Patent Description:
Wind power is considered one of the cleanest, most environmentally friendly energy sources presently available, and wind turbines have gained increased attention in this regard. A modem wind turbine typically includes a tower, a generator, a gearbox, a nacelle, and a rotor having a rotatable hub with one or more rotor blades. The rotor blades capture kinetic energy of wind using known airfoil principles. The rotor blades transmit the kinetic energy in the form of rotational energy so as to turn a shaft coupling the rotor blades to a gearbox, or if a gearbox is not used, directly to the generator. The generator then converts the mechanical energy to electrical energy that may be deployed to a utility grid.

The rotor blades generally include a suction side shell and a pressure side shell typically formed using molding processes that are bonded together at bond lines along the leading and trailing edges of the blade. Further, the pressure and suction shells are relatively lightweight and have structural properties (e.g., stiffness, buckling resistance and strength) which are not configured to withstand the bending moments and other loads exerted on the rotor blade during operation. Thus, to increase the stiffness, buckling resistance, and strength of the rotor blade, the body shell is typically reinforced using one or more structural components (e.g., opposing spar caps with a shear web configured therebetween) that engage the inner pressure and suction side surfaces of the shell halves. The spar caps and/or shear web may be constructed of various materials, including but not limited to glass fiber laminate composites and/or carbon fiber laminate composites. Many rotor blades often also include a leading edge bond cap positioned at the leading edge of the rotor blade between the suction side and pressure side shells.

Manufacturing the rotor blades and components thereof can be a challenging process as process control is currently limited. In addition, due to the size and complexity of the rotor blades, building such parts with compliant materials makes building to the intended design difficult. Small inaccuracies can have a significant impact on the aerodynamic performance of the final blade. For example, many rotor blades are formed using molds. However, changes in the mold shape due to thermal expansion due to heating and cooling cycles can offset the manufacturing process. Deviations in the finished component shape can have negative effects on wind turbine performance and safety. The document <CIT> shows a method for on-site repairing of a surface of a component in a wind turbine. In the method, a digital model of the surface is generated using a scanning device. The digital model represents the surface in damaged state. Thereafter, using a processor, a repair scheme for the surface based on the digital model and on a desired state of the surface is generated. The desired state represents a post-repair state of the surface. Consequently, the repair scheme is provided to a 3D printing arrangement.

Accordingly, the present disclosure is directed to systems and methods improving build capabilities to ensure a final part is much closer to the intended design. Additionally, the systems and methods of the present disclosure can provide an as-build model for future development and compensation.

In one aspect, the present disclosure, as disclosed in claim <NUM>, is directed to a system for manufacturing a blade component of a rotor blade of a wind turbine includes a blade mold of the rotor blade, at least one blade skin arranged atop the blade mold, and a computer numeric control (CNC) device comprising a printer head and a scanning device. The printer head is configured for printing and depositing a material onto the at least one blade skin to form the blade component. The scanning device includes a processor and a scanner communicatively coupled to the processor. The scanning device is for determining a profile of the at least one blade skin atop the blade mold as the blade component is being printed and deposited layer by layer such that the printer head is automatically adjusted to compensate for changes in the profile in at least one of a horizontal direction or a vertical direction due to at least one of thermal expansion of the blade mold, thickness variations of fibers of the at least one blade skin, or movement of the at least one blade skin atop the blade mold.

In an embodiment, the scanning device is configured to determine the profile of the at least one blade skin atop the blade mold in real-time.

In another embodiment, the at least one blade skin may further include one or more reference features formed therein for aligning the at least one blade skin atop the blade mold. Thus, in several embodiments, the scanning device is further configured to determine a starting location for the printer head to start printing and depositing the material based on locations of the one or more reference features.

In an embodiment, determining the profile of the at least one blade skin atop the blade mold may include scanning, via the scanner, the at least one blade skin as the blade component is being printed and deposited to generate one or more measurement signals, receiving, via the processor, the one or more measurement signals, and determining the at least one blade skin as the blade component is being printed and deposited in real-time based on the one or more measurement signals.

