Wind Turbine Blade Core Joint via Adhesive Injection
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Solution Overview
Problem
The manufacturing of large wind turbine blades is challenging due to difficulties in assembly and ensuring the strength of joints, which are critical for withstanding operational forces.
Innovation Solution
A method involving the use of core materials with laminates and injection holes for adhesive application, forming a structural joint that is quick, cost-effective, and sufficiently strong, utilizing self-curing adhesives and specific joint configurations like scarf and butt joints with overlaminating and intermediate pieces for enhanced strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wind turbine blades are manufactured in portions and joined on-site, then transportation difficulty is reduced, but joint strength becomes a critical concern
Solution Approach 1:
The blade is divided into multiple portions that can be manufactured separately and transported individually, then joined on-site. This segmentation enables easier transportation while the injection molding process ensures strong joints between segments.
Solution Approach 2:
A joining structure with cavity and injection holes is introduced as an intermediary element between blade portions. Adhesive is injected through the injection holes into the cavity to bond the portions together, ensuring sufficient joint strength while maintaining manufacturing ease.
2Strength
If traditional bonding or bolting methods are used for joining blade portions, then joint strength can be achieved, but manufacturing time and cost increase
Solution Approach 1:
Traditional mechanical joining methods (bonding or bolting) are replaced with an injection molding process. Adhesive is injected through injection holes into the cavity under pressure, and the joining structure is integrated into the molding process, significantly reducing manufacturing time and cost while maintaining joint strength.
Solution Approach 2:
The joining process parameters are optimized by controlling adhesive injection pressure, temperature, and curing conditions during the injection molding process. This enables rapid formation of strong joints, improving productivity compared to traditional methods.
3Productivity
If injection holes are provided in laminates for adhesive injection, then manufacturing efficiency is improved, but laminate structure becomes more complex
Solution Approach 1:
Injection holes are pre-formed in the laminates during the manufacturing process, and the joining structure with cavity is prepared in advance. This preliminary preparation enables efficient adhesive injection and rapid assembly, improving manufacturing efficiency despite the added structural complexity.
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 method enables the efficient and strong assembly of wind turbine blade components, improving manufacturing efficiency and cost-effectiveness while ensuring the structural integrity of the blade under operational forces.
Implementation Method 1
curing the adhesive injected into the cavity and thereby forming a structural joint between the end of the core material of the first portion and the end of the core material of the second portion
Data Source
AI summary
A method for manufacturing a structural element of a wind turbine blade including forming of at least one injection hole in at least one laminate provided on a top side of a core material of a first portion and a second portion of the structural element and a bottom side of a core material of the first portion and the second portion, so that the at least one injection hole is fluidically connected to the cavity. Further, injecting adhesive through the injection hole into the cavity, curing the adhesive injected into the cavity and thereby forming a joint between an end of the core material of the first portion and an end of the core material of the second portion. Further, a method for manufacturing a wind turbine blade and the structural element, the wind turbine blade is also provided.