Wind Blade Bonding Fixture for Uniform Flatback Insert Pressure
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Solution Overview
Problem
The existing methods for assembling wind turbine blade components, particularly flatback inserts, face challenges such as uneven force application leading to paste voids and inefficiencies in manufacturing, which affect the structural integrity and aerodynamic performance of larger wind turbines.
Innovation Solution
A system comprising a fixture with interconnected struts, arms, legs, and actuators that precisely positions and applies consistent force to flatback inserts within a mold, ensuring even bonding and reducing manual labor, featuring adjustable components and a template for guiding adhesive application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual force is used to lift and push flatback components against the bond surface, then assembly simplicity is maintained, but uneven force application occurs resulting in paste voids and bonding defects
Solution Approach 1:
A fixture system with arms, legs, and actuators is introduced as an intermediary device between the operator and the flatback component. The fixture applies force through distributed contact points and mechanical advantage, converting manual operation into controlled, uniform force application that eliminates paste voids while maintaining ease of use.
Solution Approach 2:
The patent replaces direct manual mechanical pushing with a mechanical system comprising actuators, struts, and linkage mechanisms. This system provides controlled, progressive force application through mechanical advantage, ensuring uniform bonding pressure without the variability of direct human force application.
2Productivity
If larger rotor blade sizes are used to increase energy production, then energy capture improves, but structural integrity challenges and manufacturing complexity increase
Solution Approach 1:
The fixture system is divided into modular components including separate arms, legs, struts, and actuators that can be independently positioned and adjusted. This segmentation allows the system to accommodate various blade sizes and configurations without requiring complete redesign, managing manufacturing complexity while supporting larger blade production.
Solution Approach 2:
The fixture incorporates adjustable and movable components including telescoping struts, articulated arms, and positionable actuators. These dynamic elements allow the system to adapt to different blade geometries and sizes, providing the flexibility needed for manufacturing larger blades without proportionally increasing complexity.
3Weight of moving object
If decreased rotor blade weight is achieved to improve efficiency, then energy efficiency improves, but structural strength and integrity become more difficult to maintain
Solution Approach 1:
The fixture system enables precise control of bonding parameters including force magnitude, distribution, and duration. By optimizing these parameters, the bonding process achieves maximum strength with minimal material, supporting weight reduction efforts while maintaining structural integrity through controlled adhesive application and compression.
Data Source
AI summary
The disclosed subject matter provides a system and method for facilitating bonding of various turbine blade components, including trailing edge inserts, or flatbacks, to the trailing edge of a wind turbine blade. The system disclosed herein ensures a consistent force is applied from root to top thereby preventing defects, e.g. paste voids, from forming. Additionally, a consistent bonding gap can be achieved due to the consistent application of force from the root to tip of the blade.