Ultrasonic testing machine for non-destructive ultrasonic testing of wind turbine blades

Abstract

An ultrasonic testing machine (1) for non-destructive testing of a wind turbine blade (16), the ultrasonic testing machine (1) comprising: a movable base (2, 3); a robotic manipulation device (4) arranged on the movable base (2, 3); a robot head (5) mounted to the manipulating device (4); an ultrasonic detection system comprising a scanning head (6) comprising at least one ultrasonic detection sensor (7), the scanning head (6) arranged on the robot head (5) slidably contacting an outer blade surface (16a) of the wind turbine blade (16); a first power supply system for supplying power to the robotic manipulating means (4), the robotic head (5) and the ultrasonic detection system, the detection machine (1) further comprising: blade marking means (8) for marking positioning marks (PM, PM ') on the outer blade surface (16a); a machine vision camera (9) and an illumination device (10) for identifying a work window (WW) on the outer blade surface (16a); a distance sensor (11) for detecting the distance between the outer blade surface (16a) and the detection machine (1); wherein the blade marking system (8), the machine vision camera (9), the lighting device (10) and the distance sensor (11) are arranged on the robot head (5); and the robot handling device (4) comprises a drive system for vertically and horizontally displacing the robot head (5) relative to each work window (WW).

Description

Technical Field

[0001] The invention relates to an ultrasonic testing device for non-destructive testing of materials, in particular for wind turbine blades. Background Art

[0002] Ultrasonic non-destructive testing (NDT) is a common method used to inspect wind turbine blades. Blade structure varies between manufacturers. Many types have a main structural beam, which is a box spar or shear web surrounded by half shells that transfer aerodynamic loads. Large blades are often made of composite materials, such as fiber-reinforced materials.

[0003] Ensuring the integrity of power generation equipment plays an important role for reliable energy production. Therefore, non-destructive testing procedures are needed, especially for turbine blades that are subject to harsh operating conditions due to phenomena such as lightning strikes, mechanical stress, humidity and corrosion. Non-destructive ultrasonic testing techniques are often applied for their predictive maintenance. Wind turbine blades are complex objects for inspection, as they have curved surfaces, are multi-layered, have variable thickness and are made of anisotropic materials.

[0004] The inspection machine used for ultrasonic NDT of wind turbine blades is usually a portable device. Using conventional portable inspection machines to perform ultrasonic inspection on wind turbine blades is cumbersome and time-consuming, which is a shortcoming that has not been effectively solved in the prior art. Summary of the invention

[0005] A first aspect of the present invention is directed to addressing the shortcomings of conventional inspection machines for ultrasonic NDT of wind turbine blades. According to the first aspect, the present invention provides an ultrasonic inspection machine for non-destructive inspection of wind turbine blades, the ultrasonic inspection machine comprising: a movable base; a robotic manipulator, the robotic manipulator being arranged on the movable base; a robotic head, the robotic head being mounted to the manipulator; an ultrasonic inspection system, the ultrasonic inspection system comprising a scanning head, the scanning head comprising at least one ultrasonic inspection sensor, the scanning head being arranged on the robotic head being able to slidably contact an outer blade surface of a wind turbine blade; and a first power supply system, the first power supply system being used to provide power to the robotic manipulator, the robotic head and the ultrasonic inspection system, wherein the inspection machine further comprises:

[0006] a blade marking device for marking a positioning mark on an outer blade surface;

[0007] a machine vision camera and lighting device for identifying working windows on the outer blade surface, each working window being defined by a positioning mark marked by a blade marking device;

[0008] A distance sensor, the distance sensor is used to detect the distance between the outer blade surface and the detection machine;

[0009] And among them,

[0010] The blade marking system, machine vision camera, lighting device and distance sensor are arranged on the robot head;

[0011] The robotic manipulator comprises a drive system for displacing the robot head vertically and horizontally relative to each working window.

[0012] The robotic manipulator is preferably a 6-axis anthropomorphic robot providing free movement of the robot head over the outer blade surface.The blade marking device may be a punching device.

