Rotor Blade Marking Device for Sensor Placement
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Solution Overview
Problem
Existing methods for installing sensors in wind turbine rotor blades, such as strain gauges for individual pitch control systems, face challenges due to variations in rotor blade design and geometry, leading to inconsistent sensor placement and unfavorable load distribution, especially since current methods restrict marking locations far from the blade flange.
Innovation Solution
A method involving marking the intersection of the rotor blade's longitudinal axis with the base plate and aligning a projection device relative to this axis allows for precise and repeatable marking of the rotor blade's inner surface, enabling sensors to be attached closer to the blade connection, independent of base plate design and without requiring a central opening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a line laser with a base plate is used to mark sensor positions, then marking can be performed, but the opening angle of light fans is restricted and only locations far from the blade flange can be marked
Solution Approach 1:
A reflective element (mirror or prism) is introduced as an intermediary between the line laser and the rotor blade inner surface. This intermediary redirects the light path, allowing the projection device to mark positions close to the blade flange that would otherwise be inaccessible due to the restricted opening angle of the light fans.
Solution Approach 2:
The marking system transitions from direct linear projection to multi-dimensional light path manipulation using reflective elements. By introducing angular redirection through mirrors or prisms, the system accesses previously unreachable spatial dimensions near the blade flange while maintaining marking precision.
2Reliability
If sensors are placed far from the blade flange to ensure consistent marking, then marking is feasible, but optimal sensor positions for IPC systems cannot be achieved
Solution Approach 1:
The reflective element serves as a mediator that decouples the marking consistency requirement from the distance constraint. By redirecting light paths, it enables consistent and repeatable marking at optimal sensor positions near the blade flange, rather than forcing sensors to distant locations for marking feasibility.
3Ease of manufacture
If the projection device is mounted on the base plate, then marking can be performed, but the base plate design with central opening is required
Solution Approach 1:
The reflective element is extracted from the base plate structure and mounted separately on the rotor blade inner surface. This extraction eliminates the requirement for a central opening in the base plate, simplifying the base plate design while maintaining the functionality of the projection system.
Solution Approach 2:
The marking system is segmented into separate functional components: the base plate for mounting, the projection device for light generation, and the reflective element for light redirection. This segmentation allows the base plate to be simple without a central opening while the reflective element handles the complex light path redirection function.
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 ensures consistent and repeatable sensor placement across rotor blades, improving the accuracy of pitch behavior and load distribution by allowing sensors to be mounted closer to the blade connection, enhancing the reliability of individual pitch control systems.
Implementation Method 1
projecting a marking on the rotor blade inner surface with the projection device
Data Source
Figure 1
Figure 2a~2b
Figure 3
AI summary
A method for projecting a mark within a rotor blade of a wind turbine, wherein the rotor blade has a longitudinal axis, an inner surface, a blade connection for joining with a rotor hub, and a base plate arranged substantially perpendicular to the longitudinal axis, and comprising the following steps: marking an intersection of the longitudinal axis of the rotor blade with the base plate, mounting a projection device on the base plate and aligning the projection device relative to the longitudinal axis of the rotor blade, and projecting a mark onto the inner surface of the rotor blade using the projection device.