Method of manufacturing reconfigurable wind turbine blade mold

Abstract

According to one aspect of the invention, there is provided a method of manufacturing a mold assembly for a wind turbine blade half shell. The method includes providing an elongate mold plug in a first position. The profile of the mold plug corresponds to a portion of the profile of the wind turbine blade half shell. The method further includes forming a mold skin section on the mold plug. The method includes providing a frame structure on top of the mold skin section on the plug, and attaching the frame structure to the mold skin section to form a subassembly including the mold skin section and the frame structure. The method further includes removing the subassembly from the mold plug and transporting the subassembly from the first location to a blade manufacturing facility. The method further includes arranging the subassembly end-to-end with one or more additional subassemblies at the blade manufacturing facility to form a mold assembly for the wind turbine blade half shell having the first geometry.

Description

Technical Field

[0001] The present invention generally relates to wind turbine blade molds, and more particularly to a method of assembling a reconfigurable wind turbine blade mold. Background Art

[0002] Modern utility-scale wind turbine blades typically include a composite outer shell. The blade may include two half-shells that are formed separately and then joined together to form the outer shell. Each half-shell can be formed by arranging a laminate of reinforcing material on a substantially concave half-shell mold surface before integrating the reinforcing material with a polymer resin and then curing the resin.

[0003] Wind turbine blade manufacturers are designing increasingly long wind turbine blades to capture more energy from the wind incident on the blades in use. For example, some modern wind turbine blades can extend more than 70 m from the root end to the tip of the blade. Thus, increasingly long wind turbine blade molds are needed to form the half-shells of such blades. This presents a number of challenges.

[0004] First, wind turbine blade molds are generally expensive tools to design and manufacture, at least in part due to their size and the complex profile of the mold surface that forms the aerodynamic profile of the blade. Manufacturing different wind turbine blades typically requires different molds, which increases the associated costs for blade manufacturers. In some cases, blade manufacturers may choose to modify or adjust an existing mold, such as changing the size of the mold and the mold surface, to manufacture a different blade. However, this generally involves permanently damaging the existing mold, such as by grinding and / or welding operations, and typically results in material waste.

[0005] In addition, molds for large wind turbine blades occupy a large amount of floor space in a blade manufacturing facility, and storing multiple blade molds may therefore be infeasible for some manufacturing facilities. Finally, the size of the mold can also impede the manufacture of the mold because transporting such a large tool is either impossible or economically infeasible. Thus, blade molds are typically manufactured at the blade manufacturing facility, which requires storing and using specialized mold manufacturing tools and equipment at the blade manufacturing facility. This places additional constraints on the location of the blade manufacturing facility.

[0006] In view of this background, the present invention has been devised. Summary of the Invention

[0007] According to one aspect of the present invention, there is provided a reconfigurable mold assembly for manufacturing wind turbine blades having different geometries. The mold assembly includes a mold skin that extends longitudinally in the spanwise direction and transversely in the chordwise direction. The mold skin defines a mold surface shaped to form a half-shell of a wind turbine blade. The mold skin includes a plurality of spanwise sections arranged end-to-end in the spanwise direction to form the half-shell. The plurality of skin sections includes one or more inner skin sections for forming the root end of the half-shell and one or more outer skin sections for forming the tip end of the half-shell. The mold assembly further includes a main frame that includes a series of independent main frame modules arranged end-to-end in the spanwise direction. The main frame modules include one or more inner main frame modules for supporting one or more inner skin sections and one or more outer main frame modules for supporting one or more outer skin sections. The mold assembly further includes intermediate support structures attached to opposite sides of each mold skin section. The intermediate support structures attached to the inner skin sections can be releasably connected to the inner main frame modules. The intermediate support structures attached to the outer skin sections can be releasably connected to the outer main frame modules.

[0008] The mold skin preferably includes independent mold skin sections, i.e., the mold skin sections can be separated from each other and form the mold skin when arranged together.

[0009] The reconfigurable mold assembly allows the mold skin sections to be easily replaced with mold skin sections having different geometries in order to manufacture wind turbine blades of different sizes. The basic main frame modules can be reused. The manufacture of longer blades may require the addition of additional main frame modules, while main frame modules can be subtracted when manufacturing shorter blades. In particular, the reconfigurable mold assembly facilitates the reuse of a large number of mold components, such as main frame modules, to manufacture different blades. This reduces the capital expenditure for manufacturing new blade designs and also significantly reduces the lead time required to manufacture new molds.

[0010] In some examples, the reconfigurable mold assembly can be referred to as a modular mold assembly, where each of the reconfigurable components of the mold can be referred to as a mold module. For example, the modular mold assembly can include a plurality of main frame modules, a plurality of mold skin modules (skin sections), and intermediate support modules (intermediate support structures) attached to opposite sides of each mold skin module.

[0011] In some preferred examples, the main frame modules can be connected to each other in a releasable manner. This facilitates simply adding or subtracting main frame modules from the mold assembly when reconfiguring the mold assembly to manufacture blades of different lengths. This also ensures that the main frame modules maintain their structural integrity when reconfiguring the blade mold to manufacture different blades, since the main frame modules can be separated without damaging the modules.

[0012] In some examples, the tooling assembly may include a plurality of inner main frame modules having substantially the same dimensions. Additionally or alternatively, the tooling assembly may include a plurality of outer main frame modules having substantially the same dimensions. Providing a plurality of main frame modules having substantially the same dimensions helps reduce manufacturing costs and complexity when manufacturing the main frame modules. This also provides greater flexibility for interchangeably attaching other components or modules to the main frame modules, since the interface between such other components and any one of the plurality of substantially identical main frame modules is the same.

[0013] In some examples, the chordwise width of the or each inner main frame module may be greater than the chordwise width of the or each outer main frame module. It should be understood that the inner portion of a wind turbine blade is typically wider and / or thicker than the outer portion of the blade. Thus, the or each inner skin section may be wider than the or each outer skin section. Accordingly, the or each inner main frame module may have a greater chordwise width than the or each outer main frame module to provide the necessary stability and structural support for the or each wider inner skin section. As previously mentioned, in preferred examples, each inner main frame module may have the same chordwise width.

