A METHOD FOR CUTTING A SHELL-TYPE OBJECT, A CUTTER SYSTEM AND A VESSEL EQUIPPED WITH THE CUTTER SYSTEM

Abstract

An object of the invention is achieved by a method for cutting an elongated shell-type object. The method may comprise acts 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.

Claims

1. A method for cutting an elongated shell-type object, the method including the following steps: providing a gantry that defines a portal, the gantry including 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 substantially perpendicular to the portal.

2. The method according to claim 1, wherein the step of providing the gantry includes providing a bottom support supporting the shell-type object at a proximal point relative to the gantry; the step of moving the shell-type object includes a step of displacing the shell-type object along a vertical-axis by displacing the bottom support.

3. The method according to claim 1, wherein the step of providing the gantry includes attaching a fastening system to the shell-type object at a distal point relative to the gantry; the step of moving the shell-type object is performed by pulling the fastening system towards the gantry.

4. The method according to claim 3, wherein the step of providing the gantry includes providing a pull system having one or more cables connected to the fastening system; the step of moving the shell-type object is performed by pulling the one or more cables as a function of the position of the distal point of the shell-type object.

5. The method according to claim 1, wherein the method further includes the following steps determining a strain on the wire grid; wherein the step of moving the shell-type object is performed as a function of the strain and/or the step of operating the wire grid is performed as a function of the strain.

6. The method according to claim 1, wherein the step of providing a gantry includes providing the gantry as an assembly kit in a container and the step of providing the gantry includes assembling the gantry.

7. Method for cutting multiple elongated shell-type objects aligned side by side and in parallel, wherein the method includes the following step of cutting one shell-type object according to claim 1; translocating the gantry along a horizontal axis perpendicular to the multiple shell-type objects; and repeating the step of cutting and translocating one or more of the other shell-type objects.

8. A cutter system for cutting an elongated shell-type object such as a wind turbine blade, the cutter system comprising means for performing the method according to claim 1.

9. A cutter system configured for cutting an elongated shell-type object, the cutter system comprising: a gantry defining a portal, the gantry having a front side configured and arranged for facing the elongated shell-type object, one or more cutter wires extending in the portal, thereby defining a wire grid, a wire drive configured for driving the one or more cutter wires, and moving means configured for moving the shell-type object through the portal.

10. The cutter system according to claim 9, the cutter system further including a bottom support positioned at the portal and/or near the front side of the gantry, the bottom support configured and arranged for supporting the shell-type object at a proximal point relative to the gantry, and is displaceable along a vertical-axis.

11. The cutter system of claim 9, wherein the moving means includes a fastening system for attaching to the shell-type object at a distal point relative to the gantry; and a pull system having one or more pull cables connected to the fastening system.

12. The cutter system of claim 9, the cutter system further including a controller; wherein the moving means is configured and arranged to be operated by the controller, and the controller being configured for determining a strain on the one or more cutter wires, and to operate the moving means as a function of the strain.

13. The cutter system according to claim 9, further including an assembly kit having; a bottom plate with hinges; two pillars, wherein each pillar having an extending top bar, thereby defining an L-shape, the extending top bar of a first pillar of the two pillars is configured for engaging the extending top bar of a second pillar of the two pillars; each pillar having, opposite to the top bar, a bottom base configured for engaging the hinges, thereby enabling each pillar to be pivotable between a horizontal position and a vertical position where the top bars engage, the assembly kit configured to be assembled into the gantry.

14. The cutter system according to claim 13, wherein the assembly kit is configured and arranged to be packed in a container.

