System and method for improving wind turbine rotor blade quality using oblique lighting

Abstract

A method for improving quality of a rotor blade of a wind turbine. The method includes activating a plurality of light sources configured to illuminate a surface of the rotor blade. The method also includes receiving, via a controller, visual data relating to the rotor blade during or after manufacturing of the rotor blade. The visual data includes a presence or an absence of a tonal variation on the surface of the rotor blade. Further, the method includes identifying, via the controller, an anomaly on the surface of the rotor blade based on the presence of the tonal variation. Moreover, the method includes automatically generating, via the controller, a quality report of the rotor blade comprising the identified anomaly. In addition, the method includes implementing, via the controller, a corrective action for the rotor blade or a subsequent manufacturing process of another rotor blade based on the quality report.

Description

701110-WO-1 / GECW-1288-PCTSYSTEM AND METHOD FOR IMPROVING WIND TURBINE ROTOR BLADE QUALITY USING OBLIQUE LIGHTINGFIELD

[0001] The present disclosure generally relates to wind turbines, and more particularly, to automated systems and methods for improving wind turbine rotor blade quality using oblique lighting.BACKGROUND

[0002] Wind power is considered one of the cleanest, most environmentally friendly energy' sources presently available, and wind turbines have gained increased attention in this regard. A modem wind turbine typically includes a tower, generator, gearbox, nacelle, and one or more rotor blades. The rotor blades capture kinetic energy of wind using known airfoil principles. For example, rotor blades typically have the cross-sectional profile of an airfoil such that, during operation, air flows over the blade producing a pressure difference between the sides. Consequently, a lift force, which is directed from a pressure side towards a suction side, acts on the blade. The lift force generates torque on the main rotor shaft, which is typically geared to a generator for producing electricity.

[0003] The rotor blades generally include a suction side shell and a pressure side shell typically formed using molding processes that are bonded together at bond lines along the leading and trailing edges of the blade. Further, the pressure and suction shells are relatively lightweight and have structural properties (e.g., stiffness, buckling resistance and strength) which are not configured to withstand the bending moments and other loads exerted on the rotor blade during operation. Thus, to increase the stiffness, buckling resistance and strength of the rotor blade, the body shell is typically reinforced using one or more structural components (e.g. opposing spar caps with a shear web configured therebetween) that engage the inner pressure and suction side surfaces of the shell halves.

[0004] The spar caps are typically constructed of various materials, including but not limited to glass fiber laminate composites and / or carbon fiber laminate composites. The shell of the rotor blade is generally built around the spar caps of the701110-WO-1 / GECW-1288-PCT blade by stacking layers of fiber fabrics in a shell mold. The layers are then typically infused together to form the rotor blade. Accordingly, some rotor blades generally have a sandwich panel configuration. Still other rotor blades are formed via a plurality of blade segments.

[0005] Existing methods for providing quality control to manufactured rotor blades are manually driven processes that generally involve non-standardized processes. Therefore, such methods are often inconsistent, time-consuming, and error prone. Accordingly, the present disclosure is directed to providing automated systems and methods of improving wind turbine rotor blade quality using oblique lighting.BRIEF DESCRIPTION

[0006] Aspects and advantages of the disclosure will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the disclosure.

[0007] In an aspect, the present disclosure is directed to a method for improving quality of a rotor blade of a wind turbine. The method includes activating a plurality of light sources configured to illuminate a surface of the rotor blade. The method also includes receiving, via a controller, visual data relating to the rotor blade during or after manufacturing of the rotor blade. The visual data includes a presence or an absence of a tonal variation on the surface of the rotor blade. Further, the method includes identifying, via the controller, an anomaly on the surface of the rotor blade based on the presence of the tonal variation. Moreover, the method includes automatically generating, via the controller, a quality7report of the rotor blade comprising the identified anomaly. In addition, the method includes implementing, via the controller, a corrective action for the rotor blade or a subsequent manufacturing process of another rotor blade based on the quality7report.

[0008] In another aspect, the present disclosure is directed to a system for improving quality of a rotor blade of a wind turbine. The system includes a controller comprising at least one processor configured to perform a plurality of operations. The plurality of operations includes receiving visual data relating to the rotor blade during or after manufacturing of the rotor blade. The visual data includes a presence or an absence of a tonal variation on a surface of the rotor blade. The plurality of701110-WO-1 / GECW-1288-PCT operations also includes identifying an anomaly on the surface of the rotor blade based on the presence of the tonal variation. Further, the plurality of operations includes automatically generating a quality report of the rotor blade comprising the identified anomaly. In addition, the plurality of operations includes implementing a corrective action for the rotor blade or a subsequent manufacturing process of another rotor blade based on the qualify' report.

