Virtual assembly fitting method for measuring the inner cavity height of full-size wind turbine blades

Abstract

The present application discloses a virtual assembly fitting method for mapping the inner cavity height of a full-size wind turbine blade, the method comprising: arranging a plurality of positioning targets on the inner surface of the pressure surface shell and the inner surface of the suction surface shell, and obtaining the corresponding first inner cavity characteristic data and second inner cavity characteristic data to determine a first data model; performing mold closing processing on the pressure surface shell and the suction surface shell to obtain a second data model; determining the inner cavity characteristic model of the full size of the blade shell in the mold closing state based on the target information, and extracting the target inner cavity height corresponding to the position of the web to be installed from the inner cavity characteristic model. The present application can fully consider the compression deformation of the blade shell mold closing process before actually manufacturing the web, and by comparing and analyzing the target inner cavity height with the web mold, it can determine whether the web manufactured based on the current web mold will have a web bearing point after manufacturing and assembly before actually manufacturing the web, and can guide the actual manufacturing and assembly of the web.

Description

Technical Field

[0001] The present application belongs to the technical field of wind turbine blade manufacturing, and in particular relates to a virtual assembly fitting method for measuring the inner cavity height of a full-size wind turbine blade. Background Art

[0002] The blade shell of a wind turbine blade consists of a pressure surface shell and a suction surface shell, wherein the pressure surface shell and the suction surface shell are respectively called the blade PS surface shell and the blade SS surface shell; before the pressure surface shell and the suction surface shell are molded together, the blade web needs to be manufactured and transferred to the inside of the pressure surface shell and the suction surface shell. During the blade mold closing process, the pressure surface shell and the suction surface shell may be deformed under the action of pressure, which will cause the blade web to conflict with the pressure surface shell and the suction surface shell and cause the web bearing point to appear. Based on this, the inner cavity height corresponding to the web bearing point and the adjacent area of ​​the web bearing point will deviate from the design value.

[0003] In the related technology, in order to control the manufacturing quality of wind turbine blades, contact scanning technology and orbital height ranging technology are currently mainly used to monitor the manufacturing process of wind turbine blades. However, both contact scanning and orbital height ranging are based on the premise that the blade shell is not deformed, and cannot detect the deformation of the main mold after the main mold is locked. In the case that the blade shell is actually deformed, the contact scanning scheme and the orbital height ranging scheme cannot accurately determine the position of the blade web after assembly, nor can it be determined whether there is a web shoulder point between the web and the blade shell. Summary of the invention

[0004] The embodiment of the present application provides a virtual assembly fitting method for mapping the inner cavity height of a full-size wind turbine blade, which can obtain the accurate characteristics of the inner cavity of the blade shell after mold closing, and perform virtual assembly and collision analysis on the web, thereby determining whether there are web bearing points and guiding the production, manufacturing and assembly of the web.

[0005] An embodiment of the present application provides a virtual assembly fitting method for mapping the inner cavity height of a full-size wind turbine blade, and the web virtual assembly fitting method includes: arranging a plurality of positioning targets on the inner surface of the pressure surface shell and the inner surface of the suction surface shell of the blade to be manufactured respectively; obtaining first inner cavity characteristic data of the pressure surface shell and second inner cavity characteristic data of the suction surface shell; obtaining a first data model of the blade to be manufactured before mold closing and capable of characterizing its inner cavity characteristics according to the first inner cavity characteristic data and the second inner cavity characteristic data; performing mold closing processing on the pressure surface shell and the suction surface shell to obtain a second data model capable of characterizing its inner cavity characteristic data of the blade to be manufactured in a real mold closing state; cross-combining the first data model and the second data model based on the target information in the first data model and the target information in the second data model to determine the full-size inner cavity characteristic model of the blade shell in the mold closing state; and extracting the target inner cavity height corresponding to the position of the web to be installed from the inner cavity characteristic model.

[0006] In some embodiments, before arranging multiple positioning targets on the inner surface of the pressure face shell and the inner surface of the suction face shell of the blade to be manufactured, the method also includes: grinding and cutting the inner cavities of the pressure face shell and the suction face shell to eliminate the shell shoulder points existing in the pressure face shell and the suction face shell themselves, and the shell shoulder points are used to characterize the mutual interference amount between the pressure face shell and the suction face shell during the mold closing process.

[0007] In some embodiments, a plurality of positioning targets are respectively arranged on the inner surface of the pressure face shell and the inner surface of the suction face shell of the blade to be manufactured, including: taking the mold seam of the pressure face shell and the suction face shell as the positioning reference, calibrating a main beam center line inside the pressure face shell and the suction face shell, and aligning the two main beam center lines along a first direction in the blade shell in a molded state; arranging a plurality of positioning targets at intervals along a second direction on the inner walls of the pressure face shell and the suction face shell, and the second direction is consistent with the extension direction of the main beam center line; arranging more than two positioning targets in the blade root area of ​​the pressure face shell and the suction face shell at intervals along a third direction and staggered along the second direction, and the third direction is consistent with the chord direction of the pressure face shell and the suction face shell.

[0008] In some embodiments, the interval L between adjacent positioning targets on the center line of the main beam along the second direction satisfies: 5m≤L≤10m, and the chordwise deviation D between adjacent positioning targets on the center line of the main beam along the third direction satisfies: D≤1.5mm.

