Method and device for automatically detecting mold joint of wind turbine blade web plate

Abstract

The present application belongs to the technical field of wind power blade detection, and particularly relates to a device for automatically detecting the joint seam of a wind power blade web, and an equipment thereof, which comprises a reference calibration device, a first space detection device and a second space detection device. The second space detection device is installed at the web installation position in the blade bottom space area to measure the displacement of the upper and lower cylindrical pins relative to the initial position, and the inner cavity profile of the web installation position near the blade bottom after the joint of the wind power blade is calculated. The reference calibration device is installed at the joint blade inlet, and the first space detection device is arranged above the reference calibration device. The laser ranging sensor is driven by a walking mechanism to measure the inner cavity profile of the web installation position near the blade top, and the inner cavity profiles of multiple webs are detected simultaneously. The device has strong applicability, and the inner cavity profile size of all web installation positions can be measured only once after the joint, without the need of installing the web during the detection operation, thereby improving the measurement efficiency.

Description

Technical Field

[0001] This invention belongs to the field of wind turbine blade inspection technology, specifically relating to an automated method and equipment for detecting the web mold gap of a wind turbine blade. Background Technology

[0002] Wind energy is a clean and renewable energy source. With the rapid development of wind power generation technology, the forming technology of wind turbine blades has also become increasingly mature. A wind turbine blade generally consists of upper and lower shells, two main beam webs in the middle, one auxiliary beam web, and one trailing edge beam web. As a crucial supporting structure for the two halves of the blade, the bonding process of the web is the most critical step in blade manufacturing, and the manufacturing quality of the web directly affects the structural safety of the entire blade. However, due to the combined effects of factors such as mold deformation, unstable hydraulic turning, installation deviations, differences in vacuum pressure, and resin content, there will be certain local deviations between the theoretically calculated web profile dimensions and the actual installed dimensions. This results in the mold gap between the web and the blade exceeding the standard of 6±4mm, causing the adhesive layer to be too thin or too thick, thus affecting the structural strength and service life of the blade.

[0003] Existing methods for measuring the web joint gap mainly involve filling the web mounting area with clay, installing the web, pressing the clay, measuring the thickness of the clay after pressing, and using the clay data to determine whether the web bonding gap meets the requirements, thus providing a basis for subsequent web profile adjustments. However, this measurement method is complex and time-consuming, affecting blade production efficiency, and its accuracy is relatively poor, which is detrimental to improving blade production quality.

[0004] Therefore, it is essential to design an automated method and equipment for detecting the web seam of wind turbine blades to address the shortcomings of existing measurement methods, such as complex operation and poor measurement accuracy. Summary of the Invention

[0005] To address the shortcomings of the prior art, this invention provides an automated method and device for detecting the mold-fitting gap of the web plate of a wind turbine blade. By installing a second space detection device at the web plate installation position in the space region near the blade base, the displacement of the upper and lower cylindrical pins relative to their initial positions is measured, and the inner cavity height of the wind turbine blade after mold fitting is calculated. A reference calibration device is installed at the blade inlet after mold fitting, and the first space detection device is positioned above the reference calibration device. A traveling mechanism drives a laser ranging sensor to measure the inner cavity profile at the web plate installation position in the region near the blade tip. The entire process is convenient to operate, requires no web plate installation, and only requires one mold fitting to complete the measurement of the inner cavity profile dimensions at all web plate installation positions, thus improving measurement efficiency.

[0006] To achieve the above objectives, the present invention adopts the following technical solution:

[0007] This invention provides an automatic detection method for the web mold joint of a modular wind turbine blade, comprising the following steps:

[0008] S1. For a pair of finished wind turbine blades, a reference calibration device is installed at the blade inlet of the mold. The working surface of the movable platform is adjusted to be parallel to the horizontal plane by a level. The laser pointer is arranged according to the web plate spacing. The height of the movable platform is determined by the laser pointer, and the laser beam is adjusted to point to the web plate extension direction.

