METHODS AND DEVICES FOR POST MOULD PROCESSING OF A COMPOSITE STRUCTURE
20240009788 ยท 2024-01-11
Inventors
- Peter BROOME (New Orleans, LA, US)
- John ARSENEAUX (New Orleans, LA, US)
- Murray FISHER (New Orleans, UA)
- Sierra VAN DIJK (New Orleans, LA, US)
- Matthew Joseph EMIG (New Orleans, LA, US)
Cpc classification
B23Q9/0014
PERFORMING OPERATIONS; TRANSPORTING
International classification
Abstract
The present invention relates to methods and devices for post mould processing of a composite structure, wherein the composite structure extends along a longitudinal direction and comprising a main composite part, and a flange section extending around a perimeter of the main composite part. The flange section comprises an upper surface having a first mating part with a specific shape in a cross-sectional plane perpendicular to the longitudinal direction, the first mating part being located at a fixed position relative to the main composite part. The method may comprise attaching a guiding device to the outer surface of the composite structure and inspecting and/or processing the surface area with a tool fitted to the guiding device.
Claims
1. A guiding device for inspection and/or processing of a surface area of an outer surface of a composite structure, the composite structure extending along a longitudinal direction, the guiding device comprising: one or more elongated base elements including a primary elongated base element adapted to be arranged on the outer surface of the composite structure, one or more attachment elements for detachably attaching the one or more elongated base elements to the composite structure, one or more displacement bars including a primary displacement bar and optionally a secondary displacement bar, the primary displacement bar being movably attached to the primary elongated base element, a support element movably attached to the one or more displacement bars and displaceable along the longitudinal direction and perpendicular to the longitudinal direction relative to the primary elongated base element, the support element being adapted to be fitted with a tool for inspecting and/or processing the surface area of the composite structure.
2. Guiding device according to claim 1, wherein the support element is movable along the one or more displacement bars.
3. Guiding device according to claim 1, wherein the one or more elongated base elements include a secondary elongated base element, and wherein the primary displacement bar is movably attached to the secondary elongated base element, the primary displacement bar extending between the primary elongated base element and the secondary elongated base element and wherein the support element is being arranged between the primary elongated base element and the secondary elongated base element.
4. Guiding device according to claim 1, wherein the primary elongated base element and/or the secondary elongated base element are adapted to be arranged parallel to the longitudinal direction of the composite structure or wherein the primary elongated base element and/or the secondary elongated base element are adapted to be arranged perpendicular to the longitudinal direction of the composite structure.
5. Guiding device according to claim 1, wherein the one or more elongated base elements includes a tertiary elongated base element and optionally a quaternary elongated base element, the tertiary elongated base element and optionally the quaternary elongated base element being arranged substantially perpendicular to the primary elongated base element and/or wherein the tertiary elongated base element and optionally the quaternary elongated base element extend between the primary elongated base element and the secondary elongated base element.
6. Guiding device according to claim 1, wherein the primary displacement bar is arranged substantially perpendicular to the primary elongated base element and/or wherein the primary displacement bar is movable along the primary elongated base element.
7. Guiding device according to claim 1, wherein the one or more displacement bars are curvilinear bars adapted to substantially follow a curvature of the surface area of the composite structure.
8. Guiding device according to claim 1, wherein the one or more displacement bars include the secondary displacement bar, and wherein the support element is arranged between the primary displacement bar and the secondary displacement bar.
9. Guiding device according to claim 1, wherein the primary displacement bar comprises a first end movably attached to the primary elongated base element and an opposite second end adapted to contact and being slidable over the outer surface of the composite structure and wherein the primary displacement bar optionally comprises a wheel arranged at the second end adapted to contact the outer surface of the composite structure.
10. Guiding device according to claim 1, wherein each of the one or more attachment elements comprises a vacuum element with a fluid outlet adapted to be connected to a vacuum source, the vacuum element being adapted to adhere to the outer surface of the composite structure by application of a negative pressure by the vacuum source and/or wherein a primary attachment element of the one or more attachment elements are arranged on the primary elongated base element, such as to be positioned between the primary elongated base element and the outer surface of the composite structure and/or wherein a tertiary attachment element of the one or more attachment elements are arranged on the tertiary elongated base element, such as to be positioned between the tertiary elongated base element and the outer surface of the composite structure.
11. A method for inspection and/or processing of a surface area of an outer surface of a composite structure, the composite structure extending along a longitudinal direction, the method comprising: attaching the guiding device according to claim 1 to the outer surface of the composite structure, wherein attaching the guiding device includes aligning the one or more elongated base elements of the guiding device with one or more datum points of the outer surface of the composite structure, fitting the support element with a tool for inspecting and/or processing the surface area of the composite structure, moving the support element to be over the surface area, inspecting and/or processing the surface area with the tool.
