Retractable mold-integrated precision pins for positioning components during the layup process for manufacturing wind turbine blades

Abstract

The wind turbine blade mold includes a first mold surface and at least one opening located within the first mold surface and configured to receive at least one pin. The at least one pin has a first end and a second end, these ends defining a length extending therebetween. The second end of the pin is disposed within a pin driver, and the pin driver is disposed on a second mold surface. The pin driver is configured to displace at least one pin from a retracted position where the first end of the at least one pin is disposed below the first mold surface to an extended position where the first end of the at least one pin is disposed above the first mold surface.

Description

Technical Field

[0001] Cross - Reference to Related Applications This application claims the benefit of priority to U.S. Provisional Patent Application No. 63 / 356,132, filed on June 28, 2022, entitled "RETRACTABLE MOLD BUILT - IN PRECISION PINS TO LOCATE COMPONENTS DURING LAYUP PROCESS FOR FABRICATION OF WIND TURBINE BLADES", which is hereby incorporated by reference in its entirety.

Background Art

[0002] Field of the Disclosed Subject Matter The disclosed subject matter relates to systems for manufacturing large composite structures, such as wind turbine blades. These large composite structures are typically formed from two - piece molds, and once the blade halves are molded, complex component positioning / attachment and subsequent mold - closing processes are required to complete the manufacturing.

[0003] The accuracy of the layup process in manufacturing wind turbine blades directly affects the quality of the final product. In recent years, overhead optical projection systems and laser tracking systems have been widely used as conventional high - precision positioning and measurement tools for arranging components and reinforcement layers during the layup process. However, due to calibration and projection errors, there are limitations to the level of accuracy and reproducibility provided.

[0004] Description of Related Art Wind turbine blades typically include a hollow blade shell made primarily of composite materials such as glass fiber - reinforced plastics. The blade shell is usually composed of two half - shells, a lower pressure - side shell and an upper suction - side shell, which are separately molded in their respective female - mold halves and then joined together along the flange at the leading and trailing edges of the blade. Exemplary views of the mold halves of a wind turbine blade are schematically shown in FIGS. 1A - 1C.

[0005] Referring to FIG. 1a, this shows a mold 10 for a wind turbine blade divided into two half - molds, namely an upper suction - side mold 10a and a lower pressure - side mold 10b, and these two half - molds are arranged side - by - side in the open configuration of the mold. The pressure - side blade shell 12a is supported on the mold surface 14a of the lower mold 10a, and the suction - side blade shell 12b is supported on the mold surface 14b of the upper mold 10b. The shells 12a, 12b are each composed of a plurality of glass fiber fabric layers joined to each other by a cured resin.

[0006] After forming the shells 12a, 12b within their respective mold halves 10a, 10b, the shear web 16 is joined to a spark plug disposed on or within the inner surface 17 of the upwind blade shell 12a. The shear web 16 is a longitudinally extending structure that bridges the two half - shells 12a, 12b of the blade and serves to transmit a shear load from the blade to the wind turbine hub during use. In the particular embodiment shown in cross - section in FIG. 1a, the shear web 16 includes a web 18 having a lower edge 19 that optionally includes a first longitudinally extending attachment flange 20 and an upper edge 21 that optionally includes a second longitudinally extending attachment flange 22. To join the shear web 16 to the respective spark plugs of each half - shell 12a, 12b, an adhesive such as epoxy is applied along these attachment flanges 22.

[0007] As shown in FIG. 1b, when the shear web 16 is joined to the upper blade shell 12a, an adhesive is applied along the second (upper) attachment flange 22 of the shear web 16 and also along the leading edge 24 and trailing edge 26 of the blade shells 12a, 12b. Next, the two blade half - shells 12a, 12b are joined to each other along the leading edge 24 and trailing edge 26, and to join the shear web 16 to the spark plug along the inner surface 28 of the upper blade shell 12b, the upper mold 10b including the upper blade shell 12b is lifted and rotated and placed on top of the lower blade mold 10a. The step of placing one half - mold on top of the other half - mold is called clamping.

[0008] Referring next to FIG. 1C, when the mold 10 is closed, there may be a problem that the shear web 16 may move slightly relative to the upper shell 12b. For example, the shear web 16 may move slightly under its own weight during mold clamping, or may be displaced by contact with the upper shell 12b. Additionally or alternatively, the shear web and the spark cap may be inaccurately positioned within the open mold halves before closing, and as a result, the blade structure may be damaged or defects may occur. Further, as shown in FIG. 1C, the concave curvature of the upper shell 12b also tends to slightly press the shear webs 16 against each other. Such movement of the shear web 16 during mold clamping may cause the shear web 16 to be joined to the spark cap and / or the upper shell 12b in a sub-optimal position.

[0009] As the blade size increases to improve the operating efficiency of wind turbines, the safety margin decreases, and therefore, it is necessary to make the manufacturing acceptance criteria and tolerances more stringent. For this reason, in order to meet strict specifications and requirements, the design and implementation of manufacturing tools that enable high-precision process checks are required.

[0010] Therefore, during the assembly stage of a wind turbine device, there is still a need for an efficient and economical method and system to provide high-precision placement and joining of internal components, such as spark caps, to ensure proper placement of the components without affecting the structure of the product. SUMMARY OF THE INVENTION

[0011] The objects and advantages of the disclosed subject matter will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the disclosed subject matter. The additional advantages of the disclosed subject matter will be realized and attained by the methods and systems particularly pointed out in the written description and claims hereof, as well as the appended drawings.