[0009] These and other features, aspects and advantages of the present disclosure will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the disclosure and, together with the description, serve to explain the principles of the disclosure.BRIEF DESCRIPTION OF THE DRAWINGS

[0010] A full and enabling disclosure of the present disclosure, including the best mode thereof, directed to one of ordinary’ skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:

[0011] FIG. 1 illustrates a perspective view of an embodiment of a wind turbine according to the present disclosure;

[0012] FIG. 2 illustrates a schematic diagram of an embodiment of a wind farm according to the present disclosure;

[0013] FIG. 3 illustrates a schematic diagram of an embodiment of a controller for a wind turbine or a wind farm according to the present disclosure;

[0014] FIG. 4 illustrates a flow diagram of an embodiment of a method for improving qualify of a rotor blade of a w ind turbine according to the present disclosure;

[0015] FIG. 5 illustrates a perspective view of an embodiment of a fixture for illuminating a surface of the rotor blade during or recently after manufacturing thereof according to the present disclosure;

[0016] FIG. 6 illustrates a perspective view of an embodiment of the fixture of FIG. 5 illuminating a surface of the rotor blade during or recently after manufacturing thereof according to the present disclosure;

[0017] FIGS. 7A-7B illustrates example visual data from a rotor blade generated701110-WO-1 / GECW-1288-PCT by systems and methods according to the present disclosure, particularly illustrating a rotor blade having anomalies being illuminated by the fixture of FIGS. 5 and 6; and

[0018] FIG. 8 illustrates an example plot representing various amplification factors for illuminating a surface of the rotor blade according to the present disclosure.DETAILED DESCRIPTION

[0019] Reference now will be made in detail to embodiments of the disclosure, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the disclosure, not limitation of the disclosure. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present disclosure without departing from the scope or spirit of the disclosure. For instance, features illustrated or described as part of an embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present disclosure covers such modifications and variations as come within the scope of the appended claims and their equivalents.

[0020] In the following specification and the claims, reference will be made to a number of terms, which shall be defined to have the following meanings.

[0021] The singular forms “a”, "an", and "the" include plural references unless the context clearly dictates otherwise.

[0022] Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as "about,’7“substantially,” and “approximately,” are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value. Here and throughout the specification and claims, range limitations may be combined and / or interchanged, such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise.

[0023] In general, the present disclosure is directed to systems and methods for701110-WO-1 / GECW-1288-PCT improving wind turbine rotor blade quality using oblique lighting. More specifically, in an embodiment, the present disclosure is directed to systems and methods that address challenges of manual practices used to detect anomalies on a part, such as a recently manufactured wind turbine rotor blade. Thus, in an embodiment, systems and methods of the present disclosure include illuminating a part and using visual data including a presence of tonal variations (e.g., such as shadows and / or highlights) on a surface of the part to detect anomalies.

[0024] In particular embodiments, for example, a plurality of light sources can be used to illuminate the part via oblique lighting. The presence of tonal variations on the surface of the part are captured via a camera having a field-of-view including the surface of the part. The plurality of light sources may be activated to continuously or intermittently illuminate the surface. In particular embodiments, the plurality’ of light sources may be mounted to a fixture that is moved across the surface of the part to illuminate the part. In addition, the plurality of light sources may emit one or more colors of light to illuminate the surface. Thus, in an embodiment, visual data including the presence of tonal variations on the surface of the part can be used to detect anomalies. For example, multiple frames of the visual data can be acquired as the plurality of light sources illuminate the surface of the part. In particular embodiments, the visual data can be input to one or more machine-learned models that can be trained to detect anomalies on the surface of the part.

[0025] Referring now to FIG. 1, a schematic perspective view of a wind turbine 100 according to the present disclosure is illustrated. As shown in the exemplary embodiment, the wind turbine 100 is a horizontal axis wind turbine. Further, as shown, the wind turbine 100 includes a tower 102 extending from a supporting surface (not shown), a nacelle 106 coupled to tower 102, and a rotor 108 coupled to nacelle 106. Moreover, as shown, the rotor 108 has a rotatable hub 1 10 and a plurality of blades 112, 114, 116 coupled to rotatable hub 110. In the illustrated embodiment, the rotor 108 has a first blade 112, a second blade 114, and a third blade 116. In alternative embodiments, the rotor 108 may have any number of blades 112. 114, 116 that enables the wind turbine 100 to function as described herein.

[0026] In certain embodiments, the tower 102 may be fabricated from tubular steel or any other suitable material that enables the wind turbine 100 to operate as701110-WO-1 / GECW-1288-PCT described herein. For example, in some embodiments, the tower 102 is any one of a lattice steel tower, guyed tower, concrete tower, and / or hybrid tower.

[0027] Still referring to FIG. 1, as shown, the blades 112. 114, 116 are positioned about the rotatable hub 110 to facilitate rotating the rotor 108 when wind flows through the wind turbine 100. Thus, when the rotor 108 rotates, kinetic energy from the wind is transferred into usable mechanical energy, and subsequently, electrical energy. During operation, the rotor 108 rotates about a rotation axis 120 that is substantially parallel to the supporting surface. In addition, in some embodiments, the rotor 108 and the nacelle 106 are rotated about the tower 102 on a yaw axis 122 to control the orientation of the blades 112. 114, 116 with respect to the direction of wind. In alternative embodiments, the wind turbine 100 includes any rotor 108 that enables the wind turbine 100 to operate as described herein.

[0028] In particular embodiments, as shown, each blade 112, 114, 116 is coupled to the rotatable hub 110 at a hub end 124 and extends radially outward from rotatable hub 110 to a distal end 126. Each blade 112, 114, 116 defines a longitudinal axis 128 extending between hub end 124 and distal end 126. In alternative embodiments, the wind turbine 100 includes any blade 112, 114, 116 that enables wind turbine 100 to operate as described herein.

