Bridging Gantry for Robotic Wind Turbine Blade Manufacturing
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Solution Overview
Problem
The increasing size of wind turbine blades poses challenges in manufacturing, requiring high accuracy and safety while handling large and heavy components, and workers are exposed to hazardous substances for extended periods, necessitating a more efficient and ergonomic manufacturing solution.
Innovation Solution
A gantry system with a frame that bridges the wind turbine blade in a cross-section direction, equipped with wheels for mobility and robotic units for automated manufacturing steps, allowing for stable and flexible operation even in limited spaces, and enabling precise and efficient processing of large blades.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the blade diameter is increased to produce more power, then the power generation capacity is improved, but the manufacturing difficulty and required manufacturing hall size increase significantly
Solution Approach 1:
The gantry system is designed to be movable rather than fixed, allowing it to be repositioned along the blade length and adjusted to different blade configurations. This dynamic capability enables the same system to handle various blade sizes without requiring completely different manufacturing setups, thereby reducing manufacturing complexity for larger blades.
Solution Approach 2:
The invention transitions from horizontal blade manufacturing to vertical blade manufacturing. By orienting the blade vertically and using a gantry system that moves along the blade length, the manufacturing process can accommodate larger blade diameters without proportionally increasing the manufacturing hall footprint, thus managing the complexity of manufacturing large blades.
2Power
If the blade diameter is increased to produce more power, then the power generation capacity is improved, but the required manufacturing hall size increases
Solution Approach 1:
The invention changes the manufacturing orientation from horizontal to vertical. The gantry system spans across the vertical blade and moves along its length, allowing large blade diameters to be manufactured in a compact horizontal footprint. This dimensional change enables power generation capacity to increase without proportionally increasing manufacturing hall area.
Solution Approach 2:
The movable gantry system can be repositioned and reconfigured for different blade sizes, allowing the manufacturing hall to accommodate various blade diameters without requiring the hall size to scale proportionally with blade size. This dynamic adaptability optimizes space utilization.
3Ease of operation
If workers manually handle large blade components, then flexibility in manufacturing is maintained, but worker safety and ergonomics deteriorate due to exposure to hazardous substances and heavy lifting
Solution Approach 1:
The system employs automated robotic units that perform manufacturing tasks independently without requiring direct worker intervention in hazardous zones. The robots handle tasks involving hazardous substances and heavy components, making the system self-sufficient for dangerous operations while improving worker safety.
Solution Approach 2:
Manual mechanical operations by workers are replaced with automated robotic systems. The robotic units equipped with specialized end effectors perform tasks such as handling, positioning, and processing of large blade components, substituting human labor with automated mechanical systems that eliminate exposure to hazardous substances and ergonomic risks.
Data Source
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AI summary
A gantry system (8) for manufacturing a wind turbine blade (3), the gantry system comprising a frame (10) for bridging the wind turbine blade (3') in a cross-section direction of the blade (3') during manufacture, wheels (12) rotatably attached to the frame (10) for locomotion of the gantry system, and one or more robotic units (9) attached to the frame (10) for performing manufacturing steps for manufacturing the blade (3'). Having the gantry system bridging the wind turbine blade in a cross-section direction of the blade during manufacture provides a stable vehicle with a large footprint for manufacturing a wind turbine blade.