A method of laying up a wind turbine blade preform

Abstract

A method for laying precast wind turbine blades involves setting up a ground rail next to a mold, and mounting a robotic arm that can move forward and backward along the ground rail. A laying mechanism is connected to the end of the robotic arm. The robotic arm drives the laying mechanism to move along the surface of the mold to complete the laying operation. Before laying, the laying operation is simulated and analyzed based on the shape of the precast component to obtain various parameters of the robotic arm and laying mechanism during operation. During the laying process, the movement state of the robotic arm and laying mechanism is controlled according to these parameters. This invention uses a low-cost and high-efficiency simulation method to obtain the motion parameters of the equipment during the laying process. Therefore, for precast components of different shapes, only different molds need to be designed, but the same set of ground rails, robotic arms, and laying mechanisms can be used, unlike existing technologies that require different laying mechanisms designed for different mold structures.

Description

Technical Field

[0001] This invention relates to a method for laying out prefabricated wind turbine blade components, belonging to the field of wind turbine blade manufacturing technology. Background Technology

[0002] With the continuous development of the wind power industry, the length of wind turbine blades is increasing year by year. This increase in blade geometry presents challenges to wind turbine blade production. More and more blade profiles are shortening the manufacturing cycle by prefabricating trailing edge (UD), root, and blunt trailing edge accessories to reduce manufacturing risks and improve product quality. The fabric laying process for wind turbine blade prefabrication requires spraying adhesive in areas where the fabric layer is prone to slippage. The fabric layer must be precisely placed into the mold cavity and flattened according to the spanwise and chordwise positioning requirements (the direction extending from the root to the tip along the blade length is called the spanwise direction; the direction perpendicular to the spanwise direction along the blade cross-section width, from the leading edge to the trailing edge, is called the chordwise direction). Currently, wind turbine blade fabric laying is mostly done manually, which is physically demanding and involves monotonous work for workers.

[0003] Existing technologies also employ mechanical equipment for fabric laying, such as the invention application CN202010912416.6 entitled "Method for Laying Wind Turbine Blade Main Beam," which uses a wind turbine blade main beam laying device. However, this device has the following problems: First, the device includes a rotating component to rotate the unwinding frame, which increases the overall component structure and weight of the laying device, thus reducing the flexibility during laying. Second, tracks need to be set on both sides of the mold, and the laying device moves along the tracks. Therefore, it is more suitable for laying precast parts with gentle surfaces, and its applicability is limited for precast parts with significant surface changes. Therefore, improvements are still needed. Summary of the Invention

[0004] This invention addresses the problem of low laying efficiency and difficulty in ensuring laying quality due to significant variations in the shape of prefabricated components. It proposes a method for laying prefabricated wind turbine blade components, which can easily complete the laying operation of prefabricated components of various shapes, greatly reducing the difficulty of operation for workers and improving the laying quality.

[0005] The technical means adopted by this invention to solve the above problems is as follows: a method for laying prefabricated wind turbine blades, wherein a ground rail is set next to the mold, and a robotic arm that can move forward and backward along the ground rail is set on the ground rail. A laying mechanism is connected to the end of the robotic arm, and the robotic arm drives the laying mechanism to move along the surface of the mold to complete the laying operation. Furthermore, before laying, the laying operation is simulated and analyzed according to the shape of the prefabricated component to obtain various parameters of the robotic arm and the laying mechanism during operation. During the laying process, the movement state of the robotic arm and the laying mechanism is controlled according to the parameters. By conducting targeted simulation operations on the laying operation of prefabricated components of different shapes, the laying operation of prefabricated components of different shapes can be realized.

[0006] Furthermore, the fabric laying mechanism includes a support frame connected to a robotic arm. The support frame is equipped with a feeding assembly for placing and continuously releasing the fabric. At the end of the support frame opposite to its forward direction, a pressing assembly is provided to press the fabric against the mold surface. During the fabric laying process, there is a distance between the support frame and the mold surface, and the pressing assembly presses the fabric onto the mold surface. Through the cooperation of the pressing assembly and the feeding assembly, the fabric can be laid smoothly on the mold surface.

[0007] Furthermore, the fabric feeding assembly includes a storage rod for holding fabric, with both ends movably connected to a support frame, and a belt positioned below the storage rod that is driven by a motor to rotate and thus release the fabric. When the belt rotates, the friction between it and the lower surface of the fabric causes the fabric to be released.

[0008] Furthermore, the pressing assembly includes a pressing rod at its end for pressing the fabric and a connecting plate for fixing the pressing rod to the support frame. The pressing rod is connected to the connecting plate by a spring. The spring connection ensures that the pressing rod can press the fabric down without applying excessive force.