[0029] The wind turbine 100 may also include a wind turbine controller 130 centralized within the nacelle 106. However, in other embodiments, the controller 130 may be located within any other component of the wind turbine 100 or at a location outside the wind turbine 100. Further, the controller 130 may be communicatively coupled to any number of the components of the wind turbine 100 in order to control the operation of such components and / or implement a corrective or control action. As such, the controller 130 may include a computer or other suitable processing unit. Thus, in several embodiments, the controller 130 may include suitable computer-readable instructions that, when implemented, configure the controller 130 to perform various different functions, such as receiving, transmitting and / or executing wind turbine control signals. Accordingly, the controller 130 may generally be configured to control the various operating modes (e.g., start-up or shutdown sequences), de-rating or up-rating the wind turbine, and / or individual components of the wind turbine 100.701110-WO-1 / GECW-1288-PCT

[0030] Referring now to FIG. 2, the wind turbine 100 described herein may be part of a wind farm 150 that is controlled according to the system and method of the present disclosure is illustrated. As shown, the wind farm 150 may include a plurality of wind turbines 152, including the wind turbine 100 described above, and a farmlevel controller 154. For example, as shown in the illustrated embodiment, the wind farm 150 includes twelve wind turbines, including wind turbine 100. However, in other embodiments, the wind farm 150 may include any other number of wind turbines, such as less than twelve wind turbines or greater than twelve wind turbines. In an embodiment, the controller 130 of the wind turbine 100 may be communicatively coupled to the farm-level controller 154 through a wired connection, such as by connecting the controller 130 through suitable communicative links 156 or networks (e.g., a suitable cable). Alternatively, the controller 130 may be communicatively coupled to the farm-level controller 154 through a wireless connection, such as by using any suitable wireless communications protocol known in the art. In addition, the farm-level controller 154 may be generally configured similar to the controller 130 for each of the individual wind turbines 152 within the wind farm 150.

[0031] Referring now to FIG. 3, a block diagram of an embodiment of a controller 200 in accordance with aspects of the present disclosure is illustrated. For example, the controller 200 may be configured to monitor a quality of rotor blades 112, 114, 116 during a manufacturing process (i.e., the controller 200 may be associated with and / or located at a manufacturing facility for rotor blades). As shown, the controller 200 may include one or more processor(s) 202 and associated memory7device(s) 204 configured to perform a variety7of computer-implemented functions (e.g., performing the methods, steps, calculations and the like and storing relevant data as disclosed herein). Additionally, the controller 200 may also include a communications module 206 to facilitate communications between the controller 200 and the various components of the wind farm 150. Further, the communications module 206 may include a sensor interface 208 (e.g., one or more analog-to-digital converters) to permit signals transmitted from one or more sensors 210, 212, 214 to be converted into signals that can be understood and processed by the processors 202. It should be appreciated that the sensors 210, 212, 214 may be communicatively coupled to the701110-WO-1 / GECW-1288-PCT communications module 206 using any suitable means. For example, as shown, the sensors 210, 212. 214 are coupled to the sensor interface 208 via a wired connection. However, in other embodiments, the sensors 210, 212, 214 may be coupled to the sensor interface 208 via a wireless connection, such as by using any suitable wireless communications protocol known in the art.

[0032] As used herein, the term ‘‘processor’" refers not only to integrated circuits referred to in the art as being included in a computer, but also refers to a controller, a microcontroller, a microcomputer, a programmable logic controller (PLC), an application specific integrated circuit, and other programmable circuits. Additionally, the memory device(s) 204 may generally comprise memory element(s) including, but not limited to, computer readable medium (e.g., random access memory’ (RAM)), computer readable non-volatile medium (e.g., a flash memory), a floppy disk, a compact disc-read only memory (CD-ROM), a magneto-optical disk (MOD), a digital versatile disc (DVD) and / or other suitable memory elements. Such memoiv device(s) 204 may generally be configured to store suitable computer-readable instructions that, when implemented by the processor(s) 252, configure the controller 200 to perform various functions as described herein.

[0033] Referring now to FIGS. 4-7B, various figures are provided to illustrate systems and methods for improving quality of a rotor blade of a w ind turbine during or recently after manufacturing according to the present disclosure. More specifically, FIG. 4 illustrates a flow' diagram of an embodiment of a method 300 for improving quality of a rotor blade of a wind turbine during or recently after manufacturing according to the present disclosure. FIG. 5 illustrates a perspective view of an embodiment of a fixture 324 having a plurality of light sources 320 for illuminating a surface 322 of the rotor blade 112 during or recently after manufacturing thereof according to the present disclosure. FIG. 6 illustrates a perspective view of an embodiment of the fixture 324 of FIG. 5 illuminating the surface 322 of the rotor blade 112 during or recently after manufacturing thereof according to the present disclosure. FIGS. 7A-7B illustrates example visual data from the rotor blade 112 generated by systems and methods according to the present disclosure, particularly illustrating the rotor blade 112 having anomalies 336 being illuminated by the fixture 324 of FIGS. 5 and 6.701110-WO-1 / GECW-1288-PCT

[0034] In general, the method 300 of FIG. 4 will be described herein with reference to the wind turbine 100 described above with reference to FIGS. 1-3 and the fixture 324 of FIGS. 5-7B. However, it should be appreciated by those of ordinary skill in the art that the disclosed method 300 may generally be utilized with any wind turbine having any suitable configuration. In addition, although FIG. 4 depicts steps performed in a particular order for purposes of illustration and discussion, the methods discussed herein are not limited to any particular order or arrangement. One skilled in the art, using the disclosures provided herein, will appreciate that various steps of the methods disclosed herein can be omitted, rearranged, combined, and / or adapted in various ways without deviating from the scope of the present disclosure. Moreover, in an embodiment, the method 300 may be performed by the controller 130, a separate controller, or via the cloud.

