Mold element support device for a manufacturing assembly of preform elements and / or precast elements and / or prepackaging elements, manufacturing assembly and manufacturing system

Abstract

A mould element support device (2) for a preform element (86) and / or a precasting element and / or a prepackaging element, in particular for a manufacturing assembly (1) of a wind turbine blade, the mould element support device (2) comprising a plurality of vertical column elements (3, 3 '), the vertical column elements (3, 3') comprising an upper support portion (10), the column elements (3, 3 ') are used for carrying longitudinal mould elements (9, 9', 9 '', 9'' ', 9 '''') for manufacturing preform elements (86) and / or pre-cast elements and / or pre-packaged elements, and the column elements (3, 3') comprise height adjusting equipment (12) for adjusting the heights of the column elements (3, 3 ') in particular separately. And the support part (10) is adjustable in distance at least in the width direction (4) of the mould element (9, 9 ', 9 '', 9''', 9 '''') via a positioning device (6) in order to adapt the mould element support device (2) to mould elements (9, 9 ', 9 '', 9''', 9 '''') of different shapes and / or sizes.

Description

Technical Field

[0001] The present invention relates to a die element support device for a manufacturing assembly for prefabricated elements and / or precast elements and / or prepackaged elements, in particular for wind turbine blades, the die element support device comprising a plurality of vertical column elements which comprise an upper support portion for carrying a longitudinal die element, in particular a die shell, for manufacturing prefabricated elements and / or precast elements and / or prepackaged elements. Furthermore, the present invention relates to a manufacturing assembly for prefabricated elements and / or precast elements and / or prepackaged elements, in particular for wind turbine blades, the manufacturing assembly comprising the die element support device, and to a manufacturing system. Background Art

[0002] Wind turbines generally comprise a rotor having a plurality of wind turbine blades. For example, such a wind turbine can convert the mechanical energy of the wind into electrical energy. Due to the search for large-scale energy production, wind turbines and thus wind turbine blades have huge dimensions, making their manufacturing a major challenge for wind turbine manufacturers. Although wind turbine blades have long been made of fiber-reinforced materials, which involves handling large parts such as fiber mats by casting the shell of the wind turbine blade, techniques have been proposed to assist in the manufacture of wind turbine blades.

[0003] For example, the use of prefabricated elements or preforms has been proposed accordingly. Such prefabricated elements are preformed smaller parts or sections of wind turbine blades, which are used to construct the corresponding wind turbine blade shell. The prefabricated elements are premanufactured separately and then arranged and aligned in a blade mold according to the required geometry of the wind turbine blade to be manufactured. The prefabricated elements can be arranged in the blade mold for casting the entire wind turbine blade or large wind turbine blade parts.

[0004] The prefabricated elements can comprise one or more components, such as one or more textile layers, wherein these components are at least partially attached to each other by using a binder / adhesive. For example, these components can comprise a plurality of fiber mats and / or core materials, which are locally attached to each other to allow their handling together. This helps in the arrangement of the components in the blade mold. The prefabricated elements can be understood as semi-solid elements. In particular, the textile components of the prefabricated elements, such as fiber mats, can be made of glass fiber, carbon fiber or aramid fiber. These layers remain unaffected by the binder so that they can be filled with resin later during the manufacture of the rotor blade. For example, the core material can comprise balsa wood, foam, etc. The use of prefabricated elements in particular allows a reduction in the cycle time for producing wind turbine blades.

[0005] As a variant, pre-packaged elements have been proposed. Here, components such as fiber mats and / or core materials are placed in a mold element so as to adopt the shape of the molding surface. This shape is preserved by tightly packing these components in a vacuum bag.

[0006] In another method, the use of pre-cast elements has also been proposed, i.e., parts or sections of a wind turbine blade that already include cured resin and can also be used to construct a wind turbine blade.

[0007] For example, a preform element can be made in a manufacturing assembly, which can also be referred to as a preform mold. Such a manufacturing assembly typically includes a mold element, such as a mold housing, which includes a molding surface shaped according to the desired shape of the preform element, and these components are placed on this molding surface so as to adopt the corresponding shape. Preferably, the preform element is covered in a vacuum bag to stabilize the stacking of the components that make up the preform element.

[0008] In modern wind turbines, wind turbine blades with different geometries, in particular different sizes, are employed. Thus, if different types / sizes of wind turbine blades are to be manufactured, the size of the preform element varies according to the size of the blade for which they are intended. In particular, the preform element varies mainly in height and width, where, additionally, even within a specific type of wind turbine blade, different shapes may occur.

[0009] However, nowadays, manufacturing assemblies for preform elements, in particular preform molds, are mostly designed for specific preform element sizes and / or shapes. In particular, a preform element of a given size and shape is manufactured in a dedicated manufacturing assembly for preform elements. However, this is not a feasible method for mass production, as a very large number of manufacturing assemblies would be required, as well as lifting and / or transportation tools in many cases.

[0010] WO 2019 / 115 522 A1 proposes a method for manufacturing at least two preforms for molding a wind turbine blade, wherein the preform mold structure used has a molding surface with a variable shape such that, by using an actuator, the shape of the molding surface can be varied at least between a first and a second configuration. However, a mold element with a molding surface of variable shape has a complex and expensive construction and, in particular, does not allow scaling of the shape provided by such an adaptable mold element. In particular, such a mold structure cannot provide molding surfaces for different widths and / or heights of the preform element to be manufactured.

[0011] Similar problems also arise for the manufacture of pre-packaged elements and pre-cast elements. Summary of the Invention

[0012] An object of the present invention is to provide an improved manufacturing arrangement which allows the production of a variety of prefabricated elements and / or precast elements and / or prepackaged elements, in particular of different sizes and / or shapes, which manufacturing arrangement is flexible, cost-effective and in particular also easily transportable.

[0013] This object is achieved by providing a die element support device according to claim 1, a manufacturing assembly according to claim 14 and a manufacturing system according to claim 15. Advantageous embodiments are described by the dependent claims.

[0014] A die element support device for a manufacturing assembly for prefabricated elements and / or precast elements and / or prepackaged elements, in particular for wind turbine blades, comprises a plurality of vertical column elements which comprise upper support portions for carrying longitudinal die elements for manufacturing prefabricated elements and / or precast elements and / or prepackaged elements, in particular die casings. As a first feature, the column elements comprise height adjustment means for adjusting, in particular individually, the height of the column elements. As a second feature, the support portions are adjustable in distance at least in the width direction of the die elements via positioning means. This first and second feature allows the die element support device to be adapted to die elements of different shapes and / or sizes.