15. An offshore vessel equipped with a cutter system according to claim 8.

Description

DESCRIPTION OF THE DRAWING

[0187] Embodiments of the invention will be described in the figures, whereon:

[0188] FIG. 1 illustrates an example of an elongated shell-type object;

[0189] FIG. 2 illustrates a method for cutting an elongated shell-type object;

[0190] FIG. 3 illustrates a method for cutting multiple elongated shell-type objects aligned side by side and in parallel;

[0191] FIG. 4 illustrates a cutter system;

[0192] FIG. 5 illustrates a cutter system cutting an elongated shell-type object;

[0193] FIG. 6 illustrates a cutter system cutting an elongated shell-type object from a side view;

[0194] FIG. 7 illustrates a wire grid (A) and a wire grid with bottom support (B);

[0195] FIG. 8 illustrates a pulley block;

[0196] FIG. 9 illustrates a cutter system with a sled cutting a wing turbine blade;

[0197] FIG. 10 illustrates moving means;

[0198] FIG. 11 illustrates an embodiment of a sled;

[0199] FIG. 12 illustrates a cutter system with a controller controlling the cutting along the lateral-axis;

[0200] FIG. 13 illustrates a cutter system with a controller controlling the cutting along the vertical-axis FIG. 14 illustrates a cutter system secured to the ground with guy lines and ground screws;

[0201] FIG. 15 illustrates an assembly kit;

[0202] FIG. 16 illustrates the placement of the cutter system using a forklift; and

[0203] FIG. 17 illustrates an offshore vessel having multiple shell-type objects and a cutter system.

DETAILED DESCRIPTION OF THE INVENTION

[0204]

TABLE-US-00001 Item No Shell-type object 10 Proximal point 12 Distal point 14 Section 16 Cutter system 100 Gantry 110 Portal 112 Front side 114 Wire drive 120 Wire grid 122 Cutter wire 124 Tension arm 126 Bottom support 140 Actuator 142 Side support 145 Roller 148 Controller 160 Guy lines 170 Ground screws 172 Moving means 190 Fastening system 200 Sled 210 Sled base 212 Sled arm 214 Sled bar 215 Sled pivot point 216 Sled jaws 218 Sled support 220 Pull system 300 Winches 310 Cables 320 Pulley block 400 Entry block 402 Exit block 404 Direction pulleys 410X, 410Y Force pulleys 420Y, 420Z Pinion 430 Guide wheels 440 Assembly kit 500 Bottom plate 510 Forklift pockets 512 Hinges 514 Pillar 520 Top bar 522 Bottom base 524 Vertical position 550 Horizontal position 560 Horizontal axis X Vertical axis Y Lateral axis Z Offshore vessel 800 Container/20″ HQ Shipping Container 900 Method for cutting 1000 Providing 1100 Attaching 1110 Operating 1200 Moving 1300 Displacing 1310 Pulling 1320 Determining 1400 Assembling 1500 Method for cutting multiple elongated 2000 shell-type objects Translocating 2100 Repeating 2200

[0205] FIG. 1 illustrates an example of an elongated shell-type object 10. The figure discloses a picture of wind turbine blade section. The blade is clearly a shell-type object 10 as the blade has a low solid volume and a high gas volume, i.e. a low solid-to-gas S/G-ratio.

[0206] The blade may be 80 m long, thereby making the transportation of the blade cumbersome and since it is to be decommissioned it will be preferred if the blade can easily be cut into sections having a lower S/G-ratio.

[0207] It is especially preferred if the blade can be cut into sections which can be fed to a standard shredder, such that the S/G-ratio is maximized.

[0208] FIG. 2 illustrates a method 1000 for cutting an elongated shell-type object.

[0209] The method for cutting 1000 an elongated shell-type object 10, the method 1000 comprising an act of providing 1100 a gantry 110 defining a portal 112 and comprising a wire grid 122 operable in the portal 112.

[0210] The method 1000 comprising an act of operating 1200 the wire grid 122.

[0211] The method 1000 comprising whilst performing the act of operating 1200 an act of moving 1300 the shell-type object 10 through the wire grid 122 along a lateral axis Z substantially perpendicular to the portal 112.

[0212] The method 1000 may be modified by modifying the act of providing 1100 to include providing a bottom support 140 supporting the shell-type object 10 at a proximal point 12 relative to the gantry 110.

[0213] The act of moving 1300 the shell-type object 10 includes an act of displacing 1310 the shell-type object 10 along a vertical axis Y by displacing the bottom support 140.

[0214] The method 1000 may be modified by modifying the act of providing 1100 to include attaching 1110 a fastening system 200 to the shell-type object 10 at a distal point 14 relative to the gantry 110.

