A platform vehicle for cutting waste fan blades

Abstract

This utility model proposes a platform vehicle for cutting waste wind turbine blades, comprising: a mounted bearing (17): including a rolling bearing and a bearing housing, fixed to the vehicle body by bolts; a roller conveyor (24) for bearing radial loads to achieve transportation, with the mounted bearing (17) supporting the rotating shaft of the roller conveyor (24); and a cross coupling (19) for connecting the drive shaft and the roller conveyor shaft, transmitting torque, and compensating for axial and radial offsets caused by installation errors or vibrations. This utility model, through modular design, intelligent control, and integration of environmental protection technologies, achieves efficient and green processing of waste wind turbine blades, providing a complete solution for the sustainable operation of the wind power industry.

Description

Technical Field

[0001] This utility model belongs to the field of wind turbine blade technology, specifically relating to a waste wind turbine blade cutting device. Background Technology

[0002] The global wind power industry is developing rapidly, leading to a surge in the retirement of wind turbine blades. These blades are primarily composed of glass fiber / carbon fiber reinforced thermosetting resins (such as epoxy resin), which are difficult to degrade naturally after curing. Existing recycling technologies require material separation through cutting and decomposition, but the irreversible bonding between the thermosetting resin and the fiber results in a decline in the performance of the recycled fibers (e.g., mechanical crushing methods cause a strength loss of over 50%), and also result in low economic value.

[0003] Existing wind turbine blade cutting technologies suffer from the following technical problems: 1. Efficiency and safety issues with manual cutting: Traditional methods rely on manual operation of large saws, requiring multiple operators, resulting in severe dust pollution, poor cutting consistency, and safety risks such as blade deformation and flying debris. Furthermore, these methods cannot meet the demands of large-scale processing. 2. Limitations of stationary equipment: Existing cutting equipment is mostly stationary, requiring blades to be transported to centralized processing plants. However, wind farms are often located in remote areas, with blade lengths exceeding 60 meters (some reaching 100 meters), leading to high transportation costs and the need for multiple machines to process sections, resulting in high overall costs. 3. Insufficient environmental friendliness: The cutting process generates large amounts of dust and wastewater, and current technologies lack efficient purification methods. 4. Insufficient adaptability of cutting processes: The blade structure is complex, consisting of three parts: the root (hollow cylinder), the middle (asymmetrical streamlined shape), and the tip (flat solid). Existing cutting methods are difficult to adapt to the structural characteristics of different parts, easily leading to uneven cutting depth, blade deformation, or wire saw tension failure.

[0004] The patent CN119347435A, "Gantry Platform for Wind Turbine Blade Post-processing," boasts significant advantages in integration, intelligence, and environmental friendliness, making it particularly suitable for the large-scale post-processing needs of centralized wind farms. However, its integration of multiple precision machining devices (such as high-pressure water jets and scanning probes) and a three-dimensional motion system with high-precision positioning results in a unit price exceeding one million US dollars, making it unaffordable for small and medium-sized enterprises. Furthermore, the diamond cutting heads and grinding heads used in its design experience rapid wear during composite material processing, leading to high maintenance costs and low material recycling rates.

[0005] Patent CN114406351B, "Destroyed Wind Turbine Blade Recycling Device and Method," significantly improves the safety and efficiency of destroyed wind turbine blade cutting through dynamic cutting modes, self-rotation coordination technology, and modular design, particularly in its innovative approach to preventing blade deformation. However, the high cost of core components such as precision guide rails, wire saw mainframes, and self-rotation drive systems makes them unaffordable for small and medium-sized recycling companies. Furthermore, its precision components, including the ring track, movable guide wheel assembly, and tightening lateral movement mechanism, require regular calibration, resulting in high maintenance costs. These factors limit its commercial potential and make it unsuitable for the recycling needs of distributed wind farms.

[0006] Patent CN212635901U, "A Mobile Automatic Blade Root Cutting Machine for Wind Turbine Blades," significantly improves the safety and environmental friendliness of blade root cutting through modular design, automated cutting, and source dust extraction technology, making it particularly suitable for batch operations in standardized wind farms. However, its high maintenance costs, limited by factors such as the need for the cutting guide rail to be pre-installed on a flat surface or fixed support, the limitation of the diamond band saw's cutting depth by the lead screw module's stroke, the diamond band saw's susceptibility to wear and frequent replacement when cutting glass fiber, and the need for regular lubrication and calibration of the lead screw module and guide rail, restrict its widespread applicability.

[0007] Patent CN118649989A, "An Environmentally Friendly Recycling and Processing System for Wind Power Blades," is innovative in its fully enclosed cutting, multi-station synchronous operation, and dust control, making it particularly suitable for the efficient recycling of standardized blades. However, the equipment is highly complex, requiring cumbersome replacement of resin inserts during use. Precision components such as the drive shaft, guide wheels, and vacuum pump require regular calibration and lubrication, and dust easily penetrates the mechanical structure, increasing the failure rate and maintenance costs. These disadvantages limit its commercial application.

[0008] Patent CN118595126A, "Method and System for Cutting Waste Wind Turbine Blades," is innovative in terms of process system and standardized cutting, but it lacks specific cutting tools and technical details, and environmental and safety issues are not fully considered. The fixing, flipping, and positioning of large blades face challenges during the cutting process. In particular, multi-step cutting requires repeated adjustments to the blade position, which increases the difficulty of operation and time costs. Parameter verification is insufficient, and the system does not involve redundant design or module replacement schemes.

[0009] In summary, with the rapid development of the wind power industry, the large-scale treatment of waste wind turbine blades has become a major challenge in the field of environmental protection. Traditional wind turbine blade cutting equipment generally suffers from problems such as large size, inconvenient transportation, low cutting efficiency, and high risk of secondary pollution, making it difficult to meet the needs of rapid on-site dismantling and green treatment. Although existing technologies have made some improvements in terms of intelligence and modularization, they generally have the following problems: (1) Low cutting efficiency: a single cut only completes the operation on one side, which takes a long time. (2) High cost: the maintenance cost of core components such as precision guide rails and self-rotation drive systems is high, which is difficult for small and medium-sized enterprises to afford. (3) Environmental defects: dust and wastewater treatment is incomplete, and the risk of secondary pollution is high. (4) Insufficient mobility: the equipment is large and complex, relies on fixed sites, and cannot adapt to the needs of distributed wind farms. Utility Model Content

[0010] To address the problems in the background technology, this utility model proposes a platform vehicle for cutting waste wind turbine blades, comprising: a bearing with a mounting bracket, including a rolling bearing and a bearing housing, fixed to the vehicle body by bolts; a roller conveyor for bearing radial loads to achieve transportation, with the bearing with the mounting bracket supporting the rotating shaft of the roller conveyor; and a cross coupling for connecting the drive shaft and the roller conveyor shaft, transmitting torque, and compensating for axial and radial offsets caused by installation errors or vibrations.

[0011] Optionally, the platform vehicle further includes a sprocket, which works with the chain to transmit the rotational power output by the drive device to the roller conveyor, driving the movement of the conveying platform vehicle or the transfer of materials. The drive end of the sprocket is mounted on the output shaft of the drive device, serving as the active sprocket and directly receiving the power input.

[0012] Optionally, the platform vehicle further includes a conveying platform roller, which directly supports the weight of the wind turbine blades. The horizontal or inclined conveying of the blades is achieved by rotating the roller, thereby reducing sliding friction.

[0013] Optionally, the roller conveyor consists of multiple parallel metal rollers connected to the drive shaft via bearings. The roller conveyor relies on seated bearings to support the shaft system and is connected to the drive system via a cross coupling to transmit power.

[0014] Optionally, the cross coupling consists of two grooved coupling discs and a central cross slider, which can slide axially. The cross coupling allows power to be transmitted from the motor or reducer to the roller conveyor.

[0015] Optionally, the sprocket is toothed and includes a hub and spokes. The hub has mounting holes and keyways and is fixed to the drive shaft or driven shaft by a key connection.

[0016] Optionally, the conveyor platform rollers are arranged in parallel on the frame of the platform vehicle, covering the entire conveying area to form a continuous roller conveyor that supports the entire length of the blades.

