Improvements relating to the manufacture of wind turbine components

Abstract

In a first aspect of the application, there is provided a method of manufacturing a wind turbine component, the method comprising: supporting a layup (14) of fibre reinforced material in a mould (12); and providing a supply of hardener (20), the supply comprising at least a first hardener (20a) and a second hardener (20b), the second hardener being faster than the first hardener; mixing resin with the first hardener and / or the second hardener to produce a resin mix (24); supplying the resin mix (24) to the layup (14) during an infusion process; monitoring one or more process parameters of the infusion process; and controlling the speed of the hardener (20) by varying the relative proportions of the first and second hardeners (20a, 20b) in the resin mix during the infusion process in dependence on the one or more process parameters.

Description

Technical Field

[0001] This invention relates generally to wind turbine components, and more specifically to methods of manufacturing wind turbine components. Background Technology

[0002] Composite materials such as glass-reinforced plastic (GFRP) are advantageously used in wind turbine components (such as wind turbine blades) due to their mechanical properties (such as their low mass and high strength). Regarding wind turbine blades, these blades can, for example, comprise a shell formed in a composite molding process, in which fiber reinforcement is impregnated with a resin mixture. The resin mixture is cured to produce a blade shell comprising reinforcing fibers anchored within a cured resin matrix. However, composite molding processes (such as vacuum-assisted resin transfer molding (VARTM)) can present numerous challenges, especially when manufacturing large wind turbine components (such as wind turbine blades).

[0003] Resin mixtures in composite molding processes typically consist of resin and a hardener, which chemically react to cure the resin mixture. As the resin mixture cures into a solid state, it becomes more viscous, i.e., less fluid. The viscosity of the resin mixture is affected by the temperature and reactivity of the hardener in the resin mixture. However, as the resin mixture cures and becomes more viscous, the impregnation rate decreases; that is, the resin mixture impregnates the fiber reinforcement more slowly. Furthermore, premature curing of the resin mixture can cause blockages, resulting in incomplete impregnation with dry points (where the fiber reinforcement is not impregnated). Therefore, hardeners are typically selected to ensure that the resin mixture cures at a specific rate, ensuring that the mixture remains sufficiently fluid (i.e., uncured) until the fiber reinforcement has been completely impregnated.

[0004] However, by definition, resin blends with long curing times also result in long cycle times between the start of impregnation and the attainment of fully cured wind turbine components. This can increase the risk of leaks during the impregnation and curing processes, and may also increase the risk of other defects. Furthermore, the extended cycle time increases the time spent in the mold (i.e., the time the wind turbine component occupies the mold), thereby reducing the production output of the manufacturing unit. Therefore, it is desirable to reduce the impregnation and curing cycle time.

[0005] This invention was developed against this backdrop. Summary of the Invention

[0006] In a first aspect of the invention, a method for manufacturing a wind turbine assembly is provided. The method includes: supporting a stack of fiber-reinforced materials in a mold and providing a resin supply. The method further includes: providing a supply of a hardener comprising at least a first hardener and a second hardener, the second hardener being faster than the first hardener; and mixing the resin with the first hardener and / or the second hardener to produce a resin mixture. The method further includes: supplying the resin mixture to the stack during an impregnation process, monitoring one or more process parameters of the impregnation process, and controlling the rate of hardening by varying the relative proportions of the first and second hardeners in the resin mixture according to one or more process parameters during the impregnation process.

[0007] One or more process parameters may be selected from the group consisting of: ambient temperature, resin mixture temperature, time elapsed since the start of the impregnation process, position of the resin mixture fluid leading edge, and vacuum pressure in the mold.

[0008] Fiber-reinforcing materials may include glass-reinforcing fibers. Fiber-reinforcing materials may be provided in the form of chopped strand mat. Preferably, the fiber-reinforcing material is provided in the form of a fabric, wherein the reinforcing fibers are arranged in a specific orientation. For example, the fiber-reinforcing material is preferably provided in the form of a fabric comprising uniaxial reinforcing fibers, biaxial reinforcing fibers, or triaxial reinforcing fibers.

[0009] The resin and hardener are preferably supplied in a liquid state. Mixing the resin and hardener to produce a resin mixture initiates a chemical reaction that ultimately causes the liquid resin mixture to cure. The time taken from the production of the resin mixture to its complete curing is called the curing time. The resin mixture remains in a substantially liquid, workable state during the initial portion of the total curing time (referred to in some examples as the "open time," "working time," or "wet lay time").

[0010] Once the open time has elapsed, the resin mixture enters the initial curing phase, also known as the "green" or "gel phase," during which the resin mixture exhibits a much higher viscosity. In the gel phase, the resin is no longer processable; that is, the resin mixture does not flow and therefore does not undergo further impregnation or layering. Following the gel phase, the resin mixture continues to cure until it reaches a fully cured solid state.

[0011] The curing time of a resin mixture is affected, at least in part, by the rate of hardening of the resin mixture. Therefore, the rate of hardening, or hardener velocity, as referred to herein, means the rate at which a resin mixture including the hardener progresses from a liquid phase through the curing phase to the gel phase, and then to complete curing, at a given temperature.

[0012] The method includes controlling the rate of hardening, i.e., changing the relative proportions of a first (slower) hardener and a second (faster) hardener in the resin mixture to adjust the curing time of the resin mixture impregnated into the laminate according to one or more process parameters throughout the impregnation process. The open time of the resin mixture is also affected by the rate of hardening in the resin mixture. Therefore, the method also includes controlling the rate of hardening by changing the relative proportions of the first and second hardeners in the resin mixture, thereby controlling the open time of the resin mixture, wherein the resin mixture is in a substantially liquid state.

