Extraction system and method for extracting magnetic elements
An automated system for extracting magnet elements from wind turbine generators addresses the challenges of safety and efficiency in magnet recycling by using actuators and positioning devices to safely and quickly separate magnets.
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- SIEMENS GAMESA RENEWABLE ENERGY AS
- Filing Date
- 2024-03-20
- Publication Date
- 2026-04-14
Smart Images
Figure 2026512138000001_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to an extraction system and respective methods for extracting one or more magnet elements from a wind turbine generator component.
[0002] Background Art Over the past several years, the size and output of wind turbines have increased significantly. Modern high-output wind turbines include direct-drive wind turbines in which the generator rotor is directly coupled to the wind turbine rotor without an intervening gearbox. Such direct-drive generators typically use permanent magnets in the generator rotor. For an exemplary wind turbine, for example, 6 tons of permanent magnets can be used in the generator rotor. For example, neodymium (Ne) iron (Fe) boron (B) permanent magnets are used because they can generate a strong magnetic field. However, the use of heavy rare earths (HREs) for manufacturing each permanent magnet faces challenges. For example, such materials are troubled by fluctuations in international HRE prices. Also, the extraction and mining of such heavy rare earths have a significant impact on the environment. Furthermore, these materials are highly important. Therefore, the manufacture of each permanent magnet provided in the generator rotor involves some difficulties.
[0003] U.S. Patent Application Publication No. 2017222506 discloses a magnet gripping system that picks up magnet elements from a magnet cradle. The magnet is then transferred to the wind turbine rotor and incorporated at a specified location.
[0004] U.S. Patent No. 5691589 discloses a magnet assembly device for a high-horsepower electric machine that utilizes a push rod to which a magnet element is attached by bolts and a magnet box that shields magnetic force during incorporation.
[0005] European Patent Application Publication No. 2930824 discloses a structure of an outer rotor that includes several rotor housing segments that enable the retention of a large number of magnetic poles.
[0006] Therefore, the inventors of this invention realized that it is desirable to reuse permanent magnet materials and, in particular, to recover such permanent magnet materials at the end of the lifespan of each wind turbine generator. However, such recovery faces several difficulties, especially because the magnets can generate such large forces that handling them by personnel can be dangerous, particularly due to their strong permanent magnetic fields. Furthermore, a generator rotor can have more than 1,000 magnets, and their recycling is expensive and time-consuming. Moreover, due to the magnetic force generated by each powerful permanent magnet, removing them from the generator rotor can also face difficulties.
[0007] Summary of the Invention Therefore, there is a need to mitigate at least some of the aforementioned drawbacks. In particular, there is a need to provide a simple and efficient way to reuse materials from permanent magnets installed in wind turbine generators.
[0008] This need is met by the features of the independent claim. The dependent claims describe embodiments of the present invention.
[0009] According to one embodiment of the present invention, an extraction system is provided configured to extract one or more magnet elements from a wind turbine generator component. The wind turbine generator component (which may be abbreviated herein as generator component or component) comprises a plurality of rows of magnet elements. Each row comprises one or more magnet elements. The extraction system comprises an extraction device comprising one or more actuators. A support structure is further provided to support the wind turbine generator component relative to the extraction device. The support structure is configured to provide alignment between the extraction device and the rows of the wind turbine generator component. The system is configured so that the extraction device automatically extracts one or more magnet elements from the (aligned) rows of the wind turbine generator component.
[0010] Such automated extraction from generator components allows for the rapid and efficient removal of magnetic elements without endangering any personnel. Eliminating worker intervention in the process enhances safety. Furthermore, it enables large-scale separation of magnetic elements from generator components, allowing for the removal of numerous magnetic elements in a short time. Such automated extraction can further facilitate the transport of magnetic elements to subsequent processing, such as demagnetization. Moreover, such automated extraction devices can overcome the large forces required to separate magnetic elements from generator components. Furthermore, compared to other possible recycling methods, it makes demagnetization and subsequent disassembly of extracted magnetic elements easier. This may be impossible without extraction, for example, as demagnetization might take a significantly longer time and be less effective.
[0011] The generator component may include, for example, multiple rows of magnetic elements that are distributed circumferentially around the component and extend in the axial direction of the component. Each row may include, for example, at least one, two, or three or more magnetic elements, such as 3 to 10.
[0012] The extraction system may be configured to extract magnet elements sequentially and automatically from multiple rows of generator components.