[0035] As shown at (302), the method 300 includes activating, via the controller 200, the plurality of light sources 320 to illuminate the surface 322 of the rotor blade 112. In an embodiment, the plurality’ of light sources 320 may be any suitable type of light source (e.g., an adjustable light emitting diode (LED), incandescent bulb, halogen bulb, etc.). In some embodiments, at least some of the plurality of light sources 320 may be arranged so as to illuminate the surface 322 of the rotor blade 112 via oblique lighting, which emits light at a non-perpendicular angle relative to a surface. In such embodiment, illuminating the surface 322 of the rotor blade 112 via oblique lighting can create tonal variations on the surface 322 caused by anomalies 336. The anomalies 336 can include, but are not limited to, surface 322 variations (e.g., bumps and / or wrinkles), ply ends, air trapped under the surface 322, surface 322 cracks, and / or any other suitable anomalous condition occurring during or after manufacturing of the rotor blade. For purposes of explanation, the tonal vanations are presented as shadows 338 on a rotor blade surface (i.e., areas of reduced brightness relative to the rest of the rotor blade surface). However, it should be appreciated that the tonal variations may be highlights on the rotor blade surface (i.e., areas of reduced brightness relative to the rest of the rotor blade surface). In additional or alternative embodiments, at least some of the plurality of light sources 320 may be arranged so as to illuminate the surface 322 at an angle perpendicular to the surface 322 (i.e., via transmissive lighting), which may enable enhanced sensitivity to detecting deeper701110-WO-1 / GECW-1288-PCT anomalies 336 (i.e., anomalies 336 below the surface 322 of the rotor blade 112).

[0036] More specifically, as shown in FIGS. 5 and 6, the plurality’ of light sources 320 mounted on the fixture 324 may be arranged in respective light groups 326 (i.e., distinct subsets of the plurality of light sources 320). For example, the fixture 324 may include a plurality of arms 328 each configured to support one respective light group 326. In some embodiments, the plurality of arms 328 may be spaced from each other in a chord-wise direction relative to the rotor blade 112. In certain embodiments, the fixture 324 may include a base 330 from which the plurality of arms 328 extend. The base 330 may, for example, include one or more components pivotally coupled to each other (as shown in FIG. 6) so as to conform to various surfaces 322 of corresponding rotor blades 112. As one example, the base 330 may include one or more pivot arms. As another example, the base 330 may be a chain (e.g., a roller chain, a leaf chain, etc.). That is, the base 330 may be configured to adapt to a radius of curvature of the rotor blade 112 so as to arrange each of the respective light groups 326 at a similar height (i.e., distance from the surface 322 of the rotor blade 112), which can improve the efficiency with which anomalies 336 can be detected across the surface 322 of the rotor blade 1 12.

[0037] In some embodiments, activating the plurality of light sources 320 may include continuously activating the plurality of light sources 320 to illuminate the surface 322 of the rotor blade 112. In such an embodiment, the method 300 may further include moving, via the controller 200, the fixture 324 along the surface 322 of the rotor blade 112 (e.g., in a spanwise direction and / or in a chordwise direction) and / or throughout an interior and / or exterior of the rotor blade 112 for illuminating portions of the rotor blade 112. For example, the fixture 324 may include a cable 323 that is coupled to a retractor (such as a winch) (not shown). In such an embodiment, the controller 200 may be configured to actuate the retractor so as to tension the cable 323 and thereby pull the fixture 324 along the surface 322 of the rotor blade 112. As another example, the fixture 324 may include wheels, tracks, propellers, or similar, or combinations thereof for moving along the rotor blade 112 (e.g., by automatically driving or otherwise controlling (such as via remote control, manual operation, the controller 200, etc.)).

[0038] In other embodiments, activating the plurality of light sources 320 may701110-WO-1 / GECW-1288-PCT include intermittently activating (i.e., flashing) the plurality of light sources 320 to illuminate the surface 322 of the rotor blade 112 for discrete intervals. In such an embodiment, the fixture 324 may remain stationary on the surface 322 of the rotor blade 1 12 at least so long as to obtain visual data for a portion of the surface 322 illuminated by the plurality of light sources 320. The fixture 324 may then be subsequently moved along the surface 322 (e.g.. via remote control, manual operation, the controller 200, etc.) to obtain visual data of another portion of the surface 322 in a similar manner.

