Device for in-service fan blade surface laser modification

Abstract

The invention discloses a device for in-service fan blade surface laser modification, relates to the technical field of in-service fan blade surface modification, and aims to solve the problem of in-service fan blade laser modification. A winch and a laser dynamic focusing mechanism are arranged on the front side and the rear side of the upper surface of a bearing platform of the device respectively. And a vacuum chuck connected with a vacuum pump through a pipeline is arranged in the middle of the self-adaptive mechanical arm mechanism. The laser dynamic focusing mechanism comprises an X-axis sliding table module, a Y-axis sliding table module and a Z-axis sliding table module, the X-axis sliding table module is assembled on the bearing platform, the Z-axis sliding table module is installed on the X-axis sliding table module, the Y-axis sliding table module is installed on the Z-axis sliding table module, and the Y-axis sliding table module is connected with the bracket to lift the laser galvanometer system. During working, the winch traction device moves, the manipulator and the vacuum chuck cooperate to fix the blade, the focusing mechanism adjusts the position and focal length of the galvanometer, and the galvanometer projects laser to complete modification. The device provides a solution for in-service fan blade laser modification, and the modification quality and the operation safety are improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of wind turbine maintenance and surface treatment, and particularly to a device for laser modification of the surface of a wind turbine blade in service. BACKGROUND

[0002] Before a wind turbine blade is coated with a protective or functional coating, it is usually necessary to modify the surface of the blade. Currently, such modification is carried out when the blade is not yet installed on the wind turbine body.

[0003] However, there is a practical need to modify the surface of an installed blade during operation of the wind turbine. For example, when a wind turbine blade needs to be repaired locally, or a special functional coating such as an anti-icing coating needs to be applied to the surface of an existing blade, it is necessary to complete the necessary surface modification under the installed state of the blade to provide suitable surface conditions for subsequent coating operations. The existing wind turbine blade modification device cannot meet the operation requirements under this state. SUMMARY

[0004] The purpose of the present application is to provide a device for laser modification of the surface of a wind turbine blade in service, to solve the problem that the surface of an installed wind turbine blade cannot be laser modified in the prior art.

[0005] To achieve the above-mentioned purpose, the present application adopts the following technical solutions:

[0006] A device for laser modification of the surface of a wind turbine blade in service, comprising a bearing platform, and a winch and a laser dynamic focusing mechanism respectively arranged on the front and rear sides of the upper surface of the bearing platform; the lower surface of the bearing platform is symmetrically provided with self-adaptive mechanical hand mechanisms on the left and right sides, the self-adaptive mechanical hand mechanisms are used for clamping wind turbine blades; a vacuum chuck is arranged in the middle of the lower surface of the bearing platform, and the vacuum chuck is connected with a vacuum pump arranged on the bearing platform through a pipeline; the laser dynamic focusing mechanism comprises an X-axis sliding table module, a Y-axis sliding table module and a Z-axis sliding table module, wherein the X-axis sliding table module is installed on the bearing platform, the Z-axis sliding table module is assembled on the X-axis sliding table module, the Y-axis sliding table module is assembled on the Z-axis sliding table module, a bracket is fixedly connected to the Y-axis sliding table module, the bracket is used for lifting a laser galvanometer system, and the laser galvanometer system is used for projecting a laser beam to the surface of the wind turbine blade.

[0007] In some embodiments, the self-adaptive mechanical hand mechanism comprises a sliding table module arranged on the left and right sides of the lower surface of the bearing platform, a connecting block is fixedly connected to the sliding block of the sliding table module, a clamping jaw is connected to the end of the connecting block away from the sliding block, and the wind turbine blade is clamped by the clamping jaw.

[0008] In some embodiments, the X-axis sliding table module comprises a first base, a first lead screw, a first sliding block, a first sliding platform, a first cover plate and a first servo motor; the first base is mounted on the bearing platform, the first lead screw is arranged in the first base along the length direction of the first base, the first sliding block is threadedly connected with the first lead screw, and the first sliding platform is fixedly connected with the first sliding block; the first cover plate is fixedly connected with the first base and covers the first sliding platform, the two side portions of the first sliding platform extend out of the first cover plate, and the Z-axis sliding table module is assembled on the two side portions of the first sliding platform; the first servo motor is used to drive the first lead screw to rotate in the first base, so as to drive the Z-axis sliding table module to slide along the length direction of the first base.

[0009] In some embodiments, the Z-axis sliding table module comprises a second base, a second lead screw, a second sliding block, a second sliding platform, a second cover plate and a second servo motor; the second base is assembled on the two side portions of the first sliding platform through a connecting rib plate; the second lead screw is arranged in the second base along the length direction of the second base, the second sliding block is threadedly connected with the second lead screw, and the second sliding platform is fixedly connected with the second sliding block; the second cover plate is fixedly connected with the second base and covers the second sliding platform, the two side portions of the second sliding platform extend out of the second cover plate, and the Y-axis sliding table module is assembled on the two side portions of the second sliding platform; the second servo motor is used to drive the second lead screw to rotate in the second base, so as to drive the Y-axis sliding table module to slide along the length direction of the second base.

[0010] In some embodiments, the Y-axis sliding table module comprises a third base, a third lead screw, a third sliding block, a third sliding platform, a third cover plate and a third servo motor; the bottom surface of the third base is assembled on the two side portions of the second sliding platform; the third lead screw is arranged in the third base along the length direction of the third base, the third sliding block is threadedly connected with the third lead screw, and the third sliding platform is fixedly connected with the third sliding block; the third cover plate is fixedly connected with the third base and covers the third sliding platform, the two side portions of the third sliding platform extend out of the third cover plate, and the bracket is fixedly connected with the two side portions of the third sliding platform; the third servo motor is used to drive the third lead screw to rotate in the third base, so as to drive the laser galvanometer system to slide along the length direction of the third base.