[0009] In some embodiments, obtaining first inner cavity characteristic data of the pressure face shell and second inner cavity characteristic data of the suction face shell includes: performing a full-size scan on the inner cavities of the pressure face shell and the suction face shell to obtain first inner cavity characteristic data and second inner cavity characteristic data that can correspond to characterize the inner cavity characteristics thereof; wherein the range of the full-size scan includes the blade root area and the blade tip area.

[0010] In some embodiments, the pressure face shell and the suction face shell are molded to obtain a second data model that can characterize the inner cavity characteristic data of the blade to be manufactured in the actual molded state, including: trial-molding the pressure face shell and the suction face shell to apply pressure to them along the circumference of the pressure face shell and the suction face shell and lock them to obtain a blade shell in the molded state; performing an inner cavity characteristic scan on the root area of ​​the blade shell in the molded state to obtain a second data model that can characterize the inner cavity characteristic data; wherein the first data model and the second data model both correspond to multiple target information corresponding to the positioning targets.

[0011] In some embodiments, based on the target information in the first data model and the target information in the second data model, the first data model and the second data model are cross-combined to determine the full-size inner cavity feature model of the blade shell in the mold-closed state, including: determining the corresponding target target information from the target information in the first data model and the second data model; aligning and matching the first data model and the second data model with the target target information as the matching reference to obtain a first corrected data model, and the first corrected data model is used to characterize the full-size inner cavity feature information of the pressure surface shell and the suction surface shell after the mold is closed; extracting the blade tip correction data sub-model corresponding to the blade tip area from the first corrected data model; combining the blade tip correction data sub-model and the second data model to determine the inner cavity feature model of the blade shell in the mold-closed state.

[0012] In some embodiments, a target inner cavity height corresponding to the position of the web to be installed is extracted from the inner cavity feature model, including: determining the main beam centerline corresponding to the pressure surface shell and the suction surface shell in the inner cavity feature model; selecting a first target target from multiple positioning targets in one of the two main beam centerlines; selecting two second target targets from multiple positioning targets in the other of the two main beam centerlines; based on the first target target and the two second target targets, determining a target plane in the inner cavity feature model to characterize the target inner cavity height corresponding to the position of the web to be installed.

[0013] In some embodiments, after extracting the target inner cavity height corresponding to the position of the web to be installed from the inner cavity feature model, the method also includes: scanning the web mold to obtain the web mold model, and determining the web size based on the web mold model; comparing the web size with the target inner cavity height to determine the web gap that exists after the web and the blade shell are assembled; when the web gap is less than or equal to a preset gap threshold, determining that there is a risk of the web carrying the film; wherein the preset gap threshold H satisfies: 2mm≤H≤6mm.

[0014] In some embodiments, when the web gap is less than or equal to a preset gap threshold, after determining that there is a risk of web carrying, the method further includes: when the web gap is less than or equal to the preset gap threshold, adjusting the size of the web mold based on the web gap to ensure that there are no web carrying points after assembly between the web and the blade shell manufactured based on the web mold.

[0015] The embodiment of the present application provides a virtual assembly fitting method for mapping the inner cavity height of a full-size wind turbine blade, which can collect the inner cavity features of the pressure surface shell and the suction surface shell before mold closing and establish a first data model, and in the case of not actually manufacturing the assembly web, the pressure surface shell and the suction surface shell are tested for mold closing and load is applied to simulate the deformation of the blade shell during the actual mold closing process. After the trial mold closing is completed, since the space in the blade tip area is small and it is difficult to collect the inner cavity feature data, only the actual feature data of the blade root area can be collected to establish the second data model, and the first data model and the second data model are digitally fitted based on the positioning target to obtain an inner cavity feature model that can truly reflect the blade shell features after mold closing, and then obtain the target inner cavity height corresponding to the position of the web to be installed. The present application can fully consider the compression deformation of the blade shell during the mold closing process, and by comparing and analyzing the target inner cavity height with the web mold, it is determined before the actual manufacture of the web whether the web manufactured based on the current web mold will have a web bearing point after manufacturing and assembly, which can guide the actual manufacture and assembly of the web. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The features, advantages and technical effects of exemplary embodiments of the present application will be described below with reference to the accompanying drawings.

[0017] Figure 1 It is a flow chart of a virtual assembly fitting method for measuring and mapping the inner cavity height of a full-size wind turbine blade provided in an embodiment of the present application;

[0018] Figure 2 It is a schematic diagram of a process for determining a full-size inner cavity feature model of a blade shell in a mold closing state provided in an embodiment of the present application;

[0019] Figure 3 It is a schematic diagram of a process for extracting a target inner cavity height from an inner cavity feature model provided in an embodiment of the present application;

[0020] Figure 4 is a cross-sectional view of a positioning target position in a pressure surface shell provided in an embodiment of the present application;

[0021] Figure 5 It is a schematic diagram of the plane layout of the pressure surface shell, the suction surface shell and the 3D scanning and mapping device provided in the embodiment of the present application;

[0022] Figure 6It is a three-dimensional schematic diagram of the inner cavity characteristic model corresponding to the pressure surface shell and the suction surface shell provided in the embodiment of the present application;

[0023] Figure 7 It is a partial cross-sectional view of the inner cavity characteristic model corresponding to the pressure surface shell and the suction surface shell provided in the embodiment of the present application;

[0024] Figure 8 It is a schematic diagram of the state of the pressure surface shell or the suction surface shell provided in an embodiment of the present application before and after mold closing.

