Method and system for manufacturing composite structure for wind turbine blade

Abstract

The invention relates to a system and a method for manufacturing a composite structure (17) of a wind turbine blade (5). A layer of fibrous material (33) is arranged in a mold (16) and a top surface of the upper layer is scanned using a measuring device (25). The data entered from the measuring device (25) is analyzed in a processor (26) to identify the location of the defect (27) and its detailed information. The position data is then transmitted to an illumination system (28) in which the position of the defect (27) on or relative to the upper layer of the composite material structure (17) is visually indicated using an illumination device (29). The present inspection method may be performed during dry stacking of respective layers, allowing for correction of defects (27) prior to infusion of the resin matrix material.

Description

Technical Field

[0001] The present invention relates to a method and a system for manufacturing a composite material structure for a wind turbine blade, wherein a measuring device is arranged above a mold having a molding surface, the measuring device being arranged relative to a movable tool for laying a fiber material layer on the molding surface or on top of a previous fiber material layer, the measuring device being connected to a processor configured to analyze data from the measuring device and to identify the location of a defect in a layer or a previous layer, wherein the location is visually indicated on or relative to the layer. Background Art

[0002] It is known that during the manufacture of large composite structures such as wind turbine blades, workers manually inspect the layup quality of individual layers. However, this inspection process is labor-intensive and time-consuming and requires high-quality training of personnel. Defects in laminated or sandwich structures may affect the structural integrity after curing and lead to increased post-manufacturing repair work. Visual inspection depends on the skills and knowledge of the workers and may result in a lack of repeatability and accuracy.

[0003] EP 2390074 B1 discloses an in-line inspection method for manufacturing prepregs or laminates, wherein during the manufacturing process, the same or different parameters of the prepreg or laminate are measured twice. The measurement may include an optical 2D measurement of the laminate surface topography during layup using imaging techniques. The optical measurement device may be positioned adjacent to the top of the layup. The captured image data is analyzed and evaluated in a processor to identify defects such as wrinkles in the prepreg or laminate.

[0004] Historical data of the prepreg or laminate can be used as input to the processor to predict whether defects identified in the prepreg or laminate will exist in the cured part and what effect these defects will have on the strength of the cured part. The processed data can be used to automatically or manually adjust parameters related to the layup process. However, no details are provided on how the results of the data processing are presented to the worker, or how the layup process parameters are adjusted.

[0005] US2013 / 0179118 A1 discloses a method and system for inspecting the layup of a wind turbine blade, wherein an optical metrology device is arranged at either end of a movable layup trolley. The device is connected to a computer, which generates a two-dimensional or three-dimensional data model of the top surface for identifying defects in the laminate during layup. This data model can also be compared with a data model generated after curing the composite part. This means that when a defect is identified, it is then isolated and removed. However, no details of this removal process are provided.

[0006] DE 102011051071 A1 discloses a method and an imaging system for inspecting fiber laminates, wherein electromagnetic waves are emitted by a transmitter toward the fiber laminates, and a receiver receives waves reflected by the fiber laminates or transmitted through the fiber laminates. An image recognition algorithm can be implemented in a computer to identify defects in the fiber laminates using the principle of synthetic aperture radar (SAR). The defects are then corrected before the resin matrix material is poured into the fiber laminates. The application implies that the images are displayed to the worker, but no further details are provided.

[0007] EP 2991034A1 discloses a method and system for inspecting fiber laminates, wherein a light source and a camera are arranged above a mold. The light source projects a light pattern onto the mold, and the camera captures an image of the light pattern. The computer then generates a reference 3D profile of the mold. Subsequently, the corresponding fiber layer is laid on the mold. Another 3D profile is generated by projecting light onto the fiber layer and capturing the reflected light pattern. The thickness difference between the corresponding 3D profiles is then calculated and compared with a threshold value. If the error exceeds the limit, an alarm is sounded and the defect can be corrected. No details are provided on how the alarm information is presented to the worker.

[0008] Likewise, it is known to project reference lines onto a mold or fiber layer using a suspended laser projection system. An example of such a laser projection system is disclosed in EP 3645255 A4, in which a computer model of the layup sequence of a core panel is generated, from which reference marks for placing the core panel are obtained. The mold includes a plurality of reflective marks that are used to calibrate the laser projection system. Deviations between the projected marks and the core panel may result in adjustments to the placement of the core panel or adjustments to the projected reference marks. This layup process still requires manual or automatic inspection for defects.

[0009] EP 1955108B1 discloses a method and system for projecting an image of a defect onto the surface of a workpiece using a laser projection device. The laser projection device is connected to a data system or database that includes information indicating defects within the workpiece. The data system uses one or more sensors to collect data related to the workpiece, which is then analyzed and evaluated in a computer. The data can be downloaded to the database before the inspection is performed. Encoders and reflective targets are used to determine the orientation and position of the laser projection device and the rotation angle of the mandrel.

[0010] This arrangement is only suitable for workpieces that rotate during manufacturing, such as disclosed in EP 2918400 B1. Each layer is inspected, any defects are recorded in a database, and a structural integrity check is performed. If necessary, instructions for correcting the defects are generated and sent to the workers. Information on the corrective measures performed is stored in a database. The inspection system is specifically designed to cooperate with a rotating mandrel and a movable gantry arranged on a track adjacent to the mandrel. A sticky tape strip is adhered to the substrate of the mandrel, wherein a compression roller presses the tape strip into contact with the substrate. Therefore, cooperation with a system for manufacturing wind turbine blades cannot be achieved.

[0011] Other systems employ optical inspection systems such as those described in WO 2015 / 028023 A1 and US 8418560 B2 to analyze composite structures after curing. However, these systems increase post-manufacturing work and increase the amount of waste. Summary of the invention

[0012] An object of the present invention is to overcome the above-mentioned problems of the prior art.

[0013] An object of the present invention is to provide a method and system that enables workers to quickly and easily locate defects in a ply structure.

[0014] It is an object of the present invention to provide a method and a system which enable improved inspection of laminate structures.

[0015] It is an object of the present invention to provide a flexible method and system which can be easily adapted to different manufacturing setups and / or interact with existing manufacturing setups.

[0016] An object of the present invention is achieved by a system for manufacturing a wind turbine blade, the system comprising:

[0017] a mold having a molding surface shaped to form a contour of a composite structure of a wind turbine blade;

[0018] a movable support structure disposed relative to the mold and configured to move in at least one direction relative to the mold;

[0019] at least one measuring device arranged on the support structure and configured to scan at least an upper layer of the composite material structure and to measure topographic data related to a top surface of at least the upper layer; and

[0020] a processor connected to the at least one measuring device and configured to analyze data input from the at least one measuring device and to determine whether a defect exists in at least the upper layer, and the processor is further configured to determine at least the location of the defect;

[0021] Characterized in that a lighting system is also connected to the processor and positioned relative to the mold, wherein at least the position of the defect is transmitted to the lighting system, the lighting system comprising at least one lighting device, which is configured to visually indicate at least the position of the defect on or relative to the upper layer.

