DEBAGGING SYSTEM AND METHOD FOR USE IN A DEBAGGING PROCESS DURING THE MANUFACTURE OF A WIND TURBINE BLADE
20250010525 ยท 2025-01-09
Inventors
Cpc classification
B29C70/44
PERFORMING OPERATIONS; TRANSPORTING
International classification
Abstract
A debagging system (100) for use in a debagging process during the manufacture of a wind turbine blade is provided. The debagging system comprises: a debagging tool (110, 210), and conveying means configured to moving the debagging tool along a longitudinal direction of a mould for manufacturing a wind turbine blade part. The debagging tool (110, 210) comprises: a lifting bar (112, 212) for insertion under infusion tools (50) and lifting the infusion tools (50) during the debagging process, the lifting bar (112, 212) having a first end and a second end, and a support frame (120, 220) for carrying the lifting bar, wherein the lifting bar (112, 212) is coupled to the support frame (120, 220), and wherein the debagging tool is suspended from the conveying means so that the debagging tool during use can be arranged above the mould and be moved along the longitudinal direction of the mould.
Claims
1-32. (canceled)
33. A debagging system for use in a debagging process during the manufacture of a wind turbine blade, the debagging system comprising: a debagging tool; and conveying means configured to move the debagging tool along a longitudinal direction of a mold for manufacturing the wind turbine blade, wherein the debagging tool comprises: a lifting bar for insertion under one or more infusion tools and lifting the one or more infusion tools during the debagging process, the lifting bar having a first end and a second end; and a support frame for carrying the lifting bar, wherein the lifting bar is coupled to the support frame, and wherein the debagging tool is suspended from the conveying means so that the debagging tool is arranged above the mold and moved along the longitudinal direction of the mold.
34. The debagging system of claim 33, wherein the lifting bar comprises a first roller.
35. The debagging system of claim 34, wherein the first roller is connected to a first drive or motor for driving the first roller.
36. The debagging system of claim 35, wherein the first roller is configured to be driven in both a first direction and a second, opposite direction.
37. The debagging system of claim 33, wherein the lifting bar is coupled to the support frame at the first and second ends of the lifting bar.
38. The debagging system of claim 33, wherein the support frame comprises attachment means for attaching the debagging tool to the conveying means.
39. The debagging system of claim 33, wherein the support frame comprises a top frame part, a first side frame part, and a second side frame part, wherein the first side frame part and the second side frame part extend from the top frame part, and wherein the first end of the lifting bar is coupled to the first side frame part and the second end of the lifting bar is coupled to the second side frame part.
40. The debagging system of claim 34, wherein the debagging tool further comprises one or more upper support rollers configured to engage with the one or more infusion tools when lifted by the lifting bar, wherein the one or more upper support rollers are coupled to the support frame.
41. The debagging system of claim 40, wherein the one or more upper support rollers are arranged and configured to be adjusted relative to the support frame.
42. The debagging system of claim 40, wherein the one or more upper support rollers are connected to one or more second drives or motors for driving the one or more upper support rollers.
43. The debagging system of claim 40, wherein both the first roller and the one or more upper support rollers are connected to drives or motors.
44. The debagging system of claim 33, wherein the support frame further comprises a lower frame part, and wherein one or more lower support rollers are mounted on the lower frame part and arranged and configured to support the lifting bar.
45. The debagging system of claim 33, wherein the conveying means comprise an overhead crane or gantry.
46. The debagging system of claim 33, wherein the debagging system is provided with a tilt sensor to monitor the inclination or tilt of one or more debagging tools relative to a mold surface of the mold.
47. The debagging system of claim 46, wherein the debagging system is configured to maintain the one or more debagging tool at a tilt angle being below a threshold angle compared to a vertical plane, the threshold angle being equal to or less than 5 degrees.
48. The debagging system of claim 33, wherein the debagging system further comprises at least one of a clamping device for clamping a part of the one or more infusion tools to the mold or a cutting device for cutting the one or more infusion tools to divide the one or more infusion tools into separate disposable parts.
49. A method for debagging infusion tools during the manufacture of a wind turbine blade part in a mold for manufacturing the wind turbine blade part, the method comprising: peeling a first part of the one or more infusion tools from the wind turbine blade part; inserting a lifting bar of a debagging tool under one or more infusion tools; moving the debagging tool along a longitudinal direction of the mold to allow the lifting bar to peel the one or more infusion tools from the wind turbine blade part; and removing the infusion tools from the mold.
50. The method of claim 49, wherein the first part of the one or more infusion tools is peeled from a root side or a tip side of the mold.
51. The method of claim 49, further comprising clamping a longitudinal end of the one or more infusion tools to the mold.
