Method and apparatus for applying a vortex generator tape to a blade of a wind turbine

Abstract

An apparatus (10) for attaching tape (11) to the blade (6) of a wind turbine (1) is described, wherein the tape (6) includes a plurality of eddy current generators (VG) or a plurality of indicator positions on the blade (6) for attaching the plurality of eddy current generators (VG). The device (10) is configured to move along a path of movement of the blade (6) in the longitudinal direction on the ground (12), and includes a gate (13) having a tape application tool (14) configured to apply tape (11) to the blade (6), the tape application tool (14) being movable in the vertical direction along the gate (13); and a distance detection device (15), preferably a laser rangefinder, configured to detect the actual distance between the tape application tool (14) and the ground (12), preferably configured to detect several reference marks (16) located on the ground (12) or at blade bearing devices such as root and tip rotating devices along the movement path of the device (10).

Description

[Technical Field]

[0001] The present invention relates to a method and apparatus for applying tape to the blade of a wind turbine, wherein the tape includes a plurality of eddy current generators or at indicating locations on which the plurality of eddy current generators are applied to the blade. [Previous Technology]

[0002] Vortex generators (VGs) are widely used in wind turbine blades to improve aerodynamic performance, thereby increasing the power output of the associated turbines. Vortex generators mix the high-energy turbulent flow of the wind with the low-energy laminar flow of the wind adjacent to the blade surface. This results in a delay in airflow separation, ensuring that the airflow does not deviate from the aerodynamic blade profile.

[0003] As the blade size increases, a large number of eddy current generators need to be installed along the entire span of the blade.

[0004] Installing the eddy current generator is a time-consuming process in blade production because it is manual and depends on the user's skill. Typically, the location of the eddy current generator is marked using tape measures according to the blade specifications. After these locations are verified, the installation process can begin.

[0005] WO 2022 / 013355 A1 describes an eddy generator tape for mounting on the outer surface of a wind turbine blade. EP 3 211 219 A1 describes a method for mounting an eddy generator onto a wind turbine blade. CN 114289269 A describes an automatically positioning gluing device for wind turbine blades. [Summary of the Invention]

[0006] There may be a need for a simpler, faster, and more accurate method to mount the eddy current generator onto the blade. This requirement can be met by the subject matter described in the independent claim. The present invention is further developed as described in the appended claim.

[0007] According to a first aspect of the invention, an apparatus is provided for applying tape to a wind turbine blade, wherein the tape includes a plurality of vortex generators (VGs) or a plurality of indicator positions for attaching the plurality of vortex generators to the blade. The apparatus is configured to be movable on the ground along a path of movement in the longitudinal direction of the blade. The apparatus includes a gantry having a tape-applying tool configured to apply tape to the blade, the tape-applying tool being movable vertically along the gantry, and a distance detection device, preferably a laser ranging device, configured to detect the actual distance between the tape-applying tool and the ground, preferably configured to detect a plurality of reference marks arranged on the ground or on a blade-bearing device such as a root and tip rotating device along the path of movement of the apparatus.

[0008] The device may further include another distance detection device for detecting the horizontal distance between the tape application tool and the blade or the spanwise position of the blade.

[0009] Advantageously, the complex and user-dependent installation of these vortex generators onto wind turbine blades becomes faster, easier, and more accurate. The gantry can reach the maximum blade chord. The device is moved beside the blade so that it can access the blade through the gantry, which may include an arm to allow horizontal movement and application of force to the blade surface. A tape application tool can be configured at the end of the gantry or arm. The gantry or arm can move upward and downward along the chord of the tower blade. A distance detection device, preferably a laser ranging device, can detect the actual height position (e.g., distance from the ground) from a reference point.

[0010] In one embodiment, the tape application tool includes a rotatable roll of tape. When the installation process of a new blade is about to begin, the user can place the tape roll on the tape application tool. The user can move the device to a starting position, such as the root of the blade. Several sensors can be configured to detect the device position relative to the blade's spanwise position. These sensors can be located within the blade-carrying device, such as the root and tip rotating mechanism, or on the ground. The user can begin moving the device, unwinding the tape, and applying pressure to the blade surface.

[0011] In one embodiment, the device further includes a control device configured to move the tape-applying tool to a target distance between the tape-applying tool and the ground, preferably to a target distance between the tape-applying tool and a reference mark detected by a distance detection device, based on the difference between the target distance and the detected actual distance. This embodiment provides further automated applications of tape, wherein the reference mark provides very accurate detection of the distance between the tape-applying tool and the ground along the entire movement path.