[0017] Optionally, the platform vehicle further includes: active swivel wheels and driven swivel wheels, wherein both the active and driven swivel wheels integrate locking and braking devices.

[0018] Optionally, the platform vehicle further includes: an anti-slip grille and a locking device installed on the platform surface of the platform vehicle to ensure the smooth transfer of large-sized blades.

[0019] Optionally, the platform vehicle's cargo box is equipped with anti-slip straps to secure various components, and features bolt locking devices and shock-absorbing pads to enhance stability.

[0020] The beneficial effects of this invention include: the blade cutting equipment improves cutting efficiency through intelligent control, and its modular design allows for mobility. Dust control meets environmental protection requirements, fills a technological gap in large-scale recycling, and addresses an urgent industry need. It achieves efficient and green treatment of waste wind turbine blades, providing a complete solution for the sustainable operation of the wind power industry. Attached Figure Description

[0021] To facilitate understanding of this invention, it will be described in more detail with reference to the specific embodiments shown in the accompanying drawings. These drawings depict only typical embodiments of this invention and should not be considered as limiting the scope of protection of this invention.

[0022] Figure 1 This is a schematic diagram of the main structure of a waste wind turbine blade cutting equipment.

[0023] Figure 2 This is a schematic diagram of a container transportation scheme for a wind turbine blade cutting system.

[0024] Figure 3 This is a schematic diagram of the guide device and guide wheel of the blade cutting system in one embodiment.

[0025] Figure 4 This is a structural schematic diagram of the platform vehicle.

[0026] Figure 5 This is a structural schematic diagram of the platform vehicle from another angle.

[0027] Figure Labels

[0028] 1-Upper crossbeam; 2-Feeding device; 3-Middle crossbeam; 4-Sheet metal cover; 5-Circulating cooling water spray system; 6-Tensioning device; 7-Wire saw; 8-Drive device; 9-Left column; 10-Right column; 11-Anti-slip electric roller; 12-Circulating cooling water tank; 13-Cutting system base; 14-PLC control cabinet; 15-40-foot container wall; 16-Guiding device; 17-Guide wheel; 18-Clamping device; 19-Cross coupling; 20-Driven caster wheel; 21-Sprocket; 22-Driven caster wheel; 23-Conveyor platform roller; 24-Roller conveyor. Detailed Implementation

[0029] The embodiments of the present invention are described below with reference to the accompanying drawings, so that those skilled in the art can better understand and implement the present invention. However, the listed embodiments are not intended to limit the present invention. In the absence of conflict, the following embodiments and the technical features in the embodiments can be combined with each other, wherein the same components are indicated by the same reference numerals.

[0030] It should be noted that the terms "comprising" and "having" and any variations thereof in the specification, claims and accompanying drawings of this application are intended to cover non-exclusive inclusion. For example, a process, method, system, product or device that includes a series of steps or units is not necessarily limited to those steps or units that are explicitly listed, but may include other steps or units that are not explicitly listed or that are inherent to such process, method, product or device.

[0031] like Figure 1 As shown, the waste wind turbine blade cutting equipment of this utility model includes a wire saw cutting system, which comprises a feeding device 2, a tensioning device 6, a drive device 8, and a wire saw 7 (preferably made of diamond beads). One end of the wire saw 7 is connected to the tensioning device 6, and the other end is connected to the drive device 8. The feeding device 2 is used to control the feed amount, speed, and path of the wire saw 7. The tensioning device 6 is used to adjust the tension of the wire saw 7 in real time to prevent slack (causing cutting deviation) or excessive tightness (causing wire breakage). The drive device 8 is used to provide power for the movement of the wire saw 7 and control the main motion speed and direction.

[0032] In one embodiment, the tensioning device 6 is mounted on the left column 9. The drive device 8 is mounted on the right column 10. The left column 9 and the right column 10 are placed vertically. When the wire saw 7 is tensioned, it is perpendicular to the left column 9 and the right column 10.

[0033] In one embodiment, the tensioning device 6 includes a cylinder, a tensioning wheel, a spring mechanism, an electric actuator, and a tension sensor (such as a load cell or a piezoelectric sensor).

[0034] The spring mechanism and electric actuator dynamically maintain the tension of the wire saw 7, ensuring that it remains at optimal tension throughout the cutting process. In actual operation, the spring provides basic tension buffering, while the electric actuator performs dynamic fine-tuning (as in CNC stone carving machines).

[0035] The tension wheel is mounted on a tension wheel bracket. A spring mechanism connects the tension wheel bracket to the main frame of the tensioning device 6. The wire saw 7 is wound around the tension wheel. The spring mechanism achieves coarse adjustment through passive extension and retraction, suitable for low-cost, low-complexity systems.

[0036] The functions of the spring mechanism include: (1) passive tension maintenance: the spring provides a constant or gradual reaction force through its own elastic deformation to counteract tension fluctuations caused by wire saw slack, thermal expansion or load changes. (2) buffering vibration and impact: when cutting hard materials (such as stone and metal), the spring can absorb the instantaneous impact force of the wire saw, reduce system vibration and protect the mechanical structure.

[0037] The functions of electric actuators include: (1) Active tension control: By driving the tension wheel with a motor (servo motor, stepper motor) or linear electric actuator, the tension of the wire saw is adjusted in real time to adapt to complex working conditions. (2) Precise closed-loop regulation: Combined with feedback from tension sensors (such as load cells), high-precision dynamic tension compensation under PID control algorithm is achieved. The electric actuator is connected to the tension wheel slide or guide wheel rotation platform, and achieves high-precision closed-loop control through active drive, which is suitable for CNC and high-dynamic scenarios.

[0038] The cylinder of the tensioning device 6 is preferably a servo electric cylinder (0.75kW, with a maximum tension force of 400kg) to tighten the wire saw 7.

[0039] The tensioning device 6 has a hydraulic adjustment mechanism connected to the wire saw 7, which is used to dynamically adjust the tension of the wire saw 7 to compensate for tension fluctuations caused by changes in cutting load or wire saw extension and contraction.

[0040] The tensioning device 6 has a tension sensor (such as a load cell or piezoelectric sensor). The tension sensor monitors the pressure of the hydraulic adjustment mechanism in real time, thus indirectly reflecting the tension of the wire saw 7. The pressure monitored by the tension sensor is transmitted to the PLC control system (described in detail below). The PLC control system controls the hydraulic adjustment mechanism to adjust the tension of the wire saw 7 based on the pressure monitored by the tension sensor. The tension control accuracy is ±0.5kN, ensuring that the flatness deviation of the cut surface is less than 5mm.

[0041] The tensioning device 6 has a guide wheel and a limit switch. The wire saw 7 is wound around the guide wheel. The limit switch is used to limit the mechanical travel of the guide wheel to prevent excessive movement that could cause structural damage.

[0042] The tensioning device 6 has a rope breakage alarm device, which detects the rope breakage or insufficient length caused by excessive wear of the rope saw 7 by the tension of the rope saw 7.

[0043] The hydraulic adjustment mechanism, pressure sensor, limit switch, and rope breakage alarm are controlled by a PLC control system. The PLC control system coordinates the operation of these components: the pressure sensor provides real-time feedback, the hydraulic adjustment mechanism maintains stable tension, the limit switch ensures safe mechanical travel, and the rope breakage alarm responds quickly to rope breakage risks (upon receiving an alarm signal, the PLC controls the hydraulic adjustment mechanism to trigger an emergency stop, simultaneously issuing an audible and visual alarm and locking the entire blade cutting equipment). This forms a closed-loop "monitoring-adjustment-protection" system, ensuring the efficiency and safety of the blade cutting equipment in wind turbine blade recycling.

[0044] The drive unit 8 is used to provide power for the movement of the wire saw 7 and to control the main movement speed and direction of the wire saw 7.

[0045] The drive unit 8 includes a servo motor or a variable frequency motor, a reducer, and a transmission mechanism (such as gears or pulleys). The servo motor or variable frequency motor drives the drive unit 8. The reducer and transmission mechanism convert the rotary motion into linear or rotary motion of the wire saw 7.

