Method for manufacturing a wind turbine blade

Abstract

The invention relates to a method for manufacturing a wind turbine blade. A method for manufacturing a wind turbine blade (3) comprises the step of monitoring (S5) a process of infusing (S1) a fiber layup (11) with resin (14) in a mold (8), wherein the monitoring (S5) is based on sensor data (22, 25) obtained (S2) from the resin infusion and / or curing process which is displayed (S4) in an augmented reality device (19). Displaying the sensor data obtained from the resin infusion and / or curing process in the augmented reality device allows for better monitoring of the resin infusion and / or curing process. As a result, the quality of the manufactured wind turbine blade can be improved.

Description

Technical Field

[0001] The invention relates to a method for manufacturing a wind turbine blade. Background Art

[0002] Wind turbine rotor blades typically include fiber reinforced laminate structures. The fiber reinforced laminate structures are manufactured by impregnating a fiber lay-up with a resin and curing the resin. The impregnation process, for example, includes infusing the fibers with the resin. The quality of the manufactured fiber reinforced laminate is highly dependent on a number of parameters related to the infusion and curing process, such as the temperature and pressure of the resin. For example, the viscosity of the resin, which depends on the temperature, affects the resin flow through the fibers. Therefore, it is desirable to monitor the parameters that affect the infusion and curing process. Further, wind turbine blades can be manufactured in closed molds, thereby preventing visual inspection of the resin flow and the curing process during the manufacturing process. Summary of the invention

[0003] It is an object of the present invention to provide an improved method for manufacturing a wind turbine blade.

[0004] Therefore, a method for manufacturing a wind turbine blade is proposed. The method comprises the steps of monitoring a process of infusing and / or curing a fiber layup with resin in a mold. The monitoring is based on sensor data obtained from the resin infusion and / or curing process displayed on an augmented reality device.

[0005] Displaying sensor data obtained from the resin infusion and / or curing process in an augmented reality device allows for better monitoring of the resin infusion and / or curing process. This allows for real-time visualization of the process. In particular, insights into the current state of the resin being infused and / or the current state of curing of the resin during the manufacturing process can be obtained. As a result, parameters affecting the infusion and / or curing process can be controlled. As a result, the quality of the manufactured wind turbine blades can be improved. For example, a uniform distribution of the resin throughout the fibers can be better achieved. For example, parts of the fibers can be better prevented from remaining dry, i.e. without resin. Another example is that the generation of enclosed bubbles in the laminate can be reduced. As a result, the laminate structure strength and durability can be improved.

[0006] A wind turbine blade is part of a wind turbine's rotor. A wind turbine is a device that converts the kinetic energy of wind into electrical energy. A wind turbine comprises, for example, a rotor having one or more of the blades, each connected to a hub; a nacelle including a generator; and a tower holding the nacelle at its upper end. The tower of the wind turbine may be connected to a foundation of the wind turbine, such as a monopile in the seabed, via a transition piece.

[0007] A wind turbine blade, for example its root section, is fixedly or rotatably connected to a hub. Apart from the (cylindrical) root section, the wind turbine blade is aerodynamically formed. A wind turbine blade comprises, for example, a pressure side (upwind side) and a suction side (downwind side). The pressure side and the suction side are connected to each other at a leading edge and a trailing edge. The pressure and suction sides and the leading and trailing edges define the airfoil of the wind turbine blade.

[0008] Wind turbine blades are manufactured, for example, by arranging fiber layups in a mold, infusing the fiber layups with resin, and curing the resin.

[0009] The fibers are arranged in the mold, for example in a dry condition (ie without resin). The fibers may also be (partially) pre-impregnated fibers (prepregs). The fibers include, for example, glass fibers, carbon fibers, aromatic fibers and / or natural fibers.

[0010] The fiber layup may include a fiber core material, such as wood, balsa, PET foam and / or PVC foam. The core material may be sandwiched between the fiber layers so as to obtain a fiber reinforced resin laminate having a core structure.

[0011] Further, the reinforcement beams may be arranged in a mould and connected to the fibre lay-up by resin infusion and curing.

