Patent Application
20240091989
The present disclosure relates a movable platform for a mould system for manufacturing turbine blades and a method for handling a mould system comprising a movable platform. More specifically, the present disclosure relates to the handling of a movable platform in a mould system during manufacturing of a wind turbine blade.
There is a constant need to improve the manufacturing facilities and the safety of operators during manufacturing of a wind turbine blade. The physical demands are high, and the operators are surrounded by chemical products which can cause health problems.
Thus, there is a need for more safe environments during manufacturing. Furthermore, the need for an optimization of the workflows of operators, reducing the manual labour and ultimately reducing the health risk of operators in the manufacturing plants of wind turbine blades.
It is an object of the present disclosure to provide a solution which at least improve the solutions of the prior art. Particularly, it is an object of the present disclosure to provide a mould system and a method for enhancing safety of wind turbine blade manufacture and facilitate optimizing manufacturing processes.
Accordingly, the present disclosure provides a movable platform for a mould system for manufacturing a wind turbine blade and a method for handling a mould system for manufacturing wind turbine blade comprising such a movable platform which overcome or ameliorate at least some of the disadvantages of the prior art.
In particular, the present disclosure provides a mould system for moulding a blade shell of a wind turbine blade. The mould system comprises a first mould for manufacturing a first blade shell part of the wind turbine blade. The first mould extends substantially along a longitudinal axis. The mould system comprises a second mould for manufacturing a second blade shell part of the wind turbine blade. The second mould extends substantially along the longitudinal axis.
The mould system comprises a turning device configured to reposition the first mould between an open mould position and a closed mould position. The first mould is arranged next to the second mould in the open mould position. The first mould is arranged on top of the second mould in the closed mould position. The turning device comprises a turning mechanism and a first primary beam connecting the turning mechanism and the first mould.
The mould system comprises a first scaffold arranged between the first mould and the second mould in the open mould position, e.g., between the turning mechanism and the first mould. The first scaffold extends along the longitudinal axis. The first scaffold comprises a first primary scaffold part and a first secondary scaffold part spaced apart in the longitudinal direction by a first primary scaffold opening. The first primary scaffold opening is configured to allow the first primary beam to move therethrough during repositioning of the first mould between the open mould position and the closed mould position.
The mould system comprises a first primary movable platform attached to the first mould and is configured to move between an extended platform position and a stored platform position. The first primary movable platform covers the first primary scaffold opening in the extended position. The first primary movable platform is arranged to expose the first primary scaffold opening in the stored platform position.
Also disclosed is a method for handling a mould system for manufacturing a wind turbine blade. The method comprises providing a mould system, such as the above described mould system, wherein the first mould of the mould system is in the open mould position, and the first primary movable platform of the mould system is in the extended platform position.
The method comprises laying up composite material in the first mould and the second mould. The method comprises positioning the first primary movable platform in the stored platform position. The method comprises securing the first primary movable platform in the stored platform position. The method comprises repositioning the first mould to the closed mould position.
It is an advantage of the present disclosure that an improved mould system for manufacturing wind turbine blades is provided. Particularly, due to a movable platform which is easier and safer to handle. It is a further advantage of the present disclosure that the movable platform is attached to the first mould, such that during repositioning of the first mould the movable platform follows the first mould and does not lay around as a separate part. Particularly, the movable platform does not create an occupational hazard in that there is reduced risk for falling over or getting body parts clamped under the movable platform.
The first scaffold may comprise a first primary gate attached to the first secondary scaffold part. The first primary gate may be configured to be positioned in an open gate position and a closed gate position. The first primary gate may comprise a first gate locking element and optionally a second gate locking element. The first primary gate in the open gate position may extend in the longitudinal direction such that the first gate locking element engages in a locking configuration with a first primary scaffold locking element of the first primary scaffold part. The first primary gate in the closed gate position may extend in a transverse direction perpendicular to the longitudinal direction such that the first gate locking element and/or the second gate locking element engages in a locking configuration with a first secondary scaffold locking element of the first secondary scaffold part in the closed gate position.