[0012] To achieve these and other advantages, and in accordance with the purpose of the disclosed subject matter which has been embodied and broadly described, the disclosed subject matter includes a wind turbine blade mold, the wind turbine blade mold including a first mold surface and at least one opening located within the first mold surface and configured to receive at least one pin, the at least one pin having a first end and a second end, the ends defining a length extending therebetween, the second end of the pin being disposed within a pin driver, the pin driver being disposed on a second mold surface, the pin driver being configured to displace the at least one pin from a retracted position in which the first end of the at least one pin is disposed below the first mold surface to an extended position in which the first end of the at least one pin is disposed above the first mold surface.

[0013] In some embodiments, displacement of the pin driver causes a rotational movement of the at least one pin.

[0014] In some embodiments, displacement of the pin driver causes a linear movement of the pin.

[0015] In some embodiments, the pin driver is displaced by a rotational movement of a driver casing.

[0016] In some embodiments, the pin driver and the at least one pin are coupled via a threaded connection.

[0017] In some embodiments, the mold further includes a plurality of openings disposed around and along the span of the first mold surface.

[0018] In some embodiments, the mold further includes a bushing disposed within the at least one opening, the bushing including a channel for receiving the at least one pin.

[0019] In some embodiments, the mold further includes a seal gasket disposed within the at least one opening.

[0020] In some embodiments, the mold further includes at least one layer of layup segments disposed on a first surface of the mold, and a second end of at least one pin is disposed above at least one layup segment.

[0021] In some embodiments, at least one pin penetrates at least one layer of layup segments.

[0022] In some embodiments, a portion of at least one pin is configured to engage a structural component of a wind turbine blade.

[0023] According to another aspect of the present disclosure, a method of manufacturing a wind turbine blade includes providing a mold having a first mold surface, forming an opening in the first mold surface, providing at least one pin having a first end and a second end, the pin being positionable in alignment with the opening and the first end being movable between a retracted position below the first mold surface and an extended position where the first end of the at least one pin is above the first mold surface, providing a bushing disposed within the opening, providing a gasket disposed within the opening and forming a seal with the at least one pin, providing a pin driver for actuating movement of the at least one pin between the retracted position and the extended position, and providing at least one layer of layup segments disposed on the first surface of the mold.

[0024] In some embodiments, actuation of at least one pin driver causes rotational and linear movement of the pin.

[0025] In some embodiments, actuation of at least one pin driver forces at least one pin to penetrate at least one layer of layup segments on the first surface of the mold.

[0026] In some embodiments, at least one pin penetrates at least one layer of layup segments without forming wrinkles in the layup segments.

[0027] In some embodiments, the actuation of at least one pin driver causes the second end of the pin to displace above at least one layup segment.

[0028] In some embodiments, the method further includes performing a resin injection process with at least one pin in an extended position.

[0029] In some embodiments, a portion of at least one pin is configured to engage with at least one structural component of a wind turbine blade.

[0030] In some embodiments, at least one pin retracts to form a cavity between adjacent structural components.

[0031] In some embodiments, at least one pin is removed from the wind turbine blade prior to the demolding process.

[0032] It should be understood that both the foregoing general description and the following detailed description are exemplary and are intended to provide further explanation of the claimed disclosed subject matter.

[0033] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate the methods and systems of the disclosed subject matter and are included to provide a further understanding. Together with the description, the drawings serve to explain the principles of the disclosed subject matter.

[0034] A detailed description of various aspects, features, and embodiments of the subject matter described in this specification is provided with reference to the accompanying drawings, which are briefly described below. The drawings are illustrative and are not necessarily drawn to scale; some components and features are exaggerated for clarity. The drawings show various aspects and features of the subject matter of the present invention and can show, in whole or in part, one or more embodiments or examples of the subject matter of the present invention.

Brief Description of the Drawings

[0035]

Figure 1A

Figure 1B

Figure 1C

Figure 2

Figure 3A

Figure 3B

Figure 4A

Figure 4B

Figure 4C

Figure 4D

Figure 5A

Figure 5B

Figure 5C

Figure 5D

Figure 6A

Figure 6B

Figure 6C

Figure 7A

Figure 7B

Figure 7C

[0036] It should be understood that both the foregoing general description and the following detailed description are exemplary and are intended to provide further explanation of the claimed disclosed subject matter.

[0037] The accompanying drawings, which are incorporated herein and constitute a part hereof, illustrate the methods and systems of the disclosed subject matter and are included to provide a further understanding. Together with the description, the drawings serve to explain the principles of the disclosed subject matter.

[0038] Now, referring in detail to exemplary embodiments of the disclosed subject matter, an example thereof is shown in the accompanying drawings. The methods and corresponding steps of the disclosed subject matter will be described in conjunction with a detailed description of the system.

[0039] One way to improve the accuracy of the layup process in the manufacture of wind turbine blades is to utilize precision pins built into the mold. In this method, by transferring the positions of critical components from the tooling plug to the mold, the highest achievable accuracy level in the placement of layup components such as reinforcement fabrics, spark caps, and cores can be obtained. Further, the physical pins function as hard stops for the components, preventing any potential movement of the layup elements during the injection process.

[0040] In particular, the present disclosure provides structural elements, such as elongated pins, having various features that facilitate both the placement and assembly of other components, such as spark caps. In some embodiments, the present disclosure provides positioning elements, such as elongated pins. Even a slight violation of the positioning tolerance of the spark cap not only impairs the structural integrity of the blade due to a decrease in bending stiffness but also exceeds the tolerance of the bonding gap due to the displacement of the core material. The present disclosure provides precise positioning of extendable and retractable pins. The physical pins function as hard stops for the components, preventing any potential movement of the layup elements during the injection process.

