Method of manufacturing wind turbine blade component
By setting visually distinct alignment features and position marks on the surfaces of the sheets and molds, combined with a visible light projection system, the problem of difficult sheet alignment for wind turbine blade components was solved, achieving an efficient and accurate manufacturing process.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- VESTAS WIND SYSTEMS AS
- Filing Date
- 2024-09-26
- Publication Date
- 2026-04-21
AI Technical Summary
Due to the large size of wind turbine blade components, precise alignment of the sheets on the mold is both time-consuming and difficult, and existing molding processes cannot achieve this efficiently.
By providing visually distinct alignment features and positional markings on the sheet and die surfaces, a visible light projection system is used to precisely align the sheet with the die surface, ensuring that the sheet is correctly oriented on the die.
It simplifies the alignment process of the sheet material on the mold, improves manufacturing efficiency, and ensures the accuracy and quality of wind turbine blade components.
Smart Images
Figure CN121909098A_ABST
Abstract
Description
Technical Field
[0001] This invention relates generally to wind turbine blades, and more specifically to methods for manufacturing wind turbine blade components. Background Technology
[0002] Modern wind turbine blades are very large structures, and consequently, components of wind turbine blades, such as blade shells or shear webs, can also be very large. Manufacturing components, such as blade shells and / or shear webs, typically involves molding processes. Molding processes, such as vacuum-assisted resin transfer molding (VARTM), typically involve arranging one or more sheets on a mold surface. However, due to the dimensions of some wind turbine blade components and the corresponding dimensions of the molds configured to form such components, precise alignment of the sheets on the mold can be both challenging and time-consuming.
[0003] In light of this background, the present invention has been developed. Summary of the Invention
[0004] In a first aspect of the invention, a method of manufacturing a wind turbine blade component is provided. The method includes: providing a sheet including a first edge, a first alignment feature positioned adjacent to the first edge and defining a first reference feature, a second edge, and a second alignment feature positioned adjacent to a second edge and defining a second reference feature. The method further includes: providing a mold defining a mold surface; and providing a first position mark indicating the first position at a first location along the mold surface. Additionally, the method includes: providing a second position mark indicating the second position at a second location along the mold surface. The method includes: disposing the sheet on the mold surface; and aligning the first reference feature with the first position mark and aligning the second reference feature with the second position mark, thereby aligning the sheet on the mold. The first alignment feature and the second alignment feature are visually different from each other. Additionally or alternatively, the first alignment feature and the second alignment feature are located at different portions of the first edge compared to their respective positions at the second edge.
[0005] Therefore, by using a combination of first and second alignment features of the sheet with corresponding position marks, this method facilitates simple alignment of the sheet on the die. This method also facilitates simple orientation of the sheet on the die surface, because the construction of the first and second alignment features allows for rapid visual recognition of the corresponding edges of the sheet, and the sheet can then be arranged on the die in the desired orientation.
[0006] The first alignment feature and the second alignment feature are located near their respective first and second edges, and are components of the sheet other than its edges. That is, the sheet includes a first edge, and the sheet also includes a first alignment feature positioned adjacent to the first edge, defining a first reference feature relative to the first edge; and the sheet includes a second edge, and the sheet also includes a second alignment feature positioned adjacent to the second edge, defining a second reference feature relative to the second edge. In other words, the first alignment feature is a feature of the sheet itself that is not the first edge, and similarly, the second alignment feature is a feature of the sheet itself that is not the second edge.
[0007] In some examples, the sheet may include a first alignment feature that is visually different from the second alignment feature, and the first alignment feature may also be located at a different portion of the first edge compared to the position of the second alignment feature at the corresponding second edge. This configuration facilitates the orientation and alignment of the sheet on the die as described above, and provides multiple visually identifiable indicators (i.e., the different forms of the alignment features and the positions of the alignment features). It also helps ensure that the sheet is correctly positioned face up on the die, i.e., not upside down.
[0008] It should be understood that the first and second position marks indicate predetermined positions on the mold surface, wherein the precise alignment of the sheet alignment features with the position marks results in the manufacturing of the wind turbine blade components conforming to the intended design.