It is a further advantage of the present disclosure that the first primary gate keeps the operator safe from the scaffold opening and keeps the operator at a safe distance from the movable platform during positioning of the movable platform.
The turning device may comprise a first secondary beam connecting the turning mechanism and the first mould. The first scaffold may comprise a first tertiary scaffold part spaced apart from the first secondary scaffold part in the longitudinal direction by a first secondary scaffold opening. The first secondary scaffold opening may be configured to allow the first secondary beam to move therethrough during repositioning of the first mould between the open mould position and the closed mould position. The first secondary scaffold part may be between the first tertiary scaffold part and the first primary scaffold part.
The mould system may further comprise a first secondary movable platform attached to the first mould. The first secondary movable platform may be configured to move between an extended platform position and a stored platform position. The first secondary movable platform may cover the first secondary scaffold opening in the extended position. The first secondary movable platform may be arranged to expose the first secondary scaffold opening in the stored platform position.
The first scaffold may comprise a first secondary gate attached to the first tertiary scaffold part. The first secondary gate may comprise a first gate locking element and optionally a second gate locking element. The first secondary gate may be configured to be positioned in an open gate position and in a closed gate position. The first secondary gate in the open gate position may extend in the longitudinal direction such that the first gate locking element engages in a locking configuration with a first secondary scaffold locking element of the first secondary scaffold part.
The first secondary gate in a closed gate position may extend in a transverse direction perpendicular to the longitudinal direction such that the first gate locking element and/or the second gate locking element engages in a locking configuration with a first tertiary scaffold locking element of the first tertiary scaffold part.
The first primary gate may be configured to rotate about a hinge attached to the first secondary scaffold part. The first secondary gate may be configured to rotate about a hinge attached to the first tertiary scaffold part.
The first primary gate may be positioned in the open gate position while the first primary movable platform is in the extended platform position. The first secondary gate may be positioned in the open gate position while the first secondary movable platform is in the extended platform position. The first primary gate may provide securing of the first primary movable platform by being configured to attach to the scaffold part on each side of the first primary movable platform. The first secondary gate may provide securing of the first secondary movable platform by being configured to attach to the scaffold part on each side of the first secondary movable platform.
The first primary gate may in the open gate position prevent the first primary movable platform to be moved to the stored platform position. The first secondary gate may in the open gate position prevent the first secondary movable platform to be moved to the stored platform position.
The first primary gate and/or the first secondary gate and/or the first tertiary gate may comprise an extendable part. The extendable part may be configured to be positioned in an extended position and a retracted position. The extendable part may be positioned in the retracted position when the first primary gate and/or the first secondary gate and/or the first tertiary gate is positioned in the open gate position. The extendable part may be positioned in the extended position when the first primary gate and/or the first secondary gate and/or the first tertiary gate is positioned in the closed gate position. The extendable part may comprise a plurality of joints joined together in a telescopic manner. The advantage of having an extendable part is that the gate may extend across the entire width, or more, of the scaffold in the closed position, such that the operator is kept safe from the scaffold opening. Furthermore, the extendable part also facilitates blockage of openings of different widths, for example, in case the openings to be blocked by the gate, respectively in the open gate position and the closed gate position, are of different widths.
The first primary movable platform in the extended platform position may be flush with a first primary surface of the first primary scaffold part and a first secondary surface of the first secondary scaffold part. For example, the surface of the first primary movable platform may be flush with the first primary surface of the first primary scaffold part and the first secondary surface of the first secondary scaffold part. The first primary movable platform may rest on shelves on the first primary scaffold part and the first secondary scaffold part in the extended platform position.
The first secondary movable platform in the extended platform position may be flush with a first secondary surface of the first secondary scaffold part and a first tertiary surface of the first tertiary scaffold part. For example, the surface of the first secondary movable platform may be flush with the first secondary surface of the first secondary scaffold part and the first tertiary surface of the first tertiary scaffold part. The first secondary movable platform may rest on shelves on the first secondary scaffold part and the first tertiary scaffold part in the extended platform position.
The first primary movable platform may be configured to rotate about a hinge (e.g., a first hinge) attached to the first mould. The first secondary movable platform may be configured to rotate about a hinge (e.g., a second hinge) attached to the first mould.