[0013] More specifically referring to the open time of the resin mixture, the first and second hardeners each have a "pot life," which is defined as the amount of time a specific mass of the resin mixture, including the resin and the corresponding hardener, remains liquid at a specific temperature. The "pot life" is an objective property that allows for direct comparison of the hardeners. Preferably, the pot life of the first hardener is longer than that of the second hardener.

[0014] The resin mixture can be a thermosetting polymer resin. The resin mixture can be a two-component thermosetting polymer resin. For example, the resin mixture can be a two-component epoxy resin or a polyurethane thermosetting resin.

[0015] The resin supply for the resin mixture may include Hexion Epikote (RTM) RIMR 135. The curing agent supply may include Hexion Epicure (RTM) RIMH137 as a first curing agent. The curing agent supply may include Hexion Epicure (RTM) RIMH1366 as a second curing agent.

[0016] The method may further include determining the initial mixing ratio of the first hardener and the second hardener based on one or more process parameters. Preferably, one or more process parameters are one or more of ambient temperature, mold temperature, lamination temperature, and initial resin temperature.

[0017] The method may also include mixing the resin primarily or solely with the first hardener at the start of the impregnation process. Therefore, a relatively slow hardener rate can be achieved at the beginning of the impregnation process.

[0018] The method may also include increasing the rate of hardening by increasing the proportion of the second hardener in the resin mixture as the impregnation process progresses. Therefore, the method may include reducing the curing time and / or open time of the resin mixture by increasing the proportion of the second hardener in the resin mixture as the impregnation process progresses.

[0019] The proportion of the second hardener can be continuously increased or decreased in a progressive process to adjust the rate at which the hardener in the resin mixture is blended as the impregnation process progresses. Alternatively or additionally, in some examples, the proportion of the second hardener can be increased or decreased in multiple discrete stages.

[0020] This method may include increasing only the proportion of the second hardener in the resin mixture throughout the impregnation process to increase the rate of hardening of the resin mixture from relatively slow (i.e., weakly reactive at the beginning of the impregnation process) to relatively fast (i.e., highly reactive at the end of the impregnation process).

[0021] The method preferably involves maintaining a substantially constant total ratio of resin to hardener throughout the impregnation process, while varying the relative ratio of the first and second hardeners. Maintaining a substantially constant total ratio of resin to hardener ensures that the mechanical properties of the wind turbine assembly are substantially uniform throughout the entire wind turbine assembly.

[0022] This method may include a vacuum-assisted resin transfer molding (VARTM) process. The mold may include a substantially rigid primary mold component and a secondary mold component. For example, the secondary mold component may be a substantially flexible vacuum membrane. The primary mold component may include a concave profile in cross-section. A laminate of fiber-reinforced material may be supported on the substantially rigid primary mold component. The method may include arranging the secondary mold component above the laminate, which is supported on the mold. Thus, the laminate may be sandwiched between the primary mold component and the secondary mold component. The method may include sealing the secondary mold component to the primary mold component to define an impregnation volume therebetween. The method may include evacuating the impregnation volume under vacuum pressure.

[0023] The mold may include multiple regions, each with its own resin inlet. The method may further include supplying a resin mixture to a stack in the first region through a first resin inlet. The method may also include monitoring the position of the fluid leading edge of the resin mixture. The method may further include increasing the proportion of a second hardener in the resin mixture as the fluid leading edge moves toward a second region adjacent to the first region.

[0024] This method may include using a camera positioned above the mold to monitor one or more process parameters of the impregnation process. For example, the method may include using a camera positioned above the mold to monitor one or more of the temperature and / or position of the resin mixture fluid leading edge. The camera is preferably an infrared camera.

[0025] The method may alternatively or additionally include using mold temperature sensors and / or stack temperature sensors to monitor the position of the fluid leading edge.

[0026] In some examples, the method may additionally or alternatively include using a visible light camera positioned above the mold to monitor one or more process parameters of the impregnation process. In examples where the resin mixture and the stack have similar or substantially the same temperature and therefore an infrared (thermal imaging) camera cannot adequately distinguish between the resin mixture and the stack, a visible light camera can be advantageous for monitoring the position of the fluid leading edge.

[0027] In an example where the method includes arranging a secondary mold component on a stack for a VARTM process, the secondary mold component is preferably at least partially translucent or transparent to facilitate visual monitoring of the position of the fluid leading edge.

[0028] When the fluid leading edge of the resin mixture reaches the second region, the method may further include reducing the rate of the hardener by decreasing the proportion of the second hardener in the resin mixture, and supplying the resin mixture to the stack in the second region through the second resin inlet.

[0029] The method may include closing the first inlet when the second inlet is opened. The hardener initially supplied to the second region through the second inlet is preferably primarily or entirely the first hardener. Therefore, the rate of hardener supply to the second region can be relatively slow at the beginning.

[0030] The method may further include increasing the proportion of the second hardener in the resin mixture as the fluid leading edge moves toward a third region adjacent to the second region. Therefore, the method may include reducing the curing time and / or open time of the resin mixture by increasing the proportion of the second hardener in the resin mixture as the fluid leading edge moves toward the third region.