[0015] Here, the die element, in particular the die casing, is a rigid shape-retaining element which has a moulded surface shaped according to the desired shape of the prefabricated element and / or precast element and / or prepackaged element, on which surface the components are placed during manufacture in order to assume the corresponding shape. By adding the die element, the die element support device on which the die element is supported provides a prefabrication die (and / or precasting die and / or prepackaging die) for the manufacturing assembly for prefabricated elements and / or precast elements and / or prepackaged elements.

[0016] The die element support device comprises a plurality of vertically extending column elements which are height-adjustable and positioning means which allow adjustment of the relative position of the support portions of the column elements, in some embodiments the column elements themselves, at least in the width direction and generally in the horizontal plane. Here, the vertical column elements comprise at least one vertically extending column section which can be lengthened or shortened by the height adjustment means. The vertical column elements may additionally comprise other, in particular horizontally extending, sections, such as arms, as will be discussed further below.

[0017] According to the present invention, a device is provided to implement a manufacturing assembly for prefabricated elements and / or precast elements and / or prepackaged elements, which is flexible in terms of the dimensions and / or shape of the prefabricated elements and / or precast elements and / or prepackaged elements to be manufactured. In particular, die elements for a large number of dimensions and / or shapes of prefabricated elements and / or precast elements and / or prepackaged elements can be provided to form a manufacturing system. To produce a prefabricated element and / or precast element and / or prepackaged element of another dimension and / or shape, the previous die elements can be removed, the die element support device can be adjusted to support the new die elements, and the new die elements can be supported on the die element support device. Adjustment is facilitated by providing highly adjustable column elements and positioning devices. The column elements can be understood as "adjustable legs", which can preferably be adjusted separately in terms of their height and the position of their support parts.

[0018] Thus, the manufacturing assembly or workstation can correspondingly handle die elements with different geometries. The manufacturing assembly is not specifically for a certain wind turbine blade, especially a certain size / dimension of a wind turbine blade. Therefore, the manufacturing assembly can be used to manufacture prefabricated elements and / or precast elements and / or prepackaged elements for several different wind turbine blade types. To achieve this, a plurality of different die elements can be provided.

[0019] Regarding the column elements and positioning devices, as will be further detailed below, the die element support device can be implemented modularly, such that it can for example be disassembled and tightly packed into a transport receptacle such as a container. If in particular multiple pairs of column elements are provided separately along the longitudinal direction of the die element, due to the modular construction, length adjustment can be easily provided by adding or removing column elements.

[0020] For example, the flange or other edge region of the die element can be supported on the support part of the column element. Here, for example due to special design features, easy adjustment of the varying height along the length of the die element is possible, such special design features can for example be provided for a lightning protection system etc. For example, if the flange of the die element is locally higher than the rest of the length, the corresponding column element can be adjusted to that greater height. Thus, the positioning device can be used for local width adjustment that is greater or smaller. However, the provided height adjustment options can also be used to generally adjust the working height, especially for additional tools or auxiliary devices used during manufacturing. For example, the flange height can be adjusted to provide optimal working conditions for the manufacturing personnel.

[0021] Generally speaking, the manufacturing equipment can also be reused, or even recycled for use with another type of wind turbine blade if the blade type is discontinued. Therefore, in addition to cost - effectiveness, a quick conversion to the manufacture of a new blade type is possible. Since only the die elements (and accordingly the die element support devices) are replaced, the process of manufacturing preform elements and / or pre - cast elements and / or pre - packaged elements can be assimilated or even standardized for different types of wind turbine blades, making it easier for the manufacturing personnel to switch between the production of different blade types. In particular, this manufacturing assembly can also be used for the manufacture of different types of wind turbine blades. For example, the manufacturing assembly described herein can be used for integral blade manufacturing as well as blade half manufacturing. Finally, the manufacturing assembly can be used for both preform element / pre - packaged element and pre - cast element manufacturing.

[0022] In particular, a manufacturing system can be envisioned in which at least one die element support device can be combined with a plurality of die elements, all of which can be used with the die element support device to construct certain different types (in particular sizes) of manufacturing assemblies for preform elements and / or pre - cast elements and / or pre - packaged elements. In particular, each such manufacturing assembly may be capable of manufacturing a preform element, such as a concave preform element, which can be packaged in a vacuum bag and / or vacuum foil. In particular, it may even be possible to package more than one preform element and / or pre - cast element and / or pre - packaged element on top of each other during manufacturing. Regarding the vacuum bag, different types and designs can be employed, such as those described in the later - published European patent application 21209596.2.

[0023] In an embodiment, each height - adjustment device may include a telescopic device and / or a controllable actuator, in particular an electric actuator or a hydraulic actuator. Therefore, different configurations can be envisioned, in which, for example, a preferably cylindrical section can be telescopically raised or lowered from a base section. Preferably, automatic height adjustment is enabled by providing a controllable actuator, which can be, for example, an electronic and / or hydraulic actuator. The die element support device may include operating elements, such as those located at each column element and / or provided as at least one remote - control device. Preferably, in addition to the actuator for height adjustment, for at least one degree of freedom, the positioning device may also include an actuator that can cause relative movement of at least the support portions of at least two column elements, in particular in response to the use of at least one operating element. Certain control processes can also be automated, for example by using a control device to control the actuator.

[0024] In a preferred embodiment, the positioning device may include a track extending in the width direction, wherein the column element is correspondingly movably guided in or on one of the tracks. In one embodiment, a pair of column elements to be placed at the opposite side edges of the die element may be guided by a common track, in particular for supporting the opposite flanges of the die element. That is, at least two column elements may be guided in the same track or on the same track, and the track defines a position along the die element support device and thus along the length of the die element and extends in the width direction. In this way, the pair of column elements may be symmetrically placed at the opposite side edges of the die element in a relative manner, in particular each supporting the flange of the die element. A simple structure that facilitates the symmetrical placement of the column elements is achieved.

[0025] However, in another embodiment, the tracks may also be assigned to each individual column element such that for at least substantially opposite column elements, those tracks and thus the column elements may also be displaced in the longitudinal direction, thereby providing additional flexibility and degrees of freedom. In particular, this allows the column elements to be positioned non-linearly with respect to their relatively placed counterparts and / or column elements that are unevenly spaced on one or both sides of the die element.