52. The method of claim 49, further comprising providing a peeling force to the one or more infusion tools, wherein the peeling force is provided in a direction that forms an angle ranging from 30 degrees to 60 degrees compared to a mold surface of the mold.
Description
BRIEF DESCRIPTION OF THE FIGURES
[0045] The invention is explained in detail below with reference to embodiments shown in the drawings, in which
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DETAILED DESCRIPTION OF THE INVENTION
[0057] In the following, a number of exemplary embodiments are described in order to understand the invention.
[0058] Modern wind turbine blades comprise an aerodynamic shell, and the suction side and the pressure side of the aerodynamic shell are often manufactured as separate parts in separate moulds.
[0059] For manufacturing the blade shell half 11, the rigid mould part 13 is provided with a mould surface 14 forming the outer surface of the shell half, i.e. the pressure side of the blade.
[0060] In the following, an example of the lay-up and tools used for manufacturing the blade shell part 11 is described. The mould part 13 is provided with an upper rim 15, as clearly seen in
[0061] A lay-up 16 comprising a number of fibre layers is placed on the mould surface 14. In the embodiment shown, the fibre lay-up 16 comprises first fibre layers 17 arranged directly on the mould surface 14 or optionally with a previously applied gelcoat. On the first fibre layers, a large number of fibre layers are placed in a longitudinally extending zone of the mould so as to provide a load-bearing structure (or spar cap) 18 of the blade shell half. As seen in the transverse direction of the mould, the zone forming the load-bearing structure 18 is provided in the lowermost area of the mould surface. Additionally, a plurality of fibre layers may be arranged on the first lower fibre layers 17 at a region corresponding to the region of the leading edge and the trailing edge, respectively, of the blade shell half to provide a leading edge fibre reinforcement 19 and a trailing edge fibre reinforcement 20. A first core material 21 may be arranged between the load-bearing structure 18 and the leading edge fibre reinforcement 19 and a second core material 22 may be arranged between the load-bearing structure 18 and the trailing edge fibre reinforcement 20. The core material can be a hard polymer foam or balsawood. The fibre lay-up 16 is completed by arranging second fibre layers 23 on top of the load-bearing structure 18, the leading edge fibre reinforcement 19, the trailing edge fibre reinforcement 20, the first core material 21 and the second core material 22. While the core materials 21, 22 are depicted as extending all the way between fibre reinforcements 18, 19, 20, the core materials 21, 22 may be arranged at a limited part of the blade shell only.
[0062] Next, a distribution layer 24 is arranged on the second fibre layers 23. Further, substantially longitudinally extending feed channels 36-42 are arranged above the fibre distribution layer 24 on either side of and laterally spaced apart from a longitudinally extending first feed channel 27 arranged above the load-bearing structure 18. Further, the additional feed channels 36-42 are placed laterally outside the load-bearing structure 18. A vacuum bag 43 is arranged on top of the distribution layer 24 and the feed channels and sealed to the rim 15 of the mould part to form a mould cavity 44 between the vacuum bag 43 and the mould surface 14 of the mould part 13. The mould cavity is then evacuated, and resin is supplied to the mould cavity via the feed channels 27, 36-42.
[0063] Finally, the resin is allowed to cure in order to form the composite structure of the blade shell part 11, after which a debagging and demoulding process can be commenced in order to finalise the assembly of the wind turbine blade.
[0064] The lay-up includes the arrangement of a peel ply, a release film, or a similar tear-off layer (not shown) on top of the inner fibre layers, e.g. arranged below the distribution layer 24. This peel ply or release film ensures that the infusion tools that do not become part of the composite structure can be removed in the debagging process. The infusion tools include the feed channels 27, 36-42, the tear-off layer, the vacuum bag as well as possible vacuum outlet channels. The infusion tools are in the following referred to by common reference number 50.
[0065] The debagging process is typically carried out manually, which is a tedious process, and which can entail unsafe conditions and acts. In order to address these problems, a new debagging tool has been developed. A first embodiment of such a debagging tool 110 is illustrated in
[0066] The first embodiment of the debagging tool 110 comprises a support frame 120 for carrying a lifting bar 112 for lifting and carrying the infusion tools during the debagging process. The lifting bar may advantageously be provided in form of a roller or comprise a roller. The support frame 120 comprises a top frame part 122, a first side frame part 124 and a second side frame part 126. The support frame may further be enforced with gussets 127 or other reinforcement elements. The lifting bar 112 is attached at a first end to the first side frame part 124 via attachments means 116. Similarly, the lifting bar 112 is attached at a second end to the second side frame part 126 via corresponding attachments means 116. The attachment means 116 may be formed for instance by bolts, nuts, and holding plates. In addition, the debagging tool 110 has two lifting ears 160 attached to the top frame part 122. The lifting ears 160 can be used for attaching the debagging tool 110 to an overhead crane or gantry via for instance chains and hooks. During the debagging process, the infusion tools 50 are inserted in the space 170 formed between the lifting bar 112 and the support frame 120.
