Installation method of heavy-weight inclined flange for wind power blade test bed
By combining a laser tracker and a slanted suspension assembly, the problems of lifting large flanges and measuring accuracy on the wind turbine blade test bench were solved, enabling precise installation and efficient measurement of flanges on the wind turbine blade test bench.
Patent Information
- Application Number
- CN202511753097.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-11-26
- Publication Date
- 2026-02-13
AI Technical Summary
On wind turbine blade test benches, existing technologies present problems such as high lifting difficulty, high safety risks, low measurement accuracy, and large workload for retesting when hoisting large flanges. In particular, the slight angular deviation of the front flange leads to a large deviation at the blade tip, and the measurement reference transfer is complicated, making it difficult to achieve precise control.
A three-dimensional reference plane is established using a laser tracker. The front flange is precisely positioned and adjusted by using a slanted lifting assembly and adjusting components in conjunction with a crane hook. The pitch and torsion angles are calculated by fitting a plane with multiple measuring target balls, avoiding reference shift and simplifying the measurement process.
It reduced the difficulty and safety risks of hoisting, improved measurement accuracy and repeatability, reduced the workload of retesting, and achieved stable stress and precise installation of the flange.
Smart Images
Figure CN121516698A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of wind power generation testing technology, specifically to a method for installing a heavy-duty inclined flange for a wind turbine blade test bench. Background Technology
[0002] Static and dynamic testing of wind turbine blades are crucial steps in verifying the structural safety and performance of the blades. During testing, the blade to be tested must be installed on a test bench. The blade mounting surface of the wind turbine blade test bench is usually formed by a secondary pouring of concrete after a large flange is installed on the concrete base. It generally has a certain tilt angle. The large flange includes a front flange (positive angle) located on the front of the test bench and a back flange (negative angle) located on the back of the test bench. During the installation of the front flange, in order to achieve the preset tilt angle, a combination of overhead crane and hoisting crane is often used for hoisting. Since wind turbine blades are quite long, and newly developed blades are generally over 100 meters, even a small angular deviation of the front flange can lead to a large blade tip deviation. Therefore, after the front flange is in place, equipment such as a total station or inclinometer is often used to measure the pitch and deflection angles of the front flange for fine adjustment.
[0003] In the aforementioned existing technologies, the coordination between the gantry crane and the crane operator relies solely on human command. This process is prone to communication breakdowns and untimely commands, increasing the difficulty of hoisting. When the front flange is in the air, it is simultaneously subjected to external forces from both the gantry crane and the crane. If the directions of these two forces are not appropriate, the front flange is highly susceptible to swaying and swinging in the air, posing a significant safety risk. Furthermore, due to the low control precision of the crane, the crane boom and hook movement speed cannot match that of the gantry crane, resulting in inaccurate control during the positioning and adjustment of the front flange, increasing adjustment time and difficulty. Since the front flange being measured is at a high altitude and has a smooth surface, the target prism is difficult to keep stably positioned for extended periods. To measure different positions and angles of the front flange, it is often necessary to move the measuring equipment or shift the reference, leading to changes in the measurement reference. Converting the measurement data into the required adjustment parameters requires the use of spatial geometry formulas, a complex and error-prone process that ultimately results in inconsistent measurement results, low accuracy, and increased retesting workload.
[0004] Therefore, there is an urgent need for an installation method for inclined flanges on a test bench, which can reduce the difficulty and risk of hoisting, accurately control the positioning and adjustment process of the front flange, reduce the measurement difficulty, and eliminate the need for reference transfer or reference conversion during the measurement process. The solution is simple, the measurement accuracy is high, and the reproducibility is good. Summary of the Invention
[0005] The present invention aims to provide an installation method for a heavy inclined flange for a wind turbine blade test bench, which can reduce the difficulty and risk of hoisting, accurately control the positioning and adjustment process of the large flange, reduce the measurement difficulty, and eliminate the need for reference transfer or reference conversion during the measurement process. The solution is simple, the measurement accuracy is high, and the reproducibility is good.
