Treatment device for treatment of a preformed round room component and method for manufacturing a round room component

Abstract

The invention relates to a trimming device for trimming a preformed circular root part and a method for manufacturing a circular root part. The trimming device (300) comprises: a support structure (302); a table (308) rotatably supported on the support structure (302) and configured to support the prefabricated circular root part (200); a trimming tool (320) secured to the support structure (302) and configured to trim, in particular remove excess material, the circular root component (200) along a periphery (204) of the circular root component (200) when the circular root component (200) is supported on the table (308).

Description

TECHNICAL FIELD

[0001] The present invention relates to a finishing device. The present invention also relates to a method of manufacturing a circular root component. BACKGROUND

[0002] Wind turbines having wind turbine rotor blades are widely known from the prior art and are used to convert wind energy into electrical energy for supply to an electrical grid. Wind turbines of this type generally comprise a rotor having a rotor hub and a plurality of wind turbine rotor blades.

[0003] A wind turbine rotor blade has a root region to be attached to the rotor hub, in particular via a pitch bearing, and a tip portion at an opposite end. The root region of a wind turbine blade generally has a substantially circular cross section. Other regions of a wind turbine rotor blade have a cross section with an aerodynamic profile.

[0004] In the region of the root region of a wind turbine rotor blade a circular root component, for example a circular base plate or a root ring, is generally provided. The circular root component is connected, in particular bonded by an adhesive, to an inner surface of a shell of the wind turbine rotor blade. SUMMARY

[0005] It is a basic task of the present invention to provide a concept for efficiently and reliably manufacturing such a circular root component.

[0006] This object is solved by the main aspect of the present invention. Advantageous embodiments are given in the further aspects of the present invention.

[0007] According to a first aspect, a finishing device is disclosed, the finishing device being configured for finishing a prefabricated circular root component of a wind turbine rotor blade. The finishing device comprises a support structure. The finishing device comprises a work table. The work table is rotatably supported on the support structure. The work table is configured to support the prefabricated circular root component. The finishing device comprises a finishing tool, the finishing tool being fixed to the support structure and being configured to finish, in particular to remove excess material, the circular root component along a circumference of the circular root component when the circular root component is supported on the work table.

[0008] The device of the application allows the circular root part to be trimmed particularly easily along its circumference. The trimming is performed by a trimming tool which is fixed on the support structure in such a way that it can trim along the circumference of the circular root part. Due to the rotatable worktable, the circular root part arranged on the worktable can be rotated, in particular while it is being trimmed. This allows the part to be trimmed uniformly, for example, along its circumference. Alternatively or additionally, a certain point or a certain area of the part can be trimmed, since the part is rotated in the respective orientation so that the trimming tool selectively trims the circular root part.

[0009] Compared to conventional methods which involve manual trimming by one or more operators, the trimming device of the application significantly reduces the total time required for trimming. This leads to an increase in productivity and allows the operators to focus on other important and critical aspects of their work. Furthermore, by minimizing the need for manual trimming, the risk of operator injuries and accidents related to trimming tools or repetitive movements is greatly reduced or even avoided.

[0010] Here and in the following, trimming means removing excess material which still exists after the circular root part has been substantially manufactured, i.e. pre-finished. The term "pre-finished" means that the part needs to be at least finished, i.e. trimmed, in order to meet the final installation specifications. With regard to the circular root part, in particular the circumference needs to be trimmed in order to install the circular root part in the root region of a wind turbine rotor blade. The excess material to be removed is for example parts or the entirety of elements like peel plies, vacuum foils, etc.

[0011] The circular root part is made of a fiber composite material. The circular root part is a circular base plate or a circular support plate. Alternatively, the circular root part is a ring-like part. For example, the circular base plate formed as a plate comprises one or more access holes. The plate serves as a stiffening member for the root of a rotor blade. Additionally or alternatively, the part serves for example as a support platform for maintenance workers. The circular root part typically has a diameter of about 2.5 m to 5 m.

[0012] The worktable can be rotated for example manually by an operator or driven electrically.

[0013] The trimming tool is for example a disc cutter, a milling tool or a saw for trimming the circular root part at its circumference. The trimming tool can also have or combine two or more different tool types, for example a saw and a disc cutter.

[0014] According to an embodiment, the support structure is a frame, in particular a metal frame. For example, the frame is built from a plurality of webs (also struts, bars). This achieves a stable and at the same time lightweight solution.

