Protective layer forming apparatus and method for controlling protective layer forming apparatus

Abstract

A protective layer forming device is provided with: a protective layer forming unit (110); a moving mechanism that moves the protective layer forming section (110) in the longitudinal direction of the blade; an articulated robot (130) which is attached to the movement mechanism and which adjusts the position of the protective layer forming unit (110) in the blade thickness direction of the windmill blade body (5a) and the orientation of the protective layer forming unit (110) so that the construction direction of the protective layer forming unit (110) faces the construction range (FA); and a control unit, the protective layer forming unit (110) having: a first spraying unit (111) for spraying a first construction material within a first construction range (SA1) centered on the first axis (X1) to form a protective layer; a second spray section (112) that forms a protective layer by spraying a second construction material within a second construction range (SA2) centered on the second axis (X2); and a first interval adjustment unit (114) that changes the inclination angle ([theta] 1) of the second axis (X2) with respect to the first axis (X1) on a plane orthogonal to the blade longitudinal direction.

Description

Technical Field

[0001] The present invention relates to a protective layer forming device and a control method of the protective layer forming device. Background Art

[0002] As the wind turbine rotor rotates, the wind turbine blades collide with foreign matter in the air (e.g., raindrops, dust, etc.) and are eroded, causing erosion on the leading edge of the wind turbine blades. To protect the wind turbine blades from this erosion, it is known to form an erosion-resistant protective layer on the leading edge of the wind turbine blades (see Patent Document 1). Furthermore, it is known to form a protective layer on the surface of a construction object by spraying a construction material onto the object being constructed from a spraying unit moved by a mobile device (see Patent Document 2).

[0003] Previous technical literature

[0004] Patent Literature

[0005] Patent Document 1: Japanese Patent Publication No. 2022-175830

[0006] Patent Document 2: Japanese Patent Publication No. 2022-103682 Summary of the Invention

[0007] Technical issues to be solved by the invention

[0008] When forming a protective layer on the leading edge of a wind turbine blade, the leading edge of the wind turbine blade is long in the blade length direction. Therefore, using a single spraying unit to form the protective layer, as in Patent Document 2, results in a long construction time. Therefore, it is conceivable to install multiple spraying units on a mobile device and simultaneously form the protective layer from the multiple spraying units, thereby expanding the area where the protective layer is formed and shortening the construction time.

[0009] However, because the curvature of a wind turbine blade's leading edge varies significantly along the blade's chord direction, simultaneous application of a protective layer from multiple spraying units may not yield the desired protective layer. For example, if the angle at which one spraying unit applies the construction material to the wind turbine blade's surface differs significantly from that of another spraying unit in an area where the curvature of the leading edge varies significantly along the blade's chord direction, the thickness and quality of the protective layer formed by one spraying unit may differ significantly from that formed by another spraying unit. In such cases, it may be impossible to form an appropriate protective layer in each area of ​​the wind turbine blade's leading edge.

[0010] The present invention was completed in view of this situation, and its purpose is to provide a protective layer forming device and a control method for the protective layer forming device, wherein the protective layer forming device can shorten the construction time for forming a protective layer on the tip and leading edge of the wind turbine blade body in the blade length direction, and obtain a protective layer with the desired thickness and quality.

[0011] Means for solving technical problems

[0012] A protective layer forming device according to one embodiment of the present invention forms a protective layer within a construction range of a tip portion and a leading edge portion of a wind turbine blade body formed of FRP in the blade length direction. The protective layer forming device comprises:

[0013] a protective layer forming unit for spraying construction materials into the construction area by conveying gas to form a protective layer;

[0014] a moving mechanism for moving the protective layer forming portion along the blade length direction of the wind turbine blade body;

[0015] an adjustment mechanism mounted on the moving mechanism and configured to adjust a position of the protective layer forming portion in a blade thickness direction of the wind turbine blade body and a direction of the protective layer forming portion so that a construction direction of the protective layer forming portion is opposite to the construction range; and

[0016] a control unit that controls the protective layer forming unit, the moving mechanism, and the adjusting mechanism;

[0017] The protective layer forming portion includes:

[0018] a first spraying unit for spraying the first construction material within a first construction range centered on the first axis to form the protective layer;

[0019] a second spraying unit for spraying the second construction material within a second construction range centered on a second axis to form the protective layer; and

[0020] The angle changing portion changes an inclination angle of the second axis relative to the first axis on a plane perpendicular to the longitudinal direction of the blade.

[0021] A control method for a protective layer forming device according to one embodiment of the present invention forms a protective layer within a construction range of a tip portion and a leading edge portion of a wind turbine blade body formed of FRP in a blade length direction.

[0022] The protective layer forming device includes a protective layer forming unit that forms a protective layer by spraying a construction material into the construction area using a conveying gas.

[0023] The protective layer forming portion includes:

[0024] a first spraying unit for spraying the first construction material within a first construction range centered on a first axis to form the protective layer; and

[0025] The second spraying part sprays the second construction material in a second construction range centered on the second axis to form the protective layer.

[0026] The control method of the protective layer forming device comprises:

[0027] an adjusting step of adjusting a position of the protective layer forming portion in a blade thickness direction of the wind turbine blade body and a direction of the protective layer forming portion so that a construction direction of the protective layer forming portion is opposite to the construction range;

[0028] an angle changing step of changing an inclination angle of the second axis relative to the first axis on a plane perpendicular to the longitudinal direction of the blade; and

[0029] In the protective layer forming step, the protective layer forming portion is moved along the blade length direction of the wind turbine blade body to form the protective layer by the protective layer forming portion.

[0030] Effects of the Invention

[0031] According to the present invention, a protective layer forming device and a control method for the protective layer forming device can be provided, wherein the protective layer forming device can shorten the construction time for forming a protective layer on the tip and leading edge of the wind turbine blade body in the blade length direction, and obtain a protective layer with the desired thickness and quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Figure 1 This is a schematic diagram showing the configuration of a wind turbine generator using a wind turbine blade according to an embodiment of the present invention.