[0031] The first and / or second hardener in the resin mixture supplied through the second resin inlet may be different from the first and / or second hardener in the resin mixture supplied through the first resin inlet.

[0032] The method may include supplying a resin mixture to a stack in a third mold region through a third resin inlet. Preferably, the resin mixture supplied to the third mold region through the third resin inlet initially comprises a mixture of resin and a primary or only first hardener. The method may include increasing the proportion of a second hardener in the resin mixture as the fluid leading edge moves away from the third resin inlet and toward the edge of the stack. Thus, when the fluid leading edge approaches the edge of the stack, the resin mixture supplied through the third resin inlet may comprise a mixture of resin and a primary or only second hardener.

[0033] The first and / or second curing agents supplied to the resin mixture in the stack via the third resin inlet may be different from the first and / or second curing agents supplied to the resin mixture via the first and / or second resin inlet.

[0034] The method preferably includes controlling the rate of hardening by varying the relative proportions of the first and second hardeners in the resin mixture to ensure that the “open time” of the resin mixture is greater than or at least equal to the time required for the resin mixture to fully impregnate the stack in a given area of ​​the mold. The method may also include controlling the rate of hardening by varying the relative proportions of the first and second hardeners in the resin mixture to ensure that during impregnation of adjacent portions of the stack in adjacent mold areas, the resin mixture in a portion of the stack in a given mold area remains in a liquid or gel phase.

[0035] If used, the resin inlet, or each resin inlet, can be disposed within a vacuum membrane. The resin inlet, or each resin inlet, can include a longitudinally extending channel within the mold. The resin inlet channel advantageously facilitates rapid resin injection by increasing the flow rate of the stacked resin mixture in the impregnation mold.

[0036] The first resin inlet is preferably located in the lowest part of the mold. This helps to achieve a square resin mixture fluid leading edge, i.e., transverse to the mold, as the resin mixture impregnates through the stack. The method preferably involves initially supplying the resin mixture to the stack through the lowest resin inlet to ensure that the resin mixture does not flow away from the resin inlet under the influence of gravity, thereby facilitating tighter control of the impregnation process. The first resin inlet is preferably positioned in the mold below the second and third resin inlets. Furthermore, the second resin inlet is preferably positioned in a portion of the mold lower than the third resin inlet.

[0037] The method may further include curing the resin mixture in one or more regions while supplying the resin mixture to one or more other regions. Preferably, the method includes curing the resin mixture by applying heat to one or more regions. Alternatively, the method may include partially curing the resin mixture in one or more regions while supplying the resin mixture to one or more other regions.

[0038] This method may include curing or partially curing a resin mixture in one or more areas by applying heat to the mold area using one or more heating elements. The method may include setting the heating element temperature to fully cure the resin mixture in the mold area. Alternatively, the method may include setting the heating element temperature to a lower temperature to partially cure the resin mixture in the mold area while performing the remainder of the impregnation process. Partially curing the resin mixture impregnated in the stack in the mold area allows resin mixtures impregnated in adjacent mold areas to chemically link to the partially cured resin mixture.

[0039] When the stack in each mold area is fully impregnated, the method preferably includes fully curing the resin mixture throughout the stack. For example, where the method includes setting one or more heating elements to partially cure the resin mixture in one or more mold areas, upon completion of the impregnation process, the method preferably includes setting all heating elements to fully cure the resin mixture impregnated in the stack.

[0040] The method may also include using an artificial intelligence system to control the impregnation process. The AI ​​system is configured to receive feedback from one or more cameras and / or sensors and to self-optimize settings of the impregnation process, such as vacuum pressure, resin supply pressure, resin mixture flow rate, hardener mixing ratio, and curing temperature. For example, the method may include using deep learning algorithms to monitor the impregnation process to optimize the impregnation and curing processes, and to optimize one or more stages of the method for future manufacturing processes.

[0041] The method may include controlling the temperature of the resin mixture. The temperature of the resin mixture can be controlled based on one or more process parameters. Therefore, the method may include heating the resin mixture. For example, the method may include heating the resin mixture to a target temperature at which the viscosity of the resin mixture is optimal for the impregnation process. The method may include controlling the temperature of the resin mixture to substantially correspond to the initial temperature of the laminate. For example, the method may include providing an input signal from a laminate temperature sensor to a control system, and may also include providing an input signal from the control system to a resin heating device to control the temperature of the resin mixture, thereby substantially matching the temperature of the laminate. In some examples, the method may include heating the resin to a target temperature such that, when mixed with a hardener to produce the resin mixture, the temperature of the resin mixture substantially corresponds to the temperature of the laminate.

[0042] Additionally or alternatively, the method may include controlling the temperature of the mold and / or stack to ensure that the resin mixture maintains an optimal viscosity throughout the impregnation process. The method may include controlling one or more heating elements to provide in-mold control of the resin mixture temperature during the impregnation process. In some examples, the method may include controlling the temperature of the mold and / or stack to substantially match the temperature of the resin mixture. This can provide an optimized impregnation process.

[0043] The method may include controlling the heating element or each heating element based on one or more process parameters. In some examples, the method may include controlling the heating element based on process parameters such as resin mixture flow rate, i.e., impregnation rate. For example, the method may include increasing the temperature of the stack based on the resin mixture flow rate, thereby reducing the viscosity of the resin mixture impregnated in the stack and increasing the impregnation rate.

