Robotic applicator device and method for applying a protection to the leading edge of a wind
By designing an automated robot applicator device, the problem of time-consuming and poor quality of the leading edge protective parts manually applied by wind turbine blades is solved, and fast, simple and efficient application of protective parts is achieved, improving the life and adhesion quality of the blades.
Patent Information
- Application Number
- CN202380072968.2
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Priority Date
- 2022-09-28
- Filing Date
- 2023-09-28
- Publication Date
- 2025-05-27
AI Technical Summary
The prior art manually applying the leading edge protector during wind turbine blade manufacturing process is time-consuming and difficult to ensure rapid curing of the adhesive, resulting in voids and damage.
A robotic applicator device is designed, including a main frame, a driver and a plurality of stations (distribution station, adhesive station, application station and curing station), applying protective members to the leading edge of the blade through automated steps, and heating the curing adhesive at the curing station.
The rapid, simple and efficient application of the leading edge protective parts of the wind turbine blade is achieved, reducing the needs of equipment and technicians, and improving the adhesion quality of the protective parts and the life of the blades.
Smart Images
Figure CN120051631A_ABST
Abstract
Description
Technical Field
[0001] The present invention generally relates to wind turbines, and more particularly to robotic applicator devices and methods for applying a protective member to a leading edge of a wind turbine blade. Background Art
[0002] Wind turbines are used to generate electrical energy using renewable resources without burning fossil fuels. Generally, wind turbines convert kinetic energy from the wind into electrical power. Conventional wind turbine equipment includes a base, a tower supported by the base, and an energy generation unit positioned on top of the tower. The energy generation unit typically includes one or more nacelles to house several mechanical and electrical components, such as a generator, a gearbox, and a main bearing, and the wind turbine also includes a rotor that is operably coupled to the components in the nacelle via a main shaft extending from the nacelle. Single-rotor wind turbines and multi-rotor wind turbines (which may have multiple nacelles) are known, but for the sake of efficiency, the following description mainly relates to single-rotor designs. The rotor in turn includes a central hub and a plurality of blades radially extending therefrom, and is configured to interact with the wind to cause rotation of the rotor. The rotor is supported on the main shaft, which is directly or indirectly operably coupled to a generator housed inside the nacelle. Thus, when the wind forces the blades to rotate, electrical energy is generated by the generator. Over the past few decades, wind power has grown significantly as many wind turbine installations are located on land and at sea.
[0003] As described above, the blades interact with the wind to produce mechanical rotation of the rotor, which can then be converted into electrical energy. Wind turbine blades are complex structures that must be constructed to withstand long-term service in abusive environments while also maximizing lift and minimizing drag. The blades move through the surrounding environment around the wind turbine at varying speeds, but this movement is typically at high speeds. Thus, due to friction from the air and potential impacts from rain, particulate matter, debris, or other items in the air, especially along the leading edge configured to face the direction of movement of the passing wind, the blades typically experience erosion and damage over time during operation. Erosion or damage along the leading edge of the blades adversely affects the aerodynamic quality of the blades over time, resulting in lower power for a given incoming wind speed. Such erosion and damage on the blades can be corrected through routine maintenance and repair procedures.
[0004] One way to minimize erosion and damage to the leading edge of a blade is to apply a leading edge protection piece during blade manufacturing. The leading edge protection piece can be applied manually, but this method is time-consuming and may cause voids, such as air bubbles, between the leading edge protection piece and the leading edge. Additionally, because the leading edge protection piece can be long and flexible and the adhesive has a long curing time, it may be difficult to hold the leading edge protection piece in its desired position along the leading edge while the adhesive cures. Further, because the leading edge protection piece is applied manually, it may not be possible to use a faster-curing adhesive because the technician cannot work quickly enough to apply such a fast-curing adhesive to the leading edge protection piece. Additionally, it is difficult for a technician to apply both the adhesive and pressure to the leading edge protection piece simultaneously.