[0025] In the drawings, the drawings are not necessarily drawn to scale.

[0026] Figure numerals: positioning target 1; pressure surface shell 2; 3D scanning surveying and mapping device 3; main beam center line 4; web 5; blade shell 6; suction surface shell 7; web gap a; web collision point b; first direction X1; second direction X2; third direction X3. DETAILED DESCRIPTION

[0027] In order to make the purpose, technical solution and advantages of the embodiments of the present application clearer, the technical solution in the embodiments of the present application will be clearly described below in conjunction with the drawings in the embodiments of the present application. Obviously, the described embodiments are part of the embodiments of the present application, not all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of this application.

[0028] Unless otherwise defined, all technical and scientific terms used in this application have the same meanings as those commonly understood by technicians in the technical field of this application; the terms used in the specification of this application are only for the purpose of describing specific embodiments and are not intended to limit this application; the terms "including" and "having" in the specification and claims of this application and the above-mentioned drawings and any variations thereof are intended to cover non-exclusive inclusions. The terms "first", "second", etc. in the specification and claims of this application or the above-mentioned drawings are used to distinguish different objects, rather than to describe a specific order or a primary and secondary relationship.

[0029] In order to solve the problems of the prior art, the embodiment of the present application provides a virtual assembly fitting method for measuring the inner cavity height of a full-size wind turbine blade. The virtual assembly fitting method for measuring the inner cavity height of a full-size wind turbine blade provided by the embodiment of the present application is introduced below.

[0030] The present application embodiment provides a flow chart of a virtual assembly fitting method for measuring the inner cavity height of a full-size wind turbine blade, such as Figure 1 As shown, the web virtual assembly fitting method may include the following steps: S110 - S160 .

[0031] S110, arranging a plurality of positioning targets on the inner surface of the pressure surface shell and the inner surface of the suction surface shell of the blade to be manufactured, wherein the positioning targets are pasted and fixed to the blade product and are used as marking points for surveying and mapping data processing and assembly.

[0032] In the embodiment of the present application, the pressure surface shell 2 and the suction surface shell 7 need to be aligned in the mold to obtain the blade to be manufactured. In order to ensure the accuracy of the mold closing process, a positioning target 1 is arranged on the pressure surface shell 2 and the suction surface shell 7 to serve as a reference for the mold closing.

[0033] S120, obtaining first inner cavity characteristic data of the pressure surface shell and second inner cavity characteristic data of the suction surface shell.

[0034] In the embodiment of the present application, in order to obtain the inner cavity features of the pressure surface shell 2 and the suction surface shell 7 before mold closing, non-contact laser scanning technology can be used to collect the feature data of the inner surface of the pressure surface shell 2 and the suction surface shell 7. It can be understood that since the inner surface of the pressure surface shell 2 and the inner surface of the suction surface shell 7 are provided with positioning targets 1, based on this, the first inner cavity feature data and the second inner cavity feature data obtained by laser scanning include corresponding target information. Among them, the non-contact laser scanning technology is a scanning technology that obtains the target surface features by emitting a laser beam and receiving a reflected laser beam.

[0035] S130, obtaining a first data model of the blade to be manufactured before mold closing and capable of characterizing its inner cavity characteristics according to the first inner cavity characteristic data and the second inner cavity characteristic data.

[0036] In an embodiment of the present application, after obtaining the first inner cavity feature data and the second inner cavity feature data that can characterize the inner cavity features of the pressure face shell 2 and the suction face shell 7 before mold closing, based on the target information in the first inner cavity feature data and the second inner cavity feature data, the pressure face shell 2 and the suction face shell 7 can be virtually molded, thereby obtaining a first data model of the blade to be manufactured in an ideal state. It can be understood that the inner cavity height corresponding to each position of the blade to be manufactured in the ideal state can be determined from the first data model.

[0037] S140, performing mold closing processing on the pressure surface shell and the suction surface shell to obtain a second data model capable of representing the inner cavity characteristic data of the blade to be manufactured in a real mold closing state.

[0038] In the embodiment of the present application, in order to fully restore the inner cavity features of the blade to be manufactured after the web 5 is actually assembled and the mold is closed, the deformation of the blade to be manufactured during the mold closing and pressing process is considered, and after obtaining the first inner cavity feature data and the second inner cavity feature data, the pressure surface shell 2 and the suction surface shell 7 are mold closed. Based on this, after the pressure surface shell 2 and the suction surface shell 7 are molded to obtain the blade shell 6 in a locked state, the aforementioned non-contact laser scanning technology is used to scan the inner wall of the cavity of the blade shell 6 to obtain its features, so as to establish a second data model.

[0039] It should be emphasized that after the pressure surface shell 2 and the suction surface shell 7 are molded together to obtain the blade shell 6 in a locked state, due to the small internal space of the blade tip area, it is difficult for operators and scanning equipment to enter the blade tip area for feature scanning. Therefore, the second data model only covers the blade root area of ​​the blade shell 6 in the molded and locked state.

[0040] S150. Based on the target information in the first data model and the target information in the second data model, the first data model and the second data model are cross-combined to determine a full-size inner cavity feature model of the blade shell in a mold closing state.

