Turbine Blade Geometry Reconstruction from Point Cloud Profiles
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Solution Overview
Problem
The specific geometrical structure of wind turbine blades is proprietary and unknown, hindering their reuse in structural and infrastructural applications due to the lack of publicly available geometry and material information.
Innovation Solution
A method and system for predicting the external geometry of turbine blades using a point cloud, generating a mesh, defining a reference axis, and matching sampling planes to a database of known airfoil profiles to create a geometrical representation, adjusting parameters to minimize a fitness score for accurate matching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the geometry and material structure of turbine blades are kept proprietary, then the original manufacturers protect their intellectual property and design advantages, but the ability to recycle and reuse the composite materials is severely hindered
Solution Approach 1:
The patent creates a digital replica or model of the turbine blade geometry through scanning and reverse engineering techniques. This digital copy contains all the geometric information needed for recycling and reuse applications without revealing or compromising the proprietary status of the original designs. The copied geometry enables manufacturing of replacement parts and structural applications while the physical blade remains protected.
2Ease of manufacture
If the turbine blade geometry is made publicly available for recycling purposes, then the ability to reuse composite materials in infrastructure applications improves, but the manufacturers lose control over their proprietary design information
Solution Approach 1:
The patent segments the information about turbine blades into different levels: the external geometry is made available for recycling purposes, while the internal material composition, manufacturing processes, and core design parameters remain proprietary. This segmentation allows different stakeholders to access appropriate levels of information - recyclers get geometry data while manufacturers retain control over critical design information.
3Loss of substance
If traditional recycling methods like shredding are used, then the composite materials can be partially reused as fuel or fillers, but the mechanical properties and structural integrity are dramatically reduced
Solution Approach 1:
The patent performs preliminary characterization and mapping of the turbine blade geometry and material structure before recycling occurs. By creating detailed digital models and understanding the internal architecture in advance, the recycling process can be optimized to preserve structural integrity. This preliminary analysis enables selective disassembly and targeted material recovery that maintains mechanical properties for high-value applications.
Data Source
AI summary
A system including a processor and a memory having instructions that, when executed by the processor, cause the system to obtain a point cloud of a turbine blade, the point cloud comprising data points corresponding to locations on an external contour of the turbine blade, generate an external mesh for the turbine blade based on the point cloud, define a reference axis along a length of the turbine blade, generate sampling planes along a length of the reference axis, each sampling plane being normal to the reference axis and having a shape defined by those portions of the external mesh intersecting the sampling plane, match each sampling plane to an airfoil profile in a database of known airfoil profiles, and create a geometrical representation of the turbine blade by placing the airfoil profiles on the reference axis and connecting the perimeter of each of the airfoil profiles.