[0044] In some examples, the method may include supplying a resin mixture comprising a hardener component to a stack in a third mold region, the hardener component being supplied on average faster than the hardener component included in the resin mixture supplied to the stack in a second mold region. In some examples, the method may include supplying a resin mixture comprising a hardener component to a stack in a second mold region, the hardener component being supplied on average faster than the hardener component included in the resin mixture supplied to the stack in a first mold region.

[0045] In some examples, the method may include providing one or more additional hardeners besides the first and second hardeners. Therefore, the method may include mixing the resin with one or more of the first, second, or additional hardeners to produce a resin mixture. A larger quantity of hardener can provide a wider range of hardener speeds. Furthermore, a larger quantity of hardener can facilitate the production of a resin mixture with a wider range of curing times. A larger quantity of hardener can also make it possible to more precisely control the hardener speed and / or the curing time of the resin mixture.

[0046] In some examples, the method may include controlling the curing time and open time of the resin mixture by additionally controlling one or more of the resin mixture temperature, mold temperature, and stack temperature. For example, the method may include increasing the temperature of the resin mixture to reduce the curing time of the resin mixture.

[0047] In some examples, one or more steps of the method can be performed by a human operator. For example, a human operator can vary the mixing ratio of the hardener in the resin mixture based on one or more process parameters. In some examples, one or more process parameters can be measured by a human operator. For example, a human operator can visually inspect the stack during the impregnation process to determine when to change the hardener mixing ratio and / or when to open and close the resin inlet.

[0048] In some examples, the method can be controlled by a control system following a predefined script, without utilizing feedback signals from sensors and / or cameras. For example, the control system could vary the hardener mixing ratio solely based on process parameters such as the time elapsed since the start of the impregnation process. Similarly, the control system could control the opening and closing of the resin inlet based on process parameters such as the time elapsed since the start of the impregnation process. Thus, once the optimal process is determined, the same method can be repeatedly executed by an automated control system without relying on inputs of measured process parameters, such as the leading edge advance of the resin mixture fluid and / or the resin mixture and lamination temperature.

[0049] In a second aspect of the invention, an apparatus for manufacturing a wind turbine assembly is provided. The apparatus includes a mold for supporting a laminate of fiber-reinforced materials, a resin supply, and a supply of a hardener comprising at least a first hardener and a second hardener, wherein the second hardener is applied faster than the first hardener. The apparatus also includes a resin mixing and supply system for mixing the resin with the first and / or second hardener to produce a resin mixture, and for supplying the resin mixture to the laminate during an impregnation process. The apparatus further includes a control system configured to control the rate of application of the hardener based on one or more process parameters of the impregnation process by varying the relative proportions of the first and second hardeners in the resin mixture during the impregnation process.

[0050] The curing agent supply unit may include a curing agent metering system arranged to mix a first curing agent and a second curing agent according to a mixing ratio determined by a control system, and to supply a predetermined amount of the mixed curing agent to a resin mixing and supply system. Alternatively, in some examples, the method may include separately supplying a predetermined amount of the first curing agent and / or the second curing agent to the resin mixing and supply system according to a mixing ratio determined by a control system. Thus, the first curing agent and the second curing agent can be mixed simultaneously with the resin to produce a resin mixture.

[0051] The apparatus may also include a pump configured to impregnate the resin mixture in the resin mixing and supply system into the stack. The pump can increase the speed of the impregnation process by stimulating the resin mixture to impregnate through the stack at a faster rate than relying solely on vacuum pressure in the impregnation volume. In other examples, the apparatus may not include a pump, and the vacuum pressure in the stack may be sufficient to draw in the resin mixture at a specified impregnation rate.

[0052] The apparatus may also include one or more sensors for determining one or more process parameters of the impregnation process. For example, the apparatus may include a temperature sensor for monitoring ambient temperature during the impregnation process. The apparatus may include a temperature sensor configured to measure the temperature of a mold. The apparatus may include a temperature sensor configured to measure the temperature of a laminate. The apparatus may include a temperature sensor for monitoring the temperature of the resin mixture.

[0053] The mold may include a substantially rigid primary mold component and a secondary mold component. The secondary mold component may be a substantially flexible vacuum membrane. In some examples where the impregnation process is vacuum-assisted, the device may include a pressure sensor configured to monitor the pressure in the impregnation volume between the mold surface and the vacuum membrane.

[0054] The device may also include a camera positioned above the mold, configured to monitor the temperature of the resin mixture and / or the position of the fluid leading edge during the impregnation process. Preferably, the camera is an infrared camera. In some examples, the device may include a visible light camera positioned above the mold.

[0055] A resin supply system, including resin supply lines, resin inlets, and any resin inlet valves, can also be referred to as a resin inlet manifold. The method preferably includes automatic control of the resin inlet manifold. For example, the method may include controlling the resin inlet manifold using a control system based on one or more process parameters.

[0056] The device may include heating elements configured to aid in the curing of a resin mixture impregnated in the laminate. The heating elements are preferably independently controllable, such that each heating element can be activated or deactivated in isolation. The heating elements may be temperature-variable heating elements, wherein the temperature of the heating element can be continuously varied within a predetermined temperature range.

[0057] The device may include a flow meter in the resin mixing and supply system to monitor the flow rate of the resin mixture, thereby calculating the impregnation rate or the speed of resin impregnation stacks. The impregnation rate may be a process parameter, based on which the control system may control one or more stages of the method.