[0011] In some embodiments, a driving assembly for driving the winch to swing is further included, the driving assembly comprises a swing cam divider, a motor, a transmission belt and a disc; the swing cam divider and the motor are arranged on one side of the bearing platform corresponding to the winch, the motor is in transmission connection with the swing cam divider through the transmission belt, the disc is fixedly connected with the output shaft of the swing cam divider, and the winch is fixedly arranged on the disc; when the motor drives the swing cam divider to act, the output shaft drives the disc and the winch to swing synchronously.

[0012] In some embodiments, four feet symmetrically arranged on the lower surface of the bearing platform are further included, and the four feet correspond to the front of the four adaptive mechanical hand mechanisms respectively.

[0013] In some embodiments, a distance sensor is arranged on the foot, which is used to detect the distance between the foot and the side edge of the fan blade, and feed back the detection signal to the control system, so as to control the moving distance of the sliding block of the sliding table module, and then realize the clamping of the fan blade through the clamp jaw.

[0014] In some embodiments, the clamp jaw is a parallel opening and closing type air clamp, and the inner side of the two clamping heads of the parallel opening and closing type air clamp is provided with a ball gasket and a pressure sensor.

[0015] In some embodiments, photoelectric sensors are arranged on the first base, the second base and the third base respectively, and photoelectric sensing sheets are arranged on the first sliding platform, the second sliding platform and the third sliding platform respectively, and the photoelectric sensing sheets are matched with the positions of the photoelectric sensors on the corresponding bases.

[0016] Compared with the prior art, the beneficial effects of the present application are:

[0017] The device for laser modification of the surface of the in-service fan blade of the present application is integrated with a winch, a laser dynamic focusing mechanism, an adaptive mechanical hand mechanism, a vacuum chuck and a laser galvanometer system arranged on the laser dynamic focusing mechanism on the bearing platform, and a "moving-fixed-focusing-modification" integrated operation structure is constructed: the device is moved on the fan blade by the winch, the adaptive mechanical hand mechanism and the vacuum chuck are cooperated to realize the stable fixation of the in-service fan blade, the laser dynamic focusing mechanism precisely adjusts the position and focal length of the laser galvanometer system through the X-axis, Y-axis and Z-axis sliding table modules, and finally the laser beam is precisely projected to the surface of the fan blade by the laser galvanometer system to complete the modification treatment.

[0018] In practical application, the device of the present application can meet various surface modification requirements such as local damage repair modification, pretreatment before special coating such as ice prevention and corrosion prevention of the in-service fan blade, greatly reduces the maintenance time of the fan blade, significantly improves the flexibility and convenience of the fan operation and maintenance, and provides technical support for long-term and efficient operation of the wind power equipment. BRIEF DESCRIPTION OF DRAWINGS

[0019] Figure 1 Fig. 1 is a perspective view of the device for laser modification of the surface of the in-service fan blade of the present application;

[0020] Figure 2 Fig. 2 is a front view of the device for laser modification of the surface of the in-service fan blade of the present application;

[0021] Figure 3 It is a left view structural schematic diagram of the device for laser modification of the surface of a wind turbine blade in service according to the present application;

[0022] Figure 4 It is a top view structural schematic diagram of the device for laser modification of the surface of a wind turbine blade in service according to the present application;

[0023] Figure 5 It is a partial sectional view structural schematic diagram of the laser dynamic focusing mechanism according to the present application;

[0024] Figure 6 It is a structural schematic diagram of the Z-axis sliding table module on which a Y-axis sliding table module is assembled according to the present application;

[0025] Figure 7 It is a structural schematic diagram of the X-axis sliding table module according to the present application;

[0026] Figure 8 It is a structural schematic diagram of the X-axis sliding table module without a first cover plate according to the present application;

[0027] Figure 9 It is a structural schematic diagram of one embodiment of the self-adaptive mechanical hand mechanism according to the present application;

[0028] Figure 10 It is a structural schematic diagram of another embodiment of the self-adaptive mechanical hand mechanism according to the present application;

[0029] Figure 11 It is a schematic diagram of the device for laser modification of the surface of a wind turbine blade in service according to the present application clamping a wind turbine blade;

[0030] Figure 12 It is a structural schematic diagram of the device for laser modification of the surface of a wind turbine blade in service according to the present application without a winch;

[0031] Figure 13 It is a bottom view angle structural schematic diagram of the device for laser modification of the surface of a wind turbine blade in service according to the present application;

[0032] Figure 14 It is a structural schematic diagram of the vacuum chuck according to the present application;

[0033] Figure 15 It is a schematic diagram of the principle of use of the device for laser modification of the surface of a wind turbine blade in service according to the present application.

[0034] In the diagram: 1. Support platform; 11. Frame; 12. Support leg; 13. Distance sensor; 2. Winch; 21. Swinging cam divider; 22. Motor; 23. Drive belt; 24. Disc; 31. First base; 32. First lead screw; 33. First slider; 34. First sliding platform; 35. First cover plate; 36. First servo motor; 41. Second base; 42. Second lead screw; 43. Second slider; 44. Second sliding platform; 45. Second cover plate; 46. Second servo motor; 47. Connecting rib plate; 48. Pad plate; 51. Third base; 52. Third lead screw; 53. Third slider; 54. Third sliding platform; 55. 56. Third cover plate, 57. Third servo motor, 68. Bracket, 69. Fourth base, 60. Fourth lead screw, 61. Fourth slider, 62. Fifth slider, 63. Slide rod, 64. First spring, 65. Block, 66. Fourth servo motor, 67. Connecting block, 68. Opening and closing type gripper, 69. Ball bearing washer, 71. Pressure sensor, 72. Vacuum suction cup, 73. Air extraction interface, 74. Second spring, 75. Silicone suction cup, 76. Vacuum pump, 77. Filter, 78. Connecting sleeve, 79. Connecting rod, 80. Control box, 81. Fiber optic path, 82. Digital galvanometer, 93. Photoelectric sensor, 94. Photoelectric sensor. Detailed Implementation

[0035] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0036] See Figure 1 - Figure 8 , Figure 11 - Figure 13 The present invention provides a device for laser modification of the surface of in-service wind turbine blades, including a support platform 1, which is set in a frame 11. The support platform 1 is symmetrically provided with adaptive manipulator mechanisms (for clamping wind turbine blades) on the left and right sides of its lower surface, and a vacuum suction cup 71 is provided in the middle. The upper surface is provided with a winch 2 and a laser dynamic focusing mechanism on the front and rear sides.