[0009] In some examples, the wind turbine blade component may be a laminated composite component. In such examples, a sheet may form at least a portion of the laminated layer of the wind turbine blade component. Therefore, the sheet may be a sheet of fibrous material, which may include reinforcing fibers such as glass fiber or carbon fiber. Thus, in some examples, the sheet may be a sheet of glass fiber material (e.g., biaxial glass fiber material).
[0010] In some other examples, the sheet may be a sheet of consumable or sacrificial material used in the molding process when manufacturing a wind turbine blade component according to an example of the invention. For example, the sheet may be a sheet of transfer film, release layer material, flow control material, release material, or sealing material.
[0011] In some examples, providing a first location mark and / or a second location mark may include providing corresponding location marks on the mold surface. For example, in some examples, the first location mark and / or the second location mark may include lines or other marks painted on or adhered to the mold surface with tape.
[0012] In some other examples, providing a first location mark may include projecting the first location mark onto the mold surface and / or sheet using a visible light projection system. Additionally or alternatively, providing a second location mark may include projecting the second location mark onto the mold surface and / or sheet using a visible light projection system.
[0013] For example, a visible light projection system may include a laser projection system. Therefore, the first and / or second position marks may include laser projection. Projecting the position marks, or each position mark, onto the mold surface and / or the sheet is an efficient and time-efficient method for aligning one or more sheets onto the mold. In particular, such a method facilitates the alignment of opaque or substantially opaque sheets onto the mold. Furthermore, such a method facilitates the vertical alignment of multiple sheets on the mold surface, where the multiple sheets would otherwise obscure the view of the position marks on the mold surface itself. The visible light projection system also facilitates the simple reconfiguration of the first and / or second position marks, allowing the same equipment to be used for aligning different layers of sheets in a wind turbine blade component, or even for manufacturing different designs of wind turbine blade components by indicating different positions for aligning the sheet or each sheet onto the mold.
[0014] In some examples, the mold can be a punch, and the mold surface can therefore be a substantially convex mold surface. Thus, in some examples, the mold can be configured to form the shear web of a wind turbine blade, and the method can therefore be a method for manufacturing the shear web of a wind turbine blade.
[0015] In some examples, the convex mold surface may include a main mold surface and one or more side surfaces extending transversely to the main mold surface. In such examples, a first position mark and a second position mark may be disposed on the main mold surface. Therefore, in some preferred examples, arranging the sheet on the mold may include arranging the sheet such that the first alignment feature and the second alignment feature are located on the main mold surface. This configuration is advantageous for ensuring that the first and second position marks, as well as the first and second alignment features, are visible from either side of the mold. Furthermore, such a configuration facilitates the use of an overhead visible light projection system located above the mold to project the first alignment feature and / or the second position mark onto the mold surface and / or the sheet, since the main mold surface is within the field of view of such a projection system.
[0016] In some examples, the main die surface may be a substantially flat, upward-facing surface of the die. Conversely, one or more side surfaces may extend laterally downward from the main die surface. For example, the main die surface may be shaped to form a web panel that forms a shear web, and the side surface, or each side surface, may be shaped to form at least a portion of a shear web mounting flange that extends laterally to the web panel for attaching the shear web to the blade housing.
[0017] In some examples, the sheet may include a third edge and a fourth edge. The third edge and the fourth edge may extend between the first edge and the second edge of the sheet, which are opposite to each other. The method may include arranging the sheet on a mold surface such that at least one of the third edge and / or the fourth edge is positioned on a side surface of the mold. Consequently, in some examples, the projection lines extending between the third edge and the visible light projection system and / or between the fourth edge and the visible light projection system may be truncated by the main mold surface. Therefore, in examples where the mold includes a convex mold surface, it is not possible to project reference lines onto the side surface of the mold for aligning the third edge and / or the fourth edge of the sheet. The method described herein advantageously facilitates the alignment of the sheet without requiring the projection of reference lines onto the side surface of the mold or each side surface.
[0018] In some other examples, the mold can be a concave mold, and the mold surface can therefore be a concave mold surface. Thus, in some examples, the mold can be configured to form at least a portion of a wind turbine blade housing, and the method can therefore be a method for manufacturing at least a portion of a wind turbine blade housing.
[0019] In some examples, the first alignment feature and / or the second alignment feature may be disposed on the surface of the sheet. For example, the alignment features may be drawn or printed onto the surface of the sheet.
