An automated production gantry integration platform and working method for wind turbine blades

Abstract

The present invention discloses an automated production gantry integration platform and working method for wind turbine blades. A gantry truss system is slidably arranged on a ground rail, a traveling mechanism is fixedly connected to the gantry truss system, a lifting platform is connected to the top end of the gantry truss system, a manipulator is connected to the lower end of the lifting platform, the end of the manipulator is connected to a quick connection mechanism, and a wind turbine blade production terminal tool is connected to the quick connection mechanism. It further includes a control system, and the traveling mechanism, the lifting platform, the manipulator, the quick connection mechanism, and the wind turbine blade production terminal tool are all controlled by the control system. By integrating and connecting various wind turbine blade production terminal tools on the gantry platform through the quick connection mechanism, the wind turbine blade production terminal tools cover all processes of wind turbine blade production. At the same time, a control system is equipped, which can realize the automated production of wind turbine blades, improve the blade production efficiency, reduce the manual labor intensity and cost, and meet the production requirements of the wind turbine blade market.

Description

Technical Field

[0001] The present invention relates to the technical field of wind turbine blade production, and particularly to an automated production gantry integration platform for wind turbine blades and a working method thereof. Background Art

[0002] Wind energy is an available energy provided to humans due to the work done by air flow. It is rich in reserves, widely distributed, clean and belongs to renewable energy. Wind turbine blades are the core components in wind turbines that convert natural wind energy into electrical energy of wind turbine generator sets, and are also the main basis for measuring the design and technical level of wind turbine generator sets. With the rapid development of the wind power industry and the continuous progress of wind power technology, the installed capacity of wind turbine generator sets has been continuously increasing, and the trend of blade enlargement is becoming increasingly significant, gradually developing towards a blade type of hundreds of meters. Blades are an industry with relatively high certainty, large market capacity, and clear profit models in wind power components. The future industry competition pattern requires manufacturers to expand in scale, reduce costs, and maintain certain advantages in technology. However, current blade manufacturing belongs to a labor-intensive industry. Since the mold surface for wind turbine blade forming is complex and irregular, it is difficult to position the equipment, and the mold is in a semi-fixed and semi-mobile form, and some operations require flipping, resulting in great difficulties in the installation and operation of the equipment on the mold. Therefore, most processes in the manufacturing process mainly rely on manual labor, and the low degree of automation, low production efficiency, and high labor cost of manual labor far cannot meet the growing market environment. How to reduce labor intensity and improve production efficiency through automated production has become a difficult problem that urgently needs to be solved in the industry. At the same time, raw materials such as fiberglass cloth and paint used in the current wind turbine blade production process will cause certain harm to the human body after long-term contact, and a large amount of dust will be generated during processes such as cutting and grinding in the blade production process, which will also endanger human health. Therefore, production personnel need to wear 3M masks or dust masks when producing blades. Therefore, in order to solve the above technical problems, it is necessary to research and develop a wind turbine blade production gantry integration platform and a working method thereof that are fully functional, easy to use, realize automated production of wind turbine blades, protect the physical health of personnel, and reduce manual labor intensity. Summary of the Invention

[0003] In view of the above technical problems, the present invention provides a wind turbine blade production gantry integration platform and a working method thereof that are fully functional, easy to use, realize automated production of wind turbine blades, protect the physical health of personnel, and reduce manual labor intensity.

[0004] To solve the above technical problems, the present invention provides the following technical solutions:

[0005] An automated production gantry integration platform for wind turbine blades, comprising a gantry truss system, a traveling mechanism, a lifting platform, a manipulator, a quick connection mechanism, and a wind turbine blade production terminal tool. The gantry truss system is slidably disposed on a ground rail. The traveling mechanism is fixedly connected to the gantry truss system and provides power for the gantry truss system. The lifting platform is connected to the top end of the gantry truss system. The lower end of the lifting platform is connected with the manipulator. The end of the manipulator is connected with the quick connection mechanism. The quick connection mechanism includes a main disk and a tool disk. One end of the main disk is fixedly connected to the end of the manipulator, and the other end is fixedly connected to the tool disk. A position detection device is connected to the main disk and the tool disk. Locking devices that cooperate with each other are arranged on the sides of the main disk and the tool disk. The end of the tool disk is connected with the wind turbine blade production terminal tool. A control system is also included. The traveling mechanism, the lifting platform, the manipulator, the quick connection mechanism, and the wind turbine blade production terminal tool are all controlled by the control system.

