Installation method of heavy-weight flange for wind power blade test bed

Abstract

The invention relates to the technical field of wind power generation testing, in particular to an installation method of a heavy-weight flange for a wind power blade test bed, which comprises the following steps of: accurately adjusting a pitch angle through a length difference between an upper sling and a lower sling and an inclined pull piece, and inclining a front flange to an inclination angle of an installation position, so that the stress is stable in a flange hoisting process; the inclined hoisting assembly achieves X-direction and Z-direction accurate movement through single driving of the crane, Y-direction fine adjustment is completed through cooperation of the inclined hoisting assembly and the adjusting piece, the problems that a traditional crane is low in control precision and poor in crane matching performance are solved, a fixed three-dimensional datum plane is established through the laser tracker, datum transfer is not needed, and the working efficiency is improved. A plurality of symmetrically distributed measuring target balls fit a plane and calculate a pitch angle and a torsion angle, manual space geometric conversion is not needed, measurement errors and remeasurement workload are reduced, and a back flange can be smoothly hoisted to an inclined mounting position from the rear of a test bed and assembled with a front flange.

Description

Technical Field

[0001] This invention relates to the field of wind power generation testing technology, and specifically to a method for installing a heavy-duty flange for a wind turbine blade test bench. Background Technology

[0002] Static and dynamic testing of wind turbine blades are key steps in verifying the structural safety and performance of the blades. During the testing process, the blades to be tested need to be installed on the test bench. The blade mounting surface of the wind turbine blade test bench is usually formed by a second pouring after a large flange is installed on the concrete base. It generally has a certain tilt angle. The large flange includes the front flange (positive angle) located on the front of the test bench and the back flange (negative angle) located on the back of the test bench.

[0003] In existing technologies, the front flange faces several challenges during hoisting, including high hoisting difficulty and process risks, inaccurate control of the positioning and adjustment process, high measurement difficulty and inconsistent benchmarks, complex calculation results, low measurement accuracy, and poor reproducibility. Furthermore, hoisting the back flange presents challenges due to the need for a negative angle and the obstruction of the concrete base above, making conventional methods impossible. While a frame-based hoisting fixture is typically used, lifting such a heavy back flange requires a large and heavy fixture. To balance the weight, controlling the fixture's weight is difficult, and significant structural reinforcement is necessary. This results in a long manufacturing cycle and high cost. Additionally, the space behind the concrete base after hoisting the back flange and the fixture is narrow, further complicating the hoisting process.

[0004] Therefore, there is an urgent need for an installation method that can install front and back flanges on a test bench, which can reduce the difficulty and risk of hoisting the front and back flanges, simplify the hoisting structure of the back flange, 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 heavy flanges used in wind turbine blade test benches, which can reduce the lifting difficulty and risk of front and back flanges, simplify the lifting structure of the back flange, 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.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: a method for installing a heavy-duty 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 plane A. The angle α formed by plane A 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. S4. After the front flange is positioned, a hollow pump is installed at the bottom of the front flange, which is directly opposite the back flange. A lifting assembly is installed on the back flange. The lifting assembly can be driven to move the back flange to the rear of the test bench. The test bench has multiple reserved holes, and tooling cables are threaded through the multiple reserved holes. One end of the tooling cable is connected to the bottom of the back flange being lifted, and the other end is connected to the hollow pump. S5. Start the hollow pump drive cable and pull the bottom of the rear flange towards the installation position. After the rear flange reaches the installation position and is parallel to the front flange, stop the hollow pump and connect the front flange and the rear flange.

[0007] Furthermore, the inclined lifting assembly and the hoisting assembly are driven by the crane hook.

[0008] 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.

[0009] 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.

[0010] 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.

[0011] 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.

[0012] Furthermore, in step S4, the lifting assembly includes a lifting sling and a lifting member. One end of the lifting member is connected to the lifting sling, and the other end is connected to the rear flange. The lifting sling is then lifted to the crane hook.

[0013] Furthermore, in step S4, the tooling cable includes a chain and a screw. One end of the chain is connected to the bottom of the rear flange lifting, and the other end is inserted through the screw into the reserved hole and connected to the hollow pump.

[0014] The beneficial effects of this solution are as follows: 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 can be tilted to the installation position at the appropriate angle, ensuring stable force during flange hoisting, significantly reducing swaying and swinging in the air, and lowering the risk of collision or falling. The inclined hoisting assembly achieves precise movement in the X and Z directions through a single drive of the crane, and completes fine-tuning in the Y direction with the adjustment components, solving 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, reducing measurement errors and retesting workload. The rear flange can be smoothly hoisted from the back of the test bench to the inclined installation position and assembled with the front flange. Attached Figure Description

[0015] 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 an oblique tie in this invention; Figure 8 This is a schematic diagram of the rear flange hoisting structure in this invention. Figure I ; Figure 9 for Figure 8 An enlarged schematic diagram of part A in the middle; Figure 10 This is a schematic diagram of the rear flange hoisting structure in this invention. Figure II .