[0013] In a preferred embodiment, each working window is horizontally and vertically bounded by a positioning mark marked by a blade marking device, and each working window includes a sweep area defined between a first vertical line and a first horizontal line and a second vertical line and a second horizontal line, both of which extend from the positioning mark, the second vertical line is opposite and parallel to the first vertical line, and the second horizontal line is opposite to the first horizontal line.

[0014] The scan head preferably comprises an array of horizontally aligned ultrasonic detection sensors.

[0015] The ultrasonic detection system may further include a water management system including at least one water flushing device, which is positioned above the scanning head to spray water between the front surface of the scanning head and the outer blade surface when the flushing device is in the water spraying position, so that the water flows downward on the outer blade surface and acts as a water film to couple each ultrasonic detection sensor with the outer blade surface acoustic wave. Each flushing device may be connected to a water supply tank by means of a water supply pumping unit.

[0016] The water management system of the ultrasonic detection system may include a water collection tray positioned below the scanning head to collect water dripping from the water film when the flushing device is in the water spraying position. The collection tray may be connected to the water collection tank by means of a water suction pump unit.

[0017] In a preferred embodiment, the movable base comprises an automatically guided vehicle for traversing the inspection machine relative to the outer blade surface along a horizontal path comprising a plurality of working windows.

[0018] The movable base may also include a support platform on which the robotic manipulator is mounted.

[0019] The automated guided vehicle preferably includes a programmable electronic guidance system for moving the inspection machine along the working window.

[0020] Furthermore, the automated guided vehicle preferably comprises drive wheels propelled by at least one electric motor powered by a second power supply system. In an embodiment, the second power supply system comprises at least one rechargeable battery mounted on the movable base. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] In order to complete the description and to provide a better understanding of the invention, a set of drawings is provided. Said drawings form an integral part of the specification and illustrate embodiments of the invention, which should not be interpreted as limiting the scope of the invention, but only as examples of how the invention can be implemented. The drawings include the following figures:

[0022] Figure 1 A front perspective view of an embodiment of an ultrasonic testing machine according to the invention is shown.

[0023] Figure 2 Shows Figure 1 A rear perspective view of an embodiment of an ultrasonic inspection machine is shown in FIG.

[0024] Figure 3 Shows Figure 1 Another perspective view of an embodiment of an ultrasonic testing machine is shown in .

[0025] Figure 4 Shows Figure 1 A rear perspective view of an automated guided vehicle of an embodiment of an ultrasonic inspection machine is shown in FIG.

[0026] Figure 5 Shows Figure 1 A rear perspective view of the support platform of the ultrasonic testing machine shown in FIG.

[0027] Figure 6 Shows Figure 1 A front perspective view of a robotic manipulator is shown of the ultrasonic inspection machine shown in FIG.

[0028] Figure 7 Shows Figure 1 A front perspective view of the robot head of the ultrasonic inspection machine shown in FIG.

[0029] Fig. 7A A schematic diagram showing an embodiment of a water management system in an ultrasonic inspection machine according to the present invention.

[0030] Figure 8 Shows Figure 7A rear perspective view of the blade marking device on the robot head shown in .

[0031] Fig. 9 Shown is a front perspective view of a machine vision camera, lighting, and range sensor.

[0032] Fig.10 Shows Figure 1 A partial view of an ultrasonic testing machine shown in FIG. 1 during one stage of operation inspecting a wind turbine blade.

[0033] Fig.11 Schematically shown is a side view of a wind turbine blade and a front view of an acoustic inspection machine in another stage of operation.

[0034] Fig.11A Shows Fig.11 Magnified view of the positioning marker shown in .

[0035] Fig.12 A diagram schematically illustrates the path of the robot head as the sweep area of ​​the scan window is scanned.

