A method for on-site modular and efficient disassembly of decommissioned wind turbine blades

Abstract

The application relates to the technical field of wind power equipment decommissioning and recycling, in particular to a decommissioned wind power blade on-site modular efficient disassembling method. First, the decommissioned wind power blade is subjected to structure scanning to obtain internal main beam area and shell structure distribution information; then, an unfoldable temporary bearing framework is introduced into the blade interior to form a temporary bearing system in the blade interior; under the condition that the temporary bearing system continuously supports, the blade shell is subjected to longitudinal unloading cutting and circumferential modular cutting; then, the bonding interface between the main beam and the shell is subjected to softening treatment, and the expansion separation mode is used to realize directional decoupling of the main beam structure and the shell structure; finally, each module formed by disassembling is turned over, transported and classified and recycled. The application can maintain the overall force stability of the blade during the disassembling process, reduce the structural collapse risk, improve the modular disassembling efficiency and the composite material classification and recycling integrity, and has good engineering application value.

Description

Technical Field

[0001] This application relates to the field of wind power equipment decommissioning and recycling technology, and in particular to a method for on-site modular and efficient dismantling of decommissioned wind turbine blades. Background Technology

[0002] As a large number of wind turbines enter their decommissioning cycle, the demand for wind turbine blade recycling and processing continues to increase. Existing decommissioned wind turbine blades are usually dismantled by hoisting them as a whole and then cutting them in a centralized manner or by crushing them directly on site. However, due to the large length of the blades and their hollow structure composed of a main beam and a composite material shell, the blades are prone to collapse, twisting, or structural instability during dismantling due to localized stress imbalances. This not only affects the safety and efficiency of dismantling but also easily leads to the mixing of the main beam, shell, and core materials, reducing the effectiveness of subsequent sorting and recycling.

[0003] To address this issue, a modular and efficient on-site disassembly method for retired wind turbine blades has been invented to resolve the problems mentioned in the background technology. Summary of the Invention

[0004] The purpose of this invention is to provide a modular and efficient on-site dismantling method for decommissioned wind turbine blades, in order to solve the problems of poor dismantling safety, difficulty in modular dismantling, and low efficiency in classification and recycling caused by structural instability during the existing decommissioned wind turbine blade dismantling process.

[0005] This application provides a modular and efficient on-site dismantling method for decommissioned wind turbine blades, which adopts the following technical solution and includes the following steps: S1. Support and fix the decommissioned wind turbine blades, and obtain information on the distribution of the main beam area and shell structure inside the blades; S2. An expandable temporary support frame is introduced from the root of the blade into the interior of the blade, and the temporary support frame forms multi-point support with the inner wall of the blade to construct a disassembly support system inside the blade. S3. While the disassembly bearing system remains supported, the blade shell is disassembled in sections and modules. S4. Perform directional decoupling treatment on the connection area between the blade main beam and the shell to gradually separate the main beam structure from the shell structure; S5. Under the support of the disassembly bearing system, the blade modules formed by disassembly are transferred, and the main beam structure, composite material shell and sandwich material are sorted and recycled respectively.

[0006] Optionally, the deployable temporary support frame includes a telescopic support unit and an inner wall locking unit. After the telescopic support unit is deployed radially along the inside of the blade, it forms a support connection with the inner wall of the blade through the inner wall locking unit to maintain the structural stability during the blade disassembly process.

[0007] Optionally, in step S3, the modular disassembly of the blade shell includes forming a longitudinal disassembly area along the blade length direction and a module boundary disassembly area along the blade circumference, so as to divide the blade into multiple independently transportable structural modules.

[0008] Optionally, the directional decoupling process includes forming a medium introduction channel in the connection area between the main beam and the shell, and introducing an interface softening medium into the connection area to reduce the connection strength between the main beam and the shell.

[0009] Optionally, after introducing the interface softening medium, an expansion force is applied between the main beam and the shell through the expansion separation component, so that a separation gap is formed between the main beam structure and the shell structure, and gradually expands along the connection area.

[0010] Optionally, the expansion separation assembly includes at least one of a wedge-shaped expander, a hydraulic expander, or an airbag expander to create a radial separation force between the main beam and the shell.

[0011] Optionally, in step S3, negative pressure adsorption is simultaneously applied to the disassembly area during the blade shell disassembly process to collect glass fiber dust and resin debris.

[0012] Optionally, in step S5, the disassembled blade module is tilted and supported by a flipping support mechanism to adjust its attitude so that the blade module remains under stable stress during transport.

