Reverse engineering method for wind turbine blade web mold model

Abstract

This invention discloses a reverse engineering method for a wind turbine blade web mold model, comprising the following steps: Step 1, separately curing and molding the first and second skin components of the wind turbine blade; Step 2, using 3D laser scanning technology to reverse engineer and generate an actual model of the inner adhesive region of the main beam; Step 3, generating a web mold model based on the model of the inner adhesive region of the main beam. When generating the model of the inner adhesive region of the main beam, the actual profile of the blade beam region is used as the scanning object, avoiding discrepancies with the theoretical model caused by differences in fabric layer placement, positioning, and adhesive application during blade production, thus more closely approximating the actual web flange requirements.

Description

Technical Field

[0001] This invention belongs to the field of wind power generation technology, specifically relating to a method for reverse engineering a mold model of a wind turbine blade web. Background Technology

[0002] After more than a decade of development, the wind power industry has experienced a period of rapid growth, characterized by a trend towards higher power and larger dimensions.

[0003] Typically, the structure of a wind turbine blade is as follows: Figure 1 As shown, it includes:

[0004] Windward side: This is the pressure surface of the wind turbine blade after it is installed, corresponding to the outward concave surface of the blade (also known as the "PS surface").

[0005] Leeward side: This is the suction side of the wind turbine blade after it is installed, corresponding to the outward convex surface of the blade (also known as the "SS side").

[0006] Leading edge: The air intake edge of the blade connecting the windward and leeward sides (also known as "LE").

[0007] Trailing edge: The exhaust edge of the blade connecting the windward and leeward sides (also known as "TE").

[0008] Main beam: The main load-bearing component of the blade that runs from the blade root to the blade tip. It includes the windward main beam and the leeward main beam, with the windward main beam located on the windward side and the leeward main beam located on the leeward side.

[0009] Web: A support-type structural component (single or multiple pieces) connecting the windward and leeward sides. It includes a front web and a rear web. The two ends of the front web are respectively connected to the main beam on the windward and leeward sides and are adjacent to the front edge, while the two ends of the rear web are respectively connected to the main beam on the windward and leeward sides and are adjacent to the rear edge.

[0010] Web flange: A prefabricated bonding area between the web and the windward and leeward main beams, specifically as follows... Figure 2 As shown.

[0011] During the production of large-sized blades, the surface of the main beam after curing may differ from the theoretical model due to manufacturing reasons. This leads to a mismatch between the outer surface of the large-sized web flange made according to the theoretical model and the actual blade beam surface, which can easily cause the adhesive thickness to be too thin or too thick. This problem directly affects the bonding strength and service life of the blade.

[0012] The commonly used debugging technique is as follows: A physical web mold is produced based on the design data of the web mold. Then, the web component is produced using the web mold. Adhesive lines are laid out on the PS-side main beam according to the theoretical axial and chordal positioning data of the web component. Using a web positioning fixture, an appropriate adhesive thickness is achieved, and the web component is bonded to the PS-side main beam. After the adhesive cures, custom-made modeling clay is placed at 0.5-meter intervals from the leaf root at the theoretical bonding position between the SS-side main beam and the web. The PS-side is then flipped onto the SS-side, completing the mold closing and locking operation. The SS-side flange of the web is pressed and deformed to simulate the adhesive layer thickness after the web is pressed down. All clay thickness data and axial position data are collected and analyzed to obtain the adhesive layer thickness under this web condition. This adhesive layer data is compared with the theoretical data to identify points and values ​​exceeding the tolerance range. The data at the corresponding positions is used to adjust the flange of the web mold.

[0013] Because the web plate mold is made of steel, the flanging adjustment process is labor-intensive and time-consuming, and often requires multiple adjustments to bring the adhesive layer within the tolerance range, which seriously affects the production schedule.

[0014] Patent CN 111070729 B provides a reverse modeling solution for web molds based on a laser tracker, but it still has the following drawbacks:

[0015] The mold closing calibration point is collected in the empty mold closing state before the blade is produced. After a long period of heating during the skin production process, the calibration point will shift. When the laser tracker scans after the skin is produced, a deviation will occur when the scan data of the windward and leeward sides are stitched together.

[0016] The sampling points of the web bonding area inside the blade were scanned from the root to the tip in an S-shaped route using a laser tracker. Due to the characteristics of the laser tracker, it can only collect points along the path of the target ball. The overall shape is S-shaped, which means there are a lot of blank areas with no data, and it is impossible to truly present the full surface features of the web bonding area.

[0017] Patent CN 115958721 A provides a method for obtaining the final web mold model by adjusting the web mold based on trial data from a physical process web, but it still has the following drawbacks:

[0018] The production process requires the production of the web plate, which involves physical bonding and matching. During this process, single / two-component adhesives, modeling clay, etc. are used to simulate and measure the adhesive layer thickness. There are intervals in the layout, generally 0.5 meters, and there are a large number of areas without data.