[0022] This provides a simple and reliable in-line inspection system for monitoring the layup process of dry fiber layers during the manufacture of composite structures. The system is suitable for manufacturing composite structures with laminated structures or sandwich structures. The system is further suitable for interacting with manual or automatic layup systems, wherein the system can cooperate with the layup system or operate as a standalone system.

[0023] The system can also be used to perform quality checks on laminated or sandwich structures after curing. This allows workers to quickly and easily locate defects in the cured composite structure that need to be repaired during the post-curing process. The system enables the measurement equipment to be moved along the length of the wind turbine blade, while the lighting system visually indicates defects on the composite structure.

[0024] Conventional robotic inspection systems are limited to automatically scanning the outer surface profile of an assembled wind turbine, wherein the scan results are displayed on a computer terminal at a remote computer station or on a platform that can be moved. However, workers still have to manually locate defects on the outer surface.

[0025] Here, the term "topographic data related to the top surface" is defined as the result of a non-contact scan of the top surface to obtain quantifiable 2D or 3D measurements of the surface topographic features. The measurement techniques may include optical measurement, microscopy measurement, interferometry or profilometry. However, other methods of measuring surface topography may also be used.

[0026] The processor of the system is configured to process input data from the measuring device and determine one or more parameters related to the surface topography based on the input data. These parameters can be combined to form a 2D map or a 3D map of the surface topography. The processor is further configured to evaluate these parameters to identify any defects in at least the upper layer, preferably using predetermined thresholds, design parameters or other reference parameters stored in the processor and / or database for identification. The defects can be wrinkles (in-plane or out-of-plane), gaps, foreign matter, ply drops or other anomalies that cause deformation of the upper surface. This enables automatic inspection of laminated structures or sandwich structures to detect defects in the production process.

[0027] In one embodiment, the lighting device is shaped as at least one row of light emitting elements arranged on or positioned relative to the mould, each row of light emitting elements extending along at least a length of the moulding surface.

[0028] The system includes a lighting system connected to the processor via a wired communication link or a wireless communication link. The lighting system includes a plurality of lighting devices configured to emit one or more light beams that form one or more visually recognizable patterns on or near the molding surface or composite structure. The light devices are directly or indirectly connected to the processor and are configured to receive data related to the results of the data analysis performed in the processor. The lighting devices are configured to emit light to visually indicate at least the location of a defect and / or indicate the absence of a defect based on the received data. This enables a worker to quickly locate a defect in the upper layer and, if necessary, perform any corrective measures.

[0029] The lighting device may be formed by light emitting diodes (LEDs) arranged on the mould. Preferably, at least one row of first LEDs may be arranged on the first side of the mould and / or at least one row of second LEDs may be arranged on the second side of the mould. These rows of first and second LEDs may extend along at least a portion of the length of the moulding surface, preferably along the entire length. This enables the worker to quickly and easily locate defects in the length direction and / or indicate the absence of defects.

[0030] Optionally, at least one row of third LEDs may further extend in the transverse direction of the mold. These rows of third LEDs may be arranged on the mold adjacent to the first LED and / or the second LED. This enables workers to quickly and conveniently further locate defects and / or absence of defects in the transverse direction.

[0031] The number of LEDs may be selected based on the length and / or width of the composite structure.Each LED may define a section of the composite structure or molding surface in the length direction and / or in the transverse direction.

[0032] In one embodiment, the light emitting elements are grouped into at least one matrix arranged on or positioned relative to the mould, each matrix of light emitting elements defining a plurality of sections of the composite material structure in the length direction and / or in the transverse direction.

[0033] Alternatively, the matrix of first LEDs and / or the matrix of second LEDs may be arranged on the first side and / or the second side of the mould. The first LEDs and / or the second LEDs in each matrix may be aligned in rows and columns. Preferably, the matrix may be arranged relative to the mould surface or the mould edge. Optionally, at least one matrix of third LEDs may further be arranged on the top surface of the mould, preferably adjacent to the matrix of first LEDs and / or the second LEDs. This enables the current position data and / or historical data to be displayed to the worker in a visual manner.

[0034] The rows or matrices of the first, second and / or third LEDs may also be arranged on a separate frame or support structure. The frame or support structure may be a stand-alone unit or may be configured to be mounted on a wall in the floor of a work area. The frame or support structure may be positioned relative to the mold so that a worker can view the LEDs as they move in or around the mold. This further enables a worker to quickly and easily view current location data of defects and / or absence of defects in a composite structure during production, and optionally, also historical data.

[0035] In one embodiment, the lighting device is shaped as at least one light projection device positioned above the mold, the light projection device being configured to project at least one light beam onto a top surface of the upper layer.

[0036] The lighting device may also be shaped as a light projection device positioned above the mold. Each light projection device may be configured to emit an electromagnetic beam that can be detected by the human eye or by using a detectable element on the top surface of the composite structure or mold. The detectable element may be a light reactive lens or smart glasses. Preferably, the emitted light is visible light, such as a wavelength between 400nm and 700nm and / or a frequency between 420THz and 750THz.

[0037] Each light projection device can be positioned above the mold, preferably in a fixed position or fixed on a movable frame structure. A plurality of light projection devices can be arranged in a working area relative to the mold so that the light projection device can project a light beam onto the entire composite material structure or molded surface. The light projection device can be a laser projector, a digital projector, or other types of light projectors. This enables the location of the defect, the unique code associated with each defect, and / or other relevant data to be visually shown on the top surface, so that workers can quickly and easily identify defects and other relevant data without having to manually locate and mark these locations.

[0038] The lighting system may include a local light controller connected to the lighting device via a wired communication link or a wireless communication link. The local light controller may also be connected to a local data processing controller in the processor. The light controller may be configured to control the operation of the lighting device and to communicate with the data processing controller and / or a database. The data processing controller may be configured to process data input from the measurement device and to communicate with the light controller and / or a database. Alternatively, the light controller and the data processing controller may be implemented as a single control unit. This enables the system to adapt to the production settings at the work area. This further enables data processing to be performed faster, thereby reducing the time delay between data input and data output.

[0039] The present system can interact with an existing light projection system such as that mentioned in EP 1955108A1, which can receive the position of the defect and project the position of the defect onto the top surface. This reduces the number of required system components and saves costs. The present light controller can optionally be implemented in a control unit of an existing light projection system.

[0040] However, conventional lighting systems such as those mentioned in EP 3645255A1 are usually only configured for projecting reference markings for layup core panels or fibre layers.

[0041] In one embodiment, the processor is connected to at least one database configured to store at least historical data related to defects in composite material structural layers, wherein the processor is further configured to process data input from at least one measuring device in real time and continuously update location data of defects in at least the upper layer.