[0014] In some examples, the tooling assembly may further include an intermediate skin section for forming at least a portion of an intermediate section between the root end and the tip end of the half shell. This may facilitate manufacturing more types of blades using the tooling assembly without the need for new or different inner and / or outer skin sections. The tooling assembly may further include one or more intermediate main frame modules for supporting the intermediate skin section. The tooling assembly may further include an intermediate support structure attached to opposite sides of the intermediate skin section. In a preferred example, the intermediate support structure may be releasably connected to the one or more intermediate main frame modules. The releasable connection between the intermediate support structure and / or each intermediate main frame module facilitates simple replacement of components when reconfiguring the tooling assembly.

[0015] In some preferred examples, the tooling assembly may include a plurality of intermediate skin sections. Providing a plurality of intermediate skin sections may facilitate more precise adjustment of the overall tooling skin to manufacture more types of blades in a reconfigurable tooling. The intermediate support structure may be attached to opposite sides of each intermediate skin section. The intermediate support structure is preferably releasably connected to each intermediate main frame module. Additionally, the or each intermediate main frame module is preferably releasably connected to an adjacent main frame module. For example, an intermediate main frame module may be connected to at least two of an adjacent inner main frame module, an adjacent intermediate main frame module, and an adjacent outer main frame module. The releasable connections facilitate simple reconfiguration of the tooling assembly.

[0016] In some examples, the tooling assembly may include a plurality of substantially identical intermediate main frame modules. In some examples, the chordwise width of the or each intermediate main frame module may be less than the chordwise width of the or each inner main frame module. Additionally, the chordwise width of the or each intermediate main frame module may be greater than the chordwise width of the or each outer main frame module.

[0017] In some examples, each intermediate support structure may include a plurality of chordwise extending ribs spaced apart from each other in the span direction. The chordwise ribs may provide structural support for the tooling skin in a portion of the tooling where support is most advantageous. This may help provide a substantially lightweight means for supporting the tooling skin. Additionally, the chordwise ribs may be shaped to help maintain the dimensional accuracy of the tooling skin. Thus, in some examples, the upper edge of each chordwise rib may substantially match the profile of the opposite side of a portion of the skin section supported by the chordwise rib.

[0018] In some examples, each intermediate support structure may include a plurality of support tubes, rods, or beams extending longitudinally in the span direction. The support tubes, rods, or beams may provide structural support and rigidity to the intermediate support structure and thus also to the tooling skin in the span direction. In examples where the intermediate support structure includes chordwise ribs, the support tubes, rods, or beams are preferably attached to the ribs. Thus, the support tubes, rods, or beams may help maintain the position of each chordwise rib relative to the other chordwise ribs in the intermediate support structure. In some examples, each support tube, rod, or beam may extend between adjacent chordwise ribs to space the ribs apart and maintain their relative spacing. In some examples, the support tubes, rods, or beams may be permanently attached to the ribs, for example, by welding or adhesive bonding. In some examples

[0019] In some examples, the main frame module may be substantially rectangular in plan view. It should be understood that "substantially rectangular" includes a square, i.e., a square main frame module. The generally rectangular shape may be advantageous when transporting and storing the main frame module and may also facilitate simple alignment of adjacent main frame modules when assembling the reconfigurable tooling assembly.

[0020] In some examples, the tooling assembly may further include a plurality of turners configured to turn the tooling assembly to position the tooling skin on top of a corresponding tooling skin of a second half shell shaped to form a blade. The turners may be spaced apart in the span direction. In a preferred example, each turner may include a turner beam configured to engage a respective main frame module.

[0021] In some examples, each main frame module may include a window to receive or engage a respective rotor beam. In a preferred example, there may be one or more empty windows between adjacent rotors. The "window" of the main frame module is a part of the module that is configured to attach a rotor (e.g., the rotor beam of the rotor) to the module. In some examples, the window of the main frame module may include a structural reinforcement part of the respective main frame module. Providing multiple windows for attaching rotors provides greater flexibility in the positioning of the rotors. Thus, each rotor can be positioned at an optimal location for loading, thereby reducing the number of rotors required in some examples and / or ensuring that each rotor is properly loaded to avoid damaging the rotors in use. In particular, when the mold assembly is reconfigured to form different wind turbine blades, this helps to reposition the rotors as needed.

[0022] In some examples, a plurality of inner rotors may be provided in the inner section of the mold assembly. Additionally or alternatively, a plurality of outer rotors may be provided in the outer section of the mold assembly. Additionally or alternatively, a plurality of intermediate rotors may be provided in the intermediate section of the mold assembly. In a preferred example, the rotor beam of each inner rotor may have an equal length in the chordwise direction. Additionally or alternatively, the rotor beam of each outer rotor may have an equal length in the chordwise direction. Additionally or alternatively, the rotor beam of each intermediate rotor may have an equal length in the chordwise direction. This configuration is particularly advantageous in examples where each main frame module in a given section has the same chordwise width as described above.

[0023] Another aspect of the present invention relates to the use of the mold assembly described herein for manufacturing wind turbine blades.

[0024] For example, in another aspect of the present invention, a method of manufacturing wind turbine blades of different sizes using the mold assembly described herein is provided. The method includes using the mold assembly to manufacture a first wind turbine blade having a first size. Subsequently, the method includes reconfiguring the mold assembly by replacing the mold skin section with a different mold skin section having a different size. Additionally, the method further includes using the mold assembly to manufacture a second wind turbine blade such that the first and second wind turbine blades have different sizes.

[0025] The method may further include replacing the intermediate support structure with a different intermediate support structure. For example, the method may include disconnecting the intermediate support structure from the main frame module and subsequently releasably connecting a different intermediate support structure to the main frame module. The method preferably includes releasably connecting each intermediate support structure to one or more main frame modules.