[0026] Preferably, each such track having at least one column element running thereon may form a module in the modular construction of the die element support device, as discussed above.

[0027] Generally, in order to prevent deflection and / or deformation of the die element, at least one, particularly a lower additional column element, may be positioned in the middle section below the die element to provide additional support. In a preferred embodiment, if a pair of column elements guided in a common track or on a common track is used, then in particular the lower additional column element may be positioned between this pair of column elements and guided in the common track or on the common track to additionally support the middle section of the die element. Generally, as an advantageous option, one or more additional column elements, i.e., support elements, may be provided to assist in supporting the die element, for example for placement in the middle section of the die element. Preferably, such additional column elements may be placed at the lowest point in the width direction of the die element at a certain length position. This lowermost point of the die element generally depends on the specific shape of the die element, which may not necessarily be symmetrically curved.

[0028] In an embodiment, the die element support device may be floor-mounted. That is, the positioning device may include an attachment device for releasably mounting the column element to the floor. This is particularly advantageous in the case of a track, which can be mounted directly to the floor, for example, at different length positions of the die element to be supported. The attachment device is preferably releasable, thus providing further flexibility, since for different die elements, different mounting positions on the floor can be selected. In other words, the die element support device can be easily moved to another position. For example, if a longer die element is to be used next, a track, especially one that carries a pair of column elements to be placed in a relative manner in the width direction, can be removed and moved to a new position corresponding to the increased length.

[0029] In another embodiment, it is also conceivable to use a track integrated into the floor for a particularly robust design.

[0030] In other alternative embodiments, the positioning device may also include wheels. In this case, preferably, the positioning device may additionally include locking means associated with the wheels, especially brakes. However, it is also conceivable to have support legs in addition to the wheels and to lower the wheels to a position below the feet of the support legs to be able to move the column element supported by the positioning device, especially supported on the wheels on a track, to a new position. One advantage of providing wheels is the option of moving the entire manufacturing assembly, i.e., the die element support device on which the die element is placed, as a whole, especially having at least one prefabricated element and / or precast element and / or prepackaged element or at least parts thereof located in the die element. In such an embodiment, for example, the prefabricated element and / or precast element and / or prepackaged element to be manufactured can be moved to a heating and / or cooling device, especially an oven.

[0031] While using a track, a releasable attachment device, and / or wheels allows repositioning of all column elements, it is also possible to integrate the positioning device at least partially into the column element, thus allowing movement of the support part. In a particularly preferred embodiment, each column element may include a horizontally extending rotating arm as part of the positioning device. At different positions of the rotating arm, the support part is in different positions with respect to the length direction and, more importantly, with respect to the width direction. Thus, such a rotating arm provides a simple way to adjust the position of the support part in the horizontal plane.

[0032] In a specific embodiment, the rotating arm may be mounted on top of the vertical column section of the column element and / or carry the support part. The column element can be mounted to the floor, especially releasably, using an attachment device or a more permanent mounting device. A track can be used additionally.

[0033] In such a configuration using a rotating arm, each column element can be understood as a module of a modularly constructed die element support device. A high degree of freedom is provided between the individual modules, i.e., the column elements. Such an embodiment is highly flexible, especially in the case of a releasable attachment device for attachment to the floor. Additionally, it is easy to transport and cost-effective in construction and use.

[0034] Preferably, the support part may include a particularly flat contact surface for contacting the die element, and tilting means, in particular a spherical joint, for tilting the contact surface into different contact orientations. The die element may have different flange designs, or generally edge designs. Additionally, the support part can be used where the die element generally has a surface that slopes outward from the horizontal plane. In all these cases, preferably, an additional degree of freedom can be provided for the support part by providing tilting means that allow the contact surface to slope outward from the horizontal plane to adjust to the orientation of the die element to which it will be joined. For example, the flange of the die element may include a sloping die surface bounded by an edge shoulder. In such an embodiment, the support part, in particular the contact surface, can be placed adjacent to the edge shoulder in an orientation corresponding to the sloping die surface. Preferably, the tilting means may include a spherical joint. In some embodiments, providing a simple joint may be sufficient, which allows tilting / pivoting only in one plane, in particular about a rotation axis extending in the longitudinal direction.

[0035] In an embodiment, the support part may also include a low-friction material and / or in particular longitudinally oriented rollers in the contact area with the die element. Having a low-friction material especially on the contact surface already mentioned allows for easy addition and removal of the die element, for example if the die element is to slide onto or off the contact surface in the contact area. The rollers, which can preferably be oriented in the longitudinal direction of the die element, allow similar advantages to be achieved.

[0036] The die element support device may further include at least one longitudinal working platform for the manufacturing personnel. Such a working platform will be placed along the longitudinal direction of the die element, wherein the positioning means are additionally adapted to at least partially position the working platform. In this way, a flexible walkway is provided for the manufacturing personnel along the die element / precast die.

[0037] In this context, preferably, if the positioning device includes at least one track extending in the width direction, the at least one working platform can also be guided in at least one of the at least one track or on at least one of the at least one track, and / or be kinematically coupled to the outermost column element in the width direction, wherein the outermost column element is guided in the track. In this way, the working platform can follow the column element and thus follow the support for the die element. Here, the working platform can run in the same track and / or be kinematically coupled to the corresponding outermost column element such that when these column elements move in the width direction, the working platform follows the die element and remains adjacent thereto.

[0038] In a preferred embodiment, the die support device can further include a height adjustment device for the working platform, in particular a telescopic device and / or a scissor mechanism. In this way, the height of the working platform can be adjusted to suit the height of the die element, so that an optimal working position for the manufacturing personnel can be achieved. In particular, the operator can reach the molding surface directly or indirectly. As a height adjustment device for the working platform, for example, a scissor mechanism can be provided. Of course, for example, other embodiments such as telescopic devices can also be used.

[0039] Generally, working platforms can be provided on each side of the die element. These working platforms can be adjusted independently in height. The working platform can further include climbing devices, such as pivotally articulated ladders or stairs.