[0013] The generator components may be components disassembled from a wind turbine generator, and the support structure may be located outside the wind turbine. This facilitates the extraction of multiple rows of magnet elements. Preferably, the support structure may be positioned on the ground, for example, in an assembly plant or workshop. Thus, the extraction process can be carried out in a safe manner.
[0014] The generator components may be components of a wind turbine generator having a nominal rated power of at least 250 kW, preferably at least 500 kW, at least 1 MW, or at least 2 MW.
[0015] The generator components may be, for example, a generator rotor, but in particular, they may be the generator stator of a direct-drive generator. The direct-drive generator may be configured to be mechanically connected to the wind turbine rotor of a wind turbine without the need for a gearbox.
[0016] The magnetic element may consist of one or more permanent magnets, or may include one or more permanent magnets. The magnetic element may include a housing that may, for example, have a base plate and a cover, and a permanent magnet block disposed within the housing. In addition to such a housing, another type of encapsulation may be provided. Thus, the magnetic element may also be a magnetic module.
[0017] Preferably, the magnetic element remains magnetized, and the system is configured to extract the magnetized magnetic element from the generator component.
[0018] The extraction device may be configured to extract one magnetic element at a time. Preferably, the extraction device is configured to extract all magnetic elements in a row.
[0019] According to one embodiment, the extraction system further comprises a positioning device configured to automatically position wind turbine generator components relative to the extraction device in order to align them between the extraction device and the rows. Thus, such a positioning device can facilitate alignment, especially in view of the potential weight of the generator components.
[0020] The positioning device may be a separate device from the wind turbine generator. It may be configured to position wind turbine generator components without using the wind turbine generator. Therefore, it is possible to align the removed wind turbine generator components with respect to the extraction device without using any components of the wind turbine.
[0021] The positioning device may include, for example, actuators configured to rotate and / or translate wind turbine generator components relative to the extraction device. Preferably, the generator components can be rotated while the extraction device remains stationary. The positioning device may include each rotation actuator.
[0022] For example, the positioning device comprises one or more motor-driven rollers that contact the outer and / or inner circumference of the wind turbine component and can be driven to rotate the wind turbine component. The number of motor-driven rollers may be adjusted, for example, according to the size / weight of the generator component, and may be between 1 and 6. The positioning device may further comprise one or more guide rollers that contact the outer and / or inner circumference of the wind turbine component. This can achieve more stable positioning. For example, there may be 3 to 10 rollers, for example 5 rollers, and some of them, preferably all of them, may be motor-driven.
[0023] The extraction system may further include a position detector configured to detect the relative position between the wind turbine generator components and the extraction device. The detected relative position can be used to align the extraction device with the rows. For example, an encoder such as a rotary encoder can be used to detect the angular direction of the generator components on the support. Such a position detector can provide feedback to the positioning device or may be used to provide feedforward control, thus ensuring accurate alignment between the rows of generator components and the extraction device.
[0024] The generator components themselves may include bearings capable of rotatably supporting the generator components. Alternatively, the support structure may include bearings that provide rotatable support for each wind turbine component.
[0025] The support structure can have an adjustable size to support wind turbine components of various sizes. The size can be adjustable, for example, such that the rollers described above abut against the wind turbine generator components. For example, the support structure can include a telescopic shaft or beam configured to allow adjustment of the size of the frame that supports the rollers.
[0026] The generator components can have a considerable size and weight. For example, the diameter can exceed 3 meters or even 5 meters, and the weight can exceed 1 or 5 tons and can be, for example, several tons.
[0027] In one embodiment, one or more actuators of the extraction device are operable to extract one or more magnet elements of a column by separating each of the one or more magnet elements from a magnet mount of a wind turbine generator component.
[0028] In one example, the extraction device can move one or more magnet elements relative to a magnet mount by an actuator to release the one or more magnet elements from the magnet mount. The magnet mount can be, for example, a slot such as a T-shaped slot from which the magnet element is pushed out or pulled out.
[0029] In another example, the actuator can loosen the fastening member of the magnet mount and release one or more magnet elements from the magnet mount. A screw or other fastening member, for example, may be removed by an actuator that may include respective robotic arms and the like. In another example, the magnet mount may be disassembled by an actuator to release one or more magnet elements from the magnet mount. For example, it is possible to destroy the mount, such as by using respective actuators to cut the elements of the mount. It is clear that the configuration of the extraction device is generally selected to correspond to the method of attaching the magnet elements to the generator components. Thus, such an extraction device can efficiently and safely remove the magnet elements from the generator components, enabling effective removal for various configurations of the generator components.
