Wind power mixed tower pipe piece manufacturing plant and wind power mixed tower pipe piece manufacturing method using same

Abstract

The application discloses a wind power mixed tower pipe piece manufacturing plant and a wind power mixed tower pipe piece manufacturing method using the same. The plant comprises one or more pipe piece molds, a base material supply device for supplying flowable pipe piece base materials, and one or more primary hoppers and secondary hoppers. The base material supply device, the primary hoppers and the secondary hoppers are sequentially connected and movable. Each primary hopper is arranged in correspondence with one or more secondary hoppers. Each secondary hopper can be moved to be connected with at least one pipe piece mold to pour the pipe piece base materials from the base material supply device into the pipe piece mold. In this way, the "mold fixed and production device moved" arrangement avoids the risk of full-line production stoppage caused by the frequent failure of the production line carrying heavy mold equipment, and reduces the investment in fixed equipment. Further, the arrangement also realizes the movable one-to-many pouring of the base material supply device and the pipe piece mold. In addition, the equipment and the hoppers can be flexibly configured according to the production requirements.

Description

Technical Field

[0001] This invention relates to the field of wind power generation, and in particular to a wind power hybrid tower segment manufacturing plant and a method for manufacturing wind power hybrid tower segments using the same. Background Technology

[0002] Wind power, as a clean energy source, is increasingly widely used. With the continuous increase in wind turbine power and rotor diameter, tower height is also increasing. Currently, to overcome the disadvantages of traditional all-steel towers, such as high steel consumption and poor economic efficiency, steel-concrete hybrid towers (referred to as "hybrid towers") are increasingly being adopted. These towers use prefabricated concrete lower sections and steel upper sections. The concrete tower section is constructed from multiple prefabricated concrete segments transported to the site for assembly.

[0003] Currently, there are two main methods for the prefabrication of concrete tunnel segments:

[0004] like Figure 1 As shown, the first method is a fixed production method, in which all segment molds 1' are fixed on the ground, leaving a transport channel 3', and the hopper is hoisted by a crane 2' to pour concrete into each segment mold 1' in sequence. This method has low investment and fast site turnover, but it has significant disadvantages: First, each segment pouring process will continuously occupy one crane 2', and the production capacity is heavily dependent on the number of cranes 2'; second, there are usually no steam curing facilities, especially in low temperature environments, the early strength growth of concrete is slow, and the turnover efficiency of segment molds 1' is low.

[0005] like Figure 2As shown, the second method is a mobile production line for segment molds. All segment molds are placed on track 4', leaving a transport channel 3'. Fixed workstations are set up according to the production process (such as steel cage installation, pouring, curing, etc. The example sets up the following workstations: post-pouring mold 111', post-demolding mold 112', pouring workstation 121', finishing workstation 122', mold closing workstation 123', embedded part installation workstation 124', steel cage installation workstation 125', release agent application workstation 126', mold cleaning workstation 127', demolding workstation 128', heating zone workstation 131', constant temperature zone workstation 132', cooling zone workstation 133'). The segment molds move on track 4' at regular intervals, passing through each workstation in sequence, and a special fixed curing kiln 5' is built for steam curing. This method improves production efficiency, but its disadvantages are also prominent: 1) It requires huge investment, including the construction of a fixed curing kiln 5', the laying of heavy-duty tracks 4' and supporting equipment foundations. Moreover, it is difficult to relocate and reuse the equipment after the project is completed, making cost amortization difficult; 2) The system has poor reliability. Because it needs to drive the movement of the segment mold group weighing tens of tons, the transmission system of track 4' has a large load and is prone to damage. If any part fails, it may lead to a complete shutdown of the production line; 3) The temperature zone control effect in the curing kiln 5' is not good. It is difficult to effectively isolate the heating, constant temperature and cooling zones, making it difficult to accurately execute the curing process. Summary of the Invention

[0006] The technical problem to be solved by the present invention is to overcome the defects of low production turnover efficiency or high investment and poor reliability in the existing technology for manufacturing wind power hybrid tower segments, and to provide a wind power hybrid tower segment manufacturing plant and a wind power hybrid tower segment manufacturing method using the same.

[0007] The present invention solves the above-mentioned technical problems through the following technical solution:

[0008] A wind turbine hybrid tower segment manufacturing plant includes one or more segment molds and a substrate supply device for supplying flowable segment substrate.

[0009] The wind power hybrid tower segment manufacturing plant also includes a primary hopper and a secondary hopper;

[0010] The substrate supply equipment, the primary hopper, and the secondary hopper are sequentially connected and all are movable;

[0011] Each of the primary hoppers is provided with one or more secondary hoppers;

[0012] Each of the secondary hoppers is movable to communicate with at least one of the segment molds to cast the segment substrate from the substrate supply equipment into the segment mold.