[0009] Furthermore, the fabric spreading mechanism also includes a guide plate set on the support frame, with one end of the guide plate close to the belt and the other end close to the pressing rod, so that the free end of the fabric moves from the storage rod to the pressing rod.

[0010] Furthermore, the guide plate is tilted towards the working surface of the mold near the end of the pressing rod. This allows the end of the fabric to be closer to the mold, making it easier to lay.

[0011] Furthermore, the fabric laying mechanism also includes an adjustment assembly mounted on the support frame. The adjustment assembly includes two baffles that move back and forth driven by a motor mounted on the support frame. Each set of adjustment assemblies has two baffles, both vertically mounted on the surfaces of the belt and guide plate, located on opposite sides of the fabric on the belt and guide plate, respectively. The motor drives the two baffles to move back and forth to adjust the position of the fabric.

[0012] Furthermore, the adjustment assembly also includes a slide rail set above the belt along the width of the fabric, a slider that moves along the slide rail driven by a motor, and a baffle fixed at the bottom of the slider that is moved by the slider.

[0013] Furthermore, the fabric laying mechanism also includes a glue spraying assembly located on the lower surface of the guide plate near one end of the pressing rod. During fabric laying, the glue spraying assembly first sprays glue onto the working surface of the mold, and then feeds the fabric above the guide plate for laying. This prevents the fabric from slipping on the mold.

[0014] Furthermore, the adhesive spraying assembly includes a cylinder and an adhesive spraying can that sprays the adhesive out after being squeezed by the cylinder.

[0015] Furthermore, the fabric feeding assembly, adjustment assembly, guide plate, pressing assembly, and glue spraying assembly of the fabric laying mechanism are all provided in two sets, arranged in two layers on the support frame in a manner perpendicular to the mold surface, and the ends of the two pressing assemblies are also arranged in a manner parallel to the mold surface.

[0016] The beneficial effects of this invention are: 1. Before the fabric laying operation, this invention employs a low-cost and highly efficient simulation method to obtain the motion parameters of the equipment during the laying process. Therefore, for prefabricated parts of different shapes, only different molds need to be designed, but the same set of ground rails, robotic arms, and fabric laying mechanisms can be used, unlike existing technologies that require different fabric laying mechanisms designed for different mold structures. Thus, it not only enables the laying of prefabricated parts of different shapes but also significantly reduces costs and improves efficiency.

[0017] 2. In the single-pass fabric laying process, the present invention can simultaneously lay two layers of fabric. After completing a single-pass fabric laying operation, the robotic arm rotates to drive the fabric laying mechanism to complete the reverse operation in order to carry out the next single-pass fabric laying operation. Therefore, there is no need to set a rotating device on the fabric laying mechanism, which simplifies the structure of the fabric laying mechanism, improves the fabric laying efficiency, and reduces costs.

[0018] 3. This invention employs a fabric feeding assembly to place the fabric onto a fabric laying mechanism, and the fabric is fed backward by the rotation of a belt. The forward movement of the robotic arm drives the entire fabric laying mechanism forward, thus completing the laying of the fabric on the mold. Simultaneously, an adjustment assembly ensures the fabric is laid in the correct chord position on the mold, and a pressing assembly ensures the fabric is flat on the mold, preventing wrinkles. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the equipment used during the fabric laying process in Example 1; Figure 2 This is a schematic diagram of the control arm and fabric laying mechanism in Embodiment 1; Figure 3 and Figure 4 These are schematic diagrams of the fabric laying mechanism from different angles in Example 1; Figure 5 for Figure 4 A schematic diagram of the internal structure of a partial view; Figure 6 for Figure 3 A schematic diagram of the structure after removing the horizontal plate and pressing component from the upper surface; Figure 7 This is a schematic diagram of the adhesive spraying assembly installed on the lower surface of the guide plate in Embodiment 1. Figure 8 for Figure 6 Another angle diagram; Figure 9This is a schematic diagram of the fabric release and adjustment structure in Example 1; Figure 10 A schematic diagram of a mold corresponding to a preform with a different shape than that in Example 1; In the diagram: 1. Fabric spreading mechanism, 11. Support frame, 111. Screw hole, 112. Horizontal plate, 113. Vertical plate, 12. Fabric feeding assembly, 121. Storage rod, 122. Belt, 123. Roller, 13. Adjustment assembly, 131. Baffle, 132. Slide rail, 133. Slider, 134. Lead screw, 14. Guide plate, 15. Pressing assembly, 151. Pressing rod, 152. Connecting plate, 153. Spring, 16. Glue spraying assembly, 161. Glue spraying can, 162. Fixing device, 2. Mold, 3. Ground rail, 4. Robotic arm, 5. Motor, 6. Cylinder, 7. Fabric. Detailed Implementation