[0033] Figure 2 It is a top view showing a windmill blade.

[0034] Figure 3 yes Figure 2 Front view of a windmill blade.

[0035] Figure 4 yes Figure 2 and Figure 3 A cross-sectional view of a windmill blade is shown.

[0036] Figure 5 This is a front view showing the installed state of the wind turbine blade when the protective layer is formed.

[0037] Figure 6 yes Figure 5 Cross-sectional view at the support position.

[0038] Figure 7 This is a partially enlarged front view showing the construction range of the protective layer formed on the tip of the wind turbine blade.

[0039] Figure 8 It is a partially enlarged front view showing the process of forming the protective layer.

[0040] Figure 9 It is a partially enlarged cross-sectional view showing the protective layer forming device of the present embodiment and the forming direction of the protective layer in the blade thickness direction.

[0041] Figure 10 This is a block diagram showing a control structure of the protective layer forming apparatus according to this embodiment.

[0042] Figure 11 It means in Figure 9 Part A is a front view showing a state where a protective layer forming portion is arranged.

[0043] Figure 12 This is a flowchart showing a method for controlling the protective layer forming apparatus according to this embodiment.

[0044] Figure 13 It means in Figure 9 Part B is a front view showing a state where a protective layer forming portion is arranged.

[0045] Figure 14 It means in Figure 9 A portion A is a plan view showing a state where a protective layer forming portion according to a modification example is arranged. DETAILED DESCRIPTION

[0046] Hereinafter, an embodiment of the present invention will be described with reference to the accompanying drawings.

[0047] like Figure 1 As shown, the wind turbine generator 1 includes a tower 3 erected on an installation surface B, a nacelle 6 installed at the upper end of the tower 3 , and a rotor head 4 rotatable about a substantially horizontal axis and installed in the nacelle 6 .

[0048] The rotor head 4 is radially mounted with multiple (e.g., three) wind turbine blades 5 around its rotational axis. The force of wind that strikes the wind turbine blades 5 from the direction of the rotor head 4's rotational axis is converted into power, which causes the rotor head 4 to rotate around its rotational axis. This power is converted into electricity by a generator (not shown) and supplied externally.

[0049] like Figure 2As shown, the windmill blade 5 includes: a blade root 10, mounted on the rotor head 4; a blade tip 12, located at the position farthest from the rotor head 4; and a blade-shaped portion 14, extending between the blade root 10 and the blade tip 12. Figure 2 In the embodiment, the blade length direction L1 is the horizontal direction.

[0050] The wind turbine blade 5 has a leading edge 16 and a trailing edge 18 from the blade root 10 to the blade tip 12. The outer shape of the wind turbine blade 5 is defined by a ventral side 20, which is a pressure surface (positive pressure surface), and a dorsal side 22, which is a negative pressure surface opposite the ventral side 20. The wind turbine blade 5 is formed of FRP (Fiber-Reinforced Plastic). Examples of FRP include carbon fiber reinforced plastic (CFRP) and glass fiber reinforced plastic (GFRP). The total length of the wind turbine blade 5 from the blade root 10 to the blade tip 12 is set to be in the order of 100 meters, for example, between 80 meters and 150 meters. Furthermore, a 200-meter-long wind turbine blade can be used as the wind turbine blade 5 of this embodiment.

[0051] like Figure 3 As shown, the wind turbine blade 5 is provided with a pre-curved portion PB on the blade tip 12 side. The amount of curvature of the pre-curved portion PB is predetermined based on the wind pressure to which the wind turbine blade 5 is subjected during operation. Therefore, the pre-curved portion PB is curved so that the ventral side 20, which is subjected to wind pressure, is concave and the dorsal side 22 is convex.

[0052] like Figure 2 As shown, a protective layer 30 is formed on the blade body 5a at the blade tip 12 of the wind turbine blade 5 and in a predetermined area (leading edge portion) including the leading edge 16. The construction range of the protective layer 30 is Figure 2 The protective layer 30 is indicated by a bold line. The construction range of the protective layer 30 in the blade longitudinal direction L1 is 20 to 40 meters, preferably approximately 30 meters, from the tip 12a of the blade tip portion 12. The protective layer 30 is composed of a construction material (sprayed material) with excellent wear resistance, such as a cermet or a Co (cobalt)-based alloy. The protective layer 30 is formed, for example, by laminating multiple pass layers using HVOF (High Velocity Oxy-Fuel) technology.

[0053] Figure 4 shows a cross section of a wind turbine blade 5. In this figure, the horizontal direction represents the blade chord direction C1. With the total length of the wind turbine blade 5 being R, (a) is a cross section at a position of 0.9R, and (b) is a cross section at a position of 0.7R.

[0054] Figure 4The blade chord length (chord length) c in the cross section of (a) is approximately 1 m. The blade thickness ratio t / c, where the maximum blade thickness is t, is 18%.

[0055] Figure 4 The blade chord length c in the cross section of (b) is about 2 m, and the blade thickness ratio t / c is 25%.

[0056] like Figure 4 Indicated by a thick line in the middle, the protective layer 30 is formed from the ventral side surface 20 to the dorsal side surface 22 across the leading edge 16. The construction range of the protective layer 30 is determined in consideration of erosion of the wind turbine blade 5 by raindrops and the like.

[0057] Next, the process of forming the protective layer 30 will be described.

[0058] like Figure 5 As shown, after the outer shape of the wind turbine blade body 5a of the wind turbine blade 5 is formed, the wind turbine blade 5 is positioned with the blade longitudinal direction L1 substantially horizontal and the leading edge 16 facing downward (position setting step). In other words, the wind turbine blade 5 is positioned longitudinally with the blade chord direction C1 of the wind turbine blade body 5a facing substantially vertically. At this time, the wind turbine blade 5 is supported from below by a plurality of support platforms 32 arranged at predetermined intervals in the blade longitudinal direction L1 (supporting step).