[0039] Moreover, in some embodiments, each of the plurality of light sources 320 may emit a same color of light (e.g., white, red, blue, green, etc ). In other embodiments, at least some of the plurality of light sources 320 may emit a first color of light and at least some of the plurality of light sources 320 may emit a second color of light. In such embodiments, the first color is different from the second color.Emitting different colors of light from the plurality' of light sources 320 can be used to approximate a moving shadow in one frame of visual data, which can allow for detection of shadows by processing the one frame of image data instead of processing a plurality of frames of image data obtained while emitting a same color of light from the plurality7of light sources 320, thereby reducing computational resources required to detect the shadows. Furthermore, in such embodiments, the plurality of light sources 320 may be intermittently activated such that the first color, the second color, or both are emitted during a particular time period.

[0040] In some embodiments, the respective light groups 326 may be selectively activated based on the radius of curvature of the surface 322 of the rotor blade 112. That is. the plurality of light sources 320 of some light groups 326 may be activated and the plurality of light sources 320 of the remaining light groups 326 may be deactivated. The light groups 326 may be selected for activation based on the light groups 326 that are positioned between upper and lower bounds 402, 404 (FIG. 8) of anomaly illumination at a given radius of curvature. In some embodiments, the arms 328 supporting the light groups 326 having the deactivated light sources 320 may be moved so as to prevent the arms 328 from casting shadows 338 on the surface 322. In some embodiments, the arms 328 may be manually removed from the base 330 (e.g., via a technician). In other embodiments, the arms 328 may, for example, be pivoted701110-WO-1 / GECW-1288-PCT about the base 330 (e.g., via a remote control, manual operation, the controller 200, etc.).

[0041] Furthermore, in some embodiments, one or more illumination parameters for each of the plurality of light sources 320 may be adjustable. As one example, the fixture 324 may include one or more actuators that can be actuated (e.g., via remote control, the controller 200, etc.) to adjust the illumination parameter(s). As another example, a technician may manually adjust the illumination parameter(s) (e.g., via releasing a locking mechanism, adjusting a light source 320, and re-engaging the locking mechanism). In alternative embodiments, the illumination parameter(s) may be fixed. In such example, the illumination parameter(s) may be determined empirically (e.g.. based on testing and / or simulation to determine illumination parameter(s) that cast detectable shadows 338 of various anomalies on surfaces having various radii of curvature). The illumination parameters may include, but are not limited to, an illumination width, a height of the light source 320, an intensity of the light, a duration of the light, a color of the light, etc.)

[0042] Referring back to FIG. 4. as shown at (304). the method 300 includes receiving, via the controller 200, visual data relating to the rotor blade 112. In an embodiment, the visual data relating to the rotor blade 112 is collected during or after manufacturing of the rotor blade 112 (e.g., before the rotor blade 112 is placed into operation on the wind turbine 100). The visual data includes a presence or an absence of one or more shadows 338 on the surface 322 of the rotor blade 1 12. In such embodiments, the shadows 338 are caused by the presence of one or more anomalies 336 on the surface 322 blocking the light emitted from the plurality of light sources 320.

[0043] Moreover, in embodiments, the method 300 may include actuating one or more cameras 334. The camera(s) 334 may be positioned such that a field-of-view of the respective camera 334 includes at least a portion of the surface 322 of the rotor blade 112. The camera(s) 334 may be actuated to obtain the visual data of the surface 322 while the plurality of light sources 320 are illuminating the surface 322. In some embodiments, the camera(s) 334 may be mounted separate from the fixture 324. In such examples, the fixture 324 may be movable relative to the camera(s) 334. In other embodiments, the camera(s) 334 may be mounted to the fixture 324.701110-WO-1 / GECW-1288-PCT

[0044] In some embodiments, for example, the visual data may include high resolution data, such as one or more 360° videos of the rotor blade 112. one or more 180° videos of the rotor blade 112. one or more 360° images of the rotor blade 112, and / or one or more 180° images of the rotor blade 112, or similar. In particular, FIGS. 7A and 7B illustrate example visual data according to an embodiment of the present disclosure. Furthermore, as shown in FIGS. 7A and 7B, the visual data may depict the presence of one or more shadows 338 (e.g.. caused by respective anomalies 336 on the surface 322 of the rotor blade 112).

[0045] In further embodiments, the method 300 may optionally include processing the visual data relating to the rotor blade 112. For example, in an embodiment, processing the data relating to the rotor blade 112 may include extracting one or more images / pictures (as shown in FIGS. 7A and 7B) from one or more videos collected by the camera(s) 334.

[0046] Referring back to FIG. 4, as shown at (306), the method 300 includes identifying, via the controller 200, one or more anomalies 336 on the surface 322 of the rotor blade 112 based on the visual data, and more particularly, the presence of the one or more shadows 338. In some embodiments, the controller 200 may be configured to detect a presence or absence of one or more shadows 338 in the visual data (e.g., according to known image processing techniques). In such embodiments, the controller 200 may be further configured to identify anomaly(ies) 336 associated with detected shadows 338. For example, the controller 200 may identify an anomaly 336 associated with a shadow sweep (i.e., a change in an angle and length of a shadow 338 cast on a surface in response to relative movement between the surface and a light source) detected across a time series of images or frame of visual data (e.g.. obtained as the fixture 324 moves along the surface 322 of the rotor blade 112).