For example, in one embodiment, the measurement signal(s) may include at least two reference points on the at least one blade skin as the blade component is being printed and deposited. As such, in an embodiment, the printer head can be automatically adjusted to compensate for changes in the profile in the horizontal and/or vertical directions by generating a printing path in real-time based the reference point(s) or correcting a predetermined printing path of the printer head based the reference point(s).

In particular embodiments, the scanner may be a proximity sensor (such as laser, ultrasound, infrared, optical, magnetic, radar and/or capacitive sensors) or a touch probe. Accordingly, in an embodiment, the method may further include using the scanner to locate one or more reference features on the blade mold.

In certain embodiments, the blade component described herein may be a blade shell, a spar cap, a shear web, a leading edge bond cap, and/or a reinforcement structure.

In another aspect, the present disclosure, as disclosed in claim <NUM>, is directed to a method for manufacturing a blade component of a rotor blade of a wind turbine. The method includes arranging at least one blade skin atop a blade mold of the blade component, printing and depositing, via a printer head of a computer numeric control (CNC) device, a material onto the at least one blade skin atop the blade mold to form the blade component, scanning, via a scanning device, a profile of the at least one blade skin atop the blade mold as the blade component is being printed and deposited layer by layer; and, automatically adjusting the printer head based on the scanning to compensate for changes in the profile in at least one of a horizontal direction or a vertical direction due to at least one of thermal expansion of the blade mold, thickness variations of fibers of the at least one blade skin, or movement of the at least one blade skin atop the blade mold.

It should be understood that the method may further include any of the additional steps and/or features as described herein.

In general, the present disclosure is directed to systems and methods for manufacturing a blade component of a rotor blade of a wind turbine. More specifically, a scanning or probing device can be used to obtain the profile of wind turbine blade components or other wind turbine components and fixtures through measurement of at least two reference points. These reference points can be used to locate features on the components/blade skins, the components/ blade skins relative to the fixtures/molds, and the components/ blade skins relative to other components/ blade skins during assemble and printing/manufacturing. In addition, the reference points can also be used on manufacturing the components, e.g. water jet the blade skins, as well as the blade assembly process.

Additionally, the scanning/probing devices described herein can be used in real time to provide closed-loop control to automated equipment such as printer heads or other tooling for compensation of where to place printed components. This allows tracking of the blade and/or mold during printing as well as tracking of previous additive layers so the printer head can compensate for deviations in print positions both horizontally and vertically. In particular, the blade molds may be heated, and due to thermal expansion, in-process measurement is required to ensure at least the first layer of printing is applied in the correct location. Thus, real-time scanning provides an as-built model for record and future evaluation of each part as well as future CAD model updates.

Scanning/probing of the reference points and/or features allows for ensuring the blade mold is in the correct position relative to printer. In addition, measurement of the mold surface allows for projecting of the grid to blade skin surface. Moreover, measurement of the mold in various thermal conditions (e.g. cold and hot conditions) helps in understanding thermal deformation of the mold for closed-loop compensation of the printer head. Further, measurement of the blade skin can account for deviations between the expected skin-in-mold position and the actual position due to insufficient manufacturing and/or clamping, which leads to shifting. Closed-loop compensation can also be used to correct a predetermined printing path or to generate a printing path in real-time. The data collected can also be used for blade quality inspection, future design, and process control/improvement through machine learning.

Referring now to the drawings, <FIG> illustrates one embodiment of a wind turbine <NUM> according to the present disclosure. As shown, the wind turbine <NUM> includes a tower <NUM> with a nacelle <NUM> mounted thereon. A plurality of rotor blades <NUM> are mounted to a rotor hub <NUM>, which is in turn connected to a main flange that turns a main rotor shaft. The wind turbine power generation and control components are housed within the nacelle <NUM>. The view of <FIG> is provided for illustrative purposes only to place the present invention in an exemplary field of use. It should be appreciated that the invention is not limited to any particular type of wind turbine configuration. In addition, the present invention is not limited to use with wind turbines, but may be utilized in any application using resin materials. Further, the methods described herein may also apply to manufacturing any similar structure that benefits from the resin formulations described herein.

