Patent Application
20250091167
The following relates to a gantry system for manufacturing a wind turbine blade and a method for manufacturing a wind turbine blade.
Producing more power using a wind turbine under given wind conditions can be achieved by increasing the size of the blades. However, the manufacture of wind turbine blades is becoming increasingly difficult for increasing blade sizes.
Manufacturing a wind turbine blade usually includes several manufacturing steps carried out in a horizontal orientation of the blade, for example in a manufacturing hall. These manufacturing steps include, for example, producing a blade shell (e.g., from fiber-reinforced laminate) and processing the outer surface of the blade shell (e.g., by cleaning, polishing, coating, painting). However, current blade diameters at the root end of a blade can be as large as 4.5 meters. It is expected that this number will keep increasing in the next years reaching blade diameters at the root end of 6 meters or more.
Manufacturing such large blades requires performing work over the entire cross-section of the blade and along the entire length of the blade in the horizontal direction. Hence, it is necessary to perform work with high accuracy in large heights and over a very large length. Further, workers may be exposed during work to hazardous substances such as paint. They may also be required to wear protective suits and masks over a long period of time or work in non-ergonomic positions.
An aspect relates to an improved tool for manufacturing a wind turbine blade and an improved method for manufacturing the wind turbine blade.
Accordingly, a gantry system for manufacturing a wind turbine blade is provided. The gantry system comprises
As blade diameters of wind turbines keep increasing, frameworks and vehicles for manufacturing wind turbine blades in the horizontal orientation of the blade are required to have a large height. For a large height of a vehicle also a large footprint of the vehicle is required for stability reasons.
Having the gantry system bridging the wind turbine blade in a cross-section direction of the blade during manufacture provides a stable vehicle with a large footprint for manufacturing a blade. This is the case even for large blade diameters which require large vehicle heights. Further, the large footprint can be provided by the gantry system even in the case that a space on one or both sides of the wind turbine blade in the horizontal orientation during manufacture is limited. For example, the proposed gantry system can be used even in a manufacturing hall being small relative to the blade size.
Having the gantry system on wheels allows a locomotion of the gantry system by driving on its wheels. In particular, the gantry system is performing a rolling movement on the wheels. Having the gantry system on wheels allows a high flexibility in maneuvering the gantry system alongside the blade. This is in particular advantageous as the blade is usually curved and tapered from a root portion to a tip portion thereof.
Having the one or more robotic units allows an automatization of manufacturing steps and, thus, an easier, faster, safer and more efficient manufacturing of the blade.
The wind turbine blade is provided to become part of a rotor of a wind turbine. The wind turbine is an apparatus to convert the wind's kinetic energy into electrical energy. The wind turbine comprises, for example, the rotor having one or more of the blades connected each to a hub, a nacelle including a generator, and a tower holding, at its top end, the nacelle. The tower of the wind turbine may be connected to a foundation of the wind turbine such as a monopile in the seabed.
In the installed state of the wind turbine, the blade, e.g., a root portion of the blade, is, for example fixedly or rotatably connected to the hub. The wind turbine blade is, for example, directly bolted to the hub, or is connected via a pitch bearing to the hub. The pitch bearing is configured to adjust the angle of attack of the blade according to the wind speed to control the rotational speed of the blade.
Apart from the essentially cylindrical root portion configured for connection with the hub, the outer surface of the wind turbine blade has an aerodynamically shaped cross-section (airfoil). The aerodynamically shaped cross-section of the wind turbine blade comprises, for example, a pressure side (upwind side) and a suction side (downwind side). The pressure side and the suction side are connected with each other at a leading edge and a trailing edge.
A blade shell of the blade is, for example, manufactured from fiber-reinforced resin. The blade shell is, for example, manufactured by vacuum-infusion of resin into a dry fiber lay-up and curing the resin. However, the blade shell may also be manufactured by a different method. The blade shell has, in particular, an outer surface and an inner surface, wherein the outer surface defines the aerodynamic profile of the blade, and the inner surface defines an inner cavity of the blade.