[0040] The manufacturing assembly for prefabricated elements and / or precast elements and / or prepackaged elements according to the invention includes a die element support device according to the invention and a die element supported on the die element support device, thus providing a complete prefabricated die (or correspondingly a precast die / prepackaged die). All the features and advantages discussed with respect to the die element support device can similarly apply to the manufacturing assembly. In particular, the manufacturing assembly can be part of a manufacturing system that includes different replaceable die elements, in particular die elements of different sizes and / or different shapes.

[0041] Here, the tooling element, in particular the tooling housing, can be constructed / manufactured as designs already proposed in the art or with alternative novel designs. For example, the tooling element can include a conventional laminate, which is relatively heavy and expensive, but suitable as it allows heat transfer through the layers of the laminate, e.g., for heating and / or cooling the binder of the preform element. In other embodiments, a sandwich structure of the core can be provided, which for example includes glass fiber layers on both sides of the core element, and the core element can be made of a core material such as balsa wood or foam. Such a construction is inexpensive, strong and relatively light in weight. However, it does not provide an ideal heat transfer through the tooling element. If carbon fiber layers are combined with a foam-based core material, such a sandwich structure can be made even lighter in weight. However, such a construction can be more expensive due to the use of carbon.

[0042] In another embodiment, the sandwich structure can be modified to include at least one layer providing internal channels and / or voids. For example, such an additional layer can be placed on the laminate stack such that the laminate stack and the additional layer can be encapsulated between outer layers made of, for example, glass fiber. For example, the additional layer can be a ParaBeam TM layer. These internal channels and / or voids in the tooling element can be advantageously used to heat and / or cool the preform element and / or the precast element and / or the prepackaged element from below, in particular by supplying a cooling or heating fluid to the internal channels and / or voids.

[0043] These internal channels can also be provided in a 3D printed construction of the tooling element. Here, the internal channels can also be used to provide cooling or heating to the preform element and / or the precast element and / or the prepackaged element from below.

[0044] In another embodiment, it is also conceivable to provide a tooling element consisting of a honeycomb-based core material sandwiched between outer layers including carbon fiber to further reduce the weight of the tooling element.

[0045] Generally, the manufacturing assembly may additionally include at least one auxiliary device that provides at least one component for the preform element and / or the precast element and / or the prepackaged element to the manufacturing personnel. For example, the at least one auxiliary device may provide fiber mats and / or fiber materials and / or core materials and / or binders. For example, the components (especially fiber mats) may be arranged on a pallet suspended from a gantry crane or a suspension crane, and the pallet may be oriented in the width direction or the longitudinal direction. Here, preferably, the height of the pallet suspended from the crane can be adjusted so that the manufacturing personnel can easily reach these components, especially the fiber mats, especially from both sides of the mold and / or on the working platform. It should be noted that if height-adjustable working platforms are provided, these working platforms can be adapted to be in the optimal working position, which especially also depends on the body size of the operator. Regarding the longitudinally oriented suspension crane or gantry crane, it should be noted that these cranes can move between the manufacturing assemblies that are parallelly oriented and positioned to provide components to multiple manufacturing positions. However, the auxiliary device can also be a fiber laying machine, which can be CNC-controlled and includes a cutting device that cuts the fiber material into the required length while laying it directly into the preform mold. The fiber material stock can be placed near the manufacturing assembly so that the fiber laying machine can be loaded separately or continuously.

[0046] It should be noted that such an auxiliary device can also be configured to directly apply a binder to the components, such as fiber mats, as has been proposed in the art.

[0047] In the present invention, the mold elements can be replaced so that preform elements and / or precast elements and / or prepackaged elements of different geometries, especially different shapes and / or sizes, can be manufactured. Here, several ways can be envisaged to replace the mold elements. For example, the transport and / or storage device for the mold elements, which can be part of the manufacturing assembly and / or the manufacturing system, can be moved to the mold element support device, and a lifting device, such as including a lifting crane and / or using a vacuum lifter, can be used to move the mold elements. For example, using the lifting device, a previously used mold element can be lifted from the support part of the mold element support device and placed in the storage position and / or the transport position on the transport and / or storage device. Then, after the mold element support device has been adjusted, especially by using height adjustment equipment and / or positioning devices, to adapt to the new mold element, another mold element can be lifted using the lifting device and moved onto the mold element support device.

[0048] Here, if the die element is transported and / or stored in an upright position, a vacuum lifter including a rotatable lifting yoke is particularly preferred. Using a vacuum lifter with a rotatable yoke, a horizontally oriented die element can be rotated to an upright vertical orientation after being lifted from the die element support device and lowered accordingly to a storage and / or transport position on the storage and / or transport device or into a warehouse.

[0049] In another method, the die elements can also be stored or transported in a horizontal position such that they can simply slide back and forth, for example, along the die element support device when the storage and / or transport device is positioned at one longitudinal end of the die element support device. In another embodiment, the storage and / or transport device can move above the die element to grip it from below and lift it from the support portion to the storage and / or transport position.

[0050] Preferably, in such an embodiment, the storage and / or transport device can be a rack including a frame structure that can move on wheels. The support element is guided in or on the vertical beams of the frame structure, and the height can be adjusted by moving the support element in or on the vertical beams. In this way, for example, once the die element is supported on the support element of the storage and / or transport device, it can be lifted upward, for example, to provide space for receiving another die element on the support element placed below a set of already used support elements. Of course, this space can also be provided by moving the already received die element downward and using a higher placed set of storage elements to receive another die element. If the die element is to be unloaded, it can be positioned at the correct unloading height in the same way and unloaded from the corresponding set of support elements of the storage and / or transport device.

[0051] Preferably, in any case, the storage and / or transport device can also be adapted to handle different geometries of die elements flexibly. For example, the support elements of the storage and / or transport device can include rotating arms as already discussed above. To provide height adjustability of the support elements, the vertical beams can include tracks in which the support elements can be mounted to move up and down, particularly also separately, especially within a group. Alternatively, releasable and movable grippers can be used. If rotating arms are used, die elements of different widths can be handled; individual height adjustability allows handling of die elements with different heights on different sides.