Referring now to <FIG> and <FIG>, various views of a rotor blade <NUM> according to the present disclosure are illustrated. As shown, the illustrated rotor blade <NUM> has a segmented or modular configuration. It should also be understood that the rotor blade <NUM> may include any other suitable configuration now known or later developed in the art. As shown, the modular rotor blade <NUM> includes a main blade structure <NUM> and at least one blade segment <NUM> secured to the main blade structure <NUM>. More specifically, as shown, the rotor blade <NUM> includes a plurality of blade segments <NUM>.

More specifically, as shown, the main blade structure <NUM> may include any one of or a combination of the following: a pre-formed blade root section <NUM>, a pre-formed blade tip section <NUM>, one or more one or more continuous spar caps <NUM>, <NUM>, <NUM>, <NUM>, one or more shear webs <NUM> (<FIG>), an additional structural component <NUM> secured to the blade root section <NUM>, and/or any other suitable structural component of the rotor blade <NUM>. Further, the blade root section <NUM> is configured to be mounted or otherwise secured to the rotor <NUM> (<FIG>). In addition, as shown in <FIG>, the rotor blade <NUM> defines a span <NUM> that is equal to the total length between the blade root section <NUM> and the blade tip section <NUM>. As shown in <FIG> and <FIG>, the rotor blade <NUM> also defines a chord <NUM> that is equal to the total length between a leading edge <NUM> of the rotor blade <NUM> and a trailing edge <NUM> of the rotor blade <NUM>. As is generally understood, the chord <NUM> may generally vary in length with respect to the span <NUM> as the rotor blade <NUM> extends from the blade root section <NUM> to the blade tip section <NUM>.

Referring particularly to <FIG>, any number of blade segments <NUM> or panels (also referred to herein as blade shells) having any suitable size and/or shape may be generally arranged between the blade root section <NUM> and the blade tip section <NUM> along a longitudinal axis <NUM> in a generally span-wise direction. Thus, the blade segments <NUM> generally serve as the outer casing/covering of the rotor blade <NUM> and may define a substantially aerodynamic profile, such as by defining a symmetrical or cambered airfoil-shaped cross-section.

In additional embodiments, it should be understood that the blade segment portion of the blade <NUM> may include any combination of the segments described herein and are not limited to the embodiment as depicted. More specifically, in certain embodiments, the blade segments <NUM> may include any one of or combination of the following: pressure and/or suction side segments <NUM>, <NUM>, (<FIG> and <FIG>), leading and/or trailing edge segments <NUM>, <NUM> (<FIG>), a non-jointed segment, a single-jointed segment, a multi-jointed blade segment, a J-shaped blade segment, or similar.

More specifically, as shown in <FIG>, the leading edge segments <NUM> may have a forward pressure side surface <NUM> and a forward suction side surface <NUM>. Similarly, as shown in <FIG>, each of the trailing edge segments <NUM> may have an aft pressure side surface <NUM> and an aft suction side surface <NUM>. Thus, the forward pressure side surface <NUM> of the leading edge segment <NUM> and the aft pressure side surface <NUM> of the trailing edge segment <NUM> generally define a pressure side surface of the rotor blade <NUM>. Similarly, the forward suction side surface <NUM> of the leading edge segment <NUM> and the aft suction side surface <NUM> of the trailing edge segment <NUM> generally define a suction side surface of the rotor blade <NUM>. In addition, as particularly shown in <FIG>, the leading edge segment(s) <NUM> and the trailing edge segment(s) <NUM> may be joined at a pressure side seam <NUM> and a suction side seam <NUM>. For example, the blade segments <NUM>, <NUM> may be configured to overlap at the pressure side seam <NUM> and/or the suction side seam <NUM>. Further, as shown in <FIG>, adjacent blade segments <NUM> may be configured to overlap at a seam <NUM>. Alternatively, in certain embodiments, the various segments of the rotor blade <NUM> may be secured together via adhesive, mechanical fasteners, welding, or infusion configured between the overlapping leading and trailing edge segments <NUM>, <NUM> and/or the overlapping adjacent leading or trailing edge segments <NUM>, <NUM>.

In specific embodiments, as shown in <FIG> and <FIG>, the blade root section <NUM> may include one or more longitudinally extending spar caps <NUM>, <NUM> infused therewith. For example, the blade root section <NUM> may be configured according to <CIT> entitled "Blade Root Section for a Modular Rotor Blade and Method of Manufacturing Same".