[0059] Figure 5 The figure shows that the leading edge 16 side of the wind turbine blade 5 is supported by a plurality of support platforms 32. Each support platform 32 is installed on the installation surface BS during construction. Furthermore, the wind turbine blade 5 only needs to be supported with the leading edge 16 side facing downward. For example, instead of supporting the wind turbine blade 5 from below with the support platforms 32 as described above, the wind turbine blade 5 can be supported by a suspension member such as a wire suspended from above the wind turbine blade 5, thereby holding and lifting the leading edge 16 facing downward.

[0060] like Figure 5 and Figure 6 As shown, with the leading edge 16 facing downward, a protective layer 30 is formed on the leading edge 16 of the wind turbine blade 5 by a protective layer forming device 100, which will be described later. The protective layer forming device 100 accelerates the heated, melted or softened construction material in the form of droplets or particles using a conveying gas and sprays the material onto the surface of the wind turbine blade body 5a.

[0061] Figure 7 3 shows a construction range FA where the protective layer 30 is formed on the blade tip portion 12 of the wind turbine blade 5. As shown in the figure, the protective layer 30 is formed in a predetermined range (leading edge portion) on the leading edge 16 side of the wind turbine blade 5.

[0062] like Figure 8As shown, when forming the protective layer 30, the spraying unit is reciprocated along the blade length direction L1 (direction indicated by (1) in the figure) (first protective layer forming step). Thus, the protective layer is laminated into multiple layers. The thickness of the protective layer is, for example, approximately 500 μm to 600 μm. The irradiation width of the spraying unit on the blade surface is, for example, approximately 10 mm.

[0063] After the first protective layer forming step, the position of the spraying portion is changed to form the protective layer 30 at an adjacent position in the blade chord direction C1 (the direction shown in (2) in the figure) (blade chord position changing step). Then, at this adjacent position, the spraying portion is reciprocated along the blade chord direction C1 in the same manner as in the first protective layer forming step to form the protective layer 30 (second protective layer forming step). The first protective layer forming step and the second protective layer forming step scan and form the first spraying portion 111, the second spraying portion 112, and the third spraying portion 113 by reciprocating along the blade length direction L1. This is because the curvature change of the blade surface in the blade length direction L1 is smaller than that in the blade chord direction C1.

[0064] Figure 9 : is a partially enlarged cross-sectional view showing the protective layer forming device of this embodiment and the forming direction of the protective layer in the blade chord direction C1. Figure 9 As shown, the position change direction in the blade chord position change step is set as the arrow in the figure, which is from one blade surface (for example, the ventral side 20) of the wind turbine blade 5 to the other blade surface (for example, the dorsal side 22) via the leading edge 16.

[0065] Next, the protective layer forming apparatus 100 according to this embodiment will be described.

[0066] Figure 9 The protective layer forming device 100 shown is a device for forming a protective layer within a construction range (FA) at the tip and leading edge of a wind turbine blade body 5 a formed of FRP in the blade length direction. Figure 10 1 is a block diagram showing the control structure of the protective layer forming apparatus 100 according to this embodiment. Figure 9 and Figure 10 As shown, the protective layer forming apparatus 100 includes a protective layer forming unit 110 , a moving mechanism 120 , a multi-jointed robot (adjustment mechanism) 130 , an acquisition unit 140 , and a control unit 150 .

[0067] The protective layer forming unit 110 is a device that forms a protective layer by spraying a construction material onto the construction area FA using a conveying gas. Figure 11 It means in Figure 9The front view of the state where the protective layer forming portion 110 is configured in the A portion is a view of the wind turbine blade 5 along the blade length direction L1. Figure 11 As shown, the protective layer forming portion 110 includes a first spraying portion 111 , a second spraying portion 112 , a connecting member 116 , a first gap adjusting portion 114 , and a second gap adjusting portion 115 .

[0068] The first spraying unit 111 sprays a construction material (first construction material) onto a first construction area SA1 centered on the first axis X1 to form a protective layer. The second spraying unit 112 sprays a construction material (second construction material) onto a second construction area SA2 centered on the second axis X2 to form a protective layer. The third spraying unit 113 sprays a construction material (third construction material) onto a third construction area SA3 centered on the third axis X3 to form a protective layer.

[0069] The connecting member 116 connects one end of the first spraying portion 111 along the first axis X1, one end of the second spraying portion 112 along the second axis X2, and one end of the third spraying portion 113 along the third axis X3. The connecting member 116 is formed from an elastically deformable member (e.g., a member formed from a resin material or a metal material) and maintains a constant distance W11 between one end of the first spraying portion 111 along the first axis X1 and one end of the second spraying portion 112 along the second axis X2. Similarly, the connecting member 116 maintains a constant distance W21 between one end of the first spraying portion 111 along the first axis X1 and one end of the third spraying portion 113 along the third axis X3.

[0070] The first gap adjustment portion 114 is a device for adjusting the gap W12 between the other end of the first spraying portion 111 along the first axis X1 and the other end of the second spraying portion 112 along the second axis X2. The second gap adjustment portion 115 is a device for adjusting the gap W22 between the other end of the first spraying portion 111 along the first axis X1 and the other end of the third spraying portion 113 along the third axis X3. Since the gap W11 remains constant, adjusting the gap W12 by the first gap adjustment portion 114 can change the inclination angle θ1 of the second axis X2 relative to the first axis X1 in a plane perpendicular to the blade length direction L1. Furthermore, adjusting the gap W22 by the second gap adjustment portion 115 can change the inclination angle θ2 of the third axis X3 relative to the first axis X1 in a plane perpendicular to the blade length direction L1.