The first primary movable platform and/or the first secondary movable platform may be configured to be positioned in the stored platform position during repositioning of the first mould. The first primary movable platform and/or the first secondary movable platform may be positioned in the stored platform position before repositioning of the first mould.
The first primary movable platform and/or the first secondary movable platform may extend in a transverse direction, perpendicular to the longitudinal direction, between a first end and a second end. The hinge may be connected to the first end. At least a part of the second end may be secured to the first mould in the stored platform position. The distance between the first end and second end may correspond to the width of the scaffold in the transverse direction. The distance between the first end and second end of the first primary movable platform may correspond to the width of the first primary scaffold part and/or the width of the first secondary scaffold part in the transverse direction. The distance between the first end and second end of the first secondary movable platform may correspond to the width of the first secondary scaffold part and/or the width of the first tertiary scaffold part in the transverse direction.
The first primary movable platform and/or the first secondary movable platform may be between 0.3-1.5 meters between the first end and the second end, e.g., in the transverse direction. The first scaffold and/or the second scaffold may have a width in the transverse direction between 0.3-1.5 meters in the transverse direction.
The first scaffold and/or the second scaffold may have a length corresponding to the length of the first mould and/or second mould in the longitudinal direction.
The first primary scaffold opening may have a size allowing the first primary beam to move therethrough. The first primary movable platform may have a size such that the first primary scaffold opening is covered in the extended platform position.
The first secondary scaffold opening may have a size allowing the first secondary beam to move therethrough. The first secondary movable platform may have a size such that the first secondary scaffold opening is covered in the extended platform position.
The first primary movable platform and/or the first secondary movable platform each may comprise a platform locking element configured to engage in a locking configuration with a corresponding mould locking element in the stored platform position. The mould locking element may be attached to the first mould. The platform locking element may be arranged at the second end. The platform locking element may comprise a platform bracket comprising an opening. The mould locking element may comprise a mould bracket comprising a pin configured to engage with the opening of the platform bracket. The pin of the mould bracket may be spring loaded.
During handling of the mould system, and after laying up composite material and before repositioning the first mould to the closed mould position, the first primary gate may be positioned in a closed gate position. After positioning the first primary gate in the closed gate position the first primary gate may be secured in the closed gate position. The first primary gate may be secured in the closed gate position with a gate locking element, such as the first gate locking element and/or the second gate locking element.
The first primary gate may be positioned and/or secured in the closed gate position before positioning the movable platform in the stored platform position. In other words, after positioning and/or securing the first primary gate in the closed gate position, the first primary movable platform may be positioned in the stored platform position.
After positioning the first primary movable platform in the stored platform position, the first primary movable platform may be secured in the stored platform position. The first primary movable platform may be secured in the stored platform position with the platform locking element of the first primary movable platform.
After positioning and/or securing the first primary movable platform in the stored platform position, the first secondary gate may be positioned in the closed gate position. After positioning the first secondary gate in the closed gate position the first secondary gate may be secured in the closed gate position. Positioning and securing the first secondary gate in the closed gate position may be performed in the same manner as positioning and securing the first primary gate in the closed gate position.
After positioning and/or securing the first secondary gate in the closed gate position, the first secondary movable platform may be positioned in the stored platform position. After positioning the first secondary movable platform in the stored platform position, the first secondary movable platform may be secured in the stored platform position. The first secondary movable platform may be secured in the stored platform position with the platform locking element of the first secondary movable platform. Positioning and securing the first secondary movable platform in the stored platform position may be performed in the same manner as positioning and securing the first primary movable platform in the stored platform position.
Positioning and securing a gate and positioning and securing a movable platform may be repeated for subsequent gates and movable platforms, e.g., a first tertiary movable platform and/or a first tertiary gate.
