Dual Scan Method for Detecting Fibre Misalignment in Wind Turbine Blades
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Solution Overview
Problem
Current methods for detecting fibre misalignment in elongated structures, such as wind turbine blades, are inadequate as they are either time-consuming, costly, or unable to detect hidden misalignments without damaging the structure.
Innovation Solution
A method involving initial surface scanning using 3D optical measurement to identify regions of interest, followed by a targeted X-ray scan to detect and quantify fibre misalignments without destroying the structure, allowing for efficient and cost-effective identification and repair of misalignments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If visual inspection with flashlight is used to detect fibre misalignment, then surface misalignments can be detected, but hidden fibre misalignments deeper in the structure cannot be detected
Solution Approach 1:
The patent introduces light as an intermediary substance to penetrate the translucent blade structure and reveal hidden fibre misalignments. By shining light through the blade and observing scattering patterns from the opposite side, inspectors can detect subsurface defects without visual contact, solving the limitation of surface-only detection while maintaining non-destructive inspection.
2Measurement precision
If ultrasonic testing methods are used to detect fibre misalignment, then internal defects can be detected, but additional material must be added which contaminates surfaces
Solution Approach 1:
The patent replaces the mechanical contact-based ultrasonic testing method with an optical inspection method. Instead of using ultrasonic waves requiring couplant material, the system uses light transmission and scattering observation to detect fibre misalignments, eliminating surface contamination while maintaining internal defect detection capability.
3Measurement precision
If X-ray scanning is applied to entire wind turbine blade structure, then hidden fibre misalignments can be detected, but the process becomes time-consuming and expensive
Solution Approach 1:
The patent applies local quality by using optical inspection targeted at specific regions suspected of containing fibre misalignments, rather than scanning the entire blade with X-ray. By concentrating the optical inspection on localized areas where misalignments are likely to occur, the method achieves hidden defect detection with significantly reduced time and cost compared to comprehensive X-ray scanning.
4Ease of manufacture
If visual inspection is used to quantify fibre misalignment, then simple tools can be used, but small surface undulations are missed and quantification is insufficient
Solution Approach 1:
The patent creates an optical copy or projection of the internal fibre structure by observing light scattering patterns from the opposite side of the blade. This optical copying allows small surface undulations and hidden misalignments to be visualized and quantified with greater precision while maintaining the simplicity of visual inspection, as the scattered light patterns directly reveal the extent and location of fibre misalignments.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces repair time and costs by enabling non-destructive detection and location of fibre misalignments, improving the reliability and safety of elongated structures like wind turbine blades by identifying and addressing hidden defects.
Implementation Method 1
scanning a surface of the elongated structure for identifying one or more surface irregularities
Implementation Method 2
surface scanning step a) comprises optically scanning the surface for creating a three-dimensional (3D) image of the surface
Implementation Method 3
examining said region of interest by scanning the elongated structure by emitting an x-ray beam in an angle compared to the orientation of the fibres, detecting scattered rays
Implementation Method 4
emitting an x-ray beam in an angle compared to the orientation of the fibres
Data Source
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AI summary
The present disclosure relates to a method for detecting a fibre misalignment in an elongated structure, such as a wind turbine blade component. The elongated structure has a length along a longitudinal direction and comprises a plurality of stacked reinforcing fibre layers. The plurality of fibre layers comprises fibres having an orientation aligned, unidirectionally, substantially in the longitudinal direction. The method comprises scanning a surface of the elongated structure for identifying one or more surface irregularities, selecting one or more regions of interest comprising said one or more surface irregularities, examining said region of interest using penetrating radiation, and determining a position and/or size of the fibre misalignment based on said examining step.