[0047] Moreover, in some embodiments, the controller 200 can be configured to determine one or more geometric characteristics (e.g., a height, a length, a width, a radius, etc.) of the anomaly(ies) 336. As one example, the controller 200 may be configured to determine a length and / or a width of an anomaly 336 based on the visual data, and more particularly, the presence of the shadow-(s) 338 (e.g., according to known image processing techniques). As another example, the controller 200 may be configured to determine a height of an anomaly 336. In such an example, the701110-WO-1 / GECW-1288-PCT controller 200 may, for example, be configured to analyze the model representation of the rotor blade 112 to identify a location of the anomaly 336 relative to a light source 320, which allows the controller 200 to determine a distance between the anomaly 336 and the light source 320 (e.g., according to known data processing techniques). When the distance is between an upper bound 402 and a lower bound 404, the controller 200 can be configured to determine an amplification factor (AF) (FIG. 8) based on the distance and a radius of curvature of the surface 322. For example, the controller 200 may access a plot 400 (e.g., stored in a memory device 204 thereof), as shown in FIG. 8, representing various amplification factors for given parameters (e.g., an illumination angle, a height, etc.) of the plurality of light sources 320. Thus, in embodiments, the controller 200 can determine the height of the anomaly 336 as a ratio of the shadow length and the amplification factor.

[0048] The amplification factor may be configured to represent a relationship between a height of an anomaly and a length of a shadow 338 cast by the anomaly for given parameters (e.g., an illumination angle, a height, etc.) of the plurality of light sources 320. The amplification factor may be determined empirically (e.g., based on illuminating various surfaces with various anomalies and comparing the length of shadows cast to distances between the various anomalies and a light source). The upper bound 402 may, for example, be a light fall off distance (i.e., a distance between the light source and an anomaly at which a shadow is not created by the anomaly). The lower bound 404 may, for example, be a shortest distance between the anomaly and the light source at which a shadow 338 can be created (e.g., within the lower bound (i.e., within a hot spot) shadows may not be created due to excessive brightness of the emitted light).

[0049] In alternative embodiments, the controller 200 may be configured to identify the anomaly(ies) 336 by using a machine-learned model. In such embodiments, the machine-learned model may receive the visual data as input and be trained to output identification of the anomaly(ies) 336. The machine-learned model may be further trained to accept as input, or otherwise access, the plot 400 and to output the geometric characteristic(s) of the anomaly(ies) 336.

[0050] In some embodiments, the machine-learned model may include a classifier that includes programming to utilize one or more conventional image classification701110-WO-1 / GECW-1288-PCT techniques. For example, the classifier can use a machine learning technique in which data known to represent various shadows cast by various anomalies is provided to a machine learning program for training the classifier. Once trained, the classifier can accept as input visual data and then provide as output, for each of one or more respective regions of interest in the image, an identification of one or more anomalies (e.g., based on detecting a presence of one or more shadows) or that no anomaly is present (e.g., based on detecting an absence of a shadow) in the respective region of interest. Further, a coordinate system (e.g., polar or cartesian) applied to an area proximate to a light source 320 or the fixture 324 can be applied to specify locations and / or areas (e.g., according to a local coordinate system of a light source 320 or the fixture 324) of anomalies identified from visual data.

[0051] In additional or alternative embodiments, the machine learned model described herein may include, for example, a neural network (e.g., deep neural networks) or another type of machine-learned model, including non-linear models and / or linear models. Neural networks can include feed-forward neural networks, recurrent neural networks (e.g., long short-term memory recurrent neural networks), convolutional neural networks, and / or other forms of neural networks. Some example machine-learned models can leverage an attention mechanism such as self-attention. For example, some example machine-learned models can include multi-headed selfattention models (e.g., transformer models). In another embodiment, the machine learning model described herein may include a rule-based approach, wherein actions are chosen based on a pre-determined set of if-then rules or mathematical expressions with pre-defmed parameters.

[0052] Thus, and referring back to FIG. 4. as shown at (308), the method 300 further includes automatically generating, via the controller 200, a quality report of the rotor blade 112 that includes the anomaly(ies) 336. For example, in such embodiments, the qualify report may generally include a location, type, and / or criticality of the identified anomaly(ies) 336. Further, the quality report may include the geometric characteristic(s) of the identified anomaly(ies) 336. Furthermore, in an embodiment, as shown at (310), the method 300 includes implementing, via the controller 200, a corrective action for the rotor blade 112 or a subsequent manufacturing process of another rotor blade based on the quality report. For701110-WO-1 / GECW-1288-PCT example, in an embodiment, implementing the corrective action for the rotor blade or the subsequent manufacturing process of another rotor blade based on the quality report may include storing the quality report in a database, scheduling a repair to correct the identified anomaly(ies) 336, modifying a manufacturing parameter, and / or halting production of subsequent rotor blades until the anomaly(ies) 336 is / are corrected.[00531 Exemplary embodiments of a method and system for improving quality of a wind turbine rotor blade during manufacturing are described herein. The systems and methods of the present disclosure are not limited to the specific embodiments described herein, but rather, components of systems and / or steps of the methods maybe utilized independently and separately from other components and / or steps described herein. For example, the methods may also be used in combination with other electronic systems and are not limited to practice with only the electronic systems, and methods as described herein. Rather, the exemplary embodiment can be implemented and utilized in connection with many other electronic systems.