[0046] In one embodiment, the drive unit 8 has a motor (e.g., a Siemens three-phase asynchronous motor with a maximum power of 30kW, driving the wire saw wire speed range of 0-40 m / s) and a frequency converter. The frequency converter achieves precise speed regulation of the three-phase asynchronous motor through power electronic modulation technology and closed-loop feedback control, realizing stepless speed regulation to adapt to the cutting requirements of different materials. Table 1 shows the adaptation logic between the frequency converter and the cutting process.

[0047] Table 1

[0048]

[0049] The PLC control system coordinates the tensioning device 6 and the drive device 8 to achieve stable cutting and extend equipment life. Precise coordination is achieved through dynamic tension control and a closed-loop logic of power-speed matching. This ensures efficient and stable cutting across all operating conditions, from glass fiber to carbon fiber composites, meeting the stringent process requirements for wind turbine blade recycling.

[0050] The feed device 2 is used to control cutting efficiency and accuracy. Its working principle and control method are as follows. The core functions of the feed device 2 include: (1) Speed ​​control: Adjusting the feed rate of the wire saw 7 to match the hardness, thickness and cutting requirements of different materials (such as stone, metal or concrete). (2) Direction control: Ensuring that the wire saw moves stably along the preset path (straight line, curve or complex geometry). (3) Pressure adjustment: Dynamically adjusting the feed pressure according to the cutting resistance to avoid overload or breakage of the wire saw.

[0051] The feed device 2 control mechanism includes two types: (1) Mechanical transmission control: power is converted into linear motion through gear, lead screw or chain mechanism to achieve precise displacement control. It is suitable for scenarios with low precision requirements or stable load (such as simple stone cutting). (2) Hydraulic / pneumatic control: the feed device is driven by hydraulic pump or cylinder to provide high thrust and impact resistance. It is often used for heavy cutting tasks (such as large cross-section concrete demolition). (3) Electric servo control: a combination of servo motor and encoder is used to adjust the feed speed and position in real time through closed-loop feedback. Advantages: high precision, fast response, suitable for complex paths or automated cutting (such as CNC wire saw system).

[0052] The feed device 2 includes a guide device: when the path turns or curves are cut, the feed device adjusts its speed synchronously with the guide device to ensure that the wire saw 7 always stays close to the guide wheel.

[0053] The feed device 2 includes sensor feedback: the cutting status is monitored in real time by force sensor and displacement sensor, and the feed parameters are adjusted (such as reducing the speed when encountering hard materials).

[0054] The feed device 2 and the tensioning device 6 are linked: the feed speed and the tension of the cutting rope are dynamically matched to avoid slippage or deviation of the cutting rope due to insufficient tension.

[0055] The feed device ensures high efficiency, precision, and safety in wire saw cutting through multi-dimensional control (speed, direction, pressure) and system coordination. The choice of control method needs to be flexibly configured based on the specific application scenario and level of automation.

[0056] The feed device 2 is mounted on the upper crossbeam 1, which is installed on the upper ends of the left column 9 and the right column 10. The feed device 2 controls the feed rate, speed, and path of the wire saw 7, matching complex cutting trajectories (such as helices and variable cross-section curves). The feed device 2 includes a servo motor and a ball screw driven by the servo motor, guide wheels, and an encoder. The ball screw is driven by the servo motor to achieve vertical feed, with a feed speed range of 0-1440 mm / min adjustable by the servo motor (2.2 kW). The displacement accuracy is ±0.1 mm, ensuring the stability of the cutting process. The position of the feed device 2 is fed back to the PLC control system via the encoder, enabling closed-loop control by the PLC system. In one embodiment, the high-precision servo drive device 8 and the ball screw feed device 2 achieve a vertical displacement accuracy of ±0.1 mm, combined with stepless speed regulation (linear speed 0-40 m / s), to adapt to different blade thickness requirements. The high-precision servo drive 8, in conjunction with the stepless speed regulation function, achieves seamless matching of precise displacement and speed primarily through the closed-loop control system and dynamic parameter adaptation of the PLC control system. During stepless speed regulation, the high-precision servo drive 8 achieves the dual goals of continuously adjustable speed and precise displacement control. Even at high speeds of 40 m / s, it maintains a vertical positioning accuracy of ±0.1 mm, meeting the process requirements of complex blade recovery scenarios.

[0057] The waste wind turbine blade cutting equipment of this utility model also includes: a cooling water spray system 5, which is installed on the middle crossbeam 3, located in the middle of the left column 9 and the right column 10. The cooling water spray system 5 has multiple nozzles located above the wire saw 7. The cooling water spray system 5 includes nozzle temperature sensors to monitor water temperature. The cooling water spray system 5 also has a flow switch to monitor flow rate (50-200L / min). Dynamic control is achieved in conjunction with the temperature sensor to ensure continuous and efficient cutting by the wire saw. The cooling water spray system 5 regulates the water temperature in real time through the temperature sensor, and triggers the flow switch only when the water flow is normal, allowing the wire saw 7 to start cutting and preventing overheating. The cooling water spray system 5 is connected to a water tank 12, and the water in the water tank 12 supplies the nozzles. The cooling water spray system 5 also includes a flow switch, pipelines, a water distribution device, a high-pressure water pump, and a multi-nozzle cooling device, etc. The cooling water flow rate is 50-200L / min, and the temperature sensor is configured to regulate the water temperature in real time. The wire saw 7 can only be activated to cut when water flows through and the flow switch outputs a signal.

[0058] During cutting, the PLC control system first activates the cooling water spray system 5, then sends signals to the tensioning device 6 and the drive device 8, which in turn control the wire saw 7 to begin cutting. Specifically, before cutting, the high-pressure water pump (pressure range 0.5-2MPa) is started in advance by the PLC control system to ensure that the water flow covers the wire saw cutting area, forming a stable lubricating film and cooling layer. Once the cooling water flow rate and pressure reach the set values ​​(e.g., flow rate 30L / min, pressure 1.2MPa), the servo electric cylinder driving the wire saw 7 starts at a preset speed (e.g., linear speed 20-40m / s) to avoid dry friction damage. After cutting, the motor driving the wire saw 7 immediately stops running, but cooling water continues to spray until the temperature of the cutting area drops to a safe value (<50℃) to prevent residual heat from burning back and damaging the diamond beads of the wire saw 7.

[0059] The waste wind turbine blade cutting equipment of this utility model also includes: an electric roller 11 and a cutting system base 13. The electric roller 11 is used for feeding material and is mounted on the cutting system base 13. The left column 9 and the right column 10 are also mounted on the cutting system base 13. The electric roller 11 is located in front of the left column 9 and the right column 10. Preferably, the surface of the electric roller 11 is covered with a polyurethane / rubber anti-slip layer, with a maximum load capacity of 10 tons. It is driven by a variable frequency motor with a linear speed of 0.16 m / s and a rotational speed range of 0-30 rpm, so as to achieve stable feeding of the blades on the cutting system base 13.

[0060] Preferably, the waste wind turbine blade cutting equipment of this utility model further includes: a wind turbine blade fixing frame. The wind turbine blade fixing frame has grooves for accommodating the wind turbine blades. The wind turbine blade fixing frame adopts a hydraulic clamping mechanism with a clamping force range of 5-20 tons, and is equipped with a laser positioning sensor with a positioning accuracy of ±1mm to ensure stability during the blade cutting process.

[0061] The waste wind turbine blade cutting equipment of this utility model also includes: a PLC control system, which is located in the PLC control cabinet 14. The PLC control system integrates wireless remote control and dust concentration monitoring functions, supports remote program upgrades, and includes rope breakage protection, low-pressure alarm, and automatic shutdown mechanism for dust exceeding the standard (threshold ≤ 10mg / m³). 3 This ensures comprehensive safety during operations.

[0062] Specifically, the PLC control system's wireless remote control system integrates a wireless communication module (5G communication module with a signal delay time of 82 milliseconds), which can receive remote control signals and thus control the entire device from a distance.

[0063] If the dust concentration monitoring system of the PLC control system detects that the dust concentration exceeds the standard, it will trigger an alarm (the time from detection of exceeding the standard to alarm is less than 2.4 seconds).

[0064] The remote program upgrade system of the PLC control system realizes the firmware program upgrade and performs program verification through CRC32, with a standard verification rate of 100%.