[0041] This design provides high-precision pin-integrated features for placement and gripping without the risk of damaging the blade during the demolding process. This system disclosed herein addresses the lack of accuracy in the placement and movement of conventional blade components and the risk of demolding (or removal of the blade after injection) defects.

[0042] The methods and systems presented herein can be used in the construction of large structures. The disclosed subject matter is particularly suitable for the construction of wind turbine blades. By way of illustration and not limitation, exemplary embodiments of a system according to the disclosed subject matter are shown in FIGS. 2 - 7C and are generally designated by reference numeral 1000. Similar reference numbers (distinguished by the leading digit) may be provided between the various figures and drawings shown herein to indicate functionally corresponding but not necessarily identical structures.

[0043] The blade may include one or more structural components configured to increase the stiffness, buckling resistance, and / or strength of the blade. For example, the blade may include a pair of longitudinally extending spar caps configured to engage the opposing inner surfaces of the pressure side and the suction side of the blade, respectively. Further, one or more shear webs may be disposed between the spar caps to form a beam-like configuration. The spar caps may generally be designed to control bending stresses and / or other loads acting on the blade generally in the spanwise direction (a direction parallel to the span of the blade) during operation of the wind turbine. Similarly, the spar caps may also be designed to withstand spanwise compression generated during operation of the wind turbine.

[0044] The disclosed spar caps can be composed of a plurality of pultruded members grouped together to form a first portion of the spar cap. In certain embodiments, the pultruded members may be formed by impregnating a plurality of fibers (e.g., glass fibers or carbon fibers) with a resin and curing the impregnated fibers. The fibers may be impregnated with the resin using any suitable means well known in the art. Further, the resin may include any suitable resin material including, but not limited to, polyester, polyurethane, polybutylene terephthalate (PBT), polyethylene terephthalate (PET), vinyl ester, epoxy, etc. Further, as shown, as the spar cap approaches the root of the blade, the pultruded members separate into one or more bundles of pultruded members to form a second portion of the spar cap.

[0045] More specifically, the spar cap is composed of a plurality of pultruded members grouped together to form one or more layers. Thus, the layers may be stacked on top of each other and joined to each other using any suitable means, such as by joining the members together by vacuum infusion or via an adhesive, semi-preg material, prepreg material, etc.

[0046] The methods and systems described herein facilitate the placement of high-precision components, such as spark plugs, during a molding process. In particular, the present disclosure provides precise geometric references across the blade span and, in some embodiments, introduces novel apparatuses and methods for providing a blade mold having retractable / extendable pins that can be used as mechanical stops for components that require a rigid support surface. In some embodiments, the present disclosure can include an overhead optical projection and laser tracking system to assist in positioning and measuring tools for placing components and reinforcement layers during a layup process.

[0047] Referring now to FIG. 2, a top view of a blade mold half with a plurality of pin location features or pins distributed along the span of the blade half is shown. This figure is not intended to limit the placement of pin locations along the blade mold half and, for example, a bottom view of a blade mold half with a plurality of pin location features or "pins" as described below distributed along the span of the blade can be shown. The pin location 100 can include a hole (extending partially or completely through the mold surface) and, for convenience, is referred to throughout as a "pin hole." The location(s) of the pin hole 100 can be specified in a 3D manufacturing model of the blade mold. In various embodiments, the pin hole 100 may be dimensionally oriented and positioned within one or more 3D manufacturing models associated with the blade mold or blade mold half. In various embodiments, separate models or orientation and dimension coordinates of the pin holes may be associated with the model of the blade mold half. In various embodiments, one or more paper or mylar engineering or manufacturing drawings associated with the blade mold half may be further defined using a pin hole model as described herein.

[0048] To manufacture a mold, a blade mold half, etc. (used in the manufacture of wind turbine blades), a male "plug" is first formed that functions as a structure for imparting a specific shape to the mold or blade mold half. During plug construction, precision pin holes 100 are formed. In various embodiments, the pin holes 100 can be machined or manufactured subtractively by a plug such as a CNC machine. For example, but not limited to, the plug may be machined using one or more computer-controlled tools or manual tools such as a ball mill. In various embodiments, the pin holes 100 may be machined on the plug surface. In various embodiments, the plug can be rotated or adjusted manually or automatically within a tool or CNC machine to form the pin holes 100. Thereafter, the pin holes 100 are transferred to the final mold and can function as reference point(s) for calibrating and verifying the proper positioning of any overhead laser projection system or Faro measurement system. Although a plurality of pin holes 100 are permanently formed in the mold, if not used to receive pins, the selected pin holes can be plugged or closed, as will be described in more detail below.

[0049] According to one aspect of the present disclosure, the blade mold is formed with precision pins incorporated therein. This improves the accuracy of the layup process in the manufacture of wind turbine blades by transferring the positions of critical components (e.g., spark caps, shear webs, reinforcement cloth, cores, etc.) from the tooling plug to the mold itself, and the highest achievable accuracy level in the placement of layup components is obtained. Further, the physical pins can function as hard stops for the components, preventing any potential movement of the layup elements during the injection process and / or the thermal cycle of the mold.

[0050] The number and location of the pin holes (100) may vary depending on the design specifications of the blade. For example, without limitation, the pin holes 100 may be modified or used based on, among other things, the number and location of spark caps, the size of the spark caps or internal braces, etc. As shown in FIG. 2, the distribution of the pin holes (100) need not be uniform; instead, it should concentrate in selected regions of the blade. The number, distribution, and shape of the pin hole(s) may vary along the blade span. For example, the pin holes (100) may be more concentrated at locations with large / heavy internal components and / or a more complex shape or surface profile. For example, the number of pin holes (100) located closer to the root may be greater compared to the tip of the blade. Further examples of pin / hole / die shapes are described in U.S. Patent No. 11,613,087 and U.S. Patent Application No. 17 / 590,451, both of which are hereby incorporated by reference in their entirety.

