Each process cycle for a rotor blade runs in exactly the same way:

It always begins with the exact positioning of the rotor blade in the HBBA. The further process steps are also always the same: the blade is “sawed” to the right length, the surfaces are “shaped” so that they are smooth, and in the final step the holes for the lengthways and crossways bolts are “drilled”. It is hard to believe, but a complete cycle lasts less that 3 hours with the HBBA! That is more than two complete rotor sets per day!

1. Positioning

The device for positioning the rotor blades feeds the blade into the HBBA and joins the blade and the HBBA exactly and firmly (positioning unit). Now the fully-automatic machining of the blade is possible with the HBBA – the Heinicke Drilling and Trimming Rig.
 
   

2. Sawing / Shortening

The sawing unit performs the first step (pre-machining). At its root, the blade is shortened to exactly the planned length (trimmed). The circular saw works at a speed of 275 mm per minute and reaches a surface tolerance of max. 0.7 mm.
 Sägen
   

3. Shaping / Smoothing

The shaping unit does the second step (finishing). The rotor blade which has been cut to the right length is then shaped in this step, in order to achieve an even surface. The speed in this step is 950 mm per minute; the surface tolerance is reduced to max. 0.1 mm. This all happens completely automatically.
 
   

4. Drilling

The HBBA’s particular strength: it fulfils both of the different drilling cycles in axial and radial directions at the same time:
  • In the axial direction (lengthways) holes are drilled for the coupling lengthways bolts with a diameter of up to 45 mm.
  • In the radial direction (crossways) holes are drilled for the crossways bolts, with a diameter of up to 80 mm.
Both drilling cycles are freely programmable.
 

The standard HBBA 2600 rig is able to machine rotor blade roots with a diameter of up to 2,600 mm.

Our new HBBA 3600 has been specifically conceived for the off-shore sector and is already in successful operation at a German rotor blades manufacturer. This rig is able to machine rotor blade roots with a diameter of up to 3,600 mm.