Wind Turbine Blade Bulkhead Drilling for Tip Access
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Solution Overview
Problem
Wind turbine blades often contain bulkheads that obstruct access to the tip, making it difficult to install ice protection systems in cold, humid regions where ice formation is a concern.
Innovation Solution
A bulkhead removal system comprising a drilling subsystem, an extension subsystem, a connection subsystem, and a control subsystem, which allows for the controlled drilling and removal of bulkheads within wind turbine blades, enabling access for ice protection system installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If bulkheads are left in place in the blade cavity, then the blade structure maintains its lifting stability, but access to the blade tip for ice protection system installation is blocked
Solution Approach 1:
The bulkhead removal device is divided into multiple independent subsystems: a drilling subsystem with drill bit, an extension subsystem with telescopic arms, a positioning subsystem with sensors and cameras, and a control subsystem. This segmentation allows each component to perform its specific function efficiently while working together to remove bulkheads without compromising blade structural integrity.
Solution Approach 2:
The patent introduces a bulkhead removal device as an intermediary tool between the operator and the bulkheads. This device includes drilling mechanisms that can penetrate bulkheads, extension subsystems that reach into the blade cavity, and control systems that coordinate the removal process, thereby enabling access to the blade tip without direct manual intervention.
2Ease of operation
If a bulkhead removal device is introduced to remove bulkheads, then access to the blade tip is enabled, but the device complexity increases
Solution Approach 1:
The bulkhead removal device is designed as a multi-functional system that can perform drilling, extension, positioning, and control functions within a single integrated platform. The drilling subsystem can handle different bulkhead materials, the extension subsystem can adjust its length, and the control subsystem can coordinate various operations, reducing the need for multiple separate devices.
Solution Approach 2:
The device employs a nested structure where the drill bit is housed within the drilling subsystem, which is in turn contained within the extension subsystem, which is nested within the positioning subsystem, and finally controlled by the control subsystem. This nested arrangement allows compact storage and efficient deployment of multiple functional components.
3Productivity
If multiple bulkheads are present in the blade cavity, then the blade maintains structural support during lifting, but the time required to remove all bulkheads increases
Solution Approach 1:
The drilling subsystem is designed to drill through multiple bulkheads in continuous succession without requiring repositioning or reconfiguration between each bulkhead. The extension subsystem maintains continuous contact with the blade cavity walls, and the control subsystem coordinates the drilling process to proceed uninterrupted from one bulkhead to the next, maximizing removal speed.
Solution Approach 2:
The positioning subsystem with sensors and cameras performs preliminary detection and mapping of bulkhead locations before the drilling process begins. This preliminary action allows the control subsystem to pre-plan the drilling sequence and positions, eliminating the need for time-consuming adjustments during the actual removal process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively removes bulkheads, providing unobstructed access to the blade tip, thereby facilitating the installation of ice protection systems and ensuring the operational efficiency and safety of wind turbines in icy conditions.
Implementation Method 1
drilling the first bulkhead may further include rotating the drill and extending the drill forward from the rest of the drilling subsystem through the first bulkhead
Implementation Method 2
rotating the drill and extending the drill forward from the rest of the drilling subsystem through the first bulkhead
Implementation Method 3
Positioning the bulkhead removal device may further include using a proximity sensor and at least one camera which provide information to an operator
Implementation Method 4
using a proximity sensor and at least one camera which provide information to an operator at a user interface
Implementation Method 5
Aligning the drill may further include using at least one laser and the at least one camera to provide alignment information to the operator
Implementation Method 6
Securing the extension system to the blade may further include extending a plurality of jackscrews out from the extension subsystem to contact an interior of the blade
Implementation Method 7
Securing the drill to the blade may further include extending a plurality of outriggers out from the drill to contact the interior of the blade
Data Source
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AI summary
Wind turbine bulkhead removal systems and methods are provided. The bulkhead removal system includes a bulkhead removal device and control subsystem. The bulkhead removal device includes a drilling subsystem with a drill for drilling at least one bulkhead within a wind turbine blade and an extension subsystem which is physically connected to the drilling subsystem and releasably securable to the wind turbine blade. The extension subsystem moves the drilling subsystem forwards and backwards along a length of the wind turbine blade to position the drill for drilling through each bulkhead. The control subsystem controls the operation of the drilling subsystem and the extension subsystem. The bulkhead removal system may also include a connection subsystem for connecting power and control components of the drilling and extension subsystems to a power source and to the control subsystem.