After the composite material forming the two blade shell parts of the first mould and second mould have been bonded together to form a wind turbine blade, the first mould may be repositioned to the open mould position, without the first blade shell part. After repositioning the first mould to the open mould position, the first secondary movable platform may be positioned in the extended platform position. The first secondary movable platform may in the extended platform position rest on the shelves of the scaffold. After positioning the first secondary movable platform in the extended platform position, the first secondary gate may be positioned and/or secured in the open gate position. After positioning and/or securing the first secondary gate in the open gate position, the first primary movable platform may be positioned in the extended platform position. The first primary movable platform may in the extended platform position rest on the shelves of the scaffold. After positioning the first primary movable platform in the extended platform position the first primary gate may be positioned and/or secured in the open gate position. Any antecedent platforms and gates, e.g., first tertiary movable platform and/or first tertiary gate, may be handled in the same manner before the first secondary movable platform and first secondary gate are handled.
After repositioning the first mould to the open mould position, and optionally after handling the platforms and gates, the wind turbine blade may be removed from the mould system. After removing the moulded wind turbine blade the mould system may be used to manufacture another wind turbine blade by repeating the disclosed method.
The first primary movable platform and/or the first secondary movable platform may each comprise a handle. The handle may assist the operator in positioning the first primary movable platform and/or the first secondary movable platform between the extended platform position and the stored platform position. The handle may be arranged at the second end.
A bias element may be attached to each of the first primary movable platform and/or the first secondary movable platform. A first end of the bias element may be attached to the first primary movable platform and/or first secondary movable platform. A second end of the bias element may be attached to the first mould. The bias element may be a pneumatic actuator or a gas spring assisting the operator in positioning the first primary movable platform and/or first secondary movable platform in the extended platform position and/or the stored platform position. For example, the bias element may provide for a smooth positioning of the first primary movable platform and/or first secondary movable platform into the extended platform position and/or the stored platform position.
A second scaffold may be arranged between the first mould and the second mould in the open mould position. The second scaffold may extend along the longitudinal axis. The first scaffold may be arranged proximate the first mould. The second scaffold may be arranged proximate the second mould. The turning device may be arranged between the first scaffold and the second scaffold.
The first scaffold and/or second scaffold may be secured to the ground or floor, e.g., the ground or floor of the manufacturing plant. The first scaffold, e.g., the first scaffold part and/or the second scaffold part, may be bolted to the floor or ground.
The mould system may comprise a third scaffold and a fourth scaffold. The third scaffold may be arranged such that the first scaffold extends on one side of the first mould and the third scaffold extends on the opposite side of the first mould. The fourth scaffold may be arranged such that the second scaffold extends on one side of the second mould and the fourth scaffold extends on the opposite side of the second mould.
The first scaffold and/or the second scaffold may each comprise a handrail. The first primary gate and/or the first secondary gate may be attached to the handrail of the first scaffold, e.g., the first secondary scaffold part and/or the first tertiary scaffold part.
The mould system may comprise a plurality of movable platforms, including the first primary movable platform and the first secondary movable platform, such as three or four movable platforms. The plurality of movable platforms may comprise similar features.
The mould system may comprise a plurality of gates, including the first primary gate and the first secondary gate, such as three or four gates. The mould system may comprise a gate on each side of the movable platform. The plurality of gates may comprise similar features.
It is envisaged that any embodiments or elements as described in connection with any one aspect may be used with any other aspects or embodiments, mutatis mutandis.
Embodiments of the invention will be described in more detail in the following with regard to the accompanying figures. Like reference numerals refer to like elements throughout. Like elements may, thus, not be described in detail with respect to the description of each figure. The figures show one way of implementing the present invention and are not to be construed as being limiting to other possible embodiments falling within the scope of the attached claim set. In addition, an illustrated embodiment needs not have all the aspects or advantages shown. An aspect or an advantage described in conjunction with a particular embodiment is not necessarily limited to that embodiment and can be practiced in any other embodiments even if not so illustrated, or if not so explicitly described.
In the following figure description, the same reference numbers refer to the same elements and may thus not be described in relation to all figures.
