Integrated wind power blade detection device

Abstract

The utility model provides a kind of integrally formed wind power blade detection device, comprising: first mobile system, along the side of integrally formed wind power blade to be detected is arranged;Second mobile system, it is parallelly arranged in the other side of blade with first mobile system;Ray receiver, movably installed on second mobile system;Ultrasonic phased array flaw detection unit;Ray transmitter;And main control and data processing module, for controlling mobile system and each detection unit;Wherein, ultrasonic phased array flaw detection unit and ray transmitter are as independently movable unit, and are installed side by side on first mobile system.The utility model is by the detection unit of two different physical principles of ultrasonic phased array flaw detection unit and ray transmitter, innovatively parallelly arranged on the first mobile system of same side, and make it all have independent moving ability.

Description

Technical Field

[0001] This utility model relates to the technical field of wind turbine blade manufacturing equipment, and in particular to an integrated wind turbine blade testing device. Background Technology

[0002] Wind power, as a clean and renewable energy source, plays a crucial role in the global energy structure transformation. Wind turbine blades are the core components of wind turbines, capturing wind energy. They are enormous, aerodynamically complex, and typically manufactured as a single piece of composite material with intricate internal structures. Therefore, quality inspection of blades before they leave the factory, especially comprehensive non-destructive testing to detect potential manufacturing defects such as cracks, delamination, bubbles, inclusions, and uneven resin curing, is a critical step in ensuring their long-term service safety and reliability. Currently, the industry widely uses non-destructive testing technologies such as ultrasonic testing and radiographic testing for blade quality control. To apply these testing technologies to the automated inspection of large blades, the industry has developed various automated testing equipment.

[0003] In existing technologies, for example, Chinese patent application CN118706960A discloses a non-destructive testing device for wind turbine blades to prevent excessive compression. The technical solution of this device mainly includes a support platform, on which the blade body is mounted and fixed by a complex blade support frame and clamping mechanism. Regarding the testing structure, a first electric slide is set on both the front and rear sides of the support platform. Support rods are mounted on the first electric slides, and a second electric slide is connected to the top of the support rods. The final testing component, an ultrasonic flaw detector, is installed below the second electric slide. Through this combination of slides and support rods, the device constructs a gantry-type or robotic arm-type three-dimensional motion system, designed to drive a single ultrasonic flaw detector to move within the three-dimensional space of the blade surface, thereby achieving sequential scanning of different positions on the blade.

[0004] However, the inventors discovered a fundamental flaw in the structural design of the aforementioned prior art, which directly led to insurmountable bottlenecks in detection efficiency and diagnostic reliability. The core problem stems from the fact that the entire complex motion system structurally serves only a single detection unit (i.e., the ultrasonic flaw detector). This "single-probe" layout inevitably results in a rigid and inefficient workflow. Specifically, this structure forces the ultrasonic flaw detector to traverse the entire massive surface area of ​​the blade point-by-point or line-by-line in a linear, serial manner, which is undoubtedly an extremely time-consuming process. For modern wind turbine blades that are often tens or even hundreds of meters long, this single scanning path directly leads to a lengthy inspection cycle, severely restricting production efficiency. Utility Model Content

[0005] The purpose of this invention is to provide an integrated wind turbine blade inspection device to solve the problems of low inspection efficiency and insufficient reliability of defect diagnosis caused by the structural design of existing wind turbine blade inspection equipment.

[0006] To achieve the above objectives, this utility model provides an integrated wind turbine blade inspection device, comprising: a first moving system disposed along one side of the integrated wind turbine blade to be inspected; a second moving system disposed parallel to the first moving system on the other side of the blade; a radiation receiver movably mounted on the second moving system; an ultrasonic phased array flaw detection unit; a radiation emitter; and a main control and data processing module for controlling the first moving system, the second moving system, and each inspection unit; wherein the ultrasonic phased array flaw detection unit and the radiation emitter are both independently movable units, mounted side-by-side on the first moving system.