[0041] In the embodiment of the present application, the first data model is a full-size inner cavity feature model of the blade shell 6 in the mold-open state, and the second data model is an inner cavity feature model of the blade root region of the blade shell 6 in the mold-closed and locked state. Based on this, in order to obtain a full-size inner cavity feature model of the blade shell 6 in the mold-closed and locked state, it is necessary to fit the first data model and the second data model based on the target information.

[0042] S160, extracting a target inner cavity height corresponding to the position of the web to be installed from the inner cavity feature model.

[0043] In the embodiment of the present application, after the inner cavity characteristic model is obtained by fitting, the target inner cavity height that can characterize the web assembly position size can be determined from the inner cavity characteristic model. The target inner cavity height can truly reflect the web assembly space of the blade shell 6 in the mold clamping and locking state.

[0044] The above is a specific implementation method of the virtual assembly fitting method for surveying the inner cavity height of a full-size wind turbine blade provided in an embodiment of the present application. This method can fully consider the compression deformation of the pressure surface shell 2 and the suction surface shell 7 during the mold closing process before actually manufacturing the web 5, and then determine whether the web 5 manufactured based on the current web mold will have a web carrying point after the lifting and mold closing process. By determining the gap between the web 5 and the blade shell 6 after virtual assembly, the manufacturing operation of the web 5 can be guided to ensure that the inner cavity space of the blade shell 6 is consistent with the design value after the assembly and production of the blade shell 6 is completed.

[0045] In some embodiments, based on the aforementioned virtual assembly fitting method for mapping the inner cavity height of a full-size wind turbine blade, the present application further provides another specific implementation of the virtual assembly fitting method for mapping the inner cavity height of a full-size wind turbine blade, and the implementation further includes before S110:

[0046] The inner cavities of the pressure surface shell 2 and the suction surface shell 7 are polished and cut to eliminate the shell shoulder points existing on the pressure surface shell 2 and the suction surface shell 7 themselves. The shell shoulder points are used to characterize the mutual interference between the pressure surface shell 2 and the suction surface shell 7 during the mold closing process.

[0047] In the embodiment of the present application, it is understandable that during the process of closing the mold of the pressure surface shell 2 and the suction surface shell 7, the actual manufacturing process may cause local defective positions in the pressure surface shell 2 and the suction surface shell 7, and the defective positions may cause the pressure surface shell 2 and the suction surface shell 7 to conflict with each other, that is, there is a shell shoulder point. Based on this, in order to eliminate the shell shoulder point, before pasting the positioning target 1 on the pressure surface shell 2 and the suction surface shell 7, it is necessary to first perform processing procedures such as grinding and cutting on the defective areas in the pressure surface shell 2 and the suction surface shell 7 to obtain the pressure surface shell 2 and the suction surface shell 7 in an ideal state.

[0048] In some embodiments, S110 (arranging a plurality of positioning targets on the inner surface of the pressure surface shell and the inner surface of the suction surface shell of the blade to be manufactured, respectively) may include the following steps:

[0049] S111. Taking the mold seam of the pressure surface shell 2 and the suction surface shell 7 as the positioning reference, a main beam center line 4 is marked inside the pressure surface shell 2 and the suction surface shell 7 respectively, and the two main beam center lines 4 are aligned along the first direction X1 in the blade shell 6 in the mold closing state.

[0050] In the embodiments of this application, please refer to Figure 4 Before pasting the positioning target 1, the position of the main beam center line 4 for installing the positioning target 1 can be determined on the inner wall of the pressure surface shell 2. Figure 4 The SPL in is the horizontal distance between the positioning target 1 and the blade leading edge mold seam, that is, the horizontal distance between the main beam center line 4 and the blade leading edge mold seam. In addition, the same method can be used to determine the position of the main beam center line 4 in the suction surface shell 7.

[0051] S112, a plurality of positioning targets 1 are arranged at intervals along the second direction X2 on the inner walls of the pressure surface shell 2 and the suction surface shell 7, and the second direction X2 is consistent with the extension direction of the center line 4 of the main beam.

[0052] In the embodiments of this application, please refer to Figure 5, multiple positioning targets 1 are arranged correspondingly on the inner walls of the pressure surface shell 2 and the suction surface shell 7, and are arranged at intervals along the extension direction of the main beam centerline 4. Among them, a group of positioning targets 1 arranged at intervals along the extension direction of the main beam centerline 4 can cover the blade root area and the blade tip area.

[0053] S113, arrange two or more positioning targets 1 in the blade root area of ​​the pressure surface shell 2 and the suction surface shell 7 at intervals along the third direction X3 and staggered along the second direction X2, and the third direction X3 is consistent with the chord direction of the pressure surface shell 2 and the suction surface shell 7.

[0054] In the embodiments of this application, please refer to Figure 5 The blade root regions of the pressure surface shell 2 and the suction surface shell 7 are both provided with positioning targets 1 arranged along the chord direction, based on which the chord-wise overlap accuracy of the pressure surface shell 2 and the suction surface shell 7 can be improved.

[0055] In one example, the interval L between adjacent positioning targets 1 on the main beam centerline 4 along the second direction X2 satisfies: 5m≤L≤10m, and the chordwise deviation D between adjacent positioning targets 1 on the main beam centerline 4 along the third direction X3 satisfies: D≤1.5mm.