[0071] As described above, the connecting member 116, the first interval adjustment portion 114 and the second interval adjustment portion 115 function as an angle changing portion, which changes the inclination angle θ1 of the second axis X2 relative to the first axis X1 on a plane perpendicular to the blade length direction L1, and changes the inclination angle θ2 of the third axis X3 relative to the first axis X1 on a plane perpendicular to the blade length direction L1.

[0072] like Figure 7 As shown, the moving mechanism 120 moves the protective layer forming unit 110 along the blade length direction L1 of the wind turbine blade body 5a. The moving mechanism 120 moves along a track 200 provided on the installation surface BS during construction in the blade length direction L1. The position of the moving mechanism 120 in the blade length direction L1 is controlled by the control unit 150.

[0073] The multi-joint robot 130 is a mechanism installed on the moving mechanism 120 and moves the protective layer forming unit 110 to any position in the three-dimensional space. Figure 9 As shown, the multi-joint robot 130 adjusts the position of the protective layer forming portion 110 in the blade thickness direction T1 of the wind turbine blade body 5a and the direction of the protective layer forming portion 110 so that the construction direction of the protective layer forming portion 110 (in Figure 11 In the embodiment, the first spraying portion 111 is opposed to the construction area FA of the wind turbine blade body 5a along the first axis X1 (a direction in which the construction material is sprayed).

[0074] The acquisition unit 140 is a device for acquiring the shape of the wind turbine blade body 5a at the position in the blade length direction L1 and the blade thickness direction T1 where the protective layer forming portion 110 is disposed. For example, the position in the blade length direction L1 and the blade thickness direction T1 where the protective layer forming portion 110 is disposed is Figure 9 Position P1 is shown. Position P1 is where the first axis X1 of the first coating portion 111 of the protective layer forming unit 110 intersects the surface of the wind turbine blade body 5a. The acquisition unit 140 includes a storage unit (not shown) that pre-stores the surface curvature of the wind turbine blade body 5a at various positions in the blade length direction L1 and the blade thickness direction T1. The acquisition unit 140 then retrieves the curvature pre-stored in the storage unit based on the position in the blade length direction L1 and the blade thickness direction T1 where the protective layer forming unit 110 is located.

[0075] Various methods can be used to pre-store the surface curvature of the wind turbine blade body 5a at various locations in the blade length direction L1 and blade thickness direction T1 in the storage unit. For example, a measuring device (not shown) can be used to pre-measure the shape of the construction area FA on the surface of the wind turbine blade body 5a and store the measured value in the storage unit. Alternatively, a measuring device (not shown) for measuring the shape of the construction area FA on the surface of the wind turbine blade body 5a can be attached to the protective layer forming unit 110. The surface curvature of the wind turbine blade body 5a at the location where the protective layer forming unit 110 is located can be measured and transmitted to the acquiring unit 140.

[0076] The control unit 150 is a device for controlling the protective layer forming unit 110, the moving mechanism 120, and the multi-joint robot 130. Figure 12 , a method for controlling the protective layer forming apparatus 100 executed by the control unit 150 will be described. Figure 12 1 is a flowchart showing a method of controlling the protective layer forming apparatus 100 according to the present embodiment. Figure 12 Each process in the program is executed by the control unit 150 reading a program stored in a storage unit (not shown).

[0077] In step S101, the control unit 150 controls the moving mechanism 120 to move the protective layer forming device 100 to the movement start position in the blade length direction L1. The movement start position is, for example, the position of the end of the working area FA on the blade root 10 side in the blade length direction L1 when the protective layer 30 is formed from the blade root 10 side of the working area FA toward the blade tip 12 ( Figure 7 shown in the location).

[0078] In step S102, the control unit 150 controls the multi-joint robot 130 so as to adjust the position and orientation of the protective layer forming unit 110. Figure 9 The protective layer forming unit 110 is positioned at a desired position in the blade thickness direction T1 and the blade chord direction C1 by adjusting the angles of the arms 131, 132, and 133 shown. When forming the protective layer 30, the control unit 150 controls the multi-jointed robot 130 to position the protective layer forming unit 110 at position P0, the starting position in the forming direction.

[0079] Furthermore, the control unit 150 adjusts the orientation of the protective layer forming portion 110 of the wind turbine blade body 5a so that the construction direction of the protective layer forming portion 110 (in Figure 11 In the embodiment, the first spraying portion 111 is opposed to the construction area FA of the wind turbine blade body 5a along the first axis X1 (a direction in which the construction material is sprayed).

[0080] In step S103, the control unit 150 controls the acquisition unit 140 to acquire the surface curvature of the wind turbine blade body 5a. The acquisition unit 140 acquires the surface curvature of the wind turbine blade body 5a at the position where the protective layer forming portion 110 is disposed in the blade length direction L1 and the blade thickness direction T1.

[0081] In step S104, the control unit 150 changes the inclination angle θ1 of the second axis X2 relative to the first axis X1 in a plane perpendicular to the blade longitudinal direction L1 based on the surface curvature of the wind turbine blade body 5a obtained in step S103. Similarly, the control unit 150 changes the inclination angle θ2 of the third axis X3 relative to the first axis X1 in a plane perpendicular to the blade longitudinal direction L1 based on the surface curvature of the wind turbine blade body 5a obtained in step S103.

[0082] Here, reference Figure 11 and Figure 13 A method of controlling the first gap adjusting unit 114 and the second gap adjusting unit 115 so as to achieve the inclination angles θ1 and θ2 corresponding to the surface curvature of the wind turbine blade body 5 a acquired in step S103 will be described. Figure 11 It means in Figure 9 A portion of FIG. 1 is a front view showing a state where the protective layer forming portion 110 is arranged. Figure 13 It means in Figure 9 Part B is a front view showing a state where the protective layer forming portion 110 is arranged.

