Automated Grinding Device for Wind Turbine Rotor Blades

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Solution Overview

Problem

The manual grinding of rotor blades for wind turbines is labor-intensive and costly due to the large surface area and viscoplastic nature of the coatings, which causes frequent clogging of grinding wheels and limits the automation of the grinding process.

Innovation Solution

A grinding device with a belt grinding unit and a dust belt unit that uses a revolving grinding belt and a dust belt to mechanically grind and clean the surface, allowing for continuous grinding and dust removal, along with a belt cleaning device to extend the service life of the belts, and a control unit for precise movement and pressure control.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If hand-held grinding machines are used for manual grinding, then the grinding work can be performed, but the process is labor-intensive and time-consuming

Engineering Contradiction:

Improvemanual operation capabilityVSAvoidgrinding speed

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The patent replaces manual hand-held grinding machines with an automated robotic grinding system that uses a grinding robot equipped with a grinding tool. The robot executes pre-programmed trajectories to automatically grind the rotor blade surface, eliminating manual labor while significantly increasing productivity and consistency.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The grinding system incorporates automatic dust extraction and chip removal mechanisms that operate without manual intervention. The system self-regulates the grinding process by continuously removing debris and maintaining optimal grinding conditions throughout the operation.

Inventive Principle:

Principle #25Self-service

2Ease of operation

If hand-held grinding machines are used, then grinding can be performed, but the large surface area requires extensive time and labor

Engineering Contradiction:

Improvesimplicity of grinding processVSAvoidgrinding time

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The robotic grinding system operates continuously along pre-programmed trajectories without the interruptions typical of manual grinding. The robot maintains constant motion and grinding contact, eliminating idle time between operations and maximizing productivity across the entire rotor blade surface.

Inventive Principle:

Principle #20Continuity of useful action

3Ease of operation

If grinding wheels are used on hand-held machines, then grinding can be performed, but the viscoplastic coating causes frequent clogging

Engineering Contradiction:

Improvegrinding capabilityVSAvoidgrinding wheel service life

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system extracts and removes grinding debris and chips from the grinding zone through integrated dust extraction mechanisms. This continuous removal prevents the viscoplastic coating material from accumulating and clogging the grinding wheel, maintaining consistent grinding performance throughout the process.

Inventive Principle:

Principle #2Taking out (Extraction)

4Productivity

If frequent grinding wheel changes are required, then grinding can continue, but the process becomes inefficient and costly

Engineering Contradiction:

Improvecontinuous grinding capabilityVSAvoidwheel change time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Inventive Principle:

Principle #20Continuity of useful action

5Ease of operation

If manual grinding is used, then the process can be performed, but the cost is very high

Engineering Contradiction:

Improvemanual process simplicityVSAvoidmanufacturing cost

Core Design Contradiction:

Ease of operationVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system implements dust extraction and chip collection mechanisms that recover grinding debris for proper disposal or recycling. This reduces waste management costs and environmental impact while maintaining efficient grinding operations.

Inventive Principle:

Principle #34Discarding and recovering

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 device automates the grinding process, significantly reduces the need for manual labor, increases the service life of grinding belts, and achieves a more even grinding result while minimizing dust exposure and environmental impact.

Implementation Method 1

A grinding device (1) is proposed for mechanical grinding of rotor blades (100) for wind turbines

Methodology Applied

Scientific EffectAbrasion: Abrasion

Implementation Method 2

a dust belt unit (40) with a revolving dust belt (42) which is guided along at least one surface (110) of a rotor blade (100) in order to pick up the grinding dust produced there

Methodology Applied

Scientific EffectSuction: Suction

Data Source

PatentEP2422929B2Grinding device for mechanical grinding of rotor blades for wind power systems

Publication Date: 2017.03.01 JOST GMBH & CO KG

AI summary

The grinding apparatus (1) comprises a belt grinding unit (10) having a revolving grinding belt (12). A drive unit (30) is provided for moving the belt grinding unit in the direction of the longitudinal axis of a rotor blade. A dust band unit (40) is provided with a circumferential dust band (42) which is guided at a surface of the rotor blade.