Movable Laser Projector Calibration for Rotor Blade Layup
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Solution Overview
Problem
The high cost and labor-intensive calibration requirements of existing laser projector assemblies for wind turbine rotor blades, due to their fixed nature and the need for multiple assemblies per mold series, are exacerbated by mold shrinkage during use, leading to inefficiencies and increased manufacturing costs.
Innovation Solution
A movable laser projector assembly with a machine learning algorithm that autonomously calibrates to each mold using target markers and imaging, allowing for quick and accurate projection of layup guides without manual intervention, and adapts to mold shrinkage by adjusting the layup plan.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a fixed laser projector assembly is used for each mold, then the projected outlines correspond exactly to the positions of composite material pieces, but the cost of manufacture increases significantly due to requiring multiple dedicated projector assemblies
Solution Approach 1:
The laser projector assembly is designed to be movable and reusable across multiple molds rather than being fixed to a single mold. The system can be positioned over different molds and calibrated for each one, allowing a single projector assembly to serve multiple molding operations and reducing the total number of projectors needed in the facility.
Solution Approach 2:
The laser projector assembly is made movable rather than fixed, allowing it to be repositioned between molds. This dynamic capability enables the same hardware to adapt to different mold positions and configurations, eliminating the need for multiple static projector installations while maintaining projection accuracy through recalibration.
2Measurement precision
If manual calibration is performed before each layup procedure, then the laser projectors can be adjusted for mold shrinkage, but the calibration process becomes time-consuming and labor-intensive
Solution Approach 1:
The system performs automatic calibration using machine vision technology. The laser projector projects calibration patterns onto the mold, cameras capture the distorted patterns, and image processing algorithms automatically calculate the distortion field and compensate for mold shrinkage. This eliminates the need for manual measurement and adjustment by technicians.
Solution Approach 2:
Manual calibration procedures are replaced with an automated optical system. Instead of technicians physically measuring and adjusting the projectors, the system uses cameras to capture images of calibration patterns, processes the images computationally to determine distortion, and automatically adjusts the projection accordingly.
3Area of stationary object
If multiple laser projector assemblies are deployed for different mold sections, then complete coverage is achieved, but the device complexity and cost increase
Solution Approach 1:
Instead of having multiple fixed projectors installed at different locations, a single movable projector assembly is used that can be repositioned to cover different mold sections. This reduces the overall system complexity while maintaining complete coverage capability through sequential positioning rather than simultaneous multi-projector operation.
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
Reduces calibration time and labor costs, enables efficient use of projector units, and ensures precise layup guides across varying mold sizes, thereby minimizing manufacturing costs and errors.
Implementation Method 1
a laser projector configured to project layup guides into the selected mould during a manual layup procedure
Implementation Method 2
an imaging arrangement with a number of cameras arranged to capture images of the selected mould
Data Source
AI summary
The invention describes a laser projector assembly (1) for use in a wind turbine rotor blade manufacturing facility (3), comprising a number of laser projector units (10), wherein each laser projector unit (10) comprises a positioning means (13) for positioning the laser projector unit (10) above a selected rotor blade mould (2), and a laser projector (12) configured to project layup guides (12G) into that mould (2) during a manual layup procedure; an imaging arrangement (11) adapted to capture images (110) of that mould (2); a machine learning algorithm (18) trained to determine coordinates of a feature (2M, 12P) in an image (110); and a calibration module (16) configured to calibrate a laser projector (12) to that mould (2) prior to the manual layup procedure on the basis of an output (180) of the machine learning algorithm (18). The invention further describes a method of manufacturing a wind turbine rotor blade (4) using such a laser projector assembly (1), a machine-learning algorithm (18) for use in such a laser projector assembly (1), and a method of training such a machine-learning algorithm.