[0030] In a particular example, the extraction device comprises a push assembly and / or a pull assembly configured to push or pull one or more magnet elements against a wind turbine component to release the one or more magnet elements from the magnet mount of the wind turbine component. In particular, the mount can provide a form-fitting connection from which the magnet element is released. Such a form-fitting connection may be provided by a slot, such as a T-shaped slot into which the magnet element is inserted, as described, for example, in European Patent Application Publication No. 2555393. This can reduce the complexity of the extraction device and provide an easy way to remove the magnet elements from the generator components.
[0031] The extraction device may include guide rails, and the push / pull assembly may include a carriage movable in the push or pull direction on the guide rails. The actuator of the extraction device can operate the carriage. The carriage can have, for example, opposing rollers that roll on the guide rails in the push / pull direction, i.e., the direction of extraction.
[0032] The actuator may be, for example, a hydraulic or pneumatic cylinder, and electrically driven actuators are also conceivable. Such a cylinder may be able to retract, for example, to pull the carriage in the extraction direction of the magnetic element, or such a cylinder may be able to push the carriage in the extraction direction.
[0033] The push assembly may include an engaging member that engages with the magnetic element in the pushing direction at the rear of the magnetic element. The actuator may be configured to push the magnetic element in the pushing direction by the engaging member by pushing or pulling the engaging member. The engaging member may be mounted, for example, on a carriage, and the actuator can push or pull the carriage to push or pull the engaging member in the extraction direction. This allows the engaging member to release the magnetic element from the magnetic mount by pushing the magnetic element in the extraction direction.
[0034] The engaging member may be a hook or other element, such as a (sufficiently strong) projection, which can be inserted behind the magnetic element being pushed. Preferably, the engaging member engages with the last magnetic element (viewed from the end of the magnet mount from which the magnetic elements are extracted) so that all magnetic elements in the row are pushed simultaneously by the push assembly. By acting the push assembly in stages, the magnetic elements can be released one by one from the magnet mount. The engaging member itself may be actuated to engage with the magnetic elements, such as each hook or plate being pushed out of the carriage so that it is positioned behind the magnetic element, or it may be driven by weight and engage passively with the magnetic elements.
[0035] In one embodiment, the extraction device may include a repositioning device configured to change the orientation of the magnet elements extracted from the row. This is particularly advantageous because, when extracting magnet elements vertically, the magnet elements can be reoriented horizontally for transport. The repositioning device can, in particular, change the orientation by approximately 90° from vertical to horizontal. In an exemplary embodiment, the repositioning device may include a support plate for supporting the magnet elements (for example, which may be pressed against the support plate during extraction) and an actuator that may include a mechanical linkage mechanism for rotating the support plate to the desired orientation. Other components of the extraction system can then move the magnet elements further.
[0036] In this regard, it should be reiterated that each magnetic element generates an excessively large attractive force due to its magnetic strength, and therefore, handling them is quite difficult.
[0037] The extraction system may further include a moving device configured, for example, to move the extracted magnetic elements to a conveying device. Such a moving device may, for example, be able to push or pull the magnetic elements. For example, it may include pneumatic or hydraulic cylinders for pushing or pulling the magnetic elements. Pulling can be achieved, for example, by holding or gripping the magnetic elements using suction (e.g., suction cups) and then pulling the magnetic elements by contracting the respective cylinders. The moving device may, for example, move the reoriented magnetic elements from a support plate to a conveying device. Depending on the equipment, the conveying device may be, for example, a horizontal, vertical, or inclined conveyor.
[0038] The wind turbine components may have a cylindrical shape, and the support structure may be configured to support the wind turbine components with their cylindrical axis oriented vertically. The extraction device can extract one or more magnet elements vertically from the wind turbine components, for example, upward or downward. In such a configuration, the system may include, for example, a vertical conveyor for transporting the extracted magnet elements vertically to a desired position. Other configurations, such as inclined conveyors, are also possible. In another embodiment, the support structure may be oriented so that the wind turbine generator components have a horizontal cylindrical axis, and the extraction device may extract the magnet elements horizontally.
[0039] The moving device can transfer the extracted magnetic elements to a vertical conveyor, an inclined conveyor, or a horizontal conveyor.