12. An assistance tool for assisting in tasks performed at a composite structure, the composite structure extending along a longitudinal direction and comprising a main composite part, and a flange section extending around a perimeter of the main composite part, the flange section comprising an upper surface having a first mating part with a specific shape in a cross-sectional plane perpendicular to the longitudinal direction, the first mating part being located at a fixed position relative to the main composite part, the assistance tool comprising a body having a bottom surface defining a second mating part shaped and dimensioned to fit with the specific shape of the first mating part of the flange section, such that when the assistance tool is arranged on the flange section and the second mating part is fitted with the first mating part, the body of the assistance tool can be moved along the flange section at a pre-determined distance from the main composite part.
13. The assistance tool according to claim 12, wherein the assistance tool comprises a cutting element, such as a circular saw, connected to the body and configured for cutting the composite structure along a cutting path defined between the main composite part and the flange section, to separate the flange section from the main composite part.
14. The assistance tool according to claim 12, wherein the second mating part in the cross-sectional plane comprises a second substantially linear section extending in a first direction, a second primary mating section extending from the second substantially linear section in a direction, which is different from the first direction, and optionally a second end section extending from the second primary mating section.
15. The assistance tool according to claim 12, wherein the position of the cutting element relative to the body is adjustable, such that the cutting element can be moved between a first position and a second position, wherein when the cutting element is arranged in the first position, the cutting element is arranged above the bottom surface of the body, when the cutting element is in a second position, at least part of the cutting element is arranged below the lower surface of the body.
16. The assistance tool according to claim 12, wherein the assistance tool is configured to be manually operated by applying a force to the assistance tool in a direction towards the first mating part, while moving the body of the assistance tool along the flange section with the second mating part fitted with the first mating part and wherein the assistance tool optionally comprises an operating handle connected to the body and configured to facilitate manual operation of the assistance tool.
17. The assistance tool according to claim 12, wherein the assistance tool comprises a datum point indicator connected to the body at a reference point and configured for marking one or more datum points on the main composite part relative to a datum point on the flange section of the composite structure, when the assistance tool is moved along the flange section, wherein the datum point indicator is an elongated element being attached at a first end to the reference point and having a datum point marker at a second end, opposite the first end.
18. The assistance tool according to claim 17, wherein the datum point marker is a flexible liner and/or a liner adjustable in at least one length direction and/or wherein the elongated element comprises telescopic cylinders and the datum point marker at an outermost cylinder of the telescopic cylinders, wherein the telescopic cylinders can be moved in and out of each other to adjust the position of the datum point marker relative to the reference point.
19. A system comprising a composite structure extending along a longitudinal direction and comprising a main composite part and a flange section extending around a perimeter of the main composite part, the flange section comprising an upper surface having a first mating part with a specific shape in a cross-sectional plane perpendicular to the longitudinal direction, the first mating part being located at a fixed position relative to the main composite part, the assistance tool according to claim 12.
20. A system according to claim 8, wherein the composite structure is a wind turbine blade, the main composite part is an airfoil of the wind turbine blade, and the flange section extends from the main composite part along a leading edge and/or a trailing edge of the airfoil.
21. Method for separating a flange section from a composite structure, wherein the composite structure extends along a longitudinal direction and comprising a main composite part, and the flange section extends around a perimeter of the main composite part, the flange section comprising an upper surface having a first mating part with a specific shape in a cross-sectional plane perpendicular to the longitudinal direction, the first mating part being located at a fixed position relative to the main composite part, and a cutting path being defined between the main composite part and the flange section, the method comprising the steps of: providing an assistance tool according to claim 12, arranging the assistance tool such that the first mating part of the composite structure and the second mating part of the assistance tool are fitted to each other, and moving the assistance tool along the flange section while operating the cutting element, to separate the flange section from the main composite part along the cutting path.
22. Method for transferring one or more datum points on a composite structure, wherein the composite structure extends along a longitudinal direction and comprising a main composite part, and the flange section extends around a perimeter of the main composite part, the flange section comprising an upper surface having a first mating part with a specific shape in a cross-sectional plane perpendicular to the longitudinal direction, the first mating part being located at a fixed position relative to the main composite part, the method comprising: providing an assistance tool according to claim 12, arranging the assistance tool such that the first mating part of the composite structure and the second mating part of the assistance tool are fitted to each other, and moving the assistance tool along the flange section while marking one or more datum points on the main composite part with the datum point marker at a pre-determined distance from respective one or more datum points on the flange section.
23. Method according to claim 10, wherein the composite structure is a wind turbine blade, the main composite part is an airfoil of the wind turbine blade, and the flange section extends from the main composite part along a leading edge and/or a trailing edge of the airfoil.
24. A method for post mould processing of a composite structure, wherein the composite structure extends along a longitudinal direction and comprising a main composite part, and a flange section extending around a perimeter of the main composite part, the flange section comprising an upper surface having a first mating part with a specific shape in a cross-sectional plane perpendicular to the longitudinal direction, the first mating part being located at a fixed position relative to the main composite part, the method comprising: providing an assistance tool according to claim 12, arranging the assistance tool such that the first mating part of the composite structure and the second mating part of the assistance tool are fitted to each other, moving the assistance tool along the flange section while marking one or more datum points on the main composite part with the datum point marker at a pre-determined distance from respective one or more datum points on the flange section, providing a guiding device according to claim 12, attaching the guiding device to the outer surface of the composite structure aligning the one or more elongated base elements of the guiding device with the one or more datum points on the main composite part, fitting the support element with a tool for inspecting and/or processing a surface area of the composite structure, moving the support element to be above the surface area, inspecting and/or processing the surface area with the tool.
