Laser-Guided Vortex Generator Tape Application on Wind Turbine Blades
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Solution Overview
Problem
The manual and time-consuming process of mounting vortex generators on wind turbine blades is inefficient and relies heavily on user skills, lacking accuracy and speed.
Innovation Solution
An apparatus and method utilizing a movable portal with a tape application tool and laser distance measuring device to automate the application of vortex generator tapes, ensuring precise positioning and faster installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual mounting process is used for vortex generators, then flexibility and adaptability are maintained, but productivity is low and manufacturing precision is poor
Solution Approach 1:
The mounting apparatus is divided into functional modules: a portal structure for support, a tape application tool for precise tape placement, and a distance detecting device for measurement. Each module performs a specific function, allowing the system to achieve high productivity while maintaining manageable complexity through modular design.
Solution Approach 2:
A tape with pre-marked positions serves as an intermediary carrier that bridges the gap between the mounting apparatus and the vortex generators. The tape is first applied to the blade surface with precise positioning, then vortex generators are mounted according to the tape markings, decoupling the positioning complexity from the mounting process.
2Manufacturing precision
If manual mounting process is used for vortex generators, then device complexity is low, but manufacturing precision and measurement accuracy are insufficient
Solution Approach 1:
The distance detecting device uses laser-based optical measurement instead of manual mechanical measurement methods. This substitution provides high measurement accuracy and objective data for positioning, replacing subjective human judgment and manual tape measuring with automated optical detection.
Solution Approach 2:
The distance detecting device provides real-time feedback on the position of the tape application tool relative to the blade surface. This feedback enables automatic adjustment of the application position, ensuring consistent high precision mounting without requiring complex manual measurement and calculation procedures.
3Loss of time
If manual mounting process is used for vortex generators, then ease of operation is maintained, but loss of time is high
Solution Approach 1:
The tape is prepared with pre-marked positions for vortex generators before application to the blade. This preliminary preparation of positioning information on the tape eliminates the need for time-consuming on-site measurements and calculations during the mounting process, significantly reducing total mounting time while keeping operations straightforward.
4Power
If larger blade sizes are used, then power output is improved, but the number of vortex generators increases leading to higher loss of time
Solution Approach 1:
The tape application tool continuously applies the positioning tape along the blade span in one continuous motion, rather than stopping and positioning individually at each vortex generator location. This continuous operation maintains high productivity even as blade size and the number of vortex generators increase, preventing mounting time from becoming prohibitive.
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
Facilitates faster, more accurate, and reliable mounting of vortex generators, reducing the need for quality checks and minimizing manual labor, especially with larger blade sizes.
Implementation Method 1
a distance detecting device, preferably a laser distance measuring device, which is configured to detect an actual distance between the tape application tool and the floor
Data Source
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AI summary
It is described an apparatus (10) for applying a tape (11) to a blade (6) of a wind turbine (1), wherein the tape (6) comprising a plurality of vortex generators (VG) or indicating locations for attaching a plurality of vortex generators (VG) on the blade (6). The apparatus (10) is configured to be movable on a floor (12) in a moving path in accordance with a longitudinal direction of the blade (6) and comprises a portal (13) having a tape application tool (14) configured to apply the tape (11) to the blade (6), the tape application tool (14) being movable along the portal (13) in a vertical direction; and a distance detecting device (15), preferably a laser distance measuring device, being configured to detect an actual distance between the tape application tool (14) and the floor (12), preferably being configured to detect reference markings (16) arranged at the floor (12) or at a blade carrying equipment such as a root- and tip turning device along the moving path of the apparatus (10) .