[0040] A vertical conveyor may be, for example, a circulating conveyor with one or more carriers attached to a chain or belt. A horizontal or inclined conveyor may similarly have multiple carriers attached to a chain or belt, or it may be a simple belt conveyor.
[0041] The system may further comprise a conveying device configured to interface with a demagnetizing system for demagnetizing magnetic elements and to transport one or more extracted magnetic elements toward the demagnetizing system. By providing such an interface, efficient and continuous processing of magnetic elements can be achieved. Such a conveying system may also be a conveyor such as a conveyor belt, a chain conveyor with carriers, a slat conveyor, etc., and may be, for example, a belt conveyor having two belts and an intermediate carrier.
[0042] In an implementation that includes both a vertical conveyor and a transport system providing an interface to a demagnetizing system, the extraction system may further include a moving device configured to move one or more extracted magnetic elements from the vertical conveyor to the transport device. Here again, the moving device can push or pull the magnetic elements in any of the manner described above.
[0043] The extraction system may further comprise a control system configured to control the extraction system. The control system may be configured to perform the steps of: (a) automatically aligning a row of wind turbine components to an extraction device (for example, by controlling a positioning device based on a position indicated by a position detector); (b) automatically extracting one or more magnet elements from the row (preferably all magnet elements in the row) (for example, by controlling each extraction device); (c) automatically transporting one or more extracted magnet elements to a further processing device (for example, to a demagnetizing system by controlling a voluntary repositioning device, a moving device, and a conveying device, such as a vertical and / or horizontal / inclined conveyor); and repeating steps (a) to (c) for one or more, preferably all rows, of wind turbine generator components.
[0044] Therefore, efficient and rapid extraction of magnetic elements from generator components can be achieved without human intervention, which significantly reduces the recycling time of such components and further improves personnel safety.
[0045] The extraction system may be a modular system provided as a module and configured to interface with a module comprising a demagnetizing system configured to demagnetize one or more magnetic elements. The extraction system is preferably configured to fit into a standard container (e.g., a 20, 24, or 40-foot container). The container may be an intermodal container, for example, one conforming to ISO standard 668:2020 or an equivalent standard. This facilitates the transportation and installation of the extraction system.
[0046] According to another embodiment of the present invention, a method is provided for extracting one or more magnet elements from a wind turbine generator component. The wind turbine generator component comprises a plurality of rows of magnet elements, each row comprising one or more magnet elements. The method includes the steps of: supporting the wind turbine generator component with a support structure for an extraction device comprising one or more actuators; aligning the rows of the wind turbine generator component with the extraction device; and automatically extracting one or more magnet elements from the (aligned) rows of the wind turbine generator component by the extraction device. Such a method can achieve advantages similar to those further outlined above.
[0047] In one embodiment, the method may further include repeating a row alignment step and an automatic extraction step for multiple rows of wind turbine generator components, wherein the alignment is performed by a positioning device that automatically positions the rows of wind turbine generator components so that they are aligned with an extraction device. Positioning may include, for example, rotating the generator components until a row of magnet elements is aligned with the extraction device.
[0048] This method may further include any of the steps described herein with respect to the extraction system. Furthermore, the control system may be configured to perform any of the methods described herein.
[0049] It should be understood that the features described above and those described below can be used not only in each of the combinations shown, but also in other combinations or individually without departing from the scope of the present invention. In particular, the features of different aspects and embodiments of the present invention can be combined with each other unless otherwise stated.
[0050] The aforementioned features and advantages of the present invention, as well as other features and advantages, will become even clearer upon further consideration of the following detailed description in conjunction with the accompanying drawings. In the drawings, similar reference numerals refer to similar elements. [Brief explanation of the drawing]
[0051] [Figure 1] This is a schematic diagram showing an extraction system according to one embodiment. [Figure 2] This is a schematic diagram showing a magnetic element according to one embodiment. [Figure 3] This is a schematic diagram showing an extraction system according to one embodiment. [Figure 4] This is a schematic diagram showing the extraction system in Figure 3 that supports the components of a wind turbine generator. [Figure 5] Figure 3 is a schematic diagram showing the details of the extraction apparatus in the extraction system. [Figure 6] Figure 3 is a schematic diagram showing the details of the magnetic element transport device for the extraction system. [Figure 7] Figure 3 is a schematic diagram illustrating the modular design of the extraction system and its transport in standard containers. [Figure 8] This is a flowchart illustrating a method for extracting magnetic elements according to one embodiment.
