Semi-automated layup process for fabrication of wind turbine blades using laser projection system
A system for fabrication of a wind turbine blade including a laser projection which identifies the dimensions for a plurality of layup segments; determines the sequence of layup segments within first and second sections of the mold, wherein the sequence of layup segments within the second section of the mold are synchronized with the layup segments within a first section of the mold. The system also includes a projection device visually depicting the boundaries of a plurality of layup segments onto the mold. This system automates fabrication of composite structures by setting a pace for each task and ensuring operators complete each task within the allotted period. The projection system and layup delivery mechanism can advance with respect the mold to ensure the pace is maintained and an overall product cycle time is adhered to.
1. A system for fabrication of a composite structure comprising:
a mold, the mold having a contoured surface;
a layup projection generator, the layup projection generator:
defines a plurality of mold sections;
identifies the dimensions for a plurality of layup segments;
specifies the sequence of layup segments within a first section of the mold;
specifies the sequence of layup segments within a second section of the mold, the sequence of layup segments within the second section of the mold synchronized with the layup segments within a first section of the mold;
a projection device, the projection device visually depicting the boundaries of a plurality of layup segments onto the mold; and
a layup delivery mechanism, the layup delivery mechanism delivering a layup segment to at least one section of the mold.
2. The system of claim 1 , wherein the projection device simultaneously depicts the boundaries of a plurality of layup segments onto the mold.
3. The system of claim 1 , wherein the projection device sequentially depicts the boundaries of each layup segment onto the mold.
4. The system of claim 1 , wherein a first section of the mold defines the root portion of a wind turbine blade.
5. The system of claim 1 , wherein a second section of the mold defines the tip portion of a wind turbine blade.
6. The system of claim 1 , wherein a density of layup segments in a first section of the mold is higher than the density of layup segments in a second section of the mold.
7. The system of claim 1 , wherein the layup delivery mechanism for layup segments of the first section of mold is different from the layup delivery mechanism for layup segments of the second section of the mold.
8. The system of claim 1 , wherein the layup projection generator is disposed above the mold.
9. The system of claim 1 , wherein the layup projection generator and mold are configured for relative movement.
10. The system of claim 1 , wherein the projection device projects the boundaries of layup segments via an optical laser.
11. A method of manufacturing a composite structure comprising:
providing a mold, the mold having a contoured surface;
providing a layup projection generator, the layup projection generator:
defining a plurality of mold sections;
identifying the dimensions for a plurality of layup segments;
specifies the sequence of layup segments within a first section of the mold, the sequence of layup segments within the first section of the mold configured as series of sub-tasks,
each sub-task having a start and end, with an endpoint of the first sub-task occurring prior to start of the next sequential sub-task;
specifies the sequence of layup segments within a second section of the mold, the sequence of layup segments within the second section of the mold synchronized with the layup segments within a first section of the mold;
projecting the boundaries of a plurality of layup segments onto the mold; and
delivering a layup segment to at least one section of the mold.
12. The method of claim 11 , wherein a first section of the mold defines the root portion of a wind turbine blade.
13. The method of claim 11 , wherein a second section of the mold defines the tip portion of a wind turbine blade.
14. The method of claim 11 , wherein layup segments within the first section of the mold are projected at a faster rate than layup segments within the second section of the mold.
15. The method of claim 11 , wherein each layup segment within the first section of the mold includes a unique boundary projection.
16. The method of claim 11 , wherein a plurality of layup segments within the second section of the mold remain projected onto the second mold section throughout at least two sub-tasks of a sequence within the first section of the mold.
17. The method of claim 11 , wherein the sequence of layup segments are predefined time intervals.
18. The method of claim 11 , wherein the cycle time for manufacturing the composite structure is defined based on the sequence of layup segments.
19. The method of claim 11 , wherein the layup projection generator is disposed above the mold.
20. The method of claim 11 , wherein the layup projection generator and mold are configured for relative movement.