The airfoil region 34 (also called the profiled region) has an ideal or almost ideal blade shape with respect to generating lift, whereas the root region 30 due to structural considerations has a substantially circular or elliptical cross-section, which for instance makes it easier and safer to mount the blade 10 to the hub. The diameter (or the chord) of the root region 30 may be constant along the entire root area 30. The transition region 32 has a transitional profile gradually changing from the circular or elliptical shape of the root region 30 to the airfoil profile of the airfoil region 34. The chord length of the transition region 32 typically increases with increasing distance r from the hub. The airfoil region 34 has an airfoil profile with a chord extending between the leading edge 18 and the trailing edge 20 of the blade 10. The width of the chord decreases with increasing distance r from the hub.
A shoulder 40 of the blade 10 is defined as the position, where the blade 10 has its largest chord length. The shoulder 40 is typically provided at the boundary between the transition region 32 and the airfoil region 34.
It should be noted that the chords of different sections of the blade normally do not lie in a common plane, since the blade may be twisted and/or curved (i.e. pre-bent), thus providing the chord plane with a correspondingly twisted and/or curved course, this being most often the case in order to compensate for the local velocity of the blade being dependent on the radius from the hub.
The wind turbine blade 10 comprises a blade shell comprising two blade shell parts or half shells, a first blade shell part 24 and a second blade shell part 26, typically made of fibre-reinforced polymer. The wind turbine blade 10 may comprise additional shell parts, such as a third shell part and/or a fourth shell part. The first blade shell part 24 is typically a pressure side or upwind blade shell part. The second blade shell part 26 is typically a suction side or downwind blade shell part. The first blade shell part 24 and the second blade shell part 26 are fastened together with adhesive, such as glue, along bond lines or glue joints 28 extending along the trailing edge 20 and the leading edge 18 of the blade 10. Typically, the root ends of the blade shell parts 24, 26 have a semi-circular or semi-oval outer cross-sectional shape.
The mould system 50 further comprises a turning device 80 configured for repositioning the first mould 52 between an open mould position (as illustrated) and a closed mould position, e.g., by lifting and rotating the first mould 52. The turning device 80 comprises a turning mechanism 82 and a beam 84 connecting the turning mechanism and the first mould.
In
In the following, a reference number without a subsequent apostrophe (e.g., 112) may be used to refer to any of a plurality of similar elements or features, individually referenced by the same reference number with an apostrophe (e.g., 112′, 112″, 112′″, 112″), i.e., the reference without an apostrophe is used to refer to any of the corresponding reference with apostrophes.
One or more turning devices 80 are arranged between the first scaffold 90′ and the second scaffold 90″ and comprises at least one beam 84. The first mould system section 51 has a plurality of handling sections 88 (four in the illustrated example) each comprising a turning device 80, a beam 84, a scaffold opening 100 and a movable platform 112 covering the respective scaffold openings 100.
The movable platforms 112 are attached to the first mould 52 and are configured to move between an extended platform position and a stored platform position. The movable platforms 112 are configured to rotate about a hinge attached to the first mould 52. In
The first scaffold 90′ comprises a first primary scaffold part 92′ and a first secondary scaffold part 92″ spaced apart by a first primary scaffold opening 100′. In the illustrated example, the first scaffold 90′ further comprises a first tertiary scaffold part 92′″, wherein the first secondary scaffold part 92″ and the first tertiary scaffold part 92′″ are spaced apart by a first secondary scaffold opening 100″. In the illustrated example, the first scaffold 90′ comprises further scaffold parts spaced apart by scaffold openings.
At the first primary handling section 88′ the first scaffold 90′ comprises the first primary scaffold part 92′ and the first secondary scaffold part 92″ spaced apart in the longitudinal direction L by the first primary scaffold opening 100′. The first primary scaffold opening 100′ is configured to allow the first primary beam 84′ to move therethrough during repositioning of the first mould 52 between the open mould position and the closed mould position. The same principle applies to the first secondary handling section 88″, the first tertiary handling section 88′″ and the first quaternary handling section 88″.
In
The first primary gate 130′ is positioned in an open gate position where the first primary gate 130′ extends in the longitudinal direction. A gate locking element 132 of the first primary gate 130′ engages in a locking configuration with a first primary scaffold locking element 106′ of the first primary scaffold part 92′. The gate locking element 132 may comprise a bracket comprising an opening and the first primary scaffold locking element 106′ may comprise a bracket comprising a pin, such as a spring bolt. Other suitable locking configurations may also be used.
