Installation for producing reinforcement cages for tower segments of wind turbines

Abstract

A system for producing reinforcing cages for wind turbine tower segments, wherein a reinforcing cage has in each case substantially horizontally oriented ring segments and substantially vertically oriented stiffening elements. It is proposed that the system has a receiving area which is adapted so as to receive the preferably inner, substantially horizontally oriented ring segments of the reinforcing cage, a first handling robot for supplying and positioning the stiffening elements, and a second handling robot for connecting the ring elements to the stiffening elements.

Claims

1. A system for producing reinforcing cages for wind turbine tower segments, wherein each reinforcing cage has substantially horizontally oriented ring elements and substantially vertically oriented stiffening elements, the system comprising: a receiving area adapted to receive the ring elements; a first handling robot configured to supply and position the stiffening elements, wherein the first handling robot is configured to bring the stiffening elements to bear against the ring elements in a substantially vertical orientation; and a second handling robot configured to connect the ring elements to the stiffening elements, wherein the stiffening elements are formed from a helically bent endless material, wherein the first handling robot has bending means and interacts with a feed unit that feeds the endless material to the bending means, and wherein the bending means in configured to bend the endless material in such a way that the stiffening elements are formed helically.

2. The system according to claim 1, comprising an electronic control unit configured to control the first and second handling robots for supplying the stiffening elements in a coordinated manner and for connecting the stiffening elements to the ring elements, respectively.

3. The system according to claim 1 wherein the receiving area is arranged on a rotatable platform.

4. The system according to claim 3 wherein the first and second handling robots are arranged adjacent to the platform.

5. The system according to claim 1 wherein the receiving area is configured to interact with a gripping device for handling one of the reinforcing cages.

6. The system according to claim 1 wherein the bending means are deflecting rollers, wherein the endless material is configured to be passed between the deflecting rollers, and wherein the deflecting rollers are adjustable such that positions of the deflecting rollers relative to one another can be modified.

7. The system according to claim 6 wherein the deflecting rollers are provided to a pivoting working head.

8. The system according to claim 1 wherein the first handling robot undertakes handling of bent steel wires.

9. The system according to claim 1 wherein the second handling robot has a pivotable working head and a connecting means is arranged on the pivotable working head, wherein the connecting means is selected from a list consisting of: an adhesive dispensing device, a welding device, a soldering device, and a device for automatically twisting metal wires.

10. The system according to claim 1 wherein the ring elements in the receiving area are a first set of ring elements and the system has an automatic winding unit for supplying a second set of substantially horizontally oriented, ring elements, wherein the ring elements of the second set are designed as helically bent endless material.

11. The system according to claim 10 wherein the automatic winding unit has a guide device and interacts with a feed unit that feeds the endless material for the second set of rings to the guide device, and wherein the guide device is configured to feed the endless material in such a way that the ring elements are formed helically.

12. The system according to claim 11, comprising an electronic control unit configured to control all handling robots of the system, and wherein the handling robots, the feed units and a rotatable platform are configured to supply the ring elements and stiffening elements and to connect the stiffening elements to the ring elements.

13. The system according to claim 10 wherein the second handling robot is configured to connect the second set of ring elements to the stiffening elements.

14. The system according to claim 10 wherein the second set of substantially horizontally oriented, ring elements are outer ring elements.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

(1) The invention is explained in detail below with the aid of preferred exemplary embodiments and with reference to the attached drawings, in which:

(2) FIGS. 1a and 1b show a schematic partial view of a system according to a first exemplary embodiment,

(3) FIGS. 2a-2g show different working positions of the first handling robot according to the first exemplary embodiment,

(4) FIGS. 3a-3c show different schematic partial views of a system according to a second exemplary embodiment,

(5) FIGS. 4a-4c show different schematic partial views of a system according to a third exemplary embodiment,

(6) FIGS. 5a and 5b show different working positions and schematic partial views of a third handling robot as examples for the second exemplary embodiment,

(7) FIGS. 6a-6c show different working positions of a further handling robot for a system according to one of the exemplary embodiments, illustrated as examples of the first exemplary embodiment; and

(8) FIG. 7 is diagram of the different connecting means.

DETAILED DESCRIPTION

(9) A system 1 according to a first exemplary embodiment of the invention is shown in FIG. 1a. The system 1 has a first handling robot 3 which is designed to form helically arranged stiffening elements 27 by means of corresponding bending means. The first handling robot 3 has a working head with a bending device 19. The first handling robot 3 is arranged in FIGS. 1a and 1b on a support structure 5. This can be a pedestal as in FIGS. 1a and 1b or another support structure, as shown for example in one of the other exemplary embodiments.