[0058] Wind turbine components can be wind turbine blades. Attached Figure Description

[0059] Embodiments of the invention will now be described by way of non-limiting example only, with reference to the accompanying drawings, in which:

[0060] Figure 1 This is a view showing the apparatus used to manufacture wind turbine components;

[0061] Figures 2a to 2c A resin mixture is shown in a first region of a mold, in which a laminate of fiber-reinforced material is impregnated, wherein the composition of the resin mixture changes as the impregnation process progresses;

[0062] Figures 3a to 3c A resin mixture of laminated fiber-reinforced materials is shown impregnated in a second region of a mold, wherein the composition of the resin mixture changes as the impregnation process progresses;

[0063] Figures 4a to 4c A resin mixture is shown in a third region of a mold, in which a laminate of fiber-reinforced material is impregnated, wherein the composition of the resin mixture changes as the impregnation process progresses; and

[0064] Figure 5 The diagram illustrates a curing stage in a method for manufacturing a wind turbine assembly, wherein resin-impregnated laminates in each region are cured to form the wind turbine assembly. Detailed Implementation

[0065] Figure 1 The view schematically illustrates an apparatus 10 for manufacturing a wind turbine assembly. The apparatus 10 includes a mold 12. In this example, the wind turbine assembly is the housing of a wind turbine blade. Thus, the cross-section of the mold 12 is concave. The mold 12 supports a laminate 14 of fiber-reinforced material, which may include reinforcing fibers, such as reinforcing glass fiber. The mold 12 may include a substantially rigid primary mold component on which the laminate 14 is supported. In some examples, the mold 12 may additionally include a secondary mold component (not shown) disposed on the laminate 14. Thus, the laminate 14 may be sandwiched between the primary mold component and the secondary mold component. In some examples, the secondary mold component may be a vacuum membrane.

[0066] Still referencing Figure 1The apparatus 10 also includes a supply of resin 16 (such as epoxy resin). The apparatus 10 also includes a supply of hardener 20. In this example, the supply of hardener 20 includes a first hardener 20a and a second hardener 20b. The apparatus 10 also includes a resin mixing and supply system 22 configured to mix resin 16 with the first hardener 20a and / or the second hardener 20b to produce a resin mixture 24 (such as epoxy resin). Figures 2a to 5 (As shown in the diagram). The second hardener 20b can be faster than the first hardener 20a, that is, the second hardener 20b can be more reactive than the first hardener 20a.

[0067] The apparatus 10 includes a control system 26 configured to change the relative proportions of the first hardener 20a and the second hardener 20b in the resin mixture 24. The control system 26 is configured to control the rate of hardener 20 by changing the relative proportions of the first hardener 20a and the second hardener 20b in the resin mixture 24. Thus, by changing the relative proportions of the first hardener 20a and the second hardener 20b in the resin mixture 24, the apparatus 10 helps to control the curing time and / or open time of the resin mixture 24. For example, mixing the second hardener 20b with resin 16 can produce a resin mixture 24 with a faster curing time and / or open time than a resin mixture 24 comprising only resin 16 and the first hardener 20a.

[0068] In some examples, device 10 includes, for example, Figure 1 The hardener metering system 28 is shown. The hardener metering system 28 is preferably arranged to mix the first hardener 20a and the second hardener 20b according to a mixing ratio determined by the control system 26. Thus, the control system 26 can control the rate of curing of the hardener 20 and / or the curing rate of the resin mixture 24 by controlling the mixing ratio in the hardener metering system 28. The hardener metering system 28 is configured to supply a defined amount of the mixed hardener 20 to the resin mixing and supply system 22.

[0069] The resin mixing and supply system 22 is preferably configured to supply the resin mixture 24 to the laminate of fiber-reinforced material 14 during the impregnation process, as will be described in more detail later with reference to the remaining figures. For supplying the resin mixture 24 to the laminate 14, the apparatus 10 may also include a plurality of resin inlets 30.

[0070] It should be understood that device 10 is only used when Figures 1 to 5The figure is schematically shown in the view. Therefore, it should be understood that in practice, the device 10 may include any number of resin inlets 30. For example, preferably, the mold 12 includes resin inlets 30 on both the right and left sides. For simplicity of representation, the resin inlet 30 is not shown on the left side of the mold 12. Furthermore, in practice, the resin inlets 30 are preferably arranged above the stack 14. For example, the resin inlets 30 may be located in a secondary mold component (such as a vacuum membrane (not shown)) arranged on top of the stack 14.

[0071] Mold 12 may include a plurality of mold regions 32a-c. Each resin inlet 30 may be associated with one of the mold regions 32. In the example shown in the figure, mold 12 includes three adjacent regions 32a-c and three corresponding resin inlets 30a-c. Each resin inlet 30a-c may each include a corresponding inlet valve 34a-c, which is configured to allow or cut off the supply of resin mixture 24 to the stack 14 through the corresponding resin inlet 30.

[0072] The control system 26 is configured to control the rate of the hardener 20 based on one or more process parameters of the impregnation process. For example... Figure 1 As shown, the apparatus 10 may therefore also include sensors for determining process parameters of the impregnation process. For example, the apparatus may include a temperature sensor 36 to measure the temperature of the mold 12. The apparatus 10 may also include a temperature sensor 38 arranged to measure the temperature of the stack 14. If used, the stack temperature sensor 38 may be disposed on or within the vacuum membrane.