[0051] Figure 3A shows the pin mechanism 1000 of pin 160, and for clarity, both the retracted state and the extended state (with respect to the blade mold), separated by dashed lines, are shown simultaneously. The bushing 110 is disposed within the inner diameter of the pin hole and is thus surrounded by the mold 120, which can be a blade mold half or another mold. As shown, the bushing 110 can be formed with a thickness equal to the thickness of the mold at the location where the pin hole is disposed (shown as the vertical height in the orientation of Figure 3A) (i.e., the thickness of the mold can vary along the length of the blade, and the bushing is sized to match its thickness accordingly). Thus, the bushing 110 can be sized such that its upper and lower surfaces are coplanar with or flush with the upper (i.e., inner) and lower (i.e., outer) surfaces of the mold 120, and as a result, the bushing does not extend over the upper (i.e., inner) surface of the mold and interfere with or obstruct the placement of any fiber layup segments. In various embodiments, the bushing 110 can be sized such that the ends of the bushing have the same extent as the contour of the mold 120 at the bushing location and are coplanar with that contour. For example, without limitation, the ends of the bushing 110 may include a complex contour that matches the inner / outer surface around the mold 120. In various embodiments, the bushing 110 may be positioned within the mold 120 such that the ends of the bushing are located within the mold 120. In various embodiments, the bushing 120 may have internal or external geometric features that function to seal the gap between the bushing 110 and the mold 120. In various embodiments, the ends of the bushing 110 may extend beyond the surface of the mold 120 such that the bushing 110 is exposed on the surface of the mold 120. In various embodiments, the bushing 110 may include a contour that forms part of the surface of the mold 120.

[0052] In the illustrated exemplary embodiments, pin 160 is configured to have an angled distal end or a faceted edge to form a penetrating tip, although other tip configurations can also be employed (e.g., a curved surface that can have recesses and / or protrusions to facilitate penetration of the layup segment without causing distortion or wrinkles, as will be described in more detail below). For example, without limitation, pin 160 may include a plurality of pin assembly 161, as shown in FIG. 3B. FIG. 3B shows the plurality of pin assembly 161 in a cross-sectional view, with the first pin and the second pin shown in phantom lines. This figure is not intended to limit the cross-sectional shape, operating mechanism, material, or other aspects of the plurality of pin assembly 161. The plurality of pin assembly 161 may include one or more pins of a plurality of diameters, a penetrating tip configuration (if present), different elongation lengths, telescoping components, and the like. For example, without limitation, the first pin 162 may be disposed in line and coincident with a second pin 163 that completely surrounds the first pin 162. The second pin 163 can extend to penetrate or partially penetrate the layup and begin to form a hole, opening, slit, or slot. Next, the first (e.g., outer circumscribing) pin 162 may extend a distance to complete the penetration process. The first pin 162 and the second pin 163 may be telescopic with respect to each other such that they can pass through each other in the same direction. According to an embodiment, the first pin 162 and the second pin 163 may be in line but not coincident such that the first pin 162 extends a first distance to begin making a hole in the layup and the second pin 163 extends a second distance from a different position to finish making a hole in the layup. According to an embodiment, the first pin 162 may have a smaller diameter than the second pin 163. According to an embodiment, the first pin 162 may include a harder material than the second pin 163. For example, without limitation, pin 160 may include a multi-stage extension mechanism. Pin 160 can first extend a first distance to penetrate the layup, then retract, and then extend a second distance longer than the first distance to finish making a hole in the layup.This multi-stage extension mechanism may be repeated as necessary, or may be repeated a predetermined number of stages such as 3, 4, 5, 10, or 100 stages of extension.

[0053] A seal gasket 130 can also be provided in the pin mechanism 1000. This seal gasket enables a liquid-tight seal to prevent leakage (e.g., resin flow) into the pin mechanism 1000 during the VARTM process. The seal 130 is sized to fit the inner diameter of the bushing 110. In some embodiments, the seal 130 is formed from an elastomer (rubber) and restricts the downward flow of resin into the pin mechanism, but allows the operation of the pin 160 between the retracted position and the extended position. In various embodiments, the seal gasket 130 may be configured to be located within the bushing 110. In various embodiments, the seal gasket 130 may be configured to be on the same plane as the surface of the mold 120 and on the same plane as the end of the bushing 110 that has the same contour as the surface of the mold 120. In various embodiments, the seal gasket 130 may be formed from a rubber configured to withstand the temperature and pressure associated with the VARTM process. In various embodiments, the seal gasket 130 may be configured to be located within a corresponding recess in the bushing 110, the mold 120, or a combination thereof.

[0054] Driver 140 is provided to operate pin 160 between a retracted position and an extended position. Driver 140 may be configured to operate pin 160 at any position between a fully retracted position and a fully extended position, including extending in a direction substantially opposite to the extended position shown in FIG. 3A. In the illustrated exemplary embodiment, driver 160 includes a threaded connection with the distal end of pin 160, and as driver 160 rotates, pin 160 proportionally extends / retracts (e.g., moves up and down as shown). In various embodiments, pin 160 may include a raised portion, rib, or thread that mates with a raised portion, rib, or thread on driver 140, such that a longitudinal force is applied to pin 160 by the rotational movement of driver 140, and pin 160 is pressed upward or downward and translated by the rotation of the driver. Additionally or alternatively, driver 140 can be configured as a fluid-driven piston, magnetic / solenoid-driven pin, or piezoelectric member that operates to extend and / or retract pin 160 in response to an input command. In various embodiments, the input command may be an analog signal that commands an extension or retraction operation depending on the current state of pin 160. In various embodiments, the input command may be a digital signal configured to command not only the extension or retraction of pin 160, but also the distance by which pin 160 extends or retracts. In various embodiments, the input command can command pin 160 to extend or retract with a different amount of force a number of times or over time. In various embodiments, the command may include the first pin (162) or the second pin (163) expanding and contracting a predetermined number of times. In various embodiments, pin 160 may be commanded to extend or retract a certain distance based on the type of layup fiber present on mold 120. Driver 140 is surrounded by driver casing 150 and may be powered via electrical, hydraulic, and / or pneumatic systems and supply lines disposed outside the blade mold.