[0006] To achieve the above objectives, the present invention adopts the following technical solution: a method for installing a heavy-duty inclined flange for a wind turbine blade test bench, comprising the following steps: S1. Heavy-duty flanges include front flanges and back flanges. The test bench is equipped with mounting positions. A laser tracker is set in front of the test bench and located on the central axis of the test bench. The laser tracker is calibrated to measure the XY reference plane. The central axis of the test bench is measured and set as the X-axis. The laser tracker generates an XZ reference plane that passes through the X-axis and is perpendicular to the XY reference plane. A measurement point is taken on the X-axis and a YZ reference plane that passes through the point and is perpendicular to both the XY and XZ reference planes is generated. S2. The front flange is equipped with a slant lifting assembly. The slant lifting assembly lifts the front flange in front of the test bench and adjusts the pitch angle of the front flange to be the same as the tilt angle of the installation position on the test bench. The slant lifting assembly can be driven to move the front flange along the X-axis and Z-axis to the installation position. The test bench is equipped with adjusting parts on the left and right sides of the front flange. The adjusting parts are used to adjust the front flange, which has been adjusted along the X-axis and Z-axis, along the Y-axis until the front flange is aligned with the installation position. S3. The front flange is equipped with multiple measuring target balls that can be measured by a laser tracker. The laser tracker measures all the measuring target balls and fits a measuring plane. The angle α formed by the measuring plane and the YZ reference plane is measured. The angle α is the pitch angle of the front flange. The distances between the left and right end points of the front flange and the YZ reference plane are measured by the laser tracker. Furthermore, the inclined lifting assembly and the hoisting assembly are driven by the crane hook.
[0007] Furthermore, in step S2, the inclined lifting assembly includes lifting lugs, inclined tie rods, upper lifting slings, and lower lifting slings. There are multiple lifting lugs, which are symmetrically arranged on the front flange along the central axis of the front flange. The upper and lower lifting slings are respectively connected to the mutually symmetrical lifting lugs and are both connected to the crane hook. The length of the upper lifting sling is less than the length of the lower lifting sling. The inclined tie rod is arranged between the lifting lugs and the lower lifting slings.
[0008] Furthermore, in step S2, the test bench is pre-set with a mounting column for installing the adjustment component. The mounting column is perpendicular to the mounting position on the test bench. One end of the adjustment component is connected to the front flange, and the other end is connected to the mounting column.
[0009] Furthermore, in step S3, the measuring target balls are mounted on the front flange via a magnetic base. There are 8 to 12 measuring target balls, which are distributed symmetrically along the circumference on the front flange. The diameter of the measuring target balls is 38.1 mm.
[0010] Furthermore, in step S3, the distances between the left and right end points of the front flange and the YZ reference plane are restored to angle β using trigonometric functions, where angle β is the torsion angle of the front flange.
[0011] The beneficial effects of this invention are: It can reduce the difficulty and safety risks of hoisting. By precisely adjusting the pitch angle through the length difference between the upper and lower slings and the diagonal tie, the front flange is tilted to the installation position at the appropriate angle, which stabilizes the force during the flange hoisting process, greatly reduces swaying in the air, and reduces the risk of collision or falling. The inclined hoisting component achieves precise movement in the X and Z directions through a single drive of the crane, and completes fine adjustment in the Y direction with the adjustment component. This solves the problems of low control accuracy and poor matching with the crane in traditional cranes. The laser tracker establishes a fixed three-dimensional reference plane without the need to transfer the reference. Multiple symmetrically distributed measurement target balls fit the plane and calculate the pitch angle and torsion angle, eliminating the need for manual spatial geometric conversion and reducing measurement errors and retesting workload. Attached Figure Description
[0012] Figure 1 This is a schematic diagram of the structure of the present invention; Figure 2 This is a side view of the present invention; Figure 3 This is a top view of the present invention; Figure 4 This is a schematic diagram of the front flange being hoisted onto the test bench in this invention; Figure 5 This is a schematic diagram of the front flange in this invention; Figure 6 This is a schematic diagram showing the front flange not being hoisted in this invention; Figure 7 This is a schematic diagram of the front flange being obliquely pulled by the diagonal tie in this invention.
[0013] The following detailed description illustrates the specific implementation method: The reference numerals in the accompanying drawings of the instruction manual include: 1. Test bench; 2. Front flange; 3. Mounting position; 4. Laser tracker; 5. XY datum plane; 6. XZ datum plane; 7. Adjustment component; 8. Measuring plane; 9. Crane hook; 10. Lifting lug; 11. Diagonal tie; 12. Upper lifting cable; 13. Lower lifting cable; 14. Mounting column; 15. Measuring target ball; 16. Detailed Implementation
[0014] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.
[0015] In the description of this invention, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.
[0016] Example 1 The basic implementation examples are as follows: Figure 1-7 As shown, Figure 1 The method shown is for installing a heavy-duty inclined flange for a wind turbine blade test bench 1. The test bench 1 is constructed on-site by concrete casting, and an installation position 3 is reserved on the test bench 1. The laser tracker 4 can be an existing Leica AT960 laser tracker 4 (measurement accuracy ±5μm / m) as the measuring device, or other existing models can be used. It is fixed on the ground directly in front of the test bench 1, ensuring that the central axis of the laser tracker 4 coincides with the central axis of the test bench 1. The trolley is a bridge type (i.e., bridge crane) as the driving device, and the movement of the trolley hook 10 meets the precise driving requirements in the X and Z axis directions.