[0073] Advantageously, the device 10 may also include a visual sensing device 40, such as a camera, disposed above the mold 12. The camera 40 may be a visible light camera to monitor the leading edge 42 of the resin mixture fluid during the impregnation process (e.g., ...). Figures 2a to 5 (as shown). In some examples, device 10 may additionally or alternatively include an infrared camera. In some advantageous examples, the infrared camera may be configured to facilitate monitoring one or both of the temperature of the resin mixture 24 and / or the fluid leading edge position 42 during the impregnation process.

[0074] In some examples, device 10 may include a heating element 44 configured to heat mold 12 and / or aid in the curing of resin-impregnated laminate 14. The heating element 44 is preferably arranged in or below mold 12 to provide heat to laminate 14. Figure 1 As shown, in some examples, the device 10 may include individual heating elements 44a-c corresponding to each mold region 32a-c. The heating elements 44 are preferably independently controllable, such that each heating element 44 can be activated or deactivated individually.

[0075] When manufacturing wind turbine components, the device 10 facilitates faster impregnation and curing of the resin mixture 24 by controlling the rate of the hardener 20. As will be described in more detail with reference to the remaining figures, according to the method of the invention, the rate of the hardener 20 is controlled by varying the relative proportions of the first hardener 20a and the second hardener 20b in the resin mixture 24 according to one or more process parameters during the impregnation process.

[0076] An example of a method for manufacturing wind turbine components (such as wind turbine blades) using the aforementioned apparatus 10 will now be described with reference to the remaining figures.

[0077] The method initially involves arranging a laminate 14 of fiber-reinforced material on a mold 12. The laminate 14, supported in the mold 12, is then impregnated with a resin mixture 24. Figure 2a As shown, the laminate 14 in the first mold region 32a is impregnated with a resin mixture 24 supplied through the first resin inlet 30a. The resin mixture 24 supplied to the laminate 14 comprises a mixture of resin 16 and one or more hardeners 20. The initial mixing ratio of the first hardener 20a and the second hardener 20b is determined based on one or more process parameters. For example, the initial mixing ratio may be determined based on feedback signals provided to the control system 26 by the mold temperature sensor 36 and / or the laminate temperature sensor 38. At the start of the impregnation process, the resin 16 is preferably mixed primarily or only with the first hardener 20a. Thus, the curing time of the resin mixture 24 can be relatively long in the initial stage of impregnation.

[0078] As more resin mixture 24 is impregnated into the stack 14, the fluid leading edge 42 advances away from the first resin inlet 30a, as... Figure 2b As shown. The position of the fluid leading edge 42 is monitored, for example, by an infrared camera 40 and / or a visible light camera and / or a stack temperature sensor 38. As the impregnation process progresses, the speed of the hardener 20 is controlled by changing the relative proportions of the first hardener 20a and the second hardener 20b in the resin mixture 24. The control system 26 can determine a second mixing ratio of hardeners 20a, 20b based on process parameters such as the time elapsed since the start of the impregnation process and / or the position of the fluid leading edge 42 of the resin mixture and / or the resin temperature. As the fluid leading edge 42 advances toward the second mold region 32b, the speed of the hardener 20 can be increased by increasing the proportion of the second hardener 20b in the resin mixture 24.

[0079] like Figure 2cAs shown, as the fluid leading edge 42 further advances from the first resin inlet 30a, the control system 26 can determine a third mixing ratio of the hardeners 20a and 20b. Preferably, the third mixing ratio is determined to further increase the velocity of the hardener 20. When the fluid leading edge 42 approaches the second resin inlet 30b, the resin mixture 24 supplied through the first resin inlet 30a may include resin 16 primarily or solely mixed with the second (faster) hardener 20b. Therefore, as the fluid leading edge 42 moves away from the first resin inlet 30a and toward the second resin inlet 30b, the velocity of the hardener 20 can be increased.

[0080] When the stack 14 disposed in the first mold region 32a is fully impregnated, that is, when the fluid leading edge 42 of the resin mixture reaches a portion of the stack 14 disposed in the second mold region 32b, the method may include curing or initiating curing of the resin mixture 24 in the first mold region 32a. For example, the resin mixture 24 may be cured by applying heat to the first mold region 32a using a first heating element 44a. Figure 3a As shown, the resin mixture 24 can be solidified in the stack 14 impregnated in the first mold region 32a while the resin mixture 24 is simultaneously supplied to the second mold region 32b.

[0081] Preferably, when the leading edge 42 of the resin mixture fluid reaches the second mold region 32b, the resin mixture 24 is supplied to the stack 14 through the second resin inlet 30b. Thus, the second resin inlet 30b can be opened when the leading edge 42 of the resin mixture fluid reaches the second mold region 32b. In some examples, such as... Figure 3a As shown, when the second resin inlet 30b is open, the first resin inlet 30a can be closed. Closing and opening the resin inlet 30 is synonymous with closing and opening the valve 34 in the resin supply system, which allows or cuts off the supply of resin mixture 24 to the stack 14 through the corresponding resin inlet 30.

[0082] Preferably, the resin inlet 30 and / or valve 34 in the resin supply system are controlled by the control system 26. Thus, the resin inlet 30 and / or valve 34 are preferably automatically controlled based on process parameters fed back to the control system 26 from the sensors and / or cameras 40. Therefore, when one or more visual sensing devices 40 or stack temperature sensors 38 detect that the leading edge 42 of the resin mixture fluid has reached the second mold region 32b, the second resin inlet 30b can be opened, while the first resin inlet 30a can be closed.