[0055] Both the driver 140 and the driver casing 150 form the driver system 170. The driver system is attached to the bottom surface (i.e., the outside) of the mold and can include a support ring 141 that surrounds the driver 140 and aligns the pins 160 so that they can be inserted into the pin holes on the mold surface. The support ring 141 may be partially fixed within the pin hole by one or more bushings or bosses that project from the support ring 141 into the pin hole. The support ring 141 can align the driver 140 and the pins 160 such that they are collinear and concentric with the pin holes. The alignment ring 141 may include one or more features such as protrusions, bosses, or pegs that correspond to one or more depressions, holes, slots, or other mating features on the mold 120 to align the driver 140 and the pins 160. In various embodiments, the alignment ring 141 may include one or more adjustment features configured to further incline or linearly translate the driver 140 and the pins 160. For example, without limitation, the alignment ring 141 can be adjustably translated toward or away from the mold 120 to incline or move a portion of the driver 140. Thus, in the illustrated exemplary embodiment, all components of the driver system 170 are disposed outside or external to the inner mold surface (the pins 160 can be inserted through the mold to a desired depth / height inside the mold, as will be described in more detail below). In various embodiments, the driver system 170 may be disposed within the mold 120. In various embodiments, the driver system 170 may be adjustably disposed within the mold 120. For example, without limitation, the driver system 170 can be used to select the pin positions along the span of the mold 120.

[0056] The installation of the pin mechanism 1000 is shown in FIGS. 4A - 4D. FIG. 4A specifically shows the tooling surface 121 of the mold 120. In various embodiments, the tooling surface 121 may be the inner surface of the mold (when in the closed configuration) and is configured to receive a layer of composite layup segments that are molded to form a blade skin within the mold 120. As shown in FIGS. 4B - 4D, an opening 101 large enough to receive and hold the bushing 110 is formed through the thickness of the mold 120 in the tooling surface 121. The opening 101 can be formed by various techniques such as drilling, punching, milling, etc. According to an embodiment, one or more seal assemblies may be included to protect the opening 101 since burrs, snags, chips, unfinished edges, or other obstructions can be formed and the layup is at risk of snagging or tearing. In the illustrated exemplary embodiment, the hole 110 extends through the entire thickness of the mold 120. FIG. 4C shows the bushing 110 installed within the opening 101 such that no portion of the bushing 110 extends beyond the tooling surface 121 of the mold 120. The bushing 110 includes an opening or channel for slidably receiving the pin 160 and simultaneously engaging the outer surface of the pin to form a liquid - tight seal to prevent resin outflow as described above. Finally, FIG. 4D shows the entire pin mechanism installed beneath the tooling surface 101 of the mold 120. The pin 160 is at the center of the mechanism and is shown in the intermediate position (i.e., retracted beneath the inner surface of the mold 120), and the driver system 170 surrounds the pin 160.

[0057] Referring now to FIGS. 5A-5D, a diagram of the stepwise extension of the pin mechanism 1000 system is shown. In FIG. 5A, a composite material reinforcement layer(s) 300 (also referred to as a layup segment) is deposited on a tooling surface 121 having an opening formed therein, and a driver 140 and a pin 160 extend from the outer surface of the mold into the opening toward the interior of the mold. The pin driver 140 operates to drive the pin 160 upward into the mold as shown in FIGS. 5A-5D and to drive it downward to retract the pin outside the mold and below the inner surface 121 of the mold. In the illustrated exemplary embodiment, the driver 140 uses a mechanical actuator that rotates perpendicular to the longitudinal axis of the pin to generate a translational movement of the pin 160 (e.g., up and down or in and out of the reinforcement layer 300). In some embodiments, the insertion / retraction depth and / or the movement speed of the pin 160 can be programmed and operated via an automated system and can include warnings (visual and / or audible) that alert the operator when a predetermined position is reached. Similarly, an alarm can be triggered when the pin approaches or exceeds a threshold position / speed. In various embodiments, the pin 160 may include one or more coloring dyes or other visual indicators to indicate to the operator or computer that the operation has been completed successfully.

[0058] According to one aspect of the present disclosure, during the forward / backward movement of the pin 160, none of the layer(s) 300 has wrinkles (thus, the final assembly of all composite layers remains wrinkle-free). This is achieved by combining the linear movement (e.g., up / down movement) and the torsional movement of the pin 160 (as indicated by the arrows shown in the figure), maximizing the penetration force of the pin through the fabric reinforcement layup layer(s) 300 without causing any jamming, wrinkles, or waves in the composite fabric layer. The rotational movement of the driver 140 can be transmitted to the pin 160 such that the pin translates and rotates simultaneously. In various embodiments, the pin 160 may be separated from the rotational movement of the driver 140, such that the pin 160 does not rotate due to the rotational movement of the driver 140, and only translational (e.g., vertical) movement is imparted to the pin 160. In various embodiments, the rotational movement of the pin 160 may operate to reduce the bundling, wrinkling, or tearing of the reinforcement layer 300 during the penetration process. In some embodiments, if it is detected that wrinkles are formed in the composite layer, the rotational movement of the pin 160 can be reversed to remove the wrinkles, i.e., "unwrinkle" them.