[0007] This invention innovatively arranges two detection units based on different physical principles—an ultrasonic phased array flaw detection unit and a X-ray emitter—side-by-side on the same side of a first moving system, enabling each to move independently. This fundamentally constructs a "dual-probe" physical layout. This structure breaks through the limitations of existing "single-probe" technologies, providing the most fundamental physical basis for efficient collaborative work between the two detection methods. It is a structural prerequisite for achieving high-efficiency, high-precision collaborative detection.

[0008] Preferably, the main control and data processing module is connected to the first moving system, the second moving system, the ultrasonic phased array flaw detection unit, the X-ray emitter, and the X-ray receiver, respectively.

[0009] This structure, through the comprehensive connection between the main control module and all motion and detection units, establishes a unified and centralized control network on top of the "dual probes on the same track" physical layout. This comprehensive connection enables the originally independent hardware units to form an organic whole that can be uniformly scheduled, providing the necessary "neural network" control foundation for the subsequent execution of complex collaborative detection strategies. It is a key step in transforming the static physical layout into a dynamically controllable system.

[0010] Preferably, the first moving system includes a first slider and a second slider, which can move independently along the length of the first moving system; the ultrasonic phased array flaw detection unit is mounted on the first slider, and the X-ray emitter is mounted on the second slider.

[0011] This structure further clarifies the specific mechanical implementation method for achieving independent movement of the "dual probes on the same track". By setting two physically decoupled independent sliders as the moving carriers of the two probes, the main control module can precisely control the two probes to perform relative movement on the same track, such as moving towards each other or rapidly following each other. This structure directly transforms the potential of collaborative control into flexible and diverse physical movement capabilities, providing a direct mechanical guarantee for achieving efficient detection modes such as "clamp-on scanning" and "same-side cross-verification".

[0012] Preferably, the one-piece molded wind turbine blade is a slender conical structure that gradually narrows from the root to the tip along its length; the first moving system and the second moving system are both linear guide rails, which are parallel to the length of the blade and are set on opposite sides of the blade.

[0013] This structure defines the macroscopic layout framework of the entire device. The dual-track, split-type parallel layout perfectly adapts to the slender and irregular shape of wind turbine blades, ensuring stable movement and precise positioning of the detection unit across the entire blade length. This highly adaptable framework provides a stable and reliable working platform for the internal, sophisticated collaborative detection structure, guaranteeing the engineering practicality and detection accuracy of advanced detection modes when dealing with large, irregularly shaped workpieces.

[0014] Preferably, the ray emitter and ray receiver are positioned opposite each other, separated by an integrally molded wind turbine blade.

[0015] This structure leverages the advantages of a parallel double-track frame to clearly define the key spatial relationships among the components of the X-ray flaw detection system. This "through-and-through" structural layout is the physical prerequisite for achieving transmission-type detection. It allows the detection signal to penetrate the complex internal structure of the blade, thereby obtaining its internal density distribution information. This transforms the advantages of the double-track frame layout into a concrete capability for detection based on a completely new physical principle.

[0016] Preferably, the ray receiver has a receiving end face on the side facing the blade; the ray emitter has an emitting end face, the area of ​​the receiving end face being larger than the area of ​​the emitting end face.

[0017] This structure further optimizes the performance of the "through-penetration" detection path by specifically defining the geometry of the X-ray receiver. The larger receiver end face physically increases the probability of capturing penetrating rays, which not only improves the sensitivity of signal acquisition but also increases the system's tolerance to small alignment errors between the transmitter and receiver. This makes the "through-penetration" detection more stable and reliable in actual operation, thereby improving the quality of the acquired internal density data.

[0018] Preferably, it also includes: an auxiliary appearance inspection module, which is disposed on one side of the first mobile system; the auxiliary appearance inspection module includes an image acquisition unit and a fill light unit, which are disposed adjacent to each other.

