As the demand for renewable energy sources grows, wind power is becoming an increasingly significant contributor to the global energy mix. A crucial component of this growth is the efficient and safe production of wind turbine rotor blades, the backbone of wind energy generation. Schmalz, a leader in vacuum handling technology, has developed a range of vacuum lifting devices specifically designed to meet the challenges of rotor blade manufacturing. These solutions ensure high precision, safety, and productivity across the production process, helping manufacturers meet industry demands efficiently and effectively.
Rotor blade lifting device
Perhaps the most critical stage in the manufacturing process is the handling of the full rotor blade, a component that demands both precision and care due to its size and fragility. The Rotor Blade Lifting Device is designed to meet these challenges head-on. With its capacity to lift components weighing up to 40 tons, and lengths ranging from 4.6 to 11.1 meters, this device is specifically engineered for the careful demoulding and handling of the complete rotor blade. Its design features suction plates that are highly adaptable to the blade’s shape, ensuring alignment during lifting and minimizing the risk of damage. The dual-level vacuum reservoirs and safety belts provide additional layers of security, ensuring safe handling throughout the process. By enabling damage-free lifting and reducing the time required for demoulding, the Rotor Blade Lifting Device streamlines a critical stage of rotor blade production, helping manufacturers save both time and costs.
Multifunctional traverse
The Multifunctional Traverse is one of Schmalz’s most versatile vacuum lifting devices, capable of handling various rotor blade components, including spar caps and webs. This flexibility is a major advantage in the rotor blade production process, where different components require precise and adaptable handling. The device’s adjustable suction plates allow it to conform to the specific shapes of different components, making it an all-in-one solution for handling various parts. With a lift capacity of 7 tons for onshore applications and 10 tons for offshore, the Multifunctional Traverse can handle large components with ease. Additionally, its redundant vacuum circuits and integrated safety belts ensure safe and reliable operations, reducing the risk of accidents. This adaptability not only improves the safety of the production line but also significantly reduces the time required to switch between different devices, enhancing overall productivity.
Root lifting device
The Root Lifting Device is an essential tool in the initial stages of rotor blade manufacturing, particularly during the demoulding of root elements. This device is carefully engineered to provide ergonomic handling of the blade’s root section, ensuring precise lifting without the need for additional mounting holes, which minimizes material stress. With a maximum lifting capacity of 2 tons, this device is designed to handle component weights up to 1.3 tons and lengths reaching up to 4 meters. Equipped with a robust vacuum reservoir and safety straps, it ensures smooth and secure operation. Additionally, the Root Lifting Device eliminates the need for trimming inside the main mould, thereby reducing production time and enhancing operational efficiency.
Preform lifting device
During the production of wind turbine rotor blades, handling preform segments is a delicate and critical task. The Preform Lifting Device by Schmalz offers a solution for handling these segments with high precision. This device is specifically designed for contour-accurate lifting of preforms, utilizing needle grippers that allow for the energy-efficient management of layered materials, such as glass and carbon fibers. Capable of lifting components weighing up to 3 tons, this device also accommodates segments as long as 15 meters. The needle grippers, which feature a stroke length of up to 25 mm, ensure secure handling while reducing the time spent in mould filling. The Preform Lifting Device is invaluable in ensuring accuracy and maintaining material integrity during this stage of rotor blade manufacturing, helping manufacturers optimize their production processes.
Conclusion
Schmalz’s vacuum lifting devices are at the forefront of innovation in rotor blade manufacturing, offering solutions that optimize efficiency, safety, and precision at every stage of production. From the Root Lifting Device’s ergonomic design to the adaptability of the Multifunctional Traverse and the robust handling capabilities of the Rotor Blade Lifting Device, these technologies play a crucial role in ensuring high-quality production of wind turbine components. As the demand for wind energy continues to grow, advanced handling systems like those developed by Schmalz will be essential in meeting the industry’s evolving needs, ensuring the consistent production of high-performance rotor blades while maintaining safety and operational excellence.
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