[0013] This technical solution provides a wind turbine hybrid tower segment manufacturing plant that adopts a "fixed mold, mobile production equipment" setup. This avoids the risk of production line shutdowns caused by the malfunction of heavy mold-carrying equipment in mobile mold assembly line production, and also reduces investment in fixed equipment. Furthermore, the plant enables mobile one-to-many casting of the substrate supply equipment and segment molds, solving the problem of a single mold occupying the substrate supply equipment for too long in fixed production methods. Moreover, the flexible configuration of the substrate supply equipment, primary hopper, and secondary hopper allows for flexible scheduling of the segment substrate and adjustment of the segment manufacturing speed according to production needs. These features collectively improve the stability, efficiency, and flexibility of segment manufacturing, while reducing manufacturing costs.

[0014] Preferably, the wind power hybrid tower segment manufacturing plant further includes a first enclosure device, which is movable;

[0015] The first enclosure device is used to protect the segment mold.

[0016] In this technical solution, the aforementioned setup allows for partial enclosure of the mold being poured during the segment substrate casting process, effectively isolating the external environment from the pouring operation and ensuring pouring quality. Enclosing the mold being poured and adjacent molds expands the working space, providing a more comfortable working environment for workers or providing preparation space for subsequent operations, thus improving the continuity and convenience of the work. The movable enclosure device allows for on-demand allocation of protective resources, avoiding the cost waste associated with configuring fixed enclosure structures for all molds.

[0017] Preferably, the wind power hybrid tower segment manufacturing plant further includes a second enclosure device, which is movable;

[0018] The second enclosure device is used to enclose the segment mold and provide a barrier for steam.

[0019] In this technical solution, the above-mentioned setup enables localized and movable steam curing of the mold for the cast-in-place segment substrate, which can accelerate the early strength growth of concrete, improve mold turnover efficiency, and has simple structural requirements, low cost, and can be flexibly moved to any mold location that needs curing, thereby improving equipment utilization and production flexibility.

[0020] Preferably, the wind power hybrid tower segment manufacturing plant also includes a steam supply pipeline;

[0021] Multiple segments mold arrays are arranged;

[0022] The steam supply pipe extends along the arrangement direction of each of the segment molds, and has multiple steam supply ports in the extending direction;

[0023] Each of the steam supply ports can be detachably connected to the second enclosure.

[0024] In this technical solution, the above-mentioned setup provides a convenient and reliable steam supply point for the movable second enclosure device, enabling it to connect to a steam source at any time and ensuring the continuity and independence of the maintenance operation. Since each steam supply port can be controlled independently, the maintenance parameters within each second enclosure device can be adjusted independently without interference, providing a hardware foundation for achieving precise, stepped maintenance.

[0025] Preferably, the second enclosure includes a temperature sensor for sensing the temperature inside the second enclosure.

[0026] In this technical solution, the above settings enable real-time and accurate monitoring of the temperature inside the enclosure device. This allows for precise control of the steam input based on the preset curing process, achieving accurate temperature control and improving the curing quality and consistency of technical indicators for the pipe segments.

[0027] Preferably, the wind power hybrid tower segment manufacturing plant further includes a first enclosure device and a second enclosure device, both of which are movable;

[0028] The first enclosure device has a first peripheral enclosure structure that can be switched between an deployed state and a retracted state;

[0029] When the first perimeter enclosure structure is in the deployed state, the first enclosure device can protect at least one of the segment molds.

[0030] When the first perimeter enclosure structure is in the retracted state, the second enclosure device can pass through the gap between the first enclosure device and the segment mold.

[0031] In this technical solution, the above-mentioned arrangement enables the movable first enclosure device and the second enclosure device to form a structural nesting relationship. After the first enclosure device is retracted, space is made up for the movement and positioning of the second enclosure device, which facilitates the coordinated work and rapid switching of pouring protection and steam curing, thereby improving space utilization and work efficiency.

[0032] Preferably, the second enclosure device has a second circumferential enclosure structure that can be switched between an deployed state and a retracted state;

[0033] When the second perimeter enclosure structure is in the deployed state, the second enclosure device can protect at least one of the segment molds;

[0034] When the second perimeter enclosure structure is in the retracted state, the secondary hopper can pass through the gap between the second enclosure device and the segment mold.

[0035] In this technical solution, the above-mentioned settings further optimize the collaborative workflow between equipment. After the segment substrate is poured, the secondary hopper needs to be removed, while the second enclosure device needs to be in place for curing. At this time, switching the second perimeter enclosure structure to the retracted state provides a passage for the removal of the secondary hopper, further facilitating the coordinated work and rapid switching between pouring protection and steam curing.

[0036] A method for manufacturing wind turbine hybrid tower segments, which adopts the wind turbine hybrid tower segment manufacturing plant as described above;

[0037] The steps of the wind power hybrid tower segment manufacturing method include:

[0038] S1. Set up each of the segment molds and prepare for casting on the segment molds;

[0039] S2. Move the substrate supply equipment, the primary hopper, and the secondary hopper so that each of the secondary hoppers can be connected to at least one of the tube sheet molds;

[0040] S3. The segment substrate is poured from the substrate supply equipment into the segment mold;

[0041] Repeat steps S2 and S3 to cast the segment substrate into other segment molds until all segment molds have been cast.