[0052] It should be noted that these storage and / or transport devices can also be used for transporting and / or storing prefabricated elements and / or precast elements and / or prepackaged elements manufactured using the said manufacturing assembly. Description of the Drawings

[0053] Other objects and features of the present invention will become apparent from the following detailed description considered in conjunction with the accompanying drawings. However, the drawings are only schematic diagrams designed for illustrative purposes only and do not limit the present invention. The drawings show: Figure 1 A perspective view of a manufacturing assembly of a first embodiment using a die element support device in a first state, Figure 2 For an embodiment in a second state using different die elements Figure 1 of, Figure 3 For an embodiment in a third state using a third die element Figure 1 of, Figure 4 The positioning of the first embodiment on the floor, Figure 5 A second embodiment of the die element support device in a first state, Figure 6 For a second embodiment in a second state, Figure 7 A third embodiment of the die element support device, Figure 8 A column element with a rotating arm, Figure 9 For Figure 8 an exploded view of the column element of, Figure 10A -C is a support portion that interacts with different flange designs of the die element, Figure 11 For possible designs of the support portion, Figure 12 A manufacturing assembly with a workstation platform, Figure 13 For a manufacturing assembly with a first auxiliary device Figure 12 of, Figure 14 For a manufacturing assembly with a second auxiliary device Figure 12 of, Figure 15 For a manufacturing assembly with a third auxiliary device Figure 12 of, Figure 16 For a manufacturing assembly with a fourth auxiliary device Figure 12 of, Figure 17 For a manufacturing assembly with a fifth auxiliary device Figure 12 of, Figure 18 A first embodiment of the layer structure of the die element, Figure 19 A second embodiment of the layer structure of the die element, Figure 20 For a third embodiment of the layer structure of a die element Figure 21 For a fourth embodiment of the layer structure of a die element Figure 22 For a fifth embodiment of the layer structure of a die element Figure 23 For a sixth embodiment of the layer structure of a die element Figure 24 Is a view showing a transport and / or storage device for a die element and a lifting device Figure 25 Is a second view showing a transport and / or storage device having a vacuum lifter as a lifting device Figure 26 Is a view showing placing a die element onto a die element support device using a vacuum lifter Figure 27 Is a view showing a second embodiment of a transport and / or storage device and a lifting device for placing a die element onto a die element support device Figure 28 Placing a die element onto a die element support device by a second embodiment of moving a transport and / or storage device above the die element support device Figure 29 Is a perspective view of a second embodiment of a transport and / or storage device Figure 30 Is a cross-sectional view of a second embodiment of a transport and / or storage device in a first state Figure 31 Is a cross-sectional view of a second embodiment of a transport and / or storage device in a second state Figure 32 Is a view showing removing a preform element from a die element Figure 33 Is a view showing using a second transport and / or storage device to remove a preform element, and Figure 34 Schematically shows an embodiment of a die element support device having wheels Detailed Description

[0054] Figure 1 Shows a manufacturing assembly 1 using a first embodiment of a die element support device 2 according to the present invention. The die element support device 2 includes a plurality of column elements 3 that are movable in a width direction 4 by being guided in a track 5 that is part of a positioning device 6. The track 5 is mounted or in other embodiments integrated into a floor 7 on which the die element support device 2 is placed

[0055] In Figures 1 to 3 In the embodiment shown, two opposite column elements 3 of a pair are guided in a common track 5, but each of the column elements 3 can be positioned independently in the width direction 4. In the longitudinal direction 8, a plurality of such pairs in the common track 5 are placed successively, such that a die element 9 can be placed on the support portions 10 of the column elements 3, as Figure 1 shown in, for a die element 9 having a large width, such that the column elements 3 are positioned, by way of example, at the outermost positions of the common track 5 in the width direction 4 to support the flanges 11 of the die element 9. The column elements 3 also include height adjustment means 12, in this case telescopic means, for adjustment respectively in the height direction 13. In Figures 1 to 3 In the first embodiment shown, the column elements 3 extend completely in the vertical direction, and thus include the height adjustment means 12 in the corresponding vertically extending column sections, and the column elements 3 can be lengthened or shortened by the height adjustment means 12, in this case by telescopically extending or retracting a cylindrical telescopic element. Although this construction using telescopic means will be shown by all the embodiments discussed herein, of course other embodiments of the height adjustment means are also conceivable, for example using linear actuators, rack and pinion, etc.

[0056] In the embodiments shown herein, a manufacturing assembly for a preform element for a wind turbine blade is described; however, embodiments of the present invention may also relate to other preform elements and / or precast elements and / or prepackaged elements.

[0057] To manufacture a preform element, the components of the preform element, such as including fiber mats, core materials and / or binders, are placed in a die element 9 which has a molding surface 14 defining the desired shape for the preform element. By placing the components on the molding surface 14, they assume the desired shape. A binder is supplied to locally attach the components together such that they can be handled as a single object, namely the preform element. As will be discussed further later, the binder can be activated by heat and hardened / cured by cooling, which may also already occur in the manufacturing assembly 1. Alternatively, an oven can be used. In many embodiments, the preform element will be packaged in a vacuum bag and / or vacuum foil for improved handling. Thus, the workstation provided by the manufacturing assembly 1 can also be referred to as a packaging station.

[0058] Due to the adjustability of the support portions 10 in the height direction 13 and the width direction 4 achieved by the positioning means 6 and the height adjustment means 12, the die element support means 2 can be used flexibly for die elements 9 of different shapes and / or sizes, as further explained with respect to Figure 2 and Figure 3 further.

[0059] In Figure 2In [the figure], a narrower die element 9' is shown instead of die element 9. Here, the corresponding pairs of post elements 3 in the common track 5 have been moved closer together such that the flange 11 can be supported on the corresponding post elements 3. If the molding surface 14 is flatter or deeper, the height can also be adjusted to provide optimal working conditions for the manufacturer.

[0060] In Figure 3 a third die element 9'' has been placed on the die element support device 2, which includes characteristic features 15, for example, regarding the lightning protection system of a wind turbine blade to be manufactured from a prefabricated element. In the region of feature 15, the flange 11 is positioned at a higher location, and the die element 9'' is locally widened with a width 16. Figure 3 Different heights 17, 18 are also indicated in [the figure]. By providing the positioning device 6 (in this case, the track 5) and the height adjustment device 12, the die element support device 2 can be perfectly adjusted to support the flange 11 along the entire length of the die element 9''.

[0061] Of course, the die elements 9, 9', 9'' are merely exemplary, and other die elements can also be used, and the die element support device 2 can be adjusted for these die elements.