[0005] In view of the above, there is a need for a device and method for applying a leading edge protection piece during the manufacture of a wind turbine blade that is simple, fast, and requires minimal equipment and few technicians. Summary of the Invention
[0006] For these and other purposes, in one aspect of the present invention, a robotic applicator device for applying a protection piece to the leading edge of a wind turbine blade is disclosed. The device includes a main frame, a drive operably coupled to the main frame and configured to move the main frame relative to the wind turbine blade, and a plurality of stations carried by the main frame for applying the protection piece to the leading edge of the wind turbine blade. The plurality of stations include: a dispensing station configured to hold and dispense a material forming the leading edge protection piece; an adhesive station configured to apply an adhesive to the adhesive surface of the dispensed protection piece material and / or the leading edge of the wind turbine blade; an application station configured to place the adhesive surface of the leading edge protection piece onto the leading edge of the wind turbine blade; and a curing station configured to cure the adhesive to bond the leading edge protection piece to the leading edge of the wind turbine blade.
[0007] In one embodiment, the plurality of stations further includes a cleaning station configured to clean the dispensed protection piece material.
[0008] In one embodiment, the dispensing station includes a conversion module, wherein the leading edge protection piece is stored in the dispensing station in a coiled configuration, and wherein the conversion module is configured to convert the leading edge protection piece from the coiled configuration to a straightened configuration.
[0009] In one embodiment, the application station includes a pressure module configured to apply pressure to the leading edge protection piece after the leading edge protection piece has been placed onto the leading edge of the wind turbine blade.
[0010] In one embodiment, the curing station includes a heating module configured to heat the adhesive applied to the adhesive surface of the leading edge protection piece and / or the leading edge of the wind turbine blade to cure the adhesive.
[0011] In one embodiment, the plurality of stations further includes a sensing station configured to determine the topographic profile of at least a portion of the leading edge of a wind turbine blade. The sensing station may be operatively coupled to the applying station, and the applying station may include a shaping module configured to conform the surface of the dispensed protective member to the topographic profile of at least a portion of the leading edge detected by the sensing station.
[0012] In one embodiment, the dispensing station is configured to dispense a preformed leading edge protective member.
[0013] In one embodiment, the actuator is supported by the wind turbine blade and is movable along the wind turbine blade. In one embodiment, the actuator is supported by a support surface disposed adjacent to the wind turbine blade and is movable along the support surface.
[0014] In one embodiment, the main frame includes an upper frame panel having opposing first and second edges, a first side frame panel coupled to the first edge, and a second side frame panel coupled to the second edge. The main frame panel and the first and second side panels generally define a U-shaped cavity configured to receive at least a portion of the wind turbine blade therein.
[0015] In another aspect of the present invention, a method for applying a protective member to the leading edge of a wind turbine blade is disclosed. The method includes providing a robotic applicator device including a main frame and a dispensing station, a bonding station, an applying station, and a curing station, each station being carried by the main frame. The method further includes moving the robotic applicator device along the leading edge of the wind turbine blade, dispensing at the dispensing station a material forming the leading edge protective member, applying at the bonding station an adhesive to the bonding surface of the dispensed protective member material and / or the leading edge of the wind turbine blade, placing at the applying station the bonding surface of the leading edge protective member onto the leading edge of the wind turbine blade, and curing at the curing station the adhesive to bond the leading edge protective member to the leading edge of the wind turbine blade.
[0016] In one embodiment, the main frame further carries a cleaning station, and the method further includes cleaning at the cleaning station the bonding surface of the dispensed protective member material and then applying an adhesive thereto.
[0017] In one embodiment, the dispensing station includes a conversion module, the leading edge protective member is stored in the dispensing station in a coiled configuration, and the method further includes converting at the conversion module the leading edge protective member from the coiled configuration to a straightened configuration.
[0018] In one embodiment, the application station includes a pressure module, and the method further includes applying pressure to the leading edge protection at the pressure module after the leading edge protection has been placed on the leading edge of the wind turbine blade.
[0019] In one embodiment, the step of curing the adhesive includes heating the adhesive.
[0020] In one embodiment, the main frame further carries a sensing station operatively coupled to the application station. The application station further includes a shaping module, and the method further includes determining the topography profile of at least a portion of the leading edge of the wind turbine blade at the sensing station and conforming the surface of the dispensed leading edge protection to the topography profile of at least said portion of the leading edge at the shaping module.
