In-Mold Optical Markers for Wind Turbine Blade Calibration
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Solution Overview
Problem
The challenge in manufacturing large-scale composite structures, such as wind turbine blades, lies in accurately positioning shear webs and spar caps during mold closure due to potential movement and misalignment, which can lead to sub-optimal bonding and compromised blade integrity, especially as blades increase in size and require stricter manufacturing tolerances.
Innovation Solution
The implementation of optical reference markers, including reflective markers magnetically attached to the mold via anchors, allows for precise calibration of digital coordinates with physical coordinates using overhead optical projection systems, ensuring accurate assembly of components without altering the mold structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If optical reference markers are installed inside the mold to calibrate optical systems, then measurement precision and manufacturing precision are improved, but the mold structure becomes more complex and requires additional components
Solution Approach 1:
The calibration system is segmented into separate components: magnetic anchors embedded in the mold and removable optical markers that attach to the anchors. This allows the mold structure to remain relatively simple while still enabling precise optical calibration when needed.
Solution Approach 2:
Magnetic anchors serve as intermediaries between the mold structure and the optical markers. The anchors are embedded in the mold and provide a mounting interface for the removable markers, enabling calibration without permanently modifying the mold structure.
2Measurement precision
If reflective optical markers are used for calibration, then calibration accuracy is improved, but there is a risk of resin ingress into marker apertures during composite manufacturing
Solution Approach 1:
The magnetic anchors are pre-installed in the mold during mold fabrication, creating sealed mounting points before the composite manufacturing process begins. This preliminary preparation prevents resin ingress during the actual manufacturing when the markers are attached and removed.
Solution Approach 2:
The optical markers are removable and can be reused across multiple manufacturing cycles. Instead of permanently installing markers that could be compromised by resin ingress, the system uses detachable markers that are removed after calibration, allowing the same physical reference points to be used repeatedly without contamination risk.
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 method enables high-precision placement of internal components during wind turbine blade assembly, maintaining structural integrity by verifying spatial positioning and avoiding resin ingress into marker apertures, thus meeting strict manufacturing specifications.
Implementation Method 1
providing at least one magnetic anchor, the at least one magnetic anchor disposed within the mold; providing at least one optical marker, the optical marker magnetically coupled to the at least one magnetic anchor
Implementation Method 2
providing an optical projector, the optical projector projecting at least one optical beam directed towards at least one optical marker; receiving at least one reflective beam from the at least one optical projector to identify the location of the optical marker disposed on the mold
Data Source
AI summary
A method for fabrication of a composite structure including providing a mold configured for forming a composite structure, providing at least one anchor member, the at least one anchor member disposed within the mold, providing at least one optical marker, the optical marker releasably coupled to the at least one anchor member, providing an optical projector, the optical projector projecting at least one optical beam directed towards at least one optical marker, receiving at least one reflective beam from the at least one optical projector to identify the location of the optical marker disposed on the mold, calibrating the optical projector by comparing a predetermined virtual optical marker location to the identified optical marker location.