Similarly, the blade tip section <NUM> may include one or more longitudinally extending spar caps <NUM>, <NUM> infused therewith. More specifically, as shown, the spar caps <NUM>, <NUM>, <NUM>, <NUM> may be configured to be engaged against opposing inner surfaces of the blade segments <NUM> of the rotor blade <NUM>. Further, the blade root spar caps <NUM>, <NUM> may be configured to align with the blade tip spar caps <NUM>, <NUM>. Thus, the spar caps <NUM>, <NUM>, <NUM>, <NUM> may generally be designed to control the bending stresses and/or other loads acting on the rotor blade <NUM> in a generally span-wise direction (a direction parallel to the span <NUM> of the rotor blade <NUM>) during operation of a wind turbine <NUM>. In addition, the spar caps <NUM>, <NUM>, <NUM>, <NUM> may be designed to withstand the span-wise compression occurring during operation of the wind turbine <NUM>. Further, the spar cap(s) <NUM>, <NUM>, <NUM>, <NUM> may be configured to extend from the blade root section <NUM> to the blade tip section <NUM> or a portion thereof. Thus, in certain embodiments, the blade root section <NUM> and the blade tip section <NUM> may be joined together via their respective spar caps <NUM>, <NUM>, <NUM>, <NUM>.

Referring to <FIG>, one or more shear webs <NUM> may be configured between the one or more spar caps <NUM>, <NUM>, <NUM>, <NUM>. More particularly, the shear web(s) <NUM> may be configured to increase the rigidity in the blade root section <NUM> and/or the blade tip section <NUM>. Further, the shear web(s) <NUM> may be configured to close out the blade root section <NUM>.

In addition, as shown in <FIG> and <FIG>, the additional structural component <NUM> may be secured to the blade root section <NUM> and extend in a generally span-wise direction so as to provide further support to the rotor blade <NUM>. For example, the structural component <NUM> may be configured according to <CIT> entitled "Structural Component for a Modular Rotor Blade". More specifically, the structural component <NUM> may extend any suitable distance between the blade root section <NUM> and the blade tip section <NUM>. Thus, the structural component <NUM> is configured to provide additional structural support for the rotor blade <NUM> as well as an optional mounting structure for the various blade segments <NUM> as described herein. For example, in certain embodiments, the structural component <NUM> may be secured to the blade root section <NUM> and may extend a predetermined span-wise distance such that the leading and/or trailing edge segments <NUM>, <NUM> can be mounted thereto.

Referring now to <FIG> and <FIG>, the present disclosure is directed to systems and method for manufacturing a blade component of a rotor blade of a wind turbine. In certain embodiments, the blade components described herein may include, for example, a rotor blade shell (a pressure side shell, a suction side shell, a trailing edge segment, a leading edge segment, etc.), a spar cap, a shear web, a leading edge bond cap, a reinforcement structure (such as a grid structure between inner and outer blade skins), or combinations thereof, as well as any other rotor blade component.

Referring particularly to <FIG>, a schematic diagram of one embodiment of a system <NUM> for manufacturing a blade component of the rotor blade <NUM> is illustrated according the present disclosure. More specifically, as shown, the system <NUM> includes a computer numeric control (CNC) device <NUM> having a printer head <NUM> coupled with a scanning device <NUM>. For example, in one embodiment, the CNC device may be a <NUM>-D printer that can be used for <NUM>-D printing an object. <NUM>-D printing, as used herein, is generally understood to encompass processes used to synthesize three-dimensional objects in which successive layers of material are formed under computer control to create the objects. As such, objects of almost any size and/or shape can be produced from digital model data. It should further be understood that the methods of the present disclosure are not limited to <NUM>-D printing, but rather, may also encompass more than three degrees of freedom such that the printing techniques are not limited to printing stacked two-dimensional layers, but are also capable of printing curved shapes. As such, any suitable CNC device may be used to print the various components described herein, one example of which is provided in <FIG>.