[0021] In one embodiment, the method further includes: supporting the robotic applicator device on the wind turbine blade as the robotic applicator device moves along the leading edge of the wind turbine blade. In an alternative embodiment, the method further includes: supporting the robotic applicator device on a support surface disposed adjacent to the wind turbine blade as the robotic applicator device moves along the leading edge of the wind turbine blade. BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The drawings incorporated in and forming a part of this specification illustrate one or more embodiments of the invention and, together with the general description of the invention given above and the detailed description given below, serve to explain the invention.
[0023] Figure 1 is a perspective view of a wind turbine having a tower and an energy generation unit.
[0024] Figure 2 is a front view of an exemplary wind turbine blade.
[0025] Figure 3 is a schematic front view of a robotic applicator device according to one embodiment of the invention.
[0026] Figure 4 is a cross-sectional view of a wind turbine blade having a leading edge protection applied thereto.
[0027] Figure 5A shows Figure 3 a schematic view of the robotic applicator device supported by the wind turbine blade.
[0028] Figure 5B shows Figure 3 a schematic view of the robotic applicator device supported by a support surface disposed adjacent to the wind turbine blade.
[0029] Figure 6A flowchart showing the steps of a method for applying a protective member to the leading edge of a wind turbine blade according to an embodiment of the present invention.
[0030] Figure 7 A schematic diagram showing the various steps of applying a protective member to the leading edge of a wind turbine blade using a Figure 3 robot applicator device. DETAILED DESCRIPTION
[0031] Referring to Figure 1 , the wind turbine 10 includes a tower 12, a nacelle 14 disposed at the apex of the tower 12, and a rotor 16 operatively coupled to a generator (not shown) via a gearbox (not shown) housed inside the nacelle 14. In addition to the generator and the gearbox, the nacelle 14 can house various components required to convert wind energy into electrical energy and to operate and optimize the performance of the wind turbine 10. The tower 12 supports the loads presented by the nacelle 14, the rotor 16, and other wind turbine components housed inside the nacelle 14, and is operative to raise the nacelle 14 and the rotor 16 to a height above the ground plane or sea level, as may be the case where airflows with lower turbulence and higher speeds are typically found.
[0032] The rotor 16 can include a central hub 18 and a plurality of wind turbine blades 20 attached to the central hub 18 at positions distributed around the circumference of the central hub 18. In a representative embodiment, the rotor 16 includes three blades 20, although the number can vary. The blades 20 projecting radially outward from the central hub 18 are configured to interact with the passing airflow to generate a rotational force that causes the central hub 18 to rotate about its longitudinal axis. The design, construction, and operation of the blades 20 are familiar to those of ordinary skill in the art of wind turbine design and can include additional functional aspects to optimize performance. For example, pitch angle control of the blades 20 can be implemented by a pitch control mechanism (not shown) responsive to wind speed to optimize power production under low wind conditions and to feather the blades if the wind speed exceeds the design limit.
[0033] The rotor 16 can be directly or indirectly coupled to the gearbox via a main shaft (not shown) extending between the central hub 18 and the gearbox. The main shaft rotates with the rotor 16 and is supported within the nacelle 14 by a main bearing support (not shown), which supports the weight of the rotor 16 and transfers the loads on the rotor 16 to the tower 12. The gearbox transfers the rotation of the rotor 16 to the generator via a coupling. Wind above a minimum level can activate the rotor 16, causing the rotor 16 to rotate in a direction substantially perpendicular to the wind, thereby applying torque to the input shaft of the generator. As will be understood by those of ordinary skill in the art, the electricity generated by the generator can be supplied to a power grid (not shown), or to an energy storage system (not shown) for later release to the power grid. In this way, the wind turbine 10 can utilize the kinetic energy of the wind to generate electricity.
[0034] Reference Figure 2 , the blade 20 includes a root end 26, a tip end 28, a leading edge 30, and a trailing edge 32. The blade 20 defines a spanwise direction (wingspan direction) S extending between the root end 26 and the tip end 28 and a chordwise direction C extending from the leading edge 30 and the trailing edge 32, wherein the spanwise direction S is substantially orthogonal to the chordwise direction C. The leading edge 30 of the blade 20 includes a contoured surface. It will be understood that the contoured surface has a shape that can vary along the leading edge 30 in the spanwise direction.