[0015] According to embodiments, the support structure comprises one or more roller bearings for supporting the worktable. This means that relatively heavy circular root parts can be firmly supported and can also be rotated, for example by hand. Roller bearings offer advantages such as low noise, smooth running, high load capacity, etc. Preferably, the roller bearings are ball transfer units. Ball transfer units, for example, comprise a housing with an integrated bearing housing, a cover, a load ball and a plurality of bearing balls. In particular, ball transfer units offer high bearing loads with a reduced self-weight and size. Furthermore, they ensure high dirt and rust resistance and are suitable for simple installation.

[0016] According to embodiments, the roller bearings are arranged on webs of the support structure which extend parallel to a lower surface of the worktable. For example, the roller bearings are distributed over and mounted on the webs. The lower surface of the worktable can also be defined as a bottom surface and thus refers to a surface facing the ground, for example a surface for placing a finishing device.

[0017] According to embodiments, the support structure comprises an electric drive which is arranged to rotate the worktable. The electric drive comprises an electric motor and is connected to the worktable such that a rotational force (torque) is transmitted to the worktable. For example, the electric drive is centrally located below the worktable. For example, the electric motor drives a motor shaft which is connected to the worktable for rotating it directly or via one or more gear units.

[0018] According to embodiments, the worktable comprises a centering device for placing a circular root part in a centered manner on an upper surface of the worktable. The centering device is arranged on a top surface of the worktable, for example a surface facing away from the ground, for example a surface for placing a finishing device. The centering device ensures that the circular root part is arranged in a predetermined position on the worktable.

[0019] According to embodiments, the centering device is one or more markings applied to the worktable. Thus, the circular root part can be centered by means of visually perceptible markings. This provides a simple, easy-to-use centering method.

[0020] According to embodiments, the centering device is one or more protrusions located on the worktable, for example on a top surface thereof, for interacting with one or more openings or recesses of the circular root part or arranged on the circular root part. This centers the circular root part by means of a form fit between the protrusions and the recesses / openings.

[0021] According to embodiments, the one or more protrusions are adapted to interact with one or more access holes provided in the circular root part. Thus, access holes which are present in the circular root part itself, formed as a plate, can also be used directly for centering.

[0022] According to embodiments, the centering device refers to one or more recesses or openings provided in the workbench, e.g. in its upper surface, for interacting with one or more protrusions of the circular root part. We refer to the above described functions and advantages, which equally apply.

[0023] According to embodiments, the workbench comprises a fixation device for holding the circular root part in a fixed position on the workbench. According to embodiments, the fixation device is designed as one or more clamps, in particular as toggle clamps. The fixation device easily and safely locks the part on the workbench, thereby enabling consistent and high-quality safety trimming.

[0024] According to embodiments, the fixation device is a vacuum device comprising one or more suction cups and a vacuum pump configured to generate a negative pressure for fixedly holding the circular root part on the workbench. For example, the vacuum pump is connected to the one or more suction cups. The suction cups are fixedly stationary with respect to the workbench. When the circular root part is placed on the workbench, the one or more suction cups are arranged at the underside of the circular root part. By providing the negative pressure, the suction cups are attracted to the circular root part and hold it in place. The vacuum device allows for a firm fixation of the circular root part to the workbench. The vacuum device provides a flexible and practical fixation option, in particular in cases where the design of the workbench does not allow for the attachment of a fixation device (e.g. in cases where the circular root part is a huge plate without any access holes).

[0025] According to embodiments, the support structure has a holder on which the trimming tool is arranged and in particular movably guided in horizontal and / or vertical direction. For example, the holder extends vertically with respect to the workbench, e.g. parallel to the motor shaft of the electric motor, as described above. Similar to the above description, the trimming tool can be manually or electrically driven to move along the holder.

[0026] According to a second aspect, a method for manufacturing a circular root part of a wind turbine rotor blade is disclosed. The method comprises the following steps:

[0027] providing a trimming device according to any of the embodiments according to the first aspect described above,

[0028] providing a prefabricated circular root part,

[0029] mounting the circular root part on a rotatable workbench of the trimming device,

[0030] rotating the workbench together with the circular root part, thereby trimming the circular root part at its circumference with the trimming tool.

[0031] The method achieves the above mentioned functions and advantages. The above described features in relation to the first aspect apply analogously to the method.

[0032] Mounting the circular root part essentially means placing the part on the work table. Rotating the part can be done manually or electrically.