25. Method according to claim 12, wherein the composite structure is a wind turbine blade comprising a leading edge and wherein the surface area includes a part of the leading edge of the wind turbine blade.
Description
BRIEF DESCRIPTION OF THE FIGURES
[0066] Embodiments of the disclosure will be described in more detail in the following with regard to the accompanying figures. 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.
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DETAILED DESCRIPTION
[0084] Various exemplary embodiments and details are described hereinafter, with reference to the figures when relevant. It should be noted that the figures may or may not be drawn to scale and that elements of similar structures or functions are represented by like reference numerals throughout the figures. It should also be noted that the figures are only intended to facilitate the description of the embodiments. They are not intended as an exhaustive description of the invention or as a limitation on the scope of the invention. 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 embodiment even if not so illustrated, or if not so explicitly described.
[0085]
[0086]
[0087] 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.
[0088] 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.
[0089] 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.
[0090] 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.
[0091]
[0092] The first mould 80 has a first moulding surface 84. The second mould 90 has a second moulding surface 94. The first and second moulding surfaces 84, 94 are configured for defining an outer shape of the blade shell parts.
[0093]
[0094] Many wind turbine blade moulds are made with a flange section 308 extending around a perimeter of each shell part of the mould. The purpose of having the flange section 308 is to facilitate assembly of the shell parts, e.g. in securing the blade part in the mould when lifting and turning the mould. However, the flange section 308 will be cut off before the end of the manufacturing process. Thus, in a certain phase of the manufacturing process, each shell part comprises a main composite part 306, i.e. the part that will be part of the finished wind turbine, and a flange section 308 which is used when assembling the two shell parts.
[0095] Thus, the composite structure 300 comprises a flange section 308 extending around the perimeter of the main composite part 306. When the flange section 308 has served its purpose, it is to be cut off along the cutting path 310. The cutting path 310 is illustrated by a dotted line.
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[0098] In this state, an assistance tool, which will be described in further detail below, can be arranged on the flange section 308 to assist in post mould processing. The assistance tool may utilize the flange section 308 in an advantageous way, allowing it to assist in different tasks performed at the wind turbine blade.
[0099] In
[0100]
[0101] As illustrated in
[0102] In
[0103] The flange section 308 of the composite structure 300 comprises an upper surface having a specific shape in a cross-sectional plane perpendicular to the longitudinal direction of the composite structure 300. At least part of the upper surface of the flange section 308 is configured to be fitted with a lower surface of the assistance tool 500 of the present invention. The part of the flange section 308 configured to be fitted with the assistance tool 500 is herein denoted as the first mating part 314. The part of the bottom surface of the assistance tool 500 configured to be fitted with the flange section 308 is herein referred to as the second mating part 516 of the assistance tool 500. The first mating part 314 and the second mating part 516 are configured such that when the assistance tool 500 is arranged on the flange section 308 and the second mating part 516 is fitted with the first mating part 314, the body 502 of the assistance tool 500 can be moved along the flange section 308 at a pre-determined distance 309 from the main composite part 306, i.e. the part of the composite structure that will be present in the finished composite structure.
[0104] In
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[0107] In
[0108] In
[0109] In
[0110] In
[0111] In
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[0113] The assistance tool 500 in
[0114] The position of the cutting element 504 relative to the body 502 of the assistance tool 500 may be adjustable, such that the cutting element 504 can be moved between a first position, as illustrated in
[0115] The assistance tool 500, as illustrated in
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[0117] In
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[0119] In
[0120] The datum point indicator 514 in
[0121]
[0122]
[0123] It is noted that the assistance tool 500 may comprise both the cutting element 504, as illustrated in
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[0126] The guiding device 700 comprises one or more elongated base elements. In the illustrated example, the guiding device comprises a primary elongated base element 704, a secondary elongated base element 706, a tertiary elongated base element 708 and a quaternary elongated base element 710. The primary elongated base element 704 and the secondary elongated base element 706 may be parallel. The tertiary elongated base element 708 and the quaternary elongated base element 710 may be parallel. The tertiary elongated base element 708 and the quaternary elongated base element 710 may be arranged substantially perpendicular to the primary elongated base element 702 and the secondary elongated base element 704.
[0127] The elongated base elements 704, 706, 708, 710 are adapted to be arranged on the outer surface of the composite structure 300. The tertiary elongated base element 708 and the quaternary elongated base element 710 may extend between the primary elongated base element 704 and the secondary elongated base element 706. The elongated base elements 704, 706, 708, 710 may be arranged parallel and/or perpendicular to the longitudinal direction L of the composite structure 300. For example, as illustrated, the primary elongated base element 704 and the secondary elongated base element 706 may be arranged parallel to the longitudinal direction L, and the tertiary elongated base element 708 and the quaternary elongated base element 710 may be arranged perpendicular to the longitudinal direction L. In an alternative embodiment the primary elongated base element 704 and the secondary elongated base element 706 may be arranged perpendicular to the longitudinal direction L.