[0042] The processor can be implemented in a local control unit or in a remote control unit, wherein the control unit can be connected to a local database or a remote database. The processor and / or the database can be implemented in a local server unit or in a remote server unit. For example, the processor can be arranged as a local control unit communicating with a remote database unit. This enables stable data processing and data communication. Alternatively, the processor and the database can be arranged as a remote server unit communicating with a local controller of, for example, a lighting system. This enables complex data processing to be performed remotely while enabling the local controller to control the operation of the system and the communication between the corresponding electrical components. The amount of local data processing is thereby reduced.

[0043] The processor can process and analyze the data input from the measurement device in real time or near real time. Here, the term "real time" includes processing the measurement data as it comes in. Here, "near real time" includes collecting the measurement data in batches and processing the measurement data in batches. The batch size can be selected as a time interval or a length interval. The processor can thus identify defects in at least the upper layer in real time or near real time.

[0044] The processor is configured to determine the location of at least any identified defects in the length direction and / or width direction. The location data of these defects in the upper layer can then be transmitted to the database and stored in the database. A local coordination system in the working area can be used to determine the location of the defects. The database can be continuously updated as the measuring device moves along the molding surface, and can also be continuously updated after each run is completed. This allows for convenient identification of defects in the current upper layer while updating historical data.

[0045] In one embodiment, at least one measuring device is configured to continuously measure data related to the surface topography as the support structure moves along the molding surface in at least one direction.

[0046] The processor may be connected to the measuring device via a wired communication link or a wireless communication link. The measuring device may be configured to continuously transmit data to the processor, or to temporarily store the measurement data before transmitting it to the processor. The amount of data transmission may depend on whether the data is processed locally or remotely. Optionally, the raw data of the measuring device may also be transmitted to a database and stored in the database.

[0047] The measuring device can be configured to perform 2D measurement or 3D measurement of the surface topography in the length direction and / or the lateral direction. For example, the measuring device can scan the top surface by transmitting an electromagnetic signal onto the top surface using one or more transmitters. Then, the measuring device can capture the reflected signal using one or more receivers. Alternatively, one or more cameras can be used to capture the top surface and one or more images of the optional light pattern projected onto the top surface. Then, the image can be processed and analyzed in the processor. The measuring device can use non-destructive imaging techniques such as ultrasound, X-rays, tomography, profilometry, digital imaging, electromagnetic radiation, or other measurement techniques to measure the top surface features.

[0048] The processor may be configured to process the measurement data to determine one or more parameters associated with the defect, as described later. The parameters may be a height variation of the top surface, a thickness variation of the upper layer, an upper layer misalignment, edge detection, and other related parameters. The processor may also be configured to determine a CTQ level or severity indication associated with the defect. The CTQ level and / or severity indication may also be visually indicated on or near the molding surface or composite structure using a lighting device.

[0049] In one embodiment, at least one lighting device is configured to visually indicate locations where defects are identified using at least one set of colors and optionally further to visually indicate locations where defects are not identified using at least one other set of colors.

[0050] The lighting device may be configured to emit a light pattern having one or more colors to visually indicate the location of a defect and / or to indicate the absence of a defect. A first set of colors may be used to visually indicate the location of a defect identified by a processor. Alternatively, a second set of colors may be used to visually indicate the location of an unidentified defect. Alternatively, no light may be used to visually indicate the location of an unidentified defect. This enables a worker to quickly locate a defect in a composite structure by the colors used.

[0051] A continuous light of a selected color with a constant intensity can be used to visually indicate the location of the defect. Alternatively, an alternating light can be used to visually indicate the location of the defect. The alternating light can be formed by emitting a selected color with different intensities. The alternating light can also be formed by emitting different colors, where the intensity of each color is the same. The alternating light can also be formed by emitting different colors with different intensities. This enables the worker to quickly identify the defect and optionally its detailed information.

[0052] In one embodiment, at least one lighting device is configured to visually indicate locations where defects are identified and / or locations where defects are not identified by emitting continuous light, alternating light and / or rhythmic light having at least one light cycle and at least one dark cycle.

[0053] The lighting device may be configured to further emit a light pattern having continuous light or alternating light, as described above. Alternatively, the light pattern may also be emitted using rhythmic light having at least one light cycle and at least one dark cycle, wherein the light cycle and the dark cycle may be selected to indicate the type of defect and / or the severity of the defect. The use of rhythmic light may be combined with the use of different colors and / or the use of continuous light or alternating light. This enables the worker to further identify detailed information of the defect by using the selected type of light.

[0054] Optionally, the above light pattern may also be adapted to visualize a chord-wise position on the surface area. This enables a worker to quickly and easily identify a selected chord-wise position using the light pattern.

[0055] In one embodiment, the processor is configured to identify the type of defect and / or the severity of the defect. Preferably, the processor is further configured to grade the type of defect and / or the severity of the defect according to one or more predetermined conditions.

[0056] The processor may be configured to classify the parameters of the identified defects according to predetermined conditions, which define a plurality of classification levels. Each classification level may be associated with the type of defect, the severity of the defect, the size of the defect and / or the CTQ level. Each classification level may be further associated with a specific light color, a rhythmic light and / or a continuous or alternating light. This enables automatic classification of the identified defects, visually displaying the severity of the defect.

[0057] The processor can be configured to identify layer loss, misalignment, or edge detection of the upper layer based on the measurement results. These defects can be classified as non-critical defects and can therefore be visually indicated using a specific type of light that is different from other types of light used. Therefore, non-critical defects can be identified and distinguished from other defects in a quick and simple manner.

[0058] In one embodiment, the system further comprises at least one layup tool configured to move in at least one direction relative to the mold, the layup tool configured to apply at least one layer of fiber material to the molding surface or upper layer.

[0059] The system may further include one or more layup tools configured to apply one or more layers of fiber material to the upper layer, wherein the fiber material may be delivered from a roll. The layup tool may be arranged on a trolley extending in a transverse direction. The trolley may be movable along a pair of tracks in a length direction. The pair of tracks may be arranged along or adjacent to the sides of the mold. Alternatively, the trolley may be configured to move along a pair of tracks arranged on a runway beam above the work area. The layup tool may further be movable along the trolley in a transverse direction and / or in a height direction relative to the trolley. This enables at least semi-automatic layup of the various fiber layers, thereby reducing the overall layup time and achieving a less labor-intensive process.

[0060] The trolley may include dual layup tools capable of applying fiber layers in both length directions. Each individual layup tool may be fed from a separate roll of fiber material. Each individual layup tool may be operated individually so that the layup process may be performed in both length directions. This further reduces the overall layup time.

[0061] The layup tool may be configured as a trolley, a robotic arm or a beam connected to a crane system on rails. The crane system may be a gantry crane or an overhead crane. The layup tool may form part of a semi-automatic or automatic layup system. The layup tool may be movable along the molding surface in the length direction and / or in the transverse direction. This enables the layers to be applied using an automatic or semi-automatic layup process, thereby reducing the overall production time and reducing the risk of defects due to human error.