[0006] Further, the wind turbine blade production terminal tool can achieve at least one of the following functions: demoulding agent spraying, gel coat spraying, paint spraying, vacuum degree detection, non-destructive detection, blade measurement, surface detection, temperature detection, component relocation and installation, installation and disassembly of root embedded bolts, root grinding, blade grinding, mold grinding, root cutting, blade flash cutting, prefabricated part flash cutting, glass fiber cloth laying, core material and auxiliary material laying, glue perfusion, and bonding glue coating.

[0007] Further, the components include precast tiles, main beams, webs, bonding angles, bolts, lightning arresters, and counterweight boxes.

[0008] Further, limit devices are arranged at both ends of the ground rail.

[0009] Further, the gantry truss system includes a cross beam, legs, and rollers. The legs are respectively fixedly connected to both ends of the cross beam. The bottom ends of the legs are rotatably connected with the rollers. The rollers are rollingly disposed on the ground rail.

[0010] Further, the traveling mechanism includes motor A fixed on the legs on both sides. The output end of the motor A is connected with a reducer. The output end of the reducer is in transmission connection with the rollers.

[0011] Further, the lifting platform includes a lead screw support seat fixedly connected to the top end of the gantry truss system, a roller screw rotatably connected to the lead screw support seat, and a vertical movement mechanism in transmission connection with the roller screw. One end of the lead screw support seat is provided with motor B. The motor B is in transmission connection with the roller screw through a reducer and a coupling in sequence. A hoist is fixedly connected inside the vertical movement mechanism. The lower end of the hoist is connected with a mounting plate. The manipulator is detachably connected to the lower end of the mounting plate.

[0012] Further, it further includes an obstacle avoidance system, which is composed of multiple sensors. The sensors are infrared sensors or laser sensors, and the sensors are evenly distributed around the gantry truss system; the sensors are connected to the control system.

[0013] Further, it further includes a positioning device, which is connected to the main disk, and the positioning device is connected to the control system.

[0014] Further, the control system includes an industrial computer, an industrial switch, an Ethernet module, and a PLC control module. The industrial computer is connected to the industrial switch, the industrial switch is connected to the Ethernet module, and the Ethernet module is connected to the PLC control module.

[0015] Further, the control system further includes a remote controller and a wireless control module. The remote controller is wirelessly connected to the wireless control module, and the wireless control module is communicatively connected to the PLC control module.

[0016] The present invention also provides a working method for an automated production gantry integration platform for wind turbine blades, including the following steps:

[0017] According to the production process of wind turbine blades, select the corresponding production program in the control system, and install the wind turbine blade production terminal tools required for the corresponding wind turbine blade production process on the quick connection mechanism;

[0018] Start the production program in the control system, so that the gantry integration platform starts to run according to the production program and completes the process operation;

[0019] After the process operation is completed, replace the corresponding wind turbine blade production terminal tools on the quick connection mechanism according to the next production process.

[0020] Further, real-time positioning is performed during the operation of the gantry integration platform.

[0021] The present invention has the following advantages compared with the prior art:

[0022] 1. By applying the gantry platform to the production process of wind turbine blades, and being able to integrally connect various wind turbine blade production terminal tools on the gantry platform through a quick connection mechanism, the wind turbine blade production terminal tools cover all processes of wind turbine blade production, and at the same time, a control system is equipped, which can realize the automated production of wind turbine blades, improve the blade production efficiency, reduce the manual labor intensity and cost, and meet the production needs of the wind turbine blade market.

[0023] 2. The present invention connects the production terminal tools of wind turbine blades through a quick connection mechanism to carry out processes such as spraying, skin laying, cutting, and grinding in the production of wind turbine blades, which can avoid workers from coming into contact with raw materials such as paint and fiberglass cloth for a long time, directly prevent workers from inhaling the dust generated in the cutting and grinding processes, and can effectively avoid the occurrence of occupational diseases for workers in the long-term working state through the application of the platform, ensuring the physical health of workers. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 It is a schematic structural diagram of the present invention.

