Adjustable Shear Web Mould System for Wind Turbine Manufacturing
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Solution Overview
Problem
Existing shear web mould systems for manufacturing wind turbine components are cumbersome, expensive, and prone to structural failures due to the need for custom-made molds for each blade type, which complicates the manufacturing process and increases the risk of fibre layup wrinkles and structural faults.
Innovation Solution
A shear web mould system with adjustable moulding plates that allow for variable angle and position settings, enabling the same system to produce multiple shear web types with customizable geometry, reducing the need for multiple molds and minimizing structural faults by providing a more controlled fibre layup process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If custom-made molds are used for each blade type, then manufacturing precision and reliability are improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent applies universality by designing a single mould system that can manufacture multiple types of shear webs for different blade models. The mould includes adjustable support members and removable inserts that can be reconfigured to produce various web geometries, eliminating the need for custom-made molds for each blade type while maintaining manufacturing precision and structural reliability.
Solution Approach 2:
The patent applies dynamics by incorporating adjustable support members and removable inserts that can be repositioned and reconfigured during the manufacturing process. This dynamic capability allows the same mould system to adapt to different shear web designs and blade types, reducing device complexity while preserving the ability to produce high-precision components.
2Ease of manufacture
If removable inserts are used in the mould system, then ease of manufacture is improved, but manufacturing precision deteriorates due to fibre layup wrinkles
Solution Approach 1:
The patent applies the intermediary principle by using a flexible membrane as a mediator between the removable inserts and the fibre reinforcement material. The membrane covers the inserts and provides a smooth surface for fibre layup, preventing wrinkles while allowing the inserts to be easily removed. This intermediary layer resolves the contradiction between ease of manufacture and manufacturing precision.
3Ease of manufacture
If fibre layers are folded around inserts, then ease of manufacture is improved, but manufacturing precision deteriorates due to wrinkles in the fibre layup
Solution Approach 1:
The patent applies the intermediary principle by introducing a flexible membrane that covers the removable inserts during fibre layup. This membrane allows fibre layers to be easily placed without direct folding around the inserts, while still providing the necessary support and shape. The membrane prevents wrinkles in the fibre layup, thus maintaining manufacturing precision while preserving ease of manufacture.
4Adaptability or versatility
If multiple custom molds are manufactured, then adaptability to different blade types is improved, but loss of substance and manufacturing cost increase
Solution Approach 1:
The patent applies universality by creating a single multi-functional mould system that can produce shear webs for various blade types. The system includes adjustable support members and removable inserts that can be reconfigured to match different web geometries. This eliminates the need to manufacture multiple custom molds, reducing material consumption and manufacturing cost while maintaining full adaptability to different blade types.
Data Source
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AI summary
A shear web mould system for manufacturing a wind turbine component in form of an I- shaped shear web having a web body and a first web foot flange at a first end of the web body and a second web foot flange at a second end of the web body is described. The system comprises a central moulding portion for forming at least a part of the web body, a first moulding plate for forming at least a part of the first web foot flange, and a second moulding plate for forming at least a part of the second web foot flange. The angles of the first moulding plate and the second moulding plate relative to the central moulding portion are adjustable.