Wind Turbine Blade Mold With Exchangeable Carrier Extension
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Solution Overview
Problem
The existing mold designs for wind turbine blades are inflexible and costly to modify, as they are designed based on initial blade geometry, making it difficult to accommodate changes in blade length during development without requiring significant reworking of the mold.
Innovation Solution
A modular mold system with a changeable second carrier that can accommodate pre-fabricated blade tips, allowing for adjustable length and precise positioning using hydraulic or pneumatic cylinders and saddle-like support elements, enabling easy adaptation to varying blade lengths without altering the entire mold setup.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the mold is designed based on initial blade geometry with fixed length, then the mold structure is simple and manufacturing is easier, but the mold cannot accommodate changes in blade length during development
Solution Approach 1:
The mold carrier is divided into multiple modular sections (first carrier means, second carrier means) that can be independently adjusted or replaced. The second carrier means can be exchanged for different length variants to accommodate different blade lengths, while the first carrier means and shell means remain unchanged. This segmentation allows the mold to adapt to different blade geometries without requiring complete redesign.
Solution Approach 2:
The mold incorporates adjustable and exchangeable components rather than fixed structures. The second carrier means is designed to be replaceable with different length versions, and the connection between carrier means allows for dynamic reconfiguration. This dynamic design enables the mold to adapt to development changes in blade length without becoming obsolete.
2Adaptability or versatility
If the mold is designed to accommodate longer blade lengths, then future blade length increases are possible, but the initial mold construction becomes more complex and costly
Solution Approach 1:
The carrier system is segmented into a first carrier means (fixed) and a second carrier means (exchangeable). By keeping the first carrier means simple and standardized, manufacturing remains easy. The second carrier means is the only component that varies with different blade length requirements, allowing future length increases without increasing overall mold complexity or cost significantly.
Solution Approach 2:
The first carrier means and shell means are designed as universal components that can work with multiple variants of the second carrier means. This multi-functionality allows the same base mold structure to accommodate different blade lengths by simply changing the second carrier means, avoiding the need to manufacture entirely different mold systems for different blade lengths.
3Strength
If the mold structure is made rigid and fixed to ensure structural strength, then the mold can carry high loads, but the mold cannot be easily modified when blade design changes
Solution Approach 1:
The mold is segmented into load-bearing fixed components (first carrier means, shell means) and replaceable components (second carrier means). The fixed components maintain structural strength and load-bearing capacity, while the replaceable components provide adaptability. This segmentation allows the mold to be both strong and easily modifiable when blade design changes occur.
Solution Approach 2:
The connection between the first and second carrier means is designed to be detachable and reconfigurable. This dynamic connection allows the second carrier means to be replaced when blade design changes, while the first carrier means remains fixed to maintain structural integrity. The system transitions from a completely fixed structure to a hybrid fixed-dynamic structure that combines strength with adaptability.
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
Enables flexible adjustment of blade length and geometry, reducing production costs and complexity by allowing for simple modification of the mold length and precise attachment of pre-fabricated blade tips, facilitating easier production and maintenance of wind turbine blades.
Implementation Method 1
adjustable length and precise positioning using hydraulic or pneumatic cylinders
Implementation Method 2
adjustable length and precise positioning using hydraulic or pneumatic cylinders
Data Source
AI summary
Provided is a mold adapted for producing a wind turbine blade, including a first carrier and a shell for accommodating blade building elements to be embedded in a resin matrix for building a blade body part, which shell is placed on the first carrier, and a second carrier changeable in its length and elongating the first carrier adapted to accommodate a prefabricated blade tip to be connected to the blade body part when the blade body part is built.