[0025] Figure 2 It is a schematic diagram of the control principle of the present invention.

[0026] In the figure: 1, ground rail; 2, cross beam; 3, support leg; 4, roller; 5, motor A; 6, lead screw support seat; 7, roller screw; 8, motor B; 9, up and down moving mechanism; 10, winch; 11, mounting plate; 12, base; 13, manipulator; 14, quick connection mechanism. DETAILED DESCRIPTION OF THE INVENTION

[0027] The following further describes the present invention in detail with reference to the drawings:

[0028] As Figure 1 , 2An automated production gantry integration platform for wind turbine blades, comprising a gantry truss system, a traveling mechanism, a lifting platform, a manipulator 13, a quick connection mechanism 14, and a production terminal tool for wind turbine blades. The ground rail 1 is fixedly connected to the foundation through anchor bolts and press plates. The foundation needs to be treated with reinforced concrete pouring and hardening. The gantry truss system is slidably arranged on the ground rail 1. The traveling mechanism is fixedly connected to the gantry truss system and provides operating power for the gantry truss system. The lifting platform is connected to the top of the gantry truss system. The lower end of the lifting platform is detachably connected with a manipulator 13. The end of the manipulator 13 is connected to the quick connection mechanism 14. The quick connection mechanism 14 includes a main disk and a tool disk. One end of the main disk is bolted to the end of the manipulator 13. An air valve is arranged on the main disk. The main disk is pneumatically tensioned and connected to the tool disk. Since the production of wind turbine blades belongs to the heavy industry, in order to ensure accurate alignment when connecting the main disk and the tool disk, and to monitor in real time during the operation of the platform to ensure the connection stability between the main disk and the tool disk, a position detection device is connected to the main disk and the tool disk. The position detection device is a set of opposed ultrasonic sensors, which includes an ultrasonic generator and an ultrasonic receiver respectively arranged on the main disk and the tool disk. It aligns by the ultrasonic generator emitting sound waves and the ultrasonic receiver receiving sound waves, and monitors the distance between the main disk and the tool disk in real time through sound wave ranging to prevent loosening between the main disk and the tool disk. When the detected distance changes, the control system timely captures the signal change and stops the platform from continuing to operate. In order to further ensure the stable connection between the main disk and the tool disk, so that even when the adsorption force is insufficient, the main disk and the tool disk will not separate, ensuring production safety, the sides of the main disk and the tool disk are locked by a bolt-type locking device; in order to facilitate the replacement of the production terminal tool for wind turbine blades, each production terminal tool for wind turbine blades is connected with a tool disk; in order to realize the operation of the automated production gantry integration platform for wind turbine blades, a control system is further included. The traveling mechanism, the lifting platform, the manipulator 13, the quick connection mechanism 14, and the production terminal tool for wind turbine blades are all controlled by the control system.

[0029] In order for this gantry integration platform to implement all processes of wind turbine blade production, the wind turbine blade production terminal tool can achieve at least one of the following functions: release agent spraying, gel coat spraying, paint spraying, vacuum degree detection, non-destructive testing, blade measurement, surface shape detection, temperature detection, component relocation and installation, installation and disassembly of root embedded bolts, root grinding, blade grinding, mold grinding, root cutting, blade flash cutting, prefabricated part flash cutting, glass fiber cloth laying, core material and auxiliary material laying, glue infusion, bonding glue coating; the components include prefabricated tiles, main beams, webs, bonding corners, bolts, lightning arresters, and counterweight boxes. The wind turbine blade production terminal tool installed in this embodiment can achieve the non-destructive testing function. This wind turbine blade production terminal tool is a non-destructive testing device installed at the end of the tool tray. This non-destructive testing device is provided with an ultrasonic generator for emitting ultrasonic waves, and an ultrasonic detection device for detecting the conduction direction and characteristics of the ultrasonic waves. In order to timely and accurately detect the defect location of the blade, an audible and visual alarm device is provided to give an audible and visual alarm when the ultrasonic detection device detects a defect. In order to facilitate auxiliary defect analysis, the ultrasonic detection device is equipped with a display, and the detected results can form a sound wave diagram on the display.