[0009] S2. At the web plate installation position in the underside space area of ​​the blade, a second space detection device is arranged at regular intervals a along the blade length direction. The first space detection device is installed in the underside space area of ​​the molded blade. The track base is adjusted so that the working surface of the track and the working surface of the movable platform are on the same plane and parallel to the laser beam of the laser pointer.

[0010] S3. The wind turbine blades are assembled into a molded blade. At this time, the upper cylindrical pin and the lower cylindrical pin in the second space detection device are relatively displaced under the action of the inner cavity of the wind turbine blade.

[0011] S4. The first space detection device begins measurement, activating the walking mechanism. The walking mechanism drives the laser rangefinder sensor and drags the pull rope of the cable sensor forward. At regular intervals 'a', the laser rangefinder sensor is activated to measure the height data X from the working surface of the track to the inner surface of the blade cavity. n1 and X n2 Where n = 1, 2, ..., are the numbers of the web plates, X n1 To measure the height of the nth web at position n from the working surface of the track to the upper surface of the blade's inner cavity, X n2 To measure the height of the nth web plate at the measurement location from the working surface of the track to the lower surface of the blade's inner cavity, M data points are measured at each web plate installation location.

[0012] S5. After the first space detection device completes its detection, the molded blade is opened. The displacement of each upper and lower cylindrical pin in the second space detection device relative to its initial position is measured. The inner cavity height at the corresponding position after the wind turbine blade is molded is calculated. The data X of the space area near the blade bottom and blade tip obtained by measurement is used. n1 and X n2 The contour curves of each web of the wind turbine blade after molding are obtained by using the k-order B-spline curve fitting formula:

[0013]

[0014] in: and These are the curve fitting values ​​of the upper and lower surfaces of the blade's inner cavity in the u-coordinate system for the nth web, respectively.n1 (i) and X n2 (i) represents the measured height data of the i-th upper and lower surfaces of the blade cavity of the n-th web, respectively. i,k (u)(i=1,2,...,M) is the value of the k-th order B-spline basis function with index i at parameter u, and its expression is:

[0015]

[0016] S6. Compare the contour curves of each web of the wind turbine blade after mold closing with the actual outer contour curve of the web to obtain the gap value of the web mold closing seam.

[0017] A second aspect of the present invention provides an automated detection device for the web mold joint of a wind turbine blade, which is part of an automated detection method for the web mold joint of a wind turbine blade. The device includes a reference calibration device, a first space detection device, and a second space detection device. The reference calibration device is located at the inlet of the molded blade. The first space detection device is mounted on the reference calibration device, and the second space detection device is directly mounted on the web installation position within the wind turbine blade. The reference calibration device includes a fixed frame, a movable platform, a laser pointer, and a level. The movable platform is located above the fixed frame. The laser pointer is sequentially mounted above the movable platform along the web location of the blade. The level is located above the movable platform. The first space detection device includes a track base, a track, a pull-wire sensor, a traveling mechanism, and a laser rangefinder. The track base is disposed in the inner cavity of the mold-closing blade. The track is installed above the track base. The traveling mechanism is disposed on the track. The laser rangefinder is sequentially installed on the traveling mechanism along the location of the blade web. The pull-wire sensor is installed at the starting end of the track, and the end of the pull-wire sensor's pull rope is fixed to the traveling mechanism. The second space detection device includes a fixed frame, an upper cylindrical pin, and a lower cylindrical pin. The upper cylindrical pin and the lower cylindrical pin are respectively disposed at both ends of the fixed frame. The axes of the upper cylindrical pin and the lower cylindrical pin are perpendicular to the horizontal plane and collinear in space.

[0018] Preferably, the number of laser pointers above the movable platform is the same as the number of webs in the wind turbine blade, the spacing between the laser pointers is consistent with the spacing between the webs in the wind turbine blade, and the laser direction of the laser pointers coincides with the extension direction of the webs.