[0012] The resin is infused into the fiber layup, for example, by a vacuum assisted resin infusion process. For example, the fiber layup is covered by a vacuum bag, and a vacuum is generated in the space covered by the vacuum bag, for example, in the space between the mold and the vacuum bag. The resin is then infused into this space due to the generated vacuum, thereby infiltrating the fibers.

[0013] The mold may include a lower mold part and an upper mold part. Fiber layups for forming a lower shell of the blade (e.g., the pressure side of the blade) may be arranged in the lower mold, and fiber layups for forming an upper shell of the blade (e.g., the suction side of the blade) may be arranged in the upper mold. The upper mold may be arranged on the lower mold, thereby forming a cavity between them. The mold may also include a mold core in the mold cavity. The fiber layups in the lower and upper molds may be covered by a vacuum bag. In the closed state of the mold (i.e., the upper mold is arranged on the lower mold), resin may be poured into the vacuum bag and the space between the lower and upper molds.

[0014] Resins include, for example, thermosetting resins, thermoplastics, epoxies, polyurethanes, vinyl esters and / or polyesters.

[0015] The resin is cured, for example by application of heat. The result is a fiber reinforced resin laminate.

[0016] Monitoring the process of infusing and / or curing the fiber layup with resin based on the sensor data displayed in the augmented reality device may include, for example, checking the displayed sensor data. It may include detecting deviations of the displayed sensor data from a desired state. It may include an alarm system to indicate such deviations.

[0017] The sensor data includes measurement data obtained by one or more sensors. The one or more sensors are arranged at or near the mold, fiber, resin and / or its surrounding environment. The one or more sensors are connected to the augmented reality device by wire or wirelessly. For example, the one or more sensors are connected to the augmented reality device by wire or wirelessly via a computing unit. The computing unit can be an external hardware computing unit separated from the augmented reality device. Alternatively, the augmented reality device itself can include a computing unit. The computing unit can also include a cloud-based computing unit.

[0018] The augmented reality device includes a monitor to display the sensor data. The augmented reality device includes, for example, augmented reality glasses, a tablet computer, a laptop computer, a mobile phone and / or a projector.

[0019] An augmented reality device is in particular a device which allows to display real world information to a user, which real world information is augmented in a computer-aided manner. Displaying the sensor data in the augmented reality device in particular comprises displaying the sensor measurement data as augmented information superimposed on a representation of the mould or the blade. The sensor data may also be displayed during manufacturing in a virtual reality device or by projection onto the mould or the blade using a projector.

[0020] According to an embodiment, the sensor data comprises measured physical quantities of the mould, of the fibre layup arranged in the mould and / or of the resin.

[0021] This allows monitoring of physical quantities of the mold, fiber layup and / or resin that affect the infusion and / or curing process.

[0022] The sensor data may also include measured physical quantities of the immediate environment of the mold, fiber layup, and / or resin.

[0023] According to another embodiment, the physical quantity comprises temperature, pressure, current position of the resin, viscosity, refractive index, density, electrical properties and / or dielectric properties.

[0024] Monitoring the temperature of the mold, the fiber layup and / or the resin allows controlling, for example, the temperature of the resin such that the temperature-dependent viscosity of the resin is adapted to the desired resin flow.

[0025] Monitoring the pressure and thus the generated vacuum (eg in the space covered by the vacuum bag) allows controlling the resin flow and / or detecting resin leaks.

[0026] Monitoring the current position of the resin allows the flow front of the resin to be controlled during infusion.

[0027] Monitoring the density of the resin and / or the refractive index of the resin (which is related to the density of the resin) allows the cure state of the resin to be controlled.

[0028] Monitoring the electrical and / or dielectric properties of the resin (which depends on the structural properties of the resin) allows the cure state of the resin to be controlled.

[0029] According to another embodiment, the sensor data includes chemical information of the resin.

[0030] This allows, for example, the curing state of the resin to be controlled.

[0031] According to a further embodiment, the sensor data comprises position data and / or time data.