[0059] Further, the system disclosed herein penetrates the layers of the layup segment starting from the layer in contact with the mold surface and then continues to proceed upward (with respect to the mold) to penetrate the topmost layer (when the two mold halves are closed in the above-described clam shell manner, the topmost layer becomes the innermost layer of the wind turbine blade). This approach or order of operation is advantageous because the weight of the layer(s) of the layup segment(s) (300) functions as an anvil or anchor against the upward force generated by the forward / penetration pin 160. In other words, first penetrating the composite layup layer 300 closest to the mold surface 121 utilizes the weight / resistance of the assembly / upper layer of the layup segment to create local tension at the penetration location, thereby suppressing / preventing the formation of wrinkles in the layup segment (wrinkles, in particular, in this layer closest to the mold surface, which becomes the outer skin surface of the blade when the mold is closed, can endanger the structural integrity of the blade).

[0060] In various embodiments, the tip of pin 160 may be adjustable or configurable based on, for example, the type / number / thickness of the material of reinforcement layer 300. In various embodiments, when there are more layers, a sharper penetrating tip of pin 160 may be used. In various embodiments, the first pin 160 (first pin 162) having a round or flat head can first extend into reinforcement layer 300, where a secondary pin (such as second pin 163) attached telescopically can then penetrate the layer with a sharp tip. FIG. 5A shows the pin in an initial retracted position, where the distal tip of the pin is positioned below the inner surface 121 of the mold or spaced from the layup segment 300 deposited on the inner surface of mold 120.

[0061] As driver 140 rotates, pin 160 rotates and translates upward, pin 160 extends from bushing 110, passes through gasket 130 and enters the interior of the mold, whereby the distal end of the pin engages and penetrates the layers of the fiber layup segment. In the snapshot shown in FIG. 5B, pin 160 has penetrated the first two layers of layup segment 300, and the three upper layers of the layup segment have not yet been penetrated by pin 160. Further actuation (e.g., rotation) of driver 140 causes pin 160 to continue to advance, such that, as shown in FIG. 5C, pin 160 engages and penetrates the next two layers of layup segment 300, with only the top layer not yet engaged by pin 160. Pin 160 continues to advance upward to its final position shown in FIG. 5D, where the distal end of pin 160 has penetrated all the layers of layup segment 300.

[0062] In some embodiments, a sensor can be incorporated at the distal end of pin 160 to detect when all layers of the layup segment 300 have been penetrated / passed through, warn the operator, and / or terminate the operation of driver 400. In various embodiments, pin 160 may include an optical sensor configured to detect the presence of light, and then pin 160 penetrates the layup segment 300. In various embodiments, pin 160 may include an optical sensor configured to detect a change in light intensity associated with light passing through successive layup segments 300. For example, the optical sensor may include an optical sensor capable of detecting light based on the number of segments that have been penetrated or the number of segments that have not yet been penetrated. For example, upon complete penetration, i.e., after pin 160 exits the layup segment 300 in FIG. 5D, the light intensity may be maximized. In various embodiments, the optical sensor can operate in any part of the electromagnetic spectrum. For example, without limitation, the optical sensor may be configured to detect light from one or more fluorescent lights. Additionally or alternatively, light of a specific wavelength may be used over the layup segment 300, and the light emitted therefrom may be absorbed or partially absorbed by the optical sensor. For example, without limitation, ultraviolet or infrared light may be an operable wavelength for this system.

[0063] In various embodiments, pin 160 may include an acoustic sensor configured to measure or detect the penetration depth of the pin within layup segment 300. The acoustic sensor may be configured to detect the intensity of sound waves or other vibrations related to the penetration depth of layup segment 300 or a successful complete penetration. In various embodiments, the acoustic sensor may be configured to detect the efficiency of the pin penetrating layup segment 300. For example, the acoustic signature may be different when the penetration is successful compared to when it fails. The acoustic sensor can provide feedback regarding the penetration depth of layup segment 300 or a successful penetration to one or more users or a computer. For example, without limitation, the acoustic sensor can notify the user that a single penetration by pin 160 at a particular pinhole 100 has failed.

[0064] In various embodiments, pin 160 may have a transducer or force sensor attached thereto. In various embodiments, the force sensor may be configured to detect the presence of layup segment 300 pressing down on the tip of pin 160. For example, without limitation, the force sensor can detect and transmit a signal when the force applied to the head of the pin decreases below a particular threshold or decreases to zero. For example, without limitation, the force sensor may be configured to measure the penetration depth based on the pressure applied by the remaining layup segment 300. For example, the greater the pressure applied to pin 160, the more layup segment 300 remains on pin 160. In various embodiments, the force sensor may be configured to compensate for the speed and force at which pin 160 extends into layup segment 300.

[0065] In various embodiments, pin 160 may include a sensor suite having two or more sensors of similar or different types, each sensor being configured to measure or detect the penetration level or wrinkle level of the layup segment 300. For example, each pin 160 may include an optical sensor and an acoustic sensor that operate in conjunction to measure the depth of penetration or completion of penetration. In various embodiments, the sensor suite may have an optical sensor, an acoustic sensor, and a force sensor, or a subset thereof. In various embodiments, the sensor suite may have sensors of the types described herein.