[0215] The act of moving 1300 the shell-type object 10 is performed by pulling 1320 the fastening system 200 towards the gantry 110.

[0216] The method 1000 may be modified by modifying the act of providing 1100 to include providing a pull system 300 comprising one or more cables 320 connected to the fastening system 200.

[0217] The act of moving 1300 the shell-type object 10 is performed by pulling 1320 the one or more cables 320 as a function of the position of a distal point 14 of the shell-type object 10. The distal point 14 being a distal point relative to the position of the gantry.

[0218] The method 1000 may further comprise acts of determining 1400 a strain on the wire grid 122.

[0219] The act of moving 1300 the shell-type object 10 is performed as a function of the strain.

[0220] The act of operating 1200 the wire grid 122 is performed as a function of the strain.

[0221] The act of moving 1300 the shell-type object 10 is performed as a function of the strain and the act of operating 1200 the wire grid 122 is performed as a function of the strain.

[0222] The method 1000 may be modified by the act of providing 1100 the gantry 10 as an assembly kit 170 in a container 900 and includes an act of assembling 1500 the gantry 10.

[0223] FIG. 3 illustrates a method 2000 for cutting multiple elongated shell-type objects 10 aligned side by side and in parallel.

[0224] The method 2000 comprises acts of cutting 1000 one shell-type object 10 according to the method described in FIG. 2 and the corresponding figure description.

[0225] This may be followed by translocating 2100 the gantry 110 along a horizontal axis X perpendicular to the multiple shell-type objects 10.

[0226] The act of cutting 1000 is then repeated for the next shell-type object 10 in-line.

[0227] The method 2000 comprises an act of repeating 2200 the act of cutting 1000 and translocating 2100 the multiple elongated shell-type objects 10 are cut.

[0228] FIG. 4 illustrates a cutter system 100. The cutter system 100 is configured for cutting an elongated shell-type object 10.

[0229] The cutter system 100 comprises a gantry 110 defining a portal 112, the gantry 110 having a front side 114 for facing the elongated shell-type object 10.

[0230] The portal 112 is substantially in a plane defined by a horizontal axis X and a vertical axis Y. The portal 112 is substantially perpendicular to a lateral axis Z along which the shell-type object 10 is to be moved.

[0231] The gantry 110 comprises two pillars 520I, 520II, wherein each pillar 520I, 520II has an extending top bar 522I, 522II, thereby defining an L-shape. Each top bar 522I, 522II is configured for engaging the top bar 522II, 522I of the other pillar 520II, 520II. Each pillar 520 has opposite to the top bar 522I, 522II a bottom base 524I, 524II.

[0232] The cutter system 100 comprises a bottom plate 510 for stabilising the cutter system 100. The bottom base 510 comprises hinges 524 being complementary to the bottom bases 524I, 524II, thereby allowing the L-shaped pillars 520I, 520II to make a pivot movement in the shown XY-plane such that the two top bars 522II, 522I engage. The two top bars 522II, 522I may be further secured using bolts, the skilled person would know how. This movement is disclosed in greater detail in FIG. 15.

[0233] The bottom base 510 further comprises forklift pockets 512, thereby enabling the cutter system to be moved using a forklift. This enables the cutter system 100 to be moved by simply means to an end of the elongated shell-type object.

[0234] The gantry 110 has on each pillar 520I, 520II four pulley blocks 400, where one pillar 520I has four entry blocks 402 and the other pillar 520II has four exit blocks 404.

[0235] An embodiment of the pulley blocks 400 is described in greater detail in FIG. 8.

[0236] The cutter system 100 further comprises four cutter wires 124 extending in the portal 112, thereby defining a wire grid 122.

[0237] The extent of the four cutter wires 124 across the portal are defined by the relative position of the entry blocks 402 and exit blocks 404.

[0238] The gantry 110 comprises several pulleys defining a wire path of the cutter wires 124, this is disclosed in detail in FIG. 7.

[0239] The gantry 110 comprises a tension arm 126 for each cutter wire 124, the tension arms 126 being pivotally connected to a top bar 522II. The pivotal movement is shown with a bold double arrow. The tension arms 126 ensure that the cutter wires 126 have little to no slack. The angle of the tension arms 126 relative to the top bar 522II can be used to determine a strain on the individual cutter wires 124.

