Wind power blade intelligent mold production management system based on Internet of Things

Abstract

The invention provides a wind power blade intelligent mold production management system based on the Internet of Things. The wind power blade intelligent mold production management system comprises a display module, a processing module, a man-machine interaction module and a local server. The processing module integrates six data plates through the Internet of Things technology to realize data intercommunication and establish various linkage control logics; and the six data plates are a mold electric heating control system, a hydraulic overturning system, a vacuum pump station control system, a mold closing seam spacing / dislocation online detection system, a working hour / working procedure statistical analysis system and an energy management system. The processing module sends an instruction to the six data plates for linkage control, the man-machine interaction module is used for interaction between an operator and the system, and the local server stores data and program instructions. According to the production management system, centralized control over all subsystems of the wind power blade mold is achieved, the production efficiency and the management precision are improved, and the cost is reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of wind turbine blade production, and in particular to an intelligent mold production and management system for wind turbine blades based on the Internet of Things. Background Art

[0002] Currently, intelligent molds for wind turbine blades primarily consist of six data modules: a mold electric heating control system, a hydraulic tilting system, a vacuum pump station control system, an online mold gap spacing / misalignment detection system, a labor time / process statistical analysis system, and an energy management system. However, existing technologies suffer from numerous shortcomings: The data in each module is independent, preventing data interoperability and linkage; mold status determination relies solely on a single data point, which can easily lead to misjudgments; and currently only enables data collection, not control functions. These issues lead to low efficiency, high misjudgment rates, and frequent manual intervention in the production management of existing intelligent molds for wind turbine blades, which urgently require improvement.

[0003] Patent CN109189015A discloses an intelligent control system for the production of large wind turbine blades, including a central control system, a video monitoring system, a blade production system, and an equipment fault detection system. The central control system is connected to the video control system, blade production system, and equipment fault detection system. The blade production system includes a mold temperature field control system, a blade vacuum infusion control system, a blade rotation control system, and a workshop environment monitoring system. The equipment fault detection system includes monitoring systems for glue dispensing equipment, drilling equipment, and paint spraying equipment. This technical solution monitors and collects functional data to achieve centralized monitoring of the operating status of all equipment, avoiding the problems of delayed feedback, inaccurate measurements, and lack of early warning associated with manual operation and decentralized monitoring equipment. However, this technology only enables data collection and cannot perform automatic logical judgment or output control, such as automatically starting a vacuum pump based on process determination. Furthermore, the data in each functional block of the patent is independent, resulting in data silos and inability to connect data. The resulting data cannot be directly put into production, requiring manual secondary judgment. Summary of the Invention

[0004] The present invention provides an Internet of Things-based intelligent mold production and management system for wind turbine blades to solve the problems of independent data modules, inability to control linkage, and easy misjudgment in the existing technology, and realize centralized control of all subsystems of the mold, thereby improving production efficiency and management accuracy and reducing costs.

[0005] The IoT-based intelligent wind turbine blade mold production and management system described in this invention includes a display module, a processing module, a human-computer interaction module, and a local server. The processing module uses IoT technology to integrate six data modules, enabling data interoperability and establishing multiple linkage control logics. These six modules are: an electric heating control system, a hydraulic turnover system, a vacuum pump station control system, an online mold gap spacing / misalignment detection system, a labor-hour / process statistical analysis system, and an energy management system. The processing module sends instructions to the six modules and implements linkage control. The human-computer interaction module allows operators to interact with the system, and the local server stores data and program instructions.

[0006] The electric heating control system is composed of a controller, a collector and a temperature sensor. The collector transmits temperature data from the temperature sensor to the electric heating control system. The controller links the electric heating control system and the electric heating wire.

[0007] The hydraulic turning system is composed of a controller, a collector and an angle sensor. The collector collects data from the angle sensor and transmits it to the hydraulic turning system. The controller is connected to the hydraulic turning system and the motor.

[0008] The vacuum pump station control system is composed of a controller, a collector and a photoelectric sensor. The collector collects data from the photoelectric sensor and transmits it to the vacuum pump station control system, and the controller connects the vacuum pump station control system and the vacuum pump.

[0009] The mold gap spacing / misalignment online detection system is composed of a collector, a laser sensor, and an angle sensor. The collector collects data from the laser sensor and the angle sensor and transmits it to the mold gap spacing / misalignment online detection system.

