GANTRY SYSTEM FOR MANUFACTURING A WIND TURBINE BLADE AND METHOD FOR MANUFACTURING A WIND TURBINE BLADE

Abstract

A gantry system for manufacturing a wind turbine blade is provided, the gantry system including a frame for bridging the wind turbine blade in a cross-section direction of the blade during manufacture, wheels rotatably attached to the frame for locomotion of the gantry system, and one or more robotic units attached to the frame for performing manufacturing steps for manufacturing the blade. Having the gantry system bridging the wind turbine blade in a cross-section direction of the blade during manufacture provides a stable vehicle with a large footprint for manufacturing a wind turbine blade.

Claims

1. A gantry system for manufacturing a wind turbine blade, the gantry system comprising: a frame (for bridging the wind turbine blade (in a cross-section direction of the wind ne blade during manufacture;: wheels rotatably attached to the frame(s) for locomotion of the gantry system, and one or more robotic units(s) attached to the frame for performing manufacturing steps for manufacturing the wind turbine blade.

2. The gantry system according to claim 1, wherein the one or more robotic units each comprise a robotic arm configured to move a tool center point of the robotic arm in six degrees of freedom.

3. The gantry system according to claim 1, wherein the wheels are arranged in two-lanes and/or the gantry system is configured such that during manufacture of the wind turbine blade at least one wheel of the gantry system is arranged on each side of the wind turbine blade in the cross-section direction of the wind turbine blade.

4. The gantry system according to claim 1, wherein one or more of the wheels are steerable wheels and/or are rotatably attached to the frame such that the respective wheel is rotatable around an axis arranged parallel to a height direction of the gantry system.

5. The gantry system according to claim 4, wherein one or more of the wheels are rotatably attached to the frame (such that the respective wheel is rotatable by an angle of at least 180 around the axis arranged parallel to the height direction of the gantry system.

6. The gantry system according to claim 1, wherein the frame comprises: two base members each having two or more of the wheels, two side pillars each connected to a respective one of the two base members, and a horizontal beam connecting the two side pillar, wherein the gantry system is configured such that the two side pillars and the horizontal beam are bridging the wind turbine blade in the cross-section direction of the wind turbine blade during manufacture.

7. The gantry system according to claim 1, wherein at least one of the one or more robotic units is movably attached to the frame for moving the respective robotic unit relative to the frame.

8. The gantry system according to claim 7, wherein at least one of the one or more robotic units is movably attached to the frame by a sled, the sled As being configured for moving the respective robotic unit in a linear direction relative to the frame, and/or at least one of the one or more robotic units is movably attached to a respective one of the side pillars by the sled, the sled being configured for moving the respective robotic unit in a height direction of the gantry system.

9. The gantry system according to claim, wherein at least one of the one or more robotic units is rotatably attached to the frame by a swing arm, and/or at least one of the one or more robotic units is rotatably attached to a respective one of the side pillars by the swing arm, the swing arm, being rotatable around an axis arranged parallel to a height direction of the gantry system for moving the respective robotic unit in a plane perpendicular to the height direction of the gantry system.

10. The gantry system according to claim 1, comprising a control unit for controlling the locomotion of the gantry system, a movement of the one or more robotic units relative to the frame of the gantry system and/or a movement of a tool center point of a respective robotic unit.

11. The gantry system according to claim 10, wherein the control unit is configured for simultaneously controlling the locomotion of the gantry system, the movement of the one or more robotic units relative to the frame and the movement of the tool center point of the respective robotic unit.

12. The gantry system according to claim 10, comprising a sensor system including one or more sensors for obtaining sensor data of the wind ne blade during manufacture and/or of the one or more robotic units, wherein the control unit is configured for controlling the locomotion of the gantry system, the movement of the one or more robotic units (relative to the frame(s) and/or the movement of the tool center point of the respective robotic unit based on the sensor data, and/or the control unit is configured for controlling a manufacturing step of the wind turbine blade-based on the sensor data.