[0037] The vacuum suction cup 71 is connected to the vacuum pump 72 on the support platform 1 via a pipeline. A vacuum filter 73 is also provided between the two. The pipeline connection follows the process of "vacuum pump 72 → vacuum filter 73 → vacuum suction cup 71": the suction port of the vacuum pump 72 is connected to the inlet of the vacuum filter 73 via a pressure-resistant vacuum hose (such as a 6mm or 8mm inner diameter PU tube) (the filter housing usually has an arrow indicating the inlet direction). The outlet of the vacuum filter 73 is then connected to the suction port 711 of the vacuum suction cup 71 via a vacuum hose. The vacuum suction cup 71 is fixedly connected to the connecting sleeve 74, which is mounted on the connecting rod 75 (the connecting rod 75 can be an aluminum alloy profile). The connecting rod 75 can be directly fixed to the lower surface of the support platform or fixed to the lower part of the support platform via a bracket or other means. Vacuum pump 72 serves as a vacuum source, creating negative pressure in the pipeline by pumping air; vacuum filter 73 is used to filter dust, particles and other impurities in the air, preventing impurities from entering vacuum pump 72 or clogging vacuum suction cup 71, thus protecting system components; vacuum suction cup 71 is connected to the pipeline at the outlet of vacuum filter 73 through top air extraction port 711, using negative pressure to achieve adsorption of workpieces.

[0038] The laser dynamic focusing mechanism includes an X-axis slide module, a Y-axis slide module, and a Z-axis slide module. The assembly relationship between the three is as follows: the X-axis slide module is installed on the support platform 1, and the Z-axis slide module is mounted on it; the Y-axis slide module is mounted on the Z-axis slide module, and a bracket 57 is fixedly connected to the Y-axis slide module. The bracket 57 is used to support the laser galvanometer system, which is used to project the laser beam onto the surface of the wind turbine blades.

[0039] Specifically, the laser galvanometer system may include an optical fiber path 82 and a digital galvanometer 83, which together with the control box 81 constitute a laser marking machine to realize laser transmission and projection: the optical fiber path 82 is made of highly flexible quartz optical fiber, one end of which is used to connect to the laser generator in the control box, and the other end is sealed and connected to the laser incident end of the digital galvanometer 83 through a quick-connect connector; the optical fiber path 82 is fixed to the preset mounting position of the bracket 57 by bolts or other means, while the control box 81 is fixed to the upper surface of the support platform 1.

[0040] The adaptive robotic arm mechanism includes a slide module, which is arranged on the left and right sides of the lower surface of the support platform 1 in the left and right direction. A connecting block 66 is fixedly connected to the sliding block of the slide module, and a gripper is connected to the end of the connecting block 66 away from the sliding block. The gripper clamps the fan blades.

[0041] The slide module can adopt two structures:

[0042] Screw-driven structure (see Figure 9The system includes a fourth base 61, a fourth lead screw 62, a fourth slider 63, a slide bar 64, and a fourth servo motor 65. The fourth base 61 is fixed to both sides of its lower surface along the left-right direction of the bearing platform 1. The fourth lead screw 62 and slide bar 64 are both arranged parallel to the length of the fourth base 61 within its internal cavity. The fourth slider 63 (i.e., the aforementioned sliding block) is connected to the fourth lead screw 62 via a threaded connection and is slidably sleeved on the slide bar 64 (the slide bar 64 guides and limits the movement of the fourth slider 63). The fourth servo motor 65 is fixed to the outer end of the fourth base 61. Its output shaft is connected to one end of the fourth lead screw 62 via a coupling or directly, driving the fourth lead screw 62 to rotate around its own axis within the fourth base 61, thereby causing the fourth slider 63 to slide smoothly along the length of the slide bar 64. This allows for adjustment of the gripper's position along the left-right direction of the bearing platform to accommodate different widths of the fan blades.

[0043] Elastic adaptive structure (see) Figure 10 The structure includes a fourth base 61, a slide bar 64, a first spring 641, a fifth slider 631, and a blocking block 642. The fourth base 61 is also positioned on both sides of the lower surface of the bearing platform 1 along the left-right direction. The slide bar 64 is fixed within the fourth base 61 along its length. The fifth slider 631 (i.e., the aforementioned sliding block) and the blocking block 642 are both slidably fitted onto the slide bar 64. The first spring 641 is fitted onto the slide bar 64, with one end abutting against the blocking block 642 and the other end abutting against the end of the fourth base 61. The first spring 641 pushes against the blocking block 642, which in turn pushes against the fifth slider 631, providing a pushing force towards the center of the bearing platform 1 for the fifth slider 631. This structure, through the elastic buffering effect of the first spring 641, avoids rigid compression damage to the surface of the wind turbine blades by the grippers. Simultaneously, the rebound force of the first spring ensures that the grippers maintain a stable clamping force, adapting to the clamping requirements of wind turbine blades of different widths.

