JÄGER Group develops decisive assembly protection for rotor blade bolts
Precisely fitting assembly of rotor blades with more than 50 bolts
Cost-effective protection for rotor blade bolts against impacts and scratches
Facilitation of the blade alignment during assembly
PP half-shells as assembly protection for rotor blade bolts
Stable and cost-effective material
Simple assembly principle via click lock
Secure protection of the rotor blade bolts against damage
Expensive replacement procedures on running systems are no longer necessary
Faster initial assembly of the rotor blades
High costs due to assembly damages
The cost calculation presses on the system manufacturer from two fronts. Not only the replacement of the rotor blade bolt strains the costing, but the actual exchange of the damaged rotor blade bolt, which must be conducted during standstill. Thus the wind turbine cannot produce any electricity during the replacement, which leads to a loss of proceeds. This potential weakness in the bolt was not considered in the initial calculation. Therefore, the development of the desired product for the bolt is now added to the servicing items. The pressure to find a solution is correspondingly high, which is following a simple and resilient path both in production and assembly.
One-klick solution: Half shells
The JÄGER experts propose an alternative: two half shells lockable with each other, manufactured with injection molding.
After the first exchange of ideas between the engineers at Jäger and the developers of the bolt manufacturer as well as the system manufacturer, the Jäger engineers manufacture the first mutual prototypes with a 3D print procedure. The prototypes made from drawings run through several steps which form the coordination process with all those involved.
The basic idea seems so simple and convincing: Two half-shells hug the area of the extension shaft and are connected via a click lock. The halfshells are made of PP (polypropylene) and offer the right aver-age between stability and dimensional tolerance of the extension shaft.
In order that the bolts are centered to the hub inside the throughway opening during the assembly process of the rotor blade the half-shell receives a slim, circumferential bulge at one place. This does not only protect the scratch-sensitive surface from material damage. The rotor blade bolt is fixed on the hub using a nut, keeping the protection of the extension shaft in the system.
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