[0042] This technical solution provides a method for manufacturing wind turbine hybrid tower segments, achieving a "fixed mold, mobile equipment" assembly line production. This avoids the risk of production line shutdown due to malfunctions of heavy mold-carrying equipment in mobile mold assembly line production, and also reduces investment in fixed equipment. Furthermore, the plant allows for mobile one-to-many casting of the substrate supply equipment and segment molds, solving the problem of a single mold occupying the substrate supply equipment for too long in fixed production methods. Moreover, the flexible configuration of the substrate supply equipment, primary hopper, and secondary hopper allows for flexible scheduling of the segment substrate and adjustment of the segment manufacturing speed according to production needs. These features collectively improve the stability, efficiency, and flexibility of segment manufacturing, while reducing manufacturing costs.

[0043] Preferably, the wind power hybrid tower segment manufacturing plant further includes a first enclosure device, which is movable;

[0044] Step S2 also includes:

[0045] S21: Move the first enclosure device so that it can protect the segment mold to which the segment substrate will be cast; or...

[0046] Move the first enclosure device so that it can protect the segment mold on which the segment substrate is being poured, and other adjacent segment molds.

[0047] In this technical solution, the above-mentioned setup provides flexible local protection for concrete pouring operations by utilizing a movable first enclosure device, thereby improving the quality of the pouring operation and the comfort of the workers.

[0048] Preferably, the wind power hybrid tower segment manufacturing plant further includes a second enclosure device, which is movable;

[0049] Step S2 also includes:

[0050] S22: Move the second enclosure device so that it can enclose the segment mold on which the segment substrate has been cast and provide steam curing to the condensing segment substrate.

[0051] In this technical solution, by using the above-mentioned setup, a movable second enclosure device is used to protect and steam-cur the poured mold, which can accelerate the early strength growth of concrete, improve the mold turnover efficiency, and has simple structural requirements, low cost, and can be flexibly moved to any mold location that needs curing, thereby improving equipment utilization and production flexibility.

[0052] The positive and progressive effects of this invention are as follows:

[0053] By providing a wind turbine hybrid tower segment manufacturing plant that adopts a "fixed mold, mobile production equipment" setup, the risk of production line shutdown due to malfunctions of heavy mold-carrying equipment, common in mobile mold assembly line production, is avoided, and fixed equipment investment is reduced. Furthermore, the plant enables mobile one-to-many casting of substrate supply equipment and segment molds, solving the problem of a single mold occupying substrate supply equipment for too long in fixed production methods. Moreover, the flexible configuration of the substrate supply equipment, primary hopper, and secondary hopper allows for flexible scheduling of substrate materials and adjustment of segment manufacturing speed according to production needs. These features collectively improve the stability, efficiency, and flexibility of segment manufacturing, while reducing manufacturing costs.

[0054] This invention provides a method for manufacturing wind turbine hybrid tower segments, achieving a streamlined production line with "fixed molds and mobile equipment." This avoids the risk of production line shutdowns caused by the malfunction of heavy mold-carrying equipment in mobile mold-based production lines, and also reduces investment in fixed equipment. Furthermore, the plant allows for mobile one-to-many casting of the substrate supply equipment and segment molds, solving the problem of a single mold occupying the substrate supply equipment for too long in fixed production methods. Moreover, the flexible configuration of the substrate supply equipment, primary hopper, and secondary hopper allows for flexible scheduling of the segment substrate and adjustment of the segment manufacturing speed according to production needs. These features collectively improve the stability, efficiency, and flexibility of segment manufacturing, while reducing manufacturing costs. Attached Figure Description

[0055] Figure 1 This is a schematic diagram of the factory layout for a fixed manufacturing method in the prior art.

[0056] Figure 2 This is a schematic diagram of the factory layout for a mold-moving assembly line manufacturing method in the prior art.

[0057] Figure 3 This is a schematic diagram of the layout of a wind power hybrid tower segment manufacturing plant according to an embodiment of the present invention.

[0058] Figure 4 for Figure 3 A magnified view of part A.

[0059] Figure 5 This is a flowchart of a method for manufacturing wind power hybrid tower segments according to an embodiment of the present invention.

[0060] Figure 6 This is a schematic diagram showing the connection relationship between the second enclosure device and the steam supply pipeline according to an embodiment of the present invention.

[0061] Explanation of reference numerals in the attached figures:

[0062] exist Figure 1 , Figure 2 middle:

[0063] Segment mold 1'

[0064] Post-pouring mold 111'

[0065] Mold 112' after demolding

[0066] Pouring station 121'

[0067] Dough finishing station 122'

[0068] Mold closing station 123'

[0069] Installation station 124'

[0070] Reinforcing cage installation station 125'

[0071] Station 126' for applying release agent

[0072] Mold cleaning station 127'

[0073] Demolding station 128'

[0074] Heating Zone Station 131'

[0075] Temperature control station 132'

[0076] Cooling area workstation 133'

[0077] Driving 2'

[0078] Transport Channel 3'

[0079] Orbit 4'

[0080] Kiln curing 5'

[0081] exist Figure 3 , Figure 4 , Figure 6 middle:

[0082] Segment mold 1

[0083] Substrate supply equipment 2

[0084] Transport Channel 3

[0085] Orbit 41

[0086] Secondary orbit 42

[0087] Primary hopper 61

[0088] Discharge port 611

[0089] Secondary hopper 62

[0090] First enclosure device 71

[0091] Second enclosure device 72

[0092] Steam supply pipeline 8

[0093] Steam supply port 81

[0094] Hose 82

[0095] First valve 83

[0096] Second valve 84 Detailed Implementation

[0097] The present invention will be further illustrated by way of embodiments below, but the present invention is not limited to the scope of the embodiments.