[0020] In some other examples, the first alignment feature may be formed as part of the sheet. Alternatively or additionally, the second alignment feature may be formed as part of the sheet. For example, the sheet may be manufactured with the first alignment feature and / or the second alignment feature integrally formed within the sheet. For example, the sheet may be a molded or pressed sheet including the first alignment feature and / or the second alignment feature. In some examples, the sheet may be a sheet of woven fibrous material, in which the first alignment feature and / or the second alignment feature are woven into the sheet during its manufacture.
[0021] In some examples, the first alignment feature may be cut into the sheet. Alternatively, a second alignment feature may be cut into the sheet. For example, the alignment features may be cut into the sheet simultaneously from a larger batch of raw material, or each alignment feature may be cut into the sheet simultaneously from a batch of raw material, as described herein. Thus, in some examples, the corresponding first and / or second alignment features may be cut into multiple sheets simultaneously.
[0022] In some preferred embodiments, the first alignment feature and / or the second alignment feature of the sheet may extend from the first edge and / or the second edge into the sheet, respectively. This configuration produces alignment features that are particularly clearly visible to a person skilled in the art when the sheet is arranged on a die. Furthermore, in examples of cutting sheets from raw materials, this configuration facilitates a particularly efficient cutting process when cutting sheets from larger raw materials, because the alignment features can be cut out in the same process step at the corresponding edges of the sheet.
[0023] In some examples, the first alignment feature and / or the second alignment feature may include a notch or cut extending from the corresponding edge into the sheet. Such an alignment feature may include a straight edge that can be identified as a corresponding reference feature. For example, the alignment feature may include a triangular cut, and the reference feature may be the edge of the triangular cut that extends substantially perpendicular to the corresponding edge of the sheet. In some other examples, the first alignment feature and / or the second alignment feature of the sheet may be a simple slit extending from the corresponding edge into the sheet. Such a slit may include a straight cut and may itself define a corresponding reference feature.
[0024] In some examples, the first and second edges of the sheet can be opposite each other. For example, the sheet can be a substantially quadrilateral shape, such as a substantially square, rectangle, trapezoid, or elongated rectangle. Therefore, in some examples, the first and second edges can be the left and right edges, or the top and bottom edges of the sheet.
[0025] In some examples, the first alignment feature may be visually distinct from the second alignment feature, and the first and second alignment features may be located at the same portions of the corresponding first and second edges of the sheet, respectively. Therefore, in such examples, the orientation of the sheet can be identified primarily by the visual difference between the first and second alignment features.
[0026] In some such examples, the first and second position marks can be aligned with each other in a first direction, and the first and second reference features can also be aligned with each other in the first direction. For example, the first and second position marks can be defined by the same line, i.e., a reference line, such as the center line of the mold surface or a single projected laser line. Such a configuration simplifies the setting of the first and second position marks, while still facilitating the precise alignment and orientation of the sheet on the mold by aligning the visually different reference features of the first and second alignment features with the corresponding position marks (i.e., with the reference line).
[0027] In some other examples, the first alignment feature may be visually identical to the second alignment feature, and the first alignment feature may be located at a different portion of the first edge compared to the position of the second alignment feature at the corresponding second edge. For example, the first and second alignment features may each be a simple slit cut into the sheet. Therefore, the first and second alignment features can be visually identical to each other. Thus, the correct orientation of the sheet can be identified primarily by observing the position of the corresponding alignment features. For example, an alignment feature located at the center of an edge can indicate that the edge is the first edge, while an alignment feature located on the side of an edge can indicate that the edge is the second edge. This facilitates a simple and efficient process for manufacturing sheets, while still enabling precise alignment and orientation of the sheet on the die.
[0028] In some examples, the method may include: providing a plurality of sheets, each sheet including a corresponding first edge, a corresponding first alignment feature positioned adjacent to the first edge and defining a corresponding first reference feature, a corresponding second edge, and a corresponding second alignment feature positioned adjacent to the second edge and defining a corresponding second reference feature. In such an example, the method may further include: arranging each sheet on a die surface with the same orientation such that each first alignment feature is located on the same side of the corresponding sheet and each second alignment feature is located on the same side of the corresponding sheet.