The “blade during manufacture” which is treated and/or processed by the one or more robotic units may be any state of the blade or portions thereof during the whole blade manufacturing process. This may include a state in which the blade shell is already closed, i.e. forming, in a cross-section view, a closed inner cavity and/or having a continuous outer surface. However, the “blade during manufacture” may also include a state in which the blade shell is not yet closed but, for example, only a half shell or another section of the blade is bridged by the frame of the gantry system and treated and/or processed by the one or more robotic units. The “blade during manufacture” is, in particular, a blade or portion thereof in a horizontal orientation of the blade.
The one or more robotic units are, for example, industrial robots. The one or more robotic units each comprise, for example, a tool attachment portion (e.g., a tool flange) for attaching various tools and/or end effectors. In particular, the tools and/or end effectors are configured for performing manufacturing steps during manufacture of the wind turbine blade. The one or more robotic units may also comprise one or more supply lines and/or exhaust/discharge/suction lines for supplying or exhausting/discharging material, fluid, gas, liquid etc.
The tool attachment portion defines, for example, a tool center point of the respective robotic unit. The respective robotic unit is, for example, capable of moving the tool center point (and, thus, the tool and/or end effector) in a translation direction and/or rotational direction.
The manufacturing steps performed by the one or more robotic units may include manufacturing steps related to the fabrication of the blade shell (e.g., the lamination process). Examples include arranging a fiber lay-up, a core material such as balsa, wood or foam, a web (e.g., shear web) in a mold etc.
The manufacturing steps performed by the one or more robotic units may include manufacturing steps related to treatment of the outer surface of the blade shell. Examples include painting, sanding, polishing, cleaning, providing filling material for filling pinholes, a quality check of the outer surface etc.
The manufacturing steps performed by the one or more robotic units may also include manufacturing steps related to other kinds of processing at the outer surface of the blade shell. Examples include installing a leading-edge protection system, vortex generators or aerodynamic blade add-ons such as trailing edge serration panels (e.g., Dinotails), spoilers, flaps or slats.
The tools and/or end effectors attachable to the one or more robotic units comprise, for example, a surface treatment tool, a polishing tool, a cleaning tool, a gripper (e.g., vacuum gripper, pneumatic gripper, hydraulic gripper, electric gripper), a claw, a robotic hand, suction means, dispensing means, a nozzle, a spray nozzle, a camera or other sensor for inspection means and/or an emitter of electromagnetic radiation (e.g., IR light, UV light, visual light and/or laser light).
The frame of the gantry system is, in particular, a framework, steel framework and/or steel construction. The frame comprises, for example, several beams/structures, in particular steel beams/steel structures.
In embodiments, the gantry system comprises two or more robotic units attached to the frame so as to perform manufacturing steps at both sides of the blade during manufacture, as seen in the cross-section view of the blade.
Thus, both sides of the blade can be treated and/or processed by the two or more robotic units simultaneously. Hence, time and cost can be saved.
In embodiments, a height of the gantry system is 6 meters or larger, 8 meters or larger, 10 meters or larger and/or 12 meters or larger.
According to an embodiment, the one or more robotic units each comprise a robotic arm, in particular a robotic arm configured to move a tool center point of the robotic arm in six degrees of freedom.
Thus, the one or more robotic units can perform various and complex manufacturing tasks. Further, they can better reach around the blade in its cross-section direction. Furthermore, the one or more robotic units can perform various and complex manufacturing tasks even in view of the varying outer profile of the blade from its root portion to its tip.
According to an embodiment, the wheels are arranged in two-lanes and/or the gantry system is configured such that during manufacture of the blade at least one wheel of the gantry system is arranged on each side of the blade in the cross-section direction of the blade.
Thus, the gantry system has a large footprint and, hence, a great stability.
According to an embodiment, one or more of the wheels are steerable wheels and/or are rotatably attached to the frame such that the respective wheel is rotatable around an axis arranged parallel to a height direction of the gantry system.
Thus, the gantry system can be positioned with respect to the blade with greater flexibility.
According to an embodiment, one or more of the wheels are rotatably attached to the frame such that the respective wheel is rotatable by an angle of at least 180° around the axis arranged parallel to the height direction of the gantry system.