[0035] The present invention contemplates a robotic applicator device for applying a protective member to the leading edge 30 of a wind turbine blade 20. Figure 3 A robotic applicator device 40 according to an embodiment of the present invention is shown. The robotic applicator device 40 includes a main frame 42 and a drive 44 operatively coupled to the main frame 42. The drive 44 is configured to move the main frame 42 relative to the wind turbine blade 20. To this end, the drive 44 can include a propulsion system, which can include a motor, a gear train, a transmission, and a drive controller. The robotic applicator device 40 further includes a plurality of stations 46, all of which are carried by the main frame 42. As will be explained in further detail below, the plurality of stations 46 cooperate to apply a protective member 48 ( Figure 4)Applied to the leading edge 30 of the wind turbine blade 20. In one embodiment, the plurality of stations 46 may include a dispensing station 50, an adhesion station 52, an application station 54, and a curing station 56. The robotic applicator device 40 can be used to apply the leading edge protection 48 during the manufacture of the wind turbine blade 20. Alternatively, the robotic applicator device 40 can be used during the repair of the leading edge 30 of the wind turbine blade 20. In a repair, the leading edge protection 48 can be applied to a used wind turbine blade 20 for the first time. In other words, before the leading edge protection is applied using the robotic applicator device 40, the leading edge 30 may never have had a leading edge protection. In another repair scenario, the wind turbine blade 20 may have had a leading edge protection that has been damaged or degraded during use. In this case, the old leading edge protection will have to be removed, and then the robotic applicator device 40 can be used to apply another leading edge protection 48 to the leading edge 30 of the wind turbine blade 20.
[0036] The dispensing station 50 is configured to hold and dispense the material 64 that forms the leading edge protection 48 ( Figure 7 ). The material 64 can be a polymeric material, such as a polyether-based polyurethane. The adhesion station 52 is configured to apply an adhesive 66 ( Figure 7 ) to the adhesive surface 68 ( Figure 7 ) of the dispensed protection material 64 and / or to the leading edge 30 of the wind turbine blade 20. To this end, the adhesion station 52 can include various components for applying the adhesive 66, including injectors, applicators, sprayers, brushes, and other types of adhesive dispensers. The adhesion station 52 can also include a holding tank or other storage container for the adhesive 66 and a pump for removing the adhesive 66 from the holding tank. The application station 54 is configured to place the adhesive surface 68 of the leading edge protection 48 onto the leading edge 30 of the wind turbine blade 20. To this end, the application station 54 can include guides, rollers, tracks, chutes, or other positioning mechanisms to assist in placing the adhesive surface 68 in the correct position on the leading edge 30 of the wind turbine blade 20. The curing station 56 is configured to cure the adhesive 66 so as to bond the leading edge protection 48 to the leading edge of the wind turbine blade 20.
[0037] In one embodiment, the plurality of stations 46 may further include a cleaning station 58, which is configured to clean the dispensed protection material 64 before the adhesive 66 is applied to the adhesive surface 68 of the dispensed protection material 64. The cleaning station can include a source of cleaning fluid / reagent / cleaner, a pump, an injector, and a brush or washer, which are configured to clean the adhesive surface 68 before the adhesive 66 is applied.
[0038] In one embodiment, the plurality of stations 46 may further include a sensing station 60, which is configured to determine the topographical profile 62 of at least a portion of the leading edge 30 of the wind turbine blade 20 ( Figure 4)。The sensing station 60 may include a vision system for determining the profile 62. The vision system may include one or more cameras, ultrasonic transducers, or lasers to interrogate the leading edge 30 to determine the profile 62. The vision system may also include a digital processor that uses known algorithms to create a digital representation of the profile 62. The sensing station 60 may be operatively coupled to the application station 54. In this regard, the application station 54 may include a forming module 70 that is configured to conform the adhesive surface 68 ( Figure 4 ) of the dispensed protective member material 64 to at least a portion of the profile 62 of the leading edge 30 detected by the sensing station 60. The forming module 70 may include one or more deformable mandrels or male molds that can be used to conform the adhesive surface 68 to the profile 62. The forming module 70 may also include a heater to heat the adhesive surface 68 to facilitate the construction process. The digital processor may be operatively connected to the forming module 70 such that the digital representation of the profile 62 can be relayed to the forming module 70, and thus, for example, the deformable mandrel can be actively manipulated to match the shape of the profile 62 of the leading edge 30. The process for conforming the adhesive surface 68 to match the profile 62 may be continuous or intermittent.