[0052] Modes for carrying out the invention Embodiments of the present invention will be described in detail below with reference to the accompanying drawings. It should be understood that the following description of embodiments is presented for illustrative purposes only and should not be construed as limiting. The drawings should be considered merely illustrative representations, and it should be noted that the elements in the drawings are not necessarily to scale with respect to each other. Rather, the representation of the various elements has been chosen so that their function and general purpose will be apparent to those skilled in the art. Where used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms unless the context clearly indicates otherwise. The terms “comprising,” “having,” “including,” and “containing” should be interpreted as non-exclusive terms (i.e., “including, but not limited to.”).
[0053] Figure 1 schematically shows an extraction system 100 according to one embodiment. This system comprises a support structure 50 that supports wind turbine generator components 200, an extraction device 20 that extracts magnet elements 10 from rows 220 of components 200, and a transport device 45 that provides an interface 47 to a demagnetization system.
[0054] Component 200 has a cylindrical shape, and the cylindrical axis of this shape extends perpendicular to the plane of the drawing. Multiple rows 220 of magnets are provided on the inner cylindrical surface, each row 220 containing one or more, for example, 1 to 10 magnet elements. Component 200 has each magnet mount 210, which may be provided in the form of a T-shaped slot 215 in this example. These T-shaped slots receive magnet elements 10, which are shown in more detail in Figure 2. The magnet element 10 includes a base plate 11, on which one or more permanent magnet blocks 15 are attached by adhesive 12. The magnet blocks 15 are covered by a cover 17, which may be made of, for example, a sheet of metal. Thus, the magnet element 10 may be a sealed or housed permanent magnet. It is clear that other types of sealing and housing are also possible, or that the magnet element 10 may simply consist of one or more permanent magnet blocks 15. Thus, it is also possible to use other types of magnet mounts 210. For example, as described in European Patent Application Publication No. 2555393, a shape-fitting connection can be provided between the base plate 11 and the T-shaped slot 215 so that the magnetic element 10 can be attached to the component 200 by inserting the magnetic element 10 into the slot 215. However, the extraction system is not limited to this configuration and can extract magnetic elements from any type of magnetic mount 210.
[0055] In the example shown in Figure 1, the component 200 is a generator rotor (particularly an outer rotor) on which a row 220 having magnet elements 10 is provided on its inner cylindrical surface. The extraction system 100 may be configured to extract magnets from other types of WT generator components, such as an inner rotor with magnets arranged on its outer cylindrical surface, or a generator stator equipped with permanent magnets.
[0056] The extraction device 20 is configured to extract one or more magnet elements from the column 220 until all elements from the column have been extracted. The system 100 is further configured to transfer the extracted magnet elements to a conveying device 45 so that they may be transported to a further processing stage, such as a demagnetizing system. The conveying device 45 may include a conveyor such as a belt or chain conveyor.
[0057] The system 100 is configured to align a row 220 of components 200 with the extraction device 20 in order to enable extraction. For this purpose, one or more positioning devices 60 may be provided. A positioning device 60 may include a roller 61 driven by a motor 62. The roller 61 interacts with the components 200 to rotate them and align the row 220 with the extraction device 20. Several such positioning devices 60 may be provided, for example, 1 to 10, preferably 1 to 5, to rotate relatively large generator components. The roller 61 can interact with an inner or outer cylindrical surface. In other embodiments, the positioning device 60 may interact with the hub of the components 200, or may include any other device suitable for aligning, in particular, the components 200 by rotation.
[0058] The support structure 50 may include a component support for supporting the component 200, and may further include any other elements that provide the necessary support to the component 200, such as a guide roller 66. The support structure 50 can support the component 200 with its cylindrical axis oriented vertically, but it is equally conceivable to support the component 200 with its cylindrical axis oriented horizontally.
[0059] The extraction system 100 may include a control system 150 that controls elements of the system 100. The control system 150 controls a positioning device 60 to align a row 220 of components 200 with the extraction device 20, and further controls the extraction device 20 to extract one or more magnet elements from the aligned row 220. Furthermore, it can also control the transfer of the extracted one or more magnet elements to a transport device 45, which may be operated continuously or also controlled by the control system 150. The extraction system 100 may include a position detector 65, such as an encoder, that provides position information to the control system 150. This facilitates the alignment of the row 220 with the extraction device 20 by activating the positioning device 60. Feedforward or feedback control based on position information may be employed by the control system 150.