Thus, the gantry system can move in all directions on a plane such as a floor of a manufacturing hall. Hence, it can be positioned even more flexible with respect to the blade.
In particular, the plane on which the gantry system moves is perpendicular to a height direction of the gantry system.
According to an embodiment, the frame comprises
Thus, the gantry system comprises several modules such as the two base members, the two side pillars, the horizontal beam and the one or more robotic units. In particular, the individual modules are configured such that they can be easily mounted to each other and dismounted from each other. For example, the individual modules may be connected to each other by bolt connections easily accessible from the outside.
Having this modular structure of the gantry system allows an easy replacement of individual modules to adjust the gantry system to a specific blade size and/or shape. For example, for a larger blade diameter at the root end, the two pillars and the horizontal beam could be replaced by two pillars and a horizontal beam having each a greater length.
According to an embodiment, at least one of the one or more robotic units is movably attached to the frame for moving the respective robotic unit relative to the frame.
Thus, the one or more robotic units can be positioned with respect to the blade not only by moving the gantry system as a whole (i.e. locomotion of the gantry system based on its wheels) but also by moving the respective robotic unit along the gantry system. Thus, a tool and/or end effector attached to the one or more robotic units can be better (e.g., closer) positioned with respect to the blade.
According to an embodiment,
Having a sled and a matching rail allows an easy movement of the one or more robotic units with respect to the frame of the gantry system. The sled is, for example, fixedly attached to the one or more robotic units and the rail is, for example, provided by and/or fixedly attached to the respective side pillar.
In embodiments, at least one of the one or more robotic units may be movably attached to the horizontal beam by a sled, the sled being configured for moving the respective robotic unit along the horizontal beam.
According to an embodiment,
By having the swing arm, the one or more robotic units can be swiveled in and out with respect to the blade.
According to an embodiment, the gantry system comprises a control unit for controlling the locomotion of the gantry system, a movement of the one or more robotic units relative to the frame of the gantry system and/or a movement of a tool center point of a respective robotic unit.
The control unit is, in particular, configured for global positioning of the gantry system by controlling the locomotion of the gantry system. The global positioning of the gantry system includes, for example, positioning of the gantry system with respect to the blade and the manufacturing environment (e.g., a manufacturing hall).
Further, the control unit is, in particular, configured for local positioning of the one or more robotic units by controlling the movement of the one or more robotic units relative to the frame of the gantry system.
Further, the control unit is, in particular, configured for local positioning of the tool center point of a respective robotic unit. Thus, the movement, path and/or pose of a tool and/or end effector of a respective robotic unit can be controlled.
Having the control unit, the position of the one or more robotic units and/or the tool center point of a respective robotic unit can be accurately controlled. For example, the one or more robotic units and/or its tool center point can be poisoned with sub-cm accuracy.
Thus, a tool and/or end effector attached to a respective robotic unit can be positioned next to the blade with high spatial accuracy. Thus, the blade can be treated and/or processed with high accuracy.
The respective units described herein, e.g., the control unit, may be implemented in hardware and/or in software. If the unit is implemented in hardware, it may be embodied as a device, e.g., as a computer or as a processor or as a part of a system such as a computer system. If the unit is implemented in software it may be embodied as a computer program product (non-transitory computer readable storage medium having instructions, which when executed by a processor, perform actions), as a function, as a routine, as a program code or as an executable object.
According to an embodiment, the control unit is configured for simultaneously controlling the locomotion of the gantry system, the movement of the one or more robotic units relative to the frame and the movement of the tool center point of the respective robotic unit.
According to an embodiment, the gantry system comprises a sensor system including one or more sensors for obtaining sensor data of the blade during manufacture and/or of the one or more robotic units, wherein
Having the sensor system and transferring sensor data from the sensor system to the control unit, the control unit may receive a feedback, for example on the current position of the gantry system, the current position of the respective robotic unit and/or the current position of the tool center point of the respective robotic unit. The current positions may be positions with respect to the blade.
Further, having the sensor system, the control unit may receive a feedback on the manufacturing process.