[0019] This structure adds a parallel auxiliary function module to the complete high-precision internal defect detection system. The adjacent configuration of the image acquisition unit and the supplementary lighting unit ensures clear image acquisition of the blade surface under any environment. This structure can correlate the detection data of internal defects with the physical characteristics of the blade surface, providing visual evidence and location reference for the detection results, greatly enhancing the integrity and traceability of the detection data.

[0020] In summary, this invention fundamentally changes the existing "lone wolf" operational mode by arranging two independently movable flaw detection units based on different principles side-by-side on the same side of the mobile system, supplemented by a through-type overall layout and an intelligent main control module. It enables rapid cross-verification and efficient parallel scanning, thereby significantly improving detection efficiency while greatly enhancing the accuracy and reliability of defect diagnosis. Attached Figure Description

[0021] Figure 1 This is a side view of the integrated wind turbine blade testing device according to one embodiment of the present invention.

[0022] Figure 2 This is a structural block diagram of an integrated wind turbine blade testing device according to one embodiment of the present invention.

[0023] Figure 3 This is a top view of the integrated wind turbine blade testing device according to one embodiment of the present invention.

[0024] Figure 4 This is a schematic diagram of the auxiliary appearance inspection module according to one embodiment of the present invention. Detailed Implementation

[0025] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0026] To achieve the above objectives, this utility model provides an integrated wind turbine blade inspection device, comprising: a first moving system 60a, disposed along one side of the integrated wind turbine blade 10 to be inspected; a second moving system 60b, disposed parallel to the first moving system 60a on the other side of the blade 10; a radiation receiver 32b, movably mounted on the second moving system 60b; an ultrasonic phased array flaw detection unit 31; a radiation emitter 32a; and a main control and data processing module 40, used to control the first moving system 60a, the second moving system 60b, and each inspection unit; wherein the ultrasonic phased array flaw detection unit 31 and the radiation emitter 32a are both independently movable units, mounted side-by-side on the first moving system 60a. This utility model innovatively arranges the ultrasonic phased array flaw detection unit 31 and the radiation emitter 32a, two inspection units based on different physical principles, side-by-side on the same side of the first moving system 60a, enabling each to move independently, fundamentally constructing a "dual-probe" physical layout. This structure breaks the limitation of the existing "single probe" technology, providing the most fundamental physical basis for the efficient collaborative work between the two detection methods, and is the structural prerequisite for achieving high-efficiency and high-precision collaborative detection.

[0027] In a preferred embodiment, the main control and data processing module 40 is connected to the first moving system 60a, the second moving system 60b, the ultrasonic phased array flaw detection unit 31, the X-ray emitter 32a, and the X-ray receiver 32b, respectively. This structure, through the comprehensive connection of the main control module 40 with all motion and detection units, establishes a unified and centralized control network on top of the "dual-probe" physical layout. This comprehensive connection allows the originally independent hardware units to form a unified and scalable organic whole, providing the necessary "neural network" control foundation for subsequent execution of complex collaborative detection strategies. This is a crucial step in transforming a static physical layout into a dynamically controllable system.

[0028] In a preferred embodiment, the first moving system 60a includes a first slider and a second slider, which can move independently along the length of the first moving system 60a; the ultrasonic phased array flaw detection unit 31 is mounted on the first slider, and the X-ray emitter 32a is mounted on the second slider. This structure further clarifies the specific mechanical implementation of the independent movement of the "dual probes on the same track". By setting two physically decoupled independent sliders as the moving carriers of the two probes, the main control module 40 can precisely control the two probes to perform relative movement on the same track, such as moving towards each other or rapidly following each other. This structure directly transforms the potential of collaborative control into flexible and diverse physical movement capabilities, providing a direct mechanical guarantee for realizing efficient detection modes such as "clamp-on scanning" and "same-side cross-verification".