[0056] In another example, the interval L between adjacent positioning targets 1 on the center line 4 of the main beam along the second direction X2 may also be less than 5 m or greater than 10 m, and the size of the interval L may be set as required with reference to the actual size of the wind turbine blade.

[0057] It can be understood that a group of positioning targets 1 arranged along the center line 4 of the main beam inside the pressure surface shell 2 and the suction surface shell 7 need to ensure the installation accuracy during the actual pasting process, wherein the chordal deviation D of adjacent positioning targets 1 along the third direction X3 needs to be controlled within 1.5 mm.

[0058] In some embodiments, S120 (obtaining first inner cavity characteristic data of the pressure surface shell and second inner cavity characteristic data of the suction surface shell) may include: performing a full-size scan of the inner cavities of the pressure surface shell 2 and the suction surface shell 7 to obtain first inner cavity characteristic data and second inner cavity characteristic data that can correspond to characterize their inner cavity characteristics; wherein the range of the full-size scan includes the blade root area and the blade tip area.

[0059] In the embodiments of this application, please refer to Figure 5After the positioning target 1 is installed on the inner wall of the cavity of the pressure surface shell 2 and the suction surface shell 7, the 3D scanning surveying and mapping device 3 can be used to perform a full-scale scan of the interior of the pressure surface shell 2 and the suction surface shell 7 to obtain the first inner cavity feature data and the second inner cavity feature data. It can be understood that the first inner cavity feature data and the second inner cavity feature data contain the features and spatial position information of each point in the inner cavity of the pressure surface shell 2 and the suction surface shell 7, and contain the corresponding target information.

[0060] In some embodiments, S140 (performing mold closing processing on the pressure surface shell and the suction surface shell to obtain a second data model capable of representing the inner cavity characteristic data of the blade to be manufactured in the actual mold closing state) may include the following steps:

[0061] S141, test-mold the pressure surface shell 2 and the suction surface shell 7 to apply pressure to the pressure surface shell 2 and the suction surface shell 7 along their circumferential directions and lock them, thereby obtaining the blade shell 6 in the mold-closed state.

[0062] In the embodiment of the present application, in order to truly simulate the inner cavity characteristics of the blade shell 6 in the mold closing state and fully consider the deformation of the pressure surface shell 2 and the suction surface shell 7 during the mold closing pressure stage, after collecting the first inner cavity characteristic data and the second inner cavity characteristic data, the pressure surface shell 2 and the suction surface shell 7 can be tried in the mold closing.

[0063] S142, performing an inner cavity feature scan on the blade root area of ​​the blade shell 6 in the mold closing state to obtain a second data model capable of representing the inner cavity feature data thereof;

[0064] Among them, the first data model and the second data model both include a plurality of target information corresponding to the positioning target 1.

[0065] In the embodiments of this application, please refer to Figure 6 and Figure 7 In order to obtain the inner cavity feature data of the blade shell 6 in the mold closing state, the 3D scanning surveying and mapping device 3 can be used to collect data on the inner cavity of the blade shell 6. It can be understood that along the extension direction of the main beam centerline 4, the inner diameter of the blade shell 6 gradually decreases from the blade root area to the blade tip area, and since the operator and equipment cannot enter the blade tip area, the inner cavity of the blade tip area cannot provide the conditions for feature collection. Therefore, at this stage, only the blade root area of ​​the blade shell 6 in the mold closing and locking state can be actually collected.

[0066] In some embodiments, please refer to Figure 2S150 (based on the target information in the first data model and the target information in the second data model, cross-combining the first data model and the second data model to determine the full-size inner cavity feature model of the blade shell in the mold closing state) may include the following steps:

[0067] S210: Determine corresponding target information from the target information in the first data model and the second data model.

[0068] In an embodiment of the present application, in order to fit the first data model and the second data model, it is necessary to determine the target information scanned in the first data model and the second data model. It can be understood that the accuracy of the fitting of the first data model and the second data model can be improved based on the corresponding target information in the pressure surface shell 2 and the suction surface shell 7.

[0069] S220, aligning and matching the first data model and the second data model with the target information as a matching reference to obtain a first corrected data model, wherein the first corrected data model is used to characterize the full-size feature information of the inner cavity of the pressure surface shell and the suction surface shell after mold closing.

[0070] In the embodiment of the present application, in the process of fitting the first data model and the second data model, based on the corresponding target information, the positions of the two sub-models corresponding to the pressure surface shell 2 and the suction surface shell 7 in the first data model can be corrected to match the second data model, and the first corrected data model can be determined based on the two corrected sub-models. The first corrected data model is processed by fitting, and compared with the aforementioned first data model, it takes into account the compressive deformation factors of the pressure surface shell 2 and the suction surface shell 7 during the mold closing process, and can more accurately characterize the inner cavity characteristics of the blade shell 6 in the mold closing locking state.

[0071] S230 , extracting a blade tip correction data sub-model corresponding to the blade tip region from the first correction data model.

[0072] In the embodiment of the present application, since the second data model is a characteristic data model of the inner cavity of the blade shell 6 in the mold clamping state that is actually measured, the second data model has higher accuracy than the first corrected data model obtained by fitting. However, since the second data model only covers the root area of ​​the blade shell 6, based on this, in order to obtain a complete and reliable data model of the blade shell 6, it is necessary to intercept the tip correction data sub-model of the tip area from the first corrected data model.

[0073] S240, combining the blade tip correction data sub-model and the second data model to determine an inner cavity feature model of the blade shell in a mold closing state.