[0066] In some embodiments, pin 160 can be configured as a cylindrical member having an arcuate outer (or outer diameter). Additionally or alternatively, pin 160 can be configured to have a linear side surface (e.g., a facet) for engaging a structural member (e.g., a spark cap) to provide a planar mating surface that functions as a stop to prevent movement of the structural member. Further, pin 160 can be configured to capture any fragile portions of the layers of the layup segment when the pin penetrates / breaks through the layer. For example, pin 160 may be hollow or may include an internal chamber for collecting these layers of the layup segment (300) when the pin is inserted into each penetrated layer. This prevents foreign object debris from interfering with or damaging the manufacturing process. Additionally, the diameter of the holes left in the layup or a portion thereof by one or more pins 160 is smaller than the allowable foreign object criteria, so foreign objects cannot enter the holes after or during the manufacturing process and damage one or more layups or portions thereof. Further, during or after the drilling process, the holes can be filled automatically or manually with putty.

[0067] According to another aspect of the present disclosure, due to the linear extension / retraction movement of pin 160, as shown in FIGS. 6A-6C, it is possible to use standardized (e.g., identical) units in all regions of the mold, even when various heights of the pin may be required. Thus, the pin mechanism 100 of the present disclosure can be configured as a versatile system that can be incorporated (and / or retrofitted) at any position within a given mold (e.g., the same pin mechanism can be used at the root and tip) and / or with any blade design / shape.

[0068] FIGS. 6A-6C show various heights "h" to which pin 160 can extend above the mold surface 121 and / or above the layers of fiber layup 300. For example, in FIG. 6A, a plurality (e.g., five) of fiber layup segments 300 are stacked on top of each other, and a structural component 400 (e.g., a spark plug, a core, etc.) is disposed on segment 300. Here, pin 160 extends into the mold by a distance or height "h" that is less than the total height of layup 300 and structural component 400, as shown. Conversely, in FIG. 6B, pin 160 extends by a distance within the mold such that the distal end of pin 160 is disposed at a height (measured with respect to mold 120) that is higher than or exceeds the total height of a (single) layup segment and structural component 400. One or more heights at which pin 160 extends into or through a part of one or more components may be configured to receive components such as brace members, or may be used as a hard stop for one or more mating components. FIG. 6C shows an embodiment in which a (single) layup segment 300 and structural component 400 extend to a height higher than the height of pin 160. These internal structural components 400, 500 can be used as a reference point for the placement pins and, in some embodiments, as load-bearing members to ensure that structural components 400, 500 are correctly positioned within the blade. For example, structural components 400, 500 can be arranged to abut against pin(s) 160 or one or more holes to prevent lateral displacement of components 400, 500.

[0069] Once the layup process is complete, the tip of pin 160 remains visible above the composite glass layer 300. These reference marks on the pin head function as a visual reference for placing the spark cap. In some embodiments, the pin can include markings indicating the height of the stack of layup segments 300, and the markings provide a visual aid for an operator to confirm that a predetermined number / height of layup segments have been installed, and / or function as a reference for comparing the state of the layup segments at a given location of the blade to another location (e.g., root and tip).

[0070] Further, an overhead optical (e.g., laser) projection system can project the placement of structural components (e.g., overlay the boundaries around the structural components) for verification or as a secondary means of proper positioning in the case of coincidence with the pin location 160. Additionally, pins with higher placement accuracy can function as a calibration reference for overhead optical projection within the mold.

[0071] Once the layup process is complete, the bag can be sealed around the mold to create a vacuum state, and the resin injection process can be carried out with the pin 160 being included in the injection area. The mating tolerance between the pin 160 and the pin hole prevents the injected resin from entering the pin hole.

[0072] Referring to FIGS. 7A-7C, there are shown structural components that can be inserted into a mold and engage (e.g., abut) with a pin at one or both of a retracted position and an extended position. FIGS. 7A-7C show structural components 400, 500 that can be inserted into a mold and engage (e.g., abut) with a pin at the extended position of pin 160 and the retracted position of the pin after injection. Referring specifically to FIG. 7A, pin 160 is in a fully extended position above mold 120. Pin 160 can be disposed between two structural components 400, 500, and a portion of structural component 500 extends beyond the distal end of pin 160. Pin 160 can remain in the illustrated extended position during resin impregnation and evacuation to prevent resin from entering the pinch channel. After the injection process is complete, pin 160 can retract to return to its initial position, which may be inside the mold, within the mold, or fully outside the mold. Structural components 400 and 500 can be internal structural components such as blade halves and ultimately spark caps, ribs, or internal braces present in the formed blade. Structural components 400 and 500 may have corresponding geometric cavities or features configured to engage with the extended pin 160. Structural components 400 and 500 may have corresponding shapes such as holes, channels, grooves, shoulders, cavities, openings, etc. In various embodiments, a portion of structural components 400, 500 may be configured to be penetrated one or more times by pin 160.

[0073] In the absence of pin 160, as shown in FIG. 7B, an empty gap or cavity 510 is formed between structural components 400 and 500. The gap or cavity 510 may be filled with putty, sealant, or another substance in semi-liquid viscous or solid form. The putty can serve to fill the cavities of the formed blade or a part thereof. In various embodiments, pin 160 may be coated with a putty or foam configured to fill cavity 510 as pin 160 retracts from the mold surface. In various embodiments, a portion of pin 160 may be configured to supply foam, putty, or sealant through one or more internal bores. For example, without limitation, pin 160 may have one or more internal channels configured to supply sealant, such as a nozzle. In various embodiments, the second end of pin 160 may be in fluid communication with components such as a hose or tube and a pump configured to supply sealant to pin 160 and cavity 510 through the tube. Next, as shown in FIG. 7C, since the cured blade is removed from the mold in the demolding process, the formed blade (e.g., joined layup segment 300) and the attached structural components 400, 500 are easily removed from the mold (note that mold 120 no longer exists). In various embodiments, the demolding process may include any part that removes layup segment 300 and / or structural components 400, 500 from mold 120. In various embodiments, the demolding process may be performed manually by one or more users / technicians. In various embodiments, the demolding process can be automated by one or more robotic arms or machines configured to grip layup segment 300 and structural components 400, 500, whether cured or uncured. In various embodiments, the demolding process may include assembly with another component, such as a corresponding blade half. In various embodiments, the demolding process may include assembly of the corresponding blade half and assembly of structural components 400, 500.According to one aspect of the present disclosure, the retractable nature of pin 160 enables rapid mold release or the quick removal of the completed blade from the mold, while avoiding the risk of damage or defects caused by undesirable engagement with the pin due to the mold release load or movement occurring during mold release.