[0065] After receiving the alarm signal from the rope breakage alarm device, the rope breakage protection system of the PLC control system brakes the movement of the rope saw 7, and the braking distance accuracy reaches 8.5 mm.

[0066] If the low-voltage protection system of the PLC control system detects that the equipment's operating voltage is cut off or the operating voltage is lower than the set value, it will alarm and activate the supercapacitor for power outage protection (lasting for more than 30 seconds).

[0067] The PLC control system features a multi-mode automatic cutting program capable of achieving dual-line, dual-vertical-plane cutting paths. The specific operation is as follows: Based on the input blade length, chord length distribution curve, and root flange diameter, the PLC control system generates a 3D topology model from a parameterized blade database, identifying the spatial distribution of key load-bearing structures such as the main beam, web, and shell. By matching material parameters (glass fiber / carbon fiber ratio, epoxy resin system, core material density) to a material cutting characteristic library, it dynamically adjusts the cutting power (5-20kW laser or diamond saw blade speed), feed speed (0.5-3m / min), and cooling parameters. A normal plane is established at a distance L1 = 1.2D from the blade root (D is the hub diameter) as the first vertical plane for positioning. Based on the preset recovery section length, a parallel plane is generated at L1 + ΔL (the specific value is adjusted according to the actual operation) as the second vertical plane. The angle between the normal vectors of the two planes is ≤0.5°, ensuring that the perpendicularity error of the cut surface is <2mm / m.

[0068] If cutting irregular shapes is required, the guide wheel needs to rotate along the path of the wire saw 7. The guide wheel is mounted on a rotatable platform, which is supported by high-precision bearings (such as crossed roller bearings) to ensure low-friction, high-rigidity rotational motion. A servo / stepper motor drives the rotating platform and bearings. The guide wheel is driven to rotate by a servo motor or stepper motor, which receives pulse signals from the PLC control system to precisely control the rotation angle and speed.

[0069] The installation location of the rotatable platform needs to be selected based on the equipment's functional requirements and the complexity of motion control. In one embodiment, the rotatable platform is integrated into the feed device 2 (cutting head / worktable), which is suitable for high-precision, multi-axis linkage cutting of complex irregular shapes. In another embodiment, the rotatable platform is installed independently (on the main frame or linkage mechanism), which is suitable for large-range angle adjustments or heavy-duty cutting scenarios. A comprehensive trade-off between mechanical design, control algorithms, and cost is achieved to ensure precise matching between the wire saw path and the workpiece contour.

[0070] Guide wheels are used to guide the wire saw's path, maintain tension, and adapt to changes in the path. In a wire saw system, when cutting irregular (complex) shapes, the number and layout of guide wheels directly affect the flexibility of the wire saw path and the cutting accuracy. Typically, at least three guide wheels are needed for dynamic steering, but the specific number needs to be adjusted based on the cutting complexity, equipment design, and motion control scheme.

[0071] In one embodiment, the guide wheel assembly includes: a drive wheel, a main guide wheel, an adjustable guide wheel, and an auxiliary guide wheel.

[0072] The drive wheel provides power to the wire saw (it is not typically considered a guide wheel). The main guide wheel is in a fixed position and defines the wire saw's baseline path. Adjustable guide wheels are mounted on a rotatable platform and dynamically adjust their direction to match irregular profiles. Auxiliary guide wheels are used for path fine-tuning or segmented control.

[0073] For complex irregular-shaped cutting, multi-axis motion is required. If the cutting path includes multi-directional bends or spatial curves, the number of guide wheels needs to be increased to control the path in segments. For example, planar irregular shapes (2D): typically 4-6 guide wheels are needed to form a closed-loop path control system. Spatial irregular shapes (3D): typically more than 6 guide wheels are needed, combined with a multi-axis rotary platform to achieve three-dimensional path adjustment.

[0074] like Figure 3 In one embodiment shown, four guide wheels 17 are provided to guide the wire saw, maintain tension, and adapt to path changes.

[0075] The motor (usually a hydraulic or electric motor) drives the wire saw 7 to rotate via the main wheel (large wheel). The motor (or hydraulic motor) drives the main wheel to move the entire wire saw. The wire saw 7 winds around multiple wheels (including tension wheels and guide wheels) in a specific path, maintaining tension and direction. The wire saw passes through the guide wheel, tension wheel, and feed wheel, finally connecting the two ends of the wire saw to form a closed loop (which can be connected with a fastener). After tensioning, the closed loop cuts.

[0076] The feed device 2 controls the wire saw to slowly advance towards the workpiece, achieving continuous cutting. The tensioning device 6 adjusts the distance between the wheels or uses hydraulic cylinder thrust to tighten the wire saw, ensuring that it does not slip during cutting.

[0077] The clamping device 18 functions as follows: In a wire saw cutting system, the clamping device 18 ensures a safe, efficient, and precise cutting process. Its core functions include:

[0078] 1. Fix the workpiece to prevent displacement.

[0079] Stable positioning: The clamping device firmly fixes the workpiece by means of mechanical clamps, hydraulic / pneumatic clamps or electromagnetic adsorption, so as to avoid workpiece displacement caused by vibration, impact or wire rope tension during the cutting process.

[0080] Adaptable to complex shapes: For workpieces of different sizes or shapes (such as irregularly shaped stones or concrete blocks), the clamping device can be designed as an adjustable clamp or a multi-point clamping structure to ensure uniform clamping and stability.

[0081] 2. Ensure cutting precision

[0082] Reduce vibration interference: Suppress workpiece vibration through rigid clamping to avoid cutting path deviation (such as the "saw running" problem in stone cutting) and ensure the flatness of the cut surface (e.g., high precision requirements within ±1mm).

[0083] Alignment of positioning reference: The clamping device is often used in conjunction with positioning pins and reference surfaces to ensure that the initial position of the workpiece is precisely aligned with the movement trajectory of the wire saw, thereby improving the consistency of processing.

[0084] 3. Improve security

[0085] Preventing workpiece detachment: Under high-speed cutting (wire saw speed can reach 20-40m / s) or heavy load conditions, the clamping device can resist the intense tension of the wire rope, preventing the workpiece from suddenly loosening and causing equipment damage or personal injury.

[0086] Emergency locking: Some systems are equipped with sensor-linked clamping devices that automatically lock in the event of abnormal vibration or power failure, providing double safety protection.

[0087] 4. Optimize cutting efficiency

[0088] Multi-station collaboration: In automated wire saw systems, clamping devices can be integrated with conveyor belts and rotary tables to enable rapid workpiece clamping and continuous cutting, reducing downtime.

[0089] Stress dispersion: By rationally designing the distribution of clamping points (such as symmetrical clamping or wrap-around clamping), the stress concentration generated during the cutting process is dispersed, reducing the risk of workpiece breakage (especially for brittle materials).

[0090] 5. Adaptable to special working conditions

[0091] Dynamic adjustment: When cutting large or flexible workpieces (such as bridge concrete beams), the intelligent clamping device can monitor the clamping force in real time and adjust it dynamically to avoid deformation caused by over-clamping.

[0092] Environmental adaptability: In humid, dusty, or high-temperature environments, the clamping device uses rust-resistant materials (such as stainless steel) or a sealed design to ensure long-term reliable operation. The PLC control system calculates the spatial trajectory of the cutting rope in real time based on the three-dimensional model of the fan blades (such as spiral lines, contour curves, etc.), generates cutting path parameters (angle, speed), and decomposes the required rotation angle of the guide wheel. The PLC sends pulse signals to the guide wheel motor to drive it to rotate to the target angle. Based on the actual angle feedback from the encoder, the PLC control system compares it with preset values ​​and dynamically adjusts the motor output through a PID algorithm, dynamically adjusting the guide wheel to drive the wire saw 7's travel path. When the tension exceeds the limit, the PLC triggers an emergency stop or reverse rotation compensation to prevent equipment damage.

[0093] During helical wire cutting, the PLC continuously controls the rotation of the guide wheel, which rotates at a constant speed according to the helical angle of the rope. During contour following cutting, the PLC control system adjusts the rotation angle in segments (e.g., ±15° intermittent correction) based on changes in blade curvature. During adaptive curve cutting, rotational deviations are dynamically compensated through real-time sensor feedback (e.g., laser ranging, tension detection).

