Self-Propelled Production Flange Trimming for Wind Turbine Blades
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Solution Overview
Problem
Manual trimming of production flanges from wind turbine blades is time-consuming and prone to inaccuracies, potentially causing damage to the blade shell due to reliance on human physical strength and skill.
Innovation Solution
A self-propelled production flange trimming apparatus that automatically follows the spanwise extending production flange using a directional control system with follower wheels and actuators, allowing precise cutting without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual trimming with hand-held circular saw is used, then the process is simple to implement, but the operation is time-consuming and prone to inaccuracies causing potential damage to the blade shell
Solution Approach 1:
The trimming apparatus is self-propelled along the production flange using its own drive system, eliminating the need for external positioning equipment or manual handling. The apparatus serves itself by independently navigating and executing the trimming operation along the entire spanwise length of the production flange
Solution Approach 2:
The manual mechanical operation of guiding and controlling a hand-held saw is replaced with an automated system that uses a drive system for propulsion, a directional control system with follower wheels for navigation, and a motorized cutting tool for execution. This substitution eliminates human physical intervention while maintaining precise control
2Reliability
If manual trimming operation is used, then the equipment requirement is minimal, but the operation relies on human physical strength leading to potential damage to the blade shell
Solution Approach 1:
The reliance on human physical strength and skill is completely replaced by an automated system. The directional control system with follower wheels passively follows the contour of the production flange, while the drive system provides consistent propulsion force. This eliminates variability in human physical capability and ensures uniform, controlled trimming throughout the operation
Solution Approach 2:
The follower mechanism provides continuous passive feedback by following the actual geometry of the production flange surface. This ensures the cutting tool maintains the correct position and orientation relative to the workpiece, automatically adapting to any variations in the flange shape without requiring active human adjustment
3Extent of automation
If automated cutting machine with rubber wheel structure is used, then the cutting automation is improved, but the friction-based propulsion may not be sufficient for precise control along the production flange
Solution Approach 1:
The apparatus propels itself along the production flange using its integrated drive system, which provides controlled mechanical propulsion. This self-service capability ensures the apparatus can reliably navigate the entire spanwise length of the production flange with consistent speed and positioning, independent of external assistance
Solution Approach 2:
The friction-based rubber wheel propulsion is replaced with a more reliable drive system that provides direct mechanical propulsion. This substitution ensures sufficient and controllable driving force for moving the apparatus along the production flange, overcoming limitations of friction-based approaches while maintaining precise operational control
Data Source
Figure 1
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Figure 4a~4c
AI summary
A method of trimming a production flange (52) from a wind turbine blade (10) during manufacture of the wind turbine blade (10). The method comprises mounting a self-propelled flange trimming apparatus (60) on the production flange (52) and using a drive system (64, 66) of the apparatus (60) to propel the apparatus (60) along the production flange (52). A directional control system controls the direction of the apparatus (60) and a cutting tool (81) cuts through the production flange (52) as the apparatus (60) travels along the production flange (52). Also, a self-propelled production flange trimming apparatus (60) comprising a carriage (61) with a drive member (64, 66), a directional control system, and a cutting tool (81) attached to the carriage (61). A system comprising a wind turbine blade moulding (50) and a trimming apparatus (60) mounted on the production flange (52) of the moulding (50).