[0039] In one embodiment, the leading edge protector 48 may be a preformed protector that is stored on a coil or spool in the dispensing station 50 in a coiled configuration. Thus, the dispensing station may include a conversion module 78 that is configured to convert the preformed leading edge protector 48 from the coiled configuration to a straightened configuration. Due to being stored in a coiled configuration, the coiled preformed leading edge protector 48 may exhibit a bent / arcuate set. In other words, for example, when the coiled leading edge protector 48 rolls off the storage spool, the leading edge protector 48 may still have a noticeable bend similar to the way it was bent in the coiled configuration. The conversion module 78 helps to eliminate or greatly minimize the bent / arcuate set such that the leading edge protector 48 is in a substantially straightened state after it is dispensed and before it is placed on the leading edge 30 of the wind turbine blade 20. To this end, the conversion module 78 may include rollers, presses, plates, or heaters to help minimize the bent / arcuate set. In another embodiment, the leading edge protector 48 may be stored in the robotic applicator device 40 as a preformed leading edge protector 48 in a linear form (such as in the form of a strip of a predetermined length), such that the conversion module 78 is not required.
[0040] In one embodiment, the dispensing station 50 may include a pressure module 80 configured to apply pressure to the leading edge protection member 48 after the leading edge protection member 48 has been placed on the leading edge 30 of the wind turbine blade 20. The pressure module 80 facilitates bonding the adhesive surface 68 of the leading edge protection member 48 to the leading edge 30 of the wind turbine blade 20 with an adhesive 66. The pressure module 80 helps to eliminate or minimize voids or air bubbles between the adhesive surface 68 of the leading edge protection member 48 and the leading edge 30 of the wind turbine blade 20. To this end, the pressure module 80 may include a roller, a pad, an inflatable bladder, a pressure plate, or other suitable means for applying pressure to the leading edge protection member 48.
[0041] In one embodiment, the curing station 56 may include a heating module 82 configured to heat the adhesive 66 applied to the adhesive surface 68 of the leading edge protection member 48 and / or the leading edge 30 of the wind turbine blade 20 in order to cure the adhesive 66 thereon. The heating module 82 may include a resistive heater, IR light, or UV light, or any other suitable means for generating heat to cure the adhesive.
[0042] In one embodiment, the drive 44 may be supported by the wind turbine blade and movable along the wind turbine blade, as Figure 5A shown. In this embodiment, the drive 44 may include spaced drive wheels 90a, 90b that contact the wind turbine blade 20 on either side of the leading edge 30 so as not to contact or interfere with the leading edge protection member 48 placed on the leading edge 30. The drive 44 may also include guide wheels 92a, 92b that contact opposite sides 94, 96 of the wind turbine blade 20. The guide wheels 92a, 92b are configured to guide the movement of the robotic applicator device 40 as the robotic applicator device 40 moves along the wind turbine blade 20. Although the drive wheels 90a, 90b are shown as the means for moving the robotic applicator device 40, in alternative embodiments, the drive 44 may include a moving track, a rack and pinion drive, a chain, a skateboard, a movable leg, and / or other types of drives.
[0043] In another embodiment, the drive 44 may be supported by a support surface 100 disposed adjacent to the wind turbine blade 20 and movable along the support surface 100, as Figure 5B shown. In this embodiment, the drive 44 may include a wheel 102( Figure 5B ) or a track 104( Figure 5B ) to move the robotic applicator device 40 relative to the wind turbine blade 20. The drive 44 may use other drive mechanisms in addition to the wheel 102 and the track 104 to move the robotic applicator device 40 along the support surface 100.
[0044] In one embodiment and continuing to refer toFigure 5A and 5B , the main frame 42 can include an upper frame panel 110 having opposite first and second edges 112 and 114, a first side frame panel 116 coupled to the first edge 112, and a second side frame panel 118 coupled to the second edge 114. The upper frame panel 110 and the first and second side panels 116 and 118 can generally define a U-shaped cavity 120 configured to receive at least a portion of a wind turbine blade 20 therein. In addition to Figure 5A and Figure 5B the frame panels 110, 116, 118 and the U-shaped cavity 120 discussed and shown therein, the main frame 42 can have different structural features and other configurations.