[0074] In the embodiment of the present application, after obtaining the blade tip correction data sub-model, the blade tip correction data sub-model is matched and combined with the second data model to obtain an inner cavity feature model that sufficiently fits the inner cavity feature data of the blade shell 6 in the real mold closing state. Figure 6 A1 and B1 are sub-units in the second data model corresponding to the pressure surface shell 2 and the suction surface shell 7 respectively, and A2 and B2 are sub-units of the blade tip correction data sub-model corresponding to the pressure surface shell 2 and the suction surface shell 7 respectively.

[0075] In some embodiments, please refer to Figure 3 S160 (extracting the target inner cavity height corresponding to the position of the web to be installed from the inner cavity feature model) may include the following steps:

[0076] S310. Determine the center line of the main beam corresponding to the pressure surface shell and the suction surface shell in the inner cavity characteristic model.

[0077] In an embodiment of the present application, after cross-combining the first data model and the second data model to determine the full-size inner cavity feature model of the blade shell 6 in the molded state, the cavity space corresponding to each position inside the blade shell 6 can be determined. Based on this, the inner cavity size corresponding to the web assembly position inside the blade shell 6 can be determined. Since the web 5 is assembled at the position corresponding to the main beam centerline 4, when determining the target inner cavity height corresponding to the web position to be installed, the main beam centerline 4 in the inner cavity feature model can be determined first.

[0078] S320, selecting a first target from a plurality of positioning targets in one of the center lines of the two main beams.

[0079] In the embodiments of this application, please refer to Figure 5 and Figure 7 , the web 5 is mounted corresponding to the position of the main beam center line 4 in the blade shell 6. Since three incompletely collinear points can determine a surface in space, a spatial surface can be determined based on the three incompletely collinear positioning targets 1. According to the mutual correspondence between the theoretical web and the spatial surface, the web installation surface can be determined. Based on this, in the process of determining the web installation surface, a positioning target 1 can be selected from multiple positioning targets 1 in one of the two main beam center lines 4 as the first target.

[0080] S330. Select two second target targets from multiple positioning targets in the other of the two main beam center lines.

[0081] In the embodiment of the present application, after the first target is determined, two positioning targets 1 are selected from the multiple positioning targets 1 in the other of the two main beam center lines 4 as the second target.

[0082] S340: Based on a first target and two second targets, determine a target plane in the inner cavity feature model to characterize a target inner cavity height corresponding to a position of a web to be installed.

[0083] In the embodiment of the present application, it can be understood that the first target and the second target correspond to the main beam center line 4 of the pressure surface shell 2 and the suction surface shell 7 respectively. Based on one first target target and two second target targets, the target plane corresponding to the position of the web to be installed can be determined, and based on the target plane, the target inner cavity height corresponding to the position of the web to be installed can be determined.

[0084] In some embodiments, based on the aforementioned virtual assembly fitting method for mapping the inner cavity height of a full-size wind turbine blade, the present application further provides another specific implementation of the virtual assembly fitting method for mapping the inner cavity height of a full-size wind turbine blade, and the implementation further includes after S160:

[0085] S161. Scan the web mold to obtain a web mold model.

[0086] In an embodiment of the present application, after determining the target inner cavity height corresponding to the position of the web to be installed in the inner cavity feature model, in order to perform collision analysis on the web 5 and the blade shell 6 to be manufactured and assembled, it is necessary to determine the size of the web 5 corresponding to the web mold based on the designed web mold. Therefore, it is necessary to collect data of the web mold to determine the web mold model.

[0087] S162. Determine the blade web size based on the web mold model.

[0088] In the embodiment of the present application, it can be understood that the web mold model determined by scanning the web model can represent the size of the web 5 to be actually manufactured.

[0089] S163, comparing the web size with the target inner cavity height to determine the web gap a existing after the web 5 and the blade shell 6 are assembled.

[0090] In the embodiment of the present application, a combined comparison analysis is performed on the size of the web 5 and the target inner cavity height corresponding to the web position to be installed, so that the web gap a between the web 5 and the blade shell 6 after actual manufacturing and assembly can be determined.

[0091] S164: When the web gap a is less than or equal to a preset gap threshold, it is determined that the web 5 has a risk of bearing the film.

[0092] In the embodiment of the present application, in order to ensure that after the web 5 is hoisted into the interior of the pressure surface shell 2 and the mold assembly between the pressure surface shell 2 and the suction surface shell 7 is completed, that is, after the pressure surface shell 2 and the suction surface shell 7 are deformed by pressure, there is no point of contact between the web 5 and the inner wall of the shell, it is necessary to ensure that the web gap a determined in the web virtual assembly fitting process meets certain allowable conditions, and then ensure that after the actual manufacturing hoisting of the web 5 and the blade mold closing process are completed, there is no risk of film contact between the web 5. It can be understood that if the web gap a determined in the web virtual assembly fitting process is less than or equal to the preset gap threshold, it can be considered that there will be a risk of web contact when the web 5 is manufactured and assembled based on the current web mold, that is, there will be a web collision point b between the web 5 and the blade shell 6.

[0093] In one example, the preset gap threshold H satisfies: 2mm≤H≤6mm. Preferably, the preset gap threshold H can be 4mm.