13. The gantry system according to claim 10, wherein the control unit is configured for controlling the locomotion of the gantry system, the movement of the one or more robotic units relative to the frame, the movement of the tool center point of the respective robotic unit and/or the manufacturing step based on a predetermined digital model of the wind turbine blade and/or based on a deviation of the predetermined digital model of the wind turbine blade from an actual shape of the wind turbine blade during manufacture obtained by the sensor data.

14. A method for manufacturing a wind turbine blade comprising: moving a gantry system on wheels with respect to a wind turbine blade during manufacture such that a frame of the gantry system bridges the wind turbine blade in a cross-section direction of the wind turbine blade; moving a tool center point of one or more robotic units attached to the frame of the gantry system with respect to the wind turbine blade; and performing a manufacturing step for manufacturing the wind turbine blade by the one or more robotic units.

Description

BRIEF DESCRIPTION

[0086] Some of the embodiments will be described in detail, with references to the following Figures, wherein like designations denote like members, wherein:

[0087] FIG. 1 shows a wind turbine according to an embodiment:

[0088] FIG. 2 shows a perspective view of a gantry system for manufacturing a wind turbine blade of the wind turbine of FIG. 1:

[0089] FIG. 3 shows a wheel of the gantry system of FIG. 3 in a top view:

[0090] FIG. 4 shows the gantry system of FIG. 3 in a front view together with a blade during manufacture:

[0091] FIG. 5 shows individual modules of the gantry system of FIG. 3, the individual modules being in an unassembled state:

[0092] FIG. 6 shows the gantry system of FIG. 3 together with a blade during painting of the blade; and

[0093] FIG. 7 shows a flowchart illustrating a method for manufacturing a blade of the wind turbine of FIG. 1 according to an embodiment.

DETAILED DESCRIPTION

[0094] FIG. 1 shows a wind turbine 1 according to an embodiment. The wind turbine 1 comprises a rotor 2 having one or more blades 3 connected to a hub 4. The hub 4 is connected to a generator (not shown) arranged inside a nacelle 5. During operation of the wind turbine 1, the blades 3 are driven by wind to rotate and the wind's kinetic energy is converted into electrical energy by the generator in the nacelle 5. The nacelle 5 is arranged at the upper end of a tower 6 of the wind turbine 1. The tower 6 is erected on a foundation 7 such as a concrete foundation or a monopile driven into the ground or seabed.

[0095] In the following a gantry system 8 with robotic units 9 for manufacturing a wind turbine blade 3 of the wind turbine 1 of FIG. 1 is described.

[0096] FIG. 2 shows a perspective view of the gantry system 8 according to an embodiment. The gantry system 8 comprises a frame 10. The frame 10 is, in particular, a steel structure. The frame 10 comprises two base members 11 each having two or more wheels 12. In the shown example, there are four wheels 12 rotatably attached to each base member 11 for locomotion of the gantry system 8. The frame 10 further includes two side pillars 13. Each side pillar 13 is connected to a respective one of the base members 11. The frame 10 includes in addition a horizontal beam 14 connecting the two side pillars 13. In particular, the two side pillars 13 and the horizontal beam 14 are configured for bridging the wind turbine blade 3 in the cross-section direction of the blade 3 during manufacture, as can be seen in FIG. 4.

[0097] The wheels 12 of the gantry system 8 are arranged in two-lanes 15 (FIG. 2). As can be seen in FIG. 4, during treatment of the blade 3 a first one of the base members 11 with a first set of wheels 12 is arranged on one side L (left side in FIG. 4) of the blade 3, and a second one of the base members 11 with a second set of wheels 12 is arranged on the other side R (right side in FIG. 4) of the blade 3. Further, both base members 11 are extended in a direction Y perpendicular to the height direction Z of the gantry system and perpendicular to an extension direction X of the horizontal beam 14. Thus, the gantry system 8 has a large footprint 16 (FIG. 2) while requiring only little space on the sides L, R of the blade 3 (FIG. 4).