[0013] In summary, this application includes the following beneficial technical effects: 1. This invention constructs a deployable temporary load-bearing frame inside the blade, enabling the blade to form a stable internal load-bearing system during disassembly. This effectively prevents the blade from collapsing or twisting due to local cutting, thus improving the safety of on-site disassembly.

[0014] 2. This invention allows for modular disassembly of the blades in a partitioned manner while maintaining support within the internal load-bearing system. This enables stable segmentation of large wind turbine blades, improving on-site disassembly efficiency and transportation convenience.

[0015] 3. This invention performs directional decoupling treatment on the connection area between the main beam and the shell, enabling the main beam structure, composite material shell and sandwich material to be gradually separated, which is beneficial for subsequent classification, recycling and resource utilization.

[0016] 4. The overall disassembly method of this invention reduces the risk of dust diffusion and structural loss of control caused by overall violent crushing, and has good engineering application value and promotion prospects. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the overall process flow of this device; Figure 2This is a schematic diagram of the temporary bearer architecture of this device; Figure 3 This is a schematic diagram of the modular disassembly structure of this device; Figure 4 This is a schematic diagram of the directional decoupling structure of the main beam of this device; Figure 5 This is a schematic diagram of the flipping, transfer, and sorting recycling of this device; The components include: 1. Deployable temporary support frame; 11. Main support truss; 12. Radial telescopic support arm; 13. Linkage drive assembly; 14. Inner wall locking assembly; 141. Arc-shaped fitting support block; 2. Circumferential mobile disassembly platform; 21. Circumferential moving guide rail; 22. Circumferential walking mechanism; 23. Multi-station disassembly assembly; 24. Negative pressure collection assembly; 241. Circumferential adsorption hood; 242. Negative pressure fan; 243. Dust collection box; 3. Expansion and separation assembly; 31. Wedge-shaped expander; 32. Hydraulic expander; 33. Airbag expander; 4. Tilting support mechanism; 41. Rotating support frame; 42. Support clamping assembly; 5. Support platform; 51. Support base; 52. Limiting clamping assembly; 6. Structural scanning device. Detailed Implementation

[0018] The present invention will now be described in further detail with reference to the accompanying drawings. Any equivalent substitutions or modifications made to the structure of the present invention by those skilled in the art without departing from the principles of the invention should fall within the protection scope of the present invention.

[0019] like Figures 1 to 5 As shown in the figure, this embodiment provides a modular and efficient on-site dismantling method for decommissioned wind turbine blades. The method follows the process sequence of "structural identification - internal load establishment - stress release dismantling - main beam directional decoupling - stable transfer and recycling", which ensures that the wind turbine blades remain under stable stress throughout the dismantling process. This reduces the risk of collapse, twisting and center of gravity imbalance after local cutting of the blades, and improves the integrity of the classification and recycling of the main beam structure and composite material shell.

[0020] In this embodiment, the decommissioned wind turbine blade is first placed horizontally on the on-site support platform 5. The support platform 5 is provided with multiple support seats 51 at intervals along the blade length direction. Each support seat 51 is fixedly connected to a rubber buffer support pad to adapt to the external curved surface structure of the blade and reduce the risk of local crushing. A limit clamping assembly 52 is fixedly installed in the root area of ​​the blade. The limit clamping assembly 52 includes a hydraulic clamping arm and an arc-shaped clamping block. The hydraulic clamping arm drives the arc-shaped clamping block to clamp the root of the blade to limit the axial movement of the blade.

[0021] After the blade is supported and fixed, the blade as a whole is in a static and stable state. At this time, the internal structure is scanned to avoid the blade shaking affecting the scanning accuracy.

[0022] Subsequently, the internal structure of the blade is inspected using the structural scanning device 6. The structural scanning device 6 is an industrial-grade ultrasonic scanner and is slidably connected to the top of the support platform 5 via a moving guide rail. The structural scanning device 6 moves along the length of the blade to scan and identify the main beam area, web connection area, core area and shell thickness variation area inside the blade.

[0023] After the structural scan is completed, a stress distribution diagram and disassembly path diagram of the blade's interior are created based on the scan results, including: The main beam area, as the primary load-bearing area, retains continuous support. The web connection region serves as the subsequent directional decoupling region. Thin-walled areas of the shell are prioritized for cutting. The sandwich area serves as a low-load disassembly area.

[0024] The scanning results are used to determine the support position of the temporary load-bearing frame 1 and the cutting path of the multi-station disassembly assembly 23, thereby avoiding premature cutting in the high load-bearing area that could lead to overall blade instability.