[0044] Regarding the specific structure of each axis slide module:

[0045] The X-axis slide module includes a first base 31, a first lead screw 32, a first slider 33, a first sliding platform 34, a first cover plate 35, and a first servo motor 36. The first base 31 is fixedly mounted on the upper surface of the support platform 1, and has an internal cavity along its length. The first lead screw 32 is located within this cavity along the length of the first base 31, and its two ends are rotatably connected to the side walls of the first base 31 via bearings. The first slider 33 is fitted onto the first lead screw 32 and engages with it via a threaded structure, moving linearly along its axial direction as the lead screw 32 rotates. The first sliding platform 34 is plate-shaped, with its bottom surface fixedly connected to the top of the first slider 33 via bolts or welding, and moves synchronously with the first slider 33. The first cover plate 35 is a long strip-shaped cover plate adapted to the length of the first base 31, with its edge fixedly connected to the top edge of the first base 31 via fasteners, covering the first sliding platform 34 and providing protection for the internal structure. Since the width of the first sliding platform 34 is greater than the width of the first cover plate 35, its two sides extend outward from the edges of the first cover plate 35. These extended portions serve as mounting positions for assembling the Z-axis slide module. The first servo motor 36 is fixedly mounted on the outer side of one end of the first base 31, and its output shaft is connected to the end of the first lead screw 32 via a coupling or gearbox. After startup, it drives the first lead screw 32 to rotate, which in turn drives the first sliding platform 34 and the Z-axis slide module to slide smoothly along the length of the first base 31 via the first slider 33, thereby realizing the position adjustment of the Z-axis slide module in the X direction.

[0046] The Z-axis slide module includes a second base 41, a second lead screw 42, a second slider 43, a second sliding platform 44, a second cover plate 45, and a second servo motor 46. The second base 41 is a long strip structure, assembled to both sides of the first sliding platform 34 via connecting ribs 47 (the connecting ribs 47 are fixed to the bottom surface of the second base 41 and the protruding part of the first sliding platform 34 respectively by welding or bolting to ensure stable installation). The second base 41 has a cavity along its length. The second lead screw 42 is located within this cavity along the Z-axis (i.e., the length direction of the second base 41), and its two ends are rotatably connected to the side walls of the second base 41 via bearings. The second slider 43 is fitted onto the second lead screw 42 and forms a threaded engagement, moving linearly along its axial direction as the second lead screw 42 rotates. The second sliding platform 44 is a plate-like structure, with its bottom surface fixedly connected to the top of the second slider 43 by bolts or welding, and moves synchronously with the second slider 43. The second cover plate 45 is fixedly connected to the top edge of the second base 41 and covers the second sliding platform 44, providing dust protection for the internal lead screw and slider structure. Since the width of the second sliding platform 44 is greater than the width of the second cover plate 45, its two sides extend outward from the edges of the second cover plate 45. These extended parts serve as mounting positions for assembling the Y-axis slide module. The second servo motor 46 is fixedly installed on the outer side of one end of the second base 41, and its output shaft is connected to the end of the second lead screw 42 via a coupling. After startup, it drives the second lead screw 42 to rotate, which in turn drives the second sliding platform 44 and the Y-axis slide module to slide smoothly along the length direction (Z-axis direction) of the second base 41 through the second slider 43, realizing the position adjustment of the Y-axis slide module in the Z-direction.

[0047] The Y-axis slide module includes a third base 51, a third lead screw 52, ​​a third slider 53, a third sliding platform 54, a third cover plate 55, and a third servo motor 56. The third base 51 is a long strip structure, with its bottom surface fixed by a pad 48 (or directly bolted, welded, etc.), and is assembled at the protruding positions on both sides of the second sliding platform 44, forming a stable vertical assembly relationship with the Z-axis slide module. The third base 51 has a receiving cavity along its length. The third lead screw 52 is located within this cavity along the Y-axis direction (i.e., the length direction of the third base 51), and its two ends are rotatably connected to the side walls of the third base 51 via bearings. The third slider 53 is fitted onto the third lead screw 52 with a threaded engagement, and moves linearly along its axial direction as the third lead screw 52 rotates. The third sliding platform 54 is a plate structure, with its bottom surface fixedly connected to the top of the third slider 53 by fasteners, and moves synchronously with the third slider 53. The third cover plate 55 is fixedly connected to the top edge of the third base 51, covering the third sliding platform 54. Since the width of the third sliding platform 54 is greater than the width of the third cover plate 55, its two sides extend outward from the edges of the third cover plate 55. These extended portions are used to fix the connecting bracket 57. The third servo motor 56 is fixedly installed on the outer side of one end of the third base 51. Its output shaft is connected to the end of the third lead screw 52 via a coupling or the like. After starting, it drives the third lead screw 52 to rotate, which in turn drives the third sliding platform 54, the bracket 57 above it, and the laser galvanometer system to slide smoothly along the length direction (Y-axis direction) of the third base 51 through the third slider 53, thereby realizing the precise position adjustment of the laser galvanometer system in the Y-axis direction.

[0048] The device also includes a drive assembly for driving the winch 2 to swing, which includes a swing cam divider 21, a motor 22, a drive belt 23, and a disc 24. Specifically, the swing cam divider 21 and the motor 22 are both fixed to the side of the support platform 1 corresponding to the winch 2 by means of bolts or other methods. The motor 22 is preferably a servo motor, with a drive pulley fixedly sleeved on its output shaft, and a driven pulley correspondingly sleeved on the input shaft of the swing cam divider 21. The drive belt 23 is wound between the drive pulley and the driven pulley to form a synchronous transmission. To improve transmission stability and prevent belt slippage, the outer circumferential surfaces of both the drive pulley and the driven pulley are provided with anti-slip teeth. The drive belt 23 is made of high-elasticity polyurethane material, and its inner side is provided with meshing grooves adapted to the teeth. The disc 24 is made of high-strength aluminum alloy and is fixedly connected to the output shaft of the swing cam divider 21 by a flat key and bolts at its center to ensure that there is no relative rotation between the two. The winch 2 is detachably fixed to the upper surface of the disc 24 by the mounting flange at the bottom. There is also a shock-absorbing pad between the mounting flange and the disc 24 to buffer the vibration generated by the winch 2 during operation and reduce the impact on the swing transmission accuracy.