(10) The system 1 has a receiving area 7. The receiving area 7 is configured so as to receive a gripping device 11. The gripping device 11 has coupling means, for example in the form of hook-shaped rake arms on which substantially horizontally oriented ring elements 13 are arranged in each case. The receiving area 7 is arranged on a preferably rotatable platform 9. The platform 9 is preferably connected to an electronic control unit by a data line so that the rotation can be effected in a coordinated fashion by means of the electronic control unit, depending on the progress of the work of the handling robots 3 and 21.

(11) The first handling robot 3 is connected, inter alia, to a feed unit 15 by means of an electronic control device and interacts with the feed unit 15 so that the latter can feed to the handling robot 3 an endless material 17 to produce the helical stiffening elements 27.

(12) The system 1 moreover has a second handling robot 21 which has a working head 25 with a connecting means, for example in the form of a welding wheel. The second handling robot 21 is preferably likewise connected to the electronic control unit and interacts in a coordinated fashion with the first handling robot 3 and the platform 9 in order to connect the generated stiffening elements 27 to the substantially horizontally oriented ring elements 13 which are held by the gripping device 11. The second handling robot 21 can be arranged, for example, on a support structure 23, adjacent to the receiving area 7, or on an alternative support structure together with the first handling robot, as shown for example in the following exemplary embodiments.

(13) The first handling robot 3 can move along multiple axes in order to enable the working head 19 to generate bends in the endless material 17 in such a way that the substantially vertically oriented stiffening elements 27 are formed. For this purpose, the working head 19 can also be reconfigured and repositioned, as is shown in FIG. 1b, and in particular as is illustrated in detail in FIGS. 2a to 2g.

(14) The system moreover has an electronic control device 10 for controlling the handling robots 3, 21 on the platform 9 in a coordinated fashion.

(15) A portion of the system 1 according to the first exemplary embodiment is shown in FIGS. 2a to 2g, in which the working head 19 of the first handling robot 3 is shown in operation. In the Figures, a first substantially vertically oriented stiffening element 27 has already been created, adjoining the ring elements 13 in the receiving area 7. The working head 19 has a base body 29 on which multiple deflecting rollers 31a, 31b, 31c (FIGS. 2c to 2g) are arranged. A first bend for a stiffening element 27 has been generated in FIG. 2a. Starting from the situation in FIG. 2a, in FIG. 2b the endless material 17 is deformed further by adding a further bend. To do this, the first handling robot 3 has performed a corresponding pivoting motion about a working axis b. In order to complete the bending of the endless material 17, the first handling robot 3 briefly withdraws from the situation in FIG. 2b and pivots the body of the handling robot 3 outwards so that the first handling robot 3 does not collide when the endless material 17 is then guided upwards to the point at which the next bend which needs to be made.

(16) The working head 19 of the first handling robot 3, formed by bending means in the form of a bending device, has adjustable deflecting rollers 31a, 31b, 31c which are arranged on the base body 29. An example of altering the position of the rollers, in conjunction with a repositioning motion of the working head 19, is illustrated in FIGS. 2c to 2g.

(17) In Figure c, the working head 19 on the first handling robot 3 is initially still situated in engagement with the endless material 17. In order to prevent twisting of the endless material 17 using the handling robot 3, in FIG. 2d the working head 19 is pivoted about an axis c on the first handling robot 3 in the direction of the arrow 33 so that the rollers 31a, 31b, 31c are brought out of engagement with the endless material 17. Then, as can be seen in FIG. 2e, the positions of the rollers 31a and 31c are altered in a first direction, whilst the deflecting roller 31b arranged between the deflecting rollers 31a, 31c is shifted in the opposite direction. The deflecting rollers 31a, 31b, 31c can be repositioned either steplessly or according to a pattern, for example by moving them into dedicated openings. Once the repositioning is complete, as shown in FIG. 2f, the working head 19 is pivoted again about the axis c in the direction of the arrow 35 so that the deflecting rollers 31a, 31b, 31c are again in engagement with the endless material 17. This situation is depicted in FIG. 2g. In FIGS. 2c to 2g, the rotated position of the base body 29 relative to the first handling robot 3 is constant. It is, however, optionally also possible to pivot the base body 29 of the working head 19 about an axis a, as can be seen, for example, by comparing FIG. 2b with FIG. 2c.