[0032] In addition to sensor measurement data obtained by the one or more sensors (such as measured physical or chemical quantities of the mold, fiber layup and / or resin), the sensor data may also include position data indicating the location where the measured quantity is measured (i.e. where the measured quantity exists). For example, a temperature sensor may be placed in a specific location within the fiber layup, and the sensor data then includes the measured temperature at this location and the spatial coordinates of this location.

[0033] Furthermore, the sensor data may also include time data indicating the time at which the measurement data was obtained.

[0034] Having position data allows displaying the measurement data as a function of the position data. Thus, it allows, for example, displaying the spatial distribution of the measurement data. For example, the temperature distribution of a mold can be displayed.

[0035] Having time data allows displaying the measurement data as a function of the time data. Thus, it allows displaying the evolution of the measurement data over time. For example, the development of the flow front of the resin can be displayed.

[0036] According to another embodiment, the sensor data displayed in the augmented reality device is processed sensor data, which includes temperature distribution, pressure distribution, resin flow front performance and / or resin curing performance.

[0037] Sensor data obtained from the resin infusion and / or curing process can be stored and processed by the computing unit. The data can be interpreted and interpolated using a data analysis model to prepare for visualization, for example. The data can be processed, for example, to derive a physical or chemical quantity of interest from the measured quantity. The data can be processed, for example, to derive a spatial and / or temporal distribution of a quantity, such as a spatial temperature distribution, a spatial pressure distribution, a spatial resin flow front state, a spatial resin curing state, a temperature evolution, a pressure evolution, a resin flow front evolution, and / or a resin curing evolution.

[0038] By displaying the processed sensor data in an augmented reality device and thereby monitoring the processed sensor data, the resin infusion and / or curing process can be better controlled.

[0039] According to an embodiment, the sensor data is displayed in an augmented reality device, superimposed onto a real world representation of the mould and / or blade.

[0040] A user of an augmented reality device (eg augmented reality glasses) sees, for example, the real mold and / or blade during manufacturing and the sensor data as augmented information superimposed thereon.

[0041] According to another embodiment, the sensor data is displayed in an augmented reality device, superimposed on the digital data of the mould and / or the blade.

[0042] The digital data may be visual data of the mold and / or blade during manufacturing. The visual data is specifically obtained by a camera. The camera may be included in the augmented reality device or may be separated from the augmented reality device. The camera (e.g., an augmented reality device comprising a camera) may include a tracking system to track the relative position of the camera relative to the mold and / or blade. For example, marker-based or model-based tracking may be used. Tracking may be accomplished by collecting visual data (a video stream or frames of a video stream) through the camera and analyzing the visual data with the aid of a computer algorithm and, for example, the computing unit. Based on the computer algorithm, the mold shape and / or blade shape during manufacturing may be identified in the visual data for tracking and subsequent superposition of enhanced information in the form of sensor data. In this case, the augmented reality device displays sensor data superimposed on the camera-based visual data of the mold or blade during manufacturing.

[0043] The digital data may also be a three-dimensional model of the mould and / or blade. In this case, the augmented reality device displays the sensor data superimposed on the three-dimensional model of the mould and / or blade.

[0044] Displaying the sensor data superimposed on the digital data of the mould and / or blade in an augmented reality device allows an intuitive and illustrative appreciation of the complex process of resin infusion and / or curing. Further, it can be seen as a direct indication of how to control the resin infusion and / or curing process.

[0045] According to another embodiment, the sensor data are collected by sensors arranged in the inner structure of the mould and / or at the inner surface of the mould.

[0046] This allows for better control of mold quantities such as the temperature of the mold which significantly affects the resin flow.

[0047] For example, one or more sensors are arranged in a borehole of the mold. For example, the borehole may have an opening toward the inner surface of the mold, and the one or more sensors are arranged in the borehole so that they are flush with the inner surface of the mold.

[0048] According to another embodiment, sensor data is collected by sensors arranged on and / or in the fiber layup.

[0049] This allows for better measurement of the fiber layup and / or amount of resin entering.

[0050] According to another embodiment, at least a portion of the sensor remains in the infused and cured fiber layup of the manufactured blade.