[0017] The laser tracker 4 is activated, and horizontal plane calibration is performed first: the XY reference plane 5 is measured using the automatic leveling function of the laser tracker 4. Horizontal data is collected at three different locations during the calibration process to ensure that the flatness error of the XY reference plane 5 is less than 0.05 mm / m. Subsequently, the centerline mark of the concrete base of the test bench 1 is scanned with a laser and set as the X-axis, generating the XZ reference plane 6, which passes through the X-axis and is perpendicular to the XY reference plane 5. As a preferred embodiment, see attached... Figure 1 As shown, the laser tracker 4 measures the position of the front end of the test bench 1 on the X-axis. After measuring the coordinates of this position, the laser tracker 4 automatically generates the YZ reference plane 7, which passes through the coordinates and is perpendicular to both the XY reference plane 5 and the XZ reference plane 6. After all the XY reference planes 5 are established, the data is stored through the reference saving function of the laser tracker 4 to avoid reference offset during subsequent measurement.
[0018] One end of the upper lifting sling 13 and the lower lifting sling 14 are respectively connected to the symmetrical lifting lugs 11 of the front flange 2, and the other end is connected together to the crane hook 10, as shown in the attached figure. Figure 4 and attached Figure 5As shown in the attached diagram, in a preferred embodiment, there are four lifting lugs 11, and two upper lifting cables 13 and two lower lifting cables 14. Figure 6 and attached Figure 7 As shown, the projections of the two upper lifting cables 13 on the XZ datum plane 6 coincide, and the projections of the two lower lifting cables 14 on the XZ datum plane 6 coincide. At this time, the pitch angle of the front flange 2 is adjusted by adjusting the diagonal tie rod 12 on the lower lifting cable 14. The length of the upper lifting cable 13 is less than the length of the lower lifting cable 14. The longer lower lifting cable 14 facilitates the adjustment of the pitch angle of the front flange 2 via the diagonal tie rod 12. Simultaneously with the adjustment of the diagonal tie rod 12, the crane is started to slowly lift the front flange 2 off the ground, assisting the diagonal tie rod 12 in applying diagonal tension to the front flange 2. (See attached...) Figure 2 As shown, the laser tracker 4 monitors in real time the measurement plane 9 fitted by the measurement target ball 16 on the front flange 2. The measurement target ball 16 is mounted on the front flange 2 via a magnetic base. There are 8 to 12 measurement target balls 16, which are distributed symmetrically along the circumference of the front flange 2. The diameter of the measurement target ball 16 is 38.1 mm. When the laser tracker 4 shows that the angle α between the measurement plane 9 and the YZ reference plane 7 reaches the tilt angle required for the front flange 2 to be installed in the mounting position 3, the adjustment of the diagonal tie 12 is stopped. At this time, the coarse adjustment of the pitch angle of the front flange 2 is completed. The diagonal tie 12 can be a conventional hand chain hoist.
[0019] Start the crane to drive the hook. The hook drives the front flange 2 to move along the X-axis of the test bench 1 mounting position 3 via the upper sling 13 and the lower sling 14. At the same time, the height in the Z-axis direction is adjusted by the crane's lifting mechanism. During the movement, a dedicated person monitors the stress state of the slings to avoid collisions between the slings and other structures of the test bench 1. When the front flange 2 moves to the installation position 3, the crane stops moving. At this time, the Y-axis adjustment is performed by adjusting the left and right sides 8. The left adjusting part 8 pushes the front flange 2 simultaneously, and the right adjusting part 8 retracts simultaneously away from the front flange 2, or vice versa. The distance between the measuring target ball 16 at both ends of the front flange 2 and the baseline of the installation position 3 is monitored by the laser tracker 4. When the distance error is less than 10mm, the Y-axis adjustment is completed. During the hoisting process, the position of the front flange 2 is adjusted according to the actual measurement data of the laser tracker 4 to ensure that the front flange 2 is accurately hoisted to the installation position 3. As a preferred embodiment, the mounting column 15 can be a pre-embedded steel bar on the test bench 1. The mounting column 15 is perpendicular to the inclined installation surface of the test bench 1. The adjusting part 8 can be a hand-operated hoist. One end can be connected to the front flange 2 by a pre-reserved ear plate on the front flange 2, and the other end is fixed to the pre-embedded steel bar.