[0029] In a preferred embodiment, the integrally molded wind turbine blade 10 is a slender conical structure that gradually narrows from its root to its tip along its length. The first moving system 60a and the second moving system 60b are both linear guides, parallel to the length of the blade 10, and positioned on opposite sides of the blade 10. This structure defines the macroscopic layout framework of the entire device. The dual-rail, split parallel layout perfectly adapts to the slender and irregular shape of the wind turbine blade 10, ensuring stable movement and precise positioning of the detection unit throughout the entire length of the blade 10. This highly adaptable framework provides a stable and reliable working platform for the internal, sophisticated collaborative detection structure, guaranteeing the engineering practicality and detection accuracy of the advanced detection mode when dealing with large, irregularly shaped workpieces.

[0030] In a preferred embodiment, the X-ray emitter 32a and the X-ray receiver 32b are positioned opposite each other across the integrally formed wind turbine blade 10. This structure utilizes the advantages of a parallel double-track frame, clearly defining the key spatial relationships of the components of the X-ray flaw detection system. This "through-and-through" structural layout is the physical prerequisite for achieving transmission-type detection, enabling the detection signal to penetrate the complex internal structure of the blade 10, thereby obtaining its internal density distribution information. This transforms the advantages of the double-track frame layout into a concrete capability for detection based on a novel physical principle.

[0031] In a preferred embodiment, the ray receiver 32b is a block-shaped device with a receiving end face on the side facing the blade 10; the ray emitter 32a has an emitting end face, and the area of ​​the receiving end face is larger than the area of ​​the emitting end face. This structure further optimizes the performance of the "through-penetration" detection path by specifically defining the geometry of the ray receiver 32b. The larger receiving end face physically increases the probability of capturing penetrating rays, which not only improves the sensitivity of signal acquisition but also increases the system's tolerance to small alignment errors between the emitter 32a and the receiver 32b, making the "through-penetration" detection more stable and reliable in actual operation, thereby improving the quality of the acquired internal density data.

[0032] In a preferred embodiment, the system further includes an auxiliary appearance inspection module 20, which is disposed on one side of the first moving system 60a. The auxiliary appearance inspection module 20 includes an image acquisition unit 21 and a supplementary light source 22, which are arranged adjacent to each other. This structure adds a parallel auxiliary functional module to the complete high-precision internal defect detection system. The adjacent configuration of the image acquisition unit 21 and the supplementary light source 22 ensures clear image acquisition of the blade 10 surface under any environment. This structure can correlate the detection data of internal defects with the physical characteristics of the blade 10 surface, providing visual evidence and positioning reference for the detection results, greatly enhancing the integrity and traceability of the detection data.

[0033] Specifically, in this embodiment, please refer to the reference. Figure 1 , Figure 2 , Figure 3 and Figure 4 The integrated wind turbine blade inspection device provided by this utility model fixes the integrated wind turbine blade 10 to be inspected on a supporting frame structure. The blade 10 itself has a slender conical structure that gradually narrows from the root to the tip, and is the object to be inspected by this device. The core structure of the device is a dual-track moving system, which includes a first moving system 60a and a second moving system 60b respectively set on opposite sides of the blade 10. Both moving systems are high-precision linear guide rails and are laid parallel to the length of the blade 10. This dual-track split design perfectly solves the problem that large blades are too wide to use traditional gantry-type inspection arms, providing a stable and accurate moving reference for the entire inspection process.

[0034] The first moving system 60a is equipped with two independent and separately movable core detection units: one is an ultrasonic phased array flaw detection unit 31, which is mounted on an independent sliding block. Its core is a phased array probe, which can electronically control the deflection and focusing of the sound beam for high-precision ultrasonic scanning of the blade to determine the specific type and size of planar defects such as cracks and delamination; the other is a X-ray emitter 32a, which is mounted on another independent sliding block of the first moving system 60a. Meanwhile, a separate X-ray receiver 32b is installed on the second moving system 60b. The X-ray emitter 32a and the X-ray receiver 32b are positioned opposite each other across the blade 10, forming a through-type detection path. Working together, they constitute a X-ray flaw detection system for quickly identifying areas of abnormal density inside the blade. Notably, the X-ray receiver 32b has a relatively large receiving end face, which helps improve X-ray receiving efficiency and increase alignment tolerance.