[0019] The axial positioning of manually placed single / two-component adhesives and modeling clay is inaccurate, which ultimately results in the adhesive layer data table failing to accurately reflect the condition of the adhesive layer.

[0020] The web mold was adjusted based on the collected adhesive layer data. However, high-precision positioning methods were not used for axial and chordal positioning, making it difficult to adjust the flange of the web mold. Summary of the Invention

[0021] The purpose of this invention is to provide a reverse manufacturing method for wind turbine blade web molds, which solves the problem of matching the flanges of large-size wind turbine web molds, ensures the quality of blade products, improves production efficiency, and reduces production costs.

[0022] To achieve the above-mentioned technical objectives, the present invention will adopt the following technical solution:

[0023] A method for reverse engineering a wind turbine blade web mold model includes the following steps:

[0024] Step 1: Separately solidify and mold the first and second skin components of the wind turbine blade.

[0025] The first skin component is cured in the cavity of the first molding mold, and the second skin component is cured in the cavity of the second molding mold; the first skin component and the second skin component can be assembled to form a complete wind turbine blade skin, and the splicing line of the first skin component and the second skin component is the axis of the wind turbine blade.

[0026] Step 2: Use 3D laser scanning technology to reverse engineer and generate a model of the actual adhesive area on the inner side of the main beam.

[0027] Step 2.1: Taking the first molding mold with the first skin segment solidified in the mold cavity as the implementation object, the point cloud data of the target bonding area of ​​the first molding mold and the first skin segment solidified in the mold cavity are obtained by three-dimensional laser scanning technology; the target bonding area of ​​the first skin segment includes at least the main beam area of ​​the first skin segment.

[0028] Step 2.2: Taking the second molding mold with the second skin segment solidified in the mold cavity as the implementation object, the point cloud data of the target bonding area of ​​the second molding mold and the second skin segment solidified in the mold cavity are obtained by three-dimensional laser scanning technology; the target bonding area of ​​the second skin segment includes at least the main beam area of ​​the second skin segment;

[0029] Step 2.3: After flipping the second molding mold with the second skin segment solidified in the mold cavity to the top of the first molding mold with the first skin segment solidified in the mold cavity, the two are locked together by a locking mechanism to form a complete blade molding mold.

[0030] Step 2.4: Use a laser scanner to scan the target patch area on the assembled first and second molding dies to obtain the corresponding patch dataset C;

[0031] Step 2.5: Using a point cloud processing program, take the point dataset C obtained in Step 2.4 as the common point dataset of the point cloud data obtained in Step 2.1 and Step 2.2, and merge the point cloud data obtained in Step 2.1 and Step 2.2 to obtain a merged dataset.

[0032] Step 2.6: Based on the combined dataset obtained in Step 2.5, reverse engineer the inner model of the main beam; the inner model of the main beam includes the edge line of the main beam; by offsetting the edge line of the main beam of the entire inner model of the main beam by the theoretical glue thickness h to the center line of the main beam of the upper and lower molds, the glued area model of the inner side of the main beam can be obtained.

[0033] Step 3: Generate the web mold model based on the adhesive bonding area model on the inner side of the main beam.

[0034] Step 3.1: Based on the adhesive region model inside the main beam obtained in Step 2.6, draw the connection surface using the edge line of the main beam as a reference. According to the theoretical distance between the web and the edge of the beam, offset the connection surface in the direction of the beam's central axis by the theoretical distance to obtain the web surface.

[0035] Step 3.2: Using the chordal centerline of the adhesive region model on the inner side of the main beam obtained in Step 2.6 as a reference, establish a reference plane, divide the surface of the adhesive region model on the inner side of the main beam into a front edge web model and a rear edge web model, and export the corresponding models respectively.

[0036] Step 3.3: Based on the inner side of the mold flange, adjust the normal plane of the web mold and the starting position of the coordinate system to generate a web mold model including the web mold flange.

[0037] Preferably, in step 2.1, the target bonding area of ​​the first skin segment includes the inner side of the blade root steel flange of the first skin segment, the main beam area of ​​the first skin segment and its outer edge, and the area where the main beams of several first skin segments transition to the front and rear edges.

[0038] Preferably, in step 2.2, the target bonding area of ​​the second skin segment includes the inner side of the blade root steel flange of the second skin segment, the main beam area of ​​the second skin segment and its outer edge, and the area where the main beams of several second skin segments transition to the front and rear edges.

[0039] Preferably, in step 2.1, the specific method for acquiring the point cloud data of the target patch area of ​​the first molding die and the first skin sub-body solidified within the die cavity includes the following steps:

[0040] Step 2.1.1: Taking the first molding mold in which the first skin segment is solidified in the mold cavity as the implementation object, reflective positioning points are pasted on the target pasting point areas of the first molding mold and the first skin segment solidified in the mold cavity respectively.