[0033] In other embodiments, the method can comprise further steps similar to the features of the first aspect described above, such as:

[0034] Moving the trimming tool along the holder as described above,

[0035] Centering the circular root part in relation to the work table,

[0036] Securing the circular root part to the work table. BRIEF DESCRIPTION OF DRAWINGS

[0037] Further advantages, features and functions explained in connection with the drawings are given in the following exemplary embodiments of the present application. In the drawings, elements of identical, similar or analogous action are provided with identical reference signs.

[0038] In the drawings:

[0039] Figure 1 A schematic view of a wind turbine is shown,

[0040] Figure 2 A schematic view of a rotor blade is shown,

[0041] Figure 3 A schematic top view of a circular root part is shown,

[0042] Figure 4 A schematic perspective view of a trimming device according to an embodiment of the present application is shown,

[0043] Figure 5 A schematic perspective view of a trimming device with a circular root part is shown,

[0044] Figure 6 A schematic flow chart of a method according to an embodiment of the present application is shown, and

[0045] Figure 7 A schematic trimming device according to another embodiment of the present application is shown. DETAILED DESCRIPTION

[0046] Figure 1A schematic view of a wind turbine 100 comprising a tower 102 is shown. The tower 102 is fixed to the ground by means of a foundation 104. At one end of the tower 102 opposite the ground, a nacelle 106 is rotatably mounted. The nacelle 106 comprises, for example, a generator which is coupled to a rotor 108 via a rotor shaft (not shown). The rotor 108 comprises one or more (wind turbine) rotor blades 110 arranged on a rotor hub 112.

[0047] During operation, the rotor 108 is arranged to be set into rotation by the action of an air flow, for example the wind. This rotational movement is transmitted to the generator via the rotor shaft and, if necessary, via a gearbox. The generator converts the mechanical energy of the rotor 108 into electrical energy.

[0048] Figure 2 An exemplary rotor blade 110 is shown. The rotor blade 110 has the shape of a conventional rotor blade and has a rotor blade root region 114 facing the rotor hub 112. The rotor blade root region 114 generally has a substantially circular cross section. The rotor blade root region 114 is followed by a transition region 116 and a profile region 118 of the rotor blade 110. The rotor blade 110 has a pressure side 122 and an opposite suction side 124 with respect to a longitudinal direction 120, also the main extension direction. The rotor blade 110 is substantially hollow on the inside. In the rotor blade root region 114, a rotor blade root end 126 with a flange connection 128 is provided, by means of which the rotor blade 110 can be mechanically connected to a pitch bearing or an extender. The rotor blade 110 can be a segmented rotor blade.

[0049] In the rotor blade root region 114, a circular root part is usually to be installed. Figure 3 Such a circular root part 200 formed as a circular base plate is shown. The circular root part 200 is made of a fiber composite material and comprises, in the present example, two access holes 202.

[0050] As already indicated in the introductory part, during the manufacturing process, the circular root part 200 is first prefabricated and comprises excess material 206 (indicated in Figure 3 the introductory part) along its circumference 204. After the prefabrication, the circular root part 200 needs to be trimmed, wherein at least the excess material 206 along its circumference 204 is removed to obtain the intended shape and / or profile for the installation within the wind turbine rotor blade 110. For example, after the trimming, the circular root part 200 has a smooth circular outer profile 208 along its circumference 204.

[0051] In the following, a method for manufacturing a circular root part 200 is described, wherein, Figures 4 to 6 the circular root part 200 is prefabricated,Figure 4 and Figure 5 Reference is made to the trimming device 300, and Figure 6 Reference is made to the schematic flow chart of the method.

[0052] In a first step S1, the trimming device 300 is provided.

[0053] As shown in Figure 3 and Figure 4 The trimming device 300 has a support structure 302. The support structure 302 is a frame 304 (or frame-like element) and is built up from a plurality of interconnected web plates 306.

[0054] The trimming device 300 further comprises a work table 308 which is rotatably supported on the support structure 302 and is configured to support a prefabricated circular root part 200. In order to rotatably support the work table 308, the support structure 302 comprises one or more roller bearings 310, wherein the roller bearings 310 are spherical transmission units. The roller bearings 310 are fixed in or incorporated in some of the web plates 306 of the support structure 302, which are the upper horizontal web plates 307 and extend parallel to the lower surface 312 of the work table 308 (see Figure 4 and Figure 5 horizontal direction H in Figure 4 The roller bearings 310 are indicated by dashed lines in Figure 4 As can be seen in the present example, the roller bearings 310 are distributed over the upper horizontal web plates 307. In particular, some of the roller bearings 310 are arranged in an outer region of the support structure 302 with respect to a radial direction originating from the center C of the support structure 302. This ensures that the work table 308 can be uniformly supported and that bending or tilting of the work table 308 is avoided, especially in case the circular root part 200 is placed on the work table 308. Note that not all bearings 310 are indicated in

[0055] It is noted that in not shown embodiments, more or less roller bearings 310 can be used and / or the position of the roller bearings 310 can vary depending on the load supported by the work table 308.

