Wind Turbine Blade Bonding Without Edge Surface Grinding
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Solution Overview
Problem
The existing methods for manufacturing wind turbine blades are labor-intensive and hazardous due to the need for surface grinding to prepare edge surfaces for bonding, which is time-consuming and poses health risks from dust and noise.
Innovation Solution
The method involves using an impregnated carrier substrate with functional moieties, such as hydroxyl groups, between shell halves along bond lines, which interacts with adhesives to enhance bonding strength and structural stability, eliminating the need for surface grinding by becoming an integral part of the blade during resin infusion and curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If surface grinding is performed to prepare edge surfaces for bonding, then bonding strength is improved, but manufacturing time increases and health risks arise from dust and noise
Solution Approach 1:
The edge surfaces of the shell halves are pre-treated with a plasma process before bonding, creating reactive functional groups on the surface that enhance adhesive bonding. This preliminary surface activation eliminates the need for subsequent grinding operations while achieving superior bonding strength, thereby reducing total manufacturing time and avoiding dust generation.
Solution Approach 2:
The mechanical grinding process is replaced with a plasma treatment process. Instead of mechanically removing material through abrasion, the plasma process chemically modifies the surface to create bonding-friendly characteristics, eliminating dust generation and noise while maintaining or improving bonding strength.
2Strength
If surface grinding is performed to prepare edge surfaces for bonding, then bonding strength is improved, but health risks increase due to dust and noise
Solution Approach 1:
The mechanical grinding process is replaced with a plasma treatment process. Instead of mechanically removing material through abrasion, the plasma process chemically modifies the surface to create bonding-friendly characteristics, eliminating dust generation and noise while maintaining or improving bonding strength.
Solution Approach 2:
The surface treatment approach is changed from mechanical removal (grinding) to chemical modification (plasma treatment). This parameter change transforms the process from a harmful mechanical operation generating dust and noise to a clean chemical process that activates surface functional groups for enhanced bonding without adverse health effects.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach simplifies the manufacturing process, improves bonding strength, and enhances structural stability of wind turbine blades while ensuring improved work safety and efficiency.
Implementation Method 1
the carrier substrate is impregnated with at least one compound having a functional moiety
Implementation Method 2
A vacuum is typically used to draw epoxy resin material into the mould
Implementation Method 3
a vacuum is drawn into the void formed by the bag and the tool such that the fibres of the part are infused with resin
Implementation Method 4
In subsequent curing, heating and subsequently cooling may be applied to harden the resin
Data Source
AI summary
The present invention relates to a method of manufacturing a wind turbine blade. The method comprises adhesively joining a suction side shell half (69) and a pressure side shell half (68) along respective bond lines (80) at their leading and trailing edges, wherein, prior to joining, an impregnated carrier substrate (76) is arranged in between the shell halves along at least part of said bond lines (80). The carrier substrate (76) is impregnated with at least one compound having a functional moiety. The shell halves may be manufactured by placing a fibre lay-up including one or more fibre layers on a mould surface (66), arranging the impregnated carrier substrate (76) on the inside surface (72) at least along part of its peripheral edge (74) and injecting or infusing the fibre lay-up and the impregnated carrier substrate with a resin and subsequently curing the same.