[0019] Preferably, the number of laser ranging sensors above the traveling mechanism is the same as the number of web plates in the blade tip space region inside the wind turbine blade, and the spacing between the laser ranging sensors is consistent with the spacing between the web plates in the blade tip space of the wind turbine blade.

[0020] Preferably, the laser rangefinders are arranged symmetrically in the walking mechanism, with the upper laser rangefinder beam pointing vertically upwards and the lower laser rangefinder beam pointing vertically downwards.

[0021] Preferably, the frictional force between the upper and lower cylindrical pins and the fixed frame is greater than the weight of the cylindrical pins themselves, so that the cylindrical pins can move along their own axial direction under the action of external force.

[0022] Preferably, in the initial position, the end of the upper cylindrical pin extends beyond the upper surface of the inner cavity of the contacted blade, and the end of the lower cylindrical pin extends beyond the lower surface of the inner cavity of the contacted blade.

[0023] Preferably, the height of the movable platform in the reference calibration device is consistent with the height of the track in the first space detection device.

[0024] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0025] (1) The automatic detection equipment for the web mold seam of wind turbine blades of the present invention has a simple structure and is easy to operate. When measuring, there is no need to install the web. The internal cavity profile size measurement of all web installation positions can be completed in one mold closing, which greatly improves work efficiency.

[0026] (2) The automatic detection device for the web mold seam of the wind turbine blade of the present invention includes a first space detection device and a second space detection device, which has strong applicability and can detect the inner cavity profile of multiple webs at the same time; at the same time, the working plane of the movable platform in the reference calibration device and the working plane of the track in the first space detection device can be adjusted to adapt to wind turbine blades of different sizes.

[0027] (3) The automatic detection equipment for the web mold gap of the wind turbine blade of the present invention uses the laser pointer of the reference calibration device to perform reference positioning of the first space detection device and the second space detection device, and uses the pull wire sensor to position the measurement position of the laser ranging sensor to improve the accuracy of the measurement results. Attached Figure Description

[0028] Figure 1 This is a flowchart illustrating the automatic detection method for the web mold gap of wind turbine blades according to the present invention.

[0029] Figure 2 This is a schematic diagram of the overall composition of the automatic detection device for the web mold joint of wind turbine blades according to the present invention.

[0030] Figure 3 This is a simplified structural diagram of the reference calibration device for the automatic detection equipment for the web mold gap of wind turbine blades of the present invention.

[0031] Figure 4 This is a simplified structural diagram of the first spatial detection device of the automatic detection equipment for the web mold joint of wind turbine blades of the present invention.

[0032] Figure 5 This is a simplified structural diagram of the second space detection device of the automatic detection equipment for the web mold gap of wind turbine blades of the present invention.

[0033] Key reference numerals:

[0034] 1-Fixed frame, 2-Movable platform, 3-Laser pointer, 4-Level, 5-Wire sensor, 6-Laser rangefinder, 7-Walking mechanism, 8-Railway, 9-Railway base, 10-Fixed frame, 11-Upper cylindrical pin, 12-Lower cylindrical pin, 13-Mold closing blade. Detailed Implementation

[0035] To provide a detailed description of the technical content, objectives, and effects of this invention, the following description will be provided in conjunction with the accompanying drawings.

[0036] This invention provides an automatic detection method for the web mold joint gap of a modular wind turbine blade, the process of which is as follows: Figure 1 As shown, the specific steps include:

[0037] S1. For a pair of finished wind turbine blades, a reference calibration device is installed at the entrance of the mold blade 13. The working surface of the movable platform 2 is adjusted to be parallel to the horizontal plane by the level 4. The laser pointer 3 is arranged according to the web plate spacing. The height of the movable platform 2 is determined by the laser pointer 3, and the laser beam is adjusted to point to the web plate extension direction.