[0036] In these figures, there are reference numerals corresponding to elements shown below:

[0037] A1 First axis

[0038] A2 Second axis

[0039] A3 Third Axis

[0040] A4 Fourth Axis

[0041] A5 Fifth Axis

[0042] A6 Sixth Axis

[0043] HL1 First vertical line

[0044] HL2 First Horizontal Line

[0045] HP Horizontal Path

[0046] PM, PM' positioning mark

[0047] SA Sweep Area

[0048] VL1 Second vertical line

[0049] VL2 Second horizontal line

[0050] WW Work Window

[0051] 1 Ultrasonic testing equipment

[0052] 2 Automated Guided Vehicles

[0053] 3 Support platform

[0054] 3a Smart Board

[0055] 4 Robotic manipulator

[0056] 4a Support base

[0057] 4b First Arm

[0058] 4c Second Arm

[0059] 4d Third Arm

[0060] 4f Rod

[0061] 4g connection board

[0062] 4r Fourth arm

[0063] 2.3 Removable base

[0064] 5 Robot Head

[0065] 6 Scanning head

[0066] 7 Ultrasonic detection sensor

[0067] 8. Blade marking device

[0068] 9 Machine Vision Camera

[0069] 10 lighting fixtures

[0070] 11 Distance Sensor

[0071] 12 Water Management System

[0072] 12a Water flushing device

[0073] 12b Water supply tank

[0074] 12c Water collection tank

[0075] 12d Water supply pumping unit

[0076] 12e Water Suction Pump Unit

[0077] 12f Water filter

[0078] 12g Water supply line

[0079] 12h water suction line

[0080] 12i Distributor Module

[0081] 12j Water discharge pipeline

[0082] 13 Water collection tray

[0083] 14 Rechargeable battery

[0084] 15 Second power supply system

[0085] 16 Wind Turbine Blades

[0086] 16a Outer blade surface

[0087] 16b Dark stripe area

[0088] 17 First Cabinet

[0089] 18 Second cabinet

[0090] 18a Console

[0091] 19 Operation Status Traffic Light

[0092] 20 Auxiliary Sensors

[0093] 21 Security Unit DETAILED DESCRIPTION

[0094] exist Figures 1 to 10 In the embodiment shown in , an ultrasonic inspection machine 1 for performing non-destructive testing on a wind turbine blade 16 comprises: movable bases 2, 3; a robot manipulator 4 arranged on the movable bases 2, 3; a robot head 5 mounted to the manipulator 4; an ultrasonic inspection system housed inside a first cabinet 17 and comprising a scanning head 6, the scanning head 6 comprising at least one ultrasonic inspection sensor 7. The scanning head 6 is arranged on the robot head 5 and can contact the outer blade surface 16a of the wind turbine blade 16 in a slidable manner.

[0095] The movable base 2, 3 comprises an AGV 2 and a support platform 3, the AGV 2 being used to move the inspection machine 1 along a horizontal path HP relative to the outer blade surface 16a (see Figure 3 , Fig.11 ) moves forward and backward, and a robot manipulator 4 is mounted on the support platform 3. The automatic guided vehicle 2 can be based on a conventional mobile platform per se, such as the KMP 1500 mobile platform of KUKA AG of Augsburg, Germany, and the automatic guided vehicle 2 includes a programmable electronic navigation system (not shown in the figure) for moving the inspection machine 1 along the working window WW. The automatic guided vehicle 2 moves via drive wheels, which are connected to corresponding electric motors and controlled by a motor control unit (not shown in the figure). The automatic guided vehicle 2 is controlled by means of a robot controller including an intelligent board 3a, such as, for example, a KUKA intelligent board.

[0096] A first cabinet 17 and a second cabinet 18 are mounted on opposite end portions of the frame of the support platform 3. The first cabinet 17 accommodates an ultrasonic detection system (not shown in the figure), while the second cabinet 18 accommodates a robot control unit for the robot manipulator 4.

[0097] Between the cabinets 17, 18 there is an intermediate frame section with an upper section on which the robot manipulator 4 is mounted. A first power supply system including a plurality of rechargeable batteries 14 of the first power supply system and a water management system 12 are mounted on the intermediate frame section below the upper section of the intermediate frame section, and the first power supply system delivers power to the robot manipulator 4, the robot head 5 and the ultrasonic detection system. At the four corner sections of the support platform 3, corresponding safety units 21 connected to the navigation system of the ultrasonic detection machine 1 are arranged (see Figure 5 ). The safety unit 21 is a short-range scanner that emits a light beam aligned in a vertical plane to avoid possible collisions of elements mounted on the support platform 3 with fixed objects and / or moving objects. An operating status traffic light 19 is mounted on the safety unit 21 on the first cabinet 17 to emit a light signal indicating the operating status of the detection machine 1 and thereby provide an operator and other persons with an alert about the operating status.