[0098] like Figure 3 , Figure 4 As shown, this embodiment provides a wind power hybrid tower segment manufacturing plant, which includes one or more segment molds 1 and a substrate supply device 2 for supplying flowable segment substrate. In this embodiment, the substrate supply device 2 is a crane, which can pour the substrate (concrete in this embodiment) from the storage tank (not shown in the figure) transported through the transport channel 3.

[0099] The wind power hybrid tower segment manufacturing plant also includes a primary hopper 61 and a secondary hopper 62; the substrate supply equipment 2, the primary hopper 61 and the secondary hopper 62 are connected in sequence and are all movable; each primary hopper 61 is provided with one or more secondary hoppers 62; each secondary hopper 62 can be moved to connect to at least one segment mold 1 to pour the segment substrate from the substrate supply equipment 2 into the segment mold 1.

[0100] This "fixed mold, mobile production equipment" setup avoids the risk of production line shutdowns caused by the malfunction of heavy mold-carrying equipment in mobile mold production lines, and also reduces investment in fixed equipment. Furthermore, the plant allows for mobile one-to-many casting of the substrate supply equipment 2 and the segment mold 1, solving the problem of a single mold occupying the substrate supply equipment 2 for too long in fixed production methods. Moreover, the flexible configuration of the substrate supply equipment 2, the primary hopper 61, and the secondary hopper 62 allows for flexible scheduling of the segment substrate and adjustment of the segment manufacturing speed according to production needs. These features collectively improve the stability, efficiency, and flexibility of segment manufacturing, while reducing manufacturing costs.

[0101] Specifically, in this embodiment, the segment molds 1 are arranged into m rows and n columns according to the number of segment molds 1 and the length of the factory building. m is generally 2 to 5; n is generally 10 to 20.

[0102] The center of the segment mold 1 is aligned in both the row and column; a net distance of 1.5m to 3m is left between adjacent rows of segment molds 1.

[0103] A primary hopper 61 is provided between two adjacent rows of segment molds 1. The bottom of the primary hopper 61 is equipped with rollers, and a primary track 41 is provided on the ground. The primary track 41 is along the column direction of the segment molds 1, and the primary hopper 61 can slide along the primary track 41. Two independent discharge ports 611 are provided on both sides of the primary hopper 61.

[0104] Each row of segment molds 1 is equipped with two independent secondary hoppers 62. The bottom of the secondary hoppers 62 is equipped with rollers, and a secondary track 42 is provided on the ground. The secondary track 42 is along the column direction of the segment molds 1, and the secondary hoppers 62 can slide along the track. The discharge port of the secondary hoppers 62 (not shown in the figure) is rectangular, and its length is 200~800mm shorter than the width of the segment molds 1. The bottom of the discharge port of the secondary hoppers 62 is 200~600mm higher than the highest point of the segment molds 1.

[0105] In this way, by setting up a primary hopper 61 and a secondary hopper 62, two to four segment molds 1 can be cast simultaneously, improving casting efficiency. In addition, since the primary hopper 61 can be set with a large storage capacity, the crane can perform other work while casting, reducing the demand on the crane.

[0106] Furthermore, since the equipment investment of traditional assembly lines is eliminated, and the enclosure device can be made with commonly used steel pipes and sandwich panels, the cost is low, which greatly reduces the initial investment and increases the speed of production.

[0107] Furthermore, since there is no assembly line equipment, the impact of downtime caused by equipment failure is avoided, which can ensure the continuity and reliability of production.

[0108] In this embodiment, the wind turbine hybrid tower segment manufacturing plant also includes a first enclosure device 71, which is movable; the first enclosure device 71 is used to enclose the segment mold 1. This allows for partial enclosure of the mold being poured during the segment substrate casting process, effectively isolating the external environment (such as wind, dust, and temperature changes) from the pouring operation and ensuring pouring quality. Enclosing the mold being poured and adjacent molds expands the working space, providing a more comfortable working environment for workers, or providing preparation space for subsequent operations (such as vibration and finishing), improving the continuity and convenience of the operation. The movable enclosure device allows protective resources to be allocated as needed, avoiding the cost waste of configuring fixed enclosure structures for all molds.

[0109] In this embodiment, the wind turbine hybrid tower segment manufacturing plant also includes a second enclosure device 72, which is movable. The second enclosure device 72 is used to enclose the segment mold 1 and provide a barrier for steam. In this way, the mold with the cast segment substrate can be locally and movable for steam curing, which can accelerate the early strength growth of concrete, improve the mold turnover efficiency, and has simple structural requirements, low cost, and can be flexibly moved to any mold location that needs curing, thereby improving equipment utilization and production flexibility.