[0030] In order to prevent derailment risks during the operation of the gantry truss system and further ensure the operation safety and stability of the gantry integration platform, limit devices are provided at both ends of the ground rail 1.

[0031] The gantry truss system includes a cross beam 2, legs 3, and rollers 4. In order to improve the load-bearing capacity and stability of the gantry truss system, four legs 3 are provided. Every two legs 3 are distributed in a V-shape, and their tops are respectively fixedly connected to both ends of the cross beam 2. In order to further improve the stability of the gantry truss system, an upper connecting rod is connected between the upper parts of the two side legs 3, and a lower connecting rod is connected between the lower parts. In order to enable the gantry truss system to roll smoothly on the ground rail 1, the bottom ends of the legs 3 are rotatably connected to the rollers 4 through bearings, and the rollers 4 are rollingly arranged on the ground rail 1.

[0032] The traveling mechanism includes motors A5 fixed on both side legs. The motors A5 are reversible motors. The output ends of the motors A5 are connected with speed reducers, and the output ends of the speed reducers are connected to the rollers 4 through chain drives.

[0033] The lifting platform includes a screw support seat 6, a roller screw 7, and an up-and-down moving mechanism 9. In order to enable the lifting platform to move left and right on the beam 2 and improve the working range of the manipulator, there are two screw support seats 6, which are fixedly connected to the two ends of the beam 2 respectively. The two ends of the roller screw 7 are rotatably arranged with the screw support seat 6 through bearings. The up-and-down moving mechanism 9 is connected to the roller screw 7 by threaded transmission. A motor B8 is arranged at one end of the screw support seat 6, and the motor B8 is connected to the roller screw 7 by transmission through a reducer and a coupling. In order to realize the lifting function, a winch 10 is fixedly connected inside the up-and-down moving mechanism 9. The lower end of the winch 10 is connected to a mounting plate 11, the lower end of the mounting plate 11 is mounted with a base 12, and the lower end of the base 12 is connected to a manipulator 13; the winch is mainly composed of a motor, a reducer, a drum, a wire rope, a brake, a clutch, and an overload protection device. The motor provides the kinetic energy required for lifting, the reducer realizes the conversion of the speed ratio, the drum provides a winding carrier for the wire rope, the wire rope is used to bear weight and play a lifting role, the brake can stop the drum from rotating, reduce the inertia affecting the winding accuracy, the clutch can cut off or transmit power, and the overload protection device is used to prevent the winch from overloading and timely block the operation.

[0034] In order to detect obstacles in time and prevent the platform from continuing to operate, and to further ensure the safety of the platform operation, an obstacle avoidance system is also set up. The obstacle avoidance system is composed of multiple sensors, which are infrared sensors or laser sensors. The sensors in this embodiment are laser sensors, and the sensors are evenly distributed around the portal truss system; in order to be able to feed back the signals obtained by the sensors to the control system, the sensors are connected to the control system.

[0035] In order to perform real-time positioning during the operation of the gantry platform, ensure that the running path is consistent with the program set path, and promptly correct the path when it deviates, a positioning device is also set up. The positioning device is connected to the main disk. In order to be able to feed back the signal obtained by the positioning device to the control system, the positioning device is connected to the control system.

[0036] In order to realize the automated production of wind turbine blades, the control system of the gantry integrated platform for automated production of wind turbine blades includes an industrial computer, an industrial switch, an Ethernet module, and a PLC control module. The industrial computer is connected to the industrial switch, the industrial switch is connected to the Ethernet module, and the Ethernet module is connected to the PLC control module.

[0037] In order to realize remote control, the control system also includes a remote controller and a wireless control module. The remote controller is connected to the wireless control module via wireless signals, and the wireless control module is communicatively connected to the PLC control module.