The one or more sensors may include laser trackers, odometry systems including motion sensors, wheel speed sensors (e.g., counting the number of wheel rotations), wheel angle sensors, radar systems (radio detection and ranging), lidar systems (light detection and ranging), optical sensors such as infrared or visual light cameras (e.g., scanning markers on a floor and/or ceiling of a manufacturing hall and/or on a blade), structured light sensors, ultrasonic sensors, encoders, laser pointer, proximity sensors, temperature sensors and/or pressure sensors.
According to an embodiment, the control unit is configured for controlling the locomotion of the gantry system, the movement of the one or more robotic units relative to the frame, the movement of the tool center point of the respective robotic unit and/or the manufacturing step based on a predetermined digital model of the wind turbine blade and/or based on a deviation of the predetermined digital model of the wind turbine blade from an actual shape of the blade during manufacture obtained by the sensor data.
Determining a position of the gantry system, the respective robotic unit and/or the tool center point of the respective robotic unit with respect to the blade is hampered by the fact that the outer shape of a wind turbine blade has usually a complex form, in particular a non-regular geometric form. The outer shape of a wind turbine blade is, in particular, defined by a cross-section varying from a cylindrical root portion to an aerodynamic profile which in turn is varying towards the tip end. Further, the blade is usually bent from the root end to the tip end.
Having the predetermined digital model of the blade allows a better control of a position of the gantry system, the respective robotic unit and/or the tool center point of the respective robotic unit with respect to the blade.
The predetermined digital model of the blade is, in particular, a CAD model of the blade. The predetermined digital model is, in particular, a 3D model of the blade.
In embodiments, the control unit is configured to determine a deviation of the predetermined digital model of the blade from an actual shape of the blade obtained by the sensor data. For example, the control unit is configured to determine a digital model of the actual shape of the blade by the sensor data.
In particular, by using the relationship between the CAD model and the sensor data, it is possible to better define and perform a manufacturing process at a given point (e.g., an exact location) on the blade. In particular, the manufacturing process at the given point can be performed with a very high accuracy and repeatability.
Furthermore, sensor data obtained from the exact location and obtained during or after performing the manufacturing process, can be fed back and saved as process data for documentation purposes and/or preparation of further manufacturing processes.
According to a further aspect, a method for manufacturing a wind turbine blade is proposed. In embodiments, the method comprises:
According to a further aspect, a computer program product is proposed. The computer program product comprises a program code for executing the above-described method when run on at least one computer.
A computer program product, such as a computer program means, may be embodied as a memory card, USB stick, CD-ROM, DVD or as a file which may be downloaded from a server in a network. For example, such a file may be provided by transferring the file comprising the computer program product from a wireless communication network.
The embodiments and features described with reference to the gantry system of the present invention apply mutatis mutandis to the method of the present invention.
Further possible implementations or alternative solutions of embodiments of the invention also encompass combinations—that are not explicitly mentioned herein—of features described above or below with regard to the embodiments. The person skilled in the conventional art may also add individual or isolated aspects and features to the most basic form of embodiments of the invention.
Some of the embodiments will be described in detail, with references to the following Figures, wherein like designations denote like members, wherein:
In the following a gantry system 8 with robotic units 9 for manufacturing a wind turbine blade 3 of the wind turbine 1 of
The wheels 12 of the gantry system 8 are arranged in two-lanes 15 (
The wheels 12 are, in particular, steerable wheels. In particular, each wheel 12 is rotatably attached to the respective base member 11 such that it can rotate around an axis A arranged parallel to a height direction Z of the gantry system 8. In
There are one or more robotic units 9 attached to the frame 10 of the gantry system 8. In the shown example, there are two robotic units 9 each attached to a respective side pillar 13 of the frame 10. The robotic units 9 are configured for performing manufacturing steps during manufacture of the blade 3′ such as painting an outer surface 17 (
Each robotic unit 9 comprises a robotic arm 18. Each robotic arm 18 comprises several joints 19 (
Each robotic arm 18 is, for example, capable to move the tool center point 22, and hence the tool/end effector 21, in six degrees of freedom (three translational and three rotational degrees of freedom).