[0010] The work time / process statistical analysis system comprises a collector, a visual sensor and a weight sensor. The collector collects data from the visual sensor and the weight sensor and transmits the data to the work time / process statistical analysis system.

[0011] The energy management system is composed of a collector, a voltage sensor and a current sensor. The collector collects data from the voltage sensor and the current sensor and transmits the data to the energy management system.

[0012] The Internet of Things-based wind turbine blade intelligent mold production management system of the present invention integrates data from six data blocks and utilizes linkage control logic set by a processing module to achieve data intercommunication and linkage control between various systems.

[0013] The processing module is used to integrate data from various systems, and the built-in program realizes data intercommunication and linkage control. The specific linkage control logic of the built-in program of the processing module is as follows: The mold electric heating control system is linked to the vacuum pump station control system: when the mold electric heating control system performs the preheating process for 3 hours, the vacuum pump station control system is automatically turned on to perform the mold vacuuming process; The vacuum pump station control system is linked to the pipeline vacuum pressure control: during the mold vacuuming process, when multiple pressure sensors arranged at the blade root, blade middle, and blade tip on the mold meet the qualified standards, the pressure holding process is automatically executed; The mold electric heating control system is linked to the vacuum pump station control system: after the system automatically performs the pressure holding process, it alerts the on-site operator through a three-color alarm light based on the pressure holding result. After the on-site operator clicks to confirm, the system automatically executes the infusion + pre-curing process of the mold electric heating control system, and the vacuum pump station control system continues to work and collects vacuum data in real time. When pressure relief occurs, an audible and visual alarm is immediately issued to alert the operator. The hydraulic flipping system is linked to the pipeline vacuum pressure control. During the web bonding process, the blade mold's upper mold is flipped 180 degrees by the hydraulic flipping system. This can only be done after the pipeline vacuum pressure reaches the set value. Sufficient vacuum pressure is required during the flipping process to prevent the product from falling off. This process is linked to the pressure value, ensuring that flipping can only occur after the pipeline vacuum pressure reaches the set value, thus preventing blades from falling off.

[0014] The working hour / process statistical analysis system is linked with other systems: the key change time nodes of temperature data, pressure data, flip data, and mold seam data are comprehensively judged to determine the start / end time nodes of the process; when several different types of data undergo certain changes at the same time, the system automatically determines that the current process has undergone certain changes, and can more accurately determine the start / end time nodes of the process.

[0015] The online mold gap gap / misalignment detection system is linked to the hydraulic flipping system: it only operates and outputs relevant data when the hydraulic flipping system is in the mold closing state. When the hydraulic flipping system is in other states, the online mold gap gap / misalignment detection system enters standby mode, reducing energy consumption.

[0016] The working hour / process statistical analysis system is linked to the energy management system: based on the precise time provided by the working hour and process statistical analysis system, the energy management system can analyze the energy consumption data corresponding to each process in more detail based on the previous energy consumption data of the entire product, thereby realizing more refined energy management.

[0017] The comprehensive judgment refers to: When the temperature reaches 50°C, the vacuum pressure value is close to 0, and the flip angle is less than 1 degree, it can be comprehensively determined that the mold is in the state of lamination completion; When the temperature starts to drop from 70℃ and the vacuum pressure value returns to normal pressure from 0, it is comprehensively determined that the mold is in the state of pre-curing completion; When the pre-curing process is completed, the temperature is at room temperature, the vacuum pressure value gradually changes from normal pressure to 0, the flip angle gradually changes from 0 degrees to 180 degrees, and the mold gap data changes from 0 to within the range of 0-100mm, it is comprehensively determined that the mold is in the first bonding process; When the temperature gradually rises from room temperature to 85°C, the flip angle remains at 180°, and the mold gap data stabilizes within the range of 10-50mm, it can be comprehensively determined that the mold is in the post-curing state.

[0018] The mold seam spacing / misalignment online detection system includes a visual sensor and a laser sensor, which are used to detect the spacing and misalignment of the mold seams.

[0019] The vacuum pump station control system includes a plurality of pressure sensors, which are respectively arranged at the blade root, blade middle and blade tip positions of the mold.