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[0068] In the initial phase of the debagging process, a part of the removable infusion tools 50 is manually peeled from the cured wind turbine shell 11. As shown in the top view in
[0069] The end of the removable infusion tools 50 needs to be held in place, e.g. by clamping using clamping means 106, to manage the opposite pulling force from the debagging tool 110 and the conveying means, as the debagging tool 110 is moved along the mould part 13.
[0070] In
[0071] As shown in
[0072] As shown in
[0073] As shown, the lifting bar 112 is advantageously be provided in form of or comprising a roller, such that the debagging tool easier can be moved along the mould part 13 in the debagging process without being stuck or tearing the removable infusion tools 50.
[0074] A second embodiment of a debagging tool 210 is shown in
[0075] The lifting bar 212 may comprise a first roller or be provided as a first roller. The first roller may be connected to a first drive or first motor 214 for driving the first roller. Thus, the first roller can actively be used for asserting a force to the infusion tools and assist in peeling the infusion tools 50 from the finished moulded structure. The first roller may advantageously be configured to be driven in both a first direction and a second, opposite direction. Accordingly, the first roller may be used for both asserting a force in a first direction and a second direction. Thereby, the first roller can also be used for first peeling the infusions tools 50 from the finished moulded structure 14 and later removing the infusion tools 50 from the mould part 13. A surface of the first roller may advantageously be provided with gripping means, e.g., by providing a rough surface or a ridged, fluted, or grooved surface. Thereby, the roller can add grip to the engagement with the infusion tools, which in turn assist in asserting the peeling force to the infusion tools.
[0076] As shown in
[0077] The one or more upper support rollers 230 are preferably as shown in
[0078] The support frame 220 preferably comprises attachment means 260, such as attachment ears, for attaching the debagging tool 210 to the conveying means 102. This provides simple means for attaching the debagging tool 210 to for instance an overhead crane or a gantry configured to move along the mould part 13. Accordingly, it is seen that the second embodiment of the debagging tool 210 may be suspended from the conveying means in a way similar to that of the first embodiment of the debagging tool 110 and as shown in
[0079] As shown in
[0080] It is clear that the second embodiment of the debagging tool 210 can be suspended and operated in a way similar to those shown in
[0081] The debagging system 100 or the debagging tool 210 may provided with a tilt sensor to monitor the inclination or tilt of the debagging tools relative to a mould surface of the mould. The tilt sensor may be provided in form of an inclinometer, accelerometers, gyros, or the like. This ensures that the debagging tool may be maintained in an acceptable orientation relative to the surface of the mould and in turn ensure that the correct pulling force and direction may be maintained. The debagging system may be configured to maintain the debagging tool at a tilt angle being below a threshold angle compared to a vertical plane, preferably the system being configured to keep the tilt angle below 5 or even below 3 degrees, more preferably below 2 degrees, and even more preferably below 1.5 degrees. The angle can be based for instance on a longitudinal axis 275 extending through the debagging tool 210 as shown in
[0082] In another embodiment, the debagging system further comprises a cutting device (not shown) for cutting the infusion tools to divide the infusion tools into separate disposable parts. Accordingly, the infusion tools may be divided into smaller parts as it is removed from the mould. The system may additionally comprise a container for collecting the separate disposable parts.
[0083] For both embodiments of the debagging tool, the width of the lifting bar may advantageously be at least 3 metres, preferably at least 3.5 metres, and more preferably at least 4 metres. In general, the lifting bar and the system should have a width so that it can be used for debagging the infusion tools at the place where the mould and moulded structure is widest. For a wind turbine blade shell part, this position is the position, where the wind turbine blade is to have the widest chord, e.g., at the shoulder of the wind turbine blade.
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[0085] As shown in step 318, the debagging tool may be operated to maintain the peeling force in a first direction, while the debagging tool is moved along the longitudinal direction, and when reaching a removal position, e.g., at one of longitudinal ends of the mould, the debagging tool is in step 320 operated to provide a force in a second direction to start removing the infusion tools from the mould. The infusion tools are then in step 322 removed from the mould. During step 322, the infusion tools may be cut in to divide the infusion tools into separate disposable parts, which can be collected in a container to easier dispose of the disposable infusion tools.