[0128] The guiding device 700 comprises one or more attachment elements 712a, 712b, 712c, 712d for detachably attaching the elongated base elements 704, 706, 708, 710 to the composite structure 300. Each of the attachment elements 712a, 712b, 712c, 712d may comprise a vacuum element 730 with a fluid outlet 732 adapted to be connected to a vacuum source, such as to be adapted to adhere to the outer surface 302 of the composite structure 300 by application of a negative pressure by the vacuum source.
[0129] In the illustrated example, the guiding device comprises a primary attachment element 712a, a secondary attachment element 712b, a tertiary attachment element 712c and a quaternary attachment element 712d. In other embodiments, the guiding device may comprise only the tertiary attachment element 712c and the quaternary attachment element 712d or only the primary attachment element 712a and the secondary attachment element 712b.
[0130] The primary attachment element 712a is arranged on the primary elongated base element 704, such as to be positioned between the primary elongated base element 704 and the outer surface 302 of the composite structure 300. The secondary attachment element 712b is arranged on the secondary elongated base element 706, such as to be positioned between the secondary elongated base element 706 and the outer surface 302 of the composite structure 300. The tertiary attachment element 712c is arranged on the tertiary elongated base element 708, such as to be positioned between the tertiary elongated base element 708 and the outer surface 302 of the composite structure 300. The quaternary attachment element 712d is arranged on the quaternary elongated base element 710, such as to be positioned between the quaternary elongated base element 710 and the outer surface 302 of the composite structure 300. It should be understood that the attachment elements may be subdivided into a plurality of attachment elements, e.g. the guiding device 700 may comprise a plurality of primary attachment elements 712a to be positioned between the primary elongated base element 704 and the outer surface 302 of the composite structure 300, and/or the guiding device 700 may comprise a plurality of secondary attachment elements 712b to be positioned between the secondary elongated base element 706 and the outer surface 302 of the composite structure 300, and/or the guiding device 700 may comprise a plurality of tertiary attachment elements 712c to be positioned between the tertiary elongated base element 708 and the outer surface 302 of the composite structure 300, and/or the guiding device 700 may comprise a plurality of quaternary attachment elements 712d to be positioned between the quaternary elongated base element 710 and the outer surface 302 of the composite structure 300.
[0131] The guiding device 700 comprises one or more displacement bars, which may be curvilinear bars adapted to substantially follow a curvature of the surface area 304 of the composite structure 300. In the present example, the guiding device 700 comprises a primary displacement bar 720 and a secondary displacement bar 722. As illustrated, the primary displacement bar 720 and the secondary displacement bar 722 may be parallel. The displacement bars 720, 722 are movably attached to the primary elongated base element 704. For example, the displacement bars 720, 722 are movable along the primary elongated base element 704. As illustrated in
[0132] The guiding device 700 comprises a support element 714 movably attached to the displacement bars 720, 722. For example, the support element 714 may be movable along the displacement bars 720, 722. Thereby, the support element 714 is displaceable along the longitudinal direction L and perpendicular to the longitudinal direction relative to the primary elongated base element 704. The support element 714 is adapted to be fitted with a tool for inspecting and/or processing the surface area 304 of the composite structure 300. The support element 714 may, as illustrated in
[0133] The guiding device 700 may be attached to the outer surface 302 of the composite structure 300, as illustrated, in order to inspect and/or process part of the surface area 304 of the composite structure. To achieve a precise position of the tool on the composite structure 300, the guiding device 700 may advantageously be attached to the composite structure 300 in accordance with known datum points, such as datum points provided by the assistance tool 500, as described in relation to previous figures. By using the disclosed guiding device 700 to inspect and/or process the surface area 304, by being attached to the composite structure 300 at a well-established position distant from the surface area 304, local imperfections within the surface area 304 have less or no influence on the measurement or processing of the surface area 304 itself. This may be of particular importance when inspecting and/or processing a leading edge of a wind turbine blade, which may be prone to many local variations influencing the aerodynamic properties of the wind turbine blade.
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[0137] As illustrated, the guiding device 700 comprises a plurality of primary attachment elements 712a arranged on the primary elongated base element 704 and positioned between the primary elongated base element 704 and the outer surface 302 of the composite structure 300. The primary attachment elements 712a comprise vacuum elements adapted to adhere to the outer surface 302 by application of a negative pressure.
[0138] Also, the guiding device 700 comprises a plurality of secondary attachment elements 712b arranged on the secondary elongated base element 706. The secondary elongated base elements are in the illustrated example provided to engage with bushings 96 of the root end 17. For a wind turbine blade 10, the positions of the bushings 96 are well-established and may serve as datum points for precise and well-established positioning of the guiding device 700 relative to the wind turbine blade 10.
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[0140] The primary displacement bar 720 is attached to and extends between the primary elongated base element 704 and the secondary elongated base element 706. The primary displacement bar 720 extends perpendicular to the primary elongated base element 704 and the secondary elongated base element 706.