[0029] Each sheet may have a first edge defining a first edge region, and each sheet may have a second edge defining a second edge region. In some examples, the method may include arranging the first and second sheets on a die such that the first edge region of the first sheet overlaps with the second edge region of the second sheet. In such examples, the corresponding first alignment feature is preferably located at a different portion of the corresponding first edge compared to the position of the corresponding second alignment feature at the corresponding second edge. Such a configuration can help further minimize confusion when aligning the first and second reference features of each sheet with the corresponding position marks.
[0030] Furthermore, in examples where the alignment features are cut or otherwise formed in the sheet without sheet material, offsetting the alignment features helps ensure that the resulting wind turbine blade component, partially formed from multiple sheets, is not weakened by the close arrangement of discontinuities (i.e., alignment features) in the constituent sheets. For example, if the sheets include fibrous material for forming the composite wind turbine blade component, offsetting the alignment features (i.e., providing a first sheet and a second sheet with corresponding alignment features located at different portions of the respective edges of the sheets) helps ensure sufficient load paths are formed in the component, thereby minimizing the risk of stress concentration in the component. In some preferred examples, the overlapping sheets can be arranged such that the first alignment feature of the first sheet is spaced apart from the second alignment feature of the second sheet by at least 10 mm, preferably at least 20 mm, and more preferably at least 30 mm in all directions.
[0031] In some examples, a first position mark may be positioned at a first location along the mold surface in a first direction, and a second position mark may be positioned at a second location along the mold surface in the first direction. Each of the first and second position marks indicates a corresponding position on the mold surface in a second direction. Therefore, the method may include aligning a first and a second reference feature of the sheet with the first and second position marks in the second direction. The second direction may be transverse to the first direction; for example, in some preferred examples, the second direction may be orthogonal to the first direction.
[0032] It is understood that in some examples where the first and second position marks are aligned with each other, the first and second position marks may be located at different positions in the first direction and aligned with each other in the second direction. For example, the first and second position marks may be located at different positions along a reference line extending in the first direction, and thus may be located at different positions in the first direction while being aligned in the second direction. As previously stated, the sheet may be arranged such that the first and second reference features are aligned with the corresponding first and second position marks in the second direction.
[0033] Conversely, in some other examples, the first and second position marks may not be aligned, and instead, they may be offset from each other in a first and a second direction. It should be understood that in such examples, the method may further include arranging the sheet such that the first and second reference features are aligned with the corresponding first and second position marks in the second direction.
[0034] The second direction can be transverse to the first direction; for example, in some preferred embodiments, the second direction can be orthogonal to the first direction. For instance, the first direction can be the spanwise direction of the resulting wind turbine blade component, while the second direction can be one of the chordal, width, or thickness directions of the resulting wind turbine blade component. In some examples, the mold surface defined by the mold can therefore extend longitudinally in the first direction, i.e., in the spanwise direction of the resulting wind turbine blade component. Consequently, the mold surface defined by the mold can also extend in a second direction transverse to the first direction, i.e., in the chordal, width, or thickness direction of the resulting wind turbine blade component.
[0035] In some examples, the method may include manually placing the sheet onto the mold surface. Providing positional markings and alignment features, as described in the examples herein, is particularly advantageous for a technician observing the fabrication process of wind turbine blade components on the mold.
[0036] The first alignment feature and / or the second alignment feature may be a cut in the sheet. In other examples, the first alignment feature and / or the second alignment feature may be a mark on the sheet. For example, the first alignment feature and / or the second alignment feature may be drawn or painted on the surface of the sheet, or may be provided on an adhesive label attached to the sheet. The first alignment feature and / or the second alignment feature may be formed as part of the sheet by weaving or sewing the alignment features into the sheet. The alignment feature may include a portion such as a straight line or a straight edge, which may be identified as a reference feature for arrangement with the corresponding position mark.
[0037] It should be understood that referring to arranging the sheet "on the mold" or "on the mold surface" is not limited to arranging the sheet directly on the mold or mold surface, i.e., in direct contact with the mold or mold surface. In some examples, the method may include arranging the sheet on the mold surface, on top of an intermediate part or material (e.g., a release layer or film).
[0038] In another aspect of the invention, an example of a shear-resistant web manufactured according to the method described herein is provided.