[0035] The "brain" of the entire device is the main control and data processing module 40, which is materialized as an industrial control cabinet. It connects to and executes motion control of the first and second moving systems 60a and 60b via data and control cables, as well as data acquisition and scheduling of the collaborative working strategies of the ultrasonic phased array flaw detection unit 31, the X-ray emitter 32a, and the X-ray receiver 32b. Based on this unique structural layout, the main control module 40 can execute efficient detection strategies. For example, in the "rapid same-side cross-verification" mode, when the X-ray flaw detection system quickly scans and detects a suspected area, the main control module 40 can immediately instruct the ultrasonic phased array flaw detection unit 31, located on the same track 60a, to quickly move to that coordinate for high-precision re-examination, greatly improving the accuracy and efficiency of diagnosis.

[0036] In addition, to assist in recording the surface condition of the blades, this device can also be equipped with an auxiliary appearance inspection module 20. For example... Figure 4 As shown, the module consists of a camera serving as an image acquisition unit 21 and a supplementary light unit 22. The auxiliary appearance inspection module 20 (e.g., via a connecting bracket) is mounted on the first moving system 60a (e.g., on the first slider carrying the ultrasonic phased array flaw detection unit 31, or on the second slider carrying the X-ray emitter 32a), and can move along the blade length direction with the slider to take pictures of specific parts of the blade for archiving when needed, so as to achieve comprehensive traceability of inspection data.

[0037] The above description is only a preferred embodiment of the present utility model and does not limit the scope of implementation of the present utility model. All equivalent changes and modifications made in accordance with the scope defined by the claims of the present utility model shall still fall within the protection scope of the present utility model.

Claims

1. A one-piece molded wind turbine blade testing device, characterized in that, include: The first moving system (60a) is set along one side of the integrally molded wind turbine blade (10) to be inspected; The second moving system (60b) is arranged parallel to the first moving system (60a) on the other side of the blade (10); A radiation receiver (32b) is movably mounted on the second mobile system (60b); Ultrasonic phased array flaw detection unit (31); Ray emitter (32a); The main control and data processing module (40) is used to control the first mobile system (60a), the second mobile system (60b) and each detection unit; The ultrasonic phased array flaw detection unit (31) and the X-ray emitter (32a) are both independently movable units, installed side by side on the first moving system (60a).

2. The integrated wind turbine blade testing device as described in claim 1, characterized in that, The main control and data processing module (40) is connected to the first mobile system (60a), the second mobile system (60b), the ultrasonic phased array flaw detection unit (31), the radiation emitter (32a), and the radiation receiver (32b), respectively.

3. The integrated wind turbine blade testing device as described in claim 2, characterized in that, The first moving system (60a) includes a first slider and a second slider, which can move independently along the length of the first moving system (60a); the ultrasonic phased array flaw detection unit (31) is mounted on the first slider, and the X-ray emitter (32a) is mounted on the second slider.

4. The integrated wind turbine blade testing device as described in claim 3, characterized in that, The integrally formed wind turbine blade (10) is a slender conical structure that gradually narrows from the root to the tip along its length direction; the first moving system (60a) and the second moving system (60b) are both linear guide rails, which are parallel to the length direction of the blade (10) and are arranged on opposite sides of the blade (10).

5. The integrated molded wind turbine blade testing device as described in claim 4, characterized in that, The ray emitter (32a) and the ray receiver (32b) are positioned opposite each other across the integrally formed wind turbine blade (10).

6. The integrated molded wind turbine blade testing device as described in claim 5, characterized in that, The ray receiver (32b) has a receiving end face on the side facing the blade (10); the ray emitter (32a) has an emitting end face, and the area of ​​the receiving end face is larger than the area of ​​the emitting end face.

7. The integrated wind turbine blade testing device as described in claim 6, characterized in that, Also includes: An auxiliary appearance inspection module (20) is provided on one side of the first mobile system (60a); the auxiliary appearance inspection module (20) includes an image acquisition unit (21) and a fill light (22), which are arranged adjacent to each other.

Images