[0094] In some embodiments, based on the aforementioned virtual assembly fitting method for mapping the inner cavity height of a full-size wind turbine blade, the present application further provides a specific implementation of a virtual assembly fitting method for mapping the inner cavity height of a full-size wind turbine blade, and the implementation further includes after S164:

[0095] S165. When the web gap a is less than or equal to a preset gap threshold, adjust the size of the web mold based on the web gap a to ensure that there is no web bearing point between the web 5 and the blade shell 6 manufactured based on the web mold after assembly.

[0096] In an embodiment of the present application, when the web gap a determined during the web virtual assembly fitting process is less than or equal to a preset gap threshold, it is necessary to adjust the size of the web mold according to the deviation between the web gap a and the preset gap threshold; thereby ensuring that the actually manufactured web 5 has no risk of film bearing after assembly.

[0097] In other embodiments, please refer to Figure 8 , sh1 represents the pressure face shell 2 or the suction face shell 7 in the open mold state, sh2 represents the pressure face shell 2 or the suction face shell 7 in the closed mold state, sh1 and sh2 can be determined based on the first data model and the second data model, and by comparing the interval between sh1 and sh2, the deformation of the pressure face shell 2 or the suction face shell 7 before and after the closing mold can be determined, and the deformation amount w can be determined.

[0098] In summary, the virtual assembly fitting method for mapping the inner cavity height of a full-size wind turbine blade provided in the embodiment of the present application can collect the inner cavity features of the pressure surface shell 2 and the suction surface shell 7 before mold closing and establish a first data model; and without actually manufacturing the assembly web 5, the pressure surface shell 2 and the suction surface shell 7 are tested for mold closing and load is applied to simulate the deformation of the blade shell 6 during the actual mold closing process. After the test mold closing is completed, the first data model and the second data model are digitally cross-fitted based on the positioning target 1 to obtain an inner cavity feature model that can truly reflect the features of the blade shell 6 after mold closing, and then obtain the target inner cavity height corresponding to the position of the web to be installed. The present application can fully consider the compression deformation of the pressure surface shell 2 and the suction surface shell 7 during the mold closing process, and by comparing and analyzing the target inner cavity height with the web mold, it is determined before actually manufacturing the web 5 whether the web 5 manufactured based on the current web mold will have web bearing points after assembly. Therefore, the present method can guide the actual manufacturing and assembly of the web 5, and ensure that after the wind turbine blade completes the production, assembly and mold closing of the web 5, there are no bearing points at both ends of the web 5 that conflict with the blade shell 6, that is, there is no web collision point b, thereby ensuring that the actual size of the inner cavity of the blade shell 6 is consistent with the design value.

[0099] Reference to "embodiment" in this application means that a particular feature, structure, or characteristic described in conjunction with the embodiment may be included in at least one embodiment of the present application. The appearance of the phrase in various places in the specification does not necessarily refer to the same embodiment, nor is it an independent or alternative embodiment that is mutually exclusive with other embodiments.

[0100] In the description of this application, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", "connected", and "attached" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a direct connection, or an indirect connection through an intermediate medium, or it can be the internal communication of two elements. For ordinary technicians in this field, the specific meanings of the above terms in this application can be understood according to specific circumstances.

[0101] In the embodiments of the present application, the same reference numerals represent the same components, and for the sake of brevity, detailed descriptions of the same components are omitted in different embodiments. It should be understood that the thickness, length, width and other dimensions of various components in the embodiments of the present application shown in the drawings, as well as the overall thickness, length, width and other dimensions of the integrated device are only exemplary descriptions and should not constitute any limitation to the present application.

[0102] The term "plurality" used in the present application refers to two or more (including two).

[0103] Although the present application has been described with reference to preferred embodiments, various modifications may be made thereto and parts thereof may be replaced with equivalents without departing from the scope of the present application. In particular, the various technical features mentioned in the various embodiments may be combined in any manner as long as there is no structural conflict. The present application is not limited to the specific embodiments disclosed herein, but includes all technical solutions falling within the scope of the claims.

Claims

1. A virtual assembly fitting method for mapping the inner cavity height of a full-size wind turbine blade, characterized in that: include: Arranging a plurality of positioning targets on the inner surface of the pressure surface shell and the inner surface of the suction surface shell of the blade to be manufactured respectively; Acquire first inner cavity characteristic data of the pressure surface shell and second inner cavity characteristic data of the suction surface shell; Obtaining a first data model of the blade to be manufactured before mold closing and capable of characterizing the full-size inner cavity features thereof according to the first inner cavity feature data and the second inner cavity feature data; Performing a mold closing process on the pressure surface shell and the suction surface shell to obtain a second data model of the blade to be manufactured in a real mold closing state that can characterize the cavity characteristic data of the blade root region; Based on the target information in the first data model and the target information in the second data model, the first data model is corrected to obtain a first corrected data model, and the blade tip correction data sub-model of the first corrected data model is combined with the second data model to determine a full-size inner cavity feature model of the blade shell in a mold-closed state; A target inner cavity height corresponding to the position of the web to be installed is extracted from the inner cavity feature model.

2. The virtual assembly fitting method for mapping the inner cavity height of a full-size wind turbine blade according to claim 1 is characterized in that: Before arranging a plurality of positioning targets on the inner surface of the pressure surface shell and the inner surface of the suction surface shell of the blade to be manufactured, the method further comprises: The inner cavities of the pressure surface shell and the suction surface shell are polished and cut to eliminate the shell shoulder points existing in the pressure surface shell and the suction surface shell themselves, and the shell shoulder points are used to characterize the mutual interference amount between the pressure surface shell and the suction surface shell during the mold closing process.