[0141] The secondary displacement bar 722 is attached to and extends between the tertiary elongated base element 708 and the quaternary elongated base element 710. The secondary displacement bar 722 extends perpendicular to the tertiary elongated base element 708 and the quaternary elongated base element 706. The secondary displacement bar 722 extends parallel to the primary elongated base element 704 and the secondary elongated base element 706. The secondary displacement bar 722 extends perpendicular to the primary displacement bar 720.
[0142] The support element 714 is arranged at the interface between the primary displacement bar 720 and the secondary displacement bar 722.
[0143] The support element 714 is displaceable along the longitudinal direction and perpendicular to the longitudinal direction relative to the primary elongated base element 704, by being movable along and together with the displacement bars 720, 722.
[0144]
[0145] While moving 1004 the assistance tool, the method may then also comprise operating 1006 a cutting element to separate the flange section from the main composite part along a cutting path.
[0146] Alternatively or additionally, the method may comprise, while moving 1004 the assistance tool, marking 1008 one or more datum points on the main composite part with a datum point marker at a pre-determined distance from respective one or more datum points on the flange section or on another part of the composite structure. The pre-determined distance may be a constant distance. However, in some embodiments, the pre-determined distance is varying with the position of the assistance tool along the longitudinal direction relative to the composite structure. Thus, the method may further comprise varying 1009 the pre-determined distance, while moving 1004 the assistance tool along the flange section.
[0147] By removing the flange section (by operating the cutting element 1006), simultaneously with transferring 1008 datum points, different post mould processing steps are combined in an improved streamlined and precise method.
[0148]
[0149]
[0150] While moving 1004 the assistance tool, the method 1100 may then also comprise operating 1006 a cutting element to separate the flange section from the main composite part along a cutting path. The method 1100 may comprise, while moving 1004 the assistance tool, marking 1008 one or more datum points on the main composite part with a datum point marker at a pre-determined distance from respective one or more datum points on the flange section or on another part of the composite structure.
[0151] Furthermore, the method 1100 comprises providing 1011 a guiding device, such as the guiding device as described in relation to
[0152] The step of attaching 1012 the guiding device is improved by the transfer and marking 1008 of datum points by the assistance tool and by aligning the guiding device relative to the transferred datum points.
[0153] For example, the guiding device may be attached 1012 to the outer surface of the composite structure by aligning the one or more elongated base elements of the guiding device with the one or more datum points on the main composite part.
[0154] The method 1100 further comprises fitting 1014 a support element of the guiding device with a tool for inspecting and/or processing a surface area of the composite structure, moving 1016 the support element to be above the surface area, and inspecting and/or processing 1018 the surface area with the tool.
[0155] Preferably, the composite structure is a wind turbine blade and the surface area to be inspected or processed includes a part of a leading edge of the wind turbine blade. In some embodiments, the specified datum points are positioned more than a first distance from the leading edge of the composite structure. In some embodiments, the surface area of the composite structure is more than a first distance from the one or more datum points on the main composite part.
[0156] The invention has been described with reference to a preferred embodiment. However, the scope of the invention is not limited to the illustrated embodiment, and alterations and modifications can be carried out without deviating from the scope of the invention.
[0157] Throughout the description, the use of the terms first, second, third, fourth, primary, secondary, tertiary etc. does not imply any particular order or importance but are included to identify individual elements. Furthermore, the labelling of a first element does not imply the presence of a second element and vice versa.
Exemplary Embodiments of the Present Disclosure
[0158] 1. An assistance tool for assisting in tasks performed at a composite structure, the composite structure extending along a longitudinal direction and comprising a main composite part, and a flange section extending around a perimeter of the main composite part, the flange section comprising an upper surface having a first mating part with a specific shape in a cross sectional plane perpendicular to the longitudinal direction, the first mating part being located at a fixed position relative to the main composite part, [0159] the assistance tool comprising [0160] a body having a bottom surface defining a second mating part shaped and dimensioned to fit with the specific shape of the first mating part of the flange section, such that when the assistance tool is arranged on the flange section and the second mating part is fitted with the first mating part, the body of the assistance tool can be moved along the flange section, at a pre-determined distance from the main composite part.
[0161] 2. The assistance tool according to item 1, wherein the assistance tool comprises a cutting element connected to the body and configured for cutting the composite structure along a cutting path defined between the main composite part and the flange section to separate the flange section from the main composite part.
[0162] 3. The assistance tool according to item 1 or 2, wherein the second mating part in the cross-sectional plane comprises a second substantially linear section extending in a first direction, a second primary mating section extending from the second substantially linear section in a direction which is different from the first direction, and optionally a second end section extending from the second primary mating section.
[0163] 4. The assistance tool according to item 3, wherein the second primary mating section is a slope or a curve or a linear section extending with an angle between 10-170 degrees from the second substantially linear section.
[0164] 5. The assistance tool according to any of the preceding items, wherein the cutting element is a circular saw.
[0165] 6. The assistance tool according to any of the preceding items, wherein the position of the cutting element relative to the body is adjustable, such that the cutting element can be moved between a first position and a second position.
[0166] 7. The assistance tool according to item 6, wherein the body comprises a track allowing the cutting element to move relative to the body, the track defining the first and second position.