[0012] In one embodiment, the device is a user-driven semi-autonomous vehicle (SAV) or an automated guided vehicle (AGV), preferably a fully automated guided vehicle (AGV). This achieves a less automated installation solution utilizing a user-driven semi-autonomous vehicle (SAV). Alternatively, it can also be a fully automated guided vehicle (AGV) when the solution is fully mature. In a fully automated solution, the AGV can perform tape application without any user intervention, except for operations such as changing the tape roll and pressing a start button. In this case, several sensors can be arranged to ensure that the operation does not involve collisions.

[0013] In one embodiment, the tape application tool includes a pressing device configured to apply pressure to the tape to adhere it to the blade. The pressing device preferably includes a pressure control device configured to control the amount of pressure applied. This feedback mechanism ensures constant and precise application pressure for smooth application.

[0014] In one embodiment, the device further includes a user interface configured to allow a user to interact with the device, wherein the user can input at least one parameter into the user interface, and the device is configured to process the parameter for applying tape to the blade, wherein the parameter includes at least one of the following: a starting position at the beginning of the device's movement path, an indication that the tape is to be applied to the pressure side or suction side of the blade, and a target height of the tape to be applied to the blade. Thus, the tape application can be flexibly adapted to the specifications of the tape and the blade.

[0015] In one embodiment, the user interface is configured to provide a signal to the user instructing the user to manually move the tape application tool vertically up or down along the portal based on the difference between the target distance and the detected actual distance. During the tape application process, the user receives a signal (e.g., on the panel user interface) that determines whether to move the tape application tool up or down and thus move the applied tape. In this case, the tape is applied at the desired height according to the specifications of the eddy current generator.

[0016] The user interface on the human-machine interface (HMI) device can display to the user the correct starting point of his / her position in the blade spanwise direction. The user can select whether he / she is on the pressure side or the suction side of the blade. According to the diagram pre-loaded into the machine software, the user can instruct the tape application tool to move to a given height according to the specifications of the eddy current generator and the blade (blade diagram).

[0017] In one embodiment, the tape includes several markings indicating the location of the vortex generators or their distance from the blades in the longitudinal direction. Since maintaining a short gap between each vortex generator is crucial, sufficient spacing or distance between the vortex generators in the longitudinal direction of the blades prevents them from bending and detaching during blade deflection in wind turbine operation.

[0018] According to a second aspect of the invention, a configuration for applying tape to a wind turbine blade is provided. The tape includes a plurality of eddy current generators or a plurality of indicator positions for attaching the plurality of eddy current generators to the blade. The configuration includes the device and reference marks arranged on the ground or on a blade-carrying device such as a root and tip rotating device, along the movement path of the device.

[0019] According to a third aspect of the invention, a method for applying tape to a wind turbine blade is provided. The tape includes a plurality of eddy current generators or a plurality of indicated positions for attaching the plurality of eddy current generators to the blade. The method uses an apparatus and includes the steps of positioning the blade on the ground; positioning the apparatus at a starting position at the beginning of a movement path; and moving the apparatus on the ground along the movement path in the longitudinal direction of the blade. During the movement of the apparatus, the method includes: detecting an actual distance between a tape-applying tool and the ground using a distance detection device; moving the tape-applying tool to a target distance between the tape-applying tool and the ground based on the difference between a target distance and the detected actual distance; and applying the tape to the blade located at the target distance using the tape-applying tool.

[0020] In one embodiment, the method further includes configuring a number of reference marks on the ground or on a blade-bearing device such as a root and tip rotating device, along the movement path of the device and in the longitudinal direction of the blade, and detecting the reference marks by a distance detection device.

[0021] In one embodiment, the method further includes one of the following: attaching the plurality of eddy current generators above or below the tape; applying adhesive above or below the tape before attaching the plurality of eddy current generators. In this embodiment, the applied tape is adhered to the blade and can be used, for example, to position the eddy current generator above or below the applied tape. The terms "above" and "below" preferably refer to the vertical direction. Eddy current generators typically come with pre-installed tape, with space above or below the tape for applying adhesive to ensure additional adhesion.

[0022] In one embodiment, the tape is a double-sided tape. After peeling off the release liner from the double-sided tape, the plurality of eddy current generators are attached to the tape. In a variation, the tape may be a single adhesive layer, wherein the eddy current generators are already prepared on the other side of the tape. In this modification, the bonding process is further enhanced because the separate bonding step for the eddy current generators can be omitted.