[0110] In this embodiment, the wind power hybrid tower segment manufacturing plant also includes a steam supply pipeline 8; multiple segment molds 1 are arranged in an array; the steam supply pipeline 8 extends along the arrangement direction of each segment mold 1, and multiple steam supply ports 81 are provided in the extension direction; each steam supply port 81 can be detachably connected to the second enclosure device 72, thereby providing a convenient and reliable steam supply point for the movable second enclosure device 72, enabling the second enclosure device 72 to be connected to a steam source at any time, ensuring the continuity and independence of the maintenance operation. Since each steam supply port 81 can be controlled independently, the maintenance parameters (such as temperature and humidity) inside each second enclosure device 72 can be adjusted independently without interference, providing a hardware foundation for achieving precise stepped maintenance (heating, constant temperature, cooling).

[0111] Specifically, in this embodiment, a steam supply pipe 8 is set on the ground along the direction of the row of segment molds 1. A steam supply port 81 is set at the middle position of every k segment molds 1, and a valve is provided. k is generally 2 to 4.

[0112] like Figure 6 As shown, in this embodiment, the steam supply port 81 is connected via a hose 82 and a second enclosure device 72. The hose 82 is provided with at least a first valve 83 and a second valve 84, wherein the first valve 83 is used for the detachable connection of the hose 82 and the second enclosure device 72, and the opening and closing of the second valve 84 is used to control the steam supply.

[0113] In this embodiment, the second enclosure device 72 includes a temperature sensor (not shown in the figure). The temperature sensor is used to sense the temperature inside the second enclosure device 72 to monitor the temperature inside the enclosure device in real time and accurately. This allows for precise control of the steam input according to the preset curing process, achieving precise temperature control and improving the curing quality and consistency of technical indicators of the pipe segments.

[0114] In this embodiment, the first enclosure device 71 has a first peripheral enclosure structure (not shown in the figure) that can switch between an extended state and a retracted state. When the first peripheral enclosure structure is in the extended state, the first enclosure device 71 can enclose at least one segment mold 1; when the first peripheral enclosure structure is in the retracted state, the second enclosure device 72 can pass through the gap between the first enclosure device 71 and the segment mold 1. In this way, the movable first enclosure device 71 and the second enclosure device 72 form a structural nesting relationship. After the first enclosure device 71 is retracted, space is made up for the movement and positioning of the second enclosure device 72, which facilitates the coordinated work and rapid switching of casting protection and steam curing, and improves space utilization and work efficiency.

[0115] In this embodiment, the second enclosure device 72 has a second peripheral enclosure structure (not shown in the figure) that can switch between an extended state and a retracted state. When the second peripheral enclosure structure is in the extended state, the second enclosure device 72 can protect at least one segment mold 1; when the second peripheral enclosure structure is in the retracted state, the secondary hopper 62 can pass through the gap between the second enclosure device 72 and the segment mold 1. This further optimizes the collaborative workflow between the equipment. After the segment substrate is poured, the secondary hopper 62 needs to be removed, while the second enclosure device 72 needs to be in place for curing. Switching the second peripheral enclosure structure to the retracted state at this time provides a passage for the removal of the secondary hopper 62, further facilitating the coordinated work and rapid switching of pouring protection and steam curing.

[0116] In this embodiment, both the first and second perimeter enclosure structures are roller shutter doors. In other embodiments, retractable doors, hinges, or any other enclosure structure that can switch states can also be used.

[0117] Specifically, in this embodiment, each row of segment molds 1 is provided with several protective devices above it. Generally, one device is provided for every k segment molds 1, where k is generally 2 to 4. The length of the device is the total length that can contain the k segment molds 1.

[0118] The enclosure device includes at least a large-sized first enclosure device 71 and a small-sized second enclosure device 72. The width of the first enclosure device 71 is 400-1000mm wider than the second enclosure device 72, and the height of the first enclosure device 71 is 200-600mm higher than the second enclosure device 72, ensuring that the second enclosure device 72 can pass through the inside of the first enclosure device 71; the width of the second enclosure device 72 is 200-600mm wider than the aforementioned secondary hopper 62, and the height of the second enclosure device 72 is 200-600mm higher than the aforementioned secondary hopper 62, ensuring that the secondary hopper 62 can pass through the inside of the second enclosure device 72.

[0119] The aforementioned enclosure device uses a frame to manufacture its skeleton (not shown in the figure), such as a box-shaped frame welded from square steel pipes; the maintenance components use lightweight insulation materials, such as rock wool sandwich panels; and four rollers are provided at the bottom of the frame so that it can slide on the ground.

[0120] Please refer to Figure 3 The segment molds 1, when arranged in an array, have row directions and column directions. The aforementioned enclosure device is provided with roller shutters (not shown in the figure) on both sides along each row direction of the segment molds 1. In the unfolded state, the roller shutters are lowered to protect one or more segment molds 1; in the retracted state, the roller shutters are retracted to allow the enclosure device to move or be passed through by other enclosure devices.

[0121] In this embodiment, the aforementioned enclosure device is configured as a fixed structure on both sides along each column direction of the segment mold 1, and is not disassembled during movement. In other embodiments, the structures on both sides of the enclosure device along each column direction of the segment mold may also be configured as detachable.