[0016] The following detailed description illustrates the specific implementation method: The reference numerals in the accompanying drawings include: 1. Test bench; 2. Front flange; 3. Mounting position; 4. Laser tracker; 5. XY datum plane; 6. XZ datum plane; 7. YZ datum plane; 8. Adjusting component; 9. Measuring plane; 10. Crane hook; 11. Lifting lug; 12. Diagonal tie; 13. Upper lifting sling; 14. Lower lifting sling; 15. Mounting column; 16. Measuring target ball; 17. Hollow pump; 18. Reserved hole; 19. Lifting sling; 20. Lifting component; 21. Chain; 22. Screw; 23. Rear flange. Detailed Implementation

[0017] 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.

[0018] 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.

[0019] 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.

[0020] 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.

[0021] 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 5 As 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.

[0022] The laser tracker 4 sends the collected information to the control unit (not shown in the figure). The control unit can be a computer, which generates a dynamic three-dimensional schematic diagram from the collected XY reference plane 5, XZ reference plane 6 and YZ reference plane 7. Based on the real-time hoisting position of the front flange 2, the computer controls the operation of the crane to adjust the position of the front flange 2 in the X and Y axes.

[0023] 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.

[0024] As attached Figure 3 As 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:

[0025] 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.

[0026] As attached Figure 8 Appendix Figure 9 and attached Figure 10As shown, after the front flange is positioned, the back flange is hoisted. The hoisting assembly includes hoisting slings and hoisting components. One end of the hoisting component is connected to the hoisting sling, and the other end is connected to the back flange. The hoisting sling is hoisted to the crane hook. In a preferred embodiment, a hand-operated hoist can be used for the hoisting component. The test bench has multiple pre-drilled holes, and tooling cables are threaded through each of these holes. One end of the tooling cable is connected to the bottom of the back flange being hoisted, and the other end is connected to a hollow pump. A pump station can be set up on-site for pressure pumping. The tooling cable includes a chain and a screw. One end of the chain is connected to the bottom of the back flange being hoisted, and the other end passes through the screw into the pre-drilled hole and out of the front flange to connect to the hollow pump. In a preferred embodiment, eight tooling cables are selected and arranged in groups of four, with two groups of tooling cables. The cables are symmetrically inserted into the pre-drilled holes near the bottom. Select any set of four screws extending from the front flange and install a core pump on them, starting it to its maximum stroke. The four screws in this set will drive the corresponding four chains to retract into the pre-drilled holes, moving the rear flange to its installation position. During this process, the chains of the other set and the screws without core pumps will also move. At this point, the screws without core pumps are locked with nuts or other existing mechanical structures. Reverse pressure is applied to retract the core pumps on the four screws. During this retraction process, since the other set of screws is already locked, the rear flange will not deviate from its moved position. Alternating between pump station pressurization and nut tightening as described above, the rear flange can be gradually pulled to its installation position. Once in place, the front and rear flanges can be installed.

[0027] 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 flange for a wind turbine blade test bench, characterized in that: Includes 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 plane A. The angle α formed by plane A 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. S4. After the front flange is positioned, a hollow pump is installed at the bottom of the front flange, which is directly opposite the back flange. A lifting assembly is installed on the back flange. The lifting assembly can be driven to move the back flange to the rear of the test bench. The test bench has multiple reserved holes, and tooling cables are threaded through the multiple reserved holes. One end of the tooling cable is connected to the bottom of the back flange being lifted, and the other end is connected to the hollow pump. S5. Start the hollow pump drive cable and pull the bottom of the rear flange towards the installation position. After the rear flange reaches the installation position and is parallel to the front flange, stop the hollow pump and connect the front flange and the rear flange.

2. The method for installing a heavy-duty flange for a wind turbine blade test bench according to claim 1, characterized in that: The inclined lifting assembly and the hoisting assembly are driven by the overhead crane hook.

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.

7. The method for installing a heavy-duty flange for a wind turbine blade test bench according to claim 2, characterized in that: In step S4, the lifting assembly includes a lifting sling and a lifting component. One end of the lifting component is connected to the lifting sling, and the other end is connected to the rear flange. The lifting sling is then lifted to the crane hook.

8. The method for installing a heavy-duty flange for a wind turbine blade test bench according to claim 7, characterized in that: In step S4, the tooling cable includes a chain and a screw. One end of the chain is connected to the bottom of the rear flange lifting, and the other end is inserted through the screw into the reserved hole and connected to the hollow pump.

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