[0041] Step 2.1.2: Attach several laser tracker target ball bases that can be distributed from the leaf root to the leaf tip at the middle position of the main beam of the first skin section;

[0042] Step 2.1.3: Plan the installation location and transfer point of the laser tracker: Based on the range of the laser tracker, and taking the laser tracker target ball base arranged in Step 2.1.2 as the reference, plan the installation location and transfer point of the laser tracker in the main beam area of ​​the first skin body.

[0043] Step 2.1.4: Obtain the detection point coordinates of the first skin segment: Set up the laser tracker at the positions planned in Step 2.1.3 on the first skin segment, and place the target ball on the attached laser tracker target ball base in sequence. When the range is exceeded, perform a station transfer operation until the coordinates of all laser tracker target ball bases are scanned and exported, and the detection point coordinates of the first skin segment can be obtained.

[0044] Step 2.1.5: Use a laser scanner to scan the reflective positioning points set in Step 2.1.1 and the reflective points set on the target ball base of the laser tracker in Step 2.1.2 to obtain the scan point dataset A.

[0045] Step 2.1.6: Using the coordinates of each detection point obtained in Step 2.1.4 as a reference, perform axial control on the data of each scanning point obtained in Step 2.1.5 to obtain the adjusted scanning point dataset A´.

[0046] In step 2.5, the point cloud data obtained in step 2.1 is processed by the point cloud processing program, which is the scan point dataset A' obtained in step 2.1.6.

[0047] Preferably, in step 2.2, the specific method for acquiring the point cloud data of the target bonding area of ​​the second molding die and the second skin component solidified within its cavity includes the following steps:

[0048] Step 2.2.1: Taking the second molding mold in which the second skin segment is solidified in the mold cavity as the implementation object, reflective positioning points are pasted on the target pasting point areas of the second molding mold and the second skin segment solidified in the mold cavity respectively;

[0049] Step 2.2.2: Attach several laser tracker target ball bases that can be distributed from the leaf root to the leaf tip at the middle position of the main beam of the second skin assembly;

[0050] Step 2.2.3: Plan the installation location and transfer point of the laser tracker: Based on the range of the laser tracker, and taking the laser tracker target ball base arranged in Step 2.2.2 as the reference, plan the installation location and transfer point of the laser tracker in the main beam area of ​​the second skin body.

[0051] Step 2.2.4: Obtain the detection point coordinates of the second skin segment: Set up the laser tracker at the positions planned in Step 2.2.3 on the second skin segment, and place the target ball on the attached laser tracker target ball base in sequence. When the range is exceeded, perform a station transfer operation until the coordinates of all laser tracker target ball bases are scanned and exported, and the detection point coordinates of the second skin segment can be obtained.

[0052] Step 2.2.5: Use a laser scanner to scan the reflective positioning points set in Step 2.2.1 and the reflective points set on the target ball base of the laser tracker in Step 2.2.2 to obtain the scan point dataset B.

[0053] Step 2.2.6: Using the coordinates of each detection point obtained in Step 2.2.4 as a reference, perform axial control on the data of each scanning point obtained in Step 2.2.5 to obtain the adjusted scanning point dataset B'.

[0054] In step 2.5, the point cloud data obtained in step 2.2 is processed by the point cloud processing program, which is the scan point dataset B' obtained in step 2.2.6.

[0055] Preferably, the width of the reflective positioning point pasted in the target marking area is 1 meter.

[0056] Preferably, the distance between two adjacent laser tracker target ball bases is 5m.

[0057] Preferably, in step one, the first skin segment is the windward skin segment, and the second skin segment is the leeward skin segment.

[0058] Preferably, in step one, the second molding mold is pivotally connected to the first molding mold via a connecting shaft, so that the second molding mold can rotate around the connecting shaft between the first and second extreme positions: when the second molding mold is in the first extreme position, the first and second molding molds are placed side by side in the horizontal direction, and the second molding mold is located to the right of the first molding mold; when the second molding mold is in the second extreme position, the second molding mold is stacked on top of the first molding mold, and the mold cavity of the second molding mold is joined with the mold cavity of the first molding mold.

[0059] Preferably, the first molding die includes a first molding die body, a first mold support frame, and a first mold support arm; the second molding die includes a second molding die body, a second mold support frame, and a second mold tilting arm.

[0060] The first molding die body has a mold cavity capable of molding the windward skin, and the lower part of the first molding die body is supported by a first mold support frame, while a first mold support arm is provided on one side of the first molding die body.

[0061] The second molding die body has a mold cavity capable of molding the leeward skin, and the lower part of the second molding die body is supported by a second mold support frame. At the same time, a second mold flipping arm is provided on one side of the second molding die body.

[0062] The first mold support arm and the second mold tilting arm are positioned and connected by a connecting shaft.

[0063] Based on the above-mentioned technical objectives, the present invention has the following advantages compared with the prior art:

[0064] 1) The actual profile of the blade beam area is used as the scanning object, which avoids the difference from the theoretical model caused by the difference in the laying, positioning and adhesive amount of the fabric during the blade production process, and is closer to the actual web flange requirements.