[0038] S2. At the web plate installation position in the underside space area of ​​the blade, a second space detection device is arranged at regular intervals a along the blade length direction. The first space detection device is installed in the underside space area of ​​the molded blade 13. The track base 9 is adjusted so that the working surface of the track 8 and the working surface of the movable platform 2 are on the same plane and parallel to the laser beam direction of the laser pointer 3.

[0039] S3. The wind turbine blades are assembled into a molded blade 13. At this time, the upper cylindrical pin 11 and the lower cylindrical pin 12 in the second space detection device are relatively displaced under the action of the inner cavity of the wind turbine blade.

[0040] S4. The first space detection device begins measurement, activating the walking mechanism 7. The walking mechanism 7 drives the laser ranging sensor 6 and drags the pull rope of the pull-wire sensor 5 forward. At regular intervals 'a', the laser ranging sensor 6 is activated to measure the height data X from the working surface of the track 8 to the inner surface of the blade cavity. n1 and X n2 Where n = 1, 2, ..., are the numbers of the web plates, Xn1 To measure the height of the nth web at position n from the working surface of track 8 to the upper surface of the blade's inner cavity, X n2 To measure the height of the nth web plate at the measurement location from the working surface of track 8 to the lower surface of the blade cavity, M data points are measured at each web plate installation location.

[0041] S5. After the first space detection device completes its detection, the molded blade 13 is opened. The displacement of each upper cylindrical pin 11 and lower cylindrical pin 12 in the second space detection device relative to their initial positions is measured. The inner cavity height at the corresponding position after the wind turbine blade is molded is calculated. The measured data X of the space area near the blade bottom and blade tip is then used. n1 and X n2 The contour curves of each web of the wind turbine blade after molding are obtained by using the k-order B-spline curve fitting formula:

[0042]

[0043] in: and These are the curve fitting values ​​of the upper and lower surfaces of the blade's inner cavity in the u-coordinate system for the nth web, respectively. n1 (i) and X n2 (i) represents the measured height data of the i-th upper and lower surfaces of the blade cavity of the n-th web, respectively. i,k (u)(i=1,2,...,M) is the value of the k-th order B-spline basis function with index i at parameter u, and its expression is:

[0044]

[0045] S6. Compare the contour curves of each web of the wind turbine blade after mold closing with the actual outer contour curve of the web to obtain the gap value of the web mold closing seam.

[0046] Automatic detection equipment for the web joint of wind turbine blades, such as... Figure 2 As shown, it includes a reference calibration device, a first space detection device, and a second space detection device. The reference calibration device is set at the inlet of the molded blade 13. The first space detection device is installed on the reference calibration device. The second space detection device is directly installed at the web mounting position in the space area near the blade bottom of the wind turbine blade. The reference calibration device provides precise positioning for the first space detection device and the second space detection device to ensure the accuracy of the measurement data.

[0047] like Figure 3As shown, the reference calibration device includes a fixed frame 1, a movable platform 2, a laser pointer 3, and a level 4. The movable platform 2 is positioned above the fixed frame 1 and can move vertically relative to the fixed frame 1. The laser pointers 3 are sequentially installed above the movable platform 2 along the positions of the blade webs. The number of laser pointers 3 is the same as the number of webs in the wind turbine blade. The spacing between the laser pointers 3 is consistent with the spacing between the webs in the wind turbine blade, and the laser direction of the laser pointers 3 coincides with the extension direction of the webs. The laser pointers 3 can ensure that the traveling mechanism 7 moves accurately along the extension direction of the webs. The level 4 is positioned above the movable platform 2 and is used to adjust the levelness of the movable platform 2.