[0038] The working method of this embodiment:

[0039] Write or import relevant programs for wind turbine blade production in the control system in advance. In this embodiment, relevant programs for wind turbine blade production are written in the control system. When the gantry integration platform runs, according to the requirements of the production process, select and connect the wind turbine blade production terminal tool with the corresponding function on the quick connection mechanism 14, that is, connect the main disk to the tool disk with the corresponding wind turbine blade production terminal tool, and lock the main disk and the tool disk with the locking device. Before this embodiment completes the previous process and launches the non-destructive testing function, operate on the industrial computer to ensure that the gantry platform is in the starting position, and switch the tool disk connected to the wind turbine blade production terminal tool on the main disk to the tool disk connected to the non-destructive testing wind turbine blade production terminal tool.

[0040] After that, operate through the industrial computer or the remote control, select the corresponding non-destructive testing program in the control system, start the gantry platform. According to the set non-destructive testing program, the gantry platform starts to adjust its position. The hoist 10 drives the mounting plate 11 to move up and down to adjust the height, and the motor B8 drives the roller screw 7 to rotate to adjust the position of the up and down moving mechanism 9, so as to determine the starting operation position of the wind turbine blade production terminal tool. Then, the motor A5 drives the roller 4 to roll on the ground rail 1, so that the whole gantry runs on the ground rail 1, and starts the non-destructive testing work according to the path of the non-destructive testing program set by the control system. The ultrasonic generator of the non-destructive testing wind turbine blade production terminal tool emits ultrasonic waves, and the ultrasonic detection device detects the conduction direction and characteristics of the ultrasonic waves. When a defect is detected, the sound and light alarm device gives a sound and light alarm. At the same time, the results detected by the ultrasonic detection device are formed into a sound wave diagram on the display in real time; during the operation process, the control system controls components such as the traveling mechanism, the lifting platform, the manipulator 13, and the quick connection mechanism 14 according to the program to achieve real-time matching between the wind turbine blade production terminal tool and the program path; at the same time, during the operation process, the positioning device performs positioning in real time and gives a feedback signal to the control system to form a real-time comparison path. When the path formed by the positioning device detection deviates from the path set by the program, the control system timely controls the gantry platform to correct the path so that it returns to the path set by the control system to work; and during the operation of the platform, the position detection device monitors the position between the main disk and the tool disk in real time to ensure the connection stability between the main disk and the tool disk; after the non-destructive testing operation is completed, the control system controls the gantry to return to the starting position.

[0041] After the process operation is completed, replace the corresponding wind turbine blade production terminal tool on the quick connection mechanism according to the next production process.

[0042] During the operation of the gantry, the obstacle avoidance system monitors obstacles in real time. The laser sensor emits laser light. When an obstacle is detected, it gives a feedback signal to the control system in time. The control system controls the gantry to stop running. After clearing the obstacle, restart the platform to run.

Claims

1. An automated production gantry integration platform for wind turbine blades, characterized in that: The invention comprises a gantry truss system, a walking mechanism, a lifting platform, a manipulator (13), a quick connection mechanism (14), and a wind turbine blade production terminal tool, wherein the gantry truss system is slidably arranged on a ground rail (1), the walking mechanism is fixedly connected to the gantry truss system and provides power for the gantry truss system, the lifting platform is connected to the top of the gantry truss system, the lower end of the lifting platform is connected to the manipulator (13), and the end of the manipulator (13) is connected to the quick connection mechanism (14); the quick connection mechanism (14) comprises a main plate and a tool plate, one end of the main plate is fixedly connected to the end of the manipulator (13), and the other end is connected to the tool plate, the main plate and the tool plate are connected to a position detection device, and the sides of the main plate and the tool plate are provided with mutually cooperating locking devices; the end of the tool plate is connected to the wind turbine blade production terminal tool; and the invention also comprises a control system, wherein the walking mechanism, the lifting platform, the manipulator (13), the quick connection mechanism (14), and the wind turbine blade production terminal tool are all controlled by the control system; The wind turbine blade production terminal tool comprises a non-destructive testing device installed at the end of the tool tray, wherein the non-destructive testing device is provided with an ultrasonic generator for emitting ultrasonic waves, and an ultrasonic detection device is provided for detecting the conduction direction and characteristics of the ultrasonic waves, and the ultrasonic detection device is provided with a display, and can form a sound wave diagram on the display with the detected results; It also includes a positioning device, which is connected to the main disk and connected to the control system.