[0098] An auxiliary sensor 20 is mounted on each of the top parts of the cabinets 17, 18. Each of the auxiliary sensors 20 is also connected to the navigation system of the ultrasonic testing machine 1. The auxiliary sensors 20 detect a specific position of the component to be tested and the position of the testing machine at a time.

[0099] The inspection machine also includes a device for marking positioning marks (PM, PM' - see Fig.11 , Fig.11A ) of the blade marking device 8 (see Figure 6 ), machine vision camera 9 (see Figure 6 ) and for identifying the working window WW on the outer blade surface 16a (see Fig.10 , Fig.11 , Fig.12 ) of the lighting device 10 (see Figure 6 Each working window WW is defined by a positioning mark PM marked by a blade marking device 8 and a distance sensor 11 for detecting the distance between the outer blade surface 16a and the detection machine 1. The blade marking device 8, the machine vision camera 9 and the lighting device 10 are also arranged on the robot head 5.

[0100] The working window WW can be detected by means of a machine vision camera 9 and lighting means 10, thanks to a vision algorithm known per se, which evaluates the contrast variations on the outer blade surface 16a and can detect previously applied positioning marks so that the positioning marks can continue at the same height of the outer blade surface 16a where they have been previously positioned. The distance sensor 11 detects the distance between the outer blade surface 16a and the inspection machine 1, and the vision algorithm uses a machine learning algorithm based on predefined templates to evaluate the quality of both the positioning mark PM and the contrast variations within the inspected material ( Fig.11 a).

[0101] Figure 6 The robot manipulator 4 shown in the figure is a 6-axis anthropomorphic robot which gives the robot head 5 free movement on the outer blade surface 16a. The robot manipulator 4 is connected to a robot control unit housed in a second cabinet 18, which includes a console 18a for operating the anthropomorphic robot (see Figure 2 ). The robot manipulator 4 comprises a support base 4a fastened to the support platform 3, a first arm 4b, a second arm 4c, a third arm 4d, a fourth arm 4e, a rod 4f and a final connecting plate 4g. The first arm 4b is rotatably connected to the support base 4a around a vertical first axis A1. The first arm 4c is rotatably connected to the second arm 4c around a horizontal second axis A2. The second arm 4c is rotatably connected to the third arm 4d around a horizontal third axis A3. The third arm 4d is rotatably connected to the fourth arm 4e around a horizontal fourth axis A4. The fourth arm 4e is rotatably connected to the rod 4f around a longitudinal fifth axis A5. The rod 4f is fixed to the connecting plate 4g, and the connecting plate 4g is obliquely connected to the robot head 5 relative to the horizontal sixth axis A6. With this arrangement, the anthropomorphic robot and the robot head can freely adopt almost any position relative to the blade surface 16a. The displacement of the above-mentioned elements about said axes A1 , A2, A3, A4, A5, A6 is actuated in a manner conventional per se by means of actuator means driven by electric motors (not shown in the figures).

[0102] Figure 7 A blade marking system 8, a machine vision camera 9, a lighting device 10 and a distance sensor 11 arranged on the robot head 5 are depicted. The robot manipulator 4 comprises a drive system for displacing the robot head 5 vertically and horizontally relative to each working window WW. Figure 8 ) is a commercial punching device (printer 40 [COLOP]) installed in the damped linear guide metal structure, which is capable of punching positioning marks PM, PM' on the outer blade surface 16a (see Fig.11 , Fig.11A), and thereafter repositioning the automated guided vehicle 2 to a position where UT scanning of the wind turbine blade 16 can continue.

[0103] The scanning head 6 is equipped with an array of horizontally aligned UT M2008 ultrasonic detection sensors 7. These sensors allow scanning the surface in question using ultrasonic waves.