Furthermore, the robotic units 9 are movably attached to the frame 10 for moving the respective robotic unit 9 relative to the frame 10. In the shown example, each robotic unit 9 is movably attached to a respective one of the side pillars 13 by a sled 23 (
In addition, each robotic unit 9 is rotatably attached to the frame 10—in the shown example to the respective sled 23 attached to the respective side pillar 13—by a swing arm 25 (
As illustrated in
In particular, the individual modules 9, 11, 13, 14, 23, 24 may be configured such that they can be easily mounted to each other and dismounted from each other. For example, the individual modules 9, 11, 13, 14, 23, 24 may be connected to each other by bolt connections (not shown) easily accessible from the outside.
Furthermore, the gantry system 8 comprises a control unit 26 (
Furthermore, the gantry system comprises a sensor system 28 including one or more sensors 29, 30, 31 for obtaining sensor data of the blade 3′ and/or of the robotic units 9. In
However, the sensors 29, 30, 31 might also be arranged at different locations of the gantry system 8 and/or there might be more or different sensors than the one shown. The sensors 29, 30, 31 may include laser trackers, odometry systems including motion sensors, wheel speed sensors (e.g., counting the number of wheel rotations), wheel angle sensors, radar systems (radio detection and ranging), lidar systems (light detection and ranging), optical sensors such as infrared or visual light cameras (e.g., scanning markers on a floor and/or ceiling of a manufacturing hall and/or on a blade), ultrasonic sensors, encoders, laser pointer, proximity sensors, temperature sensors and/or pressure sensors.
The control unit 26 is configured for controlling the locomotion of the gantry system 8, the movement (sleds 23, swing arms 25) of the robotic units 9 relative to the frame 10 and the movement of the tool center point 22 based on the sensor data from the sensor system 28.
Further, the control unit 26 is configured for controlling a manufacturing step of the wind turbine blade 3′ based on the sensor data.
In particular, the control unit 26 is configured for controlling the locomotion of the gantry system, the movement of the robotic units 9 relative to the frame 10, the movement of the tool center point 22 of the respective robotic unit 9 and/or the manufacturing step based on a predetermined digital model of the wind turbine blade 3. The predetermined digital model is, for example, a 3D CAD model (computer aided design) of the blade 3.
The control unit 26 may, for example, be configured for determining a deviation of the predetermined digital model of the blade 3 from an actual shape S of the blade 3′ during manufacture obtained by the sensor data.
In the following a method for manufacturing the wind turbine blade 3 is described with respect to
In a first step SI of the method, the gantry system 8 is moved on its wheels 12 with respect to the wind turbine blade 3′ during manufacture. The frame 10 of the gantry system 8 bridges the blade 3′ in the cross-section direction of the blade 3′, so as to provide a large footprint 16 (
In a second step S2 of the method, the robotic units 9 are moved relative to the frame 10 by the sleds 23 and swing arms 25 (
In a third step S3 of the method, the tool center point 22 of each robotic unit 9 is moved with respect to the blade 3′. The movement of the tool center point 22 is controlled by the control unit 26.
In a fourth step S4 of the method, a manufacturing step for manufacturing the blade 3′ is performed by the robotic units 9. In the shown example of
Steps S1 to S4 may be carried out simultaneously and repeatedly until the entire outer surface 17 of the blade 3′ is coated with paint 33. Having the gantry system 8 with the robotic units 9 allows to paint the outer surface 17 of a blade 3 in an automated manner.
Although the present invention has been disclosed in the form of embodiments and variations thereon, it will be understood that numerous additional modifications and variations could be made thereto without departing from the scope of the invention.
For the sake of clarity, it is to be understood that the use of “a” or “an” throughout this application does not exclude a plurality, and “comprising” does not exclude other steps or elements.
| Number | Date | Country | Kind |
|---|---|---|---|
| 21184157.2 | Jul 2021 | EP | regional |
This application claims priority to PCT Application No. PCT/EP2022/068522, having a filing date of Jul. 5, 2022, which claims priority to European Application No. 21184157.2, having a filing date of Jul. 7, 2021, the entire contents all of which are hereby incorporated by reference.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2022/068522 | 7/5/2022 | WO |