[0098] The wheels 12 are, in particular, steerable wheels. In particular, each wheel 12 is rotatably attached to the respective base member 11 such that it can rotate around an axis A arranged parallel to a height direction Z of the gantry system 8. In FIG. 2, two axes A are shown exemplarily and denoted with a reference sign. For example, each wheel 12 can rotate by an angle a of at least 180 around the axis A. FIG. 3 shows a top view onto one of the wheels 12 of FIG. 2 illustrating the angle a by which the wheel 12 is rotatable.

[0099] There are one or more robotic units 9 attached to the frame 10 of the gantry system 8. In the shown example, there are two robotic units 9 each attached to a respective side pillar 13 of the frame 10. The robotic units 9 are configured for performing manufacturing steps during manufacture of the blade 3 such as painting an outer surface 17 (FIG. 6) of the blade 3.

[0100] Each robotic unit 9 comprises a robotic arm 18. Each robotic arm 18 comprises several joints 19 (FIG. 4). Further, each robotic arm 18 comprises a tool attachment portion 20 for attaching various tools and/or end effectors 21. Each robotic arm 18 comprises a tool center point 22. The tool center point 22 is, for example, defined by the tool attachment portion 20. The tool center point 22 may also be defined by a point on the tool and/or end effector 21. It may, for example, be a tip of the tool and/or end effector 21.

[0101] Each robotic arm 18 is, for example, capable to move the tool center point 22, and hence the tool/end effector 21, in six degrees of freedom (three translational and three rotational degrees of freedom).

[0102] Furthermore, the robotic units 9 are movably attached to the frame 10 for moving the respective robotic unit 9 relative to the frame 10. In the shown example, each robotic unit 9 is movably attached to a respective one of the side pillars 13 by a sled 23 (FIG. 4) running in grooves 24 formed in the side pillars 13. Due to the sleds 23, each robotic unit 9 can be moved relative to the side pillar 13 in the height direction Z of the gantry system 8.

[0103] In addition, each robotic unit 9 is rotatably attached to the frame 10in the shown example to the respective sled 23 attached to the respective side pillar 13by a swing arm 25 (FIG. 4). Each swing arm 25 is rotatable around an axis B arranged parallel to the height direction Z of the gantry system 8. Having the swing arms 25 allows movement of the respective robotic unit 9 in a plane (XY-plane in FIG. 4) perpendicular to the height direction Z.

[0104] As illustrated in FIG. 5, the gantry system 8 may have a modular structure wherein, for example, the two base members 11, the two side pillars 13, the horizontal beam 14, the robotic units 9, the sleds 23 and the swing arms 24 are individual modules. This allows an easy replacement of individual modules to adjust the gantry system 8 to a specific blade size and/or shape. For example, for a larger blade diameter D (FIG. 4) at the root end of the blade 3, the two pillars 13 and the horizontal beam 14 could be replaced by two pillars and a horizontal beam (not shown) having each a greater length.

[0105] In particular, the individual modules 9, 11, 13, 14, 23, 24 may be configured such that they can be easily mounted to each other and dismounted from each other. For example, the individual modules 9, 11, 13, 14, 23, 24 may be connected to each other by bolt connections (not shown) easily accessible from the outside.

[0106] Furthermore, the gantry system 8 comprises a control unit 26 (FIG. 2). The control unit 26 is, for example, arranged at the one or both base members 11 (FIG. 2). However, the control unit 26 may also be arranged at a different location on the frame 10 of gantry system 8 or may be arranged remote from the frame 10. The control unit 26 is configured for controlling the locomotion of the gantry system 8 on its wheels 12, and, thus, the position of the gantry system 8 with respect to a manufacturing hall (not shown) and/or the blade 3. Further, the control unit 26 is configured for controlling a movement of the robotic units 9 relative to the frame 10 by the sleds 23 and swing arms 25 and, thus, the position of the respective robotic unit 9 with respect to the frame 10. Further, the control unit 26 is configured for controlling a movement of the tool center point 22 (FIG. 4) of a respective robotic unit 9 (e.g., a pose of the respective robotic arm 18), and, thus, the position of the respective tool center point 22 with respect to a base portion 27 (FIG. 4) of the respective robotic unit 9.