[0054] Some embodiments involve the use of one or more electronic or computing devices. Such devices typically include a processor, processing device, or controller, such as a general purpose central processing unit (CPU), a graphics processing unit (GPU), a microcontroller, a reduced instruction set computer (RISC) processor, an application specific integrated circuit (ASIC), a programmable logic circuit (PLC), a field programmable gate array (FPGA), a digital signal processing (DSP) device, and / or any other circuit or processing device capable of executing the functions described herein. The methods described herein may be encoded as executable instructions embodied in a computer readable medium, including, without limitation, a storage device and / or a memory device. Such instructions, when executed by a processing device, cause the processing device to perform at least a portion of the methods described herein. The above examples are exemplary only, and thus are not intended to limit in any way the definition and / or meaning of the term processor and processing device. Furthermore, in an embodiment, the processing capability might be located at the wind turbine, at the wind farm, or in the cloud infrastructure.

[0055] Although specific features of various embodiments of the disclosure may-701110-WO-1 / GECW-1288-PCT be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the disclosure, any feature of a drawing may be referenced and / or claimed in combination with any feature of any other drawing.

[0056] Further aspects of the disclosure are provided by the subject matter of the following clauses:

[0057] A method for improving quality of a rotor blade of a wind turbine, the method comprising: activating a plurality of light sources configured to illuminate a surface of the rotor blade; receiving, via a controller, visual data relating to the rotor blade during or after manufacturing of the rotor blade, the visual data comprising a presence or an absence of a tonal variation on the surface of the rotor blade; identifying, via the controller, an anomaly on the surface of the rotor blade based on the presence of the tonal variation; automatically generating, via the controller, a quality report of the rotor blade comprising the identified anomaly; and implementing, via the controller, a corrective action for the rotor blade or a subsequent manufacturing process of another rotor blade based on the quality report.

[0058] The method of any preceding clause, wherein identifying, via the controller, the anomaly on the surface of the rotor blade based on the presence of the tonal variation further comprises using a machine-learned model.

[0059] The method of any preceding clause, wherein the tonal variation is one of a shadow or a highlight.

[0060] The method of any preceding clause, wherein the plurality of light sources are arranged so as to illuminate the surface of the rotor blade via oblique lighting.

[0061] The method of any preceding clause, w herein activating, via the controller, the plurality of light sources further comprises: continuously illuminating the plurality of light sources; and moving a fixture along the surface of the rotor blade, the fixture comprising the plurality of light sources.

[0062] The method of any preceding clause, w herein illuminating, via the controller, the plurality of light sources further comprises intermittently illuminating the plurality of light sources.

[0063] The method of any preceding clause, further comprising actuating, via the controller, one or more cameras to obtain the visual data while illuminating the plurality' of light sources.701110-WO-1 / GECW-1288-PCT

[0064] The method of any preceding clause, further comprising, determining, via the controller, a height of the anomaly based on an amplification factor configured to represent a relationship between the height the anomaly and a distance from the anomaly to at least one of the plurality of light sources.

[0065] The method of any preceding clause, wherein at least some of the plurality of light sources emit a first color of light and at least some of the plurality of light sources emit a second color of light, the second color being different from the first color.

[0066] The method of any preceding clause, wherein implementing, via the controller, the corrective action for the rotor blade or the subsequent manufacturing process of another rotor blade based on the quality report further comprises storing the quality report in a database, scheduling a repair to correct the anomaly, modifying a manufacturing parameter, or halting production of subsequent rotor blades until the anomaly is corrected.

[0067] A system for improving quality of a rotor blade of a wind turbine, the system comprising: a controller comprising at least one processor configured to perform a plurality of operations, the plurality of operations comprising: receiving visual data relating to the rotor blade during or after manufacturing of the rotor blade, the visual data comprising a presence or an absence of a tonal variation on a surface of the rotor blade; identifying an anomaly on the surface of the rotor blade based on the presence of the tonal variation; automatically generating a qualify report of the rotor blade comprising the identified anomaly; and implementing a corrective action for the rotor blade or a subsequent manufacturing process of another rotor blade based on the quality report.

[0068] The system of any preceding clause, wherein identifying, via the controller, the anomaly on the surface of the rotor blade based on the presence of the tonal variation further comprises using a vision machine-learned model.

[0069] The system of any preceding clause, wherein the visual data is obtained by one or more cameras while a plurality of light sources illuminate the surface of the rotor blade.

[0070] The system of any preceding clause, wherein the plurality of light sources are arranged so as to illuminate the surface of the rotor blade via oblique lighting.701110-WO-1 / GECW-1288-PCT

[0071] The system of any preceding clause, wherein the plurality of operations further comprise activating the plurality of light sources to illuminate the surface of the rotor blade.

[0072] The system of any preceding clause, wherein illuminating the plurality of light sources further comprises: continuously illuminating the plurality of light sources; and moving a fixture along the surface of the rotor blade, the fixture comprising the plurality of light sources.

[0073] The system of any preceding clause, wherein illuminating the plurality of light sources further comprises intermittently illuminating the plurality of light sources.

[0074] The system of any preceding clause, wherein the plurality of operations further comprises determining, via the controller, a height of the anomaly based on an amplification factor configured to represent a relationship between the height the anomaly and a distance from the anomaly to at least one of the plurality of light sources.