[0083] like Figure 11 As shown, the control unit 150 obtains the curvature at position P2 in step S103 and changes the inclination angles θ1 and θ2 in step S104. For example, the control unit 150 controls the first spacing adjustment unit 114 so that the second axis X2 of the second coating unit 112 intersects the surface of the wind turbine blade body 5a at a right angle (90 degrees) to the inclination angle θ1. Similarly, the control unit 150 controls the second spacing adjustment unit 115 so that the third axis X3 of the third coating unit 113 intersects the surface of the wind turbine blade body 5a at a right angle (90 degrees) to the inclination angle θ2.

[0084] The reason for setting the inclination angle θ1, where the second axis X2 of the second spraying portion 112 intersects the surface of the wind turbine blade body 5a at a right angle (90 degrees), is to improve the quality of the protective layer 30 formed in the application area FA by the second spraying portion 112. Similarly, the reason for setting the inclination angle θ2, where the third axis X3 of the third spraying portion 113 intersects the surface of the wind turbine blade body 5a at a right angle (90 degrees), is to improve the quality of the protective layer 30 formed in the application area FA by the third spraying portion 113.

[0085] like Figure 13 As shown, the control unit 150 obtains the curvature at position P1 in step S103 and changes the inclination angles θ1 and θ2 in step S104. For example, the control unit 150 controls the first spacing adjustment unit 114 so that the second axis X2 of the second coating unit 112 intersects the surface of the wind turbine blade body 5a at a right angle (90 degrees) to the inclination angle θ1. Similarly, the control unit 150 controls the second spacing adjustment unit 115 so that the third axis X3 of the third coating unit 113 intersects the surface of the wind turbine blade body 5a at a right angle (90 degrees) to the inclination angle θ2.

[0086] Figure 11 The curvature at position P2 shown is greater than Figure 13 The curvature of position P1 is shown. Therefore, Figure 13 The tilt angle θ1 shown is less than Figure 11 The tilt angle θ1 is shown. And, Figure 13 The tilt angle θ2 shown is less than Figure 11 Thus, by setting the inclination angles θ1 and θ2 corresponding to the surface curvature of the wind turbine blade body 5a acquired in step S103, a high-quality protective layer 30 can be formed within the construction range FA even if the surface curvature of the wind turbine blade body 5a changes.

[0087] In step S105 , the control unit 150 controls the moving mechanism 120 to move the protective layer forming unit 110 in the blade length direction L1 .

[0088] In step S106 , the control unit 150 operates the first spraying unit 111 , the second spraying unit 112 , and the third spraying unit 113 to spray the heated, melted, or softened construction material in the form of droplets or particles onto the surface of the wind turbine blade body 5 a through the conveying gas to form the protective layer 30 .

[0089] The formation of the protective layer 30 in step S106 is performed simultaneously with the movement of the protective layer forming unit 110 in step S105. Specifically, in steps S105 and S106, the protective layer forming unit 110 is moved along the blade length direction L1 of the wind turbine blade body 5a, and the protective layer 30 is formed by the protective layer forming unit 110 (protective layer forming step).

[0090] In step S107 , the control unit 150 determines whether the protective layer forming unit 110 has reached the movement end position in the blade length direction L1 . If yes, the control unit 150 proceeds to step S108 , and if no, the control unit 150 proceeds to step S102 .

[0091] In step S108 , the control unit 150 controls the moving mechanism 120 from the point where the protective layer forming unit 110 reaches the movement end position in the blade length direction L1 to stop the protective layer forming unit 110 from moving in the blade length direction L1 , and ends the process of this flowchart.

[0092] The functions and effects of the protective layer forming apparatus 100 according to the present embodiment described above will be described.

[0093] According to the protective layer forming apparatus 100 of this embodiment, the protective layer forming unit 110 is moved by a moving mechanism 120 to any position in the blade length direction L1 of the wind turbine blade body 5a. The position and orientation of the protective layer forming unit 110 in the blade thickness direction T1 are adjusted by a multi-jointed robot 130 so that the application direction is aligned with the application area FA. Furthermore, the protective layer forming unit 110 includes multiple spraying units: a first spraying unit 111, a second spraying unit 112, and a third spraying unit 113. Therefore, the first spraying unit 111 can simultaneously spray the application material onto the first application area SA1, the second spraying unit 112 onto the second application area SA2, and the third spraying unit 113 onto the third application area SA3. This shortens the application time required to form the protective layer 30 on the blade tip 12 and leading edge 16 of the wind turbine blade body 5a in the blade length direction L1.

[0094] Furthermore, according to the protective layer forming apparatus 100 of this embodiment, the first spacing adjustment unit 114 and the second spacing adjustment unit 115 can change the inclination angle θ1 of the second axis X2, which is the center of the second application area SA2 of the second spraying unit 112, relative to the first axis X1, which is the center of the first application area SA1 of the first spraying unit 111, on a plane perpendicular to the blade longitudinal direction L1. Therefore, by changing the inclination angle θ1 to an appropriate angle corresponding to the surface shape of the wind turbine blade body 5a, a protective layer 30 having a desired thickness or quality can be obtained.

[0095] According to the protective layer forming device 100 of this embodiment, the curvature of the wind turbine blade body 5a at the position where the protective layer forming unit 110 is arranged in the blade length direction L1 and the blade thickness direction T1 is acquired by the acquisition unit 140, and the first spacing adjustment unit 114 and the second spacing adjustment unit 115 are controlled so as to achieve an inclination angle θ1 corresponding to the curvature acquired by the acquisition unit 140. Thus, the inclination angle θ1 can be changed to an appropriate angle corresponding to the surface curvature of the wind turbine blade body 5a, thereby obtaining a protective layer 30 having a desired thickness or quality.