[0023] According to a fourth aspect of the present invention, a blade is provided, the blade comprising an adhesive tape bonded by the method described above.

[0024] According to a fifth aspect of the invention, a wind turbine is provided, comprising a rotor having a plurality of rotor blades. The rotor is mounted to a nacelle to rotate at a rotor speed about a rotation axis to drive a generator to generate electrical energy, while the nacelle is mounted to a tower to rotate about a yaw axis.

[0025] According to the present invention, tape can be applied to the blade more quickly, accurately, and reliably, wherein the tape can provide identification of the eddy current generator's position markings. In principle, quality checks for correct positioning are not required, as this is already done by equipment capable of generating reports. The installation of the eddy current generator itself can also be faster, with one operator applying the adhesive (e.g., using rollers above and below the tape) while another operator applies the eddy current generator. The present invention can also reduce the workload of the platform, which is expected to increase as blade size increases.

[0026] It should be noted that embodiments of the present invention have been described with reference to different subjects. Specifically, some embodiments have been described with reference to device type request items, while others have been described with reference to method type request items. However, those skilled in the art will understand from the above and the following description that, unless otherwise stated, in addition to any combination of features belonging to one subject matter, there may be any combination of features relating to different subjects, and in particular, the association between features of device type request items and features of method type request items is considered to be disclosed together with this application.

Implementation Method

[0028] The illustrations in the figures are schematic. It is worth noting that similar or identical elements have the same reference symbols in different figures.

[0029] Figure 1 shows a configuration for attaching tape 11 to a blade 6 of a wind turbine 1 according to one embodiment. The tape 11 indicates the location where a plurality of eddy current generators (VGs) are attached to the blade 6 (see Figure 2). This configuration includes a device 10 for attaching tape 11 to the blade 6 of the wind turbine 1, wherein the device 10 is configured to move along a path of movement on a floor 12 in the longitudinal direction of the blade 6, i.e., substantially parallel to the longitudinal direction of the blade 6. The device 10 includes a portal 13 having a tape application tool 14 configured to attach tape 11 to the blade 6, wherein the tape application tool 14 is movable in a vertical direction along the portal 13. The tape application tool 14 may include a rotatable roll of tape.

[0030] The device 10 also includes a distance detection device 15, preferably a laser ranging device, which is configured to detect the actual distance between the tape application tool 14 and the ground 12.

[0031] This configuration also includes several reference markers 16, which are positioned on the ground 12 along the movement path of the device 10. The reference markers 16 can also be affixed to blade-bearing devices such as root and tip turning devices. The advantage of the latter is that it is independent of the actual position of the blades 6 within the hall. A distance detection device 15, preferably a laser ranging device, is configured to detect the reference markers 16.

[0032] The device 10 also includes a user interface 17, which is configured to provide a signal to the user instructing the user to manually move the tape application tool 14 vertically or downward along the door seat 13 based on the difference between the target distance and the detected actual distance.

[0033] Alternatively or additionally, the device 10 may also include a control device configured to automatically move the tape application tool 14 to the target distance between the tape application tool 14 and the ground 12 based on the difference between the target distance and the detected actual distance, preferably between the tape application tool 14 and the reference mark 16 detected by the distance detection device 15.

[0034] In this case, the device 10 may be an automated guided vehicle (AGV), preferably a fully automated guided vehicle (AGV), which automatically applies the tape 11 to the blade 6. However, if the tape application tool 14 is manually moved up and down along the door seat 13, the device 10 may be a semi-automatic vehicle (SAV) driven by a user. The user interface 17 may be configured to allow a user to interact with the device 10, wherein the user can input at least one parameter into the user interface 17, and the device 10 may be configured to process parameters for applying the tape 11 to the blade 6, wherein the parameter includes at least one of the following: a starting position at the beginning of the movement path of the device 10 (indicated by the start reference 18 in FIG. 2), an indication of whether the tape 11 is applied to the pressure side or the suction side of the blade 6, and a target height at the blade 6 where the tape 11 is to be applied.

[0035] The tape application tool 14 may include a pressing device (not shown) configured to apply pressure to the tape 11 to adhere the tape 11 to the blade 6. Preferably, the pressing device includes a pressure control device configured to control the magnitude of the pressing force. The control of the pressing force is preferably performed through feedback control, wherein a pressure sensor senses the actual pressing force.