[0083] When the resin mixture fluid front 42 reaches the second region 32b, the rate of hardener 20 can be reduced by decreasing the proportion of the second hardener 20b in the resin mixture 24. The mixing ratio of the first hardener 20a and the second hardener 20b is preferably determined based on one or more process parameters. The resin mixture 24 supplied to the second mold region 32b through the second resin inlet 30b preferably comprises resin 16 mainly or only mixed with the first hardener 20a. Therefore, the hardener rate can be relatively slow at the beginning of the supply to the second region 32b.

[0084] Figure 3b and Figure 3c Other stages of the impregnation process are illustrated, wherein the resin mixture fluid leading edge 42 advances away from the second resin inlet 30b. As more resin mixture 24 impregnates the stack 14 in the second mold region 32b, the fluid leading edge 42 moves toward the stack 14 in the third mold region 32c. As the fluid leading edge 42 advances toward the third mold region 32c, the proportion of the second hardener 20b in the resin mixture 24 can be increased, thereby increasing the rate of the hardener 20. Thus, as the fluid leading edge 42 advances toward the third mold region 32c, the curing time of the resin mixture 24 supplied to the second mold region 32b can be shortened, i.e., become faster. When the fluid leading edge 42 approaches the third resin inlet 30c, the resin mixture 24 supplied through the second resin inlet 30b may include resin 16 mainly or only mixed with the second (faster) hardener 20b. Therefore, as the fluid leading edge 42 moves away from the second resin inlet 30b and toward the third resin inlet 30c, the rate of the hardener 20 can be increased.

[0085] Figures 4a to 4c Other stages of the impregnation process are illustrated, wherein resin mixture 24 is supplied to the stack 14 in the third mold region 32c. While supplying resin mixture 24 to the third mold region 32c, the method may include curing or partially curing the resin mixture 24 impregnated in the stack 14 in the second mold region 32b. For example, the resin mixture 24 in the second mold region 32b may be cured by applying heat to the second mold region 32b using the second heating element 44b.

[0086] The resin mixture 24 can be supplied to the stack 14 in the third mold region 32c through the third resin inlet 30c. In some examples, such as Figure 4aAs shown, when the third resin inlet 30c is open, the second resin inlet 30b can be closed. When the leading edge 42 of the resin mixture fluid reaches the third mold region 32c, the velocity of the hardener 20 in the resin mixture 24 can be reduced. For example, the proportion of the second hardener 20b in the resin mixture 24 can be reduced. Preferably, the resin mixture 24 initially supplied to the third mold region 32c through the third resin inlet 30b comprises a mixture of resin 16 and primarily or solely the first hardener 20a.

[0087] The resin mixture fluid leading edge 42 advances through the stack 14 in the third mold region 32c and exits the third resin inlet 30c. As the impregnation process progresses in the third mold region 32c, the velocity of the hardener 20 in the resin mixture 24 can be increased. For example, based on signals input to the control system 26 from temperature sensors 36, 38 and / or camera 40 monitoring the process of the fluid leading edge 42, the control system 26 can increase the proportion of the second hardener 20b in the resin mixture 24. When the fluid leading edge 42 approaches the edge of the stack 14 and the impregnation process is nearing completion, the resin mixture 24 supplied through the third resin inlet 30c may include a mixture of resin 16 and primarily or solely the second hardener 20b.

[0088] After the impregnation process is completed, i.e., as Figure 5 As shown, when the stack 14 in each mold area 32a-c is completely impregnated with the resin mixture 24, the heating element 44 is preferably configured to cure all of the resin-impregnated stack 14.

[0089] Each production run is preferably recorded and analyzed by an artificial intelligence system (such as a machine learning system or a deep learning system). The artificial intelligence system is preferably configured to receive feedback signals from camera 40 and / or any sensors included in apparatus 10. For example, the artificial intelligence system may be integrated with control system 26. In a preferred example, the artificial intelligence system receives data input from sensors and / or camera 40 and / or process logs of the impregnation process to self-optimize the resin impregnation and curing process. For example, optimizing the impregnation process may include optimizing settings such as vacuum pressure, mold temperature, resin supply pressure, resin mixture flow rate, resin temperature, hardener selection, hardener mixing ratio, resin mixture curing temperature, resin mixture curing rate, resin inlet opening and closing conditions, and resin inlet control sequence. Thus, using the above-described method and apparatus 10, the manufacturing process can be continuously optimized with each production run.

[0090] The manufacturing method described above is preferably a substantially automated process. For example, the impregnation process can be controlled by an artificial intelligence system configured to receive feedback from one or more cameras 40 and / or sensors 36, 38 of the device 10, and to control one or more process parameters of the impregnation and curing process based on said feedback. For example, after manually arranging the fiber reinforcement material in the mold 12 and arranging the sub-mold components (if used), substantially the entire impregnation and curing process can be automated and completed without further manual input. Preferably, the control system 26 controlled by the artificial intelligence system can control process parameters such as vacuum pressure, initial resin temperature, mold temperature, resin supply pressure, resin mixture flow rate, hardener mixing ratio, resin inlet control sequence (opening and closing), and heating element control.