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Exemplary Embodiments
[0087] Exemplary embodiments of the present disclosure are set out in the following items: [0088] 1. A debagging system (100) for use in a debagging process during the manufacture of a wind turbine blade, wherein the debagging system comprises: [0089] a debagging tool (110, 210), and [0090] conveying means (104) configured to moving the debagging tool along a longitudinal direction of a mould for manufacturing a wind turbine blade part, [0091] wherein the debagging tool (110, 210) comprises: [0092] a lifting bar (112, 212) for insertion under infusion tools (50) and lifting the infusion tools (50) during the debagging process, the lifting bar (112, 212) having a first end and a second end, and [0093] a support frame (120, 220) for carrying the lifting bar, [0094] wherein the lifting bar (112, 212) is coupled to the support frame (120, 220), and [0095] wherein the debagging tool is suspended from the conveying means so that the debagging tool during use can be arranged above the mould and be moved along the longitudinal direction of the mould. [0096] 2. The debagging system of item 1, wherein the lifting bar (112, 212) comprises a first roller. [0097] 3. The debagging system of item 2, wherein the first roller is connected to a first drive or motor (214) for driving the first roller. [0098] 4. The debagging system of item 3, wherein the first roller is configured to be driven in both a first direction and a second, opposite direction. [0099] 5. The debagging system of any of items 2-4, wherein a surface of the first roller is provided with gripping means, e.g. by providing a rough surface or a ridged, fluted, or grooved surface. [0100] 6. The debagging system of any of items 1-5, wherein the lifting bar (112, 212) is coupled to the support frame (120, 220) at the first end and at the second end of the lifting bar (112, 212). [0101] 7. The debagging system of any of items 1-6, wherein the support frame comprises attachment means (160, 260), such as attachment ears, for attaching the debagging tool to conveying means, such as an overhead crane or a gantry. [0102] 8. The debagging system of any of items 1-7, [0103] wherein the support frame comprises a top frame part (122, 222) and a first side frame part (124, 224) and a second side frame part (126, 226), wherein the first side frame part (124, 224) [0104] and second side frame part (126, 226) extend from the top frame part (122, 222), and wherein the first end of the lifting bar (112, 212) is coupled to the first side frame part (124, 224), and the second end of the lifting bar (112, 212) is coupled to the second side frame part (126, 226). [0105] 9. The debagging system of any of items 1-8, wherein the debagging tool further comprises one or more upper support rollers (230) configured to engage with the infusion tools when lifted by the lifting bar (112, 212), wherein the one or more upper support rollers are coupled to the support frame (120, 220). [0106] 10. The debagging system of item 9, wherein the one or more upper support rollers (230) are arranged and configured to be height adjusted relative to the support frame (120, 220). [0107] 11. The debagging system of any of items 9-10, wherein the one or more upper support rollers (230) are connected to one or more second drives or motors (232) for driving the one or more upper support rollers (230). [0108] 12. The debagging system of any of items 9-11 and item 2, wherein both the first roller and the one or more upper support rollers (230) are connected to drives or motors. [0109] 13. The debagging system of any of items 1-12, wherein the support frame (120, 220) further comprises a lower frame part (228). [0110] 14. The debagging system of any of item 13, wherein one or more lower support rollers (240), such as idler rollers, are mounted on the lower frame part (228) and arranged and configured to support the lifting bar (112, 212). [0111] 15. The debagging system of any of items 1-14, wherein the width of the lifting bar is at least 3 metres, preferably at least 3.5 metres, and more preferably at least 4 metres. [0112] 16. The debagging system of any of items 1-15, wherein the conveying means comprise an overhead crane or gantry. [0113] 17. The debagging system of any of items 1-16, wherein the debagging system is configured to provide a pulling force in a direction that forms an angle of 30-60 degrees compared to a mould surface of the mould. [0114] 18. The debagging system of any of items 1-17, wherein the debagging system is provided with a tilt sensor to monitor the inclination or tilt of the debagging tools relative to a mould surface of the mould. [0115] 19. The debagging system of item 18, wherein the debagging system is configured to maintain the debagging tool at a tilt angle being below a threshold angle compared to a vertical plane, preferably the system being configured to keep the tilt angle below 5 degrees or even below 3 degrees, more preferably below 2 degrees, and even more preferably below 1.5 degrees. [0116] 20. The debagging system of any of items 1-19, wherein the debagging system further comprises: a clamping device for clamping a part, preferably an end part, of the infusion