SYSTEM FOR DEMOLITION OF BLADE OF WIND TURBINE AND RELATED METHOD
20230211391 · 2023-07-06
Inventors
Cpc classification
B02C18/145
PERFORMING OPERATIONS; TRANSPORTING
B02C21/02
PERFORMING OPERATIONS; TRANSPORTING
International classification
B02C23/24
PERFORMING OPERATIONS; TRANSPORTING
B02C21/02
PERFORMING OPERATIONS; TRANSPORTING
Abstract
The system and method of processing a used wind turbine blade provides for processing of a blade at the site of the windmill rather than transporting the blade to a processing facility. The blade may be held stationary while a cutter, such as a drum or plate with cutting teeth, is moved along a portion of the blade to shred the blade. This shredding may occur within a cutting chamber. The blade may be fed into the cutting chamber with a feeder. Smaller particles may be removed or filtered from the air within the cutting chamber and larger particles may be removed and collected in a receptacle. Portions of or the entire system may be made mobile by mounting or otherwise connecting the system to a mobile support, such as a trailer.
Claims
1. A system for processing a used wind turbine blade comprising: at least one gripper adapted to grip and hold the blade stationary; at least one cutter adapted to shred the blade; and a cutter support adapted to move the cutter with respect to the blade to process the blade.
2. The system of claim 1, wherein the cutter is housed within a cutting chamber.
3. The system of claim 2, further including a dust collector in communication with the cutting chamber for removing small particles from the air within the cutting chamber.
4. The system of claim 1, wherein the cutter support comprises at least one beam, and wherein the cutter is adapted to move along the beam as the cutter shreds the blade.
5. The system of claim 1, further including a drive for moving the cutter along the cutter support.
6. The system of claim 1, wherein the cutter comprises a cutter frame and a cutter head.
7. The system of claim 6, wherein the cutter head comprises a rotatable drum comprising a plurality of teeth.
8. The system of claim 6, wherein the cutter frame comprises a window on a lateral side thereof, the window adapted to receive the blade as the cutter moves along the cutter support.
9. The system of claim 8, wherein the cutter frame comprises a blade support adapted to guide the blade into the window as the cutter moves along the cutter support.
10. The system of claim 1, further including a feeder adapted to feed the blade to the cutter.
11. The system of claim 10, wherein the feeder is adapted to move with respect to the gripper in a feeding direction.
12. The system of claim 11, further including an actuator adapted to move the feeder with respect to the gripper.
13. The system of claim 10, wherein the feeder and the gripper are both actuable clamps.
14. The system of claim 1, further including a discharge conveyor adapted to receive processed pieces of the blade from the cutter and transport said processed pieces to a receptacle.
15. The system of claim 1, further including a mobile support for supporting and transporting the cutter and the cutter support.
16. A method for processing a used wind turbine blade comprising: gripping the blade and holding the blade stationary; moving a cutter along the blade to shred at least a portion of the blade.
17. The method of claim 16, wherein the moving step comprises moving the cutter along a cutter support in a direction transverse to a length of the blade.
18. The method of claim 16, further including the step of feeding the blade in a feeding direction toward the cutter.
19. The method of claim 18, wherein the step of feeding the blade comprises clamping the blade with a clamp and moving the clamp toward the cutter.
20. The method of claim 16, wherein the step of moving the cutter occurs in a cutting chamber, and wherein the cutting chamber is attached to a vacuum for collecting debris from the shredding of the blade.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Further characteristics and advantages of the invention will become apparent in the description of non-exclusive embodiments of the system, illustrated—by way of a non-limiting example-in the drawings attached hereto, in which:
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DETAILED DESCRIPTION
[0038] In the following detailed description, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration, specific embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the embodiments and like numerals represent like details in the various figures. Also, it is to be understood that other embodiments may be utilized, and that process or other changes may be made without departing from the scope of the disclosure. The following detailed description is not to be taken in a limiting sense, and the scope of the invention is defined only by the appended claims and their equivalents. In accordance with the disclosure, a system for processing and/or disposing of large-scale items such as wind turbine blades is hereinafter described.