[0096] According to the protective layer forming apparatus 100 of this embodiment, the first and second spacing adjustment units 114, 115 are controlled so that the first axis X1 is perpendicular to the surface of the wind turbine blade body 5a, and the first and second spacing adjustment units 114, 115 are controlled so that the second axis X2 is perpendicular to the surface of the wind turbine blade body 5a. Since both the first and second axes X1, X2 are perpendicular to the surface of the wind turbine blade body 5a, a protective layer having a desired thickness and quality can be obtained using both the first and second spraying units 111, 112.

[0097] According to the protective layer forming apparatus 100 of this embodiment, one end of the first coating portion 111 along the first axis X1 and one end of the second coating portion 112 along the second axis X2 are connected by a connecting member 116. The distance between the other end of the first coating portion 111 along the first axis X1 and the other end of the second coating portion 112 along the second axis X2 is adjusted by a first spacing adjustment portion 114 and a second spacing adjustment portion 115. This allows the inclination angle θ1 of the second axis X2 relative to the first axis X1 on a plane perpendicular to the blade longitudinal direction L1 to be adjusted to any desired angle.

[0098] [Other Implementation Methods]

[0099] The protective layer forming unit 110 of the protective layer forming apparatus 100 of this embodiment is configured such that one end of the first spraying unit 111 along the first axis X1, one end of the second spraying unit 112 along the second axis X2, and one end of the third spraying unit 113 along the third axis X3 are connected by a connecting member 116. However, other configurations are also possible. For example, the first spacing adjustment unit 114A may be used to adjust the spacing W11 between the one end of the first spraying unit 111 along the first axis X1 and the one end of the second spraying unit 112 along the second axis X2, and the first spacing adjustment unit 114A may be used to adjust the spacing W21 between the one end of the first spraying unit 111 along the first axis X1 and the one end of the third spraying unit 113 along the third axis X3.

[0100] Figure 14 It means in Figure 9 A portion of FIG is a top view of a state where a protective layer forming portion according to a modification example is configured. Figure 14 As shown, the protective layer forming portion 110 of the modified example has: a first spacing adjustment portion (first adjustment portion) 114A, which adjusts the spacing W11 between one end side of the first spraying portion 111 along the first axis X1 and one end side of the second spraying portion 112 along the second axis X2; and a first spacing adjustment portion (second adjustment portion) 114, which adjusts the spacing W12 between the other end side of the first spraying portion 111 along the first axis X1 and the other end side of the second spraying portion 112 along the second axis X2.

[0101] Furthermore, the protective layer forming portion 110 of the modified example has: a second spacing adjustment portion 115A, which adjusts the spacing W21 between one end side of the first spray portion 111 along the first axis X1 and one end side of the third spray portion 113 along the third axis X3; and a second spacing adjustment portion 115, which adjusts the spacing W22 between the other end side of the first spray portion 111 along the first axis X1 and the other end side of the third spray portion 113 along the third axis X3.

[0102] According to the protective layer forming apparatus 100 of this modified example, the first spacing adjustment unit 114A adjusts the spacing between one end of the first spraying unit 111 along the first axis X1 and one end of the second spraying unit 112 along the second axis X2, and the first spacing adjustment unit 114 adjusts the spacing between the other end of the first spraying unit 111 along the first axis X1 and the other end of the second spraying unit 112 along the second axis X2. Thus, the inclination angle θ1 of the second axis X2 relative to the first axis X1 along the blade thickness direction T1 can be adjusted to any angle.

[0103] Furthermore, the protective layer forming apparatus 100 of this modified example can adjust the spacing along the blade thickness direction T1 between the first application area SA1 of the first spraying unit 111 and the second application area SA2 of the second spraying unit 112, as well as the spacing along the blade thickness direction T1 between the first application area SA1 of the first spraying unit 111 and the third application area SA3 of the third spraying unit 113, to any desired spacing. Thus, the extent of overlap between the first application area SA1 and the second application area SA2, as well as the extent of overlap between the first application area SA1 and the third application area SA3, in the blade thickness direction T1 can be appropriately adjusted, thereby achieving an appropriate thickness and quality of the protective layer 30.

[0104] The protective layer forming apparatus and the control method of the protective layer forming apparatus described in each embodiment described above can be understood, for example, as follows.

[0105] A protective layer forming device 100 according to a first embodiment of the present invention forms a protective layer within a construction area (FA) at the tip and leading edge of a wind turbine blade body formed of FRP in the blade length direction. The protective layer forming device 100 comprises: a protective layer forming unit 110 for spraying a construction material onto the construction area using a conveying gas to form the protective layer; a moving mechanism 120 for moving the protective layer forming unit along the blade length direction of the wind turbine blade body; and an adjustment mechanism 130 mounted on the moving mechanism for adjusting the position of the protective layer forming unit in the blade thickness direction of the wind turbine blade body and the orientation of the protective layer forming unit. So that the construction direction of the protective layer forming part is opposite to the construction range; and a control part 150, which controls the protective layer forming part, the moving mechanism and the adjustment mechanism, the protective layer forming part comprises: a first spraying part 111, which sprays the first construction material within the first construction range centered on the first axis (X1) to form the protective layer; a second spraying part 112, which sprays the second construction material within the second construction range centered on the second axis (X2) to form the protective layer; and angle changing parts 114, 115, which change the inclination angle (θ1) of the second axis relative to the first axis on a plane perpendicular to the length direction of the blade.

[0106] According to the protective layer forming device involved in the first embodiment of the present invention, the protective layer forming unit is moved to any position in the blade length direction of the wind turbine blade body by a moving mechanism, and the position and orientation of the protective layer forming unit in the blade thickness direction are adjusted by an adjustment mechanism so that the construction direction and the construction range are opposite. In addition, the protective layer forming unit has multiple spraying units, namely a first spraying unit and a second spraying unit. Therefore, the action of spraying the construction material from the first spraying unit within the first construction range and the action of spraying the construction material from the second spraying unit within the second construction range can be carried out simultaneously. As a result, the construction time for forming the protective layer at the tip and leading edge of the wind turbine blade body in the blade length direction can be shortened.