[0062] Figure 4 Another feature of the die element support device 2 of the first embodiment is illustrated. The track 5, which forms part of the positioning device 6, is releasably attached to the floor 7 by an attachment device 19 such that a pair of post elements 3 in or on the common track 5 can be moved in the longitudinal direction 8, as indicated by the arrow 20. This allows additional adjustment in the longitudinal direction 8 by removing pairs of post elements 3 in the common track 5 or reducing the longitudinal distance between them.

[0063] Each pair of post elements 3 in or on the common track 5 forms a module of the modular die element support device 2. These modules can be easily removed, stored compactly, and transported easily due to the attachment device 19. The die element support device 2 can be easily extended or reduced by adding or removing modules. This further improves the flexibility and operability of the die element support device 2. It should be noted that this modular approach can also be preferably applied to all other embodiments discussed below, especially for the support post elements 3 additionally provided in or on the common track 5, the individual tracks 5 for each post element, and the embodiment with a rotating arm. In particular, this modularity can be achieved by providing the attachment device 19. However, embodiments can be provided where the positioning device 6 additionally includes wheels that can be attached to the track 5, especially to replace or supplement the attachment device 19. These wheels can have locking devices associated with them, especially brakes, to fix the positioning of the track 5.

[0064] Figure 5 shows a second embodiment of the mold element support device 2 according to the present invention. In this case, dedicated tracks 5 are associated with each column element 3, as Figure 6 shown, allowing a pair of associated column elements 3 to be transferred and positioned in the longitudinal direction 8.

[0065] Figure 7 shows a third embodiment of the mold element support device 2. In this case, a pair of column elements 3 for supporting the flange 11 of the mold element 9 are also guided by a common track 5. However, in each common track 5 or on each common track 5, additional column elements 3' are positioned between the pair of column elements 3 to additionally support the intermediate section 21 of the mold element 9. This additionally externally prevents deflection and / or deformation of the mold element 9. The additional column elements 3' can also be moved in or on the track 5 at this length position to be positioned at the lowest point of the mold element 9.

[0066] Of course, such additional column elements 3' can also be supported in their own tracks 5, especially for Figure 5 and Figure 6 the second embodiment.

[0067] In the previous embodiments, the column elements 3 are shown to extend substantially vertically over their entire height. However, in a preferred design applicable to all three embodiments discussed above, the column elements 3 can also include a rotating arm 22, which can preferably be positioned on top of the vertical column section 23 of the height adjustment device 12 of the column element 3. The height adjustment device 12 is again configured as a telescopic device in this case. The rotating arm 22 extends in the horizontal direction and can pivot about a vertical pivot axis by providing a corresponding hinge 24, as Figure 9 shown by the arrow 25 in the exploded view. The rotating arm 22 carries a support part 10 at its other end.

[0068] In Figure 8 shown, a pair of column elements 3 are shown positioned opposite each other in the width direction 4 at the same longitudinal position. The comparison between the dashed position 26 and the fully shown position 27 of the rotating arm 22 and thus the lateral distances 28, 29 in the width direction 4 clearly show the flexibility provided in the width direction 4 by the rotating arm 22.

[0069] Thus, the rotating arm 22 forms part of the positioning device 6 and can be used in addition to the track 5, but can also be used as an alternative. In the latter case, an attachment device 19 can be used to attach the column element 3 directly to the floor 7.

[0070] In Figure 9In the exploded view, the design of the support part 10 is also shown in more detail. As can be seen, the support part 10 includes a contact area 30, which in this case is a flat contact surface 31 for contacting the die elements 9, 9', 9''. The tilting device 32 consists of a spherical joint 33, such that the contact surface 31 can be tilted from its horizontal position to a plurality of tilted orientations, as shown by the arrow 34. The spherical joint 33 or, generally speaking, the tilting device 32 can also allow rotation of the contact area 30 / contact surface 31, as shown by the arrow 35. This allows adjustability of the contact surface 31 and thus the entire support part 10 for different designs of the flanges 11 of the die elements 9, 9', 9'', as Figures 10A - 10C further illustrated in. Here, different configurations of the flanges 11, 11' and 11'' are shown that require the contact surface 31 to be tilted by the tilting device 32. In particular, in Figure 10B and Figure 10C the flanges 11' and 11'' are shown as having shoulders 36 against which the contact area 30 of the support part 10 can be placed.

[0071] The contact surface 31 / contact area 30 can include a low-friction material, especially for allowing the die elements 9, 9', 9'' to slide on the contact surface 31. In another embodiment, as Figure 11 shown in, the contact area 30 can include rollers 37, which are preferably oriented along the width direction 4 to facilitate placement of the die elements 9, 9', 9'' on the support part 10 of the die element support device 2.

[0072] Regarding Figures 9 to 11 the features discussed apply to all embodiments of the die element support device 2 according to the present invention.

[0073] Figure 12 Another embodiment of the die element support device 2 for manufacturing the assembly 1 during use is illustrated. This fourth embodiment is based on Figures 1 to 3 the first embodiment, and additionally includes a working platform 38 that extends longitudinally along both sides of the die element 9. Two working platforms 38 are provided on top of a frame 39, which includes height adjustment means 40 for the working platform 38, which in this case is a scissor mechanism 41. Thus, the working platform 38 is also height-adjustable, as shown by the double arrow 42. A climbing device 43, especially a staircase or ladder, is pivotally mounted to the working platform 38, which may also include a safety fence 44.

[0074] The frame 39 with the working platform 38 can be guided in or on the common track 5, but in this embodiment, in any case, the common track 5 is used to couple to at least one of the pair of adjacent column elements 3. In this way, the working platform 38 is always positioned adjacent to these outermost column elements 3 and thus adjacent to the die elements 9. The mobility of the working platform 38 in the width direction is indicated by the arrow 45.

[0075] In this way, the die element support device 2 not only allows adjustment to accommodate different die elements 9, 9', 9'', but also allows finding the optimal working position with respect to the width direction 4 and the height direction 13. In Figure 12 , an exemplary map shows the manufacturing steps for a prefabricated element. Another part of the vacuum foil 46 or the vacuum bag has been placed in the die element 9. The part 47 of the prefabricated element, in this case the fiber mat 48, is currently added by the operator 49.