[0026] In some examples, the step of reconfiguring the tooling assembly can include adding or subtracting one or more main frame modules. For example, the method can include disconnecting a main frame module from an adjacent main frame module. The method can also include releasably connecting one or more additional main frame modules to the adjacent main frame module to increase the length of the tooling assembly and thereby manufacture a larger blade. Alternatively, after disconnecting the main frame module from the adjacent main frame module, the method can include removing one or more main frame modules and either a) replacing them with fewer or shorter main frame modules, or b) not replacing the removed frame modules. Thus, such examples can involve reconfiguring the tooling assembly to form a shorter wind turbine blade. In case b), two existing main frame modules can be releasably connected together, or if the method involves removing the innermost or outermost main frame module, there may simply be no further reconnecting step, whereby the combined length of the main frame modules is thereby reduced.

[0027] According to another aspect of the invention, there is provided a method of manufacturing a tooling assembly for a wind turbine blade half shell. The method includes providing an elongate tooling plug at a first location. The tooling plug has a profile corresponding to a portion of the profile of the wind turbine blade half shell. The method also includes forming a tooling skin section on the tooling plug. The method includes providing a frame structure on top of the tooling skin section on the plug and attaching the frame structure to the tooling skin section to form a sub-assembly including the tooling skin section and the frame structure. The method also includes removing the sub-assembly from the tooling plug and transporting the sub-assembly from the first location to a blade manufacturing facility. The method also includes arranging the sub-assembly end-to-end with one or more additional sub-assemblies at the blade manufacturing facility to form a tooling assembly for a wind turbine blade half shell having a first geometry.

[0028] In some examples, the step of forming a tooling skin on the plug can include providing a fiber reinforcement material on the tooling plug, providing resin to the fiber material, and at least partially curing the resin. The resin can be provided to the fiber reinforcement material, for example, under vacuum during a resin infusion process. Alternatively or additionally, the fiber reinforcement material may already contain resin before it is provided on the tooling plug, for example, it can be a "prepreg" material, which is a fiber reinforcement material pre-impregnated with resin. The method can include removing the sub-assembly from the tooling plug when the resin is fully cured or when the resin is only partially cured.

[0029] In some examples, the step of providing a frame structure on top of the tooling skin section can include lifting the frame structure, optionally rotating the frame structure, positioning the frame structure above the plug, and lowering the frame structure onto the tooling skin section. For example, the method can include using a bridge crane or an overhead crane to lift and lower the frame structure.

[0030] In some examples, the step of removing the sub - assembly from the mold plug may include lifting the sub - assembly from the mold plug. It should be understood that removing the sub - assembly from the plug involves removing the mold skin section from the plug. Thus, to facilitate removing the mold skin section from the plug, the method may include an initial step of applying a release layer or release agent to the mold plug before forming the mold skin section on the mold plug.

[0031] In some examples, the mold skin section may be shaped to form at least a portion of the root end of the half - shell or the end of the half - shell or an intermediate section between the root end and the end of the half - shell.

[0032] In some examples, the first location where the mold plug is provided may be at the same site or in the same building as the blade manufacturing facility. Thus, the method may include transporting the sub - assembly a short distance from the first location to the blade manufacturing facility. In some examples, the steps of removing the sub - assembly from the mold plug and transporting the sub - assembly may be performed in a single operation. For example, the sub - assembly may be removed from the mold plug using an overhead crane, and then the overhead crane may transport the sub - assembly to the blade manufacturing facility.

[0033] In other examples, the blade manufacturing facility may be at a location remote from the first location. For example, the blade manufacturing facility and the first location may be in different factories or buildings, which may be in different locations on the premises, or in some examples in different cities or different countries.

[0034] In examples where the blade manufacturing facility is remote from the first location, the method may further include arranging the sub - assembly in a shipping container and transporting the sub - assembly in the shipping container from the first location to the blade manufacturing facility. Thus, in a preferred example, the sub - assembly, i.e., the mold skin section and the frame structure, may be configured to fit within the shipping container. Advantageously, the shipping container protects the sub - assembly, particularly the mold skin section, during transportation.

[0035] In some examples, the sub - assembly may be transported from the first location to the blade manufacturing facility by road, rail, air, or sea. Thus, configuring the sub - assembly to fit within a shipping container (i.e., a sea - freight container) can facilitate simple and cost - effective transportation of the sub - assembly, since the methods for transporting such containers are well - established and do not require special measures. Thus, setting the mold skin of the mold assembly as multiple mold skin sections provides more freedom for transporting the mold skin and facilitates manufacturing the skin sections at locations different from the blade manufacturing facility. Thus, the mold skin sections may be produced in specialist facilities optimized for manufacturing such components, and the blade manufacturing facility does not need to additionally accommodate mold - making equipment.

[0036] In some examples, the frame structure can include one or more main frame modules connected to an intermediate support structure in a releasable manner. Thus, in some examples, the method can also include connecting the intermediate support structure to a mold skin section. In a preferred example, the method can include connecting the intermediate support structure to the mold skin section in a releasable manner.

[0037] The mold skin section can have a front side facing the mold plug and an opposite side opposite the front side. In a preferred example, the front side can have a generally concave profile, while the opposite side can have a generally convex profile. In a preferred example, the method can also include connecting the intermediate support structure to the opposite side of the mold skin section. For example, the opposite side of the mold skin section can include a plurality of attachment tabs. The method can include connecting the intermediate support structure to the plurality of attachment tabs in a releasable manner, such as via a bolt connection.

[0038] In some examples, the method can include connecting the intermediate support structure to the mold skin section before connecting the intermediate support structure to one or more main frame modules. However, in a preferred example, the method can include connecting the intermediate support structure to one or more main frame modules in a releasable manner before connecting the intermediate support structure to the mold skin section. For example, the intermediate support structure can be bolted to one or more main frame modules to form the frame structure before the frame structure is disposed on top of the mold skin section on the plug. Advantageously, this means that the main frame module and the support structure are lifted in a single operation, thereby reducing the time required to align the components on the plug and thus reducing the amount of time the plug is occupied by a given mold skin section.