[0240] This will happen if the movement of a shell-type object 10 forces the cutter wires 124 to bend, as the cutter wire 124 is substantially inelastic and thus the length of cutter wires 124 does not change, the tension arms 126 must then pivot towards the top bar 522II to reduce tension.

[0241] The gantry 110 further comprises a wire drive 120. The wire drive 120 operates the wire cutters 126 simultaneously as a single group in the present embodiment, but the wire drive 120 can in other embodiments drive the cutter wires 126 individually, i.e. at individual speeds.

[0242] The drive 120 can be used to determine a strain on the wire cutters 126 by measuring a power consumption or speed of the drive.

[0243] The gantry 110 further comprises moving means 190 in the form of a pull system 300 for pulling an elongated shell-type object 10. The pull system 300 comprises a winch 310 on each side of the portal 112.

[0244] In this embodiment, each winch 310 is connected to one of the pillars 520I, 522II.

[0245] The pull system 300 comprises pull cables 320 to be connected by a not shown fastening system 200 to a distal point 14 of a shell-type object 10.

[0246] The winches 310 on each side of the portal 112 enable the cutter system 100 to correct the movement of the shell-type object 10 by only pulling one side or by pulling each cable with a different pull speed.

[0247] The position of the distal point 14 is a good indicator for estimating whether the shell-type object 10 is being pulled towards the gantry 110 in an intended manner.

[0248] Examples of a fastening system 200 will be presented in later figures.

[0249] The cutter system 100 further comprises two bottom supports 140I, 140II. Both bottom supports 140I, 140II are in this embodiment connected to the base plate 510, thus making the cutter system 100 more compact.

[0250] The primary bottom support 140I is positioned near the front side 114 of the gantry 110 for supporting the shell-type object 10 at a proximal point 12 relative to the gantry 110.

[0251] The primary bottom support 140I positioned near the front side 114 of the gantry 110 has a greater effect on the reliability of the cutter system 100 and on the speed of operation relative to the secondary bottom support 140II shown in the present figure. The difference in effect is due to the relative positioning of the primary and secondary bottom supports 140I, 140II.

[0252] The shell-type object 10 will never be cut on the part supported by the bottom support 140I, thus there will be no structural weaknesses introduced. Likewise, since the bottom support is positioned on the front side 114, there is little risk of the shell-type object 10 moving backwards of the portal 112 after being cut in a plane substantially parallel to the portal 112.

[0253] The primary bottom support 140I is displaceable along the vertical axis by a pair of actuators 142, thereby the bottom support 140I is capable of displacing the shell-type object 10 in the vertical direction.

[0254] The four cutter wires 124 are positioned with a mutual spacing along the vertical axis Y, the bottom support 140I is capable of displacing the bottom support 140I and thus the shell-type object 10 by at least the mutual spacing. Thereby, the bottom support 140I enables the cutter system 100 to cut the shell-type object 10 into shorter sections, which will increase S/G-ratio and the sections may be fed into a standard shredder.

[0255] The primary bottom support 140I is a roller 148 having a rotation axis substantially parallel to the horizontal axis X. The roller decreases friction and increases the speed of operation.

[0256] The roller 148 is connected by two arms to the base plate 510, wherein the actuators 142 are connected to the arms.

[0257] The secondary bottom support 140II is positioned at the portal 112 for supporting the shell-type object 10 at a proximal point 12 relative to the gantry 110. The bottom support 140II comprises several rollers 140 having a rotation axis substantially parallel to the horizontal axis X.

[0258] The gantry 110 comprises on both sides of the portal 112 side supports 145 adapted for adjusting the movement of a shell-type object 10 such that collision with the gantry 110 is prevented.

[0259] The side supports 145 may be rollers 148 having a rotation axis substantially parallel to the vertical axis Y, the rollers 148 will reduce friction with the shell-type object 10.

[0260] The cutter system 100 is further secured to the ground by several guy lines 170 connected to the gantry 110 and to the ground, this may be done using not shown ground screws 172.