[0104] The ultrasonic detection system also includes a water management system 12 (see Figure 6 , Fig. 7A ), the water management system 12 comprises four water flushing devices 12a connected to a distributor module 12i, the distributor module 12i being positioned above the scanning head 6 when the flushing device 12a is in a water spraying position to spray water between the front surface of the scanning head 6 and the outer blade surface 16a, so that the water flows downward on the outer blade surface 16a, which serves as a water film for acoustically coupling each ultrasonic detection sensor 7 with the outer blade surface 16a. Each flushing device 12a is connected to a water supply tank 12b by means of a water supply line 12g connected to a water supply pumping unit 12d.

[0105] The water management system 12 further comprises a water collection tray 13, which is positioned below the scanning head 6 when the flushing device 12 is in the water spraying position to collect water dripping from the water film. The collection tray 13 is connected to the water collection tank 12c by means of a water suction line 12h connected to a water suction pump unit 12e. A water filter 12f is connected to a water suction line 16h upstream of the water suction pump unit 12e.

[0106] Both the water supply tank 12b and the water collection tank 12c are connected to a water discharge line 12j.

[0107] like Fig.10 , Fig.11 and Fig.12 As shown in FIG. 1 , each working window WW is a rectangular working window WW based on the positioning mark PM applied by the blade marking device 8 (see FIG. 1 ). Fig.12 ) is horizontally and vertically delimited and includes a sweep area SA. The sweep area SA is defined between a first vertical line VL1 and a first horizontal line HL1 and a second vertical line VL2 and a second horizontal line HL2, both of which extend from the corner where the positioning mark PM has been applied, the second vertical line VL2 is opposite and parallel to the first vertical line VL1, and the second horizontal line HL2 is opposite to the first horizontal line HL1. The horizontal and vertical extension of each sweep area SA of the working window WW is known to the programmable control logic managing the robot manipulator 4.

[0108] like Fig.12As shown in the figure, the robot head 5 is moved horizontally from one side of the working window WW to the other side by the robot manipulator 4, and the horizontal strip of the working window WW is scanned each time the robot head 5 scans the horizontal strip. After the horizontal strip has been scanned, the robot head 5 is moved vertically to the vertically adjacent horizontal strip of the working window WW by the robot manipulator 4. These vertical and horizontal movements of the robot head are performed until the entire sweep area SA of the working window WW has been scanned. When scanning the horizontal strip, the robot head in its initial position is identified by the reference numerals 5, 5', 5", 5'", 5'", and 5''"', respectively.

[0109] Once the working window WW has been scanned, the robot head 5 is rotated 90 degrees around the A4 robot axis to allow the punching of the positioning mark PM. After the punching process, the robot head 5 is rotated -90 degrees around the A4 robot axis back to the original position and the robot head 5 is displaced horizontally (see Fig.11 ) until a subsequent positioning mark PM' is detected, a subsequent working window WW' is determined based on the positioning mark PM', and the scanning of the entire sweep area SA of the working window WW' has been scanned according to the steps described before about the previous working window WW.

[0110] In this article, the terms first, second, third, etc. have been used in this article to describe several devices, elements or parameters. It will be understood that the devices, elements or parameters should not be limited by these terms because these terms are only used to distinguish one device, element or parameter from another device, element or parameter. For example, the first axis may also be referred to as the second axis, and the second axis may be referred to as the first axis without departing from the scope of the present disclosure.

[0111] In this document, the term "include" and its derivatives (such as "comprises", etc.) should not be understood in an exclusive sense, that is, these terms should not be interpreted as excluding the possibility that the described and defined contents may include other elements, steps, etc.

[0112] On the other hand, the present invention is obviously not limited to the specific embodiments described herein, but also includes any variations (for example, regarding the selection of materials, dimensions, components, configurations, etc.) considered by a person skilled in the art within the overall scope of the present invention as defined in the claims.