[0039] Reference is now made to
[0040] The system 10 may include a cutting chamber 20, which may be adapted for receiving the blade 12 for processing. The cutting chamber 20 may include at least one first cutter 22 for cutting the blade 12. The first cutter 22 may be a shredder adapted to break the blade 12 or large pieces thereof into smaller parts, such as shards, pellets, chips, shavings, or other smaller pieces for easy transport to a secondary location for disposal, recycling, or other further use. The cutting chamber 20 may include one or more sensors, such as video cameras or other monitoring device, to allow for remote operation and visualization and/or for automation.
[0041] A dust barrier 34 may be provided at an entrance to the cutting chamber 20 as a means of preventing or inhibiting escape of dust or other small particulates that are a result of processing the blade 12. The dust barrier may comprise a flap, a shroud, a curtain, a vacuum for providing a negative pressure within the cutting chamber 20, or any other barrier to inhibit the escape of dust.
[0042] In a further aspect, a dust collector may be provided with the system 10. For example, the dust collector may be adapted to create a negative pressure within the cutting chamber 20, and thus remove any airborne particulates and small particles that do not fall from the first cutter. The dust collector may comprise one or more filters or filtering means for removing dust and small particulates from the air. The dust collector may comprise a reverse pulse filtration system for automatic filter cleaning. In a non-limiting example, the dust collector may be rated at between 15,000 - 20,000 cfm. The dust collector may comprise one or more filters rated for use with fine fiberglass dust. The cutting chamber 20 may include the vacuum system needed to create the dust collector, or a separate dust collector may be fluidly connected to the cutting chamber.
[0043] The first cutter may be connected to a boom 24 or other mechanism to provide vertical and horizontal movement. The boom 24 may allow the first cutter 22 to be articulated in a plurality of directions or about a plurality of axes to provide access of the first cutter 22 to different parts of the blade 12. For example the boom 24 may be adapted to extend and retract the first cutter 20 in a direction along a longitudinal axis of the boom. The boom 24 may be adapted to pivot about one or more joints of the boom so as to move the first cutter 22 vertically and/or horizontally. In one aspect, the boom may include a joint that is adapted to pivot the first cutter about an axis transverse to or perpendicular to the longitudinal axis of the boom. The boom 24 may be further adapted to rotate the first cutter 22 about the longitudinal axis of the boom. Thus, the boom 24 may allow the first cutter 22 to reach any portion of the blade 12 introduced into the cutting chamber 20. This may allow movement of the first cutter to correspond to a thickness of the blade 12, such that the first cutter may be moved across an entire thickness of the blade in order to process the entire blade.
[0044] In some embodiments, the cutting chamber 20 may include a plurality of first cutters 22. For example, a first cutter 22 may be positioned on a top of the blade, and a first cutter 22 may be positioned on a bottom of the blade. This may allow for a more efficient processing of the blade. The plurality of first cutters 22 may be provided on a single boom, or a plurality of booms may be provided in association with the plurality of first cutters 22.
[0045] With reference to
[0046] Furthermore, the shroud can aid in sizing of the cut material by forcing large chunks to be captured and cut between the cutter and the shroud. The shroud can also provide a support for thin sections of the blade to guarantee that they are cut rather than simply bending away from the cutter.
[0047] In one aspect, the system 10 may include one or more sensors for sensing a proximity of the first cutter to the blade. The system 10 may include a controller adapted to receive a signal from the one or more sensors and maintain a preset or predetermined distance from the blade during operation of the first cutter. Accordingly, the system may be adapted to cause the first cutter to follow a contour of the blade.
