US 11,850,807 B2
Optimization of layup process for fabrication of wind turbine blades using model-based optical projection system
Amirhossein Salimi, Providence, RI (US); and Scott Larson, Somerset, MA (US)
Assigned to TPI Composites, Inc., Warren, RI (US)
Filed by TPI Composites, Inc., Warren, RI (US)
Filed on Jan. 12, 2023, as Appl. No. 18/153,807.
Application 18/153,807 is a continuation of application No. 17/146,146, filed on Jan. 11, 2021, granted, now 11,554,556.
Application 17/146,146 is a continuation of application No. 16/023,891, filed on Jun. 29, 2018, granted, now 10,889,075, issued on Jan. 12, 2021.
Claims priority of provisional application 62/625,735, filed on Feb. 2, 2018.
Claims priority of provisional application 62/527,726, filed on Jun. 30, 2017.
Prior Publication US 2023/0142673 A1, May 11, 2023
Int. Cl. B32B 41/00 (2006.01); B29C 70/30 (2006.01); B29C 70/38 (2006.01); F03D 1/06 (2006.01); B29D 99/00 (2010.01); G06F 30/00 (2020.01); G06F 30/17 (2020.01); G06F 30/20 (2020.01); B29L 31/08 (2006.01); G06F 113/24 (2020.01); G06F 113/26 (2020.01)
CPC B29C 70/30 (2013.01) [B29C 70/38 (2013.01); B29D 99/0025 (2013.01); F03D 1/0675 (2013.01); G06F 30/00 (2020.01); G06F 30/17 (2020.01); G06F 30/20 (2020.01); B29C 2945/76461 (2013.01); B29L 2031/085 (2013.01); F05B 2230/60 (2013.01); F05B 2230/604 (2013.01); F05B 2240/21 (2013.01); F05B 2260/84 (2013.01); G06F 2113/24 (2020.01); G06F 2113/26 (2020.01)] 20 Claims
OG exemplary drawing
 
1. A method for fabrication of a composite structure comprising:
receiving at least one specification for a composite structure design wherein the composite structure is a wind turbine blade including a root section and a tip section, the composite structure including a root portion having core panels and a tip portion having core panels to be located at a tip portion;
generating a manufacturing model of the composite structure design, the manufacturing model including the root portion of core panels and the tip portion of core panels;
extracting at least one optical projection file from the manufacturing model, wherein the optical projection file(s) include edges of the root and the tip core panels;
extracting a calibration file;
placing the root portion of core panels and the tip portion of core panels within the mold;
identifying a first portion of reference features associated with the root portion of core panels and a second portion of references features associated with the tip portion of core panels, wherein the first portion of reference features are greater than the second portion of reference features,
projecting at least one marking to depict an edge of the root portion of core panels or the tip portion of core panels; and
comparing core panel reference features to the at least one marking depicting the edge;
performing a quality check of the at least one marking projected in accordance with the extracted optical projection file.