Wind Turbine Blade Core Insert Alignment Without Destructive Cut-Outs

Solution Overview

Problem

Current methods for manufacturing wind turbine blades are inefficient and time-consuming due to the challenges of fitting functional components into the core material during the blade shell manufacturing process, requiring destructive and time-consuming cut-outs to achieve precise alignment.

Innovation Solution

A method involving a fibre lay-up process with a core member containing rotatable cylindrical inserts allows for easy adjustment of functional component placement, avoiding the need for destructive cut-outs and reducing mould cycle time by rotating the inserts to achieve precise positioning within the core member.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If functional components are fitted into core material during blade shell manufacturing, then the blade structure is formed, but the process becomes time-consuming and difficult to achieve precise alignment

Engineering Contradiction:

Improvealignment precision of functional componentsVSAvoidmanufacturing time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The core member is pre-formed with a recess and hole structure before being integrated into the blade shell manufacturing process. This preliminary preparation allows functional components to be easily inserted and aligned during assembly, eliminating the need for time-consuming post-manufacturing adjustments and achieving precise alignment without extending the overall manufacturing cycle

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

A cylindrical insert is introduced as an intermediary element between the core member and the functional component. This insert features a recess that precisely accommodates the functional component, facilitating easy alignment and insertion while maintaining the structural integrity of the core member. The insert acts as a mediator that simplifies the assembly process and ensures precise positioning

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If cut-outs are made in core material to adjust functional component location, then positioning accuracy is improved, but the process becomes destructive and time-consuming

Engineering Contradiction:

Improvelocation precision of functional componentsVSAvoidmanufacturing simplicity

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The core member is pre-formed with a recess and hole structure before being integrated into the blade shell manufacturing process. This preliminary preparation allows functional components to be easily inserted and aligned during assembly, eliminating the need for time-consuming post-manufacturing adjustments and achieving precise alignment without extending the overall manufacturing cycle

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

A cylindrical insert is introduced as an intermediary element between the core member and the functional component. This insert features a recess that precisely accommodates the functional component, facilitating easy alignment and insertion while maintaining the structural integrity of the core member. The insert acts as a mediator that simplifies the assembly process and ensures precise positioning

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If traditional manufacturing methods are used, then the blade structure is created, but manpower and expertise requirements are disproportionately high

Engineering Contradiction:

Improvequality controlVSAvoidconstruction complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The core member is segmented into distinct functional zones: a recess for housing functional components, a hole for inserting cylindrical elements, and integration areas for the blade shell. This segmentation allows each component to be manufactured and prepared separately with standardised processes, reducing the need for complex manual operations and specialised expertise during final assembly

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A cylindrical insert is introduced as an intermediary element between the core member and the functional component. This insert features a recess that precisely accommodates the functional component, facilitating easy alignment and insertion while maintaining the structural integrity of the core member. The insert acts as a mediator that simplifies the assembly process and ensures precise positioning

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS12138866B2Method of manufacturing wind turbine blade with core member and wind turbine blade with structural member

Publication Date: 2024.11.12 LM WIND POWER AS

AI summary

The present invention relates to a method of manufacturing a wind turbine blade (10), comprising the steps of placing a fibre lay-up including one or more fibre layers on the mould surface of a blade mould (60), arranging a load-bearing structure (45) and a core member (62) on the fibre lay-up such that the core member (62) is arranged between the load-bearing structure (45) and the leading edge (18) and/or between the load-bearing structure (45) and the trailing edge (20), and infusing resin into the blade mould to impregnate the fibre lay-up. The core member (62) comprises a first hole (64) with a circular cross section, a first cylindrical insert (70) rotatably arranged within the first hole (64) of the core member (62), the first cylindrical insert (70) having a central axis (71). A recess (80) is formed in the first cylindrical insert (70), wherein the recess (80) is arranged eccentrically with respect to the central axis (71) of the first cylindrical insert (70).