[0025] After the internal structure is identified, a deployable temporary support frame 1 is introduced into the blade from the root of the blade. The deployable temporary support frame 1 includes a main support truss 11, a radial telescopic support arm 12, a linkage drive assembly 13, and an inner wall locking assembly 14. The bottom of the main support truss 11 makes rolling contact with the inner wall of the blade through a roller assembly and is pulled into the blade through a traction steel cable.

[0026] During the entry of the temporary support frame 1, the roller assembly moves longitudinally along the inside of the blade to reduce the frictional resistance between the frame and the inner wall of the blade during movement and to avoid scratching the inner wall of the blade.

[0027] The main support truss 11 adopts a high-strength lightweight aluminum alloy truss structure, and the radial telescopic support arm 12 is rotatably connected to the outer periphery of the main support truss 11 through a hinge seat.

[0028] When the temporary support frame 1 moves to the preset support area, the linkage drive component 13 is activated. The linkage drive component 13 adopts a combination drive structure of electric push rod and synchronous link. The electric push rod is fixedly installed inside the main support truss 11, and the synchronous link is hinged to each radial telescopic support arm 12. When the electric push rod extends, it drives the synchronous link to move synchronously, thereby driving multiple radial telescopic support arms 12 to unfold outward.

[0029] The radial telescopic support arm 12 unfolds gradually in the order of "lower part first, then side part, then top part", so that the internal load of the blade is gradually transferred from bottom to top, thereby avoiding premature stress on the top support and causing the frame to shift.

[0030] After the radial telescopic support arm 12 contacts the inner wall of the blade, the inner wall locking assembly 14 is activated. The inner wall locking assembly 14 includes an arc-shaped fitting support block 141, an anti-slip rubber layer, and a mechanical locking component. The arc-shaped fitting support block 141 is fixedly connected to the end of the radial telescopic support arm 12 by bolts. The anti-slip rubber layer is bonded to the outer surface of the arc-shaped fitting support block 141. The mechanical locking component restricts the retraction of the radial telescopic support arm 12 through a gear self-locking structure. The radial telescopic support arm 12 can be retracted by releasing the self-locking mechanism so that the temporary support frame 1 can be removed from the blade.

[0031] Once all radial telescopic support arms 12 are locked, a multi-point force support system is formed between the main support truss 11, the radial telescopic support arms 12, and the inner wall of the blade. This support system can re-establish the load transfer path inside the blade during the subsequent cutting process.

[0032] Since the wind turbine blade has a tapering structure from the root to the tip, the deployment stroke of the radial telescopic support arm 12 can be adjusted according to the internal cavity size of different areas of the blade. When the temporary support frame 1 moves along the inside of the blade to different areas, each radial telescopic support arm 12 can extend and retract independently so that the temporary support frame 1 can adapt to the internal cavity structure of the blade with different cross-sectional dimensions.

[0033] After the temporary load-bearing frame 1 is fully deployed, a temporary load-bearing system is formed inside the blade. During the subsequent disassembly of the outer shell, the temporary load-bearing system continues to maintain a supporting state and redistributes the structural load around the cutting area, thereby maintaining the overall stress stability of the blade.

[0034] Subsequently, the ring-shaped mobile dismantling platform 2 is activated. The ring-shaped mobile dismantling platform 2 includes a ring-shaped moving guide rail 21, a circumferential walking mechanism 22, a multi-station dismantling component 23, and a negative pressure collection component 24. The ring-shaped moving guide rail 21 is formed by splicing multiple arc-shaped guide rail segments. The arc-shaped guide rail segments are detachably connected by bolts and are supported on the outer circumferential surface of the blade by a roller support frame.

[0035] The circumferential walking mechanism 22 is connected to the annular moving guide rail 21 by a drive roller. The drive roller is driven to rotate by a geared motor to move the circumferential walking mechanism 22 along the outer periphery of the blade. The multi-station disassembly assembly 23 is fixedly connected to the outside of the circumferential walking mechanism 22 by a mounting bracket.

[0036] The multi-station disassembly assembly 23 includes a diamond circular saw cutter, a high-pressure water jet cutting head, and an auxiliary guide rail. The diamond circular saw cutter is used for cutting composite material shells, and the high-pressure water jet cutting head is used for cutting local reinforcement layers and thick-walled connection areas.

