JP7776313B2 - Plasma cutting device and plasma cutting method - Google Patents

Description

The present invention relates to a plasma cutting device and method suitable for dismantling large components such as towers for onshore wind turbines.

In recent years, large-scale upgrades to wind power generation facilities have resulted in the generation of large amounts of dismantled wind turbine components. In the process of completely melting down and disposing of these components, large wind turbine components, such as the tower frame and blade attachment members (hubs), must be cut into pieces small enough to be fed into a blast furnace (for example, within approximately 1m x 1m). This cutting work is generally performed by skilled workers using gas cutting.

Meanwhile, a known conventional component cutting device is a plasma cutting device that cuts components using a plasma arc generated by a plasma torch (see, for example, Patent Document 1). The plasma cutting device described in Patent Document 1 includes a mounting table on which a steel plate is placed and an X-axis guide member provided to the side of the mounting table. A movable carriage is supported on the X-axis guide member so that it can move freely in the X-axis direction, and a Y-axis guide member extending in the Y-axis direction, perpendicular to the X-axis direction, is fixed to the movable carriage. A carriage equipped with a plasma torch is provided on the Y-axis guide member so that it can move freely in the Y-axis direction. The plasma torch is movable in the Z-axis direction (up and down) relative to the carriage. With this configuration, the steel plate can be cut along any desired line by moving the plasma torch to any desired position horizontally (in the X and Y-axis directions) and vertically (in the Z-axis direction) relative to the steel plate placed on the mounting table.

Japanese Patent Application Laid-Open No. 2013-202676

The tower body, which is a component used to disassemble a wind turbine, is a large, long, cylindrical component (approximately 12mm to 44mm thick) that is tapered in cross section. Therefore, after laying it horizontally on-site, a scaffolding work platform is set up around it and gas cutting is performed, which takes a long time. Furthermore, the tower body is rotated circumferentially with a crane to set up the cutting position, which requires a lot of work. For this reason, a technology that can shorten the cutting time was needed.

The present invention was made in consideration of the above, and aims to provide a plasma cutting device and plasma cutting method that can shorten cutting work time.

To solve the above problems and achieve the objectives, the plasma cutting device of the present invention comprises a holding member that can move along a linear guide member while holding a plasma torch, and cutting control means that controls the operation of the holding member and the generation of a plasma arc from the plasma torch. The cutting control means controls the holding member to move along the guide member while a plasma arc is generated from the plasma torch, thereby cutting an object to be cut that is placed close to the guide member. The device further comprises support means, an operating member that is rotatably supported on the support means and rotatably supports the guide member at its tip, angle control means that controls the rotation angle of the guide member relative to the operating member, and distance control means that controls the separation distance between the object to be cut and the plasma torch to a predetermined distance.

Another plasma cutting device according to the present invention is characterized in that, in the above-mentioned invention, the cutting control means can be remotely operated from a location away from the object to be cut.

Another plasma cutting device according to the present invention is the same as the above-mentioned invention, but further comprising an image acquisition means for acquiring an image of the object to be cut near the holding member, and a display means for displaying the image acquired by the image acquisition means, and the cutting control means can be remotely operated while viewing the image displayed on the display means.

The plasma cutting method according to the present invention is a plasma cutting method for cutting an object placed close to a guide member using the above-described plasma cutting device, and is characterized by comprising the steps of: placing a support means near the object, and then operating the operating member to position the guide member close to the surface of the object; controlling the angle control means to control the rotation angle of the guide member and position the guide member along the surface of the object; and controlling the cutting control means to move the holding member along the guide member while generating a plasma arc from the plasma torch, thereby cutting the object.

Another plasma cutting method according to the present invention is characterized in that, in the above-described invention, the cutting control means is remotely operated at a point away from the object to be cut, thereby cutting the object.

Another plasma cutting method according to the present invention is characterized in that, in the above-described invention, an image acquisition means is provided for acquiring an image of the object to be cut near the holding member, and a display means is provided for displaying the image acquired by the image acquisition means, and the object is cut by remotely operating the cutting control means while viewing the image displayed on the display means at a location away from the object.