[0167] 8. The assistance tool according to any of items 6 or 7, wherein [0168] when the cutting element is arranged in the first position, the cutting element is arranged above the bottom surface of the body, [0169] when the cutting element is in a second position, at least part of the cutting element is arranged below the lower surface of the body.
[0170] 9. The assistance tool according to any of the preceding items, wherein the assistance tool is configured to be manually operated, by applying a force to the assistance tool in a direction towards the first mating part, while moving the body of the assistance tool along the flange section with the second mating part fitted with the first mating part.
[0171] 10. The assistance tool according to any of the preceding items, wherein the assistance tool comprises an operating handle connected to the body and configured to facilitate manual operation of the assistance tool.
[0172] 11. The assistance tool according to any of the preceding items, wherein at least part of the bottom surface of the body comprises a low-friction material allowing it to be moved with low friction along the flange section.
[0173] 12. The assistance tool according to any of the preceding items, wherein the composite structure is a wind turbine blade and the main composite part is an airfoil of the wind turbine blade.
[0174] 13. The assistance tool according to any of the preceding items, wherein the first mating part of the flange section in the cross-sectional plane perpendicular to the longitudinal direction comprises a first substantially linear section extending from the main composite part in a first direction, a first primary mating section extending from the first substantially linear section in a direction which is different from the first direction, and optionally a first end section extending from the first primary mating section in the first direction.
[0175] 14. The assistance tool according to any of the preceding items, wherein the assistance tool comprises a datum point indicator connected to the body at a reference point and configured for marking one or more datum points on the main composite part relative to a datum point on the flange section of the composite structure when the assistance tool is moved along the flange section.
[0176] 15. The assistance tool according to item 14, wherein the datum point indicator is an elongated element being attached at a first end to the reference point and having a datum point marker at a second end, opposite the first end.
[0177] 16. The assistance tool according to item 14 or 15, wherein the datum point marker is a flexible liner and/or a liner adjustable in at least one length direction.
[0178] 17. The assistance tool according to any of items 15-16, wherein the elongated element comprises telescopic cylinders and the datum point marker at an outermost cylinder of the telescopic cylinders, wherein the telescopic cylinders can be moved in and out of each other to adjust the position of the datum point marker relative to the reference point.
[0179] 18. A system comprising [0180] a composite structure extending along a longitudinal direction and comprising [0181] a main composite part and [0182] a flange section extending around a perimeter of the main composite part, the flange section comprising an upper surface having a first mating part with a specific shape in a cross-sectional plane perpendicular to the longitudinal direction, the first mating part being located at a fixed position relative to the main composite part, [0183] the assistance tool according to any of the preceding items.
[0184] 19. The system according to item 18, wherein the composite structure is a wind turbine blade, the main composite part is an airfoil of the wind turbine blade, and the flange section extends from the main composite part along a leading edge and/or a trailing edge of the airfoil.
[0185] 20. The system according to any of items 18 or 19, wherein the first mating part of the flange section in the cross sectional plane perpendicular to the longitudinal direction comprises a first substantially linear section extending from the main composite part in a first direction, a first primary mating section extending from the first substantially linear section in a direction which is different from the first direction, and optionally a first end section extending from the first primary mating section in the first direction.
[0186] 21. Method for separating a flange section from a composite structure, wherein the composite structure extends along a longitudinal direction and comprising a main composite part, and the flange section extends around a perimeter of the main composite part, the flange section comprising an upper surface having a first mating part with a specific shape in a cross-sectional plane perpendicular to the longitudinal direction, the first mating part being located at a fixed position relative to the main composite part, and a cutting path being defined between the main composite part and the flange section, the method comprising the steps of: [0187] providing an assistance tool according to any of items 2-17, [0188] arranging the assistance tool such that the first mating part of the composite structure and the second mating part of the assistance tool are fitted to each other, and [0189] moving the assistance tool along the flange section while operating the cutting element, to separate the flange section from the main composite part along the cutting path.
[0190] 22. Method according to item 21, the method further comprising the step of: while moving the assistance tool along the flange section, marking one or more datum points on the main composite part with the datum point marker at a pre-determined distance from a datum point on the flange section.
[0191] 23. Method for transferring one or more datum points on a composite structure, wherein the composite structure extends along a longitudinal direction and comprising a main composite part, and the flange section extends around a perimeter of the main composite part, the flange section comprising an upper surface having a first mating part with a specific shape in a cross-sectional plane perpendicular to the longitudinal direction, the first mating part being located at a fixed position relative to the main composite part, the method comprising: [0192] providing an assistance tool according to any of items 14-17, [0193] arranging the assistance tool such that the first mating part of the composite structure and the second mating part of the assistance tool are fitted to each other, and [0194] moving the assistance tool along the flange section while marking one or more datum points on the main composite part with the datum point marker at a pre-determined distance from respective one or more datum points on the flange section.
[0195] 24. Method according to any of items 21-23, wherein the pre-determined distance is a constant distance.
[0196] 25. Method according to item 23, wherein the pre-determined distance is varying with the position of the assistance tool along the longitudinal direction relative to the composite structure.