[0037] Before the formal modular disassembly, the multi-station disassembly component 23 first forms a longitudinal unloading cutting zone along the blade length direction to release the residual stress inside the blade shell; after the longitudinal unloading is completed, a module boundary cutting zone is formed along the circumferential direction of the blade to avoid the local collapse of the blade caused by direct circumferential closed-loop cutting.

[0038] Since the blade load will be transferred to the uncut area after longitudinal unloading and cutting, the temporary load-bearing system simultaneously supports the structure around the longitudinally cut area to maintain the continuity of the blade's longitudinal stiffness.

[0039] Subsequently, the multi-station disassembly assembly 23 is modularly cut in the order of disassembling from the blade tip to the root. This is because the blade tip area has a smaller weight and lower structural load, and prioritizing disassembly can gradually reduce the overall weight, thereby reducing the support load when disassembling the root area later.

[0040] After the outer shell module is formed, the connection area between the blade main beam and the shell is subjected to directional decoupling treatment. Specifically, multiple medium inlet holes are formed in the bonding interface area between the main beam web and the shell, and an interface softening medium is injected into the connection interface using a high-pressure injection pump to reduce the connection strength between the main beam and the shell. The interface softening medium is an organic solvent-based resin softening medium or a hot melt penetration softening medium.

[0041] The interface softening medium diffuses and permeates along the adhesive interface between the main beam and the shell, softening the adhesive layer and thus reducing the mechanical separation load required for subsequent expansion and separation assembly 3.

[0042] After the interface softening is completed, the expansion separation component 3 is inserted into the connection area between the main beam and the shell. The expansion separation component 3 can be one or more of the wedge expansion component 31, hydraulic expansion component 32 or airbag expansion component 33; wherein, the hydraulic expansion component 32 adopts a hydraulic cylinder drive structure, and the airbag expansion component 33 adopts a wear-resistant rubber expansion airbag structure.

[0043] When the expansion separation component 3 is working, it applies a radial expansion force between the main beam and the shell, so that a separation gap is gradually formed between the main beam structure and the shell structure, and gradually expands along the connection area.

[0044] Because the connection interface has been pre-softened, large-scale fiber tearing will not occur during the expansion separation process, thereby improving the integrity of the main beam structure and the shell structure.

[0045] During the disassembly process, the negative pressure collection component 24 simultaneously applies negative pressure adsorption to the disassembly area to collect glass fiber dust and resin debris. The negative pressure collection component 24 includes an annular adsorption hood 241, a negative pressure fan 242, and a dust collection box 243. The annular adsorption hood 241 is connected to the negative pressure fan 242 through a flexible connecting pipe, and the negative pressure fan 242 is connected to the dust collection box 243 through a conveying pipe. The negative pressure fan 242 is an industrial centrifugal negative pressure fan to improve the fiber dust collection efficiency.

[0046] After the blade module is disassembled, the attitude of the disassembled module is adjusted by the flipping support mechanism 4. The flipping support mechanism 4 includes a rotating support frame 41 and a support clamping assembly 42. The support clamping assembly 42 is driven by a hydraulic clamping cylinder to clamp the blade module. The rotating support frame 41 adopts a slewing bearing structure and is driven to rotate by a geared motor to adjust the center of gravity of the blade module and reduce the eccentric bending moment generated during hoisting. This causes the module to flip to a stable stress posture, and then the module is transferred by hoisting equipment.

[0047] Finally, the different structural modules were classified and recycled separately. The main beam module was cut into fixed lengths for recycling, the composite material shell module was crushed and sorted, and the sandwich material module was compressed and packaged for recycling, thus completing the on-site modular and efficient dismantling of retired wind turbine blades.

Claims

1. A method for efficient modular disassembly of decommissioned wind turbine blades on-site, characterized in that: Includes the following steps: S1. Place the retired wind turbine blades on the support platform (5) and clamp and fix the blade roots using the limiting clamping assembly (52); S2. Use the structural scanning device (6) to scan and identify the main beam area, web connection area, sandwich area and shell thickness variation area inside the blade, and establish the internal force distribution diagram and disassembly path diagram of the blade based on the scanning results. S3. An expandable temporary support frame (1) is introduced from the root of the blade into the blade, and the radial telescopic support arm (12) is driven to expand into the inner wall of the blade through the linkage drive component (13). Then, the inner wall locking component (14) forms a multi-point support with the inner wall of the blade to form a temporary support system inside the blade. S4. Under the condition that the temporary bearing system is continuously supported, the blade shell is modularly disassembled using the circumferential mobile disassembly platform (2). The multi-station disassembly component (23) first forms a longitudinal unloading cutting area along the blade length direction, and then forms a module boundary cutting area along the blade circumference. S5. After the blade shell is formed into a disassembly module, a medium inlet hole is formed in the bonding interface area between the main beam web and the shell, and an interface softening medium is introduced into the bonding interface. Then, the expansion separation component (3) is used to apply a radial expansion force between the main beam structure and the shell structure, so that the main beam structure and the shell structure are gradually separated. S6. After adjusting the attitude of the disassembled blade module using the flipping support mechanism (4), the main beam module, composite material shell module and sandwich material module are sorted and recycled respectively.