[0048] like Figure 4 As shown, the first space detection device includes a track base 9, a track 8, a wire sensor 5, a traveling mechanism 7, and a laser ranging sensor 6. The track base 9 is installed inside the cavity of the mold-closing blade 13. The track 8 is installed above the track base 9. The track base 9 can drive the track 8 and the sensor above the track 8 to move vertically. The height of the track 8 in the first space detection device is consistent with the height of the movable platform 2 in the reference calibration device. The traveling mechanism 7 is installed on the track 8. The laser ranging sensors 6 are installed sequentially on the traveling mechanism 7 along the location of the blade web. The number of laser ranging sensors 6 is the same as the number of webs in the blade tip space region inside the wind turbine blade. Similarly, the spacing of the laser ranging sensors 6 is consistent with the spacing of the web plates in the space near the tip of the wind turbine blade. The laser ranging sensors 6 are symmetrically arranged vertically in the traveling mechanism 7. The laser ranging sensor 6 arranged above points its beam vertically upwards to measure the upper surface of the inner cavity of the upper wind turbine blade, and the laser ranging sensor 6 arranged below points its beam vertically downwards to measure the lower surface of the inner cavity of the lower wind turbine blade. The beams emitted by the upper and lower laser ranging sensors 6 are collinear in space. The pull-wire sensor 5 is installed at the starting end of the track 8, and the end of the pull-wire sensor 5 is fixed to the traveling mechanism 7 to provide accurate positioning and ranging for the traveling mechanism 7.

[0049] like Figure 5 As shown, the second space detection device includes a fixed frame 10, an upper cylindrical pin 11, and a lower cylindrical pin 12. The upper cylindrical pin 11 and the lower cylindrical pin 12 are respectively disposed at both ends of the fixed frame 10. The axes of the upper cylindrical pin 11 and the lower cylindrical pin 12 are perpendicular to the horizontal plane and collinear in space. The frictional force between the upper cylindrical pin 11, the lower cylindrical pin 12 and the fixed frame 10 is greater than the weight of the cylindrical pin itself. Under the action of external force, the cylindrical pin can move along its own axial direction.

[0050] Furthermore, in the initial position, the end of the upper cylindrical pin 11 extends beyond the upper surface of the inner cavity of the contacted blade, and the end of the lower cylindrical pin 12 extends beyond the lower surface of the inner cavity of the contacted blade.

[0051] The embodiments described above are merely preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Various modifications and improvements made by those skilled in the art to the technical solutions of the present invention without departing from the spirit of the present invention should fall within the protection scope defined by the claims of the present invention.

Claims

1. A method for automatically detecting the mold joint of a device-processed wind turbine blade web, characterized in that, It comprises the following steps: S1, a pair of finished wind turbine blades are installed with a reference calibration device at the entrance of the mold blade, the working surface of the movable platform is adjusted to be parallel to the horizontal plane by the level, the laser pointing instrument is arranged according to the web spacing, the height of the movable platform is determined by the laser pointing instrument, and the laser beam of the laser pointing instrument is adjusted to point to the extension direction of the web; S2, a second space detection device is arranged at the web installation position of the blade bottom web space area along the length direction of the blade at a certain distance a, a first space detection device is installed at the blade top suction space area of the mold blade, the track machine base is adjusted so that the working surface of the track is in the same plane as the working surface of the movable platform, and the laser beam of the laser pointing instrument is parallel to the pointing direction; S3, the pair of wind turbine blades are assembled to form a mold blade, at this time the upper and lower cylindrical pins in the second space detection device are relatively displaced under the action of the wind turbine blade inner cavity; S4, the first space detection device starts measuring, starts the walking mechanism, the walking mechanism drives the laser ranging sensor and drags the pull rope sensor to move forward, and the laser ranging sensor measures the height data of the working surface of the track to the inner cavity surface of the blade every interval distance a and Wherein n=1, 2…, is the number of webs, is the height from the working surface of the track to the upper surface of the inner cavity of the blade of the nth web at the measurement position, is the height from the working surface of the track to the lower surface of the inner cavity of the blade of the nth web at the measurement position, and M data are measured at each web installation position; S5, after the first space detection device finishes detection, opening the mold blade, measuring the displacement of each upper cylindrical pin and lower cylindrical pin in the second space detection device compared with the initial position, calculating the inner cavity height at the corresponding position after the wind turbine blade is molded, using the measured data of the suction side space area of the blade bottom and the pressure side space area of the blade top and , through the calculation of the k-order B-spline curve fitting formula, the profile curve of each web plate after the wind turbine blade is molded is obtained: wherein ; wherein: and are the curve-fitted values of the upper and lower surfaces of the blade internal cavity in the u coordinate for the nth web, and are the measured i-th height data of the upper and lower surfaces of the blade internal cavity for the nth web, is the value of the k-th B-spline basis function of order k at the parameter u with index i, wherein whose expression is: ； S6, the profile curve of each web after the wind turbine blade is molded is compared with the actual web outer profile curve to obtain the gap value of the web mold joint.