[0261] The cutter system 100 further comprises a controller 160 operating the wire drive 120 and/or the pull system 300 and/or the primary bottom support 140I with the actuators 142.

[0262] The controller may operate as a function of the strain on the cutter wires 124.

[0263] FIG. 5 illustrates a cutter system 100 cutting an elongated shell-type object 10. FIG. 5 is a continuation of FIG. 4 as a shell-type object 10 is being pulled along the lateral axis Z through the portal 112 whilst the wire grid 122 is operated.

[0264] The shell-type object 10 is supported at a proximal point relative to the gantry 110 by the primary bottom support 140I. Thereby stabilising the movement of the shell-type object 10.

[0265] Thereby, the shell-type object 10 is cut into elongated sections 16. If the primary bottom support 140I is not displaced, then the sections 16 will have a length equal to the length of the shell-type object 10.

[0266] In the present case, the shell-type object 10 is a wind turbine blade.

[0267] FIG. 6 illustrates a cutter system 100 cutting an elongated shell-type object 10 from a side view. FIG. 6 is FIG. 5 from a side view.

[0268] FIG. 7 illustrates a wire grid 122 (FIG. 7A) and the wire grid 122 with a bottom support 140 (FIG. 7B).

[0269] The wire grid 122 comprises four endless cutter wires 124 extending through and around a portal 112 defined by a not shown gantry 110.

[0270] The wire grid 124 is operated by a wire drive 120, which drives the cutter wires 124 clockwise as indicated by the bold straight arrows.

[0271] The slack of the cutter wires 124 are controlled by pivotal tension arms 126 creating a constant tension.

[0272] The cutter wires 124 extend across the portal 112 in a direction defined by pulley blocks 400, where the pulley blocks 400 on one side are entry blocks 402 and on the other side are exit blocks 404 forming pulley block pairs.

[0273] FIG. 8 illustrates a pulley block 400 in perspective view (FIG. 8A) and a top view (FIG. 8B). The pulley block 400 can be an entry block 402 or an exit block 404. FIG. 8 discloses part of the portal 112.

[0274] FIG. 8 discloses a lateral axis Z, a vertical axis Y and a horizontal axis X. The pulley block 400 is designed to withstand a force from a shell-type object 10 moving through the wire grid 122 along the lateral axis Z as will become apparent.

[0275] The pulley block 400 comprises four pulleys; two direction pulleys 410X, 410Y and two force pulleys 420Y, 420Z.

[0276] The purpose of the force pulley 420Y is to ensure that when the shell-type object is displaced along the vertical axis Y, then the force acted on the cutter wire 124 in the vertical direction is counteracted by the force pulley 420Y.

[0277] The purpose of the force pulley 420Z is to ensure that when the shell-type object is moved along the lateral axis Z, the force acted on the cutter wire 124 in the lateral direction is counteracted by the force pulley 420Y.

[0278] The purpose of the direction pulley 420X is to ensure that the cutter wire 124 extends substantially parallel to the horizontal axis X.

[0279] The purpose of the direction pulley 420Y is to ensure that the cutter wire 124 extends substantially parallel to the vertical axis Y.

[0280] The pulley block 400 has sides equipped with guide wheels 440 and a pinion 430 which enables the pulley block 400 to be displaced along the gantry 110 along the vertical direction Y.

[0281] FIG. 9 illustrates a cutter system 100 with a sled 210 cutting a wind turbine blade being an elongated shell-type object 10. The wind turbine blade can be 80 m long.

[0282] FIGS. 5-6 are close-ups of the cutter system 100 cutting the shell-type object 10.

[0283] The sled 210 functions as a fastening system 200 supporting the shell-type object 10 at a distal point 14 relative to the gantry 110.

[0284] The shell-type object 100 is further supported at a proximal point 12 relative to the gantry 110.

[0285] The gantry 110 is connected to the sled 210 by two cables 310.

[0286] FIG. 10 illustrates moving means 190. The moving means 190 comprises a pull system 300 and a fastening system 200 in the form of a sled 210.

[0287] The pull system 300 is disclosed in FIG. 10B and the sled 210 is disclosed in FIG. 10C.