[0060] Therefore, the control system 150 can cause the extraction system 100 to automatically extract magnet elements from multiple rows 220 of the component 200. In particular, the control system 150 can operate the system 100 to continuously extract magnet elements from the component 200 until all magnet elements have been extracted. Thus, rapid and automatic extraction of magnet elements from the component 200 without human intervention can be achieved. In such continuous operation, the conveying device 45 may operate intermittently, for example, by waiting until magnet elements have been extracted and transferred to the conveying device before continuing conveying.
[0061] The control system 150 may comprise a processing unit 151 and a memory 152. The memory 152 may contain control instructions executed by the processing unit 151. By executing instructions by the processing unit 151, the control system 150 can cause the extraction system 100 to perform any of the methods described herein. The processing unit 151 may include a microprocessor, an application-specific integrated circuit, a digital signal processor, and the like. The memory 152 may include any type of volatile and non-volatile memory, such as RAM, ROM, and flash memory. The control system 150 may comprise any other elements common to computing systems, such as input and output interfaces for receiving information and transmitting control signals, as well as a user interface.
[0062] Figure 3 shows a specific embodiment of the extraction system 100 of Figure 1, and therefore the above description applies similarly. The support structure 50 comprises a component support 55 that supports the component 200, as shown in Figure 4. The component 200 may be provided with bearings 230 to facilitate the rotation of the component 200. If such bearings are not present, the support structure 50 may provide each bearing, for example, on the component support 55. The support structure 50 further comprises a frame 51 which may have an adjustable size. The frame 51 may include a telescopic shaft 51 that allows the support structure 50 to be adapted to the size of the component 200. A positioning device 60 is mounted on the frame 51, and rollers 61 are configured to contact the component 200 when the component 200 is supported, as shown in Figure 4. By driving the rollers 61 with their respective motors, the component 200 is rotated to align the row 220 with the extraction device 20.
[0063] The extraction device 20 of system 100 in Figure 3 is shown in more detail in Figure 5. It comprises guide rails 21 that allow a carriage 22 to move in the direction of extraction of magnetic elements. The carriage 22 may have wheels that run on each rail of the guide rails 21. In the example in Figure 5, the extraction device 20 further comprises an engaging member 23 provided on the carriage 22 in the form of a hook. The engaging member 23 engages with the last magnetic element of row 220 behind the magnetic element when viewed in the extraction direction. In this example, the extraction direction is vertically upward. There may be available space behind the last magnet of the row into which the engaging member 23 can be inserted. Engagement may be performed by the weight of the engaging member, for example, by the weight of the hook causing the hook to rotate downwards on the magnetic element. Alternatively, it may be performed actively, for example, by a pneumatic, hydraulic, or electric actuator.
[0064] The hydraulic cylinder 25 (see also Figure 3) moves the carriage 22 to a position where the engaging member 23 can engage with the magnetic element. The hydraulic cylinder 25 then moves the carriage 22 upward to release the uppermost magnetic element from the magnetic mount 210, particularly pushing it out of the slot 215. The carriage 22 can be moved in the extraction direction by the length of one magnetic element so that one magnetic element is released. This can be continued one magnetic element at a time so that one magnetic element is released at a time.
[0065] The extraction system 100 may be configured to transfer the extracted and released magnetic elements onto transport devices 40, 45. In this example, the extraction device includes a support plate 28, a repositioning device 27 including a mechanical linkage mechanism 29 and a hydraulic or pneumatic cylinder 30. When the magnetic elements are released from the magnetic mount 210, they adhere firmly to the support plate 28. By acting the cylinder 30, and therefore the linkage mechanism 29, the orientation of the support plate 28, and therefore the magnetic elements, is changed from vertical to horizontal. The moving device 31 then transfers the magnetic elements to the transport device 40. In this example, the moving device 31 includes a suction cup 32 that grips or adheres to the magnetic elements, and a hydraulic or pneumatic cylinder 33. After gripping the magnetic elements, the cylinder 33 retracts, and therefore pulls the magnetic elements to the transport device 40.
[0066] In this example, the conveying device 40 is a vertical circulating conveyor that includes a carrier 41 which may be supported and driven by two belts or chains that travel along their respective guides, for example, as is commonly known in the art.
[0067] Figure 6 shows further details of the conveying device 40, which includes a conveyor support 42 containing a belt or chain. In this example, the extracted magnetic elements are conveyed vertically downward. A further moving device 31 having a cylinder 33 transfers the magnetic elements 10 from the conveying device 40 to a further conveying device 45, which in this example is a conveyor belt 46. The conveying device 45 provides an interface 47 to the next processing step, in particular to a demagnetizing system.