[0049] The working process of the motor 22 driving the swing cam divider 21 is as follows: After receiving the pulse signal from the control system, the motor 22 starts, and the output shaft drives the drive pulley to rotate. The power is transmitted to the driven pulley through the transmission belt 23, which in turn drives the input shaft of the swing cam divider 21 to rotate. The swing cam divider 21 converts the continuous rotation of the input shaft into the intermittent and precise swing of the output shaft through the meshing transmission of the internal cam and roller (the swing angle can be preset by the control system, preferably with an adjustment range of 0°-90°, and the swing positioning accuracy can reach ±0.02mm). Finally, the output shaft of the swing cam divider 21 drives the disc 24 and the winch 2 fixed on it to achieve a smooth swing at the preset angle.

[0050] In this embodiment, the selection of the swing cam divider 21 significantly improves the adaptability of the device: when dealing with wide blades, the swing angle can be increased (e.g., 60°-90°), extending the force application point of the winch 2's traction rope towards both sides of the blade, assisting the carrying platform in adjusting the lateral position of the blade; when handling curved blades, the local posture of the blade can be finely adjusted by intermittent small-angle swings (e.g., 5°-15°), ensuring that the laser beam projected by the laser galvanometer system accurately covers the arc-shaped area of ​​the blade edge, avoiding blind spots in edge modification caused by blade curvature, especially suitable for the non-planar operation requirements of wind turbine blade airfoil structures. (Note: Existing products can be selected for the swing cam divider, such as the product with announcement number CN204976635U and patent name "left-right swinging cam divider".)

[0051] Furthermore, a torque sensor is also provided between the motor 22 and the swing cam divider 21. The torque sensor is connected in series between the output shaft of the motor 22 and the drive pulley 221 to detect the torque value in real time during the transmission process and feed the detection signal back to the control system. When the detected torque exceeds the preset threshold, the control system immediately controls the motor 22 to stop to avoid overload and damage to the transmission components, thereby improving the safety protection performance of the device.

[0052] In other embodiments, the device further includes four legs 12 symmetrically arranged on the lower surface of the support platform 1. The four legs 12 are respectively positioned in front of the four adaptive manipulator mechanisms (in the operating feed direction of the support platform, i.e., the direction in which the winch 2 drives the support platform to move via the traction rope). Distance sensors 13 are provided on the legs 12. The distance sensors 13 are used to detect the distance between the legs 12 and the side of the wind turbine blades and feed the detection signal back to the control system. The control system then controls the movement distance of the sliding block of the adaptive manipulator mechanism's slide module, thereby clamping the wind turbine blades through the grippers.

[0053] The gripper is a parallel opening and closing pneumatic gripper 67, with ball bearing pads 68 and pressure sensors 69 on the inner sides of its two grippers. The ball bearing pads 68 convert the friction between the grippers and the fan blades into rolling friction, which reduces wear on the surface of the fan blades during clamping and improves the smoothness of the gripper's opening and closing motion. The pressure sensors 69 collect clamping pressure data in real time and feed it back to the control system, enabling precise monitoring and adjustment of the clamping force, avoiding workpiece deformation due to excessive pressure or workpiece detachment due to insufficient pressure.

[0054] In addition, photoelectric sensors 92 are respectively provided on the first base 31, the second base 41, and the third base 51, and photoelectric sensing plates 91 are respectively provided on the first sliding platform 34, the second sliding platform 44, and the third sliding platform 54. The positions of the photoelectric sensing plates 91 and the photoelectric sensors 92 on the corresponding bases are adapted to each other. When the first sliding platform 34 moves along the first base 31, the second sliding platform 44 moves along the second base 41, and the third sliding platform 54 moves along the length of the third base 51, the photoelectric sensing plates 91 move synchronously with the corresponding sliding platforms. When the photoelectric sensing plates 91 enter the sensing range of the photoelectric sensors 92, the photoelectric sensors 92 feed back the detection signal to the control system to realize the limit control or precise positioning of the movement stroke of each sliding platform.

[0055] It should be noted that the control system of this invention can be a PLC control system. This PLC control system centrally controls the actions of the actuators, such as the winch 2, motor 22, first servo motor 36, second servo motor 46, third servo motor 56, fourth servo motor 65, vacuum pump 72, and solenoid valve controlling the parallel opening and closing gripper 67. Simultaneously, it receives real-time detection signals from various sensors, including pressure sensor 69, distance sensor 13, torque sensor, and photoelectric sensor 92, and automates the operation of the device according to a preset program logic. Specifically, the PLC control system can adjust the gripping position of the adaptive manipulator based on the detection data from distance sensor 13, adjust the gripping force of the gripper based on feedback from pressure sensor 69, control the travel limits of each slide module based on the signal from photoelectric sensor 92, and implement overload protection for the transmission system based on the detection value from torque sensor, ultimately ensuring the accuracy, stability, and safety of the laser modification process for wind turbine blades.

[0056] The device of this invention supports both manual operation mode and PLC automatic control mode. The specific process is as follows:

[0057] 1. Manual Operation Mode

[0058] (1) Preliminary preparation: blade attitude adjustment

[0059] Rotate the fan blades to a vertical position (see...) Figure 15The staff stand on the ladder that comes with the wind turbine (the blades are located on one side of the ladder for easy operation).

[0060] (2) Equipment hoisting and positioning

[0061] Take the traction rope of winch 2, fix one end to the preset fixing point at the top of the fan blade (such as the lifting lug at the top of the blade), and fix the other end to the drum of winch 2.

[0062] The winch 2 is started manually (the operator stands on the ladder and uses a manual control switch that is electrically connected to the winch; all manual operations can be performed using this method). The drum winds up the traction rope, and the entire device is slowly hoisted to the preset modification area on the surface of the wind turbine blade, ensuring that the bearing platform 1 is parallel to the surface of the blade.