[0107] Furthermore, the protective layer forming apparatus according to the first aspect of the present invention can use the angle changing unit to change the inclination angle of the second axis, which is the center of the second application range of the second spraying unit, relative to the first axis, which is the center of the first application range of the first spraying unit, on a plane perpendicular to the longitudinal direction of the blade. Therefore, by changing the inclination angle to an appropriate angle corresponding to the surface shape of the wind turbine blade body, a protective layer having a desired thickness or quality can be obtained.

[0108] The protective layer forming device involved in the second embodiment of the present invention has an acquisition unit 14 in the first embodiment, which acquires the shape of the windmill blade body at the position in the blade length direction and the blade thickness direction where the protective layer forming unit is configured, and the control unit controls the angle changing unit to make it the inclination angle corresponding to the shape acquired by the acquisition unit.

[0109] In the protective layer forming device according to the second aspect of the present invention, the acquisition unit acquires the shape of the wind turbine blade body at the position where the protective layer forming unit is disposed in the blade length direction and the blade thickness direction, and the angle changing unit is controlled to achieve an inclination angle corresponding to the shape acquired by the acquisition unit. This allows the inclination angle to be changed to an appropriate angle corresponding to the surface shape of the wind turbine blade body, thereby obtaining a protective layer having a desired thickness or quality.

[0110] The protective layer forming device according to a third aspect of the present invention, in the second aspect, further comprises the following configuration: the acquisition unit acquires a curvature of the wind turbine blade body along the blade thickness direction, and the control unit controls the angle changing unit so as to achieve the inclination angle corresponding to the curvature acquired by the acquisition unit.

[0111] In the protective layer forming device according to the third aspect of the present invention, the acquisition unit acquires the curvature of the wind turbine blade body along the blade thickness direction at the position where the protective layer forming unit is located, and the angle changing unit is controlled to achieve an inclination angle corresponding to the curvature acquired by the acquisition unit. This allows the inclination angle to be changed to an appropriate angle corresponding to the curvature of the wind turbine blade body surface in the blade thickness direction, thereby obtaining a protective layer having a desired thickness and quality.

[0112] The protective layer forming device according to a fourth aspect of the present invention, in the second aspect, further comprises the following configuration: the control unit controls the adjustment mechanism so that the first axis is perpendicular to the surface of the wind turbine blade body, and controls the angle changing unit so that the second axis is perpendicular to the surface of the wind turbine blade body.

[0113] According to the protective layer forming device according to the fourth aspect of the present invention, the angle changing unit is controlled so that the first axis is perpendicular to the surface of the wind turbine blade body, and the angle changing unit is controlled so that the second axis is perpendicular to the surface of the wind turbine blade body. Since both the first axis and the second axis are perpendicular to the surface of the wind turbine blade body, a protective layer having a desired thickness or quality can be obtained using both the first spraying unit and the second spraying unit.

[0114] The protective layer forming device according to a fifth aspect of the present invention, in any of the first to fourth aspects, further comprises the following configuration: Specifically, the angle changing section includes: a connecting member 116 connecting one end of the first spraying section along the first axis and one end of the second spraying section along the second axis; and gap adjusting sections 114 and 115 for adjusting the gap between the other end of the first spraying section along the first axis and the other end of the second spraying section along the second axis.

[0115] In the protective layer forming device according to the fifth aspect of the present invention, a connecting member connects one end of the first spraying portion along the first axis to one end of the second spraying portion along the second axis, and a gap adjustment member adjusts the gap between the other end of the first spraying portion along the first axis and the other end of the second spraying portion along the second axis. This allows the inclination angle of the second axis relative to the first axis on a plane perpendicular to the blade longitudinal direction to be adjusted to any desired angle.

[0116] The protective layer forming apparatus according to a sixth aspect of the present invention, in any one of the first to fourth aspects, further comprises the following configuration: Specifically, the protective layer forming section includes: a first adjustment section 114A for adjusting the distance between one end of the first spraying section along the first axis and one end of the second spraying section along the second axis; and a second adjustment section 114B for adjusting the distance between the other end of the first spraying section along the first axis and the other end of the second spraying section along the second axis.

[0117] According to the protective layer forming device of the sixth aspect of the present invention, the first adjustment unit adjusts the distance between one end of the first spraying unit along the first axis and one end of the second spraying unit along the second axis, and the second adjustment unit adjusts the distance between the other end of the first spraying unit along the first axis and the other end of the second spraying unit along the second axis. This allows the inclination angle of the second axis relative to the first axis in the blade thickness direction to be adjusted to any desired angle.

[0118] A method for controlling a protective layer forming device according to a seventh aspect of the present invention is a method for forming a protective layer within a construction range of a tip portion and a leading edge portion of a wind turbine blade body formed of FRP in the blade length direction.

[0119] The protective layer forming device includes a protective layer forming unit that forms a protective layer by spraying a construction material into the construction area using a conveying gas.

[0120] The protective layer forming portion includes:

[0121] a first spraying unit for spraying the first construction material within a first construction range centered on a first axis to form the protective layer; and

[0122] The second spraying part sprays the second construction material in a second construction range centered on the second axis to form the protective layer.

[0123] The control method of the protective layer forming device comprises:

[0124] an adjusting step of adjusting a position of the protective layer forming portion in a blade thickness direction of the wind turbine blade body and a direction of the protective layer forming portion so that a construction direction of the protective layer forming portion is opposite to the construction range;

[0125] an angle changing step of changing an inclination angle of the second axis relative to the first axis on a plane perpendicular to the longitudinal direction of the blade; and

[0126] In the protective layer forming step, the protective layer forming portion is moved along the blade length direction of the wind turbine blade body to form the protective layer by the protective layer forming portion.