(18) FIGS. 3a and 3b show schematically a portion of a system 100 according to a second exemplary embodiment of the invention. The essential features are the same as in the first exemplary embodiment. In particular, the type of arrangement of a first handling robot 103 of the system 100 and a second handling robot 121 of the system 100 can in principle be swapped or combined with the type of arrangement for the system 1. On its working head 119, the first handling robot 103 of the system 100 has a gripping device by means of which the handling robot 103 can grip stiffening elements 127 on the inside and hold them in a non-slip fashion. The stiffening elements 127 according to the second exemplary embodiment are separate, preferably closed brackets. The first handling robot 103 is designed to remove the bracket-like stiffening elements 127 from a stocking unit using the working head 119 designed as a gripping device, bring them to bear against the ring elements 13 on the gripping device 11 of the system 100, and hold them there until the second handling robot 121 has connected the stiffening elements 127 to the ring elements 13 using its working head 125 designed as a welding device, for example as a welding wheel. In FIGS. 3a and 3b, the first handling robot 103 and the second handling robot 121 are arranged on an annular platform 105 surrounding the gripping device 11 and the (not shown) rotatable platform 9 (FIG. 1a). However, support structures like those for example in FIGS. 1a and 1b could also be chosen, in exactly the same way as a support structure like the platform 105 depicted here could be chosen in the first exemplary embodiment of the system 1 in FIGS. 1a and 1b.

(19) The precise design of the stocking unit is not shown in this exemplary embodiment for reasons of clarity. It can, for example, be a stocking unit like the stocking unit 204 from the exemplary embodiment of FIGS. 4a to 4c explained below.

(20) In the situation in FIG. 3a, the second handling robot 121 is positioned in such a way that a stiffening element 127 is connected to one of the ring elements 13 in the upper area of the reinforcing cage to be created. On the other hand, in FIG. 3b the second handling robot 121 is positioned such that the working head 125 can connect the stiffening element 127, in a lower area of the reinforcing cage to be produced, to a ring element in the gripping device 11, or alternatively effects a weld on the stiffening element 127 itself. During these processes, the first handling robot 103 holds the stiffening element 127 in position in a non-slip manner. This happens by means of pivotable coupling links which are arranged at opposite ends of the working head 119. FIG. 3c shows the coupling link 141, although it is covered by the working head 125 of the second handling robot 121. The coupling link with its component parts is likewise also explained in greater detail in an exemplary embodiment which is still to be discussed below.

(21) The coupling link 141, which can be seen in FIG. 3c, has at its first end a guide roller 145 which is configured so as to be inserted into the bend, and therefore the corner, of a stiffening element 127 and to grasp the stiffening element there. At the opposite end of the coupling link 141 from the guide roller 145, a support section 147 is arranged which is configured so as to exert, when the coupling link 141 is pivoted together with the guide roller 145, a spreading force on the stiffening element 127 which is great enough to be able to hold the stiffening element 127 in a non-slip manner.

(22) The coupling link 141 can preferably be displaced by means of an actuator 143.

(23) A system 200 for producing reinforcing cages according to a third exemplary embodiment is shown in FIGS. 4a to 4c. The third exemplary embodiment is very similar in structure to the second exemplary embodiment so reference is only made to structural differences. In contrast to the system 100, the system 200 has a height-adjustable portal 206 on which a second handling robot 221 is arranged so that its height can be altered. A first handling robot 203 is mounted on a support structure 205 separately from the second handling robot 221. The system 200 has a stocking unit 204 for stiffening elements 127. The first handling robot 203 is configured so as to remove these stiffening elements 127 from the stocking unit 204 and place them against the ring elements 13 which are held on the gripping device 11 and are arranged in the receiving area 7 on a rotatable platform 9. This removal process is shown by way of example in FIG. 4a. In FIG. 4b, which shows the same system 200 from FIG. 4a from a different point of view, the first handling robot 203 has brought a previously removed stiffening element 127 to bear against the ring elements 13 on the gripping device 11. Starting from the operating situation in FIG. 4b, the second handling robot 221 is configured so as to shift heightwise along the portal 206 to the appropriate point and then bring a working head 225 into position, which creates a connection of the stiffening element 127 in each case to a section of a ring element 13 at different heights along the reinforcing cage which is to be produced.

(24) In the exemplary embodiments shown hereabove, the substantially horizontally oriented ring elements 13 were the ring elements for a so-called internal helix of the reinforcing cage to be produced. It is likewise within the scope of the invention that these ring elements represent a so-called external helix, wherein the stiffening elements could then be arranged on the inside with respect to these ring elements. Not all combinations of corresponding shifts of the positions of the handling robots are shown here in order to make the view clear.