[0063] (3) Blade fixing

[0064] Adjust the slide module by manually controlling the switch (the screw-driven type requires manual triggering of the fourth servo motor, while the elastic adaptive type can directly push the gripper) so that the parallel opening and closing type air gripper 67 is aligned with both sides of the blade. Manually control the solenoid valve to supply air and drive the air gripper to close and clamp the blade.

[0065] Start the vacuum pump 72 (manual control switch) to create negative pressure through the pipeline, so that the vacuum suction cup 71 is tightly attached to the blade surface, and together with the gripper, the device is stably fixed.

[0066] (4) Laser modification parameter adjustment and operation

[0067] By manually controlling the first to third servo motors, the X, Z, and Y axis slide modules are driven to move, which in turn moves the bracket 57 and the laser galvanometer system to adjust their positions, so that the laser projection end of the digital galvanometer 83 is aligned with the target modification area, ensuring the laser beam focusing accuracy (the projected spot can be previewed through the control box 81 for auxiliary calibration); the laser marking machine is turned on (manual control switch), the laser generator in the control box 81 is started, and the laser is transmitted to the digital galvanometer 83 through the fiber optic path 82. The galvanometer accurately projects the laser beam onto the blade surface, and the modification operation begins (the operator observes the modification effect by climbing the ladder, and fine-tunes the laser parameters or galvanometer position if necessary).

[0068] (5) Modified region switching

[0069] Once the current area modification is complete, manually turn off the laser marking machine to stop laser projection; turn off the vacuum pump 72 to release the negative pressure of the vacuum suction cup 71, and manually control the solenoid valve to switch the air supply direction, so that the air gripper opens and releases the clamping.

[0070] Start the winch 2 to loosen the traction rope, slowly move the device to the next modification area, and repeat steps (3)-(4) until the entire target area of ​​the blade is modified.

[0071] After all operations are completed, reverse the operation of winch 2 to lift the device off the blades, remove the traction rope, and complete the operation.

[0072] 2. PLC automatic control mode

[0073] This invention can also replace manual operation through a PLC control system to achieve full process automation. The specific logic is as follows:

[0074] (1) The device is hoisted from the ground to the blade: automatic positioning and clamping.

[0075] Workers on the ground fix one end of the traction rope of winch 2 to the hoisting lug on the top of the wind turbine blade, and connect the other end to the winch drum; after receiving the "hoisting start" signal, the PLC controls winch 2 to start, and the drum winds up the traction rope at a uniform speed, driving the device to rise from the ground towards the blade.

[0076] During the lifting process, the distance sensor 13 on the support leg 12 detects the distance between the device and the side of the blade in real time and feeds the distance data back to the PLC; when the distance shrinks to the preset clamping distance, the PLC controls the winch 2 to stop lifting.

[0077] Based on the blade width data fed back by the distance sensor 13, the PLC automatically calculates the movement of the adaptive robotic arm slide module and outputs a pulse signal to the fourth servo motor 65. The fourth servo motor 65 drives the fourth lead screw 62 to rotate, which in turn moves the fourth slider 63 and the gripper along the slide bar 64 to the target clamping position.

[0078] The PLC controls the air supply to the gripper via a solenoid valve, driving the parallel opening and closing type pneumatic gripper 67 to close; when the gripper contacts the blade, the pressure sensor 69 inside the gripper collects the gripping pressure data in real time and feeds it back to the PLC.

[0079] If the pressure reaches the preset value, the PLC controls the solenoid valve to reduce the air supply pressure, maintain a constant clamping force, and avoid dents on the blade surface or damage to the internal structure.

[0080] If the pressure is lower than the preset lower limit, the PLC will immediately issue an audible and visual alarm signal, and at the same time control the solenoid valve to increase the air supply pressure, driving the gripper to close again until the pressure reaches the standard.

[0081] (2) Vacuum adsorption fixation:

[0082] After the gripper clamps achieve the required clamping speed, the PLC automatically starts the vacuum pump 72. This is due to the structure of the second spring 712 built into the vacuum suction cup 71 (see...). Figure 14 During the hoisting process, the vacuum suction cup 71 uses its own elastic extension and pushing action to ensure that the silicone suction cup 713 of the vacuum suction cup is always in close contact with the surface of the fan blades.

[0083] The PLC uses an added vacuum pressure sensor (connected in series between the vacuum filter 73 and the suction cup) to detect the negative pressure value of the pipeline in real time. When the negative pressure meets the minimum negative pressure required for blade adsorption, the adsorption is deemed qualified, and the vacuum pump 72 is controlled to switch to "pressure holding mode". At the same time, a "prepare for modification" signal is sent to the laser system.

[0084] (3) Laser modification: autofocus and uniform scanning

[0085] After receiving the "adsorption qualified" signal, the PLC controls the first to third servo motors (36, 46, 56) to work together:

[0086] The first servo motor 36 drives the X-axis slide module, which moves the laser galvanometer system along the blade length to the starting point of the first modified region.

[0087] The second servo motor 46 drives the Z-axis slide module to adjust the vertical distance between the galvanometer system and the blade surface (focusing distance, such as 100mm, matched according to the laser wavelength).

[0088] The third servo motor 56 drives the Y-axis slide module to fine-tune the projection angle of the galvanometer, ensuring that the laser beam is perpendicularly incident on the blade surface.

[0089] Throughout the focusing process, photoelectric sensors 92 on the first, second, and third bases detect the position of the sliding platform in real time and send feedback signals to the PLC to ensure that the focusing deviation is ≤ ±0.1mm.

[0090] After focusing is completed, the PLC controls the laser marking machine to start. The laser generated by the laser generator is transmitted to the digital galvanometer 83 through the fiber optic path 82. The galvanometer projects the laser beam according to the modification path pre-stored by the PLC (such as a "zigzag" path along the blade length direction with a path spacing of 2mm to meet the uniformity requirements of blade surface modification). At the same time, the PLC controls the X-axis slide module to move at a preset modification speed, driving the galvanometer system to complete the scanning modification of the current area.