[0045] As described above, the leading edge protector 48 can be a preformed protector stored in a dispensing station 50 in a coiled configuration. In another embodiment, the dispensing station 50 can include a dispensing module 126 in which the dispensed protector material 64 can flow to form the leading edge protector 48. To this end, the dispensing module 126 will dispense the flowable protector material 64, and when the flowable protector material 64 is applied to the leading edge 30 of the wind turbine blade 20, an application module 128 in the application station 54 will form the flowable protector material 64 into a predetermined profile of the leading edge profile 48. In this embodiment, the dispensing station 50 can include a liquid holding tank or other suitable container for holding the flowable protector material 64. The dispensing station 50 can also include a pump to move the flowable protector material 64 from the holding tank to the dispensing module 126.
[0046] The robotic applicator device 40 can include a central controller 130, which can be operably coupled to all or some of the various stations and modules discussed above. The central controller is configured to manage the various stations and modules when the robotic applicator device 40 moves along the leading edge 30 to apply the leading edge protector 48. The central controller 130 can include a wireless receiver such that a technician can wirelessly communicate with the central controller 130 when the robotic applicator device 40 is operable.
[0047] The present invention also contemplates a method for applying a protector 48 to the leading edge 30 of a wind turbine blade 20. Referring to Figure 6 and Figure 7 , a method 136 for applying a protector 48 to the leading edge 30 according to one aspect of the present invention is shown. Exemplary steps of the method 136 are outlined in the flowchart of Figure 6 and these steps are in Figure 7is schematically shown in. The first step 138 of method 136 is to provide a robotic applicator device 40, which includes a main frame 42, a dispensing station 50, an adhesion station 52, an application station 54, and a curing station 56. Each station 50, 52, 54, 56 is carried by the main frame 42. The second step 140 of method 136 includes moving the robotic applicator device 40 along the leading edge 30 of the wind turbine blade 20. The third step 142 of method 136 includes dispensing a protective member material 64 that forms the leading edge protector 48 at the dispensing station 50. The fourth step 144 of method 136 includes applying an adhesive 66 to the adhesive surface 68 of the dispensed protective member material 64 and / or the leading edge 30 of the wind turbine blade 20 at the adhesion station 52. The fifth step 146 of method 136 includes placing the adhesive surface 68 of the leading edge protector 48 onto the leading edge 30 of the wind turbine blade 20 at the application station 54. The sixth step 148 of method 136 includes curing the adhesive 66 at the curing station 56 so as to bond the leading edge protector 48 to the leading edge 30 of the wind turbine blade 20.
[0048] In one embodiment of method 136, the main frame 42 also carries a cleaning station 58, and method 136 may also include cleaning the adhesive surface 68 of the dispensed protective member material 64 at the cleaning station 58 and then applying the adhesive 66 thereto.
[0049] In one embodiment of method 136, the dispensing station 50 may include a conversion module 78, and the leading edge protector 48 may be stored in the dispensing station 50 in a coiled configuration. Method 136 may also include converting the leading edge protector 48 from the coiled configuration to a straightened configuration at the conversion module 78.
[0050] In one embodiment of method 136, the application station 54 may include a pressure module 80, and method 136 may also include applying pressure to the leading edge protector 48 at the pressure module 80 after the leading edge protector 48 has been placed on the leading edge 30 of the wind turbine blade 20.
[0051] In one embodiment of method 136, the step 148 of curing the adhesive includes heating the adhesive 66.
[0052] In one embodiment of method 136, the main frame also carries a sensing station 60 operatively coupled to the application station 54, and the application station 54 also includes a shaping module 70. Method 136 also includes determining a topography profile 62 of at least a portion of the leading edge 30 of the wind turbine blade 20 at the sensing station 60 and conforming the adhesive surface 68 of the dispensed leading edge protector 48 to the topography profile 62 of at least a portion of the leading edge 30 at the shaping module 70.
[0053] In one embodiment, method 136 may further include: supporting the robotic applicator device 40 on the wind turbine blade 20 as the robotic applicator device 40 moves along the leading edge 30 of the wind turbine blade 20. In an alternative embodiment, method 136 may further include: supporting the robotic applicator device 40 on a support surface 100 disposed adjacent to the wind turbine blade 20 as the robotic applicator device 40 moves along the leading edge 30 of the wind turbine blade 20.