[0020] The present invention will be further described below with reference to the accompanying drawings. The drawings are for illustrative purposes only, representing schematic diagrams rather than actual physical objects, and should not be construed as limiting the scope of this patent. To better illustrate the embodiments of the present invention, some components in the drawings may be omitted, enlarged, or reduced, and do not represent the actual dimensions of the product. It is understandable to those skilled in the art that some well-known structures and their descriptions may be omitted in the drawings. Example 1

[0021] A method for laying out prefabricated wind turbine blade components, such as Figure 1 As shown, a ground rail 3 is set along the length of the mold 2 next to the mold 2. A robotic arm 4 is set on the ground rail 3 and moves back and forth along the ground rail 3. A fabric laying mechanism 1 is set at the end of the robotic arm 4. The robotic arm 4 drives the fabric laying mechanism 1 to lay the fabric 7 back and forth along the surface of the mold 2.

[0022] like Figure 2 and Figure 3 As shown, the upper surface of the fabric laying mechanism 1 has screw holes 111, which are connected to the robotic arm 4 via flanges. During operation, the robotic arm 4 lifts the fabric laying mechanism 1 and lays the fabric 7 along one end of the mold 2 to the other end, completing one single-pass fabric laying operation. Then, the robotic arm 4 rotates the fabric laying mechanism 1 180 degrees. o After completing the reverse rotation of the fabric laying mechanism 1, the next single-pass fabric laying operation is carried out.

[0023] like Figure 3 and Figure 4As shown, the fabric laying mechanism 1 includes a support frame 11 that provides support. The support frame 11 includes two parallel horizontal plates 112 and two vertical plates 113 that connect the two ends of the two horizontal plates 112 respectively. The two horizontal plates 112 and the two vertical plates 113 form a frame with gaps at the front and back. The upper surface of the upper horizontal plate 112 is provided with screw holes 111 so that the robotic arm 4 can be connected to the top of the fabric laying mechanism 1 to avoid interference with the fabric laying operation.

[0024] The fabric laying mechanism 1 also includes a fabric feeding component 12 installed on the support frame 11 for storing and feeding the fabric 7, an adjustment component 13 for adjusting the position of the fed fabric 7, a guide plate 14 for guiding the fed fabric 7, a pressing component for pressing the fed fabric 7 to adhere it to the surface of the mold 2, and an adhesive spraying component 16 for spraying adhesive onto the surface of the mold 2 to bond the fabric 7 and prevent it from slipping.

[0025] like Figure 8 and Figure 9 As shown, the fabric feeding assembly 12 includes a storage rod 121 for holding the roll of fabric 7 and a belt 122 for pushing the free end of the fabric 7 forward to continuously feed the fabric 7. The two ends of the storage rod 121 are respectively movably mounted on two vertical plates 113, and the storage rod 121 passes through the center of the roll of fabric 7 to fix the fabric 7. The belt 122 is located below the storage rod 121. In the entire structure of the fabric laying mechanism 1, it is preferable that the storage rod 121 is located at the rearmost position of the support frame 11, while the belt 122 is located at the frontmost position. The fabric end coming down from the storage rod 121 is draped on the belt 122. In this embodiment, the length of the belt 122 extends all the way to the frontmost position of the support frame 11, forming a ring formed by upper and lower layers. Rollers 123 are provided at both ends inside the ring. A motor 5 is also provided on the support frame 11. The motor drives the rollers 123 to rotate, thereby pushing the fabric end forward and feeding the fabric 7 out.

[0026] like Figure 6 and Figure 9 As shown, one end of the guide plate 14 is fixed to two vertical plates 113 and close to the belt 122, while the other end extends beyond the support frame 11 and is inclined downwards, so that the end of the guide plate 14 is as close as possible to the mold surface 2. After the free end of the fabric 7 is fed out from the belt 122, it moves to the guide plate 14 and is then fed to the mold surface 2.