[0091] Modification process monitoring: The PLC receives the operating current (normal range 5-10A) and internal temperature (normal ≤55℃) signals of the laser galvanometer system in real time. If the current exceeds 12A (indicating an abnormal laser optical path) or the temperature is >60℃ (indicating insufficient heat dissipation), the PLC immediately stops the laser output and starts the built-in cooling fan of the control box. After the current / temperature returns to normal, the modification continues from the paused position to avoid local overheating of the blades or damage to the laser components.

[0092] (4) Current area modification completed: automatic release and smooth lifting

[0093] Modification Stop and Release Control: When photoelectric sensor 92 detects that the X-axis slide module has moved to the end point of the current modification area (e.g., a pre-stored path length of 1m), the PLC controls the laser marking machine to stop working and simultaneously executes the release action.

[0094] The control gripper's matching solenoid valve switches the air supply direction, supplying air to the "opening chamber" of the gripper, driving the gripper to open and release the grip;

[0095] Control the vacuum pump 72 to stop working, and at the same time open the pipeline pressure relief valve (which can be added) to release the negative pressure in the vacuum suction cup 71, so as to avoid the device from sticking to the blade due to the residual negative pressure.

[0096] After the release is completed, the PLC controls the winch 2 to restart, and the drum continues to wind up the traction rope, driving the device towards the tip of the blade (entering the next modification area); during the lifting process, the distance sensor 13 continuously detects the distance between the device and the side of the blade. If the distance on one side increases due to the curvature of the blade (such as the leading edge curvature of an airfoil blade) (e.g., from 50mm to 70mm), the PLC immediately outputs a signal to the motor 22:

[0097] After receiving the signal, the motor 22 drives the input shaft of the swing cam divider 21 to rotate. Through the cam-roller meshing transmission, the swing angle of the divider output shaft is adjusted (e.g., swinging 5°-8° to the side where the distance increases).

[0098] The output shaft of the divider drives the disc 24 to swing synchronously with the winch 2, causing the force direction of the winch traction rope to shift towards the side of the blade, correcting the offset trend of the device until the distance sensor 13 detects that the distance on both sides has returned to the preset 50mm, and the PLC controls the motor 22 to stop, maintaining the current swing angle.

[0099] This process ensures that the device moves smoothly along the curved surface of the blade, avoiding collisions with the blade or deviation from the modification path due to deviations in the angle of the traction rope.

[0100] (5) Complete modification of all blades: automatic finishing and safe shutdown

[0101] When distance sensor 13 detects that the device has moved to the tip of the blade (which can be observed visually or measured by the sensor), or when the "total number of modified areas" pre-stored by the PLC is completed, the PLC controls the winch 2 to stop lifting and simultaneously performs the finishing action:

[0102] Power off all servo motors (36, 46, 56, 65) and lock the slide module;

[0103] The control solenoid valve and vacuum pump 72 are completely de-energized, and the gripper remains open.

[0104] Generate a work report (including the area of ​​the modified region, the duration of modification in a single region, the number of failures, and the total power consumption), store it in the SD storage module of the control box 81, and simultaneously upload it to the background management system via the Ethernet interface (optional).

[0105] During the entire automatic process, if the torque sensor (connected in series between motor 22 and the drive pulley) detects that the transmission torque exceeds the preset threshold (e.g., 50 N·m, indicating that the winch traction is obstructed), or the distance sensor 13 detects a sudden change in distance (e.g., ≤20 mm, indicating that the device is about to collide with the blade), the PLC immediately triggers an "emergency stop," cutting off the power to the winch, laser system, and servo motor. At the same time, it controls the winch 2 to loosen the rope in the reverse direction, slowly lowering the device back to the ground to avoid damage to the equipment or the blade.

[0106] Of course, the control of this device is not limited to the aforementioned manual or PLC automatic control; it can also be remotely operated via wireless control. This is particularly suitable for scenarios where wind turbine blades are high (e.g., over 50m), ladder-climbing operations are risky, or the blade surface curvature is complex and requires real-time manual intervention. Wireless control uses a PLC as the core execution unit and a wireless communication module as the signal transmission carrier to achieve two-way interaction of remote command transmission and data feedback. A specific solution is as follows:

[0107] Hardware configuration:

[0108] On the device side: A wireless communication module is added to the control box 81 (optional LoRa long-range module, industrial-grade Wi-Fi module, or 4G / 5G module, depending on the working environment: LoRa is suitable for low-power long-distance transmission within 1km, suitable for remote wind farms; Wi-Fi is suitable for high-speed transmission within 50m, suitable for near-field precision operation; 4G / 5G is suitable for unobstructed wide-area transmission, suitable for cross-regional wind farm cluster control). The module communicates with the PLC via RS485 or Ethernet interface. At the same time, a high-definition camera (with night vision function) is added to key locations on the device (such as next to the laser galvanometer and at the gripper) to collect the operation scene in real time.

[0109] Operation terminal: Equipped with an industrial-grade handheld wireless terminal (such as a tablet computer with waterproof and dustproof functions or a customized remote control). The terminal has a built-in corresponding wireless communication module. The interface can display real-time data (distance sensor values, pressure sensor data, negative pressure value, laser power, etc.) and operation screen, and has physical / virtual operation buttons (start / pause, emergency stop, parameter adjustment, etc.).