[0054] Figure 7 Steps 138, 140, 142, 144, 146, 148 of method 136 are schematically illustrated. On the Figure 7 left side, the robotic applicator device 40 is provided. Additionally, a driver 44 moves the robotic applicator device 40 along the leading edge 30 of the wind turbine blade 20. A protective member material 64 forming the leading edge protective member 48 is dispensed from a dispensing station 50. Additionally, an adhesive station 52 applies an adhesive 66 to an adhesive surface 68 of the dispensed protective member material 64. On the Figure 7 middle, the robotic applicator device 40 has moved further down along the leading edge 30 of the wind turbine blade 20. Moreover, an application station 54 places the adhesive surface 68 of the leading edge protective member 48 onto the leading edge 30 of the wind turbine blade 20. On the Figure 7 right side, a curing station 56 is curing the adhesive 66, for example by applying heat, in order to bond the leading edge protective member 48 to the leading edge 30 of the wind turbine blade 20. In one embodiment, the heating station 56 provides a part of a controlled environment, such as limited humidity and / or limited temperature variation, to allow a self-curing adhesive to cure without specifically activating the adhesive.
[0055] Advantageously, all stations 50, 52, 54, 56 are carried by the main frame 42. That is, all necessary devices and leading edge materials required to apply the leading edge protective member 48 to the leading edge 30 of the blade 20 are carried by the main frame 42. Accordingly, the robotic applicator device 40 is a self-contained device capable of applying the leading edge protective member 48 without external devices to apply the leading edge protective member 48. As described above, for the above purposes, the robotic applicator device 40 may further include a cleaning station 58 and a sensing station 60.
[0056] While the invention has been shown by the description of various embodiments, and while these embodiments have been described in considerable detail, it is not the intention of the applicant to restrict or in any way limit the scope of the appended claims to such details. Those skilled in the art will readily envision additional advantages and modifications. Accordingly, the invention in its broader aspects is not limited to the specific details, representative apparatus and methods, and illustrative examples shown and described. Thus, departures may be made from such details without departing from the spirit or scope of the applicant's general inventive concept.
Claims
1. A robotic applicator device (40) for applying a protective element (48) to a leading edge (30) of a wind turbine blade (20), the robotic applicator device (40) comprising: a main frame (42); a drive (44) operatively coupled to the main frame (42) and configured to move the main frame (42) relative to the wind turbine blade (20); and a plurality of stations (46) carried by the main frame (42) for applying the protective element (48) to the leading edge (30) of the wind turbine blade (20), the plurality of stations (46) including: a dispensing station (50) configured to hold and dispense a material (64) forming the leading edge protective element (48); an adhesion station (52) configured to apply an adhesive (66) to an adhesion surface (68) of the dispensed protective element material (64) and / or to the leading edge (30) of the wind turbine blade (20); an application station (54) configured to place the adhesion surface (68) of the dispensed protective element material (64) onto the leading edge (30) of the wind turbine blade (20); and a curing station (56) configured to cure the adhesive (66) to bond the leading edge protective element (48) to the leading edge (30) of the wind turbine blade (20).
2. The robotic applicator device (40) according to claim 1, wherein, the plurality of stations (46) further includes a cleaning station (58) configured to clean the dispensed protective element material (64).
3. The robotic applicator device (40) according to claim 1 or 2, wherein, the dispensing station (50) includes a conversion module (78), wherein the leading edge protective element (48) is stored in the dispensing station (50) in a coiled configuration, and wherein the conversion module (78) is configured to convert the leading edge protective element (48) from the coiled configuration to a straightened configuration.
4. The robotic applicator device (40) according to any one of the preceding claims, wherein, the application station (54) includes a pressure module (80) configured to apply pressure to the leading edge protective element (48) after the leading edge protective element (48) has been placed on the leading edge (30) of the wind turbine blade (20).
5. The robotic applicator device (40) according to any one of the preceding claims, wherein, the curing station (56) includes a heating module (82) configured to heat the adhesive (66) applied to the adhesion surface (68) of the dispensed protective element material (64) and / or to the leading edge (30) of the wind turbine blade (20) to cure the adhesive (66).