[0076] Figure 13 Another example of the die element support device 2 is shown, in particular the fifth embodiment, which is based on Figure 7 the third embodiment and thus also has additional column elements 3' that support the intermediate section 21 of the die element 9. Since the working platform 38 can be applied to each embodiment, Figure 13 the working platform 38 extending along the two longitudinal directions of the die element 9 is shown again. Here, the manufacturing assembly 1 additionally includes an auxiliary device 50 for providing the part 47, in this case the fiber mat 48. The auxiliary device 50 includes a suspension crane 51 having a pallet 52 on which the fiber mat 48 is arranged. The auxiliary device 50 can be moved according to the arrow 53 so that the operator 49 can easily access the fiber mat 48 on the pallet 52. If the height of the pallet 52 is not adjustable or can only be adjusted in a limited way, the height of the column elements 3 and the working platform 38 can be adjusted to achieve the best working conditions. Thus, the flexibility of the die element support device 2 also applies to the auxiliary device 50.

[0077] Although Figure 13 the suspension crane 51 in Figure 14 is a transverse crane in the width direction 4,

[0078] In Figure 15 , an additional embodiment of the manufacturing assembly using a suspension crane 54 is shown. The suspension crane 54 is longitudinally oriented and can be moved, for example, in the width direction 4 for use at the parallel extending manufacturing assembly 1 / die element 9.

[0079] In Figure 16In the example, the working platform 38 is not used, but the working platform 38 may be provided in other embodiments. In this case, the fiber placement machine 56 is used as the auxiliary device 50. The fiber placement machine 56 includes a cutter that cuts the fiber mat 48 in the current length while laying it directly into the mold element 9, particularly onto the mold surface 14 that has been provided with the vacuum foil 46. The fiber material stock 57 can be placed near the mold element 9 so that the fiber placement machine 56 can be loaded separately or continuously.

[0080] Figure 17 Another example is illustrated, in which a CNC-controlled fiber placement machine 58 is used so that the fiber material / fiber mat 48 is correctly positioned on the molding surface 14.

[0081] In particular, in embodiments using the fiber placement machines 56, 58, and also in other embodiments and in the case of having other auxiliary devices 50, the binder can be directly applied to the fiber mat 48.

[0082] The mold elements 9, 9', 9'' can generally be made of or constituted by a layer structure accordingly. Here, Figure 18 A first embodiment of the layer structure 59 of the mold elements 9, 9', 9'' is shown. Here, a conventional laminate 60 is used, which is relatively heavy and expensive, but allows heat transfer through the layers of the laminate 60, making it possible to heat or cool the mold elements 9, 9', 9''. In Figure 19 In the second embodiment of the layer structure 59 shown in, a sandwich structure is used, in which a core material 61 (in this case balsa wood) is sandwiched between outer layers 62 made of glass fiber. This is cheap, strong, and relatively light in terms of weight variation, but provides less heat transfer through the layer structure 59.

[0083] In Figure 20 In the third embodiment of the layer structure 59 of, a particularly lightweight sandwich structure is used, in which the core material 63 is foam and the outer layer 62 is also based on carbon fiber.

[0084] In Figure 21 In the particularly advantageous fourth embodiment of, two core materials are sandwiched between the outer layers 62 in the layer structure 59, namely the first core layer 64 that can be a laminate stack, and the second additional layer 65 made of a material (such as ParaBeam™) including internal channels and / or voids. These voids and / or internal channels can be used as cooling and / or heating channels through which cooling and / or heating fluids can be supplied to heat and / or cool the preform element from below.

[0085] Figure 22Illustrated is a fifth embodiment of the layer structure 59 for the die elements 9, 9', 9'', wherein in the sandwich structure, between the outer layers 62 made of carbon fiber, a core material 66 with a honeycomb structure is used to further reduce the weight.

[0086] In Figure 23 a sixth embodiment, a 3D printed formed housing is used as the layer structure 59, which preferably also includes cooling and / or heating channels 67 for supplying cooling and / or heating fluid.

[0087] Figure 24 Illustrated is a first way of storing and / or transporting and moving the die elements 9, 9', 9'', 9''', for example when the die elements 9, 9', 9'', 9''' are to be replaced at the die element support device 2. For this purpose, a transport and / or storage device 68 can be used, wherein Figure 24 a first embodiment of such a transport and / or storage device 68 is shown. The transport and / or storage device 68 includes a frame 69, vertical beams 70 are positioned on the frame 69, and height-adjustable holders 71 are mounted thereon to hold the vertically positioned die elements 9, 9', 9'', 9''' in an upright position, i.e., vertically oriented. To move the die elements 9, 9', 9'', 9''' to and from the die element support device 2, a lifting device 72 can be employed, which in Figure 24 is a crane 73 with a gripper 89.

[0088] Regarding Figure 25 and Figure 26 a particularly preferred embodiment is shown. Here, a vacuum lifter 74 with a rotatable yoke 75 is used as the lifting device 72, wherein the yoke 75 is rotatable such that for placing the die element 9 lifted by vacuum on the support part 10 of the die element support device 2, the die element 9 can be rotated from the Figure 25 vertically position shown in Figure 26 to the horizontal orientation shown in

[0089] The die elements 9, 9', 9'', 9''' can also be transported and / or stored practically in a horizontal orientation, as shown for example in Figures 27 to 33 . Here, a different embodiment of the transport and / or storage device 68 is used, which will be described in detail later. Using a suspension crane 76 with a gripper 77, the die element 9' can be pulled out from the transport and / or storage device 68 above the already adjusted die element support device 2, and then it can be lowered onto the support part 10. In particular, the die elements 9, 9', 9'', 9''' can also be slid onto the die element support device 2, especially if the contact surface 31 has a low-friction material and / or includes rollers 37.

[0090] Alternatively, asFigure 28 As shown in Figure 28 , if the horizontal beam 78 of the transport and / or storage device 68 is removed, the transport and / or storage device 68 can even move above the die element support device 2, such that the lowest die element 9 can simply be lowered onto the support part 10 of the column element 3.

[0091] Generally speaking, as Figure 28 shown in the partial view of Figure 28 , the transport and / or storage device in the second embodiment may also include a frame structure 79, which includes vertical beams 80. In the embodiment shown here, three sets of support elements 81 are mounted to the vertical beams 80, wherein, for each beam 80, the first set of support elements 81 is in the corresponding lowest position, the second set of support elements 81 is in the middle position, and the third set of support elements 81 is in the uppermost position. All the support elements include rotary arms 82 for adjusting to different widths of the die elements 9, 9', 9'', 9'''. In addition, all the support elements 81 are height-adjustable. Now, as Figure 30 shown in Figure 30 , if the die element has been placed on a set of uppermost support elements 81, the third set of support elements 81 can be moved upward to bring the die element 9 into the corresponding transport and / or storage position. Here, the die element 9 is also supported on its flange 11.

