Wind Turbine Blade Sheet Overlap Marking for Precise Layup
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manual arrangement and measurement of sheet overlaps in the manufacturing of wind turbine blade components, such as blade shells and shear webs, is time-consuming and inefficient, leading to increased material usage and costs due to excessive overlap, which can restrict resin flow and increase component mass.
Innovation Solution
A method involving the use of an overlap tolerance indicator on the first sheet, comprising markers for minimum and maximum intended overlap distances, providing a visual indication of the overlap accuracy when the second sheet is correctly positioned, facilitating fast and accurate verification of the overlap within a predetermined tolerance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sheets are arranged with greater overlap to ensure continuous load path and proper resin flow, then structural integrity and manufacturing reliability are improved, but component mass and material cost increase
Solution Approach 1:
The patent replaces manual measurement and verification methods with an automated optical scanning system. The system uses a scanner to capture images of overlap tolerance indicators on sheet edges, automatically processes these images to measure overlap dimensions, and verifies compliance with tolerance specifications. This substitution of mechanical/manual measurement with automated optical detection eliminates human error and significantly improves measurement precision and productivity.
2Manufacturing precision
If manual measurement and verification of sheet overlap is performed, then overlap precision can be verified, but manufacturing time and labor cost increase
Solution Approach 1:
The patent replaces manual measurement and verification methods with an automated optical scanning system. The system uses a scanner to capture images of overlap tolerance indicators on sheet edges, automatically processes these images to measure overlap dimensions, and verifies compliance with tolerance specifications. This substitution of mechanical/manual measurement with automated optical detection eliminates human error and significantly improves measurement precision and productivity.
Solution Approach 2:
The patent creates visual copies of the overlap tolerance indicators through optical scanning and image capture. The scanner generates digital images of the indicators on sheet edges, which are then processed to determine overlap dimensions. This copying approach allows for rapid, non-contact measurement and automated verification without physically touching or disturbing the sheets.
3Strength
If excessive overlap between sheets occurs, then continuous load path is ensured, but resin flow is restricted and material waste increases
Solution Approach 1:
The patent implements an automated feedback system that scans overlap tolerance indicators on sheet edges, automatically measures overlap dimensions, and provides immediate verification of compliance with tolerance specifications. This real-time feedback mechanism ensures that overlap remains within the optimal range, preventing both excessive overlap (which would restrict resin flow and waste material) and insufficient overlap (which would compromise structural integrity).
Data Source
Figure 1
Figure 2
Figure 3a~3b
AI summary
In a first aspect of the present invention there is provided a method of making a wind turbine blade component. The method comprises providing a first sheet comprising a first edge region defining a first edge. The first sheet further comprises an overlap tolerance indicator provided in the first edge region for locating a second sheet relative to the first sheet. The overlap tolerance indicator comprises a first marker located at a maximum intended overlap distance from the first edge and a second marker located at a minimum intended overlap distance from the first edge. The method further comprises providing a second sheet comprising a second edge region defining a second edge. The method further comprises arranging the second sheet with the first sheet such that the second edge region of the second sheet overlaps the first edge region of the first sheet and the second edge of the second sheet is located between the first and second markers of the overlap tolerance indicator such that the overlap tolerance indicator is partially covered by the second sheet. The overlap tolerance indicator provides a visual indication that the extent of overlap of the sheets is within a predetermined tolerance when the overlap tolerance indicator is only partially covered by the second sheet.