[0094] This invention features a system with high precision adaptability to complex curved surfaces: the guide wheel rotation accuracy can reach 0.01mm, matching the aerodynamic profile of the fan blades. It also boasts fast dynamic response: the servo motor response time is <10ms, meeting high-speed cutting requirements (e.g., 5m / min). Furthermore, it exhibits strong anti-interference capabilities: closed-loop control can counteract the effects of vibration and temperature differences on mechanical deformation.

[0095] In summary, the PLC control system can automatically adjust the cutting path according to the shape of the wind turbine blade, including: straight vertical cutting, spiral cutting, contour following cutting, and adaptive curve cutting. In one embodiment, straight vertical cutting is applicable to the straight section of the blade root, with a preferred cutting rate of 5 m / min. Spiral cutting is applicable to the conical blade tip, with a preferred cutting rate of 2.5 m / min. Contour following cutting is applicable to the S-shaped leading or trailing edge of the blade, with a preferred cutting rate of 1.8 m / min. Adaptive curve cutting is applicable to the variable cross-section transition zone of the blade, with a preferred cutting rate of 3.2 m / min. An example of the blade cutting path parameters of this invention is shown in Table 2.

[0096] Table 2 Automatic generation parameters for blade cutting path

[0097]

[0098] The cutting system uses three axes (X, Y, Z) to achieve precise control of complex paths.

[0099] Contour-following cutting (X+Y+Z linkage). The X / Y axes horizontally position the blade contour, the Z axis controls the cutting depth, and the three axes move in a proportional and coordinated manner to complete the high-precision cutting (±0.2mm) of the S-shaped leading edge.

[0100] Spiral wire cutting (A+Z axis extended linkage) is based on X / Y / Z, adding a rotary axis (A axis) to control the guide wheel angle, realizing the spiral trajectory of the conical blade tip (the number of linkage axes is extended to four axes).

[0101] The linear guide includes X / Y / Z axis guides: each axis uses a high-rigidity linear guide to ensure motion direction accuracy (e.g., ±0.01mm). Guide wheels are mounted on the XYZ axis guides, and the guide wheels can rotate 360 ​​degrees around the XYZ axis linear guides.

[0102] 1. First embodiment of the rotating mechanism

[0103] The rotating mechanism includes guide wheels, bearings, linear guides, and a rotary drive unit. The guide wheels are mounted on the slider of the linear guide via precision bearings (such as crossed roller bearings or ball bearings). The bearings allow the guide wheels to rotate freely about the axis of the linear guide (such as the longitudinal axis of the X-axis guide) while maintaining the accuracy of linear motion.

[0104] Rotary drive unit: If active control of rotation is required, a servo motor and harmonic reducer are integrated to drive the guide wheel to rotate through gear or synchronous belt transmission, and an encoder is used to achieve closed-loop control (accuracy up to ±0.01mm).

[0105] 2. A second embodiment of the rotating mechanism

[0106] The rotating mechanism includes guide wheels, universal joints or ball joints, linear guides, and a rotary drive unit. Universal joints or ball joints: In scenarios requiring multi-directional adjustment (such as at the end effector of a robotic arm), guide wheels are connected via universal joints or ball joints, allowing rotation around multiple axes. For example, the guide wheel at the end of the Z-axis guide can simultaneously tilt around the X / Y axes, achieving omnidirectional motion in conjunction with its own rotation.

[0107] 3. A third embodiment of the rotating mechanism

[0108] The rotating mechanism includes a composite motion module: a linear guide rail and a rotating module (such as a rotary table) are superimposed to form a composite axis of "linear + rotation". For example, a rotary table is mounted on the slider of the X-axis guide rail, and the guide wheel is fixed on the rotary table, realizing movement along the X-axis while rotating around the X-axis.

[0109] The wire saw feed of this invention has precision assurance measures.

[0110] Preload and backlash elimination: Preload bearings or double-nut ball screws are used to eliminate backlash during rotation and ensure repeatability of positioning accuracy.

[0111] Rigid structure design: The guide rail and rotating mechanism are made of high rigidity materials (such as hardened steel or aluminum alloy), and the structure is optimized through finite element analysis to reduce the impact of deformation on accuracy.

[0112] The 360° rotation function of the guide wheel is achieved through the collaborative design of precision bearings, multi-degree-of-freedom mechanisms, and high-rigidity guide rails, ensuring both the accuracy of linear motion (±0.01mm) and expanding the system's flexibility. In practical design, the appropriate rotation mechanism and materials need to be selected according to the specific application scenario (such as load, speed, and environment).

[0113] Ball screw drive: converts the rotary motion of the servo motor into linear motion, providing high-precision positioning (e.g., the Z-axis is responsible for cutting depth control).

[0114] Frame support: The aluminum alloy or steel structure frame supports the triaxial system and resists vibration and load during the cutting process.

[0115] The drive system uses servo motors and drivers. Each axis (X, Y, Z) is independently equipped with a servo motor, which receives pulse / analog signals from the PLC to control speed and position. The driver interprets the instructions in real time, and the drive motor moves according to the set trajectory (e.g., contour following cutting requires synchronous acceleration and deceleration of the three axes).

[0116] Reducer (optional): Increases torque output to adapt to heavy-duty cutting (such as high-speed cutting of the blade root straight section).

[0117] Motion control is implemented by a PLC control system. It generates path instructions (such as G-code) based on the blade's 3D model, decomposing them into three-axis linkage coordinates (X+Y+Z). The PLC control system integrates interpolation algorithms (linear interpolation and circular interpolation) to ensure smooth three-axis coordinated motion trajectories (such as the continuous curve of an S-shaped leading edge). The PLC control system also integrates an AI prediction module (adaptive cutting): it optimizes path parameters through machine learning and dynamically adjusts the three-axis speed and acceleration.

[0118] The feedback and closed-loop control of the cutting system are achieved by the encoder and linear scale of the feed device 2. Each axis motor has a built-in encoder that provides real-time feedback of the rotation angle, which is then converted into linear displacement. The high-precision linear scale directly measures the guide rail position, forming a fully closed-loop control (accuracy up to ±0.005mm). The encoder, servo motor, and ball screw together constitute a drive-feedback closed-loop system, responsible for real-time monitoring and adjustment of the motor motion.

[0119] PID control of the cutting system: compare the target position with the actual position, dynamically correct the motor output, and eliminate accumulated errors (such as the effect of temperature drift during long-term cutting).

[0120] The components of the cutting system have a collaborative linkage mechanism, and its synchronous control protocol uses EtherCAT or Profinet bus communication to ensure real-time synchronization of three-axis commands (response time < 1ms).

[0121] The cutting system has a dynamic load distribution mechanism: it adjusts the torque of each axis according to the cutting resistance (e.g., the Z-axis needs to be quickly compensated in the variable cross-section transition zone).

[0122] The cutting system features anti-collision functionality, achieved through limit switches and soft limits, to prevent overtravel. The cutting system also has an emergency braking function: in case of an anomaly, all three axes stop synchronously (e.g., triggered by a rope breakage sensor).

[0123] This system integrates three-axis mechanical structure, servo drive, and intelligent control through mechatronics design, becoming the core technology for automated cutting of large wind turbine blades.

[0124] Through the aforementioned path planning and multi-axis collaboration, the wire saw system, even when limited by vertical movement, can still efficiently complete the full-shape cutting of wind turbine blades, meeting the precision and flexible production requirements of composite material recycling.

[0125] The waste wind turbine blade cutting equipment of this utility model also includes: a wastewater treatment system, which is mobile and has a cyclone separator and a centrifugal pump. The solid particle separation efficiency is ≥95% and the filtered water recycling rate is ≥90%, effectively solving the problem of wastewater pollution from cutting.

[0126] The following example uses a wire saw cutting system for stone cutting to demonstrate the connection method and coordinated operation of each component (linear guide, feed device, tensioning device, drive device) through structural analysis and workflow description.

[0127] The linear guide rail is made of high-precision carbide and is fixed parallel to both sides of the frame. The linear guide rail is bolted to the frame and its surface is coated with a wear-resistant coating. The linear guide rail meshes with the slider of the feed device, and the slider achieves linear movement on the linear guide rail via a ball screw. The hydraulic cylinder (or servo motor) of the feed device drives the ball screw, causing the slider to move along the guide rail. A pressure sensor of the feed device is embedded in the hydraulic cylinder, providing real-time feedback on the propulsion resistance. The slider is rigidly connected to the drive device and tensioning device, thus allowing the drive device and tensioning device to advance as a whole along the guide rail.