[0122] This allows for steam curing of the segments, rapidly improving their early strength, accelerating the turnover efficiency of the segment mold 1, and increasing production efficiency. Furthermore, by setting independent enclosure devices for each segment mold 1, precise heating, constant temperature, and cooling of the segments can be achieved, significantly improving the quality of the segments.

[0123] like Figure 5 As shown, this embodiment also provides a method for manufacturing wind turbine hybrid tower segments, which adopts the wind turbine hybrid tower segment manufacturing plant as described above; the steps of the wind turbine hybrid tower segment manufacturing method include:

[0124] S1. Set up each segment mold 1 and prepare for casting on the segment mold 1;

[0125] S2, mobile substrate supply equipment 2, primary hopper 61 and secondary hopper 62, wherein each secondary hopper 62 is connected to at least one segment mold 1;

[0126] S3. Cast the segment substrate from the substrate supply equipment 2 into the segment mold 1;

[0127] Repeat steps S2 and S3 to pour the segment substrate into other segment molds 1 until all segment molds 1 have been poured.

[0128] This achieves a "fixed mold, mobile equipment" assembly line production, avoiding the risk of production line shutdown due to malfunctions of heavy mold-carrying equipment in mobile mold assembly lines, and reducing investment in fixed equipment. Furthermore, the plant allows for mobile one-to-many casting of the substrate supply equipment 2 and the segment mold 1, solving the problem of a single mold occupying the substrate supply equipment 2 for too long in fixed production methods. Moreover, the flexible configuration of the substrate supply equipment 2, the primary hopper 61, and the secondary hopper 62 allows for flexible scheduling of the segment substrate and adjustment of the segment manufacturing speed according to production needs. These features collectively improve the stability, efficiency, and flexibility of segment manufacturing, while reducing manufacturing costs.

[0129] In this embodiment, the wind power hybrid tower segment manufacturing plant also includes a first enclosure device 71, which is movable; step S2 further includes:

[0130] S21: Move the first enclosure device 71 so that it can protect the segment mold 1 to which the segment substrate is to be poured; or...

[0131] Move the first protective device 71 so that it can protect the segment mold 1 on which the segment substrate is being poured and other adjacent segment molds 1.

[0132] In this way, the movable first enclosure device 71 provides flexible local protection for concrete pouring operations, improving the quality of the pouring operation and the comfort of the workers.

[0133] In this embodiment, the wind power hybrid tower segment manufacturing plant also includes a second enclosure device 72, which is movable; step S2 further includes:

[0134] S22: Move the second enclosure device 72 so that the second enclosure device 72 can protect the segment mold 1 of the cast segment substrate and provide steam curing for the condensing segment substrate.

[0135] In this way, by using the movable second enclosure device 72 to enclose and steam-cur the poured mold, the early strength growth of concrete can be accelerated, the turnover efficiency of mold can be improved, and the structure is simple, the cost is low, and it can be flexibly moved to any mold location that needs curing, thereby improving the utilization rate of equipment and the flexibility of production.

[0136] In this embodiment, concrete segments can be manufactured specifically as follows:

[0137] Transport the steel cage from the steel reinforcement workshop to the segment production workshop;

[0138] The roller shutters on both sides of the first enclosure device 71 in a certain row are retracted and moved to the top of the adjacent segment mold 1 that needs to be poured in the segment mold 1 in that row.

[0139] Open the cover plate of two adjacent segment molds 1 in a row, use a crane to lift the steel cage into the segment mold 1, install the relevant embedded parts, and close the cover plate after inspection and approval;

[0140] Move the primary hopper 61 to the middle position of the two segment molds 1, and move the two independent secondary hoppers 62 to the middle of the two segment molds 1 respectively. All discharge ports 611 are closed.

[0141] The transport vehicle transports the concrete from the mixing plant to the segment production workshop using a storage tank, and the overhead crane pours all the concrete from the storage tank into the primary hopper 61.

[0142] Open the two discharge ports 611 of the primary hopper 61 and pour the concrete into the two secondary hoppers 62 respectively;

[0143] Open the discharge port 611 of the secondary hopper 62 and pour the concrete into the segment mold 1;

[0144] According to the specifications, every 30-50cm of concrete poured should be vibrated to ensure it is compacted before pouring more concrete. This process should be repeated until the two concrete segments are completed.

[0145] Move the primary hopper 61 and the secondary hopper 62 to the two adjacent uncast segment molds 1 to cast the two concrete segments; as needed, only one concrete segment can be cast at a time.

[0146] Raise the roller shutters on both sides of the smallest enclosure and move them above the already cast segment mold 1.

[0147] Lower the roller shutters on both sides of the enclosure and open the valves;

[0148] Based on the temperature displayed by the temperature sensor, adjust the amount of steam entering to ensure that the temperature inside the enclosure is strictly in accordance with the curing process;

[0149] Continue pouring the other segments in the same row of molds and then curing them;

[0150] When the maintenance period is over, close the valves on the enclosure device;

[0151] Retract the roller shutters on both sides of the enclosure;

[0152] Move the enclosure to the other side;

[0153] Open the cover plate of segment mold 1, hoist the segment to the transport vehicle, transport it to the storage yard for later curing, and transport it to the wind farm after it reaches the factory strength.