[0127] According to the control method for a protective layer forming device according to the seventh embodiment of the present invention, the protective layer forming unit is moved to any position in the blade length direction of the wind turbine blade body through a movement step, and the position and orientation of the protective layer forming unit in the blade thickness direction are adjusted through an adjustment step so that the construction direction and the construction range are aligned. Furthermore, the protective layer forming unit includes multiple spraying units, namely a first spraying unit and a second spraying unit. Therefore, the first spraying unit can spray the construction material within the first construction range, and the second spraying unit can spray the construction material within the second construction range simultaneously. This shortens the construction time required to form a protective layer at the tip and leading edge of the wind turbine blade body in the blade length direction.

[0128] Furthermore, according to the control method for the protective layer forming apparatus according to the seventh aspect of the present invention, the angle changing step allows the inclination angle of the second axis, which is the center of the second application range of the second spraying unit, relative to the first axis, which is the center of the first application range of the first spraying unit, on a plane perpendicular to the longitudinal direction of the blade to be changed. Therefore, by changing the inclination angle to an appropriate angle corresponding to the surface shape of the wind turbine blade body, a protective layer having a desired thickness or quality can be obtained.

[0129] Explanation of symbols

[0130] 5a-windmill blade body, 10-blade root, 12-blade tip, 12a-tip, 14-blade-shaped portion, 16-leading edge, 18-trailing edge, 20-ventral side, 22-dorsal side, 30-protective layer, 32-support platform, 100-protective layer forming device, 110-protective layer forming portion, 111-first spraying portion, 112-second spraying portion, 113-third spraying portion, 114, 114A-first spacing adjustment portion, 115, 115A-second spacing adjustment portion, 116- Connecting parts, 120-moving mechanism, 130-multi-joint robot (adjustment mechanism), 140-acquisition part, 150-control part, 200-track, B-setting surface, BS-setting surface during construction, C1-blade chord direction, FA-construction range, L1-blade length direction, SA1-first construction range, SA2-second construction range, SA3-third construction range, T1-blade thickness direction, X1-first axis, X2-second axis, X3-third axis, θ1, θ2-tilt angles.

Claims

1. A protective layer forming device for forming a protective layer within a construction range of a tip portion and a leading edge portion of a wind turbine blade body formed of FRP in a blade length direction, the protective layer forming device comprising: a protective layer forming unit for spraying construction materials into the construction area by conveying gas to form a protective layer; a moving mechanism for moving the protective layer forming portion along the blade length direction of the wind turbine blade body; an adjustment mechanism mounted on the moving mechanism and configured to adjust a position of the protective layer forming portion in a blade thickness direction of the wind turbine blade body and a direction of the protective layer forming portion so that a construction direction of the protective layer forming portion is opposite to the construction range; and a control unit that controls the protective layer forming unit, the moving mechanism, and the adjusting mechanism; The protective layer forming portion includes: a first spraying unit for spraying the first construction material within a first construction range centered on the first axis to form the protective layer; a second spraying unit for spraying the second construction material within a second construction range centered on a second axis to form the protective layer; and The angle changing portion changes an inclination angle of the second axis relative to the first axis on a plane perpendicular to the longitudinal direction of the blade.

2. The protective layer forming device according to claim 1, wherein: An acquisition unit is provided for acquiring the shape of the wind turbine blade body at a position in the blade length direction and the blade thickness direction where the protective layer forming portion is arranged, The control unit controls the angle changing unit so as to obtain the inclination angle corresponding to the shape acquired by the acquisition unit.

3. The protective layer forming device according to claim 2, wherein: The acquiring unit acquires the curvature of the wind turbine blade body along the blade thickness direction, The control unit controls the angle changing unit so as to obtain the inclination angle corresponding to the curvature acquired by the acquisition unit.

4. The protective layer forming device according to claim 2, wherein: The control unit controls the adjustment mechanism so that the first axis is perpendicular to the surface of the wind turbine blade body, and controls the angle changing unit so that the second axis is perpendicular to the surface of the wind turbine blade body.

5. The protective layer forming apparatus according to any one of claims 1 to 4, wherein: The angle changing portion includes: a connecting member connecting one end side of the first coating portion along the first axis and one end side of the second coating portion along the second axis; and The interval adjustment portion adjusts the interval between the other end side of the first coating portion along the first axis and the other end side of the second coating portion along the second axis.

6. The protective layer forming apparatus according to any one of claims 1 to 4, wherein: The protective layer forming portion includes: a first adjustment portion for adjusting a distance between one end side of the first coating portion along the first axis and one end side of the second coating portion along the second axis; and The second adjustment portion adjusts the distance between the other end side of the first coating portion along the first axis and the other end side of the second coating portion along the second axis.

7. A method for controlling a protective layer forming device for forming a protective layer within a construction range of a tip portion and a leading edge portion of a wind turbine blade body formed of FRP in a blade length direction. The protective layer forming device includes a protective layer forming unit that forms a protective layer by spraying a construction material into the construction area using a conveying gas. The protective layer forming portion includes: a first spraying unit for spraying the first construction material within a first construction range centered on a first axis to form the protective layer; and The second spraying part sprays the second construction material in a second construction range centered on the second axis to form the protective layer. The control method of the protective layer forming device comprises: an adjusting step of adjusting a position of the protective layer forming portion in a blade thickness direction of the wind turbine blade body and a direction of the protective layer forming portion so that a construction direction of the protective layer forming portion is opposite to the construction range; An angle changing step of changing an inclination angle of the second axis relative to the first axis on a plane perpendicular to the longitudinal direction of the blade; and In the protective layer forming step, the protective layer forming portion is moved along the blade length direction of the wind turbine blade body to form the protective layer by the protective layer forming portion.

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