Electric Motor Clamping Tool for Wind Turbine Blade Tips
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Solution Overview
Problem
The handling of large wind turbine blade tips is challenging due to their size and weight, requiring complex and expensive hydraulic lifting tools, and there is a need for precise control of clamping forces to prevent damage during assembly.
Innovation Solution
A tool using an electric motor with a control system that measures currents to determine and apply a predetermined clamping force, accounting for internal losses by measuring currents without a component to accurately control the clamping force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If hydraulic clamps are used for lifting and manipulating blade tip parts, then the clamping force and lifting capability are sufficient, but the device complexity and cost increase significantly
Solution Approach 1:
The patent replaces the hydraulic mechanical system with an electric motor-driven system. The electric motor (20) drives the actuator (45) through a reduction gear, eliminating the need for hydraulic pumps, hoses, and control valves. This substitution maintains sufficient clamping force while significantly reducing device complexity and cost.
2Power
If hydraulic mechanisms are used for handling blade tips, then adequate lifting and clamping capability is achieved, but the cost becomes excessively high
Solution Approach 1:
The patent substitutes expensive hydraulic components with more cost-effective electric motor components. The electric motor (20) with integrated actuator (45) provides the necessary lifting and clamping power at a lower cost than hydraulic systems, which require multiple expensive components including pumps, reservoirs, and control valves.
Solution Approach 2:
The patent combines the motor (20), actuator (45), and clamp seats (12, 14, 16) into an integrated assembly. This merging of functions reduces the total number of separate components, simplifying manufacturing and reducing overall cost while maintaining adequate power for handling blade tips.
3Device complexity
If electric motor is used instead of hydraulic mechanism, then device complexity and cost are reduced, but precise control of clamping force becomes difficult
Solution Approach 1:
The patent implements a feedback control system where the control unit (30) continuously monitors the current consumption of the electric motor (20) and adjusts the motor's power output accordingly. Since motor current is directly proportional to the torque and clamping force being applied, this feedback mechanism enables precise control of clamping force despite the simpler electric drive system.
Solution Approach 2:
The patent controls the clamping force by adjusting electrical parameters (current, voltage, frequency) of the electric motor rather than mechanical parameters. The control unit (30) varies the electrical input to the motor (20) to achieve the desired clamping force, providing precise control through electrical parameter modulation instead of mechanical adjustment.
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 solution provides a less complex and cost-effective method for handling wind turbine blade tips, ensuring precise control of clamping forces to prevent damage and ensure secure assembly, while adapting to varying internal friction over the tool's lifetime.
Implementation Method 1
an electric motor (20) for driving the actuator (45)
Implementation Method 2
a control (30) configured to control the electric motor (20) by determining currents in the electric motor (20) and to control the electric motor (20) to provide the predetermined clamping force based on the determined currents
Data Source
AI summary
The disclosure relates to methods and tools for handling a component, the tools (10) comprising a first clamp seat (12) for receiving a first surface of the component and a second clamp seat (14, 16) for receiving a second surface of the component, the second surface being opposite to the first surface. The tool further comprises an actuator (45) for moving the first clamp seat to clamp the component between the first clamp seat and the second clamp seat with a predetermined clamping force, and an electric motor (40) for driving the actuator (45). The tool (10) further comprises a control configured to determine currents in the electric motor and to control the electric motor to provide the predetermined clamping force based on the determined currents. Also methods for determining a desired current level in an electric motor driving an actuator for clamping a component and methods for controlling a clamping force in a tool are provided.