The plasma cutting device of the present invention comprises a holding member that can move along a linear guide member while holding a plasma torch, and cutting control means that controls the movement of the holding member and the generation of a plasma arc from the plasma torch. The holding member is moved along the guide member while a plasma arc is generated from the plasma torch under the control of the cutting control means, thereby cutting an object to be cut that is placed close to the guide member. The device also comprises a support means, an operating member that is rotatably supported on the support means and rotatably supports the guide member at its tip, an angle control means that controls the rotation angle of the guide member relative to the operating member, and a distance control means that controls the separation distance between the object to be cut and the plasma torch to a predetermined distance, thereby achieving the effect of significantly reducing the cutting time for large materials compared to manual gas cutting.

Furthermore, with another plasma cutting device according to the present invention, the cutting control means can be remotely operated from a location away from the object to be cut, thereby achieving the effect of improving work safety.

In addition, another plasma cutting device according to the present invention further comprises an image acquisition means for acquiring an image of the object to be cut near the holding member, and a display means for displaying the image acquired by the image acquisition means. The cutting control means can be remotely operated while viewing the image displayed on the display means, thereby achieving the effect of improving work safety as well as work accuracy and work efficiency.

The plasma cutting method of the present invention uses the above-described plasma cutting device to cut a workpiece placed close to a guide member, and includes the steps of: placing a support means near the workpiece, and then operating the operating member to position the guide member near the surface of the workpiece; controlling the angle control means to control the rotation angle of the guide member and position the guide member along the surface of the workpiece; and controlling the cutting control means to move the holding member along the guide member while generating a plasma arc from the plasma torch, thereby cutting the workpiece. This has the effect of significantly reducing the cutting time for large workpieces compared to manual gas cutting.

Furthermore, according to another plasma cutting method of the present invention, the cutting control means is remotely operated from a location away from the object to be cut, thereby improving work safety.

In addition, another plasma cutting method according to the present invention includes an image acquisition means for acquiring an image of the object to be cut near the holding member, and a display means for displaying the image acquired by the image acquisition means.The cutting control means is then remotely operated from a location away from the object to be cut while viewing the image displayed on the display means, thereby achieving the effect of improving work safety as well as work accuracy and work efficiency.

FIG. 1 is a side view showing an embodiment of a plasma cutting device and a plasma cutting method according to the present invention. FIG. 2 is a top view of FIG. FIG. 3 is a front view of FIG. FIG. 4 is a perspective view of the main parts of the holding member (movable carriage) and the guide member (traveling rail). FIG. 5 is a schematic diagram showing the distance control means (separation distance guide mechanism), where (1) is a side view and (2) is a top view.

The following describes in detail an embodiment of a plasma cutting device and a plasma cutting method according to the present invention, with reference to the drawings. Note that the present invention is not limited to this embodiment.

As shown in Figures 1 to 3, a plasma cutting device 10 according to an embodiment of the present invention is placed to the side of a wind turbine tower body P that has been temporarily placed sideways at a demolition site. This plasma cutting device 10 includes a construction machine 12 and a plasma cutting mechanism 14 attached to the end of the arm of the construction machine 12. The tower body P is the object to be cut and is made of a long, cylindrical member that is tapered in cross section from the side, and has a shape that expands or contracts in diameter as it progresses axially along the tower.

The construction machine 12 used is a self-propelled mini hydraulic excavator with the bucket at the end of the arm removed. This construction machine 12 comprises a lower traveling body 16 (support means), a work implement 18, and an upper rotating body 20. The upper rotating body 20 is rotatably supported on the lower traveling body 16, and the work implement 18 is attached to the upper rotating body 20. The lower traveling body 16 is driven by power from an engine (not shown) to propel the construction machine 12. The lower traveling body 16 comprises a pair of left and right crawlers 22. Note that the support means of the present invention is not limited to the lower traveling body 16, and any structure that can support the plasma cutting mechanism 14 in an adjustable position may be used.

