1: Based on the input blade length, chord length distribution curve, and root flange diameter, a 3D topological model is generated to identify the spatial distribution of key load-bearing structures such as the main beam, web, and shell.

[0134] S2, by matching the material cutting characteristics through material parameters (glass fiber / carbon fiber ratio, epoxy resin system, core material density), adjust the cutting power (5-20kW laser or diamond saw blade speed), feed speed (0.5-3m / min) and cooling parameters.

[0135] S3, establishing a normal plane at a distance of L1 = 1.2D (D is the hub diameter) from the blade root as the first vertical plane positioning.

[0136] S4: Based on the preset recovery section length, a parallel plane is generated at L1+ΔL as the second vertical plane. The angle between the two plane normal vectors is ≤0.5°, ensuring that the verticality error of the truncation surface is less than 2mm / m.

[0137] 2. Efficient cutting and cooling: Start the wire saw 7, adjust the linear speed to 30m / s through the frequency converter, and advance the feed device 2 at a constant speed; the circulating cooling water spray system 5 is simultaneously turned on, and multiple nozzles evenly cover the cutting area. The water temperature is monitored in real time and the flow rate is adjusted to prevent the wire saw from overheating; during the cutting process, the PLC monitors the wire break alarm sensor and the dust concentration (threshold ≤10mg / m 3 ), if abnormal, shut down immediately.

[0138] 3. Waste treatment and resource recovery: The wastewater generated by cutting is passed through a cyclone separator (separation efficiency ≥ 95%) to remove glass fiber debris, and a centrifugal pump returns the filtered water (recycling rate ≥ 90%) to the water tank for circulating cooling 12. The glass fiber debris is collected and used for thermal cracking.

[0139] The present invention has the following innovations.

[0140] 1. Wire saw dynamic control technology

[0141] The tensioning device 6 compensates for the slack caused by rope saw wear in real time through the servo electric cylinder, and combines the pressure sensor feedback to maintain the tension fluctuation ≤±5kg; at the moment of rope breaking, the hydraulic adjustment mechanism triggers an emergency stop, and the PLC issues an audible and visual alarm and locks the equipment.

[0142] 2. Intelligent control and remote management

[0143] The PLC control cabinet 14 has built-in multiple programs (such as "fast cutting" and "high-precision mode"), which support operators to switch through wireless remote control; the remote monitoring platform receives equipment status data (such as water temperature and dust concentration) in real time, and supports fault diagnosis and program OTA upgrades.

[0144] 3. Emergency maintenance and environmental protection measures

[0145] Equipped with a movable sewage treatment system to deal with sudden wastewater leakage and ensure that there is no pollution on site; regularly check the wear of the polyurethane anti-slip layer of the electric roller 11 (replace when the thickness is less than 2mm) to avoid the risk of blade slippage.

[0146] The system of the present invention has been verified for its effectiveness: a single wire saw takes ≤15 minutes to complete double-sided cutting of a 2.5m long blade, which is 100% more efficient than traditional equipment (30 minutes); environmental verification: the sewage treatment system reduces wastewater discharge by 90%, and the solid waste collection rate is ≥98%; economic verification: the containerized design reduces transportation costs by 40%, and on-site installation time is shortened to within 4 hours.

[0147] In another aspect of the present invention, a method for cutting waste fan blades is provided.

[0148] S1, start the driving device, the driving wheel of the driving device rotates, and the rope saw moves at high speed.

[0149] Specifically, the drive unit provides power, driving the diamond wire saw's high-speed rotation. It consists of a motor, a reducer, and a drive pulley. Typically, the drive unit uses a variable-frequency motor or servo motor, which adjusts the speed based on the material's hardness to ensure cutting efficiency.

[0150] S2, apply initial tension to the tensioning device to eliminate slack in the rope saw.

[0151] Specifically, the wire saw is connected between a drive unit and a tensioning device. The tensioning device maintains constant tension in the wire saw to prevent slipping, vibration, or breakage. The tensioning device includes a hydraulic cylinder or spring mechanism, a tension sensor, and a guide wheel. The tensioning device dynamically adjusts the wire saw's tension to compensate for elastic deformation and wear during the cutting process.

[0152] The drive and tensioning devices are connected to the linear guide rails, and the feed mechanism pushes the linear guide rails via the slider. The linear guide rails provide high-precision guidance for the feed mechanism, ensuring the straightness of the cutting path. Linear guide rails consist of sliders, guide rails, and a lubrication system. They offer high rigidity and wear resistance, reducing vibration and deflection.

[0153] The feeding device pushes the wire saw forward, wherein the feeding device is connected to the driving device and the tensioning device.

[0154] During S3 cutting, the feed mechanism pushes the wire saw along a linear guide toward the material, gradually increasing the cutting force. The linear guide ensures a stable feed direction and prevents path deviation. The drive mechanism monitors the load torque in real time. If the material hardness is too high, the speed is reduced to prevent overloading the wire saw. If the cutting resistance decreases (e.g., to penetrate the material), the speed is automatically increased to optimize efficiency. The tensioning mechanism dynamically adjusts the tension: feedback from the tension sensor compensates for changes in wire saw length due to stretching or wear; in the event of an emergency stop or a jam, the tension is quickly released to protect the wire saw.

[0155] The feed mechanism preferably controls cutting speed and depth, propelling the wire saw into the material. The feed mechanism includes a hydraulic cylinder / ball screw, a servo motor, and a pressure sensor. The feed mechanism automatically adjusts the feed speed based on the material's resistance, preventing overloading or cutting stalls.