In
The first primary gate 130′ may comprise an extendable part 136. The extendable part 136 may be positioned in an extended position and a retracted position. The extendable part 136 is useful in the case where the first primary gate 130′ extends across the first primary movable platform 112′ in the open gate position from the first primary scaffold part 92′ to the first secondary scaffold part 92″ (as illustrated in
A second gate locking element 134 engages in a locking configuration with a first secondary scaffold locking element 106″ of the first secondary scaffold part 92″ in the closed gate position, e.g., when the extendable part 136 is in the extended position. The first secondary locking element 106″ may be an opening in the first secondary scaffold part 92″, such as an opening in the first secondary surface 94″.
A bias element 126 may be connected between the first primary movable platform 112′ and the first mould 52 to assist the operator in positioning the first primary movable platform 112′ between the extended platform position and the stored platform position. The bias element 126 may be a pneumatic actuator or a gas spring supporting the positioning to the stored platform position. The first primary movable platform 120′ in the extended platform position may rest on shelves 138 attached to the first primary scaffold part 94′ and the first secondary scaffold part 94″.
In the extended platform position of
During handling of the mould system 50 the operator will start the handling process in the extended platform position, such as illustrated in
In
The method 200 comprises providing 202 a mould system, such as the mould system of
The method 200 comprises laying up 208 composite material in the first mould and the second mould. The composite material may be laid up by an operator moving along the scaffold of the mould system.
The method 200 may comprise positioning 210 and securing 212 the first primary gate in a closed gate position. The first primary gate may be secured in the closed gate position with the gate locking element and the scaffold locking element.
After positioning 210 the first primary gate in the closed gate position, the method 200 comprises positioning 214 the first primary movable platform in the stored platform position. The first primary gate may be positioned 210 and secured 212 before positioning 214 the movable platform in the stored platform position.
After positioning 214 the first primary movable platform in the stored platform position, the method 200 comprises securing 216 the first primary movable platform in the stored platform position with the platform locking element and the mould locking element.
After positioning 214 the first primary movable platform in the stored platform position, the method 200 may comprise positioning 210′ and securing 212′ the first secondary gate in closed gate position. Positioning 210′ and securing 212′ the first secondary gate in the closed gate position may be performed in the same manner as positioning 210 and securing 212 the first primary gate in the closed gate position.
After positioning the first secondary gate in the closed gate position, the method 200 may comprise positioning 214′ and securing 216′ the first secondary movable platform in stored platform position. Positioning 214′ and securing 216′ the first secondary movable platform in stored platform position may be performed in the same manner as positioning 214 and securing 216 the first primary movable platform in the stored platform position.
Positioning and securing a gate and positioning and securing a movable platform may be repeated for subsequent gates and movable platforms.
The method 200 comprises repositioning 220 the first mould to the closed mould position by lifting and rotating the first mould and positioning the first mould on top of the second mould.
After the two blade shell parts of the first mould and second mould have been bonded together to form a wind turbine blade, the first mould may be repositioned 222 to the open mould position. After repositioning 222 the first mould, the first secondary movable platform may be positioned 224 in the extended platform position. The first secondary movable platform will in this position rest on the shelves of the scaffold. The first secondary gate may be positioned 228 and secured 230 in the open gate position. Then the first primary movable platform may be positioned 224 in the extended platform position and the first primary gate may be positioned 228′ and secured 230′ in the open gate position. Any antecedent platforms and gates may be handled in the same manner before the first secondary movable platform and first secondary gate are handled.
After removing the moulded wind turbine blade the mould system is now ready for manufacturing another wind turbine blade by repeating above steps.
The invention has been described with reference to preferred embodiments. However, the scope of the invention is not limited to the illustrated embodiments, and alterations and modifications can be carried out without deviating from the scope of the invention.
| Number | Date | Country | Kind |
|---|---|---|---|
| 21157981.8 | Feb 2021 | GB | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2022/053631 | 2/15/2022 | WO |
