Automation transformation can increase the efficiency of the core production line of offshore wind power installation ships by 30% -60%, shorten the installation cycle of single wind turbines by 25% -40%, and reduce manual safety risks by more than 80%.
1, Core efficiency improvement scenario
(1) Tower assembly welding production line
Manual mode: Multiple people are required for collaborative positioning and welding, with a groove accuracy of ± 2mm and a welding efficiency of approximately 15 meters per day;
After automation transformation, robots are used for automatic assembly and multi axis welding, with a groove accuracy of ± 0.5mm and a 45% increase in welding efficiency. The welding cycle for single section tower assembly has been reduced from 24 hours to 13 hours. (2) Blade lifting and docking
Manual mode: The crane operator collaborates with the ship crane operator, relying on visual judgment, with a docking time of about 30 minutes and an error of ≥ 5mm;
After automation transformation: equipped with visual navigation automatic lifting equipment, the docking time has been shortened to 8 minutes, and the error is controlled within ± 1mm, avoiding blade damage caused by manual misoperation. (3) Submarine cable laying operation
Manual mode: manually monitor tension and angle, laying speed is about 1500m/h, tension fluctuation ≥ ± 15%;
After automation transformation, the PLC automatic control system synchronously adjusts the laying tension and angle, and the laying speed is increased to 2500m/h. The tension fluctuation is controlled within ± 5% (in accordance with the requirements of GB/T 31032-2014).
2, Key indicators of quantitative gain
Single fan installation cycle: shortened from 8 days/unit in manual mode to 5 days/unit after automation, a reduction of 37.5%;
Scale of operators: The number of single ship operators has been reduced from 120 to 40, reducing the probability of casualties in high-risk operations at sea;
Capacity stability: The interruption rate of operations has been reduced from 15% to 2%, the attendance rate has been increased to 98%, and the annual installed capacity can be increased by 2-3 units (for 10MW level fans).
3, Adaptation boundary and security requirements
Applicable scenarios: Fixed foundation wind power installation at water depths of 30-100m, and pre production line renovation of floating wind power equipment;
Restrictions: It is necessary to reserve space for the installation of automation equipment and support remote operation and maintenance of shore based data centers;
Safety regulations: Automation equipment must comply with CCS/DNV classification society certification for offshore operation equipment, and personnel with special operation qualifications are required to operate the central control room. It is strictly prohibited to touch the safety protection devices of the equipment without authorization.