[0039] In some examples, the intermediate support structure or each intermediate support structure can include a plurality of chordally extending ribs spaced apart from each other in the span direction. Additionally or alternatively, the intermediate support structure or each intermediate support structure can include a plurality of tubes, rods, or beams longitudinally extending in the span direction. The method can include connecting the chordally extending ribs and / or the spanwise extending tubes, rods, or beams to the mold skin section.

[0040] In some examples, the method can also include connecting the main frame module of the subassembly to the main frame module of another subassembly at the blade manufacturing facility in a releasable manner. Additionally or alternatively, the method can include connecting the intermediate support structure of the subassembly to the intermediate support structure of another subassembly in a releasable manner. Thus, the method can include connecting the subassembly to one or more other subassemblies at the blade manufacturing facility in a releasable manner to form a mold assembly. Connecting the subassembly to another subassembly in a releasable manner by releasably connecting the main frame modules and / or the intermediate support structures of adjacent subassemblies facilitates reconfiguration of the mold assembly to form different wind turbine blades.

[0041] In some examples, the frame structure may further include one or more rotator beams attached to one or more main frame modules. This configuration advantageously minimizes the time required to assemble the mold assembly at the blade manufacturing facility since the sub-assembly is provided to the blade manufacturing facility where the or each rotator beam is already attached to one or more main frame modules. Additionally or alternatively, the frame structure may include one or more lifting beams for lifting the frame structure. Such lifting means can provide a suitable location for attaching lifting equipment to the sub-assembly to avoid damaging the sub-assembly during transportation and positioning of the sub-assembly.

[0042] In some examples, the method may further include reconfiguring the mold assembly at the blade manufacturing facility such that the mold assembly is adapted to manufacture a wind turbine blade half shell having a second geometry different from the first geometry.

[0043] For example, reconfiguring the mold assembly may include separating or disconnecting an intermediate support structure of the sub-assembly from one or more main frame modules, removing a mold skin section and attached intermediate support structure from the mold assembly, providing a different mold skin section attached to the intermediate support structure, and connecting the intermediate support structure of the different mold skin section to one or more main frame modules.

[0044] The method may also include releasably connecting the intermediate support structure of the different mold skin section to one or more main frame modules. For example, the intermediate support structure of the different mold skin section may be connected to one or more main frame modules via a bolt connection.

[0045] In some examples, the second geometry may be longer than the first geometry, i.e., a wind turbine blade half shell having the second geometry may be longer than a wind turbine blade half shell having the first geometry. In such examples, the method may include adding additional main frame modules to the mold assembly and additionally connecting the intermediate support structure of the different mold skin section to the additional main frame modules.

[0046] In other examples, the second geometry may be shorter than the first geometry, i.e., a wind turbine blade half shell having the second geometry may be shorter than a wind turbine blade half shell having the first geometry. In such examples, the method may include removing main frame modules from the mold assembly.

[0047] In some examples, different mold skin sections may be provided on a vehicle with an intermediate support structure releasably connected to the different mold skin sections. The vehicle can advantageously provide the necessary structural support for the mold skin sections and / or the intermediate support structure during its transportation, i.e., before connecting the intermediate support structure of the different mold skin sections to one or more main frame modules. In a preferred example, the method may include releasing the different mold skin sections from the vehicle before connecting the intermediate support structure of the different mold skin sections to one or more main frame modules to form a mold assembly. BRIEF DESCRIPTION OF THE DRAWINGS

[0048] Examples of the present invention will now be described, by way of non-limiting example only, with reference to the accompanying drawings, in which:

[0049] Figure 1 is a schematic exploded view of a wind turbine blade;

[0050] Figure 2 is a schematic perspective view of a reconfigurable mold assembly including a mold skin, an intermediate support structure, and a main frame;

[0051] Figure 3 is a schematic perspective view of a reconfigurable mold assembly, in which the inner part of the mold assembly is shown in a schematic exploded view;

[0052] Figure 4a is a schematic perspective view of a main frame module;

[0053] Figure 4b is a schematic perspective view of a plurality of main frame modules arranged together to form part of a main frame;

[0054] Figures 5a to 5c schematic side views showing the inner, middle, and outer parts of the mold assembly respectively;

[0055] Figure 6 is a schematic end view of the mold assembly, showing a rotator configured to rotate the mold assembly;

[0056] Figure 7 is a schematic side view of a reconfigurable mold assembly;

[0057] Figure 8 is a schematic plan view of a reconfigurable mold assembly;

[0058] Figures 9a to 9c schematically shows the process of manufacturing sub-assemblies of the mold assembly;

[0059] Figure 10 is a schematic perspective view showing the reconstruction stage of the mold assembly; and

[0060] APPENDIXFigures 11a to 11c Schematically illustrates the process of manufacturing different mold skin sections to replace existing mold skin sections when reconfiguring a mold assembly. DETAILED DESCRIPTION

[0061] Figure 1 A schematic exploded view of a wind turbine blade 10 is shown. The blade 10 includes a first half-shell 12a and a second half-shell 12b, which are joined together to form the outer shell of the blade 10. Each half-shell 12a, 12b longitudinally extends from a root end 16 to a tip end 18 in a spanwise direction (S) and transversely extends between a leading edge 20 and a trailing edge 22 in a chordwise direction (C). The root end 16 of the blade 10 is preferably configured to be attached to a rotor hub of a wind turbine (not shown). Thus, the root end 16 can be referred to as the inner end of the blade 10, and the tip end 18 can be referred to as the outer end of the blade 10.

[0062] Each of the half-shells 12a, 12b includes an outer profile that, when the half-shells 12a, 12b are joined together, defines a part of the aerodynamic profile of the blade 10. Each half-shell 12a, 12b can be manufactured separately before the half-shells 12a, 12b are joined together to form the outer shell of the blade 10. The half-shells 12a, 12b can be manufactured using a reconfigurable mold assembly 24 that will now be described with reference to Figures 2 to 8 .