6. The robotic applicator device (40) according to any one of the preceding claims, wherein, The plurality of stations (46) further includes a sensing station (60) configured to determine a profile (62) of at least a portion of a leading edge (30) of the wind turbine blade (20).
7. The robotic applicator device (40) according to claim 6, wherein, the sensing station (60) is operatively coupled to the application station (54), and wherein the application station (54) includes a shaping module (70) configured to conform an adhesive surface (68) of the dispensed protective member material (64) to the profile (62) of at least the portion of the leading edge (30) detected by the sensing station (60).
8. The robotic applicator device (40) according to claims 1-5, wherein, the dispensing station (50) is configured to dispense a preformed leading edge protector (48).
9. The robotic applicator device (40) according to any one of the preceding claims, wherein, the drive (44) is supported by the wind turbine blade (20) and is movable along the wind turbine blade (20).
10. The robotic applicator device (40) according to any one of claims 1-8, wherein, the drive (44) is supported by a support surface (100) disposed adjacent to the wind turbine blade (20) and is movable along the support surface (100).
11. The robotic applicator device (40) according to any one of the preceding claims, wherein, the main frame (42) includes an upper frame panel (110) having opposite first and second edges (112, 114), a first side frame panel (116) coupled to the first edge (112), and a second side frame panel (118) coupled to the second edge (114), the upper frame panel (110) and the first and second side frame panels (116, 118) defining a U-shaped cavity (120) configured to receive at least a portion of the wind turbine blade (20) therein.
12. A method for applying a protector (48) to a leading edge (30) of a wind turbine blade (20), the method comprising: providing a robotic applicator device (40) including a main frame (42) and a dispensing station (50), an adhesion station (52), an application station (54), and a curing station (56), each station being carried by the main frame (42); moving the robotic applicator device (40) along the leading edge (30) of the wind turbine blade (20); dispensing at the dispensing station (50) a material (64) for forming the leading edge protector (48); applying an adhesive (66) at the adhesion station (52) to an adhesive surface (68) of the dispensed protective member material (64) and / or to the leading edge (30) of the wind turbine blade (20); Place the adhesive surface (68) of the dispensed protective member material (64) on the leading edge (30) of the wind turbine blade (20) at the application station (54); and Cure the adhesive (66) at the curing station (56) to bond the leading edge protector (48) to the leading edge (30) of the wind turbine blade (20).
13. The method according to claim 12, wherein, The main frame (42) further carries a cleaning station (58), and wherein the method further comprises: Clean the adhesive surface (68) of the dispensed protective member material (64) at the cleaning station (58), and then apply the adhesive (66) thereto.
14. The method according to claim 12 or 13, wherein, The dispensing station (50) includes a conversion module (78), and wherein the leading edge protector (48) is stored in the dispensing station (50) in a coiled configuration, and wherein the method further comprises: Convert the leading edge protector (48) from the coiled configuration to a straightened configuration at the conversion module (78).
15. The method according to any one of claims 12-14, wherein, The application station (54) includes a pressure module (80), and wherein the method further comprises: Apply pressure to the leading edge protector (48) at the pressure module (80) after the leading edge protector (48) has been placed on the leading edge (30) of the wind turbine blade (20).
16. The method according to any one of claims 12-15, wherein, The step of curing the adhesive (66) includes heating the adhesive (66).
17. The method according to any one of claims 12-16, wherein, The main frame (42) further carries a sensing station (60) operatively coupled to the application station (54), wherein the application station (54) further includes a shaping module (70), and wherein the method further comprises: Determine the profile (62) of at least a portion of the leading edge (30) of the wind turbine blade (20) at the sensing station (60); and At the shaping module (70), conform the adhesive surface (68) of the dispensed protective member material (64) to the profile (62) of at least said portion of the leading edge (30).
18. The method according to any one of claims 12-17, further comprises: Support the robotic applicator device (40) on the wind turbine blade (20) as the robotic applicator device (40) moves along the leading edge (30) of the wind turbine blade (20).
19. The method according to any one of claims 12-17, further comprises: Support the robotic applicator device (40) on a support surface (100) disposed adjacent to the wind turbine blade (20) as the robotic applicator device (40) moves along the leading edge (30) of the wind turbine blade (20).