The work implement 18 is an operating member that receives power from an engine (not shown) and is driven. The work implement 18 includes a boom 24, an arm 26, and a support mechanism 28, which can be hydraulically driven independently. The boom 24 has its base end supported on the front of the upper rotating body 20 so that it can rotate in the vertical direction, and is rotated by a telescopically movable boom cylinder 30. The arm 26 has its base end supported on the tip of the boom 24 and is rotated by a telescopically movable arm cylinder 32. The support mechanism 28 has its base end supported on the tip of the arm 26 and is rotated by a telescopically movable support mechanism cylinder 34. The boom 24 and arm 26 form a multi-joint structure, and the boom 24 is located at the base end of the elements that make up the multi-joint structure.

The upper rotating body 20 is configured to be able to rotate around a vertical axis relative to the lower running body 16 via a rotating bearing (not shown). The upper rotating body 20 is equipped with a driver's seat for operating each function of the construction machine 12, a drive engine, a motor for rotating the upper rotating body 20, and other components. The boom cylinder 30, arm cylinder 32, and support mechanism cylinder 34 are operated by hydraulic oil from a hydraulic pump driven by the engine. By rotating the upper rotating body 20 with the motor, the arm 26 can be rotated around a vertical axis. Note that each function of the construction machine 12, including this arm rotation function, may be configured to be remotely operable from a location away from the driver's seat.

As shown in FIG. 4, the plasma cutting mechanism 14 includes a mobile carriage 42 (holding member) that can move along a long, plate-shaped (long, linear) traveling rail 40 (guide member) while holding the plasma torch 36 with a clamping mechanism 38, and a cutting control means 44 that controls the operation of the mobile carriage 42 and the generation of a plasma arc from the plasma torch 36. The cutting control means 44 may be configured to be remotely operable from a remote location. By moving the mobile carriage 42 along the traveling rail 40 while generating a plasma arc from the plasma torch 36 under the control of the cutting control means 44, it is possible to cut the tower body P located close to the traveling rail 40. The plasma cutting mechanism 14 may utilize existing automatic plasma cutting equipment, such as CutRunner (registered trademark), used in factories, etc.

The running rail 40 is supported at its longitudinal midsection so that it can pivot relative to the support mechanism 28 at the tip of the arm 26. The pivot angle of the running rail 40 relative to the support mechanism 28 can be controlled by an angle control means 46, which adjusts the pivot position of the running rail 40 relative to the support mechanism 28.

The angle control means 46 includes a swivel bearing 46A that supports the running rail 40 relative to the support mechanism 28 so that it can swivel up and down, a swivel shaft 46B that supports the running rail 40 so that it can swivel left and right, and an auxiliary mechanism 46C that tiltably fixes the running rail 40 relative to the support mechanism 28. The angle control means 46 of this embodiment is configured to adjust the swivel angle of the running rail 40 by a predetermined angle θ in two orthogonal swivel directions (e.g., 5° each in the vertical and horizontal directions (10° total)) to accommodate the placement and cutting direction of the tower body P. Because the tower body P has a tapered cylindrical shape, when placed horizontally on level ground at a demolition site, the axial direction of the tower body P is slightly oblique to the horizontal. Therefore, in this embodiment, the swivel angle of the running rail 40 is adjustable in the vertical and horizontal directions so that the boundary between the upper and lower semicircles of the tower body P can be easily cut in the generatrix direction in this state. This allows the traveling rails 40 to be positioned closely along the surface of the tower body P. Furthermore, even if the relative positions of the construction machine 12 and the tower body P are slightly misaligned, the arm rotation function of the construction machine 12 and the rotation function of the traveling rails 40 allow the traveling rails 40 to be positioned closely along the surface of the tower body P.

A distance guide mechanism 48 (distance control means) is provided at both longitudinal ends of the traveling rail 40 to maintain a constant distance between the surface of the tower body P to be cut and the tip of the plasma torch 36. As shown in FIG. 5, this distance guide mechanism 48 has a pair of approximately crescent-shaped plate members 50 protruding from both longitudinal ends of the traveling rail 40 in a direction perpendicular to the longitudinal direction. The plate members 50 are rotatable about shafts 52 fixed to both ends of the traveling rail 40, and rollers 54 are rotatably attached to both ends. By pressing the rollers 54 of the plate members 50 at both ends against the surface of the tower body P, the distance between the surface of the tower body P and the tip of the plasma torch 36 during plasma cutting can be maintained at a constant distance.