[0128] The output shaft of the variable frequency motor of the drive unit is equipped with a drive wheel (with a wire saw groove). The drive wheel is located at one end of the linear guide rail, and the wire saw passes around the drive wheel and the guide wheel of the tensioning device to form a closed loop. The variable frequency motor is directly connected to the reducer through a coupling, and the reducer flange is fixed to the frame.

[0129] The tensioning device includes a hydraulic cylinder and a guide wheel assembly, which can slide laterally along a linear guide rail. The hydraulic cylinder piston rod is hinged to the guide wheel bracket, and the wire saw tension is changed by adjusting the piston stroke. A tension sensor is mounted on the guide wheel bearing housing to monitor the real-time tension value.

[0130] The workflow for each module when cutting granite slabs is as follows.

[0131] Step 1, System Start-up. The variable frequency motor of the drive unit starts, driving the drive wheel to rotate at a linear speed of 15 m / s. The hydraulic cylinder of the tensioning device applies an initial tension of 2.5 kN to eliminate slack in the wire saw (diamond beaded wire). The hydraulic cylinder of the feed device preloads, and the slider locks in the starting position of the guide rail.

[0132] Step 2, cutting into the stone. The hydraulic cylinder of the feeding device pushes the slider to slowly feed towards the stone along the guide rail (speed 5cm / min). The linear guide rail ensures the linearity of the slider's movement trajectory, with a deviation of <0.05mm. When the drive device detects that the load torque has increased to 80% of the rated value, it automatically reduces the speed to 12m / s to prevent overload. Due to the stretching of the wire saw, the tension of the tensioning device drops to 2.3kN, and the hydraulic cylinder compensates with 0.2kN to restore the set value.

[0133] Step 3: Dynamic Adjustment. When the resistance suddenly changes, i.e., when cutting into the internal cracks of the stone, the resistance drops sharply. The drive unit detects the decrease in torque and increases the speed to 18m / s to accelerate the cutting. Due to the increased centrifugal force of the wire saw, the hydraulic cylinder of the tensioning device is pressurized to 2.8kN to prevent the wire saw from swinging. Closed-loop feedback: The PLC automatically optimizes parameters based on the pressure sensor (feed resistance), tension sensor, and speed signals.

[0134] Step 4: Emergency Stop. If the wire saw breaks unexpectedly, the tension sensor detects that the tension has dropped to zero, and the drive unit immediately cuts off power and brakes. The hydraulic cylinder of the feed device quickly retracts, and the slider returns to a safe position.

[0135] The coordination mechanism of the several devices is as follows. The guide rail and slider provide rigid support: when the feed device advances, the drive device and tensioning device move together with the slider to ensure that the wire saw is perpendicular to the cutting surface. The closed-loop path of the wire saw is: drive wheel (drive end) → stone cutting surface → guide wheel (tensioning end) → return drive wheel.

[0136] The control logic of the device is to match speed and tension. Adjustments are made based on a tension reference, taking into account the wire saw speed and centrifugal force.

[0137] In one implementation, the feed adaptation rule is as follows: if the pressure sensor value > threshold, then the feed rate × 0.8 and the tension × 1.2. If the pressure sensor value < threshold, then the feed rate × 1.5 and the tension × 0.9.

[0138] In one embodiment, the linear guide rail is 3m long with a repeatability of ±0.02mm. The feed device has a maximum thrust of 10kN and a speed of 1-50cm / min. The drive device has a motor power of 22kW and a speed of 0-40m / s. The tensioning device has a tension range of 1-5kN and a response time of 0.1s. The wire saw has a diameter of Φ11mm and a diamond bead spacing of 40mm.

[0139] In this implementation, the linear guide rail serves as the motion reference, ensuring the accuracy of the feed trajectory. The drive unit and tensioning device dynamically balance the centrifugal force and cutting resistance of the wire saw. The rigid connection between the feed unit and the guide rail enables stable propulsion. Closed-loop control coordinates the parameters of the feed unit, drive unit, and tensioning device in real time, adapting to complex working conditions. This structural design is widely used in scenarios such as stone quarries and bridge demolition, balancing efficiency and safety.

[0140] The cutting system of this utility model has the following innovations.

[0141] 1. Wire saw dynamic control technology

[0142] The tensioning device 6 compensates for the slack caused by the wear of the wire saw in real time through a servo electric cylinder, and maintains the tension fluctuation ≤ ±5kg in combination with the feedback of the pressure sensor; at the moment of rope breakage, the hydraulic adjustment mechanism triggers an emergency stop, and at the same time the PLC issues an audible and visual alarm and locks the equipment.

[0143] 2. Intelligent control and remote management

[0144] The PLC control cabinet 14 has built-in multi-segment programs (such as "rapid cutting" and "high precision mode"), which can be switched by the operator via wireless remote control; the remote monitoring platform receives equipment status data (such as water temperature and dust concentration) in real time and supports fault diagnosis and OTA program upgrades.

[0145] 3. Emergency maintenance and environmental protection measures

[0146] Equipped with a mobile wastewater treatment system to deal with sudden wastewater leaks and ensure no pollution on site; regularly check the wear of the polyurethane anti-slip layer on the electric roller 11 (replace when the thickness is <2mm) to avoid the risk of blade slippage.

[0147] The system of this utility model has been verified for its effectiveness: a single wire saw can complete a double-sided cut of a 2.5m long blade in ≤15 minutes, which is 100% more efficient than traditional equipment (30 minutes); environmental protection verification: the sewage treatment system reduces wastewater discharge by 90% and the solid waste collection rate is ≥98%; economic verification: the containerized design reduces transportation costs by 40% and shortens on-site installation time to within 4 hours.

[0148] The cutting method of the cutting system is as follows.

[0149] S1, start the drive unit, the drive unit's drive wheel rotates, and the wire saw moves at high speed.

[0150] Specifically, the drive unit provides power to rotate the diamond wire saw at high speed. The drive unit includes a motor, a reducer, and a drive wheel. The drive unit typically uses a variable frequency motor or a servo motor, which can adjust the speed according to the material hardness to ensure cutting efficiency.

[0151] S2 applies initial tension to the tensioning device to eliminate slack in the wire saw.

[0152] Specifically, the wire saw connects the drive unit and the tensioning device. The function of the tensioning device is to maintain a constant tension on the wire saw and prevent slippage, vibration, or breakage. The tensioning device includes: a hydraulic cylinder or spring mechanism, a tension sensor, and guide wheels. The tensioning device can dynamically adjust the tension to compensate for the elastic deformation and wear of the wire saw during the cutting process.

[0153] The drive unit and tensioning device are connected to the linear guide rail, and the feed unit pushes the linear guide rail via a slider. The linear guide rail provides high-precision guidance for the feed unit, ensuring the straightness of the cutting path. The linear guide rail includes: slider, guide rail, and lubrication system. The linear guide rail has high rigidity and wear resistance, reducing vibration and misalignment.

[0154] The feed device drives the wire saw to feed, and the feed device is connected to the drive device and the tensioning device.

[0155] S3, During cutting, the feed device pushes the wire saw along the linear guide rail towards the material, and the cutting force gradually increases. The linear guide rail ensures a stable feed direction and avoids path deviation. Drive unit: Real-time monitoring of load torque: If the material hardness is too high, the speed is reduced to prevent wire saw overload. If the cutting resistance decreases (e.g., when penetrating the material), the speed is automatically increased to optimize efficiency. Tensioning device dynamically adjusts tension: Feedback from the tension sensor compensates for changes in wire saw length due to stretching or wear; in case of emergency stop or jamming, the tension is quickly released to protect the wire saw.

[0156] Preferably, the feeding device controls the cutting speed and depth, propelling the wire saw into the material. The feeding device includes a hydraulic cylinder / ball screw, a servo motor, and a pressure sensor. The feeding device automatically adjusts the feed speed based on material resistance to prevent overload or cutting stall.