[0051] This allows sensor data to be measured within the fiber layup (eg, in an inner structure of the fiber layup) without the need to remove the sensor afterwards.

[0052] For example, an optical fiber may be used as a sensor, with (a portion of) the optical fiber remaining in the manufactured blade.

[0053] According to another embodiment, the method comprises, after the step of monitoring, the step of changing the resin infusion process based on the monitoring result.

[0054] This allows to modify the infusion and / or curing process based on the sensor data displayed in the augmented reality device. The infusion and / or curing process can be quickly manipulated based on the sensor data displayed in the augmented reality device. For example, it allows intervention when process parameters are not suitable or not conducive for the production of wind turbine blades.

[0055] According to another embodiment, the resin infusion process is modified by opening resin inlet channels, heating the mold and / or increasing the infusion pressure.

[0056] For example, as soon as the mold temperature is appropriate, one or more first resin inlet channels may be opened to begin resin infusion.

[0057] Another example is that the mold may include multiple resin inlet channels that are configured to be opened subsequently. The multiple resin inlet channels may be distributed along the longitudinal direction of the mold and / or along the circumferential direction. After one or more first resin inlet channels in the multiple resin inlet channels have been opened to start resin infusion, additional resin inlet channels may be opened based on the monitored resin flow.

[0058] Another example is that if a dry spot of the fibre is detected, the mould may be heated locally in the environment of the detected dry spot in order to reduce the viscosity of the resin and cause it to flow to a point that is still dry.

[0059] Other possible implementations or alternative solutions of the present invention also cover combinations of features described above or below with respect to the embodiments (which are not explicitly mentioned in this document). A person skilled in the art may also add single or isolated aspects and features to the most basic form of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0060] Further embodiments, features and advantages of the present invention will become apparent from the subsequent description and the dependent claims, taken in conjunction with the accompanying drawings, in which:

[0061] Figure 1 A wind turbine according to an embodiment is shown;

[0062] Figure 2 Shown for manufacturing Figure 1 A cross-sectional view of a mold of a wind turbine blade of a wind turbine;

[0063] Figure 3 Shown with Figure 2 A similar diagram, but with the resin partially infused into the fiber layup of the blade;

[0064] Figure 4 FIG. 1 shows an embodiment of an embodiment of a device superimposed with augmented information from a manufacturing process (as viewed through an augmented reality device) Figure 1 3D images of wind turbine blades;

[0065] Figure 5 FIG. 1 shows a diagram of a device superimposed with augmented information from a manufacturing process (as viewed through an augmented reality device) according to another embodiment. Figure 1 3D images of wind turbine blades; and

[0066] Figure 6 shows a diagram for making Figure 1 Flow chart of a method for providing a wind turbine blade for a wind turbine. DETAILED DESCRIPTION

[0067] In the drawings, like reference numbers indicate similar or functionally equivalent elements unless otherwise indicated.

[0068] While the invention has been described in terms of preferred embodiments, it will be apparent to those skilled in the art that modifications may be made in all embodiments.

[0069] Figure 1A wind turbine 1 according to an embodiment is shown. The wind turbine 1 comprises a rotor 2 having one or more blades 3 connected to a hub 4. The hub 4 is connected to a generator (not shown) arranged inside a nacelle 5. During operation of the wind turbine 1, the blades 3 are driven by the wind to rotate and the kinetic energy of the wind is converted into electrical energy by the generator in the nacelle 5. The nacelle 5 is arranged at the upper end of a tower 6 of the wind turbine 1. The tower 6 is erected on a foundation 7, such as a monopile or a triple pile. The foundation 7 is connected to and / or driven into the ground or the seabed.

[0070] In the following, reference Figure 2-6 An improved method for manufacturing a wind turbine blade 3 is described.