[0154] Specifically, the manufacturing scheme for the wind turbine hybrid tower segments of a certain wind turbine hybrid tower project is as follows:

[0155] There are 48 segment molds 1, which are planned to be arranged in a workshop that is 120m long and 36m wide. The segment mold 1 adopts a horizontal casting method. The maximum size of the segment mold 1 is 6m × 3.5m, and the maximum height of the segment mold 1 is 1.9m.

[0156] Based on the number of segment molds 1 and the length of the factory building, the segment molds 1 are arranged into 4 rows and 12 columns, as follows: Figure 3 As shown. The centers of the aforementioned segment molds 1 are aligned in both rows and columns. The first and second rows of segment molds 1 are located on one side of the factory building, while the third and fourth rows of segment molds 1 are located on the other side. The transport channel 3 is located in the middle of the factory building. The net distance between the first row of segment molds 1 and the edge of the factory building is 1.9m, and the net distance between the first row of segment molds 1 and the second row of segment molds 1 is 4.2m.

[0157] A primary hopper 61 is provided between the first row of segment molds 1 and the second row of segment molds 1, and between the third row of segment molds 1 and the fourth row of segment molds 1. The primary hopper 61 is equipped with rollers at its bottom, and a primary track 41 is provided on the ground. The primary track 41 is arranged along the column direction of the segment molds 1, and the primary hopper 61 can slide along the primary track 41. Four independent discharge ports 611 are provided on both sides of the primary hopper 61, and the discharge ports 611 can be rotated.

[0158] Each row of segment mold 1 is equipped with two independent secondary hoppers 62. The bottom of the secondary hopper 62 is equipped with rollers, and a secondary track 42 is provided on the ground. The secondary track 42 is arranged along the column direction of the segment mold 1, and the secondary hopper 62 can slide along the secondary track 42. The discharge port of the secondary hopper 62 is rectangular, with a length of 3200mm and a width of 800mm. The bottom height of the discharge port of the secondary hopper 62 is 2.2m, and the top height is 3.1m.

[0159] Four protective devices are provided above each row of segment molds 1, that is, one protective device is used for every three segment molds 1; the protective devices are provided in two specifications, wherein the first protective device 71 is 22m long, 6.1m wide and 3.9m high; the second protective device 72 is 22m long, 5.3m wide and 3.5m high; the first protective device 71 and the second protective device 72 are arranged alternately in the column direction of the segment molds 1.

[0160] The secondary hopper 62 can pass through the inside of the first enclosure device 71; the first enclosure device 71 can pass through the inside of the second enclosure device 72.

[0161] The aforementioned enclosure frame is constructed by welding square steel pipes into a box-shaped frame; the maintenance components are made of rock wool sandwich panels.

[0162] The frame of the aforementioned enclosure device is equipped with four rollers at the bottom, allowing it to slide on the ground;

[0163] The aforementioned enclosure device has roller shutter doors on both sides of the first row of the segment mold;

[0164] The aforementioned enclosure device has a steam supply port 81 in the direction of the first row of the segment mold, and is equipped with a valve;

[0165] A steam supply pipe 8 is installed on the ground along the direction of the segment mold 1. A steam supply port 81 is installed at the middle position of every three segment molds 1, and a valve is provided.

[0166] Concrete tunnel segments are manufactured using the following method, taking mold 1 for the second row of tunnel segments as an example:

[0167] Transport the steel cage from the steel reinforcement workshop to the segment production workshop;

[0168] Raise the roller shutters on both sides of the first enclosure device 71 and move them above the 4th to 6th segment molds 1 in the second row;

[0169] Open the cover plates of the first and second segment molds 1 in the second row, use a crane to lift the steel cage into the segment mold 1, install the relevant embedded parts, and close the cover plates after inspection and approval (*).

[0170] Move the primary hopper 61 between the first and second row segment molds 1 to the middle position of the two segment molds 1, and move the two independent secondary hoppers 62 to the middle of the first and second segment molds 1 respectively, with all discharge ports 611 in the closed state.

[0171] The transport vehicle transports the concrete from the mixing plant to the segment production workshop using a storage tank. It then delivers the concrete to the designated location via transport channel 3 and uses a crane to pour all the concrete from the storage tank into the primary hopper 61.

[0172] Open the two discharge ports 611 of the primary hopper 61 located on the side of the second row of segment mold 1, and pour the concrete into the two secondary hoppers 62 respectively;

[0173] Open the discharge port 611 of the secondary hopper 62 and pour the concrete into the segment mold 1;

[0174] According to the specifications, every 30-50cm of concrete poured should be vibrated and compacted before pouring more concrete. This process is repeated until the first and second segments of the segment mold 1 are poured.

[0175] Move the primary hopper 61 and the secondary hopper 62 to the third segment mold 1. At this time, simply open one discharge port 611 of the primary hopper 61 to pour concrete into the segment mold 1 and pour the segments of the third segment mold 1.

[0176] Before the initial setting of the tunnel lining segments, the outer surface of the segments is smoothed and finished.