[0157] Preferably, the drive unit monitors the load torque and reduces the motor speed when the material hardness exceeds a set threshold. When the material hardness is less than the set threshold and a decrease in resistance is detected, the motor speed is increased.

[0158] S4 provides dynamic adjustment and feedback for the drive unit, tensioning device, and feed device. The PLC control system collects data monitored by each component: the drive unit's speed and torque; the real-time tension value of the tensioning device; and the pressure or displacement signal of the feed device. The monitored data is calculated and analyzed to perform adaptive feed speed; tension-speed matching; and dynamic adjustment of the tensioning device.

[0159] Adaptive feed speed refers to the following: when cutting hard material (judged by monitoring the drive unit's speed and torque), the speed is reduced (feed speed decreases) and tension is increased (wire saw tension increases); when cutting soft material, the speed is increased (feed speed increases) and tension is stabilized (wire saw tension decreases). Tension-speed matching refers to: when the drive unit operates at high speed, the tension of the tensioning device is increased to prevent the wire saw from swinging due to centrifugal force. Dynamic adjustment of the tensioning device: when the tensioning device's sensor detects wear on the wire saw, the tension of the tensioning device is increased. When the wire saw is detected to stop abruptly or jam, the tension of the tensioning device is released.

[0160] This invention provides an efficient, compact, and mobile blade processing solution, addressing issues of poor mobility, low efficiency, and secondary pollution. It enables efficient on-site dismantling and green recycling of blades, providing technical support for the recycling of waste composite materials.

[0161] According to the second aspect of this utility model, as Figure 4-5 As shown, a blade transport platform vehicle 16 is also proposed, which includes the diamond wire saw cutting system described above and a sheet metal cover 4, with the diamond wire saw cutting system located inside the sheet metal cover 4. The blade transport platform vehicle adopts a 40-foot standard container vehicle design.

[0162] The sheet metal outer cover 4, upper crossbeam 1, middle crossbeam 3, left column 9, right column 10, base 13, water tank 12, circulating cooling water spray system 5, feeding device 2, and PLC control cabinet 14 are all designed as standardized modules. After disassembly, they can be assembled... Figure 2 The pre-designed layout shown is fitted into a standard 40-foot container. Anti-slip straps are used inside the container to secure all components, ensuring no displacement during transport; bolt locking devices and shock-absorbing pads further enhance stability.

[0163] The wind turbine blade transport platform vehicle 16 has external dimensions of 5000mm in length, 2300mm in width, and 400mm in height, with a ground clearance of 400mm. It is made of high-strength materials and has a total weight of 2 tons per unit. After arriving at the wind farm, the container side door is opened, and the various components of the cutting system are removed one by one using a forklift or crane. The assembly of the cutting system can be completed within a few hours. It is adaptable to complex terrain and uneven construction sites, and is suitable for frequent relocation operations.

[0164] The sheet metal outer cover 4, upper crossbeam 1, middle crossbeam 3, left column 9, right column 10, base 13, water tank 12, circulating cooling water spray system 5, feeding device 2, and PLC control cabinet 14 are all designed as standardized modules. After disassembly, they can be assembled... Figure 2 The pre-designed layout shown is fitted into a standard 40-foot container. Anti-slip straps are used inside the container to secure all components, ensuring no displacement during transport; bolt locking devices and shock-absorbing pads further enhance stability.

[0165] The wind turbine blade transport platform vehicle 16 has external dimensions of 5000mm in length, 2300mm in width, and 400mm in height, with a ground clearance of 400mm. It is made of high-strength materials and has a total weight of 2 tons per unit. After arriving at the wind farm, the side door of the container is opened, and the various components of the cutting system are removed one by one using a forklift or crane. The assembly of the cutting system can be completed within a few hours.

[0166] The platform vehicle includes a seated bearing 17, a roller conveyor 24, and a cross coupling 19.

[0167] The mounted bearing 17 includes a rolling bearing (such as a ball bearing or roller bearing) and a bearing housing, which is bolted to the vehicle body. The mounted bearing 17 supports the rotating shaft of the roller conveyor 24, bears radial loads (such as the weight of goods), reduces friction, and ensures smooth roller rotation. It provides stable support for the roller conveyor 24 and is fundamental to the rotation of the rollers.

[0168] Roller conveyor 24 is used to directly carry goods, achieving horizontal transport of goods through roller rotation and reducing movement resistance through rolling friction. Roller conveyor 24 consists of multiple parallel metal rollers connected to a drive shaft via bearings. Roller conveyor 24 relies on mounted bearings to support the shaft system, which is connected to the drive system via couplings to transmit power.

[0169] The cross coupling 19 is used to connect the drive shaft and the roller conveyor shaft, transmit torque, and compensate for axial and radial misalignment caused by installation errors or vibration. The cross coupling 19 consists of two grooved coupling discs and a central cross slider, allowing axial sliding. The cross coupling 19 ensures efficient power transmission from the motor / reducer to the roller conveyor, while accommodating shaft misalignment and avoiding wear caused by rigid connections.

[0170] The mounted bearing 17, roller conveyor 24, and cross coupling 19 together constitute an efficient and stable conveying system. The mounted bearing 17 provides support, the roller conveyor 24 realizes transportation, and the cross coupling 19 ensures reliable power transmission and adapts to mechanical deformation. It is suitable for heavy-duty conveying in factories, logistics and other scenarios, adapts to complex terrain and uneven construction sites, and meets the needs of frequent mobile operations.

[0171] The fan-driven conveyor platform 16 includes a sprocket 21, which works with a chain to transmit the rotational power output from the drive unit (such as a motor or reducer) to the roller conveyor 24 or other moving parts, driving the movement of the conveyor platform or the transfer of materials. The drive end of the sprocket 21 is mounted on the output shaft of the drive unit (such as the end of the reducer), serving as the driving sprocket and directly receiving the power input.

[0172] Sprocket 21 features a toothed design, employing ISO or ANSI standard roller sprocket teeth (such as involute tooth profiles) to ensure smooth meshing with the chain rollers. Sprocket 21 undergoes wear-resistant treatment: high-frequency hardening or plating (such as carburizing or chrome plating) of the tooth surfaces enhances wear resistance and adapts to high-load conditions. The sprocket body of sprocket 21 includes a hub and spokes. The hub has mounting holes and keyways, securing it to the drive or driven shaft via a key connection. The spokes have spoke plates or perforated plates to reduce weight and maintain rigidity (e.g., aluminum alloy sprockets are used in light-duty conveyors).

[0173] Speed ​​and torque regulation are achieved through combinations of sprockets 21 with different numbers of teeth (such as driving and driven sprockets): the transmission ratio is adjusted to match the conveying speed and load requirements. In a multi-sprocket system, the multiple sprockets 21 need to be synchronously controlled to ensure the synchronized operation of multiple roller conveyors or moving parts (such as preventing material deviation).

[0174] The wind turbine blade transport platform 16 includes a transport platform roller 23. Its function is to carry and transport: directly supporting the weight of the wind turbine blades, and using the rotation of the rollers to achieve horizontal or inclined transport of the blades, reducing sliding friction and ensuring smooth movement.

[0175] The conveyor platform rollers 23 are arranged in parallel on the frame of the platform vehicle, covering the entire conveying area, forming a continuous roller track, and supporting the entire length of the blades.

[0176] The conveyor platform roller 23 consists of an outer cylinder, a shaft, and bearings. The outer cylinder is made of high-strength carbon steel (such as Q345B) or stainless steel (for corrosion-resistant applications), with a galvanized or wear-resistant coating on the surface. The shaft and bearings provide internal support. The shaft runs through the center of the roller and is fixed to the frame at both ends by seated bearings. It is made of 40Cr tempered steel to ensure bending strength. The bearings are deep groove ball bearings or self-aligning roller bearings, suitable for high-speed rotation and radial loads (e.g., a single roller can bear up to 5 tons).

[0177] The bottom of the wind turbine transport platform vehicle 16 is equipped with four sets of double-row swivel wheels, of which the active swivel wheel 22 and the driven swivel wheel 20 are both integrated with locking and braking devices, and each wheel can bear a load of 1.5 tons.

[0178] The blade transport platform vehicle is equipped with anti-slip grating (friction coefficient ≥0.6) and locking device on the platform surface to ensure the smooth transfer of large blades and adapt to the needs of complex site operations.