[0036] Figure 2 shows an adhesive tape 11 attached to a blade 6 according to one embodiment. The adhesive tape 11 includes markings 20 indicating the distance between eddy current generators VG in the longitudinal direction of the blade 6. Alternatively or additionally, markings may be provided on the adhesive tape 11 to indicate the location where the eddy current generators VG are to be attached.

[0037] The operation of device 10 is as follows: the blade 6 is positioned on the ground 12, and device 10 is positioned at the starting position shown by the starting reference 18 of the starting point of the movement path in FIG2, which is located at the starting point of the movement path of device 10. In one embodiment, this starting position is detected or identified by a distance detection device 15.

[0038] Next, the device 10 moves along a longitudinal path of the blade 6 on the ground 12. During the movement of the device 10, the distance detection device 15 detects the actual distance between the tape application tool 14 and the ground 12, and moves the tape application tool 14 to the target distance between the tape application tool 14 and the ground 12 based on the difference between the target distance and the detected actual distance. The movement of the tape application tool 14 is preferably performed through feedback control. During the movement of the tape application tool 14, the tape 11 is applied to the blade 6 located at the target distance by the tape application tool 14.

[0039] If the distance detection device 15 is configured to detect the reference mark 16, the reference mark 16 is pre-arranged on the ground 12 along the moving path of the device 10 in the longitudinal direction of the blade 6, so that the distance between the tape application tool 14 and the ground 12 is detected by the distance detection device 15 detecting the reference mark 16.

[0040] After the tape 11 is attached to the blade 6, a plurality of eddy current generators VG can be attached above or below the tape 11. Before attaching the plurality of eddy current generators VG, adhesive can be applied above or below the tape 11 through the adhesive dispenser 19.

[0041] In one embodiment, the tape 11 is a double-sided tape, and after the release tape on the double-sided tape 11 is torn off, the plurality of eddy current generators VG are adhered to the tape 11.

[0042] In a variation, when the tape 11 has been applied to the blade 6, the tape 11 may already include the eddy current generator VG.

[0043] Figure 3 shows a wind turbine 1 according to one embodiment. The wind turbine 1 includes a nacelle 3 and a tower 2. The nacelle 3 is mounted on top of the tower 2. The nacelle 3 is mounted via a yaw bearing so that it can rotate relative to the tower 2. The axis of rotation of the nacelle 3 relative to the tower 2 is called the yaw axis 9.

[0044] The wind turbine 1 also includes a rotor 4 having three rotor blades 6, of which Figure 1 shows two rotor blades 6. At each blade 6, at least one tape 11 and several eddy current generators VG (not shown) are attached. Each blade 6 is configured to pitch about its pitch axis at a pitch angle. The rotor 4 is mounted via a main bearing 7 so that it can rotate relative to the nacelle 3 about a rotation axis 8 (rotor shaft).

[0045] The wind turbine 1 also includes a generator 5. The generator 5 further includes a rotor that connects the generator 5 to the rotor 4. If the rotor 4 is directly connected to the generator 5, the wind turbine 1 is called a gearless, direct-driven wind turbine. Such a generator 5 is called a direct-drive generator 5. Alternatively, the rotor 4 can also be connected to the generator 5 through a gearbox. This type of wind turbine 1 is called a geared wind turbine. The present invention applies to both types of wind turbines 1.

[0046] The generator 5 is housed within the engine compartment 3. The generator 5 is configured to convert the rotational energy from the rotor 4 into electrical energy in the form of alternating current.

[0047] It should be noted that the word "comprising" does not exclude other elements or steps, and "a" or "an" does not exclude multiple. Elements described in relation to different embodiments may also be combined. It should also be noted that reference numerals in the request should not be construed as limiting the scope of the request.

[0048] Regardless of its grammatical usage, the term includes individuals who identify as male, female, or other genders. [Simplified Explanation of the Diagram]

[0027] The above and other aspects of the present invention will become apparent from examples of embodiments described below, and will be explained with reference to examples of embodiments. The present invention will be described in more detail below with reference to examples of embodiments, but the invention is not limited thereto: FIG1 shows an arrangement for applying tape to a blade of a wind turbine according to an embodiment; FIG2 shows an application of tape to a blade according to an embodiment; FIG3 shows a wind turbine and its various components according to an embodiment.

