Development and metrological validation of a new automated scanner system for freeform measurements on wind turbine blades in the production

Abstract

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Dimensional artefacts to achieve metrological traceability in advanced manufacturing

“…An example of application to a turbine blade is shown in Figure 23-right; the geometry of the blade was simulated by an assembly of a cylinder and two flat surfaces, estimating a freeform measuring uncertainty of the order of 2 µm to 3 µm for contact scanning on a high-accuracy CMM [254]. Other examples of traceability transfer using the MFG concept are given elsewhere [102] [199]. Using a section of a wind turbine blade calibrated following the MFG approach, shown in Figure 24, an expanded uncertainty (k = 2) of 665 µm was documented for automated freeform optical scanner measurements of the leading edge geometry on a 55 m blade [199].…”

“…Other examples of traceability transfer using the MFG concept are given elsewhere [102] [199]. Using a section of a wind turbine blade calibrated following the MFG approach, shown in Figure 24, an expanded uncertainty (k = 2) of 665 µm was documented for automated freeform optical scanner measurements of the leading edge geometry on a 55 m blade [199].…”

“…Establishment of the traceability of automated freeform optical scanner measurements on wind turbine blades in the production [199]. Left: calibration of freeform surface of a wind turbine blade section.…”

“…Typical range of measurement uncertainty vs. part dimension for different categories of measurement systems along with dimensions and calibration uncertainty of some examples of freeform artefacts (in blue). Adapted and updated after[253] and[199].…”

3D printing on freeform surface: Real-time and accurate 3D dynamic dense surface reconstruction with HoloLens and displacement measurement sensors

“…First, this study makes a major contribution in demonstrating an efficient sampling method that enables the acquisition of a small amount of data points in reconstructing an accurate dynamic curved surface executing in real-time. Secondly, inspired by Lyngby et al, 15 a novel efficient and accurate system is introduced to scan the twisting and bending state of a large-scale metal sheet bent by industrial robots. We provide empirical proof of our method by comparing the results produced by HoloLens to robotic laser scans of fabricated models.…”