Wind Turbine Blade Cradle Bonding System
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current wind turbine blade manufacturing processes are hindered by the high cost and long lead time associated with producing and transporting expensive blade moulds, as well as inefficiencies in the two-step infusion process for reinforced structures, which limits productivity and stability of the blades.
Innovation Solution
The method involves forming cured blade elements in cradles with moulding surfaces that provide a seal for vacuum-assisted resin infusion, allowing for the creation of reinforced sections independently of the vacuum tightness of the blade elements, and using cradles to efficiently bond and shape the blade shells, reducing the dependency on precise mould alignment and vacuum integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If expensive blade moulds are used to ensure accurate blade profiles and enable shell turning for bonding, then manufacturing precision and ease of operation are improved, but device complexity and manufacturing cost increase significantly
Solution Approach 1:
The blade manufacturing process is segmented into two independent stages: (1) forming blade shells in open moulds without requiring closing mechanisms, and (2) bonding shells together using a separate bonding apparatus. This segmentation eliminates the need for complex hinged closing mechanisms in the moulds, reducing mould complexity while maintaining manufacturing precision through dedicated bonding equipment.
Solution Approach 2:
The shell closing and bonding function is extracted from the mould system and performed by a separate bonding apparatus. The moulds are used solely for forming the blade shells, while the bonding apparatus handles the closing and bonding operations. This separation reduces mould complexity and enables more precise bonding control.
2Strength
If blade shells are bonded together using hinged moulds with pressure application, then bonding strength is improved, but manufacturing time and device complexity increase
Solution Approach 1:
Adhesive is applied to the shell edges before the bonding operation, and the shells are pre-positioned in the bonding apparatus. This preliminary preparation enables faster bonding cycles by eliminating setup time during the actual bonding process, reducing overall manufacturing time while maintaining bonding strength through controlled application conditions.
3Stability of the object's composition
If a two-step infusion process is used to form reinforced structures after initial shell moulding, then blade stability and strength are improved, but productivity and manufacturing time deteriorate
Solution Approach 1:
The reinforced structures (spar caps, main laminates) are merged into the initial shell forming process by placing reinforcement elements in the open moulds before resin infusion. This single-step integrated process eliminates the need for a separate post-moulding reinforcement step, improving productivity while maintaining blade stability through proper structural integration.
Solution Approach 2:
Reinforcement elements are positioned in the moulds before the resin infusion process begins. This preliminary placement of reinforcements allows them to be incorporated into the blade structure during the initial curing cycle, eliminating subsequent post-moulding operations and improving manufacturing throughput while ensuring proper structural integration.
4Manufacturing precision
If extensive tooling and manufacturing of blade moulds is performed to accommodate minor blade characteristic variations, then manufacturing precision is improved, but loss of time and manufacturing cost increase
Solution Approach 1:
The bonding apparatus is designed with adjustable and reconfigurable components that can be dynamically adjusted to accommodate different blade shell sizes and characteristics. This dynamic adaptability allows the same bonding apparatus to handle various blade types without requiring dedicated moulds for each configuration, reducing setup time and manufacturing costs while maintaining precision through programmable positioning and control systems.
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 enhances the throughput and geometry fit of wind turbine blades, reduces manufacturing time and costs, and allows for improved stability and efficient use of moulds by separating the formation of aerodynamic shells and load-carrying structures, enabling quicker and more cost-effective production.
Implementation Method 1
A vacuum is typically used to draw epoxy resin material into a mould
Implementation Method 2
followed by resin infusion
Implementation Method 3
an adhesive glue is applied to the edges of the shells while in the moulds
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The present invention relates to a method and system for manufacturing a wind turbine blade. The method comprising the steps of forming a cured blade element (102) of a first blade shell, forming a cured blade element (102) of a second blade shell, transferring the cured blade element (102) of the first blade shell to a first cradle (92), and transferring the cured blade element (102) of the second blade shell to a second cradle (94). Each cradle comprises a mould body (96, 98) having a moulding surface for abutting against a surface of the cured blade element to advantageously form a seal therebetween.