[0027] like Figure 8 and Figure 9As shown, the adjustment assembly 13 includes a baffle 131 vertically positioned above the surfaces of the belt 122 and guide plate 14, a slider 133, a slide rail 132, and a lead screw 134 that cooperate with the motor 5 to move the baffle 131 back and forth along the width direction of the fabric 7. The lead screw 134 has two ends movably mounted on two vertical plates 113. The motor 5 is located on the outer side of one vertical plate 113, and one end of the lead screw 134 is connected to the motor 5 and rotates under the motor's drive. Slide rails 132, with their ends fixed to the two vertical plates 113, are provided on both sides of the lead screw 134. Both the slide rails 132 and the lead screw 134 pass through the slider 133. When the motor 5 drives the lead screw 134 to rotate, the slider 133 moves back and forth along the lead screw 134, guided by the slide rails 132. The baffle 131 is fixed to the lower surface of the slider 133, and moves along with the baffle 131 when the slider 133 moves. An adjustment assembly 13 includes two baffles 131, which are respectively disposed on both sides of the fabric 7 to clamp and adjust the fabric 7 from both sides.

[0028] like Figures 3-5 As shown, the pressing assembly 15 includes a connecting plate 152 located above the guide plate 14, one end of which is connected to two vertical plates 113, and a pressing rod 151 disposed at the other end of the connecting plate 152. The end of the connecting plate 152 away from the vertical plates 113 is inclined downward so that it is close to the mold surface 2, and the pressing rod 151 at the end is a row of multiple rods with a total width greater than or equal to the width of the fabric 7. The pressing rod 151 is connected to the connecting plate 152 by a spring 153. The length of the connecting plate 152 is greater than the length of the guide plate 14 that it cooperates with, so that the pressing rod 151 can extend beyond the end of the guide plate 14.

[0029] like Figure 4 and Figure 7 As shown, the glue spraying assembly 16 includes a retainer 162 and a cylinder 6 fixed to the lower surface of the guide plate 14, and a glue spraying can 161 placed inside the retainer 162. The movable end of the cylinder 6 is connected to the spray nozzle of the glue spraying can 161. When the cylinder 6 squeezes the spray nozzle, the glue in the glue spraying can 161 can be sprayed out. Preferably, the glue spraying assembly 16 is fixed to the guide plate 14 near its free end, so that when the fabric 7 extends from the guide plate 14, it can come into contact with the glue, allowing the fabric 7 to better adhere to the surface of the mold 2.

[0030] In this embodiment, the fabric feeding assembly 12, the adjustment assembly 13, the guide plate 14, the pressing assembly 15, and the glue spraying assembly 16 are all provided in two sets, arranged in two layers on the support frame 11. The lengths of the guide plate 14 and the connecting plate 152 on the upper layer are greater than the lengths of the guide plate 14 and the connecting plate 152 on the lower layer, so that the two layers of fabric 7 are fed out in a certain interval, ensuring that the two layers of fabric 7 can be laid at the same time.

[0031] The specific fabric laying method in this embodiment is as follows: First, the fabric laying operation is simulated and analyzed based on the shape of the prefabricated component. The working state parameters of the robotic arm 4 and the fabric laying mechanism 1 during the fabric laying operation are simulated and obtained. The parameters are then input into the control center that controls the state of the robotic arm 4 and the fabric laying mechanism 1. Then, the control center controls the robotic arm 4 and the fabric laying mechanism 1 to move back and forth along the ground rail 3 and the mold 2 to complete the fabric laying operation of the wind turbine blade prefabricated component.

[0032] During fabric laying, the robotic arm 1 and the fabric laying mechanism 1 are first placed at one end of the mold 2. The roll of fabric 7 is placed on the support frame 11 via the storage rod 121, and the fabric end is pulled onto the belt 122. The motor 5 drives the roller 123 to rotate, which in turn drives the belt 122 to rotate, thereby pushing the fabric 7 forward. After passing the guide plate 14, it falls onto the surface of the mold 2. At the same time, the cylinder 6 presses the glue spray can 161 to spray out the glue. During the first single-pass fabric laying operation, the glue from the next layer is sprayed onto the surface of the mold 2, so that layer of fabric 7 is adhered to the mold 2. The glue from the previous layer is sprayed onto the next layer of fabric 7, so that the previous layer of fabric is adhered to the next layer of fabric 7, and so on. During the fabric laying process, the motor 5 drives the lead screw 134 to rotate, which in turn drives the baffle 131 to move left and right to adjust the position of the fabric 7. The entire fabric laying mechanism 1, except for the pressing rod 151, maintains a certain distance from the mold 2 surface. Only the pressing rod 151 is attached to the surface of the mold 2 or the surface of the fabric 7 on the mold 2, so that the fabric 7 forms a smooth bonding surface and avoids wrinkles.