[0068] The above describes only exemplary embodiments of the extraction system 100, and it is clear that several modifications are possible and are within the scope of this disclosure. The engaging member 23 does not need to be, for example, mounted on the carriage, but may simply slide within a slot such as a guide rail 21. When extraction is performed horizontally, the repositioning device 27 and the vertical transport device 40 may not be necessary. Furthermore, in addition to using the vertical and horizontal transport devices 40, 45, only a single inclined transport device may be used. It is equally possible to pull out the magnetic elements instead of pushing them out of the row 220 by the engaging member 23. Similarly, the moving device 31 in Figure 5 may push the magnetic elements instead of pulling them. Furthermore, the hydraulic / pneumatic cylinders 25, 30, 33 may be replaced with other actuators such as electrically driven actuators.
[0069] The extraction system 100 can also extract magnetic elements from generator components having different types of magnetic mounts 210. If the magnets are attached by fasteners such as screws or bolts, the extraction device 20 may include, for example, a robotic arm having an actuator or other equipment for loosening such fasteners and then transferring the magnetic elements onto a transport device. In yet another embodiment, the elements of the magnetic mount 210 may need to be disassembled by either removal or destructive disassembly to release the magnetic elements. Such disassembly may also be performed by the respective components of the extraction device 20.
[0070] Figure 8 shows a flowchart of a method according to one embodiment that can be performed by the extraction system of Figure 1 or Figure 3. In step 81, the generator components 200 are attached to the support structure 50 of the extraction system 100. In step 82, a row 220 of the generator components 200, including one or more magnet elements 10, is aligned with the extraction device 20. After alignment, one or more magnet elements 10, preferably all magnet elements, are extracted from the row 220 (step 83). This may be done by engaging the hooks of the carrier 22 and lifting the carrier 22 with the hydraulic cylinder 25 to push the magnet elements out of the slots 215. The extracted magnet elements may optionally be rearranged in step 84, for example by reorienting them using the device 27. The extracted magnet elements are then moved to the transport device in step 85, for example by being moved onto the transport device 40 by the moving device 31. This is preferably done for all magnet elements extracted from the row.
[0071] In step 86, it is checked whether each column 220 of the component 200 has been processed, that is, whether all magnets have been extracted from the component 200. If not, the method proceeds to step 82, and the next column containing the magnet elements is aligned. If each column has been processed, the method ends in step 87.
[0072] The component 200 may comprise, for example, more than 250 rows, each containing more than five magnetic elements. Therefore, more than 1000 magnetic elements must be extracted. The extraction system 100 makes such extraction remarkably quick and easy without creating a dangerous situation for human workers.
[0073] The extraction system 100 is preferably an extraction module configured to work in cooperation with a further processing module for the extracted magnets, such as a demagnetizing module. More preferably, the extraction system 100 is configured to fit into a standard container, as shown in Figure 7. A standard container 70 (e.g., a 20 or 40-foot container) will accept all the elements of the extraction system 100. Thus, the extraction system 100 can be easily transported. For example, it can be transported to a port and installed at the port where the decommissioned wind turbine components of an offshore wind farm arrive. This minimizes the transport distance required for large and heavy wind turbine generator components. In addition to reducing the amount of heavy rare earth material required to manufacture new magnets by extracting and recycling magnet elements from generator components, energy required for transport can be saved.
[0074] The extraction system can achieve extraction speeds of, for example, 100 magnet modules per hour. In particular, automatic alignment using positioning devices and position detectors enables faster extraction processes. Therefore, safe and large-scale extraction becomes possible.
[0075] While specific embodiments are disclosed herein, various changes and modifications can be made without departing from the scope of the invention. These embodiments should be considered in all respects as illustrative and not limiting, and all changes that fall within the meaning of the appended claims and the scope of equivalents are intended to be encompassed therein.
Claims
1. An extraction system (100) configured to extract one or more magnet elements (10) from a wind turbine generator component (200), wherein the wind turbine generator component (200) comprises a plurality of rows (220) of magnet elements (10), and each row (220) contains one or more magnet elements (10), The extraction system (100) is - An extraction device (20) equipped with one or more actuators (25), - A support structure (50) configured to support the wind turbine generator components (200) with respect to the extraction device (20) and to provide alignment between the extraction device (20) and the row (220) of wind turbine generator components (200) and It is equipped with, The extraction device (20) is configured to automatically extract one or more magnet elements (10) from the row (220) of the wind turbine generator components (200). Extraction system.