[0039] In another aspect of the invention, a wind turbine blade housing manufactured according to an example of the method described herein is provided. Attached Figure Description
[0040] Examples of the invention will now be described by way of non-limiting example only, with reference to the accompanying drawings, in which: Figure 1 It is a schematic exploded view of a wind turbine blade; Figure 2This is a schematic perspective view of a mold used to manufacture wind turbine blade components; Figure 3 It is a schematic cross-sectional view of the mold and the visible light projection system used to provide position markings on the mold; Figure 4a It is a schematic three-dimensional diagram of the sheets arranged on the mold; Figure 4b This is an enlarged view of the alignment features of the sheet, which are arranged with corresponding position marks to align the sheet onto the die; and Figures 5a to 5c These are schematic plan views of different examples of sheets with alignment features of different constructions. Detailed Implementation
[0041] Figure 1 This is a schematic exploded view of an example wind turbine blade 10. The blade extends longitudinally in the spanwise direction (S) between a root tip 12 and a tip tip 14, and in the chordwise direction (C) between a leading edge 16 and a trailing edge 18. The blade 10 also extends in a thickness direction (T) orthogonal to the spanwise (S) and chordwise (C) directions. The blade 10 includes a shell, which may be formed by a first half-shell 20a and a second half-shell 20b joined together. The wind turbine blade 10 may also include a shear web 22, which extends longitudinally within the shell in the spanwise direction (S). The shear web 22 may include a longitudinally extending web face 24 and one or more web flanges 26 configured to connect the shear web 22 to the shell of the blade 10.
[0042] Wind turbine blade components (such as half-shells 20a, 20b and shear web 22) can be formed using molding processes such as vacuum-assisted resin transfer molding (VARTM). The method for manufacturing wind turbine blade components will now be described with reference to the remaining figures.
[0043] First refer to Figure 2 , Figure 2 A schematic perspective view of a portion of a mold 28 defining a mold surface 30 is shown. Figure 2 In the example shown, mold 28 is a punch, meaning that mold surface 30 is a substantially convex mold surface. For example, mold surface 30 may include a main mold surface 32 and one or more side surfaces 34 extending transversely to the main mold surface 32. Therefore, mold 28 may be configured to form a shear web 22, for example... Figure 1 The shear-resistant web 22 is shown as an example. The main mold surface 32 can be formed to form the web panel 24, while the side surface 34 can be formed to form the web flange 26.
[0044] The mold surface 30 extends longitudinally in a first direction X, which can be the spanwise direction (S) of the resulting wind turbine blade component formed on the mold 28. The mold surface 30 also extends in a second direction Y, which is transverse to the first direction X. In some examples, the second direction Y can be orthogonal to the first direction X; for example, the second direction Y can be the thickness direction (T) of the resulting wind turbine blade component. It should be understood that in other examples, the second direction Y can be the chordal direction (C) of the resulting wind turbine blade component.
[0045] Refer to later Figures 4a to 5c The arrangement of sheet 36 on mold 28 is described in more detail. However, to facilitate precise arrangement of sheet 36 on mold 28, the method includes providing, for example... Figure 2 and Figure 3 The position marks 38a and 38b are shown. For example, the first position mark 38a is provided at a first position along the mold surface 30 to indicate the first position. Similarly, the second position mark 38b is provided at a second position along the mold surface 30 to indicate the second position. The first position mark 38a and the second position mark 38b may be provided at separate positions along the mold surface 30 in the first direction X, and each mark 38a, 38b may indicate a corresponding position on the mold surface 30 in the second direction Y.
[0046] In different examples, position markers 38a and 38b can be provided in different ways. (Still refer to...) Figure 2 and Figure 3 In some preferred embodiments, a visible light projection system 40 can be used to project the first position mark 38a and the second position mark 38b onto the mold surface 30. In an example where the mold surface 30 is convex, the first position mark 38a and the second position mark 38b are preferably disposed on the main mold surface 32. The design of the manufacturing process such that the marks 38a and 38b are disposed on the main mold surface 32 helps ensure that the desired positions of the marks 38a and 38b are within the field of view 41 of the visible light projection system 40 arranged above the mold 28. Distributing the position marks 38a and 38b on the main mold surface 32 also helps ensure that, during component manufacturing, assembly technicians can see the marks from all sides of the mold 28.