[0020] The production management system displays system data and operating status through a display module. The processing module, serving as its core, receives data from various system collectors (such as temperature and pressure sensors) and performs logical processing according to pre-programmed instructions to control the operation of each system. For example, after the mold electric heating control system has preheated for three hours, the processing module automatically activates the vacuum pump station control system. During the vacuuming process, the processing module monitors the data from each pressure sensor in real time. When all data meet acceptable standards, it initiates the pressure-holding process. The human-computer interaction module allows operators to interact with the system, while the local server stores data and program instructions.

[0021] The control method of the wind turbine blade intelligent mold production management system based on the Internet of Things is as follows: Software: The intelligent mold production management system is located on the industrial computer system at the blade mold operation station. Administrators pre-program relevant parameters such as temperature, hydraulic pressure, vacuum pressure, and mold gap, enabling the system to automatically run according to pre-set procedures. During production, operators simply click the start or stop button to start or stop the system.

[0022] Hardware: Leveraging IoT technology, the data from the mold electric heating control system, hydraulic turnover system, vacuum pump station control system, mold gap spacing / misalignment online detection system, working hour / process statistical analysis system, and energy management system are integrated into the industrial computer on the operating console via wired connections using 485 / Ethernet / EtherCAT communications.

[0023] The beneficial effects of the wind turbine blade intelligent production management system based on the Internet of Things of the present invention are as follows: The first is data integration and linkage control: breaking the limitations of the existing technology in which each data block is independent of each other, integrating the six data blocks through Internet of Things technology, realizing data interoperability, and establishing a variety of linkage control logics, such as the timing linkage of mold electric heating and vacuum pump station, the linkage of vacuum pressure and pressure holding process, etc., so that each system can work together instead of operating independently.

[0024] Comprehensive judgment of multiple data: Change the previous method of relying on a single data to judge the mold status. Through the working time / process statistical analysis system, the key time nodes of multiple data (temperature, pressure, turnover, mold gap, etc.) are comprehensively judged, which improves the accuracy of the judgment of the process start / end time node and reduces misjudgment.

[0025] Automatic control function: The existing technology can only realize data collection. The present invention realizes the leap from data collection to automatic control through the program instruction setting of the processing module, such as automatically starting the vacuum pump station, automatically executing the pressure holding process, and automatically triggering subsequent processes according to the pressure holding results, etc., which reduces manual intervention and improves the degree of automation of production management. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 : Structure diagram of wind turbine blade intelligent mold production management system based on Internet of Things.

[0027] Figure 2 : Screenshot of the main page of the intelligent mold production management system.

[0028] Figure 3 : Submodule data display page.

[0029] Figure 4 : Visual data display board. DETAILED DESCRIPTION

[0030] Taking the web bonding process in wind turbine blade production as an example, the specific implementation method is as follows: Utilizing Internet of Things technology, the data from the mold electric heating control system, hydraulic turnover system, vacuum pump station control system, mold gap spacing / misalignment online detection system, working hour / process statistical analysis system, and energy management system are integrated into the industrial computer on the operating table through wired connections and Ethernet communication.

[0031] The intelligent mold production management system is located on the industrial computer system of the blade mold on-site operating table. The administrator sets relevant parameters such as temperature, hydraulic flip, vacuum pressure, and mold gap into the program in advance so that it can run automatically according to the preset program.

[0032] The specific steps are as follows: (1): The operator only needs to click the start button, the intelligent mold production management system starts to start, the processing module automatically triggers the mold electric heating control system, starts the preheating process, the mold starts to heat, and the processing module starts timing.

[0033] (2): When preheating is performed for 3 hours or manually switched, the processing module automatically triggers the vacuum pump station control system and starts the mold vacuuming process. The vacuum pipeline valve automatically opens, and the vacuum pump quickly extracts the gas in the vacuum pipeline and vacuum bag film. At the same time, the pressure sensors at the blade root, blade middle, and blade tip on the mold collect data in real time and transmit it to the processing module.

[0034] (3): The processing module determines whether the data from each pressure sensor meets the qualified standards. If so, the pressure holding process is automatically executed, and the vacuum pipeline valve is automatically closed during the pressure holding process. The processing module automatically records the pressure and value. If the pressure drops by 3mbar within 15 minutes, it is judged to be qualified. If it fails, a buzzer alarm is used to remind the operator to check. (The above judgment standards can be manually adjusted in the system).

[0035] (4): After the pressure holding process is completed, the processing module controls the three-color alarm light to remind the operator according to the pressure holding result. After the operator verifies that it is correct, he clicks the confirmation button through the human-computer interaction module.