[0056] In the present example, the support structure 302 comprises an electric drive 314 which is arranged to rotate the work table 308. The electric drive 314 comprises an electric (gear) motor 316 and a motor shaft 318. In the shown example, the electric drive 314 is centrally arranged on the support structure 302 below the work table 308. The motor shaft 318 extends vertically and is fixedly connected to the work table 308 (see Figure 4 andFigure 5 The motor shaft 318 is coupled to the worktable 308, in particular to the upper surface 326 of the worktable 308. The motor shaft 318 is coupled to the worktable 308 in such a way that the worktable 308 is rotatable about the vertical direction V) upon driving the electric motor 316. Upon driving the electric motor 316, the motor shaft 318 is rotated and, thus, the worktable 308 is rotated.

[0057] The trimming device 300 further comprises a trimming tool 320. The trimming tool 320 is fixed to the support structure 302 via a holder 322. In the shown example, the trimming tool 320 is movably guided on the holder 322, in particular along the vertical direction V. The trimming tool 320 is a disc cutter, but can also be a saw, a milling tool, etc. or a combination thereof. The trimming tool 320 is configured to trim the circular root part 200 along the circumference 204 of the circular root part 200 while the circular root part 200 is supported on the worktable 308.

[0058] The worktable 308 comprises centering means 324 for placing the circular root part 200 in a centered manner on an upper surface 326 (opposite to the lower surface 312) of the worktable 308. The centering means 324 are two protrusions 328 on the worktable 308 for a form-fitting interaction with corresponding access holes 202 provided in the circular root part 200. Here, the protrusions are ring-shaped or circular-shaped.

[0059] Further, the worktable 308 comprises fixing means 330 to hold the circular root part 200 in a fixed position on the worktable 308. Here, the fixing means 330 are designed as one or more clamps 332, in particular toggle clamps (not shown in the figures). The clamps 332 are configured to clamp the circular root part 200 in a fixed position on the worktable 308. Figure 4 and Figure 5 all examples are referred to).

[0060] In a next step S2, a prefabricated circular root part 200 as shown in Figure 3 is provided.

[0061] In a next step S3, the prefabricated circular root part 200 is mounted on the upper surface 326 of the rotatable worktable 308 (see Figure 5 ). The circular root part 200 is placed such that the protrusions 328 are at least partially inserted into the access holes such that the circular root part 200 is centered on the worktable 308 and in a predetermined orientation.

[0062] In a next step S4, the circular root part 200 is fixed to the worktable 308 by the fixing means 330.

[0063] In a next step S5, the work table 308 is rotated by actuating the electric drive 314. Thus, the circular root component 200 is identically rotated. Subsequently, the trimming tool 320 is used and operated to trim the circular root component 200 at the circumference 204 of the circular root component 200. Thus, the excess material 206 of the circular root component 200 is removed, e.g. cut off.

[0064] For trimming all excess material 206, the position of the trimming tool 320 can be adjusted before and / or during the trimming process. In this regard, the trimming tool 320 is moved along the holder 322.

[0065] In an embodiment not shown, the holder 322 and the trimming tool 320 can be configured such that the trimming tool 320 can be moved horizontally and vertically along the respective directions H and V.

[0066] Figure 7 A schematic trimming device 200 according to another embodiment of the present application is shown. The trimming device 200 as shown essentially corresponds to the trimming device as described above with respect to Figure 4 and Figure 5 Compared to the above, the fixation device 330 is different. Here, the fixation device 330 is a vacuum device 334. The vacuum device 334 has one or more suction cups 336 and a vacuum pump 338. The vacuum pump 338 is connected to the one or more suction cups 336 via one or more conduits 340. The suction cups 336 are fixedly secured with respect to the work table 308. For example, the suction cups 336 are integrated into the work table 308 such that the suction cups 336 are flush with the upper surface 326 of the work table 308. In this setup, there are no clamps or protrusions on the work table 308.

[0067] When placing the circular root component 200 on the work table 308, the suction cups 340 are thus arranged at the lower side 210 of the circular root component 200. By the vacuum pump 338 providing a negative pressure to the suction cups 340, the suction cups 340 are attracted to the circular root component 200 and fixedly hold the circular root component 200 in place on the work table.