[0047] Now for reference Figure 4aThis illustrates a sheet 36 arranged on the mold surface 30. As previously described, position marks 38a and 38b are provided to facilitate precise alignment of the sheet 36. Therefore, the sheet 36 includes a plurality of alignment features 42a and 42b configured to correspond to the position marks 38a and 38b to facilitate alignment of the sheet 36 on the mold 28. The sheet 36 includes a first alignment feature 42a located near a first edge 44a of the sheet 36 and a second alignment feature 42b located near a second edge 44b of the sheet 36. Figure 4a As shown, the first edge 44a and the second edge 44b may be opposite each other. In some examples, the sheet may include a third edge 44c and a fourth edge 44d that may be located on the side surface 34 of the mold 28.
[0048] The first alignment feature 42a defines a first reference feature 46a for aligning the sheet 36 with the first position mark 38a, and the second alignment feature 42b defines a second reference feature 46b for aligning the sheet 36 with the second position mark 38b. Figure 4b A detailed view of the first alignment feature 42a is provided. In this example, the first alignment feature 42a includes a triangular notch extending from the first edge 44a into the sheet 36. In this example, a reference feature 46a is defined by a side of the triangular notch that is substantially perpendicular to the first edge 44a. The sheet 36 is positioned by aligning the first reference feature 46a with a first position mark 38a, and in particular, the sheet 36 can be arranged such that the reference feature 46a is aligned with the position mark 38a in a second direction Y.
[0049] Although not shown in a separate detailed view, it is understood that the second reference feature 46b is aligned with the corresponding second position mark 38b in a similar manner. By aligning the first reference feature 46a and the second reference feature 46b with their respective position marks 38a, 38b, the sheet 36 is rotatably aligned on the mold 28 both in the second direction Y. Precise positioning of the sheet 36 in the first direction X can be achieved by aligning the first edge 44a or the second edge 44b of the sheet 36 with a reference line or mark (not shown), such as a projected reference line indicating the desired position along the mold surface 30 in the first direction X.
[0050] Figures 5a to 5cDifferent examples of sheet 36 are shown, including a first alignment feature 42a and a second alignment feature 42b, which are configured to correspond to a first position mark 38a and a second position mark 38b to facilitate alignment of sheet 36 on die 28. In each of these examples, alignment features 42a, 42b may be formed as part of sheet 36. For example, alignment features 42a, 42b may, and therefore corresponding reference features 46a, 46b may also be formed by cutting these features into sheet 36.
[0051] Figure 5a An example of sheet 36 is shown, which includes a first alignment feature 42a that is visually different from the second alignment feature 42b. For example, the first alignment feature 42a may be a triangular cut, while the second alignment feature 42b may be a linear slit cut into the sheet 36. A technician can easily identify which alignment feature is the first alignment feature 42a or the second alignment feature 42b based on the visual differences between the alignment features. In this way, a technician can easily determine the correct orientation of the sheet 36 on the die 28.
[0052] like Figure 5a As shown, in some examples, the first alignment feature 42a and the second alignment feature 42b may be located at the same portion of the corresponding first edge 44a and second edge 44b of the sheet 36, for example, as Figure 5a The central portion is shown. In such an example, the first reference feature 46a and the second reference feature 46b can be aligned with each other in the first direction X. Consequently, the corresponding first position mark 38a and second position mark 38b can also be aligned with each other, and in some examples, the first position mark 38a and the second position mark 38b can be defined by different portions of the same reference line (e.g., a center line) extending in the first direction X. Such a configuration makes it easier for a person skilled in the art to observe when arranging the sheet 36. Although the alignment features 42a and 42b are located in the same portions of the corresponding edges 44a and 44b, as previously stated, the visual difference between the alignment features 42a and 42b facilitates the simple orientation of the sheet 36.
[0053] See now Figure 5b In some other examples, the first alignment feature 42a may be located at a different portion of the first edge 44a compared to the position of the second alignment feature 42b at the corresponding second edge 44b. In such examples, the first alignment feature 42a may be visually identical to the second alignment feature 42b. Therefore, in these examples, which alignment feature is the first alignment feature 42a or the second alignment feature 42b can be identified based on the position of each alignment feature. For example, as... Figure 5bAs shown, an alignment feature located in the central portion of an edge can indicate that the alignment feature is the first alignment feature 42a, and therefore the edge is the first edge 44a. Conversely, an alignment feature located outside the central portion (e.g., closer to the third edge 44c or the fourth edge 44d) can indicate that the alignment feature is the second alignment feature 42b, and the corresponding edge is the second edge 44b. Therefore, the positions of alignment features 42a, 42b provide an indication of which position markers 38a, 38b the corresponding alignment feature should be arranged with.