[0197] 26. Method according to any of items 21-25, wherein the composite structure is a wind turbine blade, the main composite part is an airfoil of the wind turbine blade, and the flange section extends from the main composite part along a leading edge and/or a trailing edge of the airfoil.
[0198] 27. A guiding device for inspection and/or processing of a surface area of an outer surface of a composite structure, the composite structure extending along a longitudinal direction, the guiding device comprising: [0199] one or more elongated base elements including a primary elongated base element adapted to be arranged on the outer surface of the composite structure, [0200] one or more attachment elements for detachably attaching the one or more elongated base elements to the composite structure, [0201] one or more displacement bars including a primary displacement bar and optionally a secondary displacement bar, the primary displacement bar being movably attached to the primary elongated base element, [0202] a support element movably attached to the one or more displacement bars and displaceable along the longitudinal direction and perpendicular to the longitudinal direction relative to the primary elongated base element, the support element being adapted to be fitted with a tool for inspecting and/or processing the surface area of the composite structure.
[0203] 28. Guiding device according to item 27, wherein the one or more elongated base elements include a secondary elongated base element, and wherein the primary displacement bar is movably attached to the secondary elongated base element, the primary displacement bar extending between the primary elongated base element and the secondary elongated base element, and the support element being arranged between the primary elongated base element and the secondary elongated base element.
[0204] 29. Guiding device according to any of items 27-28, wherein the primary elongated base element and/or the secondary elongated base element are adapted to be arranged parallel to the longitudinal direction of the composite structure.
[0205] 30. Guiding device according to any of items 27-29, wherein the primary elongated base element and/or the secondary elongated base element are adapted to be arranged perpendicular to the longitudinal direction of the composite structure.
[0206] 31. Guiding device according to any of items 27-30, wherein the one or more elongated base elements include a tertiary elongated base element and optionally a quaternary elongated base element, the tertiary elongated base element and optionally the quaternary elongated base element being arranged substantially perpendicular to the primary elongated base element.
[0207] 32. Guiding device according to item 31 as dependent on at least item 28, wherein the tertiary elongated base element and optionally the quaternary elongated base element extend between the primary elongated base element and the secondary elongated base element.
[0208] 33. Guiding device according to any of items 31-32, wherein the one or more elongated base elements include the quaternary elongated base element, and wherein the support element is arranged between the tertiary elongated base element and the quaternary elongated base element.
[0209] 34. Guiding device according to any of items 27-33, wherein the primary displacement bar is arranged substantially perpendicular to the primary elongated base element.
[0210] 35. Guiding device according to any of items 27-34, wherein the primary displacement bar is movable along the primary elongated base element.
[0211] 36. Guiding device according to any of items 27-35, wherein the support element is movable along the one or more displacement bars.
[0212] 37. Guiding device according to any of items 27-36, wherein the one or more displacement bars are curvilinear bars adapted to substantially follow a curvature of the surface area of the composite structure.
[0213] 38. Guiding device according to any of items 27-37, wherein the one or more displacement bars include the secondary displacement bar, and wherein the support element is arranged between the primary displacement bar and the secondary displacement bar.
[0214] 39. Guiding device according to any of items 27-38, wherein the primary displacement bar comprises a first end movably attached to the primary elongated base element and an opposite second end adapted to contact and being slidable over the outer surface of the composite structure.
[0215] 40. Guiding device according to item 39, wherein the primary displacement bar comprises a wheel arranged at the second end adapted to contact the outer surface of the composite structure.
[0216] 41. Guiding device according to any of items 27-40, wherein each of the one or more attachment elements comprises a vacuum element with a fluid outlet adapted to be connected to a vacuum source, the vacuum element being adapted to adhere to the outer surface of the composite structure by application of a negative pressure by the vacuum source.
[0217] 42. Guiding device according to any of items 27-41, wherein a primary attachment element of the one or more attachment elements are arranged on the primary elongated base element, such as to be positioned between the primary elongated base element and the outer surface of the composite structure.
[0218] 43. Guiding device according to any of items 27-42, wherein a tertiary attachment element of the one or more attachment elements are arranged on the tertiary elongated base element, such as to be positioned between the tertiary elongated base element and the outer surface of the composite structure.
[0219] 44. A method for inspection and/or processing of a surface area of an outer surface of a composite structure, the composite structure extending along a longitudinal direction, the method comprising: [0220] attaching the guiding device according to any of items 27-43 to the outer surface of the composite structure, [0221] fitting the support element with a tool for inspecting and/or processing the surface area of the composite structure, [0222] moving the support element to be over the surface area, [0223] inspecting and/or processing the surface area with the tool.
[0224] 45. Method according to item 44, wherein attaching the guiding device includes aligning the one or more elongated base elements of the guiding device with one or more datum points of the outer surface of the composite structure.
[0225] 46. Method according to item 45, wherein the one or more datum points are located outside the surface area of the composite structure.
[0226] 47. Method according to any of items 44-46, wherein the composite structure is a wind turbine blade comprising a leading edge.