[0063] First, referring to the appended Figure 2 and Figure 3 , the appended Figure 2 and Figure 3 show examples of a reconfigurable mold assembly 24 in a schematic perspective view and a schematic exploded view, respectively. The reconfigurable mold assembly 24 includes a mold skin 26 that defines a mold surface 28, which is shaped to form a half-shell 12 of the wind turbine blade 10, such as Figure 1 the half-shells 12a, 12b of the blade 10 shown in the example of

[0064] The mold skin 26 longitudinally extends in the spanwise direction (S) and transversely extends in the chordwise direction (C). Figure 2 and Figure 3 shown. The mold skin 26 includes a plurality of spanwise sections 30 for being arranged end-to-end in the spanwise direction (S) to form the half-shell 12. The mold assembly 24 includes at least one inner skin section 30a for forming the root end 16 of the half-shell 12 and at least one outer skin section 30b for forming the tip end 18 of the half-shell 12. In some examples, as

[0065] The tooling assembly 24 further includes intermediate support structures 32a-c attached to opposite sides of each tooling skin section 30a-c. The intermediate support structures 32a-c support the tooling skin sections 30a-c to assist in maintaining the dimensional accuracy of the tooling skin 26 during manufacture of the half shell 12. Thus, the intermediate support structures 32a-c may include a plurality of chordally extending ribs 34 spaced apart from each other in the span direction (S) (most clearly shown in Figure 6 and Figure 9a ). Additionally, for example, as shown in Figure 3 , in some examples, the intermediate support structures 32a-c may include a plurality of support tubes, rods, or beams 36 extending longitudinally in the span direction (S).

[0066] Also referring to Figure 4a and Figure 4b , the tooling assembly 24 further includes a main frame 38 that supports the intermediate support structures 32a-c and the tooling skin 26. The main frame 38 includes a series of separate main frame modules 40a-c, as shown in Figure 4a , which are arranged end-to-end in the span direction (S) to form the main frame 38, a portion of which is shown in Figure 4b . For example, the tooling assembly 24 includes at least one inner main frame module 40a for supporting the inner or each inner skin section 30a and at least one outer main frame module 40b for supporting the outer or each outer skin section 30b. In some examples, the tooling assembly 24 may further include one or more intermediate main frame modules 40c for supporting the intermediate skin section 30c.

[0067] To facilitate simply reconfiguring the tooling assembly 24 to manufacture different wind turbine blades 10 having different geometries, the intermediate support structures 32a-c are attached to the main frame 38, i.e., the main frame modules 40a-c, in a releasable manner. For example, the intermediate support structure 32a attached to the inner skin section 30a is connected to the inner main frame module 40a in a releasable manner, and the intermediate support structure 32b attached to the outer skin section 30b is connected to the outer main frame module 40 in a releasable manner. In examples including an intermediate support structure 32c attached to opposite sides of the intermediate skin section 30c, such intermediate support structure 32c is preferably similarly connected to one or more intermediate main frame modules 40c in a releasable manner. The releasable connection between the intermediate support structures 32a-c and the corresponding main frame modules 40a-c facilitates simply replacing different tooling skin sections 30a-c and intermediate support structures 32a-c to form blades 10 having different geometries using the tooling assembly 24.

[0068] Still referring to Figure 4a and Figure 4b, in some preferred examples, the main frame modules 40a-c are substantially rectangular in a plan view. This is beneficial for aligning the main frame modules 40a-c to form the main frame 38, and is also beneficial for transporting and storing the main frame modules 40a-c. In some examples, the main frame modules 40a-c can be connected to each other in a releasable manner, that is, adjacent main frame modules 40a-c can be connected together in a releasable manner. This configuration can provide additional rigidity to the mold assembly 24 while still facilitating simple reconfiguration of the mold assembly 24 as needed.

[0069] In some advantageous examples, the mold skin 26, i.e., the plurality of mold skin segments 30a-c, may not be directly connected to the main frame modules 40a-c. For example, the provision of the intermediate support structures 32a-c causes the main frame modules 40a-c to be detached or slightly separated from the mold skin 26. Thus, the main frame modules 40a-c are not directly affected by the varying profile of the mold skin 26. Instead, the intermediate support structures 32a-c absorb the varying geometry of the mold skin 26 along their lengths and provide a substantially uniform interface for connection to the main frame modules 40a-c.

[0070] In this way, in a preferred example, the main frame modules 40a-c can have substantially the same dimensions in each spanwise section of the mold assembly 24. This modularity reduces the engineering work and costs associated with manufacturing each main frame module design.

[0071] For example, each inner main frame module 40a preferably has a substantially identical chordwise width W1, as Figure 5a shown in the schematic side view of, which shows a part of the mold assembly 24 including the inner main frame module 40a and the attached intermediate support structure 32a. Each inner main frame module 40a preferably has a chordwise width W1 that is greater than the chordwise width W2 of each outer main frame module 40b.

[0072] Referring to Figure 5b , in an example where the mold assembly 24 includes a plurality of intermediate main frame modules 40c, such main frame modules 40c are preferably substantially identical. For example, each intermediate main frame module 40c can have a substantially identical chordwise width W3. Each intermediate main frame module 40c preferably has a chordwise width W3 that is less than the chordwise width W1 of each inner main frame module 40a and greater than the chordwise width W2 of each outer main frame module 40b.

[0073] Referring to Figure 5cSchematic side view, which shows a part of the mold assembly 24 including the outer main frame module 40b and the attached intermediate support structure 32b, and each outer main frame module 40b preferably has substantially the same dimensions. For example, each outer main frame module 40b preferably has substantially the same chordal width W2.

[0074] The foregoing description of the mold assembly 24 has been provided with reference to the mold skin 26 that defines the mold surface 28 that is shaped to form the half shell 12a of the wind turbine blade 10. Now refer to Figure 6 , Figure 7 and Figure 8 , in some examples, the mold assembly 24 may include a plurality of rotators 42 configured to rotate the mold assembly 24 to position the mold skin 26a on top of the corresponding mold skin 26b, which is shaped to form the second half shell 12b of the blade 10. For example, manufacturing the wind turbine blade 10 may involve forming the half shells 12a, 12b on each mold skin 26a, 26B. Subsequently, the rotator 42 may arrange the mold skin 26a on top of the second mold skin 26b such that the half shell 12a formed on the mold skin 26a is arranged on top of the half shell 12b formed on the second mold skin 26b.