[0054] exist Figure 5c Another example of sheet 36 including alignment features 42a, 42b is shown. As illustrated, in some examples, sheet 36 may include alignment features 42a, 42b that are visually distinct from each other and located at different portions of the respective sheet edges 44a, 44b. For example, as... Figure 5c As shown, the first alignment feature 42a can be a triangular cutout located in the central portion of the sheet 36, while the second alignment feature 42b can be a linear slit located at the portion of the second edge 44b near the third edge 44c (i.e., outside the central portion). This configuration offers the same advantages as previously described in terms of aligning and orienting the sheet 36 on the die 28. Furthermore, the visually distinct and differently positioned alignment features 42a and 42b of the sheet 36 provide a simple means for technicians to determine the correct position of the sheet 36 on the die 28.
[0055] Although Figures 5a to 5c Alignment features 42a, 42b have been described with reference to those cut into sheet 36, but in some other examples (not shown), alignment features 42a, 42b may be provided in different ways. For example, the first alignment feature 42a and / or the second alignment feature 42b may be drawn or painted on the surface of sheet 36, or may be provided on an adhesive label attached to sheet 36. In some other examples, alignment features 42a, 42b, or each alignment feature 42a, 42b, may be formed as part of sheet 36 by weaving or sewing alignment features 42a, 42b into the sheet itself. It is noteworthy that in each example, alignment features 42a, 42b include portions such as straight lines or straight edges that can be identified by a person skilled in the art as reference features 46a, 46b arranged together with corresponding position marks 38a, 38b.
[0056] The method for arranging and aligning sheet 36 described herein can be used to arrange different sheets during the manufacture of wind turbine blade components. For example, sheet 36 may be a sheet of sacrificial or consumable material used in a molding process. However, this method is particularly advantageous for arranging reinforcing material sheets (e.g., glass fiber sheets) on or within mold 28.
[0057] In some examples (not shown), the method may include arranging a plurality of sheets 36 on the mold 28, such as those described herein. Thus, each sheet 36 may include a corresponding first edge 44a and a second edge 44b, and corresponding first alignment features 42a and second alignment features 42b located near the corresponding edges. As described above, the corresponding first alignment features 42a and second alignment features 42b may define a first reference feature 46a and a second reference feature 46b. Each sheet 36 may be arranged on the mold surface 30 with the same orientation. This means that a person skilled in the art can easily identify how each sheet 36 should be oriented by simply observing the first alignment features 42a and / or the second alignment features 42b of each sheet 36. Subsequently, after each sheet 36 has been correctly arranged on the mold 28, the first alignment feature 42a of each sheet 36 may be located on the same side of the corresponding sheet 36.
[0058] While the above description and figures are provided with reference to punch 28, which defines, for example, a punch surface 30 for manufacturing a shear web 22 of a wind turbine blade, it should be understood that other examples of this method are equally applicable to manufacturing other wind turbine blade components, such as wind turbine blade half-shells 20a, 20b. Consequently, in such other examples, die 28 can be configured differently to form the corresponding wind turbine blade components. For example, to form wind turbine blade half-shells 20a, 20b, die 28 can define a concave die surface 30 on which one or more sheets 36 are arranged.
[0059] In some other examples, the mold surface 30 may be substantially flat. The benefits of the method described herein are applicable to the arrangement of the sheet 36 on any mold surface 30, because the position and / or configuration of the first alignment feature 42a and the second alignment feature 42b provide easily identifiable indicators for precisely positioning the sheet 36 on the mold 28.
[0060] The accompanying drawings have been described with reference to an example in which a first position mark 38a and a second position mark 38b are provided by a visible light projection system 40 that projects the position marks 38a and 38b onto the mold surface 30. It should be understood that in some examples, particularly where multiple sheets 36 are arranged on the mold 28, the method may include projecting the first position mark 38a and / or the second position mark 38b onto the sheets 36 already arranged on the mold 28. Providing position marks 38a and 38b on the sheets 36 already arranged on the mold 28 can facilitate the precise arrangement of overlapping sheets 36.