Claims

1. An apparatus (10) for attaching an adhesive tape (11) to a blade (6) of a wind turbine (1), the adhesive tape (11) comprising a plurality of eddy current generators (VGs) or a plurality of indicator positions on the blade (6) for attaching the plurality of eddy current generators (VGs), wherein the apparatus (10) is configured to be movable on the ground (12) along a movement path in a longitudinal direction of the blade (6), the apparatus (10) comprising: A door seat (13) has a tape application tool (14) configured to apply the tape (11) to the blade (6), the tape application tool (14) being movable along the door seat (13) in a vertical direction; and a distance detection device (15) configured to detect an actual distance between the tape application tool (14) and the ground (12).

2. The device (10) of claim 1 further includes a control device configured to move the tape application tool (14) to a target distance between the tape application tool (14) and the ground (12).

3. The device (10) of claim 1, wherein the device (10) is a semi-autonomous vehicle (SAV) driven by a user or an automated guided vehicle (AGV).

4. The device (10) of claim 1, wherein the tape application tool (14) includes a rotatable roll of tape.

5. The device (10) of claim 1, wherein the tape application tool (14) includes a pressing device configured to apply a pressing force to the tape (11) to apply the tape (11) to the blade (6).

6. The device (10) of claim 1 further includes a user interface (17) configured to enable a user to interact with the device (10), wherein the user is able to input at least one parameter into the user interface (17), and the device (10) is configured to process the parameter for attaching the tape (11) to the blade (6), wherein the parameter includes at least one of the following: a starting position of a movement path of the device (10), an indication of a pressure side or a suction side of the tape being attached to the blade (6), and a target height at which the tape (11) is to be attached at the blade (6).

7. The device (10) of claim 6, wherein the user interface (17) is configured to provide the user with a signal that instructs the user to manually move the tape application tool (14) up or down in the vertical direction along the door seat (13) based on the difference between a target distance and a detected actual distance.

8. The device (10) of any one of claims 1 to 7, wherein the tape (11) includes a plurality of markings (20) indicating the location of the plurality of eddy current generators (VG) or a distance between the plurality of eddy current generators (VG) in the longitudinal direction of the blade (6).

9. An arrangement for attaching a tape (11) to a blade (6) of a wind turbine (1), the tape (11) including a plurality of eddy current generators (VGs) or a plurality of indication positions on the blade (6) for attaching the plurality of eddy current generators (VGs), the arrangement including the device (10) as claimed in any of claims 1 to 8 and a plurality of reference marks (16) disposed on the ground (12) along the movement path of the device (10).

10. A method for attaching an adhesive tape (11) to a blade (6) of a wind turbine (1), the adhesive tape (11) comprising a plurality of vortex generators (VGs) or a plurality of indication positions on the blade (6) for attaching the plurality of vortex generators (VGs), wherein the method uses the device (10) as claimed in any one of claims 1 to 9, and comprises the steps of: positioning the blade (6) on a ground (12); positioning the device (10) at a starting position at the beginning of a movement path of the device (10); moving the device (10) on the ground (12) along the movement path in the longitudinal direction of the blade (6), wherein during the movement of the device (10), the method comprises the step of: detecting an actual distance between the tape application tool (14) and the ground (12) by a distance detection device (15); Based on the difference between the target distance and the detected actual distance, the tape application tool (14) is moved to one of the target distances between the tape application tool (14) and the ground (12); and the tape (11) is applied to the blade (6) at the target distance using the tape application tool (14).

11. The method of claim 10 further includes a plurality of reference marks (16) disposed on the ground (12) or on a blade-bearing device such as a root and tip rotating device, along the movement path of the device (10) according to one of the longitudinal directions of the blade (6); and detecting the reference marks (16) by the distance detection device (15).

12. The method of claim 11 further includes one of the following: attaching a plurality of eddy current generators (VGs) above or below the tape (11); applying an adhesive above or below the tape (11) before attaching the plurality of eddy current generators (VGs).

13. The method of any one of claims 10 to 12, wherein the tape (11) is a double-sided tape, and the plurality of eddy current generators (VGs) are attached to the tape (11) after the release tape on the double-sided tape (11) is removed.

14. A wind turbine (1) comprising a rotor (4) having a plurality of rotor blades (6) as claimed in claim 1, wherein the rotor (4) is mounted on a nacelle (3) to drive a generator (5) at a rotor speed about a rotation axis (8) for generating electrical energy, and the nacelle (3) is mounted on a tower (2) to rotate about a yaw axis (9).

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