[0036] (5): After the processing module receives the confirmation signal, the mold electric heating control system automatically switches from the preheating process to the infusion + pre-curing process. During this period, the vacuum pump station control system continues to work and collects vacuum data in real time. If the data drops by more than 2mbra within 1 minute (this data can be manually adjusted in the system), it is determined that a pressure relief has occurred, and the operator is immediately reminded through an audible and visual alarm.

[0037] (6) After the preset time of the infusion + pre-curing process ends, the processing module issues an instruction, and the mold electric heating control system switches from the infusion + pre-curing process to the web bonding process, and the processing module starts timing.

[0038] (7): During the web bonding process, the upper mold of the blade mold needs to be flipped 180 degrees. At this time, the processing module monitors the pipeline vacuum pressure value. When the pressure reaches the set value, the hydraulic flipping system is allowed to perform the flipping action to avoid the product falling off during the flipping process.

[0039] (8): The online detection system for mold gap spacing / misalignment works when the hydraulic flip system is in the mold closing state and is in standby mode in other states to reduce energy consumption. When working, the processing module automatically reads the data and automatically determines whether the data is qualified. The processing module controls the three-color alarm light to remind the production personnel based on the pressure holding result.

[0040] (9): When the web bonding process is executed for 3h or manually switched, the mold electric heating control system is switched from the web bonding process to the post-curing process.

[0041] (10): When the post-curing process preset end time, the intelligent mold production management system automatically switches from start to stop state. The processing module automatically stops the mold electric heating control system, and the mold starts to cool down. At the same time, the processing module automatically stops the vacuum pump control system, the vacuum pipeline valve is automatically opened, the pipeline pressure is restored from vacuum state to atmospheric pressure, and the mold opening condition is created.

[0042] (11) After the system automatically ends, the processing module will remind the production personnel in the form of sound and light. After the production personnel click to confirm, it is automatically switched to standby state, waiting for the next start.

[0043] (12): During the whole process of blade production and manufacturing, the working hours / process statistical analysis system comprehensively analyzes the key change time nodes of temperature, pressure, turning, mold joint, etc. The start / end time of the process is accurately determined, and the time is provided to the energy management system: the energy management system analyzes the energy consumption data of each process in detail, and realizes more precise energy management.

Claims

1. An intelligent mold production management system for wind turbine blades based on the Internet of Things, characterized by: Including display module, processing module, human-computer interaction module and local server; The processing module integrates six data modules through Internet of Things technology to achieve data interoperability and establish multiple linkage control logics. The six data modules are the mold electric heating control system, the hydraulic turnover system, the vacuum pump station control system, the mold gap spacing / misalignment online detection system, the working time / process statistical analysis system, and the energy management system. The processing module sends instructions to the six data panels and controls them in a linked manner. The human-computer interaction module is used for operators to interact with the system. The local server stores data and program instructions. The electric heating control system is composed of a controller, a collector and a temperature sensor. The temperature data of the temperature sensor of the collector is transmitted to the electric heating control system. The controller links the electric heating control system and the electric heating wire. The hydraulic flip system is composed of a controller, a collector and an angle sensor; the collector collects data from the angle sensor and transmits it to the hydraulic flip system, and the controller connects the hydraulic flip system and the motor; The vacuum pump station control system is composed of a controller, a collector and a photoelectric sensor; the collector collects data from the photoelectric sensor and transmits it to the vacuum pump station control system, and the controller links the vacuum pump station control system and the vacuum pump; The mold gap spacing / misalignment online detection system is composed of a collector, a laser sensor and an angle sensor; the collector collects data from the laser sensor and the angle sensor and transmits it to the mold gap spacing / misalignment online detection system; The working time / process statistical analysis system is composed of a collector, a visual sensor and a weight sensor; the collector collects data from the visual sensor and the weight sensor and transmits it to the working time / process statistical analysis system; The energy management system is composed of a collector, a voltage sensor and a current sensor. The collector collects data from the voltage sensor and the current sensor and transmits the data to the energy management system.