[0062] The layup tool or sled may include a position sensor configured to measure the position of the layup tool, wherein the position sensor may be connected to the processor via a communication link. The processor may determine the position of the layup tool based on input from the position sensor.

[0063] In one embodiment, the support structure forms part of a layup tool, wherein the measuring device is connected to the layup tool such that it moves with the layup tool.

[0064] The measuring device may be connected to the layup tool or the trolley so that it moves with the layup tool or the trolley. The processor may determine the position of the measuring device using data input from a position sensor on the layup tool or the trolley. Optionally, at least the data processing controller may be arranged on the layup tool or the trolley. This enables the fiber layer to be applied in a combined operation while scanning the upper layer.

[0065] A first measuring device may be arranged at one end of the dual layup tool and a second measuring device may be arranged at the opposite end of the dual layup tool. Both the first measuring device and the second measuring device may be connected to a processor. This enables scanning of the upper surface in two length directions, depending on the movement of the layup tool.

[0066] In one embodiment, the support structure is shaped as a beam or a frame, the beam or the frame is constructed to be connected to a crane system, a pulley or a guided vehicle system, the crane system, the pulley or the guided vehicle system is configured to move the beam or the frame in at least one direction relative to the mold, preferably, the crane system, the pulley or the guided vehicle system is configured to move the beam or the frame independently relative to the layup tool.

[0067] The measuring device may also be arranged on a support structure that is configured to be connected to a crane system or a trolley on which the layup tool is located. Alternatively, the support structure may be moved along a separate crane system, trolley or guided vehicle system that is further arranged relative to the mold. The guided vehicle system may be an automated guided vehicle (AGV) system. Thus, the support structure with the measuring device may be arranged so that it can be moved independently relative to the layup tool. This enables scanning of the upper layer and laying of the fiber material in separate, independent operations. For example, scanning may be performed between layers of the fiber layer.

[0068] Conventional inspection systems use a movable support or platform such as a self-propelled vehicle or a robotic arm to position and orient the 3D scanner or scanning probe relative to the cured composite structure. However, this increases the complexity of the entire system and requires the composite structure to be moved to the finishing area.

[0069] In one embodiment, a single measuring device or at least two measuring devices are arranged on the support structure in a lateral direction, wherein the position and / or the direction in which the measuring devices are arranged on the support structure is fixed or adjustable.

[0070] Preferably, the measuring device is an optical metrology device such as a distance sensor, or a profilometer configured to scan at least the top surface of the upper layer. The optical metrology device or profilometer may include at least one light source for illuminating the upper layer. For example, a laser source or a digital light source may be used to project one or more patterns onto the top surface. The optical metrology device or profilometer may further include at least one camera for capturing an image of the inspection area. This enables a cost-effective and reliable measurement of the surface topography.

[0071] The processor may be configured to determine parameters of the top surface topography and / or 2D surface profile or 3D surface profile based on data input from an optical metrology device or a profilometer. The processor may identify defects using a base model that defines a nominal surface line or profile in the length direction and / or the lateral direction. This enables simple and reliable automatic defect detection in the processor.

[0072] The system can use a single measuring device to scan the entire lateral width of a composite structure or a molding surface. Alternatively, two or more measuring devices can be positioned relative to each other and applied to the entire lateral width of a composite structure or a molding surface. This enables the configuration of the measuring device settings to be adapted to the size of the composite structure and its geometrical profile.

[0073] The measuring devices may preferably be arranged on a support structure so that it / they can scan the entire top surface of the composite structure while moving along the mould. Each measuring device may be connected to the support structure in a fixed position and a fixed orientation so that the measuring device moves with the support structure. Alternatively, the measuring device may be configured to rotate about a local transverse axis and / or a local length axis so that the measuring device can be correctly oriented relative to the inspection area of ​​the top surface. This enables the measuring device to be adjusted relative to the geometrical contour of the moulding surface or the composite structure during scanning.

[0074] In one embodiment, the system further comprises at least one feedback device configured to input a feedback signal to the processor, wherein the feedback device is configured to communicate with the processor directly or through a measurement device or a lighting system.

[0075] The system may further include one or more feedback devices that allow workers to input feedback signals in a quick and easy manner without having to manually enter information on a central terminal.

[0076] The feedback device may be one or more buttons, such as push buttons, arranged along the row of LEDs. The buttons may be distributed along the length of the LEDs and may be connected to a processor for inputting one or more feedback signals. The feedback signal may, for example, indicate approval of the selected upper layer portion. This enables the worker to input feedback signals in a quick and simple manner.

[0077] The feedback device can be one or more handheld devices configured to communicate with the processor via a wireless communication link or a wired communication link, such as a smart phone, a tablet phone, a tablet computer, or a remote control. A user interface such as a graphical user interface (GUI) on the handheld device can be used to input feedback signals and / or receive detailed information related to the selected defect. Optionally, the handheld device can be configured to scan a selected unique code shown on the top surface. This enables the worker to input feedback signals and view detailed information in a quick and simple manner.

[0078] Alternatively, the feedback device may be one or more smart glasses configured to communicate with the processor via a wireless communication link or a wired communication link. The smart glasses may be configured to receive data related to the defect from the processor, such as location data, historical data, instructions for corrective actions, or other relevant data. This enables the worker to continue interacting with the composite structure while receiving detailed information related to the selected defect. The worker may input feedback signals through the smart glasses, which may be transmitted back to the processor. This also enables the worker to input feedback signals and view detailed information in a quick and simple manner.

[0079] Alternatively, the feedback device can be one or more reflective devices configured to reflect feedback signals back to the light projection device. The reflective devices can each include a unique code incorporated into the reflection pattern. The processor or light controller can be configured to detect the reflected signal and decode the feedback signal. This enables the worker to input the feedback signal by simply positioning the reflective device within the illustrated area on the top surface.

[0080] In an embodiment, the composite structure is a spar cap, a shear web, a trailing edge stiffener, a leading edge stiffener, a blade shell portion or a blade root portion.

[0081] The system is suitable for use in manufacturing large composite structures, such as wind turbine blades. The shape of the mold surface of the mold can be designed to form a wind turbine blade component. The wind turbine blade component can be a spar cap, a shear web, a trailing edge reinforcement, a leading edge reinforcement, a suction side blade shell, a pressure side blade shell or a blade root section.

[0082] The system can be incorporated into an existing automated layup system to reduce the number of components and lower installation costs. Alternatively, the system can be implemented as a stand-alone inspection system.

[0083] An object of the present invention is also achieved by a method of manufacturing a wind turbine blade, the method comprising:

[0084] Arranging composite material structure layers of a wind turbine blade on a molding surface of a mold, the composite material structure having a laminate structure or a sandwich structure;

[0085] scanning at least an upper layer of the composite structure using at least one measurement device and transmitting topographic data related to a top surface of at least the upper layer to a processor;

[0086] analyzing, in a processor, data input from the measurement device, wherein the processor determines whether a defect exists in at least the upper layer and further determines at least the location of the defect;

[0087] At least the position of the defect is transmitted to a lighting system, wherein at least the position of the defect on or relative to the upper layer is visually indicated using the lighting system.