[0177] Move the first enclosure device 71 above the first to third segment molds 1;

[0178] Lower the roller shutters on both sides of the enclosure and open the valves;

[0179] Based on the temperature displayed by the temperature sensor, adjust the amount of steam entering to ensure that the temperature inside the enclosure is strictly in accordance with the curing process (**).

[0180] Raise the roller shutters on both sides of the second enclosure device 72 and move them above the first to third segment molds 1 in the second row;

[0181] Repeat steps (*) to (**) to continue pouring concrete for the 4th to 6th segments of the 2nd row of the tunnel lining mold 1, and then cure them.

[0182] Repeat the above steps to pour concrete segments for all segments in mold 1 of the second row;

[0183] When the maintenance period is over, close the valves on the enclosure device;

[0184] Retract the roller shutters on both sides of the first enclosure device 71; move the first enclosure device 71 onto the 4th to 6th segment mold 1;

[0185] Open the cover plate of segment mold 1, hoist the segment to the transport vehicle, transport it to the storage yard for later curing, and transport it to the wind farm after it reaches the factory strength.

[0186] While specific embodiments of the present invention have been described above, those skilled in the art should understand that these are merely illustrative examples, and the scope of protection of the present invention is defined by the appended claims. Those skilled in the art can make various changes or modifications to these embodiments without departing from the principles and essence of the present invention, but all such changes and modifications fall within the scope of protection of the present invention.

Claims

1. A wind turbine hybrid tower segment manufacturing plant, comprising one or more segment molds and a substrate supply device for supplying flowable segment substrate, characterized in that: The wind power hybrid tower segment manufacturing plant also includes a primary hopper and a secondary hopper; The substrate supply equipment, the primary hopper, and the secondary hopper are connected in sequence and are all movable; Each of the primary hoppers is provided with one or more secondary hoppers; Each of the secondary hoppers is movable to communicate with at least one of the segment molds to cast the segment substrate from the substrate supply equipment into the segment mold.

2. The wind power hybrid tower segment manufacturing plant as described in claim 1, characterized in that, The wind power hybrid tower segment manufacturing plant also includes a first enclosure device, which is movable; The first enclosure device is used to protect the segment mold.

3. The wind power hybrid tower segment manufacturing plant as described in claim 1, characterized in that, The wind power hybrid tower segment manufacturing plant also includes a second enclosure device, which is movable; The second enclosure device is used to enclose the segment mold and provide a barrier for steam.

4. The wind power hybrid tower segment manufacturing plant as described in claim 3, characterized in that, The wind power hybrid tower segment manufacturing plant also includes steam supply pipelines; Multiple segments mold arrays are arranged; The steam supply pipe extends along the arrangement direction of each of the segment molds, and has multiple steam supply ports in the extending direction; Each of the steam supply ports can be detachably connected to the second enclosure.

5. The wind power hybrid tower segment manufacturing plant as described in claim 3, characterized in that, The second enclosure includes a temperature sensor for sensing the temperature inside the second enclosure.

6. The wind power hybrid tower segment manufacturing plant as described in claim 1, characterized in that, The wind power hybrid tower segment manufacturing plant also includes a first enclosure device and a second enclosure device, both of which are movable; The first enclosure device has a first peripheral enclosure structure that can be switched between an deployed state and a retracted state; When the first perimeter enclosure structure is in the deployed state, the first enclosure device can protect at least one of the segment molds. When the first perimeter enclosure structure is in the retracted state, the second enclosure device can pass through the gap between the first enclosure device and the segment mold.

7. The wind power hybrid tower segment manufacturing plant as described in claim 6, characterized in that, The second enclosure device has a second circumferential enclosure structure that can be switched between an deployed state and a retracted state; When the second perimeter enclosure structure is in the deployed state, the second enclosure device can protect at least one of the segment molds; When the second perimeter enclosure structure is in the retracted state, the secondary hopper can pass through the gap between the second enclosure device and the segment mold.

8. A method for manufacturing wind turbine hybrid tower segments, characterized in that, It adopts the wind power hybrid tower segment manufacturing plant as described in any one of claims 1-7; The steps of the wind power hybrid tower segment manufacturing method include: S1. Set up each of the segment molds and prepare for casting on the segment molds; S2. Move the substrate supply equipment, the primary hopper, and the secondary hopper so that each of the secondary hoppers can be connected to at least one of the tube sheet molds; S3. The segment substrate is poured from the substrate supply equipment into the segment mold; Repeat steps S2 and S3 to cast the segment substrate into other segment molds until all segment molds have been cast.

9. The method for manufacturing wind power hybrid tower segments as described in claim 8, characterized in that, The wind power hybrid tower segment manufacturing plant also includes a first enclosure device, which is movable; Step S2 also includes: S21: Move the first enclosure device so that it can protect the segment mold to which the segment substrate will be cast; or... Move the first enclosure device so that it can protect the segment mold on which the segment substrate is being poured, and other adjacent segment molds.

10. The method for manufacturing wind power hybrid tower segments as described in claim 8, characterized in that, The wind power hybrid tower segment manufacturing plant also includes a second enclosure device, which is movable; Step S2 also includes: S22: Move the second enclosure device so that it can enclose the segment mold on which the segment substrate has been cast and provide steam curing to the condensing segment substrate.

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