[0156] Preferably, the drive device monitors the load torque and reduces the motor speed when the material hardness exceeds a set threshold, and increases the motor speed when the material hardness is less than the set threshold and the resistance is detected to be reduced.

[0157] S4 dynamically adjusts and provides feedback for the drive, tensioner, and feeder. The PLC control system collects data from each component: the drive's speed and torque; the tensioner's real-time tension; and the feeder's pressure or displacement signal. This data is analyzed and calculated to adapt the feed speed, adjust tension-speed matching, and dynamically adjust the tensioner.

[0158] Adaptive feed speed refers to the following: when cutting hard materials (determined by monitoring the drive unit's speed and torque), the speed is reduced (feed speed is reduced) and the tension is increased (wire tension is increased); when cutting soft materials, the speed is increased (feed speed is increased) and the tension is stabilized (wire tension is reduced). Tension-speed matching refers to increasing the tension of the tensioning device at high drive unit speeds to prevent centrifugal force from causing the wire rope to whip. Dynamic adjustment of the tensioning device: When the tensioning device's sensor detects wear on the wire rope, the tension is increased. If the wire rope is detected to have stopped suddenly or jammed, the tension of the tensioning device is released.

[0159] The present invention realizes an efficient, compact and mobile blade processing solution, solves the problems of poor mobility, low efficiency and secondary pollution, realizes efficient on-site disassembly and green recycling of blades, and provides technical support for the recycling of waste composite materials.

[0160] The embodiments described above are merely preferred embodiments of the present invention. The phrases "in one embodiment," "in another embodiment," "in yet another embodiment," or "in other embodiments" used in this specification may refer to one or more of the same or different embodiments of the present disclosure. Any common changes and substitutions made by those skilled in the art within the scope of the present invention are intended to be encompassed within the scope of protection of the present invention.

Claims

1. A waste fan blade cutting device, characterized in that: A wire saw cutting system is provided, wherein the wire saw cutting system comprises: A feed device for controlling the feed rate, speed and path of the wire saw; A tensioning device for adjusting the tension of the wire saw; A driving device for driving the wire saw to rotate; The rope saw passes around the driving wheel of the driving device and the guide wheel of the tensioning device to form a closed loop; The rotating mechanism is provided with a guide wheel, and the guide wheel is used to change the path of the rope saw.

2. The waste fan blade cutting device according to claim 1 is characterized in that: The rotating mechanism includes: a linear guide rail and a slider, the slider is installed on the linear guide rail, the tensioning device and the driving device are rigidly connected to the slider, the feeding device is engaged with the slider to push the slider to perform linear motion on the linear guide rail, and the guide wheel is installed on the linear guide rail, and the guide wheel can rotate around the longitudinal axis of the linear guide rail.

3. The waste fan blade cutting device according to claim 2, characterized in that: The linear guide rail comprises: The X-axis linear guide rail is provided with an X-axis guide wheel, which can rotate around the X-axis linear guide rail to change the direction of the wire saw. The Y-axis linear guide rail is provided with a Y-axis guide wheel, which can rotate around the X-axis linear guide rail to change the direction of the wire saw. The Z-axis linear guide rail is equipped with a Z-axis guide wheel, which can rotate around the X-axis linear guide rail to change the direction of the wire saw.

4. The waste fan blade cutting device according to claim 2, characterized in that: Also includes: The A-axis is a rotating shaft, and the guide wheel group is installed on the A-axis rotating shaft. The rope saw changes its running trajectory through the guide wheel group to achieve spiral cutting.

5. The waste fan blade cutting device according to claim 1, characterized in that: The tensioning device comprises: A hydraulic adjustment mechanism connected to the wire saw for dynamically adjusting the wire saw tension to compensate for tension fluctuations caused by changes in cutting load or wire saw extension and retraction; The pressure sensor monitors the pressure of the hydraulic adjustment mechanism in real time, thereby indirectly reflecting the tension of the rope saw; Guide wheel and limit switch, one end of the rope saw is connected to the guide wheel, and the limit switch is used to limit the mechanical travel of the guide wheel to prevent structural damage caused by over-limit movement.

6. The waste fan blade cutting device according to claim 1, characterized in that: The PLC control system controls the hydraulic adjustment mechanism, pressure sensor, limit switch and rope break alarm device to work together: the pressure sensor provides real-time feedback, the hydraulic adjustment mechanism maintains stable tension, the limit switch ensures the safe travel of the machine, and the rope break alarm device quickly responds to the risk of rope breakage.

7. The waste fan blade cutting device according to claim 1, characterized in that: The feeding device includes a servo motor and a ball screw, and the ball screw is driven by the servo motor to realize vertical feeding.

8. The waste fan blade cutting device according to claim 1, characterized in that: Also includes: A cooling water spray system (5) is provided, wherein the cooling water spray system (5) has a plurality of spray heads, and the plurality of spray heads are located above the rope saw (7).

9. The waste fan blade cutting device according to claim 1, characterized in that: Also includes: A motorized roller (11) for transporting the fan blades; A cutting system base (13), a motorized roller (11) is mounted on the cutting system base (13), and a left column (9) and a right column (10) are mounted on the cutting system base (13).

10. The waste fan blade cutting device according to claim 1, characterized in that: Based on the input blade length, chord length distribution curve and root flange diameter, the PLC control system calls the parametric blade database to generate a three-dimensional topological model, identifies the spatial distribution of key load-bearing structures such as the main beam, web, and shell, and dynamically adjusts the cutting power, feed speed and cooling parameters by matching the material parameters with the material cutting characteristic library.

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