[0065] 2) The entire beam bonding area was scanned, avoiding the problem that the original 0.5-meter interval for detecting the thickness of the putty was too low and could not accurately reflect the thickness of the adhesive layer;

[0066] 3) Axial positioning is based on the inner flange of the blade root to ensure uniform high axial accuracy;

[0067] 4) By scanning and splicing the beam areas of the PS and SS surfaces into a unified data model, the problem of the original method where the adhesive thickness on the PS side is fixed while the SS side needs to bear more adjustment, and the required adjustment may exceed the upper and lower limits of the adjustable range is avoided.

[0068] 5) Perform reverse scanning under the condition of web bonding to remove the deformation effect caused by temperature changes during skin production. Attached Figure Description

[0069] Figure 1 It is a cross-sectional view of a wind turbine blade;

[0070] Figure 2 This is a schematic diagram of the bonding between the web and the main beam in a wind turbine blade.

[0071] Figure 3 This is a flowchart of the reverse manufacturing method of the wind turbine blade web mold model described in this invention;

[0072] Figure 4 This is a schematic diagram of the reflective dots pasted on the main beam area of ​​the first molding mold in which the first skin component is solidified inside the mold cavity.

[0073] Figure 5 This is the common area scanned during the mold closing state of the blade forming die;

[0074] Figure 6 This is a schematic diagram of the adhesive region model on the inner side of the main beam obtained by the reverse manufacturing method described in this invention;

[0075] Figure 7 This is a schematic diagram of the web mold obtained by the reverse manufacturing method described in this invention.

[0076] In the diagram: 1-1, First mold support frame; 1-2, Second mold support frame; 2-1, First skin segment; 2-2, Second skin segment; 3, Mold main beam area; 4-1, First mold connector; 4-2, Second mold connector; 5, Leaf root flange; 6, Main beam transition to front and rear edge steel frame area; 7, Reflective positioning point; 8, Laser tracker target ball base; 9, Laser tracker; 10, Laser tracker target ball; 11, Handheld laser scanner; 12, Mold locking mechanism; 13, Upper and lower mold beam edge lines; 14, Web plate plane; 15, Web plate flange. Detailed Implementation

[0077] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit the present invention or its application or use. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention. Unless otherwise specifically stated, the relative arrangement, expressions, and values ​​of components and steps set forth in these embodiments do not limit the scope of the present invention. Techniques, methods, and devices known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and devices should be considered part of the specification. In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may have different values.

[0078] For ease of description, spatial relative terms such as "above," "over," "on the upper surface of," "above," etc., are used here to describe the spatial positional relationship of a device or feature as shown in the figure with other devices or features. It should be understood that spatial relative terms are intended to encompass different orientations in use or operation besides the orientation of the device as described in the figure. For example, if the device in the figure is inverted, a device described as "above" or "above" other devices or structures would subsequently be positioned as "below" or "under" other devices or structures. Thus, the exemplary term "above" can include both "above" and "below." The device may also be positioned in other different ways (rotated 90 degrees or in other orientations).

[0079] like Figure 3-7 As shown, this invention discloses a reverse engineering method for a wind turbine blade web mold model. The web mold model produced is based on the following technologies:

[0080] 1. Based on the actual surface of the blade skin, the actual adhesive area model of the inner side of the main beam is reverse-engineered using three-dimensional laser scanning technology.

[0081] 2. The data of the first skin segment (PS surface) and the second skin segment (SS surface) are stitched together through the common area of ​​the front and rear edges.

[0082] 3. Offset the model inward according to the theoretical adhesive layer data. The offset position is the theoretical web flange position.

[0083] 4. Generate the web plate mold plane by measuring the distance between the web plate beam edges.

[0084] Therefore, the reverse fabrication method for the web plate mold model described in this invention specifically includes the following steps:

[0085] Step 1: Separately solidify and mold the first and second skin components of the wind turbine blade.

[0086] The first skin segment is cured in the cavity of the first molding mold, and the second skin segment is cured in the cavity of the second molding mold. After the first and second skin segments are cured, the auxiliary materials in the main beam area are cleaned and dust is removed. In the attached diagram, the first skin segment is the windward skin, and the second skin segment is the leeward skin. Of course, the first skin segment can also be the leeward skin, in which case the second skin segment is the windward skin. The first and second skin segments can be assembled to form a complete wind turbine blade skin, and the splicing line of the first and second skin segments is the axis of the wind turbine blade (a straight line passing through the leading and trailing edges of the wind turbine blade).

[0087] The second molding die is pivotally connected to the first molding die via a connecting shaft, allowing the second molding die to rotate around the connecting shaft between first and second extreme positions. When the second molding die is in the first extreme position, the first and second molding dies are placed side-by-side laterally, with the second molding die located to the right of the first molding die. Details are as follows... Figure 3 As shown; when the second molding die is in the second extreme position, the second molding die is stacked on top of the first molding die, and the cavity of the second molding die is joined with the cavity of the first molding die, as detailed below. Figure 4 As shown.