[0088] This provides an improved method for inspecting composite structures of wind turbine blades which can be used during layup of dry layers of the composite structure and during post-curing. The method can be implemented with existing automated layup systems to save installation costs and reduce the overall number of components.

[0089] As the measuring device moves along the molded surface or composite structure, the top surface is scanned. The data from the measuring device is then processed and analyzed in a processor, which transmits at least the location data of the defects to the lighting system. The lighting system visually indicates the location of these defects to the worker so that defects in the upper layer can be quickly identified and repaired if necessary.

[0090] Conventional automated inspection systems are limited to scanning the assembled wind turbine blades during the finishing step, where a platform runs along the floor while scanning the outer surface of the wind turbine blade. The scan results are displayed in real time on a computer terminal on the platform or on a remote computer station. Information about defects needs to be passed manually or via a handheld computer device to the worker, who then has to manually find and repair these defects before the coating can be applied.

[0091] Other conventional inspection systems utilize a portable handheld scanner tool that scans a small surface area and projects the results onto the surface using color.

[0092] In one embodiment, the location of defects along the length of the mold is visually indicated using light emitting elements of the lighting system that define multiple sections of the composite structure in the length direction and / or the transverse direction.

[0093] The rows of first LEDs and / or second LEDs in the matrix can be used to visually indicate the current location of defects in the entire upper layer and / or indicate the absence of defects. The rows of first LEDs and / or second LEDs in the matrix can also be used to visually indicate the historical data of defects in one or more layers and / or indicate the absence of defects. The LEDs can be positioned on the mold or on a separate frame or support structure positioned relative to the mold. This enables workers to visually view the location and / or historical data of defects in the upper layer during layup or during post-curing.

[0094] The LEDs can be positioned on existing mouldings and assembled to the required length in a quick and easy manner, enabling fast and simple installation.

[0095] In one embodiment, the location of the defect on the top surface of the upper layer is visually indicated using at least one light projection device of the illumination system, which projects at least one light pattern onto the top surface of the upper layer.

[0096] The location of the defect can also be indicated visually on the top surface by emitting light patterns from the light projection devices. Each light projection device can emit one or more light patterns onto the top surface within the projected area, thereby enabling a worker to visually locate multiple defects in the upper layer. Preferably, the projected combined area of ​​the light projection devices can correspond to at least the entire top surface of the composite material structure.

[0097] The light pattern may be a borderline around the defect, a local width and local length of the defect and / or a surface area of ​​the defect. Other light patterns may also be used. The emitted light pattern may be corrected for the angle between the light projection device and the top surface.

[0098] If light projection devices are already installed above the work area, these can be used to visually indicate the location of defects. The present light controller can then be implemented into or communicate with existing light controllers. This enables defects as well as the ply pattern to be shown visually on the top surface.

[0099] In one embodiment, the data is analyzed in real time by a processor and / or the location of the defect is visually indicated in real time by a lighting system.

[0100] The data from the measuring device can be transmitted to the processor and processed in real time. The raw data of the measuring device can also be optionally stored in a database. The processor can determine the parameters of the surface topography in real time and further identify defects in at least the upper layer in real time. The location data of the defect, the type of defect, the severity of the defect and other historical data can be continuously stored in the database. This enables the identification of defects in real time.

[0101] The location data, historical data and other data of the defect can be transmitted to the lighting system, wherein the lighting device visually indicates the location of the defect and optionally other data in real time. This enables workers to quickly isolate and begin repairing the defect in at least the upper layer of the composite structure. This saves time in the production process because corrective measures can be performed during dry layup.

[0102] In one embodiment, defects are graded by a processor according to one or more predetermined conditions, wherein each graded level is associated with a different color group and / or with a different rhythm frequency.

[0103] The processor may evaluate the measured surface topography parameters to provide detailed information about the identified defects. Defects may be classified according to predetermined grading criteria, such as the height, width and / or length of the defect, the type of defect, the severity of the defect, or other criteria. Each grading level may be associated with a set of colors, rhythm frequencies, and / or intensities of the emitted light. This enables detailed information about the defect to be visually indicated to the worker through the emitted light and / or light pattern.

[0104] This detailed information enables workers to more efficiently perform corrective actions on each defect, since the need for manual assessment of each defect is reduced.

[0105] In one embodiment, the composite structure extends in a length direction from a first end to a second end and further in a width direction from a first edge to a second edge, wherein a scan is performed on the top surface as the measuring device moves along the length direction, wherein the scan is further performed over at least a portion of the width of the composite structure and / or over at least a portion of the length of the composite structure.

[0106] The scan may be performed along only a portion of the total surface area, preferably along the surface area of ​​the planned arrangement of the next fiber layer of the upper layer or along a critical portion of the surface area. The scan may also be performed over another surface area of ​​interest. The measuring device may be run two or more times to scan the entire surface area of ​​the selected layer of the composite structure. Alternatively, the entire surface area of ​​the selected layer of the composite structure may be performed in a single run. The historical data may be updated after each run or continuously updated. This enables flexible scanning of the top surface.

[0107] The orientation of the measurement device in the length direction and / or the lateral direction may be adjusted to orient the measurement device correctly relative to the top surface during scanning. The adjustment may be performed manually or automatically.

[0108] In one embodiment, the scanning of the top surface is performed while at least one layer of fiber material is laid on the upper layer.

[0109] The scanning of the top surface and the laying up of the fiber layers can be performed simultaneously in a combined step. The measuring device can scan the previous upper layer just before the laying up, or the measuring device can scan the next upper layer after the laying up, depending on the location of the measuring device. This reduces the total number of production steps.

[0110] Arranging the composite structure layer on the molding surface comprises laying a plurality of fiber material layers on the molding surface of the mold, wherein the layers together form the composite structure of the wind turbine blade. The fiber material layers may form an inner skin, an outer skin and / or a laminate of the composite structure layer. This enables scanning to be performed during dry layup of the respective layers forming the composite structure. Thereby improving the quality of the layup and reducing the overall number of defects occurring in the composite structure after curing.

[0111] In one embodiment, a scan of the top surface is performed after laying down at least one layer of fiber material on the upper layer, and optionally before laying down at least one further layer of fiber material.

[0112] Arranging the composite structure layers on the molding surface also includes laying up all the composite structure layers, infusing the layers with a resin matrix material, and curing the infused layers to form a cured structure. This enables scanning of the cured composite structure to be performed during a post-curing process.

[0113] This can be achieved while the cured composite structure is still in the mould or after it has been moved to a finishing area. This also enables the same inspection system to be used during layup and after curing, increasing the flexibility of the system and reducing costs.

[0114] In one embodiment, the method further comprises the step of inputting at least one feedback signal to the processor, preferably via a graphical user interface, the feedback signal indicating that at least one predetermined action has been performed with respect to the selected defect.