2. An apparatus for automatically detecting the mold joint of a wind power blade web according to the method of claim 1, characterized in that, It comprises a reference calibration device, a first space detection device and a second space detection device, the reference calibration device is arranged at the entrance of the mold blade, the first space detection device is installed on the reference calibration device, and the second space detection device is directly installed at the web installation position in the wind turbine blade; The reference calibration device comprises a fixed frame, a movable platform, a laser pointing instrument and a level, the movable platform is arranged above the fixed frame, the laser pointing instrument is sequentially arranged above the movable platform along the position of the blade web, and the level is arranged above the movable platform; The first space detection device comprises a track machine base, a track, a pull wire sensor, a walking mechanism and a laser ranging sensor, the track machine base is arranged in the mold blade inner cavity, the track is installed above the track machine base, the walking mechanism is arranged on the track, the laser ranging sensor is sequentially installed on the walking mechanism along the position of the blade web, the pull wire sensor is installed at the starting end of the track, and the pull rope end of the pull wire sensor is fixed on the walking mechanism; The second space detection device comprises a fixed frame, an upper cylindrical pin and a lower cylindrical pin, the upper and lower cylindrical pins are arranged at the two ends of the fixed frame respectively, the axes of the upper and lower cylindrical pins are perpendicular to the horizontal plane and are collinear in space.

3. The apparatus for automatic detection of the closed mould seam of a wind turbine blade web according to claim 2, characterized in that The number of laser pointing instruments above the movable platform is the same as the number of webs in the wind turbine blade, the spacing of the laser pointing instruments is consistent with the spacing of each web in the wind turbine blade, and the laser pointing direction of the laser pointing instrument coincides with the extension direction of the web.

4. The apparatus for automatic detection of the closed mould seam of a wind turbine blade web according to claim 2, characterized in that The number of laser ranging sensors above the walking mechanism is the same as the number of webs in the inner blade top space area of the wind turbine blade, and the spacing of the laser ranging sensors is consistent with the spacing of the webs at the blade top space area of the wind turbine blade.

5. The apparatus for automatic detection of the closed mold joint of the wind blade web according to claim 2, wherein, The laser ranging sensors are symmetrically arranged in the walking mechanism, the laser beam of the laser ranging sensor arranged above is vertically pointed upward, and the laser beam of the laser ranging sensor arranged below is vertically pointed downward.

6. The apparatus for automatic detection of the closed mold joint of the wind blade web according to claim 2, wherein, The friction between the upper and lower cylindrical pins and the fixed frame is greater than the weight of the cylindrical pins, and the cylindrical pins can move along the axial direction under the action of external force.

7. The apparatus for automatic detection of the closed mold joint of the wind blade web according to claim 2, wherein, In the initial position, the end of the upper cylindrical pin is located beyond the upper surface of the inner cavity of the blade, and the end of the lower cylindrical pin is located beyond the lower surface of the inner cavity of the blade.

8. The apparatus for automatic detection of the closed mold joint of the wind blade web according to claim 2, wherein, The height of the movable platform in the reference calibration device is consistent with the height of the track in the first space detection device.

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