[0074] It should be noted that references herein to "upper", "lower", "upper part", "lower part", etc. are relative and not limiting. This is because the structures and techniques described herein are equally applicable to the spark caps formed on the suction side and pressure side of the blade.

[0075] Although the disclosed subject matter is described herein with respect to specific preferred embodiments, those skilled in the art will recognize that various modifications and improvements can be made to the disclosed subject matter without departing from its scope. Further, although the individual features of one embodiment of the disclosed subject matter may be discussed herein or shown in the drawings of one embodiment and not in other embodiments, it should be apparent that the individual features of one embodiment can be combined with one or more features of another embodiment or the features of multiple embodiments.

[0076] It will be apparent to those skilled in the art that various modifications and variations can be made to the methods and systems of the disclosed subject matter without departing from the spirit or scope thereof. Accordingly, the disclosed subject matter is intended to cover modifications and variations that are within the scope of the appended claims and their equivalents.

Claims

1. A wind turbine blade mold, comprising: a first mold surface; and at least one opening located within the first mold surface and configured to receive at least one pin, wherein the at least one pin has a first end and a second end, the ends defining a length extending therebetween, and the second end of the pin is disposed within a pin driver, the pin driver is disposed on a second mold surface, and the pin driver is configured to displace the at least one pin from a retracted position in which the first end of the at least one pin is disposed below the first mold surface to an extended position in which the first end of the at least one pin is disposed above the first mold surface.

2. The wind turbine blade mold according to claim 1, wherein a rotational movement of the at least one pin is generated by displacement of the pin driver.

3. The wind turbine blade mold according to any one of the preceding claims, wherein a linear movement of the pin is generated by displacement of the pin driver.

4. The wind turbine blade mold according to any one of the preceding claims, wherein the pin driver is displaced by a rotational movement of a driver casing.

5. The wind turbine blade mold according to any one of the preceding claims, wherein the pin driver and the at least one pin are coupled via a threaded connection.

6. The wind turbine blade mold according to any one of the preceding claims, further comprising a plurality of openings disposed around and along the span of the first mold surface.

7. The wind turbine blade mold according to any one of the preceding claims, further comprising a bushing disposed within the at least one opening, the bushing further comprising a channel for receiving the at least one pin.

8. The wind turbine blade mold according to any one of the preceding claims, further comprising a seal gasket disposed within the at least one opening.

9. The wind turbine blade mold according to any one of the preceding claims, further comprising at least one layer of layup segments disposed on the first surface of the mold, wherein the second end of the at least one pin is disposed above the at least one layer of layup segments.

10. The at least one pin penetrates the at least one layer of layup segments, the wind turbine blade mold according to any one of the preceding claims.

11. A part of the at least one pin is configured to engage with a structural component of a wind turbine blade, the wind turbine blade mold according to any one of the preceding claims.

12. A method of manufacturing a wind turbine blade, comprising: providing a mold having a first mold surface; forming an opening in the first mold surface; providing at least one pin having a first end and a second end, the pin being aligned with the opening and movable between a retracted position where the first end is located below the first mold surface and an extended position where the first end of the at least one pin is located above the first mold surface; providing a bushing, the bushing being disposed within the opening; providing a gasket, the gasket being disposed within the opening and forming a seal with the at least one pin; providing a pin driver for actuating movement of the at least one pin between the retracted position and the extended position; providing at least one layer of layup segments disposed on the first surface of the mold; displacing the at least one pin from the retracted position to the extended position to penetrate the at least one layer of layup segments. A method of manufacturing a wind turbine blade.

13. By actuation of the at least one pin driver, a rotational movement and a linear movement of the pin are generated, the method of manufacturing a wind turbine blade according to any one of the preceding claims.

14. By actuation of the at least one pin driver, the at least one pin is forced to penetrate the at least one layer of layup segments on the first surface of the mold, the method of manufacturing a wind turbine blade according to any one of the preceding claims.

15. The method of manufacturing a wind turbine blade according to any one of the preceding claims, wherein the at least one pin penetrates the at least one layer of layup segments without forming wrinkles in the layup segments.

16. The method of manufacturing a wind turbine blade according to any one of the preceding claims, wherein, by the operation of the at least one pin driver, the second end of the pin is displaced above the at least one layup segment.

17. The method of manufacturing a wind turbine blade according to any one of the preceding claims, further comprising performing a resin injection process with the at least one pin in the extended position.

18. The method of manufacturing a wind turbine blade according to any one of the preceding claims, wherein a part of the at least one pin is configured to engage with at least one structural component of the wind turbine blade.

19. The method of manufacturing a wind turbine blade according to any one of the preceding claims, wherein the at least one pin retracts to form a cavity between adjacent structural components.

20. The method of manufacturing a wind turbine blade according to any one of the preceding claims, wherein the at least one pin is removed from the wind turbine blade before a demolding process.

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