[0071] Figure 2 The cross section shows the Figure 1 A mold 8 of one of the wind turbine blades 3 is provided. The mold 8 comprises a lower mold part 9 and an upper mold part 10. The mold 8 is Figure 2 1 is shown in a closed state, wherein an upper mould part 10 is arranged on a lower mould part 9. Furthermore, a dry fibre lay-up 11 is arranged in the mould 10. The fibre lay-up 11 may also comprise core material and / or reinforcing beams (not shown). In addition, shear webs may also be arranged in the mould 8 (not shown).

[0072] In step S1 of the method, the fiber layer 11 is cast by a known vacuum infusion process. In the vacuum infusion process, the fiber layer 11 is covered by a vacuum bag 12 ( Figure 2 Then, a vacuum is generated in the space covered by the vacuum bag 12. After that, one or more resin inlet channels 13 ( Figure 2 Not visible in the cross-section view, only Figure 4 ) is opened and, due to the vacuum generated, the resin 14 is infused into the fiber layup 11 ( Figure 3 ). The resin 14 is then cured, resulting in a fiber reinforced resin laminate structure.

[0073] In order to monitor the resin infusion process and the resin curing process, there are a plurality of sensors 15, 16 arranged in the mould 8 and in the fibre lay-up 11. As an example, Figure 2 The sensors 15 are shown arranged in the inner structure of the mould 8. The mould 8 comprises a plurality of bores 17 having openings towards an inner surface 18 of the mould 8. Each sensor 15 is arranged in one of the bores 17 such that the respective sensor 15 is flush with the inner surface 18 of the mould 8.

[0074] As another example of a sensor, Figure 2A sensor 16 is shown which is arranged within, ie embedded in, the fiber layup 11. The mould 8 may comprise one or more or all of the shown sensors 15, 16. The mould 8 may also comprise additional sensors which are not shown in the drawings.

[0075] Figure 4 Shown based on the use of Figure 2 and Figure 3 A first example of monitoring a resin infusion process using sensor data obtained by one or more of the sensors 15 and / or the sensors 16. Figure 4 In the example, except Figure 2 and Figure 3 In the circumferential direction shown in FIG, the sensors 15 and 16 are also distributed along the longitudinal direction L of the blade 3 at longitudinal positions X0, X1, X2, X3, X4 and X5.

[0076] In step S2 of the method, sensor data is obtained by sensors 15, 16. Step S2 can be performed before step S1, simultaneously with step S1 or after step S1. For example, before opening the one or more resin inlet channels 13 ( Figure 4 ), sensor data, such as the temperature of the mold 8 (step S2), may be obtained before starting infusion (step S1) with the mold 8. This allows resin infusion to start only when the mold 8 has an appropriate temperature (step S1). In another example, sensor data of the mold 8, the fiber layup 11, or the resin 14 may be obtained (step S2) during infusion and / or curing of the resin 14 (step S1).

[0077] In step S3, the acquired sensor data is processed by a computing unit (not shown), which is included, for example, in the augmented reality device 19. The sensor is connected to the computing unit in the augmented reality device 19 wirelessly, for example.

[0078] Sensor data is interpreted and interpolated, for example using data analysis models, in preparation for visualization. Figure 4 In the example of FIG. 1 , the data is processed to deduce the spatial distribution of the flow front of the resin 14 .

[0079] In step S4 , the processed sensor data is displayed in the augmented reality device 19 . Figure 4 The augmented reality device 4 is in the form of augmented reality glasses 19 (AR glasses) worn by the worker 20. The acquired and processed sensor data are displayed in the AR glasses 19 and superimposed on a digital three-dimensional representation 21 of the blade 3.

[0080] Figure 4 A worker 20 is shown monitoring the manufacturing process of the blade 3. In reality, the worker 20 stands in front of the closed mold 8 (see Figure 2 and Figure 3 ) and cannot see inside the mold 8. However, with the help of the AR glasses 19, the worker 20 can still obtain information related to the infusion process. Figure 4 An example of what the worker 20 sees in the display of the AR glasses 19 is shown. The worker 20 sees a three-dimensional model 21 of the blade 3 in the AR glasses 19. In addition, superimposed on the three-dimensional model 21 is processed sensor data representing the infused resin 14 ( Figure 3 ) of the flow front 22 ( Figure 4 The area of ​​the fiber layer 11' that has been impregnated with the resin 14 (i.e., the impregnated portion of the blade 3) is Figure 4 The still dry area of ​​the fiber layer 11 is indicated by 23. Figure 4 Indicated by 24 in the middle.

