Wind Turbine Blade Layup Inspection With Optical Defect Projection
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Solution Overview
Problem
Existing methods for inspecting the layup of composite structures, such as wind turbine blades, are labor-intensive, lack repeatability, and require skilled personnel, leading to potential defects that affect structural integrity and increase post-manufacturing work.
Innovation Solution
A system comprising a mould, a moveable support structure with a measuring device, and a processor that analyzes topography data to identify defects, coupled with a lighting system to visually indicate defect locations, allowing for quick and easy defect detection during the layup process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual inspection is used to check the quality of layup, then workers can identify defects, but the process becomes labor-intensive and time-consuming
Solution Approach 1:
The patent replaces manual visual inspection with an automated optical measurement system that uses cameras and image processing algorithms to detect defects in the composite structure during manufacturing. This substitution eliminates the need for manual labor while maintaining high detection reliability and significantly increasing inspection speed.
Solution Approach 2:
The system enables self-inspection by equipping the manufacturing line with automated measurement devices that continuously monitor the layup process. The system automatically captures images, processes them through algorithms, and identifies defects without requiring external manual inspection, making the process self-sufficient and highly efficient.
2Reliability
If visual inspection by workers is used, then defects can be detected, but repeatability and accuracy are compromised due to dependency on worker skills
Solution Approach 1:
The patent replaces human visual inspection with an automated optical measurement system that uses standardized imaging and image processing algorithms. This eliminates variability in worker skills and provides consistent, repeatable measurements with high precision, as the system applies the same detection criteria uniformly across all inspections.
Solution Approach 2:
The system transforms the inspection process from subjective visual assessment to objective quantitative measurement by capturing images and analyzing specific parameters such as surface topology, layer thickness, and defect characteristics. This parameter-based approach ensures high measurement precision and repeatability independent of operator expertise.
3Reliability
If manual inspection processes are used, then quality checking can be performed, but additional repair work is required after manufacturing due to missed defects
Solution Approach 1:
The patent implements inspection during the manufacturing process itself, performing defect detection in advance before the curing and completion stages. This preliminary action allows defects to be identified and addressed while the structure is still accessible and modifiable, preventing the need for time-consuming post-manufacturing repairs and ensuring structural integrity.
Solution Approach 2:
The system provides real-time feedback during manufacturing by continuously monitoring the layup process and immediately identifying defects. This feedback loop allows for immediate corrective actions to be taken during production, preventing defective structures from proceeding to later stages and eliminating the need for subsequent repair work.
4Productivity
If automated measurement systems are implemented, then inspection speed and accuracy improve, but device complexity increases
Solution Approach 1:
The patent employs a multi-functional optical measurement system that integrates image capture, processing, and defect identification capabilities into a single unified platform. The system performs multiple inspection functions simultaneously, reducing the need for separate dedicated devices and thereby managing complexity while maintaining high productivity and accuracy.
Solution Approach 2:
The system uses optical copying techniques to create digital representations of the physical structure through imaging. These digital copies are then analyzed using software algorithms, replacing the need for complex physical measurement instruments and simplifying the overall system while enabling high-speed automated inspection.
Data Source
AI summary
The invention relates to a system and method for manufacture of a composite structure (17) of a wind turbine blade (5). Layers of a fibrous material (33) are arranged in a mould (16) and the top surface of the upper layer is scanned using a measuring device (25). The data inputted from the measuring device (25) is analysed in a processor (26) to identify the locations of defects (27) and detailed information thereof. The location data is then transmitted to a lighting system (28), where the locations of the defects (27) are visually indicated on or relative to the upper layer of the composite structure (17) using lighting devices (29). The present inspection method can be performed during dry layup of the respective layers, thereby allows defects (27) to be corrected before infusion of the resin matrix material.