3. The virtual assembly fitting method for mapping the inner cavity height of a full-size wind turbine blade according to claim 1 is characterized in that: The method of arranging a plurality of positioning targets on the inner surface of the pressure surface shell and the inner surface of the suction surface shell of the blade to be manufactured respectively comprises: Taking the mold seam of the pressure surface shell and the suction surface shell as a positioning reference, a main beam center line is marked inside each of the pressure surface shell and the suction surface shell, and the two main beam center lines are aligned along a first direction in the blade shell in a mold closing state; A plurality of positioning targets are arranged at intervals along a second direction on the inner walls of the pressure surface shell and the suction surface shell, wherein the second direction is consistent with the extension direction of the center line of the main beam; Two or more positioning targets are arranged in blade root regions of the pressure surface shell and the suction surface shell at intervals along a third direction and staggered along the second direction, and the third direction is consistent with a chord direction of the pressure surface shell and the suction surface shell.

4. The virtual assembly fitting method for mapping the inner cavity height of a full-size wind turbine blade according to claim 3 is characterized in that: The interval L between adjacent positioning targets on the center line of the main beam along the second direction satisfies: 5m≤L≤10m, and the chordwise deviation D between adjacent positioning targets on the center line of the main beam along the third direction satisfies: D≤1.5mm.

5. The virtual assembly fitting method for mapping the inner cavity height of a full-size wind turbine blade according to claim 1, characterized in that: The obtaining of the first inner cavity characteristic data of the pressure surface shell and the second inner cavity characteristic data of the suction surface shell comprises: The inner cavities of the pressure surface shell and the suction surface shell are scanned in full size to obtain first inner cavity characteristic data and second inner cavity characteristic data that can correspond to characterize the inner cavity characteristics thereof; wherein the range of the full size scan includes the blade root area and the blade tip area.

6. The virtual assembly fitting method for mapping the inner cavity height of a full-size wind turbine blade according to claim 1, characterized in that: The step of performing mold closing processing on the pressure surface shell and the suction surface shell to obtain a second data model capable of characterizing the inner cavity characteristic data of the blade root region of the blade to be manufactured in a real mold closing state comprises: Performing a trial mold closing on the pressure surface shell and the suction surface shell, so as to apply pressure to the pressure surface shell and the suction surface shell along their circumferential directions and lock the two, thereby obtaining a blade shell in a mold closing state; Performing an inner cavity feature scan on the blade root region of the blade shell in the mold closing state to obtain a second data model capable of representing the inner cavity feature data thereof; The first data model and the second data model both include a plurality of target information corresponding to the positioning target.

7. The virtual assembly fitting method for mapping the inner cavity height of a full-size wind turbine blade according to claim 1, characterized in that: The method comprises: modifying the first data model based on the target information in the first data model and the target information in the second data model to obtain a first modified data model, combining the blade tip correction sub-model of the first modified data model with the second data model to determine the full-size inner cavity feature model of the blade shell in the mold closing state, including: Determining mutually corresponding target information from the target information in the first data model and the second data model; The first data model and the second data model are aligned and matched with each other based on the target information to obtain a first corrected data model, wherein the first corrected data model is used to characterize the full-size feature information of the inner cavity of the pressure surface shell and the suction surface shell after mold closing; Extracting a blade tip correction data sub-model corresponding to the blade tip region from the first correction data model; The blade tip correction data sub-model and the second data model are combined to determine an inner cavity feature model of the blade shell in a mold closing state.

8. The virtual assembly fitting method for mapping the inner cavity height of a full-size wind turbine blade according to claim 1, characterized in that: The step of extracting a target inner cavity height corresponding to the position of the web to be installed from the inner cavity feature model comprises: Determine the main beam centerline corresponding to the pressure surface shell and the suction surface shell in the inner cavity characteristic model; Selecting a first target from a plurality of said positioning targets in one of the two center lines of said main beams; Selecting two second target targets from the plurality of positioning targets in the other of the two main beam center lines; Based on the one first target and the two second targets, a target plane in the inner cavity feature model is determined to characterize a target inner cavity height corresponding to a position of a web to be installed.

9. The virtual assembly fitting method for mapping the inner cavity height of a full-size wind turbine blade according to claim 1, characterized in that: After extracting the target inner cavity height corresponding to the position of the web to be installed from the inner cavity feature model, the method further includes: Scan the web mold to obtain the web mold model. Determining the web size based on the web mold model; Comparing the web size with the target inner cavity height to determine the web gap existing after the web is assembled with the blade shell; When the web gap is less than or equal to a preset gap threshold, it is determined that the web has a risk of carrying the film; wherein the preset gap threshold H satisfies: 2mm≤H≤6mm.

10. The virtual assembly fitting method for mapping the inner cavity height of a full-size wind turbine blade according to claim 9, characterized in that: When the web gap is less than or equal to a preset gap threshold, after determining that the web has a risk of film bearing, the method further includes: When the web gap is less than or equal to a preset gap threshold, the size of the web mold is adjusted based on the web gap to ensure that there is no web bearing point between the web manufactured based on the web mold and the blade shell after assembly.

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