[0048] Various types of cutter heads may be used for processing the blade 12. For example, as shown in
[0049] With reference to
[0050] During the processing of the blade, the feed rate of the blade 12 to the first cutter 22 may be adjusted to optimize cutting speed without overloading the cutter. This adjustment of the feed rate of the blade may be conducted manually by an operator, or may be automatic within the system. In the automatic mode, the system 10 may include one or more sensors to sense a load on or a torque induced by the first cutter. If the load or torque exceeds a predetermined or preset amount, then a feed rate of the blade may be decreased until the load or torque is below a threshold value to maximize overall efficency.
[0051] When not in use, the boom 24, with or without the first cutter 22 attached, may be stored or transported within a boom storage chamber 25. In one aspect, the boom 24 may be mounted within the boom storage chamber 25. The boom storage chamber 25 may be connected to the cutting chamber 20 such that the boom 24 may extend from the boom storage chamber 25 into the cutting chamber 20.
[0052] A receptacle 26 may be provided to collect the pieces of the blade 12 after they have been processed by the first cutter 22. This receptacle 26 may be a normal dumpster, such as a 30 yard dumpster that is known in the art and may be transported by forklift and/or tractor-trailer. The receptacle may be located below the cutting chamber 20, so that processed pieces of the blade 12 may simply fall into the receptacle 26. In one aspect, the cutting chamber may be open at the bottom to allow processed pieces of the blade 12 to fall freely into the receptacle 26. In another aspect, the cutting chamber 20 may have a retractable base or an openable and closable aperture in its bottom to allow processed pieces of the blade to be selectively emptied from the cutting chamber 20 into the receptacle.
[0053] In another aspect, the system 10 may include a conveyor 14, such as a blade feed system. This conveyor 14 may be adapted to feed the blade 12 to the cutting chamber 20 for processing, such as in a feed direction F. This conveyor 14 may comprise one or more rollers 16, which may support the blade 12 at a desired height to facilitate loading the blade into the cutting chamber. The conveyor 14 may be adjustable in height to facilitate such loading at different heights, depending on blade size, size, height, or door size of the cutting chamber, or to account for uneven ground surrounding the cutting chamber.
[0054] One or more feeders 30 may further assist in feeding the blade 12 into the cutting chamber 20. For example, feeder 30 may comprise a feed roller. The feeder 30 may contact the blade 12 and push the blade into or toward the cutting chamber 20. In one aspect, the feed roller may include a gripping surface, such as knurling, teeth, or a helical groove to provide additional friction against the blade 12.
[0055] One or more lateral rollers 33 may be provided to further assist in moving the blade 12 toward the first cutter 22 in the cutting chamber 20. These lateral rollers 33 may comprise a pair of pinch rollers adapted to contact or grip a lateral side of the blade 12. These lateral rollers 33 may be adapted to move toward and away from each other so as to grip the blade 12 at different lateral widths of the blade. This is particularly helpful as the blades of wind turbines may have a non-uniform profile, as can most easily be seen in
[0056] In yet another aspect, one or more second cutters 28 may be provided. The second cutter 28 may be adapted to remove any portion of the blade 12 that will not be processed by the first cutter 22. For example, the hub portion of the blade (or the portion of the blade that connects to the hub of the wind turbine) may be removed prior to processing the remainder of the blade.
[0057] This second cutter 28 may be adapted to break the blade 12 down into smaller pieces that are more easily processed by the first cutter 22. For example, the second cutter 28 may comprise a cutoff saw, such as a chainsaw (which may be arranged to cut in a vertical direction), a laser, or any other cutting device for breaking the larger blade 12 into pieces of sufficiently small size to be introduced into the cutting chamber 20.
[0058] The system 10 may further include an operator cab 32, which may comprise one or more controls for operating one or more elements of the system 10 described herein. The operator cab 32 may include air processing, such as a filtration and/or HVAC system, noise insulation, appropriate lighting, sensors, and controls. The operator cab 32 may be fixed in a position sufficiently distanced from the first cutter and/or the second cutter to protect an operator from flying debris during processing of a blade 12.