[0088] In this embodiment, the first molding die includes a first molding die body, a first die support frame, and a first die support arm; the second molding die includes a second molding die body, a second die support frame, and a second die flipping arm.

[0089] The first molding die body has a mold cavity capable of forming the windward skin, and the lower part of the first molding die body is supported by a first mold support frame. At the same time, a first mold support arm is provided on one side of the first molding die body (the right side in the attached figure).

[0090] The second molding die body has a mold cavity capable of molding the leeward skin, and the lower part of the second molding die body is supported by a second mold support frame. At the same time, a second mold flipping arm is provided on one side of the second molding die body (left side in the attached figure).

[0091] The first mold support arm and the second mold tilting arm are positioned and connected by a connecting shaft.

[0092] Step 2: Use 3D laser scanning technology to reverse engineer and generate a model of the actual adhesive area on the inner side of the main beam.

[0093] Step 2.1: Taking the first molding mold with the first skin component solidified in the mold cavity as the implementation object, use three-dimensional laser scanning technology to acquire the point cloud data of the target bonding area of ​​the first molding mold and the first skin component solidified in the mold cavity; specifically including the following steps:

[0094] Step 2.1.1: Taking the first molding mold with the first skin component solidified in the mold cavity as the implementation object, attach reflective positioning points approximately 1 meter wide to the target placement areas of the first molding mold and the first skin component solidified in the mold cavity, as detailed below. Figure 4 As shown.

[0095] Figure 4-7 The functions of the reference numerals in the attached figures are as follows:

[0096] 1-1. First mold steel frame, used to support the first skin forming mold; 1-2. Second mold steel frame, used to support the second skin forming mold; 2-1. First skin segment; 2-2. Second skin segment; 3. Mold main beam area, where the blade web flange will eventually be bonded; 4-1. First mold connector; 4-2. Second mold connector; 5. Blade root flange, its inner side is the starting point of the blade root; 6. Main beam transition to the front and rear edge steel frame area, used to transition and connect the main beam area and the common area of ​​the steel frame during laser scanning; 7. Reflective positioning point, used for laser scanning; 8. Laser tracker target ball base, used to place the laser tracker target ball and can be used for laser scanner point acquisition; 9. Laser tracker, used for large-space precision measurement; 10. Laser tracker target ball, used to receive and reflect the laser from the laser tracker; 11. Handheld laser scanner, used to collect the surface point cloud data of all the bonding areas; 12. Mold locking mechanism, a relatively stable steel mechanical structure, used in the common area before and after mold closing. 13- Upper and lower formwork beam edge lines: Generate the inner surface edge lines of the main beam based on the beam edge features in the point cloud data; 14- Web plate plane: Connect the planar structure of the two side flanges; 15- Web plate flange: Used to bond the connection area between the main beam and the web plate.

[0097] Step 2.1.2: Attach several laser tracker target ball bases, distributed from the leaf root towards the leaf tip, to the middle of the main beam of the first skin segment. The distance between any two adjacent laser tracker target ball bases is 5m. Each laser tracker target ball base has a reflective positioning point. The laser tracker target ball bases set in this step can form the detection points for the laser tracker set in subsequent steps.

[0098] Step 2.1.3: Planning the installation location and relocation points of the laser tracker: Based on the range of the laser tracker, and using the laser tracker target ball base arranged in Step 2.1.2 as a reference, plan the installation location and relocation points of the laser tracker in the main beam area of ​​the first skin section. Generally, the laser tracker should be installed in an area with as few relocation points as possible during planning.

[0099] Step 2.1.4: Obtain the coordinates of the detection points of the first skin segment: Set up the laser tracker at the planned mounting positions on the first skin segment, and place the target ball on the attached laser tracker target ball base in sequence. When the range is exceeded, perform a station transfer operation until the coordinates of all laser tracker target ball bases are scanned and exported, and the coordinates of the detection points of the first skin segment can be obtained.

[0100] Step 2.1.5: Use a handheld laser scanner to scan the reflective positioning points set in Step 2.1.1 and the reflective points set on the target ball base of the laser tracker in Step 2.1.2 to obtain the scan point dataset A.

[0101] Step 2.1.6: Using the coordinates of each detection point obtained in step 2.1.4 as a reference, adjust the axial direction of each scanning point data obtained in step 2.1.5 to obtain the adjusted scanning point dataset A', so as to improve the stitching accuracy of each scanning point in the axial direction.

[0102] Step 2.2: Taking the second molding mold with the second skin component solidified in the mold cavity as the implementation object, use three-dimensional laser scanning technology to acquire the point cloud data of the target bonding area of ​​the second molding mold and the second skin component solidified in the mold cavity; specifically including the following steps:

[0103] Step 2.2.1: Taking the second molding mold in which the second skin component is solidified in the mold cavity as the implementation object, attach reflective positioning points about 1 meter wide to the target bonding area of ​​the second molding mold and the second skin component solidified in the mold cavity.

