Wind Turbine Blade Structural Component Manufacturing via Mold-Aligned Tooling Pins
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Solution Overview
Problem
The manufacturing of structural components for wind turbine rotor blades is complex and prone to quality issues due to the need for precise machining and custom drilling, which can result in defective components if not done correctly.
Innovation Solution
A method involving the use of molds and tooling pins to lay up fiber layers and infuse resin materials, with mandrels providing a base shape, to form structural components like beam structures or receiving sections, allowing for precise alignment and integration of pin joints without the need for expensive custom drilling machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If complex fixturing processes and custom drilling machines are used to ensure precise pin hole alignment, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
The mold incorporates pre-integrated tooling pins and alignment features before the composite layup process begins. These tooling pins are permanently embedded in the mold structure to provide precise reference points for pin hole drilling, eliminating the need for complex temporary fixturing during manufacturing.
Solution Approach 2:
The mold design includes simplified replica features that replicate the final pin joint geometry and alignment requirements. By using the mold itself as the alignment reference rather than complex external fixturing, the system achieves high precision through the mold's inherent geometric accuracy.
2Manufacturing precision
If complex fixturing and custom drilling machines are used, then manufacturing precision is improved, but manufacturing cost increases
Solution Approach 1:
The invention replaces expensive, custom-built drilling machines and complex fixturing systems with simpler, more economical tools. The mold's built-in tooling pins serve as disposable or reusable alignment references that are far less costly than specialized drilling equipment.
Solution Approach 2:
The mold serves multiple functions: it shapes the composite structure, provides alignment references through embedded tooling pins, and guides the drilling process. This multi-functionality eliminates the need for separate, expensive alignment and drilling equipment.
3Manufacturing precision
If the entire structural component is discarded due to drilling quality issues, then manufacturing precision is maintained, but material waste increases
Solution Approach 1:
The mold provides pre-established alignment references through embedded tooling pins before drilling begins. This preliminary alignment setup ensures that pin holes are drilled with consistent precision, preventing quality issues that would otherwise require scrapping the entire component.
Solution Approach 2:
The tooling pins embedded in the mold serve as intermediary reference elements between the mold and the drilling process. These intermediaries provide stable, precise alignment during drilling, ensuring quality consistency without requiring the entire component to be discarded if minor deviations occur.
Data Source
AI summary
A method for manufacturing a structural component of a blade segment for a segmented rotor blade of a wind turbine includes forming first and second portions of the structural component. The first and second portions include respective holes that align in a chord-wise direction. The method also includes placing the first and second portions of the structural component into a mold such that their respective holes align in the chord-wise direction. Further, the method includes placing a tooling pin through the aligned holes. In addition, the method includes infusing the first and second sides together in the second mold via a resin material so as to form the structural component. Moreover, the method includes removing the tooling pin after the structural component has cured.