[0092] As Figure 31 shown in Figure 31 , the support elements 81 can be adjusted in height separately to provide a height difference 83, as shown for the die element 9'''' supported by the second set of support elements 81 in Figure 31 . Similar to what has been discussed about the rotary arm 22, similarly, the rotary arms 82 allow adjustment to different widths 84, 85, as shown for the first and second sets of support elements 81 in Figure 31 . Therefore, the transport and / or storage device 68 of this embodiment can be easily adjusted to different shapes and / or sizes of the die elements 9, 9', 9'', 9''', 9'''', which is similar to the die element support device 2.

[0093] Similar or even identical transport and / or storage devices 68 can also be used for transporting and / or storing the manufactured prefabricated elements. For example, as Figure 32 shown in Figure 32 , a transport and / or storage device 68 as described in EP 22174530.0 can be used. Here, it is also shown that the lifting device for the die elements 9, 9', 9'', 9''', 9'''' can also be used to lift the manufactured or at least packaged prefabricated element 86 from the molding surface 14 to the transport and / or storage device 68.

[0094] As Figure 33 shown in Figure 33 , most preferably, as already described with respect to Figures 27 to 29 ​​​​The described transport and / or storage device 68 can also be used for the prefabricated element 86, for example by sliding the prefabricated element 86 from the die element 9 and its molding surface 14 onto a support element 81 that has been adjusted to the shape and dimensions of the prefabricated element 86.

[0095] Finally, Figure 34 It is shown that instead of or in addition to the attachment device 19, wheels 87 can also be mounted on the track 5 to form modules that can be easily positioned. A locking device 88, in particular a brake, can be provided in association with the wheels 87 to fix the position.

[0096] Although the invention has been described in detail with reference to preferred embodiments, the invention is not limited to the disclosed examples, and other variations can be obtained by those skilled in the art from the disclosed examples without departing from the scope of the invention.

Claims

1. A mold element support device (2) for a prefabricated element (86) and / or a precast element and / or a prepackaged element, in particular for a manufacturing assembly (1) of a wind turbine blade, the mold element support device (2) comprising a plurality of vertical column elements (3, 3'), the vertical column elements (3, 3') comprising upper support portions (10) for carrying longitudinal mold elements (9, 9', 9'', 9''', 9'''') for manufacturing the prefabricated element (86) and / or the precast element and / or the prepackaged element. It is characterized in that The column elements (3, 3') comprise height adjustment means (12) for adjusting, in particular separately, the height of the column elements (3, 3'), and the support portion (10) is distance-adjustable at least in the width direction (4) of the mold elements (9, 9', 9'', 9''', 9'''') via positioning means (6) so that the mold element support device (2) can be adapted to mold elements (9, 9', 9'', 9''', 9'''') of different shapes and / or sizes.

2. The mold element support device according to claim 1, characterized in that, Each height adjustment means (12) comprises a telescopic device and / or a controllable, in particular electric and / or hydraulic, actuator.

3. The mold element support device according to claim 1 or 2, characterized in that, The positioning means (6) comprises a track (5) extending in the width direction (4) in which the column elements (3, 3') are movably guided.

4. The mold element support device according to claim 3, characterized in that, A pair of column elements (3) to be placed at opposite side edges of the mold element (9, 9', 9'', 9''', 9'''') and in particular for supporting opposite flanges (11, 11', 11'') of the mold element (9, 9', 9'', 9''', 9'''') are guided in a common track (5).

5. The mold element support device according to claim 4, wherein, At least one, in particular lower, additional column element (3') is positioned between the pair of column elements (3) and is guided in or on the common track (5) to additionally support an intermediate section (21) of the mold element (9, 9', 9'', 9''', 9'''').

6. The mold element support device according to any one of the preceding claims, characterized in that, The positioning means (6) comprises attachment means (19) for releasably mounting the column elements (3, 3') to the floor (7) and / or the positioning means (6) comprises wheels (87).

7. The mold element support device according to any one of the preceding claims, characterized in that, Each column element (3, 3') comprises a horizontally extending rotary arm (22) which is part of the positioning means (6).

8. The mold element support device according to claim 7, wherein The rotary arm (22) is mounted on top of the vertical column section (23) of the column element (3, 3') and / or carries the support portion (10).

9. The mold element support device according to any one of the preceding claims, characterized in that, The support portion (10) comprises a particularly flat contact surface (31) for contacting the mold element (9, 9', 9'', 9''', 9'''') and tilting means (32), in particular a spherical joint (33), for tilting the contact surface (31) to different contact orientations.

10. The mold element support device according to any one of the preceding claims, characterized in that, The support part (10) includes a low-friction material and / or in particular longitudinally oriented rollers (37) in the contact area (30) with the die elements (9, 9', 9'', 9''', 9'''').

11. The mold element support device according to any one of the preceding claims, characterized in that, The die element support device further includes at least one longitudinal working platform (38) for a manufacturing personnel (49) to be longitudinally placed along the die elements (9, 9', 9'', 9''', 9''''). The positioning device (6) is additionally adapted to at least partially position the working platform (38).

12. The mold element support device according to claim 11, wherein, If the positioning device (6) includes at least one track (5) extending in the width direction (4), the at least one working platform (38) is also guided in at least one of the at least one track (5) or on at least one of the at least one track (5), and / or is motion-coupled to the outermost column element (3) guided in or on the track (5) along the width direction (4).

13. The mold element support device according to claim 11 or 12, characterized in that, The die element support device further includes a height adjustment device (40) for the working platform (38), in particular a telescopic device and / or a scissor mechanism (41).

14. A manufacturing assembly (1) for prefabricated elements (86) and / or precast elements and / or prepackaged elements, comprising a die element support device (2) according to any one of the preceding claims and die elements (9, 9', 9'', 9''', 9'''') supported on the die element support device (2).

15. A manufacturing system for prefabricated elements (86) and / or precast elements and / or prepackaged elements, comprising at least one die element support device (2) according to any one of the preceding claims and a plurality of replaceable die elements (9, 9', 9'', 9''', 9'''') that can be supported on the die element support device (2).

Images