[0115] As previously described, the worker may input electronic feedback signals into the system using a handheld device or mobile device. The user interface of the handheld device or mobile device may be configured to allow for quick and convenient input of feedback signals. The feedback signal may be a false detection signal, a corrective action completion signal, a continue monitoring signal, or another feedback signal. This enables quick and convenient input of feedback signals.

[0116] Workers can also input feedback signals using a reflective feedback device with an integrated unique code. Feedback signals can be input by simply positioning the reflective device relative to the specified defect within the illumination area of ​​the light projection device. The processor can then read the reflected code and store the feedback signal along with detailed information about the defect.

[0117] The worker can also input feedback signals through the smart glasses, which can be transmitted back to the processor. Voice commands or push buttons can be used to input feedback signals to the smart glasses. Optionally, the smart glasses can be configured to scan the top surface and detect the light pattern projected onto the upper layer. The light pattern can be a unique code (barcode or QR code (Quick Response Code)) and / or the location of the defect.

[0118] This enables a hands-free workflow during production.

[0119] In one embodiment, after each scan, historical data relating to defects in a particular layer of the composite structure is stored in a database, and preferably, feedback signals input to the processor are further stored in the database.

[0120] Data from the measuring device may be stored in a database, and data relating to defects in the layer may also be stored in the database, which data may be updated for each run of the measuring device. Any feedback signals may also be stored in the database.

[0121] Detailed information about the corrective actions may further be stored in a database. The detailed information may be accessed through a handheld device or a mobile device or smart glasses.

[0122] In one embodiment, historical data relating to defects in at least a previous layer are transmitted by a processor to the lighting system, wherein the lighting device visually indicates the historical data, preferably together with current data relating to defects in the upper layer.

[0123] The historical data may be visually shown in a first-in-first-out (FIFO) order, preferably updated after each run of the measuring device. Alternatively, the historical data may be visually shown on demand. Alternatively, the historical data may be visually shown by switching between different historical data after a predetermined period of time. This enables the historical data of interest to be visually indicated to the worker.

[0124] The historical data and / or detailed information can further be displayed in real time or near real time in the user interface. This enables the results of data processing to be displayed to workers quickly and conveniently. BRIEF DESCRIPTION OF THE DRAWINGS

[0125] The present invention is described by way of example only and with reference to the accompanying drawings, in which:

[0126] Figure 1 shows an exemplary embodiment of a wind turbine,

[0127] Figure 2 shows an exemplary embodiment of a wind turbine blade,

[0128] Figure 3 A first embodiment of a system for manufacturing a composite material structure for a wind turbine blade is shown,

[0129] Figure 4 Showing the mold and the prior art trolley with double layup tool,

[0130] Figure 5 An exemplary embodiment of a trolley with a double-ply tool according to the invention is shown,

[0131] Figure 6 An exemplary embodiment showing a light beam projected onto a top surface,

[0132] Figure 7 a and Figure 7 b shows two alternative configurations of the measuring device on the support structure,

[0133] Figure 8 Shows the sled moving along the molding surface while visually indicating defects in real time,

[0134] Fig. 9 shows a matrix of light emitting elements arranged on a die,

[0135] Fig.10 shows a matrix of light emitting elements arranged on a separate support structure, and

[0136] Fig.11 A feedback device is shown interacting with the projected light pattern on the top surface of the upper layer.

[0137] In the following, each of the drawings will be described one by one, and different parts and positions seen in the drawings will be numbered with the same numbers in different drawings. It is not necessary to identify all parts and positions shown in a particular drawing with that drawing. Figure 1 Start discussing. DETAILED DESCRIPTION

[0138] Figure 1An exemplary embodiment of a wind turbine 1 is shown, comprising a wind turbine tower 2, a nacelle 3 arranged on top of the wind turbine tower 2 and a rotor connected to a drive train in the nacelle 3. The rotor comprises a hub 4 and at least one wind turbine blade 5 connected to the hub 4. Here, three wind turbine blades 5 are shown, but the hub may be connected to more or fewer wind turbine blades.

[0139] The wind turbine 1 is shown here as an onshore wind turbine, but the wind turbine 1 may also be an offshore wind turbine 1. The wind turbine blade may be a continuous wind turbine blade or a modular wind turbine blade.

[0140] Figure 2 A blade shell 6 of a wind turbine blade 5 is shown, wherein the blade shell 6 forms a pressure side 9 and a suction side 8. The blade shell 6 extends in a length direction between a first end 10 (e.g. a root end) and a second end 11 (e.g. a tip end), as shown in FIG. Figure 1 The blade shell 6 further extends between a first edge 12 (eg, a leading edge) and a second edge 13 (eg, a trailing edge) in the chord direction. Figure 2 shown.

[0141] The spar caps 14 are bonded or incorporated into the blade shell portion forming the pressure side 9. Furthermore, another spar cap 14 is bonded or incorporated into the blade shell portion forming the suction side 8. One or both spar caps 14 may be formed as a single, continuous spar cap or as a split spar cap. The split spar caps may optionally be connected at or near the second end 11.

[0142] The shear web 7 extends in the thickness direction between the spar caps 14. The shear web 7 is bonded or incorporated into the spar caps 14 at respective web joints. The shear web 7 may be formed as a single shear web or a double shear web. The double shear web may be spaced apart in the chord direction.

[0143] Optionally, one or more reinforcing webs 15 are further arranged within the blade shell 6. The reinforcing webs 15 are positioned at a distance from the first edge 12 and / or the second edge 13. The reinforcing webs 15 are bonded or incorporated into the blade shell parts forming the pressure side 9 and / or the suction side 8.

[0144] Figure 3A first embodiment of a system for manufacturing a composite material structure of a wind turbine blade 5 is shown. The system comprises a mould 16 having a moulding surface shaped to form a profile of a composite material structure 17. The composite material structure 17 extends in a length direction 20 of the moulding surface between a first end 18 and a second end 19. The composite material structure 17 extends in a width direction 23 of the moulding surface between a first edge 21 and a second edge 22.

[0145] A movable support structure 24 is arranged relative to the mold 16, wherein the support structure 24 is configured to move in at least one direction 20, 23 relative to the mold 16. At least one measuring device 25 is arranged on the support structure 24, wherein the measuring device 25 is configured to scan at least an upper layer of the composite material structure 17 and to measure surface topography data related to a top surface of at least the upper layer.

[0146] The processor 26 is connected to the measuring device 25 via a communication link. The processor 26 is configured to analyze the data input from the measuring device 25 and determine whether there is a defect 27 in at least the upper layer. The processor 26 is further configured to determine at least the location of the defect. Preferably, the processor 26 is configured to determine the location, severity and / or type of the defect 27. The historical data and other data related to the defect 27 are optionally stored in a database 31, which is connected to the processor 26 via a communication link.