[0075] The rotators 42 are preferably spaced apart in the span direction (S) to distribute the load of the mold assembly 24 over the rotators 42. The mold assembly 24 preferably includes one or more inner rotators 42a provided in the inner part of the mold assembly 24. In addition, one or more outer rotators 42b may be provided in the outer section of the mold assembly 24, and one or more intermediate rotators 42c may be provided in the intermediate section of the mold assembly 24. Each rotator 42a-c is preferably configured to engage with the corresponding main frame module 40a-c. For example, each rotator 42a-c preferably includes a rotator beam 44a-c extending in the chordal direction (C) for attachment to the main frame module 40a-c. Advantageously, the rotator beam 44a-c can be releasably connected to the main frame module 40a-c, for example by a bolt connection, again facilitating simple reconfiguration of the mold assembly 24 when needed.

[0076] To connect the rotator 42, each main frame module 40a-c preferably includes a "window" 46, i.e., an attachment location, which may include a structurally reinforced portion of the main frame module 40a-c for engaging the rotator beam 44a-c. The main frame 38 forming the plurality of main frame modules 40a-c advantageously provides a plurality of windows 46 for attaching the rotator beam 44. As in Figure 7Most clearly shown in the schematic side view of the mold assembly 24 therein, the mold assembly may thus include one or more empty windows 46 between adjacent rotators 42. The attachment windows 46 provided by each main frame module 40a-c further facilitate the reconfiguration of the mold assembly 24 for forming blades 10 of different geometries, since the rotators 42 can be repositioned along the mold assembly 24 according to the loading requirements of each mold configuration.

[0077] Briefly return to the reference Figures 5a to 5c , except that Figure 8 outside, the rotator beam 44a of the inner rotator 44a preferably has an equal length L1 in the chordwise direction (C). The rotator beams 44b of the outer rotators 42b preferably also have equal lengths L2 with respect to each other in the chordwise direction (C). Similarly, the rotator beam 44c of the intermediate rotator 42c preferably has an equal length L3 in the chordwise direction (C). In some examples, the chordwise length L of each rotator beam 44a-c can be determined by or at least related to the chordwise width W of the main frame module 40a-c to which it is attached.

[0078] Thus, the foregoing preferred example in which each main frame module 40a-c has the same chordwise width W in the respective spanwise direction section of the mold assembly 24 can be further advantageous for reconfiguring the mold assembly 24. For example, such a configuration can mean that each inner rotator 42a can be attached to any inner main frame module 40a, each outer rotator 42b can be attached to any outer main frame module 40b, and, where included, each intermediate rotator 42c can be attached to any intermediate main frame module 40c.

[0079] Now referring more specifically to Figure 8 the schematic plan view of the reconfigurable mold assembly 24 therein, how the mold assembly 24 can be used to manufacture wind turbine blades 10 of different geometries will be explained. As previously mentioned, the mold assembly 24 can be used to form a first half shell 12a and a second half shell 12b, which are then joined together to form the outer shell of the blade 10. Thus, the mold assembly 24 can be used to manufacture a first wind turbine blade 10.

[0080] Subsequently, the mold assembly 24 can be reconfigured such that the second wind turbine blade 10 has different dimensions from the first blade 10. For example, one or more mold skin sections 30a-c can be replaced with one or more different mold skin sections 30a-c having different dimensions. In some examples, this can also involve replacing one or more intermediate support structures 32a-c with one or more different intermediate support structures 32a-c (not shown) to support the different skin sections 30a-c. In Figure 8In the example shown, a plurality of different intermediate skin sections 30c are provided to replace the existing intermediate skin section 30c of the tooling assembly 24, thereby manufacturing blades 10 of different lengths. It should be understood that in other examples, any combination of one or more of the skin sections 30a-c can be replaced with different skin sections 30a-c.

[0081] In the case where the tooling assembly 24 is reconfigured with one or more different tooling skin sections 30a-c, the tooling assembly 24 can then be used to manufacture a second wind turbine blade 10. For example, this can involve disposing a reinforcement material on the tooling skin 26 and integrating the reinforcement material with a resin to form a half shell 12 having different dimensions than the half shell 12 of the first blade 10. Thus, the first and second wind turbine blades 10 can advantageously have different dimensions.

[0082] It should be noted that reconfiguring the tooling assembly 24 does not necessarily require reconfiguring the main frame 38. The different tooling skin sections 30a-c and the corresponding intermediate support structures 32a-c can be releasably connected to the existing main frame 38. In this way, blades 10 having different geometries can be manufactured in the tooling assembly 24 without changing the main frame 38.

[0083] However, in some other instances, the second blade 10 can have a different length than the first blade 10, or at least one of the different tooling skin sections 30a-c can have a different length than the corresponding tooling skin section 30a-c of the first blade 10. In such an example, reconfiguring the tooling assembly 24 can include adding or subtracting one or more main frame modules 40a-c. As Figure 8 shown, when it is necessary to support the skin sections 30a-c to form different blades 10 of different lengths, a plurality of different main frame modules, such as inner and / or outer and / or intermediate main frame modules 40a-c, can be provided to be included in the tooling assembly 24. In the case of including additional main frame modules 40a-c, reconfiguring the tooling assembly 24 can involve connecting the different intermediate support structures 32a-c of the different tooling skin sections 30a-c to the additional main frame modules 40a-c.

[0084] Accordingly, it should be understood that the mold assembly 24 described herein facilitates simple reconfiguration to form different blades 10 having different geometries. This significantly reduces the mold downtime when reconfiguring the mold assembly 24 to form different blades 10 and also reduces the cost and engineering effort involved in producing different mold assemblies 24. In particular, the reconfigurable mold assembly 24 facilitates reconfiguration of any spanwise portion of the mold assembly 24, such as the inner portion, the outer portion, or the intermediate portion, for example by replacing one or more mold skin segments 30a-c and / or adding or removing one or more main frame modules 40a-c. A method of manufacturing a mold assembly 24 for a wind turbine blade half-shell 12 will now be described with reference to the remaining drawings.