[0081] A worker 20 with AR glasses 19 can walk around the closed mold 8 and check the impregnation process of the fiber layup 11, 11'. The AR glasses 19 are equipped with a tracking system (not shown) which collects the closed mold 8 ( Figure 3 ) and is able to identify the mold shape for tracking and subsequent superimposition of enhanced information in the form of a resin flow front 22 ( Figure 4 ).

[0082] The worker 20 monitors the resin infusion process and / or the resin curing process based on the processed sensor data displayed in the AR glasses 19 in step S5 .

[0083] In the event that the worker 20 recognizes, for example, that the resin flow front 22 is not developing as desired, she can take steps to change the infusion process at step S6. For example, if the worker 20 recognizes that there are still dry spots in the fiber layup 11 in certain areas, the mold 8 can be heated locally. Heating the mold 8 affects the viscosity of the resin 14. At higher temperatures, the viscosity of the resin 14 decreases, and thus the resin flow is improved.

[0084] In the embodiment, except for the longitudinal position X0, the mold 8 ( Figure 2 , Figure 3 ) also includes resin inlet channels 13 ( Figure 4 ). In this case, the worker 20 can monitor the resin infusion process, and once the resin flow front 22 reaches or passes a certain position x1 to x5, the resin inlet channel at this position can be opened.

[0085] Figure 5 Another example of monitoring the resin infusion and / or curing process is shown. Figure 4In the example of FIG. 1 , a worker 20 sees a three-dimensional model 21 of a blade 3 in the AR glasses 19. In addition, superimposed on this three-dimensional model are processed sensor data representing, for example, the inner surface 18 ( Figure 2 ) temperature distribution 25 ( Figure 4 ).

Claims

1. A method for manufacturing a wind turbine blade (3), comprising the steps of monitoring (S5) a process of infusing (S1) a fiber layup (11) with resin (14) in a mold (8), wherein: The monitoring (S5) is based on sensor data (22, 25) obtained (S2) from the resin infusion and / or curing process, which is displayed (S4) in an augmented reality device (19), the sensor data (22, 25) including the viscosity of the resin (14); After the step of monitoring (S5), the resin infusion process is changed (S6) by locally heating the mold (8) based on the monitoring results.

2. The method according to claim 1, wherein: The sensor data (22, 25) include measured physical quantities of the mold (8), the fiber layup (11) arranged in the mold (8) and / or the resin (14).

3. The method according to claim 2, wherein: The physical quantity includes at least one of temperature, pressure, current position of the resin (14), refractive index, density, electrical properties and dielectric properties.

4. The method according to claim 1, wherein: The sensor data (22, 25) includes chemical information of the resin (14).

5. The method according to claim 1, wherein: The sensor data (22, 25) includes at least one of position data and time data.

6. The method according to claim 1, wherein: The sensor data (22, 25) displayed in the augmented reality device (19) is processed sensor data (22, 25), and the sensor data (22, 25) includes at least one of temperature distribution, pressure distribution, resin flow front performance and resin curing performance.

7. The method according to claim 1, wherein: The sensor data (22, 25) are displayed in the augmented reality device (19) and superimposed on the digital data (21) of the mold (8) and / or the blade (3).

8. The method according to one of claims 1 to 3, wherein: The sensor data (22, 25) are collected by sensors (15) arranged in the internal structure of the mold (8) and / or at the inner surface (18) of the mold (8).

9. The method according to claim 1, wherein: The sensor data (22, 25) are collected by sensors (16) arranged on and / or within the fiber layup (11, 11').

10. The method according to claim 9, wherein: At least a portion of the sensor (16) remains in the infused and cured fiber layup (11') of the manufactured blade (3).

11. The method according to claim 1, wherein: The resin infusion process is changed (S6) by opening a resin inlet channel (13) and / or increasing the infusion pressure.

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