2. The automated production gantry integration platform for a wind turbine blade according to claim 1, wherein: The wind turbine blade production terminal tool can realize at least one of the following functions: release agent spraying, gel coat spraying, paint spraying, vacuum detection, non-destructive testing, blade measurement, surface detection, temperature detection, component relocation and installation, installation and removal of blade root embedded bolts, blade root grinding, blade grinding, mold grinding, blade root cutting, blade flash cutting, prefabricated part flash cutting, glass fiber cloth laying, core material and auxiliary material laying, glue pouring, and adhesive coating.

3. The automated production gantry integration platform for wind turbine blades according to claim 2, wherein: The components include prefabricated tiles, main beams, webs, bonding angles, bolts, lightning arresters, and counterweight boxes.

4. The automated production gantry integrated platform for wind turbine blades according to claim 1, characterized in that: Limiting devices are provided at both ends of the ground rail (1).

5. The automated production gantry integration platform for wind turbine blades according to claim 1, characterized in that: The portal truss system comprises a crossbeam (2), a leg (3), and a roller (4); the leg (3) is fixedly connected to both ends of the crossbeam (2), the bottom end of the leg (3) is rotatably connected to the roller (4), and the roller (4) is rotatably arranged on the ground rail (1).

6. The automated production gantry integration platform for a wind turbine blade according to claim 5, characterized in that: The walking mechanism comprises a motor A (5) fixed on the supporting legs at both sides, the output end of the motor A (5) is connected to a reducer, and the output end of the reducer is drivingly connected to the roller (4).

7. An automated production gantry integrated platform for wind turbine blades according to claim 1, characterized in that: The lifting platform includes a lead screw support base (6) fixedly connected to the top of the gantry truss system, a roller lead screw (7) rotatably connected to the lead screw support base (6), and a vertically moving mechanism (9) drivingly connected to the roller lead screw (7). One end of the lead screw support base (6) is provided with a motor B (8), and the motor B (8) is drivingly connected to the roller lead screw (7) through a reducer and a coupling in sequence. A hoist (10) is fixedly connected inside the vertically moving mechanism (9), and the lower end of the hoist (10) is connected to a mounting plate (11). The manipulator (13) is detachably connected to the lower end of the mounting plate (11).

8. An automated production gantry integration platform for wind turbine blades according to claim 1, characterized in that: It further includes an obstacle avoidance system, which consists of multiple sensors. The sensors are infrared sensors or laser sensors, and the sensors are evenly distributed around the gantry truss system; the sensors are connected to the control system.

9. An automated production gantry integrated platform for a wind power blade according to claim 1, characterized in that: The control system includes an industrial computer, an industrial switch, an Ethernet module, and a PLC control module. The industrial computer is connected to the industrial switch, the industrial switch is connected to the Ethernet module, and the Ethernet module is connected to the PLC control module.

10. The automated production gantry integration platform for wind turbine blades according to claim 9, characterized in that: The control system further includes a remote controller and a wireless control module. The remote controller is wirelessly connected to the wireless control module, and the wireless control module is communicatively connected to the PLC control module.

11. A working method of an automated production gantry integration platform for wind turbine blades, characterized in that: Applied to a wind power blade automated production gantry integrated platform as described in any one of claims 1-10, the working method includes the following steps: According to the wind power blade production process, select the corresponding production program in the control system, and install the wind power blade production terminal tool required for the corresponding wind power blade production process on the quick connection mechanism, that is, connect the main disk to the tool disk with the corresponding wind power blade production terminal tool, and lock the main disk and the tool disk with the locking device. Start the production program in the control system, so that the gantry integrated platform starts to run according to the production program and completes the process operation. After the process operation is completed, replace the tool disk connected to the corresponding wind power blade production terminal tool on the main disk according to the next production process.

12. The working method of an automated production gantry integration platform for wind turbine blades according to claim 11, characterized in that: Real-time positioning is performed during the operation of the gantry integrated platform.

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