2. The extraction system according to claim 1, further comprising a positioning device (60) configured to automatically position the wind turbine generator component (200) relative to the extraction device (20) in order to bring about the alignment between the extraction device (20) and the row (220).
3. The extraction system according to claim 2, wherein the positioning device (60) comprises actuators (61, 62) configured to rotate and / or translate the wind turbine generator components (200) relative to the extraction device (20).
4. The extraction system according to claim 2 or 3, wherein the positioning device (60) comprises one or more motor-driven rollers (61) configured to contact the outer and / or inner circumference of the wind turbine generator component (200) and capable of driving the wind turbine generator component (200) to rotate.
5. The extraction system according to any one of claims 1 to 4, wherein one or more actuators (25) of the extraction device (20) are operable to extract one or more magnet elements (10) of a row (220) by separating each of the one or more magnet elements (10) from the magnet mount (210) of the wind turbine generator component (200).
6. The extraction device (20) is controlled by the actuator (25), - To move one or more of the magnetic elements (10) relative to the magnetic mount (210) and release the one or more of the magnetic elements (10) from the magnetic mount (210), - Loosening the fastening member of the magnet mount to release one or more magnet elements (10) from the magnet mount, and - Disassemble the magnetic mount and release one or more magnetic elements (10) from the magnetic mount. The extraction system according to claim 5, configured to separate one or more magnetic elements (10) from the magnetic mount (210) by at least one of the elements.
7. The extraction system according to any one of claims 1 to 6, wherein the extraction device (20) comprises a push assembly and / or pull assembly configured to push or pull one or more of the magnetic elements (10) relative to the wind turbine generator component (200) to release the one or more magnetic elements (10) from the magnet mount (210) of the wind turbine generator component (200), in particular from the shape-fit connection provided by the magnet mount (210).
8. The extraction system according to claim 7, wherein the extraction device (20) comprises a guide rail (21), the push assembly and / or the pull assembly comprises a carriage (22) that can move on the guide rail (21) in a pushing or pulling direction, and the actuator (25) of the extraction device (20) acts on the carriage (22).
9. The extraction system according to claim 7 or 8, wherein the push assembly comprises an engaging member (23) that engages with the magnetic element (10) in the extraction direction at the rear of the magnetic element (10), and the actuator (25) is configured to push or pull the engaging member (23) to push the magnetic element (10) in the extraction direction with the engaging member (23).
10. The extraction system according to any one of claims 1 to 9, further comprising an extraction device (20) and a repositioning device (27) configured to change the orientation of the magnetic elements (10) extracted from the row.
11. The extraction system according to any one of claims 1 to 10, wherein the extraction device (20) further comprises a moving device (31) configured to move the extracted magnetic elements (10) to a transport device (40, 45).
12. The extraction system according to any one of claims 1 to 11, wherein the extraction device (20) extracts one or more magnet elements (10) vertically from the wind turbine generator component (200), and the system further comprises a vertical conveyor (40) for transporting the extracted magnet elements (10) vertically.
13. The extraction system according to any one of claims 1 to 12, further comprising a transport device (45) configured to interface with a demagnetizing system and transport the one or more extracted magnetic elements (10) to the demagnetizing system.
14. A control system (150) configured to control the extraction system (100) such that (a) automatically aligns a row (220) of the wind turbine generator components (200) with the extraction device (20), (b) automatically extracts one or more magnet elements (10) from the row (220), and (c) automatically transports the one or more extracted magnet elements (10) to a further processing device, and repeats steps (a) to (c) for one or more, preferably all, rows (220) of the wind turbine generator components (200). The extraction system according to any one of claims 1 to 13, further comprising:
15. A method for extracting one or more magnet elements (10) from a wind turbine generator component (200), wherein the wind turbine generator component (200) comprises a plurality of rows (220) of magnet elements (10), and each row (220) contains one or more magnet elements (10), The aforementioned method, - The step of supporting the wind turbine generator component (200) with a support structure (50) relative to an extraction device (20) equipped with one or more actuators (25), - The step of aligning the row (220) of the wind turbine generator components (200) with the extraction device (20), - The extraction device (20) automatically extracts one or more magnet elements (10) from the row (220) of the wind turbine generator components (200) and A method that includes this.