[0061] In some other examples, the first position mark 38a and the second position mark 38b may be provided in different ways. For example, position marks 38a and 38b may be defined by marks on the mold surface 30, such as painted or drawn marks, or adhesive marks (such as tape or labels). In some examples, position marks 38a and 38b may also be provided by alignment fixtures arranged on the mold surface 30.
[0062] The description provided herein is intended to illustrate several possible embodiments of the invention. It should be understood that features described with respect to any of the foregoing embodiments can be readily combined with any other features described with reference to other embodiments without departing from the scope of the invention as defined by the appended claims.
Claims
1. A method for manufacturing a wind turbine blade component, the method comprising: A sheet is provided, the sheet including a first edge, a first alignment feature positioned adjacent to the first edge and defining a first reference feature, a second edge, and a second alignment feature positioned adjacent to the second edge and defining a second reference feature; A mold that defines the mold surface; A first position mark indicating the first position is provided at a first position along the surface of the mold, and a second position mark indicating the second position is provided at a second position along the surface of the mold; The sheet is arranged on the surface of the mold; and Align the first reference feature with the first position mark and align the second reference feature with the second position mark, thereby aligning the sheet on the mold; Wherein, the first alignment feature is visually different from the second alignment feature, and / or the first alignment feature is located at a different part of the first edge compared to the position of the second alignment feature at the corresponding second edge.
2. The method according to claim 1, wherein, Providing the first position mark includes: projecting the first position mark onto the mold surface and / or the sheet using a visible light projection system; and / or Providing the second position mark includes: projecting the second position mark onto the mold surface and / or the sheet using a visible light projection system.
3. The method according to any one of the preceding claims, wherein, The mold is a punch, and the mold surface is a substantially convex mold surface.
4. The method according to claim 3, wherein, The convex mold surface includes a main mold surface and one or more side surfaces extending transversely to the main mold surface, wherein the first position mark and the second position mark are disposed on the main mold surface.
5. The method according to any one of the preceding claims, wherein, The first alignment feature is formed as part of the sheet, and / or wherein the second alignment feature is formed as part of the sheet.
6. The method according to claim 5, wherein, The first alignment feature is cut into the sheet, and / or the second alignment feature is cut into the sheet.
7. The method according to any one of the preceding claims, wherein, The first and second edges of the sheet are opposite to each other.
8. The method according to any one of the preceding claims, wherein, The first alignment feature is visually different from the second alignment feature, and wherein the first alignment feature and the second alignment feature are located at the same portion of the corresponding first edge and second edge of the sheet, respectively.
9. The method according to claim 8, wherein, The first position mark and the second position mark are aligned with each other in a first direction, and the first reference feature and the second reference feature are also aligned with each other in the first direction.
10. The method according to any one of claims 1 to 7, wherein, The first alignment feature and the second alignment feature are visually identical, and wherein the first alignment feature and the second alignment feature are located at different portions of the first edge compared to their positions at the corresponding second edge.
11. The method according to any one of the preceding claims, the method comprising: A plurality of sheets are provided, each sheet including a corresponding first edge, a corresponding first alignment feature positioned adjacent to the first edge and defining a corresponding first reference feature, a corresponding second edge, and a corresponding second alignment feature positioned adjacent to the second edge and defining a corresponding second reference feature; and Each sheet is arranged on the mold surface with the same orientation, such that each first alignment feature is located on the same side of the corresponding sheet and each second alignment feature is located on the same side of the corresponding sheet.
12. The method according to any one of the preceding claims, wherein, The first position mark is disposed at a first position along the mold surface in a first direction, wherein the second position mark is disposed at a second position along the mold surface in the first direction, and wherein each of the first position mark and the second position mark indicates a corresponding position on the mold surface in a second direction.
13. The method according to claim 12, wherein, The second direction is transverse to the first direction, and preferably orthogonal to the first direction.
14. The method according to claim 12 or 13, wherein, The first direction is the spanwise direction of the obtained wind turbine blade component, and the second direction is one of the chord direction, width direction or thickness direction of the obtained wind turbine blade component.
15. The method according to claim 14, wherein, The mold surface defined by the mold extends longitudinally in the first direction.