tools to the mould. [0117] 21. The debagging system of any of items 1-20, wherein the debagging system further comprises: a cutting device for cutting the infusion tools to divide the infusion tools into separate disposable parts. [0118] 22. A debagging tool (110, 210) for use in a debagging process during the manufacture of a wind turbine blade, wherein the debagging tool (110, 210) comprises: [0119] a lifting bar (112, 212) for insertion under infusion tools (50) and lifting the infusion tools (50) during the debagging process, the lifting bar (112, 212) having a first end and a second end, and [0120] a support frame (120, 220) for carrying the lifting bar, [0121] wherein the lifting bar (112, 212) is coupled to the support frame (120, 220). [0122] 23. A method for debagging infusion tools during the manufacture of a wind turbine blade part in a mould for manufacturing the wind turbine blade part, wherein the method comprises the steps of: [0123] inserting a lifting bar of a debagging tool under the infusion tools; [0124] moving the debagging tool along a longitudinal direction of the mould in order for the lifting bar to peel the infusion tools from the wind turbine blade part; and [0125] removing the infusion tools from the mould. [0126] 24. The method according to item 23, wherein the method comprises the step of: [0127] prior to inserting the lifting bar of the debagging tool under the infusion tools, peeling a first part of the infusion tools from the wind turbine blade part. [0128] 25. The method according to item 24, wherein the first part of the infusion tools is peeled from a root side or a tip side of the mould. [0129] 26. The method according to any of items 23-25, wherein the method comprises the step of: clamping a longitudinal end of the infusion tools to the mould. [0130] 27. The method according to any of items 23-26, wherein the method comprises the step of: providing peeling force to the infusion tools, e.g., via one or more rollers and drives. [0131] 28. The method according to item 28, wherein the peeling force is provided in a direction that forms an angle of 30-60 degrees compared to a mould surface of the mould. [0132] 29. The method according to any of items 27-28, wherein [0133] The debagging tool is operated to maintain the peeling force in a first direction, while the debagging tool is moved along the longitudinal direction, and [0134] when reaching a removal position, e.g., at one of longitudinal ends of the mould, the debagging tool is operated to provide a force in a second direction to start removing the infusion tools from the mould. [0135] 30. The method according to item 29, wherein the method comprises the step of: [0136] while removing the infusion tools from the mould, cutting the infusion tools to divide the infusion tools into separate disposable parts. [0137] 31. The method according to any of items 23-30, wherein the method comprises the step of: [0138] maintaining the debagging tool at a tilt angle below a threshold angle compared to a vertical plane, preferably keeping the tilt angle below 5 degrees or even below 3 degrees, more preferably below 2 degrees, and even more preferably below 1.5 degrees. [0139] 32. A method of manufacturing a wind turbine blade part, e.g., a wind turbine blade shell or a spar cap, wherein the method comprises the steps of: [0140] proving a mould for manufacturing the wind turbine blade part; [0141] arranging fibre reinforcement material on a mould surface of the mould; [0142] arranging infusion tools on top of the fibre reinforcement material, the infusion tools comprising a vacuum bag; [0143] sealing the vacuum bag against the mould to form a mould cavity; [0144] supplying resin into the mould cavity; [0145] curing the resin to form the wind turbine blade part; and [0146] carrying out a debagging process according to any of items 23-31.
LIST OF REFERENCE NUMERALS
[0147] 11 blade shell half [0148] 13 mould part [0149] 14 mould surface [0150] 15 upper rim [0151] 16 fibre lay-up [0152] 17 first fibre layers [0153] 18 load-bearing structure [0154] 19 leading edge fibre reinforcement [0155] 20 trailing edge fibre reinforcement [0156] 21 first core material [0157] 22 second core material [0158] 23 second fibre layers [0159] 24 distribution layer [0160] 27 first feed channel/first resin inlet [0161] 36-42 additional feed channel [0162] 43 vacuum bag [0163] 44 mould cavity [0164] 50 infusion tools [0165] 100 debagging system [0166] 102 chains [0167] 104 conveying means/overhead crane/gantry [0168] 106 clamping means [0169] 110, 210 debagging tool [0170] 112, 212 lifting bar/first roller [0171] 214 first drive/first motor [0172] 116 attachment means [0173] 120, 220 support frame [0174] 122, 222 top frame part [0175] 124, 224 first side frame part [0176] 126, 226 second side frame part [0177] 127, 227 reinforcement element/gusset [0178] 228 bottom frame part [0179] 230 upper support roller [0180] 232 second drive/second motor [0181] 240 lower support rollers [0182] 242 frame for lower support rollers [0183] 250 height adjustment drive/motors [0184] 252 attachment frame [0185] 254 slot [0186] 160, 260 attachment means/lifting ears [0187] 170, 270 space for inserting infusion tools [0188] 275 vertical axis