[0179] The 16-unit fan blade transport platform vehicle can be used in groups of four for transporting long fan blades before cutting. Figure 3-4 As shown. It can also be used separately after the wind turbine blades have been cut.

[0180] The present invention is described below through an example. The core components, such as the diamond wire saw cutting system, circulating cooling water tank 12, sewage treatment system, and PLC control cabinet 14, are standardized modules, arranged according to... Figure 2 The layout shown is designed for loading into a standard 40-foot container. Anti-slip straps secure all components inside the container to ensure no displacement during transport; bolt locking devices and shock-absorbing pads further enhance stability. Each of the 16 fan blade transport platform trucks, when folded, measures 2500mm long × 1200mm wide × 400mm high; four trucks are stacked within the same container for transport.

[0181] Upon arrival at the wind farm, open the container side door and use a forklift or crane to remove the cutting system components one by one. Assemble them according to the following steps: Install the cutting system base 13 and the circulating cooling water tank 12, adjusting the levelness error to ≤0.5mm / m; Install the left column 9 and the right column 10; Install the tensioning device 6 and the drive device 8; Connect the diamond wire saw 7 between the tensioning device 6 and the drive device 8, and calibrate the wire saw tension to 400kg via the PLC control cabinet 14 after powering on; Install the intermediate crossbeam 3 and the circulating cooling water spray system 5; then install the upper crossbeam 1; the feed device 2 and multiple sheet metal covers 4; Connect the pipeline of the circulating cooling water system 5, and start the high-pressure water pump after filling the water tank 12 with water, verifying the linkage function of the flow switch (flow rate ≥50L / min) and the temperature sensor (set threshold ≤40℃); Deploy 4 wind turbine transport platform vehicles 16 to the cutting area. The wind turbine transport platform vehicles 16 can be used in combination for transporting long wind turbine blades before cutting. Figure 4 As shown. It can also be used separately after the wind turbine blades have been cut.

[0182] The blade cutting operation procedure is as follows.

[0183] 1. Blade Fixing and Positioning: The discarded wind turbine blades are transported to the cutting system using the blade transport platform 16. The anti-slip electric roller 11 is activated to transport the blades to the position of the blade fixing frame. The root and tip of the blades are locked by the hydraulic clamping mechanism to ensure the stability of the cut section. The PLC control cabinet 14 is operated to select the preset cutting program (such as blade length and material parameters) to generate a double vertical plane cutting path. The specific operation is as follows: S1, based on the input blade length, chord length distribution curve and root flange diameter, a three-dimensional topology model is generated to identify the spatial distribution of key load-bearing structures such as the main beam, web, and shell.

[0184] S2 matches the material cutting characteristics by adjusting the material parameters (glass fiber / carbon fiber ratio, epoxy resin system, core material density), cutting power (5-20kW laser or diamond saw blade speed), feed speed (0.5-3m / min), and cooling parameters.

[0185] S3, establish a normal plane at a distance of L1 = 1.2D from the blade root (D is the hub diameter) as the first vertical plane for positioning.

[0186] S4. Based on the preset length of the recovery section, a parallel plane is generated at L1+ΔL as the second vertical plane. The angle between the normal vectors of the two planes is ≤0.5°, ensuring that the perpendicularity error of the cut surface is <2mm / m.

[0187] 2. High-efficiency cutting and cooling: The diamond wire saw 7 is started, and the linear speed is adjusted to 30m / s via a frequency converter, allowing the feed device 2 to advance at a uniform speed. The circulating cooling water spray system 5 is simultaneously activated, with multiple nozzles evenly covering the cutting area. Water temperature is monitored in real time, and the flow rate is adjusted to prevent overheating of the wire saw. During the cutting process, the PLC monitors the wire breakage alarm sensor and dust concentration (threshold ≤10mg / m³) in real time. 3 If any abnormality occurs, the machine should be stopped immediately.

[0188] 3. Waste treatment and resource recycling: The wastewater generated from cutting is treated by a hydrocyclone separator (separation efficiency ≥95%) to remove glass fiber debris. The filtered water (recycling rate ≥90%) is pumped back to the water tank for circulating cooling 12 by a centrifugal pump. The glass fiber debris is collected and used for pyrolysis.

[0189] The segmented blades (1.9-2.5m in length) are transported to the pyrolysis reactor station by the fan blade transport platform vehicle (16). The anti-slip grating (friction coefficient ≥0.6) on the surface of the platform vehicle and the wheel brake device ensure smooth transportation.

[0190] This utility model provides a waste wind turbine blade cutting system and a wind turbine blade transportation platform vehicle based on a 40-foot container truck. Through modular design and innovative technology integration, it achieves an efficient, compact, and mobile blade processing solution, solving the problems of poor mobility, low efficiency, and secondary pollution. It enables efficient on-site dismantling and green recycling of blades, providing technical support for the recycling of waste composite materials.

[0191] This system can be quickly deployed to wind farm sites and is ready to use immediately via container trucks. After efficient blade cutting, the transport platform vehicle directly transfers the segmented blades (1.9-2.5m in length) to the downstream pyrolysis or recycling stage, forming an integrated closed-loop process of "cutting-transportation-processing". This provides key technical equipment support for the large-scale green treatment of waste wind turbine blades.

[0192] The embodiments described above are merely preferred embodiments of this utility model. The terms "in one embodiment," "in another embodiment," "in yet another embodiment," or "in still another embodiment" used in this specification all refer to one or more of the same or different embodiments according to this disclosure. Ordinary variations and substitutions made by those skilled in the art within the scope of this utility model's technical solution should be included within the protection scope of this utility model.

Claims

1. A platform vehicle for cutting waste wind turbine blades, characterized in that, include: Mounted bearing (17): includes a rolling bearing and a bearing housing, which is fixed to the vehicle body by bolts; Roller conveyor (24), used to bear radial loads for transport, with a mounted bearing (17) supporting the rotating shaft of roller conveyor (24); and A cross coupling (19) is used to connect a drive shaft to a roller shaft, transmit torque, and compensate for axial and radial offsets caused by installation errors or vibrations.

2. The platform vehicle according to claim 1, characterized in that, Also includes: The sprocket (21), in conjunction with the chain, transmits the rotational power output by the drive device to the roller conveyor (24), driving the movement of the conveyor platform vehicle or the material transfer. The drive end of the sprocket (21) is mounted on the output shaft of the drive device, serving as the active sprocket and directly receiving the power input.

3. The platform vehicle according to claim 1, characterized in that, Also includes: The conveying platform roller (23) directly supports the weight of the fan blades. The horizontal or inclined conveying of the blades is achieved by rotating the roller, reducing sliding friction.

4. The platform vehicle according to claim 1, characterized in that, The roller conveyor (24) consists of multiple parallel metal rollers connected to the drive shaft via bearings. The roller conveyor (24) relies on the bearing seat (17) to support the shaft system and is connected to the drive system via a cross coupling (19) to transmit power.

5. The platform vehicle according to claim 1, characterized in that, The cross coupling (19) consists of two grooved coupling discs and a central cross slider, which can slide axially. The cross coupling (19) allows power to be transmitted from the motor or reducer to the roller conveyor (24).

6. The platform vehicle according to claim 2, characterized in that, The sprocket (21) is toothed and includes a hub and spokes. The hub has mounting holes and keyways and is fixed to the drive shaft or driven shaft by a key connection.

7. The platform vehicle according to claim 2, characterized in that, The conveyor platform rollers (23) are arranged in parallel on the frame of the platform vehicle, covering the entire conveying area, forming a continuous roller track, and supporting the entire length of the blades.

8. The platform vehicle according to claim 1, characterized in that, Also includes: The active caster wheel (22) and the driven caster wheel (20) are integrated with locking and braking devices.

9. The platform vehicle according to claim 1, characterized in that, Also includes: Anti-slip gratings and locking devices installed on the platform surface of the platform vehicle ensure smooth transport of large-sized blades.

10. The platform vehicle according to claim 1, characterized in that, Also includes: The platform vehicle's cargo box is equipped with anti-slip straps to secure various components, as well as bolt locking devices and shock-absorbing pads to enhance stability.

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