[0227] 48. Method according to item 47, wherein the one or more datum points are positioned more than a first distance from the leading edge of the wind turbine blade
[0228] 49. Method according to any of items 47 or 48, wherein the surface area includes a part of the leading edge of the wind turbine blade.
[0229] 50. A method for post mould processing of a composite structure, wherein the composite structure extends along a longitudinal direction and comprising a main composite part, and a flange section extending around a perimeter of the main composite part, the flange section comprising an upper surface having a first mating part with a specific shape in a cross-sectional plane perpendicular to the longitudinal direction, the first mating part being located at a fixed position relative to the main composite part, the method comprising: [0230] providing an assistance tool according to any of items 14-17, [0231] arranging the assistance tool such that the first mating part of the composite structure and the second mating part of the assistance tool are fitted to each other, [0232] moving the assistance tool along the flange section while marking one or more datum points on the main composite part with the datum point marker at a pre-determined distance from respective one or more datum points on the flange section, [0233] providing a guiding device according to any of items 27-43, [0234] attaching the guiding device to the outer surface of the composite structure aligning the one or more elongated base elements of the guiding device with the one or more datum points on the main composite part, [0235] fitting the support element with a tool for inspecting and/or processing a surface area of the composite structure, [0236] moving the support element to be above the surface area, [0237] inspecting and/or processing the surface area with the tool.
[0238] 51. Method according to item 50, wherein the surface area of the composite structure is more than a first distance from the one or more datum points on the main composite part.
[0239] 52. Method according to any of items 50-51, wherein the composite structure is a wind turbine blade comprising a leading edge.
[0240] 53. Method according to item 52, wherein the specified datum points are positioned more than a first distance from the leading edge of the composite structure.
[0241] 54. Method according to any of items 52 or 53, wherein the surface area includes a part of the leading edge of the wind turbine blade.
[0242] 55. Method according to any of items 50-54, wherein the assistance tool further comprises a cutting element connected to the body and configured for cutting the composite structure along a cutting path defined between the main composite part and the flange section to separate the flange section from the main composite part, and the method comprising operating the cutting element to separate the flange section from the main composite part along the cutting path while moving the assistance tool along the flange section.
[0243] 56. Method according to any of items 50-55, wherein the pre-determined distance is a constant distance.
[0244] 57. Method according to any of items 50-55, wherein the pre-determined distance is varying with the position of the assistance tool along the longitudinal direction relative to the composite structure.
LIST OF REFERENCES
[0245] 2 wind turbine [0246] 4 tower [0247] 6 nacelle [0248] 8 hub [0249] 10 blade [0250] 14 blade tip [0251] 15 tip end [0252] 16 blade root [0253] 17 root end [0254] 18 leading edge [0255] 20 trailing edge [0256] 24 first blade shell part (pressure side) [0257] 26 second blade shell part (suction side) [0258] 28 bond lines/glue joints [0259] 30 root region [0260] 32 transition region [0261] 34 airfoil region [0262] 34a first airfoil region [0263] 34b second airfoil region [0264] 36 first shell part flange [0265] 38 second shell part flange [0266] 40 shoulder [0267] 42 shear web or spar side [0268] 74 first spar cap [0269] 76 second spar cap [0270] 78 mould system [0271] 80 first mould [0272] 84 first moulding surface [0273] 90 second mould [0274] 94 second moulding surface [0275] 96 bushings [0276] 300 composite structure [0277] 302 outer surface [0278] 304 surface area [0279] 306 main composite part [0280] 308 flange section [0281] 309 pre-determined distance [0282] 310 cutting path [0283] 314 first mating part [0284] 316 first substantially linear section [0285] 318 first primary mating section [0286] 320 first end section [0287] 322 datum point on flange section [0288] 324 datum point on composite structure [0289] 500 assistance tool [0290] 502 body [0291] 504 cutting element [0292] 506 reference point [0293] 510 first end [0294] 512 second end [0295] 514 datum point indicator [0296] 515 datum point marker [0297] 516 second mating part [0298] 518 second substantially linear section [0299] 520 second primary mating section [0300] 522 second end section [0301] 524 track [0302] 526 operating handle [0303] 700 guiding device [0304] 704 primary elongated base element [0305] 706 secondary elongated base element [0306] 708 tertiary elongated base element [0307] 710 quaternary elongated base element [0308] 712a-712d attachment elements [0309] 714 support element [0310] 716 tool (for inspecting and/or processing surface area) [0311] 720 primary displacement bar [0312] 722 secondary displacement bar [0313] 724 first end [0314] 726 second end [0315] 728 wheel [0316] 730 vacuum element [0317] 732 fluid outlet [0318] 1000 method [0319] 1001 providing assistance tool [0320] 1002 arranging the assistance tool [0321] 1004 moving the assistance tool [0322] 1006 operating the cutting element [0323] 1008 marking one or more datum points [0324] 1009 varying pre-determined distance [0325] 1010 method [0326] 1011 providing a guiding device [0327] 1012 attaching the guiding device [0328] 1014 fitting a support element of the guiding device with a tool [0329] 1016 moving the support element to be over surface area [0330] 1018 inspecting and/or processing the surface area with the tool [0331] L longitudinal direction