Optimization of layup process for fabrication of wind turbine blades using model-based optical projection system
A method to design the kits and layup the reinforcement layers and core using projection system, comprising a mold having a contoured surface; a layup projection generator which: defines a plurality of mold sections; identifies the dimensions and location for a plurality of layup segments. A model-based calibration method for alignment of laser projection system is provided in which mold features are drawn digitally, incorporated into the plug(s) which form the wind turbine blade mold, and transferred into the mold. The mold also includes reflective targets which are keyed to the molded geometry wherein their position is calculated from the 3D model. This method ensures the precision level required from projection system to effectively assist with fabrication of wind turbine blades. In this method, digital location of reflectors is utilized to compensate for the mold deformations.
1. A method for fabrication of a wind turbine blade comprising:
receiving at least one specification for a blade design, the blade design including a plurality of core panels;
creating a mold, the mold configured for forming the blade and having a plurality of reflective targets included therein;
generating a 3D manufacturing model of the blade design, the manufacturing model including a plurality of core panels;
extracting at least one optical projection file from the manufacturing model, the optical projection file(s) having coordinates for projection of a marking(s) within a mold and digital coordinates for the reflective targets;
calibrating an optical projection apparatus;
wherein calibration includes comparing the projected marking to the digital location of the reflective target, wherein the digital location of the reflective target is different than the physical location of the reflective target; and
wherein the calibration is performed while the mold is at a temperature above room temperature.
2. The method of claim 1 , wherein projecting is performed by a plurality of lasers.
3. The method of claim 1 , wherein the optical projection file(s) include edges of core panels.
4. The method of claim 1 , wherein all core panel geometry is projected simultaneously.
5. The method of claim 1 , wherein select core panel markings are projected in a serial fashion.
6. The method of claim 1 , wherein the mold is created from a plug, the plug including reflective projector targets which are embedded into the mold.
7. The method of claim 1 , wherein the projection apparatus includes a plurality of lasers, each laser aligned with six or more reflective targets.
8. The method of claim 1 , wherein the projection apparatus includes a plurality of lasers, adjacent laser projectors aligned with one or more shared reflective targets.
9. The method of claim 1 , wherein the projection apparatus includes a plurality of lasers, the lasers are configured for relative movement with respect to the mold.
10. The method of claim 1 , wherein the projection apparatus includes a plurality of lasers, the lasers are configured for relative movement with respect to each other.
11. The method of claim 1 , wherein the reflective targets are embedded within the mold.
12. The method of claim 1 , wherein the reflective targets are configured as mirrors.