[0104] Step 2.2.2: Attach several laser tracker target ball bases, distributed from the leaf root towards the leaf tip, to the middle of the main beam of the second skin segment. The distance between any two adjacent laser tracker target ball bases is 5m. Each laser tracker target ball base has a reflective positioning point. The laser tracker target ball bases set in this step can form the detection points for the laser tracker set in subsequent steps.

[0105] Step 2.2.3: Planning the installation location and relocation points of the laser tracker: Based on the range of the laser tracker, and using the laser tracker target ball base arranged in Step 2.1.2 as a reference, plan the installation location and relocation points of the laser tracker in the main beam area of ​​the second skin segment. Generally, the laser tracker should be placed in an area with as few relocation points as possible during planning.

[0106] Step 2.2.4: Obtain the coordinates of the detection points of the second skin segment: Set up the laser tracker at the planned mounting positions on the second skin segment, and place the target ball on the attached laser tracker target ball base in sequence. When the range is exceeded, perform a station transfer operation until the coordinates of all laser tracker target ball bases are scanned and exported, and the coordinates of the detection points of the second skin segment can be obtained.

[0107] Step 2.2.5: Use a handheld laser scanner to scan the reflective positioning points set in Step 2.2.1 and the reflective points set on the target ball base of the laser tracker in Step 2.2.2 to obtain the scan point dataset B.

[0108] Step 2.2.6: Using the coordinates of each detection point obtained in step 2.2.4 as a reference, perform axial control on the data of each scanning point obtained in step 2.2.5 to obtain the adjusted scanning point dataset B', so as to improve the axial stitching accuracy of each scanning point.

[0109] Step 2.3: After flipping the second molding mold with the second skin segment solidified in the mold cavity above the first molding mold with the first skin segment solidified in the mold cavity, a locking mechanism is used to lock the two together to form a complete blade molding mold. The specific structure is as follows: Figure 5 As shown.

[0110] Step 2.4: Use a handheld laser scanner to scan the target patch areas on the first and second molding dies to obtain the corresponding patch dataset C;

[0111] Step 2.5: Using a point cloud processing program, take the patch dataset C obtained in Step 2.4 as the common point dataset of the adjusted scan point dataset A' obtained in Step 2.1.6 and the adjusted scan point dataset B' obtained in Step 2.2.6, and merge the adjusted scan point dataset A' obtained in Step 2.1.6 and the adjusted scan point dataset B' obtained in Step 2.2.6 to obtain the merged dataset M;

[0112] Step 2.6: Based on the combined dataset M obtained in Step 2.5, reverse engineer the inner model of the main beam; this inner model includes the main beam edge line; by offsetting the main beam edge line of the entire inner model of the main beam by 4mm (theoretical adhesive thickness) to the center line of the upper and lower mold main beams, the adhesive region model of the inner side of the main beam can be obtained, the specific structure of which is as follows. Figure 6 As shown.

[0113] Three-dimensional laser scanning technology is used to acquire point cloud data of the target bonding area of ​​the first skin segment. This is to enable the reverse generation of the actual adhesive area model of the main beam inside the first skin segment. Similarly, three-dimensional laser scanning technology is used to acquire point cloud data of the target bonding area of ​​the second skin segment. This is to enable the reverse generation of the actual adhesive area model of the main beam inside the second skin segment. Furthermore, three-dimensional laser scanning technology is used to acquire point cloud data of the target bonding areas on the first molding mold with the first skin segment and the second molding mold with the second skin segment. This is to obtain point cloud data of common bonding points, ensuring that the point cloud data of the target bonding area of ​​the first skin segment can be accurately combined with the point cloud data of the target bonding area of ​​the second skin segment, thereby obtaining a complete adhesive area model of the main beam inside the wind turbine blade.

[0114] Therefore, in this step, the target bonding area for the first skin segment includes the inner side of the blade root steel flange of the first skin segment, the main beam area of ​​the first skin segment, and its outer edge (approximately 10 cm). The target bonding area on the first forming mold includes: the outer edge of the non-flipping arm area of ​​the front and rear edges of the first skin segment, and the area where the main beam of the first skin segment transitions to the front and rear edge steel frame. Similarly, the target bonding area for the second skin segment includes the inner side of the blade root steel flange of the second skin segment, the main beam area of ​​the second skin segment, and its outer edge (approximately 10 cm). The target bonding area on the second forming mold includes: the outer edge of the non-flipping arm area of ​​the second forming mold corresponding to the front and rear edges of the second skin segment, and the steel frame area of ​​the second forming mold adjacent to the main beam of the second skin segment transitioning to the front and rear edges.

[0115] Step 3: Generate the web mold model based on the adhesive bonding area model on the inner side of the main beam.

[0116] Step 3.1: Based on the adhesive region model inside the main beam obtained in Step 2.6, draw the connection surface using the edge line of the main beam as a reference. According to the theoretical distance between the web and the edge of the beam, offset the connection surface in the direction of the beam's central axis by the theoretical distance to obtain the web surface.

