Wind Blade Bonding Fixture for Uniform Flatback Insert Assembly

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Solution Overview

Problem

Existing methods for assembling trailing edge inserts in wind turbine blades, such as flatbacks, face challenges due to uneven force application leading to paste voids and unreliable structural integrity.

Innovation Solution

A fixture system with adjustable arms, legs, and actuators is used to precisely position and install flatback inserts within the mold, ensuring consistent force application and alignment, and a storage rack to facilitate the assembly of the flatback components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If manual force is used to lift and push the flatback component against the bond surface, then the assembly process is simple, but uneven force is applied resulting in paste voids and unreliable structural integrity

Engineering Contradiction:

Improveassembly process simplicityVSAvoidstructural integrity

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

A fixture system with arms and actuators is introduced as an intermediary device between the operator and the flatback component. The fixture applies force uniformly across multiple points on the flatback component through pneumatic or hydraulic actuators, eliminating the uneven force application that occurs with manual pushing while maintaining operational simplicity.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The manual mechanical pushing action is replaced with a controlled actuation system using pneumatic or hydraulic actuators. These actuators provide precise, uniform, and controllable force application to the flatback component, ensuring consistent bonding pressure without the variability inherent in manual operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If uniform force application is achieved through automated fixtures, then paste voids are reduced and structural integrity improves, but device complexity increases

Engineering Contradiction:

Improvestructural integrityVSAvoidfixture system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The fixture system is divided into modular components including multiple arms, individual actuators for each arm, and separate positioning mechanisms. This segmentation allows the complex function of uniform force application to be achieved through multiple simple, independent units that can be adjusted and maintained separately, reducing overall system complexity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The fixture system is designed to perform multiple functions: positioning the flatback component, applying uniform bonding force, and potentially accommodating different component sizes. The arms and actuators can be adjusted to work with various blade configurations, reducing the need for multiple specialized fixtures and simplifying the overall manufacturing process.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentEP3807083B1Wind blade component bonding fixture

Publication Date: 2025.12.24 TPI COMPOSITES INC

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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.