More specifically, as shown, the printer head <NUM> (or extruders) may include a print nozzle <NUM> mounted to a gantry <NUM> or frame structure such that the printer head <NUM> can move in multiple directions. In addition, as shown, the printer head <NUM> may be secured above the blade mold <NUM>. Thus, as shown, the print nozzle <NUM> of the printer head <NUM> is configured to print and deposit a material onto a printing surface atop the blade mold <NUM> to form or build up the blade component.

The material described herein may include any suitable flowable material including polymers, concrete, metals, etc. For example, suitable polymer materials may include thermoplastics, which generally encompass a plastic material or polymer that is reversible in nature. For example, thermoplastic materials typically become pliable or moldable when heated to a certain temperature and returns to a more rigid state upon cooling. Further, thermoplastic materials may include amorphous thermoplastic materials and/or semi-crystalline thermoplastic materials. For example, some amorphous thermoplastic materials may generally include, but are not limited to, styrenes, vinyls, cellulosics, polyesters, acrylics, polysulphones, and/or imides. More specifically, exemplary amorphous thermoplastic materials may include polystyrene, acrylonitrile butadiene styrene (ABS), polymethyl methacrylate (PMMA), glycolised polyethylene terephthalate (PET-G), polycarbonate, polyvinyl acetate, amorphous polyamide, polyvinyl chlorides (PVC), polyvinylidene chloride, polyurethane, or any other suitable amorphous thermoplastic material. In addition, exemplary semi-crystalline thermoplastic materials may generally include, but are not limited to polyolefins, polyamides, fluropolymer, ethyl-methyl acrylate, polyesters, polycarbonates, and/or acetals. More specifically, exemplary semi-crystalline thermoplastic materials may include polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polypropylene, polyphenyl sulfide, polyethylene, polyamide (nylon), polyetherketone, or any other suitable semi-crystalline thermoplastic material.

Referring still to <FIG>, the printing surface may correspond to one or more blade skins <NUM> arranged atop a blade mold <NUM> of the rotor blade <NUM>. As such, the printer head <NUM> may be configured to print and deposit the material directly onto the blade skin(s) <NUM> to form the blade component.

Referring particularly to <FIG>, the scanning device <NUM> may include a processor <NUM> and one or more scanners <NUM> communicatively coupled to the processor <NUM>. As such, the scanning device <NUM> is configured to determine a profile of the blade skin(s) <NUM> atop the blade mold <NUM> as the blade component is being printed and deposited such that the printer head is automatically adjusted to compensate for changes in the profile in horizontal and/or vertical directions. In certain instances, the changes in the profile in the horizontal and/or vertical directions may be due to at least one of thermal expansion of the blade mold <NUM>, thickness variations of fibers of the blade skin(s) <NUM>, movement of the blade skin(s) atop the blade mold <NUM>, or material shrinkages on previous printed layers.

For example, in an embodiment, the scanner(s) <NUM> is configured to scan the blade skin(s) <NUM> atop the blade mold <NUM> (or the current printing surface) to generate one or more measurement signals. In one embodiment, as shown in <FIG>, the scanner(s) <NUM> may be a proximity sensor <NUM> (such as laser, ultrasound, infrared, optical, magnetic, radar and/or capacitive sensors), a touch probe, a marker, and/or combinations thereof. Accordingly, as shown, the scanner(s) <NUM> is configured to scan the blade skin(s) <NUM> atop the blade mold <NUM> (or current printing surface) to generate the measurement signal(s). In such embodiments, as shown in <FIG>, the illustrated scanning device <NUM> includes multiple scanners <NUM> used to position and/or mark one or more reference features <NUM> on the blade skin(s) <NUM> atop the blade mold <NUM>. For example, as shown, the scanners <NUM> can be used to mark or etch a location for one or more reference features on the blade skin(s) <NUM>. Thus, in one embodiment, a visible laser or marking can be used to locate placement of stops that can be attached, e.g. permanently, to the blade mold <NUM> as bump stops for blade component locating. Moreover, as shown, the scanners <NUM> can be arranged in such a manner as to ensure monitoring of the printing surface at the location of the nozzle <NUM> so as to avoid the nozzle <NUM> from causing damage to the skins, the mold <NUM>, and/or the printer.