[0147] The lighting system 28 is connected to the processor 26 via a communication link. The lighting system 28 includes a plurality of lighting devices 29, each of which is positioned relative to the mold 16. The location of at least the defect 27 is transmitted from the processor 26 to the lighting system 28, such as to the light controller 30. The lighting devices 29 are configured to visually indicate the location of at least the defect 27 on or relative to the upper layer.

[0148] Optionally, the system includes a layup tool 32 that is configured to be directly or indirectly connected to a crane system (not shown) positioned relative to the mold 16. The layup tool 32 includes a roll of fiber material 33 and is configured to apply a fiber layer to the molding surface or upper layer. The applied fiber layer forms part of a laminate or sandwich structure of the composite structure 17 in a height direction 34. The crane system is configured to move the layup tool 32 relative to the mold 16 in at least one direction 20, 23.

[0149] Here, the support structure 24 is shaped as a beam configured to be connected to a crane system. The crane system is configured to further move the beam in at least one direction 20, 23 relative to the mold 16. Preferably, the crane system is configured to enable the beam and the layup tool 32 to be moved independently.

[0150] The layup tool 32 and the support structure 24 may optionally be joined together to form a combined structure. Thus, the measuring device 25 moves following the layup tool 32 .

[0151] Figure 4 The mold 16 and a prior art trolley 35 having a dual layup tool are shown, wherein the trolley 35 is arranged on a pair of tracks 36 extending along the mold 16. The trolley 35 is thus movable along the length of the molding surface 37. A first layup tool having a first roll of fiber material 33 is used to apply fiber layers in one length direction. A second layup tool having a second roll of fiber material 33 is used to apply fiber layers in the opposite length direction.

[0152] Figure 5 An exemplary embodiment of a trolley 35' having a dual layup tool according to the present invention is shown. The trolley 35' includes a position sensor (not shown) connected to the processor 26. The processor 26 determines the position of the trolley 35' based on data input from the position sensor.

[0153] The first measuring device 25a is arranged at one end of the trolley relative to the first layup tool. The second measuring device 25b is arranged at the opposite end of the trolley relative to the second layup tool. Here, the first measuring device 25a and the second measuring device 25b are configured as optical metrology devices. For the skilled person, the configuration of the optical metrology device is known and will not be described in detail.

[0154] Figure 6 An exemplary embodiment of a beam 38 projected onto the top surface of an upper layer is shown. Here, the optical metrology device projects a beam, for example, a laser beam, which can be detected by a camera located in the optical metrology device. The beam 38 extends along the entire width of the composite structure 17.

[0155] Figure 7 a and Figure 7 b shows two alternative configurations of the measuring device 25 on the support structure 24. Figure 7 As shown in FIG. 1 , a single measuring device 25' is positioned on a support structure 24. The measuring device 25' is configured to scan a portion of the upper layer in the width direction 23. The measuring device 25' is connected to the support structure at an adjustable position. For example, the measuring device 25' can be moved along the support structure 24 in the width direction 23 to adjust the position of the measuring device 25' relative to the mold 16. For example, the measuring device 25' can be rotated around the local length axis to adjust the orientation of the measuring device 25' relative to the mold 16.

[0156] Two measuring devices 25" are positioned on the support structure 24, such as Figure 7b. Each measuring device 25" is configured to scan a portion of the upper layer in the width direction 23. The data of the measuring devices 25" are superimposed in the processor to form a set of combined data.

[0157] Figure 8 The sled 35' is shown moving along the molding surface 37 while the defects 27 are visible in real time. The processor 26 processes the data input from the measuring device 25 in real time and grades the defects 27, 27' according to predetermined conditions. The light emitting element 29b is used to visually indicate the location of the defects 27, 27' and the location of the non-defect 40.

[0158] A first light having a selected color, intensity and / or frequency may be used to visually indicate a critical defect 27. A second light having a selected color, intensity and / or frequency may be used to visually indicate a less critical defect, i.e., defect 27'. Optionally, a third light having a selected color, intensity and / or frequency may be used to visually indicate a non-defect 40. A non-defect 40 may also be visually indicated by turning off the light.

[0159] Fig. 9 A matrix of light emitting elements 29b is shown arranged on the mold 16. The matrix of light emitting elements 29b arranged in columns and rows is arranged on the side of the mold 16. Optionally, another matrix of light emitting elements 29b arranged in columns and rows is arranged on the top surface of the mold 16.

[0160] The matrix of light emitting elements 29b is used to visually indicate the history of defects 27 in the composite structure 17. The matrix of light emitting elements 29b is optionally also used to visually indicate the chordwise location of the defect 27.

[0161] Fig.10 A matrix of light emitting elements 29b is shown, wherein each light emitting element 29b defines a section of the composite material structure 17 in the length and width directions 20, 23. The matrix of light emitting elements 29b may optionally be arranged on a separate frame structure positioned relative to the mould 16.

[0162] The number of individual rows and individual columns is adapted to the geometrical dimensions of the composite structure 17. Here, the first row of light emitting elements 29b indicates the trailing edge region. The second row of light emitting elements 29b indicates the intermediate region between the trailing edge region and the spar cap region. The third row of light emitting elements 29b indicates the spar cap region. The fourth row of light emitting elements 29b indicates the intermediate region between the spar cap region and the leading edge region. The fifth row of light emitting elements 29b indicates the leading edge region.

[0163] Fig.11A feedback device 43 is shown interacting with the projected light pattern on the top surface of the upper layer. The light projection device 29a projects a light pattern indicating the location of the defect 27 onto the upper layer of the composite structure 17. The light projection device 29a optionally further projects a unique code 41 associated with the defect 27. The unique code 41 is associated with detailed information about the defect 27 stored in the database 31.

[0164] The feedback device 43 may be a handheld communication device such as a smart phone or smart glasses configured to scan the unique code 41 and display to the user detailed information stored in the database 31. The handheld communication device is connected to the processor 26 via a communication link.

[0165] The feedback device 43 may be a reflective device having a unique code incorporated into the reflective pattern. The reflective device is positioned within the illustrated area 42 of the light projection device 29a. The light projection device 29a is configured to detect a reflected signal of the reflective device, wherein the processor 26 reads the unique code and executes an instruction associated with the unique code. For example, the instruction may be to store the feedback signal together with data related to the defect 27.

Claims

1. A system for manufacturing a wind turbine blade (5), the system comprising: a mould (16) having a moulding surface (37) shaped to form a contour of a composite material structure (17) of the wind turbine blade (5); a movable support structure (24) disposed relative to the mold (16) and configured to move in at least one direction relative to the mold (16); at least one measuring device (25) arranged on the support structure (24) and configured to scan at least an upper layer of the composite material structure (17) and to measure topographic data related to at least the upper layer; and a processor (26) connected to the at least one measuring device (25) and configured to analyze data input from the at least one measuring device (25) and to determine whether a defect (27) exists in at least the upper layer, and the processor (26) is further configured to determine at least the location of the defect (27); Characterized in that a lighting system (28) is also connected to the processor (26) and positioned relative to the mold (16), wherein at least the position of the defect (27) is transmitted to the lighting system (28), and the lighting system (28) includes at least one lighting device (29), which is configured to visually indicate at least the position of the defect (27) on the upper layer or relative to the upper layer.