The operation and function of the above configuration will now be described.
First, the construction machine 12 is positioned near the side of the tower body P, which is placed sideways at the demolition site. Next, the work equipment 18 is operated to position the traveling rail 40 near the surface of the tower body P. Next, the angle control means 46 is controlled to adjust the rotation angle of the traveling rail 40, so that the traveling rail 40 is positioned along the surface of the tower body P, and the roller 54 of the separation distance guide mechanism 48 is pressed against the surface of the tower body P. In this state, the cutting control means 44 is controlled to move the mobile carriage 42 along the traveling rail 40 while a plasma arc is generated from the plasma torch 36. In this manner, the tower body P is plasma-cut along the traveling rail 40.

In conventional gas cutting, the cutting position was set up by setting up a scaffolding work platform or using a crane to rotate the tower body P. However, with the plasma cutting device 10 of this embodiment, which has a plasma cutting mechanism 14 attached to the end of the arm of a construction machine 12, the upper half of the tower body P can be plasma cut without changing the cutting position. Plasma cutting is approximately three times faster than manual gas cutting, significantly reducing the work time required to cut large components such as the tower body P. This allows for rapid cutting without moving the tower body P placed horizontally at the demolition site. The combined operation of the construction machine's 12 arm rotation function and the running rail 40 rotation function allows the running rail 40 to be easily positioned close to the surface of the tower body P in various positions, improving cutting efficiency. Furthermore, compared to gas cutting, there is no risk of worker heatstroke, burns, or falls, improving work safety.

In the above embodiment, an operator may perform plasma cutting work by remotely operating the plasma cutting device 10 from a distance from the cutting position on the tower body P. This can further improve work safety.

Furthermore, a wireless communication network such as a Wi-Fi (registered trademark) environment may be established around the demolition site, and multiple cameras (image acquisition means) may be installed in locations where the cutting status can be visually confirmed, such as around the traveling rails 40. An operator wearing a wearable device (display means) may then remotely operate the cutting control means 44 and angle control means 46 of the plasma cutting device 10, the arm rotation function of the construction machine 12, and other functions to perform the cutting work, while checking the cutting status using images transmitted from the cameras via the wireless communication network. This can improve work safety as well as work accuracy and efficiency.

As described above, the plasma cutting device of the present invention comprises a holding member that can move along a linear guide member while holding a plasma torch, and cutting control means that controls the movement of the holding member and the generation of a plasma arc from the plasma torch. The holding member is moved along the guide member while a plasma arc is generated from the plasma torch under the control of the cutting control means, thereby cutting an object to be cut that is placed close to the guide member. The device also comprises a support means, an operating member that is rotatably supported on the support means and rotatably supports the guide member at its tip, an angle control means that controls the rotation angle of the guide member relative to the operating member, and a distance control means that controls the separation distance between the object to be cut and the plasma torch to a predetermined distance. Therefore, the time required for cutting large materials can be significantly reduced compared to manual gas cutting.

Furthermore, with another plasma cutting device according to the present invention, the cutting control means can be remotely operated from a location away from the object to be cut, thereby improving work safety.

In addition, another plasma cutting device according to the present invention further comprises an image acquisition means for acquiring an image of the object to be cut near the holding member, and a display means for displaying the image acquired by the image acquisition means. The cutting control means can be remotely operated while viewing the image displayed on the display means, thereby improving work safety as well as work accuracy and work efficiency.

In addition, the plasma cutting method of the present invention uses the above-mentioned plasma cutting device to cut a workpiece placed close to a guide member. The method includes the steps of: placing a support means near the workpiece, and then operating the operating member to position the guide member near the surface of the workpiece; controlling the angle control means to control the rotation angle of the guide member and position the guide member along the surface of the workpiece; and controlling the cutting control means to move the holding member along the guide member while generating a plasma arc from the plasma torch, thereby cutting the workpiece. Therefore, the cutting time for large workpieces can be significantly reduced compared to manual gas cutting.