[0288] The pull system 300 comprises two winches 310 on each side of a portal 112 defined by the gantry 110, but only one of the winches is disclosed in FIG. 10B.

[0289] The winches 310 are adapted for pulling the two cables 320 connected to the sled 210.

[0290] The sled 210 in FIG. 10C comprises a sled base 212 and a sled support 220 extending from the sled base 212. The sled support 220 having a central support valley adapted for supporting a shell-type object 10.

[0291] FIG. 11 illustrates an embodiment of a sled 210.

[0292] The sled 210 comprises a sled base 212, two pairs of sled arms 214 pivotally connected to the sled base 212. Each pair of sled arms 214 is interconnected by a sled bar 215 extending between the sled arms 214, wherein two sled supports 220 extend between the two sled bars 215. The sled supports 220 are flexible supports such as softslings.

[0293] The sled arms 214 are equipped with a plurality of sled jaws 218. The sled jaws 218 are adapted for increasing the friction between the sled 210 and the shell-type object 10. The friction can be increased by choosing a suitable material which has a high friction coefficient with the material of the shell-type object.

[0294] The sled jaws 218 are saw-toothed to increase friction even further.

[0295] The pivotal arms 214 will when a shell-type object 10 is positioned and supported by the sled support 220 pivot towards each other thereby gripping the shell-type object 10 with the sled jaws 218 as shown in FIG. 11A-C.

[0296] FIG. 12 illustrates a cutter system 100 with a controller 160 controlling the cutting along the lateral-axis Z. The system 100 is shown in FIG. 5. The controller controls the pulling force acted by the winches 310 and the speed of the wire drive 120.

[0297] This may be done as function of the strain of the cutter wires 124 as previously described.

[0298] FIG. 13 illustrates a cutter system 100 with a controller 160 controlling the cutting along the vertical axis Y.

[0299] The controller 160 controls the displacement of a primary bottom support 140I and/or the secondary bottom support 140II and the speed of the wire drive 120.

[0300] The displacement enable the cutter system 100 to cut the shell-type object 10 into shorter sections 16 along the lateral axis, since the displacement will cause the cutter wires 124 to cut the shell-type object 10 along the vertical axis Y.

[0301] FIG. 14 illustrates a cutter system 100 secured to the ground with guy lines 170 and ground screws 172.

[0302] FIG. 15 illustrates an assembly kit 50 and how the assembly kit 500 is assembled and transported in a container 900.

[0303] The assembly kit 500 comprises a bottom plate 510 with hinges 514 and forklift pockets 512 for being moveable by a forklift.

[0304] The assembly kit 500 comprises two pillars 520, wherein each pillar 520 has an extending top bar 522, thereby defining an L-shape. The top bar 522 is configured for engaging the top bar 522 of the other pillar 520.

[0305] Each pillar 520 having opposite to the top bar 522 a bottom base 524 configured for engaging the hinges 514, thereby enabling each pillar 520 to be pivotable between a horizontal position 560 and a vertical position 550 where the top bars 522 engage.

[0306] FIG. 16 illustrates the placement of the cutter system 100 using a forklift at one end of a shell-type object 10. This is shown in FIGS. 16A to 16D, wherein FIG. 16D discloses how the bottom support 140 engages the shell-type object 10 at a proximal point 12 thereby replacing a temporary support shown as a bold triangle.

[0307] A fastening system 200 in the form of a sled 210 already supports the shell-type object 10. The sled 210 is simple and cheap relative to the gantry 110 and thus the sled can be sent in advance and in larger numbers such as three sleds 210 to three wind turbine blades, while the same gantry 210 is used to cut all tree blades.

[0308] FIG. 17 illustrates an offshore vessel 800 having multiple shell-type objects 10 and a cutter system 100.

[0309] The offshore vessel 800 with the cutter system 100 can be used to decommission off-shore wind turbine generators.

[0310] The offshore vessel 800 having three fastening systems 200 each of the multiple shell-type objects 10 and a single cutter system 100 is used for cutting the multiple shell-type objects 10 into sections 16.

[0311] The offshore vessel 800 may further comprise a shredder for shredding the sections 16.