[0068] List of reference signs

[0069] 100 wind turbine

[0070] 102 tower

[0071] 104 foundation

[0072] 106 nacelle

[0073] 108 rotor

[0074] 110 rotor blade

[0075] 112 rotor hub

[0076] 114 rotor blade root region

[0077] 116 transition region

[0078] 118 profile region

[0079] 120 longitudinal direction

[0080] 122 pressure side

[0081] 124 suction side

[0082] 126 rotor blade root end

[0083] 128 flange connection

[0084] 200 circular root part

[0085] 202 access hole

[0086] 204 circumference

[0087] 206 excess material

[0088] 208 circular outer contour

[0089] 300 dressing device

[0090] 302 support structure

[0091] 304 frame

[0092] 306 web

[0093] 307 upper horizontal web

[0094] 308 worktable

[0095] 310 roller bearing

[0096] 312 lower surface

[0097] 314 electric drive

[0098] 316 electric motor

[0099] 318 motor shaft

[0100] 320 dressing tool

[0101] 322 holder

[0102] 324 centering device

[0103] 326 upper surface

[0104] 328 protrusion

[0105] 330 fixing device

[0106] 332 clamp

[0107] 334 vacuum device

[0108] 336 suction cup

[0109] 338 vacuum pump

[0110] 340 conduit

[0111] C center

[0112] H horizontal direction

[0113] V vertical direction

[0114] S1-S4 steps

Claims

1. A trimming device (300) for trimming a prefabricated circular root component (200) for use as a wind turbine rotor blade (110), the trimming device (300) comprising: Support structure (302). A worktable (308) is rotatably supported on the support structure (302) and configured to support the prefabricated circular root component (200). A trimming tool (320) is fixed to the support structure (302) and configured to trim the circular root component (200) along its periphery (204) when the circular root component (200) is supported on the worktable (308), specifically removing excess material.

2. The trimming device (300) according to claim 1, wherein, The supporting structure (302) is a frame (304), particularly a metal frame.

3. The trimming device (300) according to any one of the preceding claims, wherein, The support structure (302) includes one or more roller bearings (310) for supporting the worktable (308).

4. The trimming device (300) according to claim 3, wherein, The roller bearing (310) is a ball conveying unit.

5. The trimming device (300) according to claim 3 or 4, wherein, The roller bearing is disposed on the web (306) of the support structure (302), the web (306) extending parallel to the lower surface (312) of the worktable (308).

6. The trimming device (300) according to any one of the preceding claims, wherein, The support structure (302) includes an electric actuator (314) arranged to rotate the worktable (308).

7. The trimming device (300) according to any one of the preceding claims, wherein, The worktable (308) includes a centering device (324) for centrally positioning the circular root component (200) on the upper surface (326) of the worktable (308).

8. The trimming device (300) according to claim 7, wherein, The centering device (324) is one or more marks applied to the worktable (308).

9. The trimming device (300) according to claim 7, wherein, The centering device (324) is one or more protrusions (328) located on the worktable (308), which are used to interact with one or more openings or recesses of the circular root component (200).

10. The trimming device (300) according to claim 9, wherein, The one or more protrusions (328) are adapted to interact with one or more access holes (202) provided in the circular root component (200).

11. The trimming device (300) according to any one of the preceding claims, wherein, The workbench (308) includes a fixing device (330) for holding the circular root component (200) in a fixed position on the workbench (308).

12. The trimming device (300) according to claim 12, wherein, The fixing device (330) is designed as one or more clamps (332), particularly toggle clamps.

13. The trimming device (300) according to claim 12, wherein, The fixing device (330) is a vacuum device (334), which includes one or more suction cups (336) and a vacuum pump (338) configured to generate negative pressure for fixing the circular root component (200) on the worktable (308).

14. The trimming device (300) according to any one of the preceding claims, wherein, The support structure (302) has a retainer (322) on which the trimming tool (320) is arranged and is guided in a movable manner, particularly in the horizontal (H) and / or vertical (V) directions.

15. A method for manufacturing a circular root component (200) for use in a wind turbine rotor blade (110), the method comprising the steps of: Provide a trimming device (300) according to any one of the preceding claims. Prefabricated circular root components (200) are provided. The round root component (200) is mounted on the rotatable worktable (308) of the trimming device (300). The worktable (308) is rotated together with the circular root component (200), thereby trimming the circular root component at its periphery (204) by the trimming tool (320).

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