Claims

1. A device for laser modification of the surface of in-service wind turbine blades, characterized in that, The system includes a support platform (1), and a winch (2) and a laser dynamic focusing mechanism respectively located on the front and rear sides of the upper surface of the support platform (1); adaptive manipulators are symmetrically arranged on the left and right sides of the lower surface of the support platform (1), and the adaptive manipulators are used to clamp the wind turbine blades; a vacuum suction cup (71) is provided in the middle of the lower surface of the support platform (1), and the vacuum suction cup (71) is connected to a vacuum pump (72) located on the support platform (1) through a pipeline; the laser dynamic focusing mechanism includes an X-axis slide module, a Y-axis slide module and a Z-axis slide module, wherein the X-axis slide module is installed on the support platform (1), the Z-axis slide module is equipped on the X-axis slide module, the Y-axis slide module is equipped on the Z-axis slide module, and a bracket (57) is fixedly connected to the Y-axis slide module, the bracket (57) is used to support the laser galvanometer system, and the laser galvanometer system is used to project a laser beam onto the surface of the wind turbine blades.

2. The device for laser modification of the surface of in-service wind turbine blades according to claim 1, characterized in that, The adaptive manipulator mechanism includes a slide module, which is set on the left and right sides of the lower surface of the support platform (1). A connecting block (66) is fixedly connected to the sliding block of the slide module. A gripper is connected to the end of the connecting block (66) away from the sliding block, and the gripper clamps the fan blades.

3. The device for laser modification of the surface of in-service wind turbine blades according to claim 1, characterized in that, The X-axis slide module includes a first base (31), a first lead screw (32), a first slider (33), a first sliding platform (34), a first cover plate (35), and a first servo motor (36). The first base (31) is mounted on the support platform (1). The first lead screw (32) is located inside the first base (31) along the length direction of the first base (31). The first slider (33) is threadedly engaged with the first lead screw (32). The first sliding platform (34) is fixedly connected to the first slider (33). The first cover plate (35) is fixedly connected to the first base (31) and covers the first sliding platform (34). The two sides of the first sliding platform (34) extend out of the first cover plate (35), and the Z-axis slide module is assembled on the two sides of the first sliding platform (34). The first servo motor (36) is used to drive the first lead screw (32) to rotate inside the first base (31) so as to drive the Z-axis slide module to slide along the length direction of the first base (31).

4. The apparatus for laser modification of the surface of in-service wind turbine blades according to claim 3, characterized in that, The Z-axis slide module includes a second base (41), a second lead screw (42), a second slider (43), a second sliding platform (44), a second cover plate (45), and a second servo motor (46). The second base (41) is assembled to both sides of the first sliding platform (34) via connecting ribs (47). The second lead screw (42) is disposed within the second base (41) along the length direction of the second base (41). The second slider (43) is threadedly engaged with the second lead screw (42). The platform (44) is fixedly connected to the second slider (43); the second cover plate (45) is fixedly connected to the second base (41) and covers the second sliding platform (44). The two sides of the second sliding platform (44) extend out of the second cover plate (45), and the two sides of the second sliding platform (44) are equipped with Y-axis slide modules; the second servo motor (46) is used to drive the second lead screw (42) to rotate in the second base (41) so as to drive the Y-axis slide module to slide along the length direction of the second base (41).

5. The apparatus for laser modification of the surface of in-service wind turbine blades according to claim 4, characterized in that, The Y-axis slide module includes a third base (51), a third lead screw (52), a third slider (53), a third sliding platform (54), a third cover plate (55), and a third servo motor (56). The bottom surface of the third base (51) is mounted on both sides of the second sliding platform (44). The third lead screw (52) is located inside the third base (51) along the length direction of the third base (51). The third slider (53) is threadedly engaged with the third lead screw (52). The third sliding platform (54) is fixedly connected to the third slider (53). The third cover plate (55) is fixedly connected to the third base (51) and covers the third sliding platform (54). Both sides of the third sliding platform (54) extend out of the third cover plate (55), and both sides of the third sliding platform (54) are fixedly connected to brackets (57). The third servo motor (56) is used to drive the third lead screw to rotate inside the third base, so as to drive the laser galvanometer system to slide along the length direction of the third base.

6. The apparatus for laser modification of the surface of in-service wind turbine blades according to claim 1, characterized in that, It also includes a drive assembly for driving the winch (2) to swing. The drive assembly includes a swing cam divider (21), a motor (22), a transmission belt (23), and a disc (24). The swing cam divider (21) and the motor (22) are both set on the support platform (1) on one side corresponding to the winch (2). The motor (22) is connected to the swing cam divider (21) through the transmission belt (23). The disc (24) is fixedly connected to the output shaft of the swing cam divider (21). The winch (2) is fixed on the disc (24). When the motor (22) drives the swing cam divider (21) to move, its output shaft drives the disc (24) and the winch (2) to swing synchronously.

7. The apparatus for laser modification of the surface of in-service wind turbine blades according to claim 2, characterized in that, It also includes four legs (12) symmetrically arranged on the lower surface of the support platform (1), and the four legs (12) are respectively arranged in front of the four adaptive manipulator mechanisms.

8. The apparatus for laser modification of the surface of in-service wind turbine blades according to claim 7, characterized in that, A distance sensor (13) is provided on the support leg (12). The distance sensor (13) is used to detect the distance between the support leg (12) and the side of the wind turbine blade, and feeds the detection signal back to the control system. The control system controls the movement distance of the sliding block of the slide module, and then the gripper clamps the wind turbine blade.

9. The apparatus for laser modification of the surface of in-service wind turbine blades according to claim 2, characterized in that, The gripper is a parallel opening and closing pneumatic gripper (67), and the inner sides of the two grippers of the parallel opening and closing pneumatic gripper (67) are provided with ball gaskets (68) and pressure sensors (69).

10. The apparatus for laser modification of the surface of in-service wind turbine blades according to claim 5, characterized in that, The first base (31), the second base (41), and the third base (51) are respectively provided with photoelectric sensors (92), and the first sliding platform (34), the second sliding platform (44), and the third sliding platform (54) are respectively provided with photoelectric sensor sheets (91), and the positions of the photoelectric sensor sheets (91) and the photoelectric sensors (92) on the corresponding bases are adapted to each other.

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