2. The wind turbine blade intelligent mold production management system based on the Internet of Things according to claim 1 is characterized in that: The processing module is used to integrate data from various systems, and the built-in program realizes data intercommunication and linkage control. The specific linkage control logic of the built-in program of the processing module is as follows: The mold electric heating control system is linked to the vacuum pump station control system: when the mold electric heating control system performs the preheating process for 3 hours, the vacuum pump station control system is automatically turned on to perform the mold vacuuming process; The vacuum pump station control system is linked to the pipeline vacuum pressure control: during the mold vacuuming process, when multiple pressure sensors arranged at the blade root, blade middle, and blade tip on the mold meet the qualified standards, the pressure holding process is automatically executed; The mold electric heating control system is linked to the vacuum pump station control system: after the system automatically performs the pressure holding process, it alerts the on-site operator through a three-color alarm light based on the pressure holding result. After the on-site operator clicks to confirm, the system automatically executes the infusion + pre-curing process of the mold electric heating control system, and the vacuum pump station control system continues to work and collects vacuum data in real time. When pressure relief occurs, an audible and visual alarm is immediately issued to alert the operator. The hydraulic flipping system is linked to the pipeline vacuum pressure control: During the web bonding process, when the blade mold is flipped 180 degrees by the hydraulic flipping system, flipping can only be performed after the pipeline vacuum pressure reaches the set value. Sufficient pressure must be maintained by vacuum during the flipping process, otherwise there is a risk of product falling off. This process adds a pressure value linkage judgment, and flipping can only be performed when the pipeline vacuum pressure reaches the set value, preventing blades from falling off. The working time / process statistical analysis system is linked with other systems to comprehensively determine the key change time nodes of temperature data, pressure data, flip data, and mold gap data; To determine the start / end time nodes of the process; when several different types of data change at the same time, the system automatically determines that the current process has changed, and can more accurately determine the start / end time nodes of the process; The online detection system for mold gap spacing / misalignment is linked to the hydraulic turnover system: it only operates and outputs relevant data when the hydraulic turnover system is in the mold closing state. When the hydraulic turnover system is in other states, the online detection system for mold gap spacing / misalignment enters standby mode to reduce energy consumption. The working hour / process statistical analysis system is linked to the energy management system: based on the precise time provided by the working hour and process statistical analysis system, the energy management system can analyze the energy consumption data corresponding to each process in more detail based on the previous energy consumption data of the entire product, thereby realizing more refined energy management.

3. The wind turbine blade intelligent mold production management system based on the Internet of Things according to claim 2 is characterized in that: The comprehensive judgment refers to: When the temperature reaches 50°C, the vacuum pressure value is close to 0, and the flip angle is less than 1 degree, it can be comprehensively determined that the mold is in the state of lamination completion; When the temperature starts to drop from 70℃ and the vacuum pressure value returns to normal pressure from 0, it is comprehensively determined that the mold is in the state of pre-curing completion; When the pre-curing process is completed, the temperature is at room temperature, the vacuum pressure value gradually changes from normal pressure to 0, the flip angle gradually changes from 0 degrees to 180 degrees, and the mold gap data changes from 0 to within the range of 0-100mm, it is comprehensively determined that the mold is in the first bonding process; When the temperature gradually rises from room temperature to 85°C, the flip angle remains at 180°, and the mold gap data stabilizes within the range of 10-50mm, it can be comprehensively determined that the mold is in the post-curing state.

4. The wind turbine blade intelligent mold production management system based on the Internet of Things according to claim 1 is characterized in that: The mold seam spacing / misalignment online detection system includes a visual sensor and a laser sensor, which are used to detect the spacing and misalignment of the mold seams.

5. The wind turbine blade intelligent mold production management system based on the Internet of Things according to claim 1 is characterized in that: The vacuum pump station control system includes a plurality of pressure sensors, which are respectively arranged at the vacuum pipeline positions of the blade root, blade middle and blade tip of the mold.

6. The control method for the wind turbine blade intelligent mold production management system based on the Internet of Things according to any one of claims 1 to 4, characterized in that: Software: The intelligent mold production management system is located on the industrial computer system at the blade mold on-site operation station. The administrator pre-programs relevant parameters such as temperature, hydraulic pressure, vacuum pressure, and mold gap, enabling it to automatically run according to the preset program. During production operations, the operator simply clicks the start or stop button to start or stop the system. Hardware: Leveraging IoT technology, the data from the mold electric heating control system, hydraulic turnover system, vacuum pump station control system, mold gap spacing / misalignment online detection system, working hour / process statistical analysis system, and energy management system are integrated into the industrial computer on the operating console via wired connections using 485 / Ethernet / EtherCAT communications.

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