[0117] Step 3.2: Using the chordal centerline of the adhesive region model on the inner side of the main beam obtained in Step 2.6 as a reference, establish a reference plane, divide the surface of the adhesive region model on the inner side of the main beam into a front edge web model and a rear edge web model, and export the corresponding models respectively.

[0118] Step 3.3: Based on the inner side 5 of the mold flange, adjust the normal plane of the web mold and the starting position of the coordinate system to generate a web mold model including the web mold flange. The specific structure is as follows: Figure 7 As shown.

Claims

1. A method for reverse engineering a mold model of a wind turbine blade web, characterized in that, Includes the following steps: Step 1: Separately solidify and mold the first and second skin components of the wind turbine blade. The first skin segment is cured in the cavity of the first molding mold, and the second skin segment is cured in the cavity of the second molding mold. The first skin segment and the second skin segment can be assembled to form a complete wind turbine blade skin, and the splicing line of the first skin segment and the second skin segment is the axis of the wind turbine blade. Step 2: Use 3D laser scanning technology to reverse engineer and generate a model of the actual adhesive area on the inner side of the main beam. Step 2.1: Taking the first molding mold with the first skin segment solidified in the mold cavity as the implementation object, reflective positioning points are pasted onto the target bonding areas of the first molding mold and the first skin segment solidified in the mold cavity; point cloud data of the target bonding areas of the first molding mold and the first skin segment solidified in the mold cavity are obtained by using three-dimensional laser scanning technology; the target bonding area of ​​the first skin segment includes at least the main beam area of ​​the first skin segment; Step 2.2: Taking the second molding mold with the second skin segment solidified in the mold cavity as the implementation object, the point cloud data of the target bonding area of ​​the second molding mold and the second skin segment solidified in the mold cavity are obtained by three-dimensional laser scanning technology; the target bonding area of ​​the second skin segment includes at least the main beam area of ​​the second skin segment; Step 2.3: After flipping the second molding mold with the second skin segment solidified in the mold cavity to the top of the first molding mold with the first skin segment solidified in the mold cavity, the two are locked together by a locking mechanism to form a complete blade molding mold. Step 2.4: Use a laser scanner to scan the target patch area on the assembled first and second molding dies to obtain the corresponding patch dataset C; Step 2.5: Using a point cloud processing program, take the point dataset C obtained in Step 2.4 as the common point dataset of the point cloud data obtained in Step 2.1 and Step 2.2, and merge the point cloud data obtained in Step 2.1 and Step 2.2 to obtain a merged dataset. Step 2.6: Based on the combined dataset obtained in Step 2.5, reverse engineer the inner model of the main beam; the inner model of the main beam includes the edge line of the main beam; by offsetting the edge line of the main beam of the entire inner model of the main beam by the theoretical glue thickness h to the center line of the main beam of the upper and lower molds, the glued area model of the inner side of the main beam can be obtained. Step 3: Generate the web mold model based on the adhesive bonding area model on the inner side of the main beam. Step 3.1: Based on the adhesive region model inside the main beam obtained in Step 2.6, draw the connection surface using the edge line of the main beam as a reference. According to the theoretical distance between the web and the edge of the beam, offset the connection surface in the direction of the beam's central axis by the theoretical distance to obtain the web surface. Step 3.2: Using the chordal centerline of the adhesive region model on the inner side of the main beam obtained in Step 2.6 as a reference, establish a reference plane, divide the surface of the adhesive region model on the inner side of the main beam into a front edge web model and a rear edge web model, and export the corresponding models respectively. Step 3.3: Based on the inner side of the mold flange, adjust the normal plane of the web mold and the starting position of the coordinate system to generate a web mold model including the web mold flange.

2. The reverse engineering method for wind turbine blade web mold model according to claim 1, characterized in that, In step 2.1, the target bonding area of ​​the first skin segment includes the inner side of the blade root steel flange of the first skin segment, the main beam area of ​​the first skin segment and its outer edge, and the area where the main beams of several first skin segments transition to the front and rear edges.

3. The reverse engineering method for wind turbine blade web mold model according to claim 1, characterized in that, In step 2.2, the target bonding area of ​​the second skin segment includes the inner side of the blade root steel flange of the second skin segment, the main beam area of ​​the second skin segment and its outer edge, and the area where the main beams of several second skin segments transition to the front and rear edges.