[0085] As Figure 9a shown, an elongate mold plug 48 is disposed in a first position. The mold plug 48 has a profile corresponding to a portion of the profile of the wind turbine blade half-shell 10. The mold plug 48 may define a substantially convex profile and may be referred to as a male mold. A mold skin segment 30 is formed on the mold plug 48, such as the mold skin segments 30-a-c described previously with reference to the Figures 2 to 8 drawings. For example, the mold skin segment 30 may be a composite structure and may be formed by arranging a fiber material (such as fiberglass) on the mold plug 48 before integrating the fiber material with a polymer resin.

[0086] The mold skin segment 30 formed on the mold plug 48 may be shaped to form at least a portion of the root end 16 of the half-shell 12, the tip end 18 of the half-shell 12, or the intermediate segment of the half-shell 12 between the root end 16 and the tip end 18. It should be understood that the same method may be used to form each skin segment 30a-c of the mold assembly 24, but different mold plug profiles may be required for each different mold skin segment 30a-c.

[0087] Still referring to Figure 9a , after forming the mold skin segment 30, a frame structure 50 is disposed on top of the mold skin segment 30 on the plug 48. The frame structure 50 may be lifted (and in some examples rotated) and positioned above the plug 48 and lowered onto the mold skin segment 30 to provide the frame structure 50 on top of the mold skin segment 30 on the plug 48. In some examples, the frame structure 50 may include one or more lifting beams 52 to provide lifting points and protect the frame structure 50 during the lifting operation.

[0088] In some examples, as Figure 9aAs shown, the frame structure 50 may include one or more main frame modules 40 releasably connected to the intermediate support structure 32. For example, the intermediate support structure 32 may be bolted to the said or each main frame module 40. As previously described, each intermediate support structure 32 may include a plurality of chordally extending ribs 34 spaced apart from each other in the span direction (S). In some examples, the intermediate support structure 32 may also include a plurality of tubes, rods or beams 36 longitudinally extending in the span direction (S), as Figure 9a shown.

[0089] Additionally, in some examples, the frame structure 50 disposed on top of the tool skin section 30 may include one or more rotator beams 44 attached to the said or each main frame module 40. For example, the frame structure 50 may be assembled prior to being disposed on the tool skin section 30 disposed on the tool plug 48, including the said or each rotator beam 44. Alternatively, in some examples, after the main frame module 40 and the intermediate support structure 32 releasably connected thereto are disposed on top of the tool skin section 30 of the plug 48, the rotator beam 44 or each rotator beam 44 may be attached to the main frame module 40 or each main frame module 40. This may advantageously provide improved access to the main frame module 40 and the window 46 for attaching the rotator beam 44 or each rotator beam 44 to the main frame module 40.

[0090] As Figure 9b shown, by disposing the frame structure 50 on top of the tool skin section 30 of the plug 48, the frame structure 50 is attached to the tool skin section 30 to form a subassembly 54. The subassembly 54 includes the tool skin section 30 and the frame structure 50, as Figure 9c most clearly shown in. Attaching the frame structure 50 to the tool skin section 30 may involve connecting the intermediate support structure 32 or each intermediate support structure 32 to the tool skin section 30. The frame structure 50 is preferably attached to the tool skin section 30 in a releasable manner, for example via bolt connections. For example, the tool skin section 30 may include a plurality of tabs (not shown) on opposite sides of the tool skin section 30, and the frame structure 50 may be connected to the skin section 30 via the tabs.

[0091] Now referring to Figure 9c , the subassembly 54 is removed from the tool plug 48 and transported from the first location to a blade manufacturing facility. It should be understood that also referring to Figure 9b, removing the sub - assembly 54 from the mold plug 48 may include lifting the sub - assembly 54 from the mold plug 48. To transport the sub - assembly 54 from the first location to a blade manufacturing facility, the sub - assembly 54 may be arranged and transported within a shipping container (not shown). This may help protect the sub - assembly 54 during transportation, especially the mold skin section 30. Transporting the sub - assembly 54 within a shipping container is further advantageous because established container shipping methods and routes can be used without the need for expert logistics solutions.

[0092] After transportation, to form a mold assembly 24 for forming a wind turbine blade half - shell 12 having a first geometry, the sub - assembly 54 is arranged end - to - end with one or more additional sub - assemblies 54 at the blade manufacturing facility. Figure 2 An example of a mold assembly 24 including a plurality of sub - assemblies 54 arranged end - to - end is shown. In some examples, the main frame modules 40a - c of the sub - assembly 54 may be releasably connected to the main frame modules 40a - c of an additional sub - assembly 54 at the blade manufacturing facility. Additionally, to increase rigidity and structural support, the intermediate support structures 32a - c of the sub - assembly 54 may be releasably connected to the intermediate support structures 32a - c of an additional sub - assembly 54.

[0093] As previously referenced in the appendix Figures 2 to 8 As described, the mold assembly 24 may be reconfigured at the blade manufacturing facility such that the mold assembly 24 is adapted to manufacture a wind turbine blade half - shell 12 having a second geometry different from the first geometry. For example, referring to Figure 10 , reconfiguring the mold assembly 24 may involve separating the intermediate support structures 32a - c of the sub - assembly 54 from one or more of the main frame modules 40a - c. This may further involve removing the mold skin sections 30a - c and the attached intermediate support structures 32a - c from the mold assembly 24. Different mold skin sections 30a - c attached to different intermediate support structures 32a - c may be provided, and the different intermediate support structures 32a - c may be bolted, for example, to one or more existing main frame modules 40a - c.

[0094] It should be understood that examples involving removing the main frame modules 40a - c from the mold assembly 24 to manufacture shorter blades 10 and other examples involving adding additional main frame modules 40a - c to the mold assembly 24 to manufacture longer blades 10 have been previously described with reference to Figure 8 and will not be described in detail here.