In additional embodiments, the blade skin(s) <NUM> may include the reference features <NUM> formed therein. Thus, the blade skin(s) <NUM> can be easily aligned atop the blade mold <NUM> using the reference features <NUM>. Thus, in several embodiments, the scanning device <NUM> may also be configured to determine a starting location for the printer head <NUM> to start printing and depositing the material based on locations of the reference features <NUM>.

Alternatively or in addition, as shown in <FIG>, the scanner <NUM> may be a touch probe <NUM> that is used to scan or probe the blade skin(s) <NUM> atop blade mold <NUM> (or current printing surface) to generate the measurement signal(s). For example, in one embodiment, the measurement signal(s) may include at least two reference points on the blade skin(s) <NUM> atop the blade mold <NUM> as the blade component is being printed and deposited.

Thus, the processor <NUM> of the scanning device <NUM> is configured to receive the measurement signal(s) and determine the profile of the blade skin(s) atop the blade mold <NUM> as the blade component is being printed and deposited in real-time based on the measurement signal(s). For example, as shown in <FIG>, the processor <NUM> may be configured to generate a model <NUM> of the blade skin(s) <NUM> atop the blade mold <NUM> (or current printing surface) that can be used to automatically adjust the printer head <NUM> to accommodate or compensate for the changes in the model <NUM> in the horizontal and/or vertical directions. More specifically, in one embodiment, the processor <NUM> may generate a printing path in real-time based the reference point(s). Alternatively, the processor <NUM> may correct a predetermined printing path of the printer head <NUM> based the reference point(s).

Referring now to <FIG>, a flow diagram of one embodiment of method <NUM> for manufacturing a blade component of a rotor blade of a wind turbine is illustrated. In general, the method <NUM> is described herein as implemented for manufacturing the rotor blade components described above. However, it should be appreciated that the disclosed method <NUM> may be used to manufacture any other rotor blade components as well as additional components as desired. In addition, although <FIG> depicts steps performed in a particular order for purposes of illustration and discussion, the methods described herein are not limited to any particular order or arrangement. One skilled in the art, using the disclosures provided herein, will appreciate that various steps of the methods can be omitted, rearranged, combined and/or adapted in various ways.

As shown at (<NUM>), the method <NUM> includes arrange at least one blade skin atop a blade mold of the blade component. As shown at (<NUM>), the method <NUM> includes printing and depositing, via the printer head <NUM> of the CNC device <NUM>, a material onto the at least one blade skin atop the blade mold to form the blade component. As shown at (<NUM>), the method <NUM> includes scanning, via the scanning device <NUM>, a profile of the at least one blade skin atop the blade mold as the blade component is being printed and deposited layer by layer. As shown at (<NUM>), the method <NUM> includes automatically adjusting the printer head <NUM> based on the scanning to compensate for changes in the profile in at least one of a horizontal direction or a vertical direction due to at least one of thermal expansion of the blade mold, thickness variations of fibers of the at least one blade skin, or movement of the at least one blade skin atop the blade mold.

Claim 1:
A system (<NUM>) for manufacturing a blade component of a rotor blade (<NUM>) of a wind turbine, the system (<NUM>) comprising:
a blade mold (<NUM>) of the rotor blade (<NUM>);
at least one blade skin (<NUM>) arranged atop the blade mold (<NUM>); and,
a computer numeric control (CNC) device (<NUM>) comprising a printer head (<NUM>) and a scanning device (<NUM>),
the printer head (<NUM>) for printing and depositing a material onto the at least one blade skin (<NUM>) to form the blade component (<NUM>),
wherein the scanning device (<NUM>) comprises a processor (<NUM>) and a scanner (<NUM>) communicatively coupled to the processor (<NUM>), the scanning device (<NUM>) for determining a profile of the at least one blade skin (<NUM>) atop the blade mold (<NUM>) as the blade component is being printed and deposited layer by layer characterized in that the printer head (<NUM>) is automatically adjusted to compensate for changes in the profile in at least one of a horizontal direction or a vertical direction due to at least one of thermal expansion of the blade mold (<NUM>), thickness variations of fibers of the at least one blade skin (<NUM>), or movement of the at least one blade skin (<NUM>) atop the blade mold (<NUM>).