[0075] The system of any preceding clause, wherein at least some of the plurality of light sources emit a first color of light and at least some of the plurality of light sources emit a second color of light, the second color being different from the first color.

[0076] The system of any preceding clause, wherein implementing the corrective action for the rotor blade or the subsequent manufacturing process of another rotor blade based on the quality report further comprises storing the quality report in a database, scheduling a repair to correct the anomaly , modifying a manufacturing parameter, or halting production of subsequent rotor blades until the anomaly is corrected.

[0077] This written description uses examples to disclose the disclosure, including the best mode, and to enable any person skilled in the art to practice the disclosure, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent701110-WO-1 / GECW-1288-PCT structural elements with insubstantial differences from the literal languages of the claims.

Claims

701110-WO-1 / GECW-1288-PCTWHAT IS CLAIMED IS:

1. A method for improving quality of a rotor blade of a wind turbine, the method comprising: activating a plurality of light sources configured to illuminate a surface of the rotor blade; receiving, via a controller, visual data relating to the rotor blade during or after manufacturing of the rotor blade, the visual data comprising a presence or an absence of a tonal variation on the surface of the rotor blade: identifying, via the controller, an anomaly on the surface of the rotor blade based on the presence of the tonal variation; automatically generating, via the controller, a quality report of the rotor blade comprising the identified anomaly; and implementing, via the controller, a corrective action for the rotor blade or a subsequent manufacturing process of another rotor blade based on the quality report.

2. The method of claim 1. wherein identifying, via the controller, the anomaly on the surface of the rotor blade based on the presence of the tonal variation further comprises using a machine-learned model.

3. The method of claim 1. wherein the tonal variation is one of a shadow or a highlight.

4. The method of claim 1, wherein the plurality of light sources are arranged so as to illuminate the surface of the rotor blade via oblique lighting.

5. The method of claim 1, wherein activating, via the controller, the plurality of light sources further comprises: continuously illuminating the plurality of light sources; and moving a fixture along the surface of the rotor blade, the fixture comprising the plurality of light sources.

6. The method of claim 1 , wherein illuminating, via the controller, the701110-WO-1 / GECW-1288-PCT plurality7of light sources further comprises intermittently illuminating the plurality of light sources.

7. The method of claim 1, further comprising actuating, via the controller, one or more cameras to obtain the visual data while illuminating the plurality7of light sources.

8. The method of claim 1, further comprising, determining, via the controller, a height of the anomaly based on an amplification factor configured to represent a relationship between the height the anomaly and a distance from the anomaly to at least one of the plurality of light sources.

9. The method of claim 1, wherein at least some of the plurality of light sources emit a first color of light and at least some of the plurality of light sources emit a second color of light, the second color being different from the first color.

10. The method of claim 1, wherein implementing, via the controller, the corrective action for the rotor blade or the subsequent manufacturing process of another rotor blade based on the quality report further comprises storing the quality report in a database, scheduling a repair to correct the anomaly, modifying a manufacturing parameter, or halting production of subsequent rotor blades until the anomaly is corrected.

11. A system for improving quality of a rotor blade of a wind turbine, the system compnsing: a controller comprising at least one processor configured to perform a plurality of operations, the plurality7of operations comprising: receiving visual data relating to the rotor blade during or after manufacturing of the rotor blade, the visual data comprising a presence or an absence of a tonal variation on a surface of the rotor blade; identifying an anomaly on the surface of the rotor blade based on the presence of the tonal variation;701110-WO-1 / GECW-1288-PCT automatically generating a quality report of the rotor blade comprising the identified anomaly; and implementing a corrective action for the rotor blade or a subsequent manufacturing process of another rotor blade based on the quality report.

12. The system of claim 11, wherein identifying, via the controller, the anomaly on the surface of the rotor blade based on the presence of the tonal variation further comprises using a vision machine-learned model.

13. The system of claim 11, wherein the visual data is obtained by one or more cameras while a plurality of light sources illuminate the surface of the rotor blade.

14. The system of claim 13, wherein the plurality of light sources are arranged so as to illuminate the surface of the rotor blade via oblique lighting.

15. The system of claim 13, wherein the plurality of operations further comprise activating the plurality of light sources to illuminate the surface of the rotor blade.

16. The system of claim 15, wherein illuminating the plurality of light sources further comprises: continuously illuminating the plurality of light sources; and moving a fixture along the surface of the rotor blade, the fixture comprising the plurality of light sources.

17. The system of claim 15, wherein illuminating the plurality of light sources further comprises intermittently illuminating the plurality of light sources.

18. The system of claim 11, wherein the plurality of operations further comprises determining, via the controller, a height of the anomaly based on an amplification factor configured to represent a relationship between the height the701110-WO-1 / GECW-1288-PCT anomaly and a distance from the anomaly to at least one of the plurality of light sources.

19. The system of claim 11, wherein at least some of the plurality of light sources emit a first color of light and at least some of the plurality' of light sources emit a second color of light, the second color being different from the first color.

20. The system of claim 11, wherein implementing the corrective action for the rotor blade or the subsequent manufacturing process of another rotor blade based on the quality' report further comprises storing the quality report in a database, scheduling a repair to correct the anomaly, modifying a manufacturing parameter, or halting production of subsequent rotor blades until the anomaly is corrected.

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