Adjustable Plug for Rotor Blade Moulds
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Solution Overview
Problem
The existing manufacturing process for rotor blade moulds is time-consuming, costly, and requires significant resources due to the need for multiple rigid plugs, each with a large surface area, which are difficult to transport and store, and require specialized equipment, limiting flexibility in aerodynamic design changes.
Innovation Solution
A plug with a flexible skin and adjustable articulated actuators that can be configured to form various rotor blade geometries, allowing a single plug to be used for multiple moulds, with actuators arranged in a matrix for vertical and horizontal adjustment, and a controller to manage shape changes, reducing the need for multiple plug types and simplifying design updates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple rigid plugs are manufactured for different blade types, then each specific blade geometry can be produced with high precision, but the total cost increases, storage space requirements increase, and transportation becomes complex and time-consuming
Solution Approach 1:
The plug structure is transformed from a static rigid form to a dynamic adjustable form. The articulated arms with multiple segments can be reconfigured to different positions and angles, allowing the same plug to generate different blade geometries. This dynamic capability enables one plug to replace multiple dedicated plugs, reducing storage and transportation requirements while maintaining manufacturing precision for various blade types
Solution Approach 2:
The plug is designed as a universal device that can perform multiple functions by adjusting its articulated components. Instead of requiring separate plugs for suction side and pressure side, or for different blade designs, a single multi-functional plug can be reconfigured to produce any required blade geometry, thereby eliminating the need for multiple specialized plugs
2Ease of manufacture
If large rigid plugs are transported to mould factories, then mould production can proceed, but transportation time increases, damage risks increase, and special transportation equipment is required
Solution Approach 1:
The plug is divided into multiple articulated segments that can be independently adjusted and folded. This segmentation allows the plug to be compacted into a smaller configuration for transportation, reducing the need for special transportation equipment and minimizing damage risks, while still maintaining the capability to form complete blade geometries when deployed at the mould factory
Solution Approach 2:
The articulated structure enables the plug to transition between compact transportation configuration and expanded operational configuration. This dynamic transformation capability significantly reduces transportation time and eliminates the need for dedicated large-scale transportation arrangements, while ensuring the plug arrives at the mould factory ready for immediate use
3Manufacturing precision
If dedicated plugs are manufactured for each blade type, then specific blade geometries can be produced accurately, but the number of plugs required increases, leading to increased storage space requirements
Solution Approach 1:
A single universal plug with articulated arms can replace multiple dedicated plugs for different blade types. By adjusting the articulation angles and positions, the same plug generates accurate geometries for various blade designs, thereby eliminating the need for extensive storage space required for multiple separate plugs
Solution Approach 2:
The dynamic adjustability of the articulated arms allows one plug to assume multiple geometric configurations, each suitable for producing different blade types with required precision. This eliminates the need to store multiple static plugs, significantly reducing storage space requirements
4Adaptability or versatility
If new plugs are manufactured for updated blade designs, then aerodynamic improvements can be implemented, but the manufacturing lead time increases and flexibility in design changes is reduced
Solution Approach 1:
The articulated plug structure allows for rapid reconfiguration to accommodate design changes. Instead of manufacturing new plugs for updated blade designs, the existing plug can have its articulated arms repositioned to generate the new geometry, dramatically reducing the time required to implement aerodynamic improvements
Solution Approach 2:
The universal plug design enables quick adaptation to different blade geometries through adjustment of its articulated components. This flexibility allows design modifications to be implemented rapidly without the lengthy manufacturing lead time associated with producing entirely new dedicated plugs
Data Source
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Figure 3~4
AI summary
A plug (1) with a predetermined shape for forming a mould, whereby the plug (1) comprises a flexible skin (2) covering multiple actuators (3) which can be adjusted in order to generate the predetermined shape.