(25) In order to remain within the above-described exemplary embodiment of an internal helix for the substantially horizontally oriented ring elements 13, it is provided within the scope of a further exemplary embodiment, which is to be understood as a supplement to all the exemplary embodiments shown above, but by way of example is only illustrated with the aid of the exemplary embodiment from FIGS. 3a to 3c, that the substantially horizontally oriented ring elements 13 represent a first set of ring elements. In FIGS. 5a and 5b, an automatic winding unit 150 is additionally provided in the system 100, which is configured so as to supply a second set of substantially horizontally oriented ring elements 14 on an opposite side of the stiffening elements 127 (or also of the helically formed stiffening elements 27 in the first exemplary embodiment) with respect to the first set of ring elements. In the exemplary embodiment shown in FIGS. 5a and 5b, the winding unit 150 has a guide device 153 which is configured so as to apply endless material, which can be the same endless material for the helically formed stiffening elements 27 of FIGS. 1a to 2g, annularly or spirally around the stiffening elements 127. To do this, the winding unit 150 is shifted heightwise on a portal 151 whilst the platform 9 is rotated about a vertically oriented axis e together with the gripping device 11, the ring elements 13 and the stiffening elements 127. As can be seen from FIG. 5b, the endless material is preferably supplied by a feed device in the form of a stocking unit 155 which can hold ready a cylindrical spool of the endless material. The guide device can have multiple guide rollers which allow the endless material to be dispensed in a specific fashion in order to form the rings 14. The winding unit 150 is preferably connected via a data line to a central electronic control unit, for example the one mentioned above, which coordinates the work of the different system components such as the handling robots, winding unit and rotatable platform. This control unit is indicated in FIG. 1a.

(26) The winding unit which is shown in FIGS. 5a and 5b can, for example, also be the feed device 15 which is used in the exemplary embodiment of FIGS. 1a to 2g in order to supply the endless material 17.

(27) An additional option for a combination of features, given by way of example, of the above-described different exemplary embodiments in FIGS. 6a to 6c is described below with reference to a further exemplary embodiment. The system 1 according to the exemplary embodiment from FIGS. 1a to 2g preferably has a further handling robot 61. The handling robot 61 in particular has an identical design to the first handling robot 103 from the exemplary embodiment of FIGS. 3a to 3c. Although there is no need to supply prefabricated stiffening elements from a stocking unit in the system 1, this handling robot 61 can also advantageously be used in the system 1 by it engaging in the already formed helical stiffening elements 27 in order to stabilize them and hold them in a non-slip manner until the second handling robot 21 has carried out the necessary work of connecting the stiffening elements 27 to the ring elements 13.

(28) In FIGS. 6b to 6c, further details are shown with respect to the working head 63 of the handling robot 61, visible in FIG. 6a and designed as a gripping device, which, to simplify the drawing, were omitted in the case of the working head 119 from the exemplary embodiment of FIGS. 3a to 3c and similarly in the exemplary embodiment of FIGS. 4a to 4c. The coupling device, which has the reference numeral 67 instead of 141, is arranged on the working head 63 so that it can be shifted by means of an actuator 65. The supporting section now has the reference numeral 71 and the guide roller the reference numeral 69. The operating mode of the coupling link is shown by way of example in FIGS. 6b and 6c. The gripping device 63 is first brought into the situation shown in FIG. 6a. In this situation, the coupling link 67 shown in FIG. 6b is situated in the internal area of a corner of a spiral of the stiffening elements 27. From this position, a piston rod 75 is extended in the direction of the arrow 73 by means of the actuator 65.

(29) According to FIG. 6c, this has the consequence that the guide roller 69 of the coupling link comes to bear against an end area 27a of the stiffening element 27 and, when the piston rod 75 continues to move, rolls in the direction of one of the corners caused by the bending. In FIG. 6c, the guide roller 69 has reached the corner 27b caused by the bending. The piston rod 75 is displaced so far by means of the actuator 65 that the supporting section 71 arranged at the opposite end of the coupling link 67, with respect to the guide roller 69, bears against an substantially vertical section 27c of the stiffening element 27. In this position, the actuator 65 is, by virtue of the piston rod 75 being pushed out further, capable of exerting a spreading force on the stiffening element 27 by means of which the latter is fixed and stabilized. In this position, it is possible for the stiffening elements directly adjacent to the held stiffening element 27, and including the stiffening element 27 itself, to be connected by the second handling robot 21.

(30) For the sake of clarity, a spring return for the coupling link and different sensor means which are part of the system equipment and assist error-free and collision-free operation of the system have not been shown.

(31) As is apparent from the above embodiments, features which are shown in the respective exemplary embodiments can be combined with one another so that different system components from the different exemplary embodiments can be used to form a common system in a common exemplary embodiment.