Furthermore, according to another plasma cutting method of the present invention, the cutting control means is remotely operated from a location away from the object to be cut, thereby improving work safety.

In addition, another plasma cutting method according to the present invention includes an image acquisition means for acquiring an image of the object to be cut near the holding member, and a display means for displaying the image acquired by the image acquisition means.The cutting control means is then remotely operated from a location away from the object to be cut while viewing the image displayed on the display means, thereby improving work safety, work accuracy, and work efficiency.

As described above, the plasma cutting device and plasma cutting method of the present invention are useful for dismantling large components such as wind turbine towers, and are particularly suitable for shortening cutting work times.

10 Plasma cutting device 12 Construction machine 14 Plasma cutting mechanism 16 Undercarriage (support means)
18 Working machine (operating member)
20 Upper rotating body 22 Crawler 24 Boom 26 Arm 28 Support mechanism 30 Boom cylinder 32 Arm cylinder 34 Support mechanism cylinder 36 Plasma torch 38 Clamp mechanism 40 Traveling rail (guide member)
42 Mobile cart (holding member)
44 Cutting control means 46 Angle control means 48 Separation distance guide mechanism (distance control means)
50 Plate member 52 Shaft portion 54 Roller P Tower body (object to be cut)

Claims (6)

A plasma cutting device comprising: a holding member capable of moving along a linear guide member while holding a plasma torch; and cutting control means for controlling the operation of the holding member and the generation of a plasma arc from the plasma torch; wherein the holding member is moved along the guide member while a plasma arc is generated from the plasma torch under the control of the cutting control means, thereby cutting an object to be cut that is disposed close to the guide member,
The cutting apparatus further comprises a support means, an operating member that is rotatably supported by the support means and that rotatably supports the guide member at a tip end thereof, an angle control means that controls the rotation angle of the guide member relative to the operating member, and a distance control means that controls the separation distance between the workpiece and the plasma torch to a predetermined distance ,
the object to be cut is a tapered cylindrical member placed horizontally on a horizontal surface, the tapered cylindrical member having a shape in which the diameter increases or decreases as the tapered cylindrical member advances in the cylindrical axis direction, the cylindrical axis direction being oblique to the horizontal,
The distance control means comprises a plate member that is rotatable about an axis fixed to both ends of the longitudinal direction of the guide member and extends in a direction perpendicular to the longitudinal direction, and rollers that are rotatably attached to both ends of the plate member in the extending direction, and by pressing the rollers against the surface of the object to be cut, the plasma cutting device maintains a constant distance between the surface of the object to be cut and the tip of the plasma torch during cutting . 2. The plasma cutting device according to claim 1, wherein the cutting control means is remotely operable from a location away from the object to be cut. 3. The plasma cutting device according to claim 2 , further comprising an image acquisition means for acquiring an image of the object to be cut in the vicinity of the holding member, and a display means for displaying the image acquired by the image acquisition means, wherein the cutting control means can be remotely operated while viewing the image displayed on the display means. A plasma cutting method for cutting the workpiece arranged in proximity to the guide member using the plasma cutting device according to any one of claims 1 to 3,
a step of controlling the angle control means to control the rotation angle of the guide member and position the guide member along the surface of the object to be cut ; a step of maintaining a constant distance between the surface of the object to be cut and the tip of the plasma torch by pressing the roller of the distance control means against the surface of the object to be cut; and a step of controlling the cutting control means to move the holding member along the guide member while generating a plasma arc from the plasma torch, thereby cutting the object to be cut. 5. The plasma cutting method according to claim 4, wherein the cutting control means is remotely operated at a point away from the object to be cut , thereby cutting the object to be cut. 6. The plasma cutting method according to claim 5 , further comprising providing an image acquisition means for acquiring an image of the object to be cut in the vicinity of the holding member, and a display means for displaying the image acquired by the image acquisition means, and then remotely operating the cutting control means while viewing the image displayed on the display means at a point away from the object to be cut, thereby cutting the object to be cut.