[0059] In a further aspect, the system 10 may be portable or mobile. For example, one or more of the elements of the system 10 may be mounted on or transported via mobile supports 18, such as trailers. These trailers may be adapted for tow-behind standard tractor rig or semi-truck. Accordingly, one or more of the elements of the system 10 described herein, including the entirety of the system 10 described herein, may be transported to a site of a wind turbine. Thus, a used blade 12 that has been removed from the wind turbine may be processed by the system at the location of the wind turbine, rather than transported to a different facility, thereby avoiding expensive transportation costs associated with transporting a wind turbine blade.
[0060] With further reference to
[0061] In one aspect, the system 100 may be mobile, so that it may be transported to the location of a wind turbine blade for processing. For example, the system 100 may include one or more mobile support 118, such as a trailer. The trailer may be a tow-behind style trailer, such as one that is standard for a tractor rig or semi-truck.
[0062] The system 100 may include a gripper 128, such as a grip press, adapted for holding the blade 112 while the cutter 122 processes at least a portion of the blade 112. As illustrated in
[0063] A feeder 130, such as a feed press, may be provided for feeding the blade 112 along a feed direction F into the cutting chamber 120. The feeder 130 may be mobile or otherwise movable, such as by an actuator 134, in order to effectuate the movement of the blade 112 into the cutting chamber 120. The actuator 134 may comprise a hydraulic cylinder or other driving mechanism for moving the feeder 130 along the feed direction F back and forth with respect to the gripper 128. Thus, as illustrated in
[0064] One or both of the gripper 128 and the feeder 130 may comprise clamps, which may be hydraulically driven. These clamps may be adapted to crush or flatten the blade 112 prior to cutting by the cutter 122. This crushing or flattening of the blade 112 may provide a more compact surface area upon which the cutter 122 must act, thereby allowing for more cutting efficiency in processing the blade. In one aspect, the gripper 128 and/or the feeder 130 may be adapted to crush or flatten the blade 112 to a height of no more than 2 feet. This crushing or flattening may be provided by clamps able to apply significant pressure, sufficient to flatten the structure of the blade. As one example, the clamps may be capable of applying 80 tons of clamping force (although different clamping force may be used in association with different compositions of blade material to be flattened).
[0065] The cutter 122 may be adapted to travel in a cutting direction C so as to move along or across the blade 112 for processing. With further reference to
[0066] Turning to
[0067] The cutter head 140 may comprise a drum or a plate and may include one or more teeth, tips, or bits (collectively “teeth”) on an outer surface of the cutter head. In one example, the cutter head 140 comprises a drum that is 5 feet in diameter with a 3 ton mass. As can be seen in the drawings, the teeth may be positioned on the lateral or axial side faces of the cutter head 140 so that movement of the cutter 122 across the blade 112 causes the teeth, tips, or bits to contact and shred the blade. These teeth, tips, or bits may include, but are not limited to, those illustrated and described in
[0068] The cutter frame 136 may include one or more connectors 138 for engaging with the cutter support 131. In one aspect, the connectors 138 may comprise receivers for receiving at least a portion of the cutter support 131. In one example, the connectors 138 may comprise beams or sections of beams adapted to nest or otherwise slide alone a length of the beams of the cutter support 131. For example, the connectors 138 may comprise arms that may fit inside of the beams of the cutter support, and may slide therewithin. One or more friction reducing elements may be included, such as rollers, wear pads, or a bearing or bearing surface to facilitate the movement of the cutter along the cutter support.
[0069] The cutter frame 136 may include a window 142 adapted to receive a portion of the blade 112 for processing. The window 142 may comprise an opening in the lateral sides of the cutter frame 136 that may expose at least a portion of the cutter head 140 to the blade 112. The frame 136 may further include a blade support 144 for supporting at least a portion of the blade 112 as it enters the window 142. The blade support 144 may take the form of a projection. This projection may extend in a lateral direction. In one aspect, the blade support 144 may include an inclined surface that may direct the blade into and through the window 142.