[0020] As attached Figure 3As shown, after the front flange 2 is calibrated at the mounting position 3 using the pitch angle and three XY reference planes 5, the distance between the target ball at both ends of the front flange 2 and the YZ reference plane 7 is measured using a laser tracker 4. In a preferred embodiment, the distance between the left end point and the YZ reference plane 7 is taken as b, and the distance between the right end point and the YZ reference plane 7 is taken as c. The torsion angle β is calculated using trigonometric functions, and the formula is:
[0021] Where r is the diameter of the front flange 2, the torsion angle can be adjusted by tightening or loosening the set screws on the front flange 2 at the mounting position 3, and finally the position of the front flange 2 on the X and Z axes is finely adjusted by the crane so that the mounting hole of the front flange 2 is precisely aligned with the pre-embedded bolts on the base of the test bench 1. After alignment, all target ball data are re-measured to ensure that the pitch angle °, torsion angle β and all accuracy parameters meet the design requirements. Then the pre-embedded bolts are tightened to complete the fixing of the front flange 2.
[0022] The above descriptions are merely embodiments of the present invention, and common knowledge such as specific technical solutions and / or characteristics are not described in detail here. It should be noted that those skilled in the art can make various modifications and improvements without departing from the technical solutions of the present invention, and these should also be considered within the scope of protection of the present invention. These modifications and improvements will not affect the effectiveness of the implementation of the present invention or the practicality of the patent. The scope of protection claimed in this application should be determined by the content of its claims, and the specific embodiments described in the specification can be used to interpret the content of the claims.
Claims
1. A method for installing a heavy-duty inclined flange for a wind turbine blade test bench, characterized in that: Includes the following steps: S1. Heavy-duty flanges include front flanges. The test bench is equipped with mounting positions for front flanges. A laser tracker is set in front of the test bench and located on the central axis of the test bench. The laser tracker is calibrated to measure the XY reference plane. The central axis of the test bench is measured and set as the X-axis. The laser tracker generates an XZ reference plane that passes through the X-axis and is perpendicular to the XY reference plane. A measurement point is taken on the X-axis and a YZ reference plane that passes through the point and is perpendicular to both the XY and XZ reference planes is generated. S2. The front flange is equipped with a slant lifting assembly. The slant lifting assembly lifts the front flange in front of the test bench and adjusts the pitch angle of the front flange to be the same as the tilt angle of the installation position on the test bench. The slant lifting assembly can be driven to move the front flange along the X-axis and Z-axis to the installation position. The test bench is equipped with adjusting components on the left and right sides of the front flange. The adjusting components adjust the front flange, which has been adjusted along the X-axis and Z-axis, along the Y-axis until the front flange is aligned with the installation position. S3. The front flange is equipped with multiple measuring target balls that can be measured by a laser tracker. The laser tracker measures all the measuring target balls and fits a measuring plane, and measures the angle α formed by the measuring plane and the YZ reference plane. The angle α is the pitch angle of the front flange. The distances between the left and right end points of the front flange and the YZ reference plane are measured by the laser tracker.
2. The method for installing a heavy-duty flange for a wind turbine blade test bench according to claim 1, characterized in that: Inclined lifting assembly and hoisting assembly, crane hook drive.
3. The method for installing a heavy-duty flange for a wind turbine blade test bench according to claim 2, characterized in that: In step S2, the inclined lifting assembly includes lifting lugs, inclined tie rods, upper lifting slings, and lower lifting slings. There are multiple lifting lugs, which are symmetrically arranged on the front flange along the central axis of the front flange. The upper and lower lifting slings are respectively connected to the symmetrical lifting lugs and are both connected to the crane hook. The length of the upper lifting sling is less than the length of the lower lifting sling. The inclined tie rod is arranged between the lifting lugs and the lower lifting slings.
4. The method for installing a heavy-duty flange for a wind turbine blade test bench according to claim 3, characterized in that: In step S2, the test bench is pre-set with a mounting column for installing the adjustment component. The mounting column is perpendicular to the mounting position on the test bench. One end of the adjustment component is connected to the front flange, and the other end is connected to the mounting column.
5. The method for installing a heavy-duty flange for a wind turbine blade test bench according to claim 2, characterized in that: In step S3, the measuring target balls are mounted on the front flange via a magnetic base. There are 8 to 12 measuring target balls, which are distributed symmetrically along the circumference of the front flange. The diameter of the measuring target balls is 38.1 mm.
6. The method for installing a heavy-duty flange for a wind turbine blade test bench according to claim 5, characterized in that: In step S3, the distance between the left and right ends of the front flange and the YZ reference plane is restored to angle β using trigonometric functions. Angle β is the torsion angle of the front flange.