[0095] Figures 11a to 11c An example of a process for manufacturing and providing different mold skin sections 30i attached to different intermediate supports 32 for reconfiguring the mold assembly 24 is shown. Similar to the reference in the appendixFigures 9a to 9c As provided in the description, different mold skin sections 30i can be formed on the mold plug 48i, and the frame structure 50i can be attached to the different mold skin sections 30i, as Figure 11b shown.

[0096] However, when manufacturing different mold skin sections 30i to replace the existing mold skin section 30 of the mold assembly 24, the frame structure 50i can include a conveyance 56 instead of one or more main frame modules 40. Thus, the frame structure 50i attached to the different mold skin sections 30i can include a conveyance 56 of an intermediate support structure 32i that is releasably connected to the different mold skin sections 30i.

[0097] During transportation, the conveyance 56 can advantageously provide structural rigidity for the different mold skin sections 30i and the intermediate support structure 32i. Additionally, the conveyance 56 can further provide a plurality of lifting points such that the different mold skin sections 30i can be transported and lifted without the risk of damaging the mold skin sections 30i. In some examples, the conveyance 56 can be adjustable, i.e., reconfigurable, such that it can be used to transport a variety of different mold skin sections 30i and their corresponding intermediate support structures 32i.

[0098] Figure 11c Shown are the different mold skin sections 30i, the attached intermediate support structure 32i, and the conveyance 56 after these have been lifted from the mold plug 48i. The different mold skin sections 30i, the intermediate support structure 32i, and the conveyance 56 can be transported in the same manner as the subassembly 54 described previously with reference Figures 9a to 9c to. The different mold skin sections 30i can be released from the conveyance 56 before including the different mold skin sections 30i in the mold assembly 24. It should be understood that the process for including different mold skin sections 30i and the associated intermediate support structure 32i has been described in detail previously, e.g., with reference Figure 10 to, and for the sake of brevity, will not be repeated here. After including the different mold skin sections 30i in the mold assembly 24, the mold assembly 24 can then be used to manufacture a wind turbine blade half-shell 12 having a second geometry different from the first geometry.

[0099] It should be understood that the description provided above is for illustrative purposes of a plurality of possible examples of the present invention. Without departing from the scope of the present invention as defined in the appended claims, the features described with respect to any one of the above examples can be readily combined with any other features described with reference to different examples.

Claims

1. A method of manufacturing a tooling assembly for a wind turbine blade half-shell, the method comprising: providing an elongate tooling plug at a first location, the profile of the tooling plug corresponding to a portion of the profile of the wind turbine blade half-shell; forming a tooling skin section on the tooling plug; providing a frame structure on top of the tooling skin section on the plug and attaching the frame structure to the tooling skin section to form a sub-assembly including the tooling skin section and the frame structure; removing the sub-assembly from the tooling plug; transporting the sub-assembly from the first location to a blade manufacturing facility; and arranging the sub-assembly end-to-end with one or more additional sub-assemblies at the blade manufacturing facility to form a tooling assembly for a wind turbine blade half-shell having a first geometry, wherein the frame structure includes one or more main frame modules releasably connected to an intermediate support structure, and wherein the method includes connecting the intermediate support structure to the tooling skin section.

2. The method according to claim 1, wherein The step of providing the frame structure on top of the tooling skin section includes: lifting the frame structure, optionally rotating the frame structure, positioning the frame structure above the plug, and lowering the frame structure onto the tooling skin section.

3. The method according to any one of the preceding claims, wherein, The step of removing the sub-assembly from the tooling plug includes: lifting the sub-assembly from the tooling plug.

4. The method according to any one of the preceding claims, wherein, The tooling skin section is shaped to form at least a portion of the root end of the half-shell, or the tip end of the half-shell, or an intermediate section of the half-shell between the root end and the tip end.

5. The method according to any of the preceding claims, the method further comprising arranging the sub-assembly in a shipping container and transporting the sub-assembly within the container from the first location to the blade manufacturing facility.

6. The method according to any one of claims 1 to 5, wherein The intermediate support structure is bolted to the one or more main frame modules.

7. The method according to any one of claims 1 to 6, wherein The intermediate support structure or each intermediate support structure includes a plurality of chordwise extending ribs spaced apart from each other in the spanwise direction and / or a plurality of tubes, rods or beams longitudinally extending in the spanwise direction.

8. The method according to any of claims 1 to 7, the method further comprising releasably connecting the main frame modules of the sub-assembly to the main frame modules of an additional sub-assembly and / or releasably connecting the intermediate support structure of the sub-assembly to the intermediate support structure of the additional sub-assembly at the blade manufacturing facility.

9. The method according to any one of claims 1 to 8, wherein The frame structure further includes one or more swivel beams attached to the one or more main frame modules and / or one or more lifting beams for lifting the frame structure.

10. The method according to any of claims 1 to 9, the method further comprising reconfiguring the tooling assembly at the blade manufacturing facility such that the tooling assembly is suitable for manufacturing a wind turbine blade half-shell having a second geometry different from the first geometry.

11. The method according to claim 10, wherein, Reconfiguring the die assembly includes removing the intermediate support structure of the subassembly from the one or more main frame modules, removing the die skin section and the attached intermediate support structure from the die assembly, providing different die skin sections attached to the intermediate support structure, and connecting the intermediate support structure of the different die skin sections to the one or more main frame modules.

12. The method according to claim 11, the method including bolt - connecting the intermediate support structure of the different die skin sections to the one or more main frame modules.

13. The method according to claim 11 or 12, the method further including adding additional main frame modules to the die assembly and additionally connecting the intermediate support structure of the different die skin sections to the additional main frame modules in the case where the second geometry is longer than the first geometry, or removing main frame modules from the die assembly in the case where the second geometry is shorter than the first geometry.

14. The method according to any one of claims 11 to 13, wherein, The different die skin sections are disposed on a vehicle that is releasably connected to the intermediate support structure of the different die skin sections, and the method includes releasing the different die skin sections from the vehicle before including the different die skin sections in the die assembly.

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