Achieving Speed and Precision in a Complex blade Installation Process
Customer challenge: outdated blade installation tool
A world-leading wind turbine manufacturer faced a persistent obstacle in optimizing their blade installation process. The existing turner gear blade installation tool was outdated—too simplistic and slow to meet the rigorous demands of modern wind turbine assembly. This inefficiency resulted in delays, increased labor costs, and difficulty maintaining precise installation parameters under variable conditions such as wind speed and load. To overcome these obstacles, they required an advanced solution that would enable efficient, safe, and reliable blade mounting with minimal downtime, enhancing their overall operations.
The following video demonstrates a Factory Acceptance Test (FAT) conducted on the largest of our three Turner gear models:
Solution: PLC controlled high-speed Turner Gear tool
AS SCAN was selected as the partner of choice in a competitive bidding process, thanks to our proven expertise in hydraulic and electronic systems. Collaborating closely with the client’s team, we developed a cutting-edge PLC-controlled Turner Gear solution with a unique high-speed blade installation tool, addressing the need for efficiency and control.
Inside a control box on the latest turner gear tool from AS SCAN.
This innovative solution featured:
- Hydraulic Power & Precision: Robust hydraulics combined with advanced electronic controls enabled safe, efficient, and precise blade installations.
- High-Speed Operation: A tailored feature that significantly reduced blade mounting time, boosting productivity while maintaining high safety standards.
- Advanced PLC Control: The PLC ensured intuitive operation with significantly more features.
AS SCAN technician making adjustment to turner gear control box.
Remote Connectivity
Given the often-remote locations of wind turbine installations, on-site support can be both time-consuming and expensive. To overcome this, we integrated a remote connectivity feature into the turner gear, enabling:
- Real-time troubleshooting and updates via PC connectivity.
- Remote access for machine log data recording and service application adjustments, streamlining parameter tuning and enhancing reliability.
The HMI control interface used for managing and monitoring the Turner Gear.
Tailored to the Wind Industry’s Rigorous Standards
Our experience in the offshore industry and high standards ensured the solution met the demanding documentation and safety requirements of the wind energy sector. Before the product is deployed on-site, we conduct rigorous internal testing to ensure reliability and performance under various conditions. This commitment to quality was critical in creating a tool that clients could trust, regardless of environmental challenges.
An AS SCAN technician monitors the gear testing process on the Turner Gear Test Board, ensuring all parameters and diagnostics meet quality standards.
Versatility in Design
AS SCAN now offers three distinct models of the Turner Gear, each customized for different wind turbine types. Despite their compact designs, these tools deliver high power and precision, setting a new industry benchmark.
A close-up of the robust turner gear components and hydraulic systems.
Ensuring Reliability with Advanced Testing
To further enhance the reliability of our turner gears, AS SCAN has introduced a cutting-edge test board that ensures all components meet the highest quality standards before deployment. All components are assembled and programmed in-house, ensuring full control over quality and performance.
Screens displaying AS SCAN's software for monitoring and testing Turner Gear components.
This new tool reflects AS SCAN’s dedication to delivering superior solutions for the global wind energy sector.
Key Features of the Test Board:
- Detailed Signal Overview: The test board provides a comprehensive view of all signals connected to the control unit in the nacelle. Technicians can click on individual signals to identify their functions and locations within the HDC connectors.
- Simulation and Scenario Testing: By simulating digital and analog inputs while reading outputs, the test board allows the creation of various scenarios to evaluate how the control unit responds under different conditions.
- Automated Control Unit Testing: Equipped with automated testing capabilities, the test board verifies that all signals are correctly placed for the four controllers. This ensures consistent performance across all units and eliminates potential errors.
- Comprehensive Reporting: Following each test, the board generates a detailed report documenting the testing process and identifying any issues. This level of transparency provides customers with confidence in the product’s reliability.
Control panel with multiple settings for testing and adjusting the Turner Gear system during operations.
Key project outcomes
The implementation of our advanced Turner Gear delivered tangible benefits, including:
- Faster and Safer Installations: The optimized blade installation significantly reduced installation times while simultaneously enhancing overall project efficiency.
- Minimized Downtime: Remote connectivity ensures rapid resolution of potential issues, reducing operational delays.
- Global Reliability: Trusted by turbine installers worldwide, these tools are supported by comprehensive training and remote assistance, ensuring smooth operation.
The Impact
Through this innovative collaboration, AS SCAN not only addressed the client’s immediate needs but also contributed to shaping a new standard for blade installation tools in the wind energy industry. Our Turner Gear solutions empower turbine manufacturers and installers with unparalleled performance, reliability, and support.
If you would like to learn more about our Turner Gear solutions, feel free to contact us.