Claims

1. An ultrasonic testing machine (1) for non-destructive testing of a wind turbine blade (16), comprising: A movable base (2, 3), a robotic manipulator (4), said robotic manipulator (4) being arranged on said movable base (2, 3), a robot head (5), the robot head (5) being mounted to the manipulator (4), An ultrasonic detection system, comprising a scanning head (6), the scanning head (6) comprising at least one ultrasonic detection sensor (7), the scanning head (6) arranged on the robot head (5) being capable of slidably contacting an outer blade surface (16a) of the wind turbine blade (16), a first power supply system, the first power supply system being used to provide power to the robot manipulator (4), the robot head (5) and the ultrasonic detection system, wherein the detection machine (1) further comprises: a blade marking device (8), the blade marking device (8) being used to mark positioning marks (PM, PM') on the outer blade surface (16a); a machine vision camera (9) and a lighting device (10), wherein the machine vision camera (9) and the lighting device (10) are used to identify working windows (WW) on the outer blade surface (16a), each working window (WW) being defined by a positioning mark (PM) marked by the blade marking device (8); a distance sensor (11), the distance sensor (11) being used to detect the distance between the outer blade surface (16a) and the detection machine (1); and The leaf marking system (8), the machine vision camera (9), the lighting device (10) and the distance sensor (11) are arranged on the robot head (5); The robot manipulator (4) comprises a drive system for vertically and horizontally displacing the robot head (5) relative to each working window (WW).

2. The ultrasonic testing machine according to claim 1, wherein: The robotic manipulator (4) is a 6-axis anthropomorphic robot providing free movement of the robotic head (5) on the outer blade surface (16a).

3. The ultrasonic testing machine according to any one of claims 1 to 2, wherein: The blade marking device (8) is a punching device.

4. The ultrasonic testing machine according to any one of claims 1 to 3, wherein: Each working window (WW) is horizontally and vertically bounded by a positioning mark (PM) marked by the blade marking device (8), and each working window (WW) includes a sweep area (SA), which is defined between a first vertical line (VL1) and a first horizontal line (HL1) and a second vertical line (VL2) and a second horizontal line (HL2), wherein both the first vertical line (VL1) and the first horizontal line (HL1) extend from the positioning mark (PM), the second vertical line (VL2) is opposite to and parallel to the first vertical line (VL1), and the second horizontal line (HL2) is opposite to the first horizontal line (HL1).

5. The ultrasonic testing machine according to any one of claims 1 to 4, wherein: The scanning head (6) comprises an array of horizontally aligned ultrasonic detection sensors (7).

6. The ultrasonic testing machine according to any one of claims 1 to 5, wherein: The ultrasonic detection system further comprises a water management system (12), wherein the water management system (12) comprises at least one water flushing device (12a), wherein the at least one water flushing device (12a) is positioned above the scanning head (6) when the flushing device (12a) is in a water spraying position to spray water between the front surface of the scanning head (6) and the outer blade surface (16a), so that the water flows downward on the outer blade surface (16a) and serves as a water film for acoustically coupling each ultrasonic detection sensor (7) with the outer blade surface (16a).

7. The ultrasonic testing machine according to claim 6, wherein: The water management system (12) of the ultrasonic detection system comprises a water collection tray (13) which is positioned below the scanning head (6) when the flushing device (12a) is in the water spraying position to collect water dripping from the water film.

8. The ultrasonic detection device according to claim 6 or 7, wherein: Each flushing device (12a) is connected to a water supply tank (12b) by means of a water supply pumping unit (12d).

9. The ultrasonic testing machine according to claim 7, wherein: The collecting tray (13) is connected to the water collecting tank (12c) by means of a water suction pump unit (12e).

10. The ultrasonic testing machine according to any one of claims 1 to 9, wherein: The movable base (2, 3) comprises an automatically guided vehicle (2) for moving the inspection machine (1) back and forth relative to the outer blade surface (16a) along a horizontal path (HP) comprising a plurality of working windows (WW).

11. The ultrasonic testing machine according to claim 10, wherein: The movable base (2, 3) comprises a support platform (3) on which the robotic manipulator (4) is mounted.

12. The ultrasonic testing machine according to claim 10 or 11, wherein: The automatic guided vehicle (2) comprises a programmable electronic navigation system for moving the inspection machine (1) along the working window (WW).

13. The ultrasonic testing machine according to claim 10, 11 or 12, wherein: The automatic guided vehicle (2) comprises drive wheels propelled by at least one electric motor powered by a second power supply system (15).

14. The ultrasonic testing machine according to claim 13, wherein: The second power supply system (15) comprises at least one rechargeable battery mounted on the movable base (2, 3).

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