Stationary Gantry Wire Cutting for Wind Turbine Blade Sectioning
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Solution Overview
Problem
The transportation and decommissioning of large wind turbine blades and other elongated shell-type objects are challenging due to their size and low solid-to-gas volume ratio, requiring complex and large equipment like shredders that are difficult to transport and install, and existing cutting methods cause instability and downtime.
Innovation Solution
A method and system using a stationary gantry with a wire grid that cuts objects by moving them through a portal, allowing for stable and controlled cutting into sections, utilizing a gantry with a wire grid and supports to stabilize the object, and a pull system to facilitate movement, enabling efficient cutting into manageable sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a shredder is used to decommission wind turbine blades on-site, then the blades can be processed without transportation, but the shredder becomes extremely large and difficult to transport and install
Solution Approach 1:
The invention divides the blade processing into two stages: first cutting the blade into smaller sections using a portable cutter system, then feeding these sections into a standard-sized shredder. This segmentation allows the use of compact equipment rather than requiring a single large on-site shredder
Solution Approach 2:
The blade is pre-cut into smaller sections before being fed to the shredder. This preliminary action reduces the size of material needing to be processed by the shredder, enabling the use of standard-sized equipment rather than extremely large on-site shredders
2Ease of manufacture
If a vehicle-mounted wire saw with rails is used to cut blades, then cutting capability is achieved, but the system requires 80 meters of rail that must be transported and installed, increasing complexity
Solution Approach 1:
Instead of moving the cutter system along rails through the blade, the invention inverts the approach by moving the blade through a stationary compact cutter. This eliminates the need for extensive rail infrastructure while maintaining cutting capability
Solution Approach 2:
The invention changes the cutting approach from longitudinal cutting along the blade axis to transverse cutting perpendicular to the blade axis. This dimensional change allows use of a compact stationary cutter rather than a long rail-mounted system
3Productivity
If blades are sectioned only along the longitudinal axis, then cutting is achieved, but the sections still have excessive width and height for standard shredder input
Solution Approach 1:
The invention applies multi-directional cutting to divide the blade into smaller cubic sections that meet shredder input requirements. By cutting in multiple directions (longitudinally, laterally, and vertically), the blade is segmented into manageable pieces rather than long sections
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
This approach simplifies and stabilizes the cutting process, reduces downtime, and allows for easier transportation and recycling of the sections by eliminating the need for extensive rail systems, enhancing reliability and efficiency.
Implementation Method 1
a wire grid operable in the portal and adapted for cutting an object moving through the portal
Data Source
AI summary
An object of the invention is achieved by a method for cutting an elongated shell-type object. The method may include steps of providing a gantry defining a portal and comprising a wire grid operable in the portal; operating the wire grid, whilst moving the shell-type object through the wire grid along a lateral-axis (Z) substantially perpendicular to the portal. The method is performed by a stationary gantry, where the shell-type object is moved through the portal. Thereby, the method is simplified as there is no need for a rail system for moving the gantry.