2. The method for efficient modular disassembly of decommissioned wind turbine blades on-site according to claim 1, characterized in that: The structure scanning device (6) adopts an industrial-grade ultrasonic scanner and is slidably connected to the top of the support platform (5) via a moving guide rail. The structure scanning device (6) moves along the blade length direction to obtain information on the internal structure distribution of the blade. The scanning results are used to determine the support position of the deployable temporary support frame (1) and the cutting path of the multi-station disassembly assembly (23) to avoid premature cutting in the main support area, which could lead to blade structure instability.

3. The method for efficient modular dismantling of decommissioned wind turbine blades on-site according to claim 1, characterized in that: The deployable temporary support frame (1) includes a main support truss (11), a radial telescopic support arm (12), a linkage drive assembly (13), and an inner wall locking assembly (14). The bottom of the main support truss (11) rolls into contact with the inner wall of the blade through a roller assembly and is pulled into the blade by a traction steel cable; The linkage drive assembly (13) adopts a combination drive structure of electric push rod and synchronous link. The electric push rod drives the synchronous link to move, so as to drive multiple radial telescopic support arms (12) to unfold outward synchronously.

4. The method for efficient modular dismantling of decommissioned wind turbine blades on-site according to claim 1, characterized in that: The inner wall locking assembly (14) includes an arc-shaped fitting support block (141), an anti-slip rubber layer, and a mechanical locking component; The arc-shaped fitting support block (141) is fixedly connected to the end of the radial telescopic support arm (12), and the mechanical locking component restricts the retraction of the radial telescopic support arm (12) through a gear self-locking structure; The radial telescopic support arm (12) unfolds gradually in the order of "lower part first, then side part, then top part" so that the internal load of the blade is gradually transmitted from bottom to top.

5. The method for efficient modular dismantling of decommissioned wind turbine blades on-site according to claim 1, characterized in that: The encircling mobile dismantling platform (2) includes an annular mobile guide rail (21), a circumferential walking mechanism (22), a multi-station dismantling assembly (23), and a negative pressure collection assembly (24). The circumferential traveling mechanism (22) is connected to the annular moving guide rail (21) by a drive roller and is driven by a geared motor to move along the outer circumference of the blade; The multi-station disassembly assembly (23) includes a diamond circular saw cutter, a high-pressure water jet cutter head, and an auxiliary guide rail. The diamond circular saw cutter is used for cutting composite material shells, and the high-pressure water jet cutter head is used for cutting local reinforcement layers and thick-walled connection areas.

6. The method for efficient modular dismantling of decommissioned wind turbine blades on-site according to claim 1, characterized in that: The interface softening medium is an organic solvent-based resin softening medium or a hot-melt penetration softening medium. The interface softening medium is injected into the bonding interface between the web of the main beam and the shell through a high-pressure injection pump, and diffuses and penetrates along the adhesive layer to reduce the bonding strength of the adhesive interface.

7. The method for efficient modular disassembly of decommissioned wind turbine blades on site according to claim 1, characterized in that: The expansion separation assembly (3) includes at least one of a wedge-shaped expander (31), a hydraulic expander (32), or an airbag expander (33); Among them, the hydraulic expansion component (32) adopts a hydraulic cylinder drive structure, and the airbag expansion component (33) adopts a wear-resistant rubber expansion airbag structure; After the interface softening medium has completed its penetration, the expansion separation component (3) applies a radial expansion force between the main beam structure and the shell structure to reduce fiber tearing during the separation process.

8. The method for efficient modular disassembly of decommissioned wind turbine blades on site according to claim 1, characterized in that: The flipping support mechanism (4) includes a rotating support frame (41) and a support clamping assembly (42). The supporting and clamping assembly (42) clamps the blade module by a hydraulic clamping cylinder, and the rotating support frame (41) adopts a slewing bearing structure and is driven to rotate by a geared motor; The flipping support mechanism (4) is used to adjust the center of gravity of the blade module to reduce the eccentric bending moment generated during hoisting and transportation.

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