[0091] In the example described herein with reference to the accompanying drawings, the hardener 20 supplied to the resin mixing and supply system 22 is premixed, i.e., the hardener 20 supplied to the resin mixing and supply system 22 comprises a first hardener 20a and / or a second hardener 20b in relative proportions according to a mixing ratio determined by the control system 26. However, in some examples, the method may include providing predetermined amounts of the first hardener 20a and / or the second hardener 20b to the resin mixing and supply system 22, respectively, according to a mixing ratio determined by the control system 26. Thus, the first hardener 20a and the second hardener 20b can be mixed together simultaneously with the resin 16 to produce a resin mixture 24.

[0092] In the above example, the supply of hardener 20 includes at least a first hardener 20a and a second hardener 20b. However, in some examples, the method may include providing one or more additional hardeners besides the first hardener 20a and the second hardener 20b. Therefore, the method may include mixing resin 16 with one or more of the first hardener, the second hardener, or the additional hardener to produce a resin mixture 24.

[0093] Many modifications can be made to the above examples without departing from the scope of the invention as defined in the appended claims. It should be understood that the features described with respect to each of the above examples can be readily combined with features described in any other examples described herein without departing from the scope of the invention as defined by the appended claims.

Claims

1. A method for manufacturing a wind turbine component, the method comprising: The fiber-reinforced material stack (14) is supported in the mold (12); Provide a supply of resin (16); A supply of a hardener (20) is provided, the supply of the hardener comprising at least a first hardener (20a) and a second hardener (20b), the second hardener being faster than the first hardener; The resin is mixed with the first hardener and / or the second hardener to produce a resin mixture (24). The resin mixture (24) is supplied to the laminate (14) during the impregnation process. Monitor one or more process parameters of the impregnation process; as well as The rate of the hardener (20) is controlled by changing the relative proportions of the first hardener (20a) and the second hardener (20b) in the resin mixture (24) during the impregnation process, according to one or more process parameters.

2. The method according to claim 1, wherein, The one or more process parameters are selected from the group consisting of: ambient temperature, resin mixture temperature, time elapsed since the start of the impregnation process, position of the resin mixture fluid leading edge, and vacuum pressure in the mold.

3. The method according to claim 1 or 2, further comprising: The initial mixing ratio of the first hardener and the second hardener is determined based on one or more process parameters.

4. The method according to claim 3, wherein, The one or more process parameters are one or more of ambient temperature, mold temperature, stacking temperature and initial resin temperature.

5. The method according to claim 1, further comprising: At the start of the impregnation process, the resin is mixed primarily or solely with the first hardener.

6. The method according to claim 1, further comprising: As the impregnation process progresses, the rate of hardening is increased by increasing the proportion of the second hardener in the resin mixture.

7. The method according to claim 1, wherein, The mold includes multiple regions, each region having its own resin inlet, and the method further includes: The resin mixture is supplied to the stack in the first region through the first resin inlet; Monitor the position of the fluid front of the resin mixture; and As the fluid front moves toward a second region adjacent to the first region, the proportion of the second hardener in the resin mixture increases.

8. The method according to claim 7, wherein, When the fluid leading edge of the resin mixture reaches the second region, the method further includes: The rate of hardening is reduced by decreasing the proportion of the second hardener in the resin mixture; and The resin mixture is supplied to the stack in the second region through a second resin inlet.

9. The method according to claim 8, further comprising: As the fluid leading edge moves toward a third region adjacent to the second region, the proportion of the second hardener in the resin mixture is increased.

10. The method according to any one of claims 7 to 9, further comprising: The resin mixture is cured in one or more regions while the resin mixture is supplied to one or more other regions.

11. The method according to claim 10, wherein, The resin mixture is cured by applying heat to one or more areas.

12. The method according to claim 1, further comprising: A camera positioned above the mold is used to monitor one or more process parameters of the impregnation process.

13. The method according to claim 12, wherein, The camera in question is an infrared camera.

14. The method according to claim 12, wherein, The one or more process parameters of the impregnation process include the temperature and / or position of the resin mixture fluid front.

15. The method according to claim 1, further comprising: The impregnation process is controlled using an artificial intelligence system configured to receive feedback from one or more cameras and / or sensors and to self-optimize the settings of the impregnation process.

16. The method according to claim 15, wherein the impregnation process is configured with vacuum pressure, resin supply pressure, resin mixture flow rate, hardener mixing ratio, and curing temperature.

17. An apparatus (10) for manufacturing wind turbine components, the apparatus comprising: Mold (12) used to support the stack of fiber-reinforced materials; Supply of resin (16); A supply of hardener (20), the supply of hardener comprising at least a first hardener (20a) and a second hardener (20b), the second hardener being faster than the first hardener; A resin mixing and supply system (22) is used to mix the resin with the first hardener and / or the second hardener to produce a resin mixture (24), and to supply the resin mixture to the stack (14) during the impregnation process. as well as A control system (26) is configured to control the rate of the hardener by changing the relative proportions of the first hardener and the second hardener in the resin mixture during the impregnation process, based on one or more process parameters of the impregnation process.

18. The apparatus according to claim 17, wherein, The curing agent supply unit includes a curing agent metering system, which is arranged to mix the first curing agent and the second curing agent according to a mixing ratio determined by the control system, and to supply a defined amount of the mixed curing agent to the resin mixing and supply system.

19. The apparatus of claim 17 or 18, further comprising one or more sensors for determining one or more process parameters of the impregnation process.

20. The apparatus of claim 17 or 18, further comprising a camera disposed above the mold and configured to monitor the temperature and / or fluid leading edge of the resin mixture during the impregnation process.

21. The apparatus according to claim 20, wherein, The camera is an infrared camera.

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