2. The system according to claim 1, characterized in that The lighting device (29) is shaped to be arranged in at least one row of light emitting elements (29b) positioned on or relative to the mold (16), each row of light emitting elements (29b) extending along at least a length of the molding surface (37).

3. The system according to claim 2, characterized in that The light emitting elements (29b) are grouped into at least one matrix arranged on or positioned relative to the mold (16), each matrix of the light emitting elements (29b) defining a plurality of sections of the composite material structure (17) in the longitudinal direction and / or in the transverse direction.

4. The system according to any one of claims 1 to 3, characterized in that The lighting device (29) is shaped as at least one light projection device (29a) positioned above the mold (16), the light projection device (29a) being configured to project at least one light beam onto a top surface of the upper layer.

5. The system according to any one of claims 1 to 4, characterized in that The processor (26) is connected to at least one database (31), which is configured to store at least historical data related to the defects (27) in the layers of the composite material structure (17), wherein the processor (26) is further configured to process data input from the at least one measuring device (25) in real time and to continuously update the position data of at least the defects (27) in the upper layer.

6. The system according to any one of claims 1 to 5, characterized in that The at least one measuring device (25) is configured to continuously measure data related to surface topography while the support structure (24) moves along the molding surface (37) in at least one direction.

7. The system according to any one of claims 1 to 6, characterized in that The at least one lighting device (29) is configured to visually indicate locations where the defects (27) are identified using at least one set of colors and optionally further to visually indicate locations without defects (40) using at least one other set of colors.

8. The system according to any one of claims 1 to 7, characterized in that The at least one lighting device (29) is configured to visually indicate the location of the identified defect (27) and / or the location of the non-defect (40) by emitting continuous light, alternating light and / or rhythmic light having at least one light cycle and at least one dark cycle.

9. The system according to any one of claims 1 to 8, characterized in that The processor (26) is configured to identify the type of the defect (27) and / or the severity of the defect (27). Preferably, the processor (26) is further configured to grade the type of the defect (27) and / or the severity of the defect (27) according to one or more predetermined conditions.

10. The system according to any one of claims 1 to 9, characterized in that The system further comprises at least one layup tool (32) configured to move in at least one direction relative to the mold (16), the layup tool (32) being configured to apply at least one layer of fiber material (33) to the molding surface (37) or the upper layer.

11. The system according to claim 10, characterized in that The support structure (24) forms part of the layup tool (32), wherein the measuring device (25) is connected to the layup tool (32) so that it moves following the layup tool (32).

12. The system according to claim 10, characterized in that The support structure (24) is shaped as a beam or a frame, and the beam or the frame is constructed to be connected to a crane system, a pulley or a guide vehicle system, and the crane system, the pulley or the guide vehicle system is configured to move the beam or the frame in at least one direction relative to the mold (16). Preferably, the crane system, the pulley or the guide vehicle system is configured to move the beam or the frame independently relative to the layup tool (32).

13. The system according to any one of claims 1 to 12, characterized in that A single measuring device (25) or at least two measuring devices (25) are arranged on the support structure (24) in the lateral direction, wherein the position and / or direction of the measuring device on the support structure (24) is fixed or adjustable.

14. The system according to any one of claims 1 to 13, characterized in that The system further comprises at least one feedback device (43) configured to input a feedback signal to the processor (26), wherein the feedback device (43) is configured to communicate with the processor (26) directly or through the measurement device (25) or the lighting system (28).

15. The system according to any one of claims 1 to 14, characterized in that The composite material structure (17) is a spar cap (14), a shear web (7), a trailing edge reinforcement (15), a leading edge reinforcement (15), a blade shell portion or a blade root portion.

16. A method of manufacturing a wind turbine blade (5), the method comprising: Arranging a layer of a composite material structure (17) of the wind turbine blade (5) on a molding surface (37) of a mold (16), the composite material structure (17) having a laminated structure or a sandwich structure; scanning at least an upper layer of the composite structure (17) using at least one measuring device (25) and transmitting topographic data related to at least a top surface of the upper layer to a processor (26); analyzing data input from the measuring device (25) in the processor (26), wherein the processor (26) determines whether a defect (27) exists in at least the upper layer, and further determines at least the location of the defect (27); At least the position of the defect (27) is transmitted to a lighting system (28), wherein the lighting system (28) is used to visually indicate at least the position of the defect (27) on or relative to the upper layer.

17. The method according to claim 16, characterized in that The location of the defect (27) along the length of the mold (16) is visually indicated using light-emitting elements (29b) of the lighting system (28), the light-emitting elements (29b) defining multiple sections of the composite structure (17) in the longitudinal direction and / or the transverse direction.

18. The method according to claim 16 or 17, characterized in that The location of the defect (27) on the top surface of the upper layer is visually indicated using at least one light projection device (29a) of the illumination system (28), the light projection device (29a) projecting at least one light pattern onto the top surface of the upper layer.

19. The method according to any one of claims 16 to 18, characterized in that The data is analyzed in real time by the processor (26) and / or the location of the defect (27) is visually indicated in real time by the lighting system (28).

20. The method according to any one of claims 16 to 19, characterized in that The defects (27) are graded by the processor (26) according to one or more predetermined conditions, wherein each grade is associated with a different color group and / or with a different rhythm frequency.

21. The method according to any one of claims 16 to 20, characterized in that The composite structure (17) extends in a length direction from a first end to a second end and further in a width direction from a first edge to a second edge, wherein, when the measuring device (25) moves in the length direction, a scan is performed on the top surface, wherein the scan is performed over at least a portion of the width of the composite structure (17) and / or over at least a portion of the length of the composite structure (17).

22. The method according to any one of claims 16 to 21, characterized in that The scanning of the top surface is performed while at least one layer of fiber material (33) is laid on the upper layer.

23. The method according to any one of claims 16 to 22, characterized in that After laying down at least one layer of fiber material (33) on the upper layer, and optionally before laying down at least one further layer of fiber material (33), a scan of the top surface is performed.

24. The method according to any one of claims 16 to 23, characterized in that The method further comprises the step of inputting at least one feedback signal to the processor (26), preferably via a graphical user interface, the feedback signal indicating that at least one predetermined action has been performed in response to the selected defect.

25. The method according to any one of claims 16 to 24, characterized in that After each scan, historical data relating to the defect (27) in a particular layer of the composite structure (17) is stored in a database and preferably, a feedback signal input to the processor (26) is further stored in the database.

26. The method according to claim 25, characterized in that The historical data relating to the defect (27) in at least a previous layer is transmitted by the processor (26) to the lighting system (28), wherein the lighting device (29) visually indicates the historical data, preferably together with current data relating to the defect (27) in the upper layer.

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