[0070] As the cutter 122 travels in the cutting direction C, the window 142 may allow the blade 112, fixed in position by one or more of the gripper 128 and the feeder 130, to make contact with the cutter head 140 through the window 142. As the blade 112 contacts the cutter head 140, the blade is shredded by the one or more teeth, tips, or bits on the cutter head 140.
[0071] With reference to
[0072] As shown in
[0073] Larger particles resulting from the processing of a blade 112 within the cutting chamber 120 may fall to or through the bottom of the cutting chamber 120. In one aspect, a receptacle may be placed below the cutting chamber in order to directly collect these larger particles. In another aspect, as illustrated in
[0074] In other embodiments, the discharge conveyor 124 may be below the cutting chamber 120, such as on or near a surface of the mobile support 118. In these embodiments, the discharge conveyor 124 may be adapted to receive the larger particles, such as from an outlet at or near a floor of the cutting chamber, or a retractable base or an openable and closable aperture at the bottom of the cutting chamber, and carry these larger particles away. As illustrated in
[0075] Each of the following terms written in singular grammatical form: “a”, “an″, and the”, as used herein, means “at least one”, or “one or more”. Use of the phrase “one or more” herein does not alter this intended meaning of “a”, “an”, or “the”. Accordingly, the terms “a”, “an”, and “the”, as used herein, may also refer to, and encompass, a plurality of the stated entity or object, unless otherwise specifically defined or stated herein, or, unless the context clearly dictates otherwise. For example, the phrases: “a unit”, “a device”, “an assembly”, “a mechanism”, “a component, “an element”, and “a step or procedure”, as used herein, may also refer to, and encompass, a plurality of units, a plurality of devices, a plurality of assemblies, a plurality of mechanisms, a plurality of components, a plurality of elements, and, a plurality of steps or procedures, respectively.
[0076] Each of the following terms: “includes”, “including”, “has”, “having”, “comprises”, and “comprising”, and, their linguistic/grammatical variants, derivatives, or/and conjugates, as used herein, means “including, but not limited to”, and is to be taken as specifying the stated components), feature(s), characteristic(s), parameter(s), integer(s), or step(s), and does not preclude addition of one or more additional components), feature(s), characteristic(s), parameter(s), integer(s), step(s), or groups thereof. Each of these terms is considered equivalent in meaning to the phrase “consisting essentially of. Each of the phrases “consisting of and “consists of,” as used herein, means “including and limited to.”
[0077] The phrase “consisting essentially of,” as used herein, means that the stated entity or item (system, system unit, system sub-unit device, assembly, sub-assembly, mechanism, structure, component element or, peripheral equipment utility, accessory, or material, method or process, step or procedure, sub-step or sub-procedure), which is an entirety or part of an exemplary embodiment of the disclosed invention, or/and which is used for implementing an exemplary embodiment of the disclosed invention, may include at least one additional feature or characteristic being a system unit system sub-unit device, assembly, sub-assembly, mechanism, structure, component or element or, peripheral equipment utility, accessory, or material, step or procedure, sub-step or sub-procedure, but only if each such additional feature or characteristic does not materially alter the basic novel and inventive characteristics or special technical features, of the claimed item.
[0078] The term “method,” as used herein, refers to steps, procedures, manners, means, or/and techniques, for accomplishing a given task including, but not limited to, those steps, procedures, manners, means, or/and techniques, either known to, or readily developed from known steps, procedures, manners, means, or/and techniques, by practitioners in the relevant field(s) of the disclosed invention.
[0079] Terms of approximation, such as the terms about, substantially, approximately, etc., as used herein, refers to ± 10% of the stated numerical value.
[0080] It is to be fully understood that certain aspects, characteristics, and features, of the invention, which are, for clarity, illustratively described and presented in the context or format of a plurality of separate embodiments, may also be illustratively described and presented in any suitable combination or sub-combination in the context or format of a single embodiment. Conversely, various aspects, characteristics, and features, of the invention which are illustratively described and presented in combination or sub-combination in the context or format of a single embodiment may also be illustratively described and presented in the context or format of a plurality of separate embodiments.