[0033] Because the shapes of wind turbine blade prefabricated components are not all exactly the same, and not all are parallel to the horizontal plane, such as... Figure 10 As shown, in certain shapes, the fabric 7 needs to be laid almost perpendicular to the ground. Therefore, it is inconvenient for the fabric laying mechanism 1 to walk directly on the mold 2. This method of the robotic arm 4 being suspended and moving forward can solve this problem well.

[0034] The above embodiments are for illustrative purposes only and are not intended to limit the invention. Those skilled in the art can make various changes or modifications without departing from the spirit and scope of the invention. Therefore, all equivalent technical solutions should also fall within the protection scope of the invention, which should be defined by the claims.

Claims

1. A method for laying out prefabricated wind turbine blade components, characterized in that: A ground rail (3) is set next to the mold (2), and a robotic arm (4) that can move forward and backward along the ground rail (3) is set on the ground rail (3). A fabric laying mechanism (1) is connected to the end of the robotic arm (4). The robotic arm (4) drives the fabric laying mechanism (1) to move along the surface of the mold (2) to complete the fabric laying operation. Before laying the fabric, the fabric laying operation is simulated and analyzed according to the shape of the preform to obtain the parameters of the robotic arm (4) and the fabric laying mechanism (1) when they are working. During the fabric laying process, the movement state of the robotic arm (4) and the fabric laying mechanism (1) is controlled according to the parameters.

2. The method for laying out prefabricated wind turbine blades as described in claim 1, characterized in that: The fabric laying mechanism (1) includes a support frame (11) connected to the robotic arm (4). The support frame (11) is provided with a fabric feeding component (12) for placing the fabric (7) and continuously pushing the fabric (7) out. The support frame (11) is provided with a pressing component (15) at the end opposite to its forward direction to press the fabric (7) so that the fabric (7) adheres to the mold (2) surface. During the fabric laying process, there is a distance between the support frame (11) and the mold (2) surface, and the pressing component (15) presses the fabric (7) onto the mold (2) surface.

3. The method for laying out prefabricated wind turbine blades as described in claim 2, characterized in that: The fabric feeding assembly (12) includes a storage rod (121) for placing fabric (7) which is movably connected to the support frame (11) at both ends, and a belt (122) located below the storage rod (121) which is driven by a motor (5) to rotate and push the fabric (7) out.

4. The method for laying out prefabricated wind turbine blades as described in claim 3, characterized in that: The pressing assembly (15) includes a pressing rod (151) at the end for pressing the fabric (7) and a connecting plate (152) for fixing the pressing rod (151) to the support frame (11). The pressing rod (151) is connected to the connecting plate (152) by a spring (153).

5. The method for laying out prefabricated wind turbine blades as described in claim 4, characterized in that: The fabric laying mechanism (1) also includes a guide plate (14) set on the support frame (11). One end of the guide plate (14) is close to the belt (122), and the other end is close to the pressing rod (151), so that the free end of the fabric (7) moves from the storage rod (121) to the pressing rod (151).

6. The method for laying out prefabricated wind turbine blades as described in claim 5, characterized in that: The guide plate (14) is inclined toward the working surface of the mold (2) near the end of the pressing rod (151).

7. The method for laying out prefabricated wind turbine blades as described in claim 5, characterized in that: The fabric laying mechanism (1) also includes an adjustment assembly (13) set on the support frame (11). The adjustment assembly (13) includes a baffle (131) that moves back and forth driven by a motor (5) set on the support frame (11). There are two baffles (131) in a set of adjustment assemblies (13), which are vertically set on the surface of the belt (122) and the guide plate (14), respectively located on both sides of the fabric (7) on the belt (122) and the guide plate (14).

8. The method for laying out prefabricated wind turbine blades as described in claim 5, characterized in that: The adjustment assembly (13) also includes a slide rail (132) set above the belt (122) along the width direction of the fabric (7), a slider (133) driven by the motor (5) to move along the slide rail (132), and a baffle (131) fixed at the bottom of the slider (133) and moved by the slider (133).

9. The method for laying out prefabricated wind turbine blades as described in claim 5, characterized in that: The fabric laying mechanism (1) also includes a glue spraying assembly (16) located on the lower surface of the guide plate (14) near the end of the pressing rod (151). When laying the fabric, the glue spraying assembly (16) first sprays glue onto the working surface of the mold (2), and then sends out the fabric (7) above the guide plate (14) for laying.

10. The method for laying out prefabricated wind turbine blades as described in claim 9, characterized in that: The glue spraying assembly (16) includes a cylinder (6) and a glue spraying can (161) that sprays out glue after being squeezed by the cylinder (6).

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