4. The reverse engineering method for wind turbine blade web mold model according to claim 1, characterized in that, In step 2.1, the specific method for acquiring the point cloud data of the target bonding area of ​​the first molding die and the first skin sub-body solidified within the die cavity includes the following steps: Step 2.1.1: Taking the first molding mold in which the first skin segment is solidified in the mold cavity as the implementation object, reflective positioning points are pasted on the target pasting point areas of the first molding mold and the first skin segment solidified in the mold cavity respectively. Step 2.1.2: Attach several laser tracker target ball bases that can be distributed from the leaf root to the leaf tip at the middle position of the main beam of the first skin section; Step 2.1.3: Plan the installation location and transfer point of the laser tracker: Based on the range of the laser tracker, and taking the laser tracker target ball base arranged in Step 2.1.2 as the reference, plan the installation location and transfer point of the laser tracker in the main beam area of ​​the first skin body. Step 2.1.4: Obtain the detection point coordinates of the first skin segment: Set up the laser tracker at the positions planned in Step 2.1.3 on the first skin segment, and place the target ball on the attached laser tracker target ball base in sequence. When the range is exceeded, perform a station transfer operation until the coordinates of all laser tracker target ball bases are scanned and exported, and the detection point coordinates of the first skin segment can be obtained. Step 2.1.5: Use a laser scanner to scan the reflective positioning points set in Step 2.1.1 and the reflective points set on the target ball base of the laser tracker in Step 2.1.2 to obtain the scan point dataset A. Step 2.1.6: Using the coordinates of each detection point obtained in Step 2.1.4 as a reference, perform axial control on the data of each scanning point obtained in Step 2.1.5 to obtain the adjusted scanning point dataset A´. In step 2.5, the point cloud data obtained in step 2.1 is processed by the point cloud processing program, which is the scan point dataset A' obtained in step 2.1.

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5. The reverse engineering method for wind turbine blade web mold model according to claim 1, characterized in that, In step 2.2, the specific method for acquiring the point cloud data of the target bonding area of ​​the second molding die and the second skin component solidified within its cavity includes the following steps: Step 2.2.1: Taking the second molding mold in which the second skin segment is solidified in the mold cavity as the implementation object, reflective positioning points are pasted on the target pasting point areas of the second molding mold and the second skin segment solidified in the mold cavity respectively; Step 2.2.2: Attach several laser tracker target ball bases that can be distributed from the leaf root to the leaf tip at the middle position of the main beam of the second skin assembly; Step 2.2.3: Plan the installation location and transfer point of the laser tracker: Based on the range of the laser tracker, and taking the laser tracker target ball base arranged in Step 2.2.2 as the reference, plan the installation location and transfer point of the laser tracker in the main beam area of ​​the second skin body. Step 2.2.4: Obtain the detection point coordinates of the second skin segment: Set up the laser tracker at the positions planned in Step 2.2.3 on the second skin segment, and place the target ball on the attached laser tracker target ball base in sequence. When the range is exceeded, perform a station transfer operation until the coordinates of all laser tracker target ball bases are scanned and exported, and the detection point coordinates of the second skin segment can be obtained. Step 2.2.5: Use a laser scanner to scan the reflective positioning points set in Step 2.2.1 and the reflective points set on the target ball base of the laser tracker in Step 2.2.2 to obtain the scan point dataset B. Step 2.2.6: Using the coordinates of each detection point obtained in Step 2.2.4 as a reference, perform axial control on the data of each scanning point obtained in Step 2.2.5 to obtain the adjusted scanning point dataset B'. In step 2.5, the point cloud data obtained in step 2.2 is processed by the point cloud processing program, which is the scan point dataset B' obtained in step 2.2.

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6. The reverse engineering method for wind turbine blade web mold model according to claim 4 or 5, characterized in that, The width of the reflective positioning point to be pasted in the target area is 1 meter.

7. The reverse engineering method for wind turbine blade web mold model according to claim 4 or 5, characterized in that, The distance between the bases of two adjacent laser tracker target balls is 5m.

8. The reverse engineering method for wind turbine blade web mold model according to claim 1, characterized in that, In step one, the first skin segment is the windward skin segment, and the second skin segment is the leeward skin segment.

9. The reverse engineering method for wind turbine blade web mold model according to claim 1, characterized in that, In step one, the second molding mold is pivotally connected to the first molding mold via a connecting shaft, allowing the second molding mold to rotate around the connecting shaft between the first and second extreme positions. When the second molding mold is in the first extreme position, the first and second molding molds are placed side by side in the horizontal direction, with the second molding mold located to the right of the first molding mold. When the second molding mold is in the second extreme position, the second molding mold is stacked on top of the first molding mold, and the mold cavity of the second molding mold is joined with the mold cavity of the first molding mold.

10. The reverse manufacturing method for the wind turbine blade web mold model according to claim 9, characterized in that, The first molding die includes a first molding die body, a first mold support frame, and a first mold support arm; the second molding die includes a second molding die body, a second mold support frame, and a second mold tilting arm. The first molding die body has a mold cavity capable of molding the windward skin, and the lower part of the first molding die body is supported by a first mold support frame, while a first mold support arm is provided on one side of the first molding die body. The second molding die body has a mold cavity capable of molding the leeward skin, and the lower part of the second molding die body is supported by a second mold support frame. At the same time, a second mold flipping arm is provided on one side of the second molding die body. The first mold support arm and the second mold tilting arm are positioned and connected by a connecting shaft.

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