[0107] Furthermore, the gantry system comprises a sensor system 28 including one or more sensors 29, 30, 31 for obtaining sensor data of the blade 3 and/or of the robotic units 9. In FIG. 4, there are exemplarily shown a sensor 29 attached to the frame 10 (in particular to the base member 11) of the gantry system 8, a sensor 30 attached to the base portion 27 of the robotic unit 9, and a sensor 31 attached close to the tool attachment portion 20 of the robotic unit 9.

[0108] However, the sensors 29, 30, 31 might also be arranged at different locations of the gantry system 8 and/or there might be more or different sensors than the one shown. The sensors 29, 30, 31 may include laser trackers, odometry systems including motion sensors, wheel speed sensors (e.g., counting the number of wheel rotations), wheel angle sensors, radar systems (radio detection and ranging), lidar systems (light detection and ranging), optical sensors such as infrared or visual light cameras (e.g., scanning markers on a floor and/or ceiling of a manufacturing hall and/or on a blade), ultrasonic sensors, encoders, laser pointer, proximity sensors, temperature sensors and/or pressure sensors.

[0109] The control unit 26 is configured for controlling the locomotion of the gantry system 8, the movement (sleds 23, swing arms 25) of the robotic units 9 relative to the frame 10 and the movement of the tool center point 22 based on the sensor data from the sensor system 28.

[0110] Further, the control unit 26 is configured for controlling a manufacturing step of the wind turbine blade 3 based on the sensor data.

[0111] In particular, the control unit 26 is configured for controlling the locomotion of the gantry system, the movement of the robotic units 9 relative to the frame 10, the movement of the tool center point 22 of the respective robotic unit 9 and/or the manufacturing step based on a predetermined digital model of the wind turbine blade 3. The predetermined digital model is, for example, a 3D CAD model (computer aided design) of the blade 3.

[0112] The control unit 26 may, for example, be configured for determining a deviation of the predetermined digital model of the blade 3 from an actual shape S of the blade 3 during manufacture obtained by the sensor data.

[0113] In the following a method for manufacturing the wind turbine blade 3 is described with respect to FIGS. 6 and 7.

[0114] In a first step SI of the method, the gantry system 8 is moved on its wheels 12 with respect to the wind turbine blade 3 during manufacture. The frame 10 of the gantry system 8 bridges the blade 3 in the cross-section direction of the blade 3, so as to provide a large footprint 16 (FIG. 2) and good stability of the gantry system 8. The movement of the gantry system 8 on its wheels 12 is controlled by the control unit 26.

[0115] In a second step S2 of the method, the robotic units 9 are moved relative to the frame 10 by the sleds 23 and swing arms 25 (FIG. 4). The movement of the robotic units 9 relative to the frame 10 is controlled by the control unit 26.

[0116] In a third step S3 of the method, the tool center point 22 of each robotic unit 9 is moved with respect to the blade 3. The movement of the tool center point 22 is controlled by the control unit 26.

[0117] In a fourth step S4 of the method, a manufacturing step for manufacturing the blade 3 is performed by the robotic units 9. In the shown example of FIG. 6 this manufacturing step includes painting the outer surface 17 of the blade 3. For this purpose, the end effector 21 of each robotic unit 9 comprises a spray nozzle 32 for spraying paint 33 onto the outer surface 17 of the blade 3. Further shown in FIG. 6 are tanks 34 containing paint and arranged on the base member 11.

[0118] Steps S1 to S4 may be carried out simultaneously and repeatedly until the entire outer surface 17 of the blade 3 is coated with paint 33. Having the gantry system 8 with the robotic units 9 allows to paint the outer surface 17 of a blade 3 in an automated manner.

[0119] Although the present invention has been disclosed in the form of embodiments and variations thereon, it will be understood that numerous additional modifications and variations could be made thereto without departing from the scope of the invention.

[0120] For the sake of clarity, it is to be understood that the use of a or an throughout this application does not exclude a plurality, and comprising does not exclude other steps or elements.