Wind Turbine Blade Mold Infusion Using Upper Resin Inlets
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Solution Overview
Problem
Manufacturing large wind turbine blades with vacuum-assisted infusion is challenging due to gravitational forces and resin density, making it difficult to raise resin to the top of the blade, leading to incomplete wetting and increased manufacturing time.
Innovation Solution
The method involves arranging an upper mold with at least one upper resin inlet at its top portion, allowing resin infusion through this inlet and supporting the flow with gravitational force, combined with additional resin inlets at different heights and sensors to monitor and control the resin flow, ensuring complete wetting of the fiber lay-up.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If vacuum-assisted resin infusion is used to manufacture large wind turbine blades, then the resin can be infused into the fiber lay-up, but the gravitational force and resin density make it difficult to raise the resin to the top of the blade, resulting in incomplete wetting and dry areas
Solution Approach 1:
The patent inverts the traditional resin infusion approach by providing resin through inlets at the upper portion of the mold rather than at the bottom. This inversion allows resin to flow downward under gravity assistance, overcoming the gravitational force that previously prevented complete wetting of the fiber lay-up in large blade cross-sections
Solution Approach 2:
The patent introduces multiple resin inlets at different heights (upper, middle, and lower portions) of the mold, adding a vertical dimension to resin supply. This multi-level inlet arrangement ensures resin can reach all regions of the fiber lay-up regardless of blade size, preventing dry areas and incomplete wetting
2Productivity
If vacuum-assisted resin infusion is used for large blade cross-sections, then the resin infusion process can be performed, but the time needed for infusing the entire blade increases significantly
Solution Approach 1:
The patent segments the resin supply system into multiple inlets distributed at different heights and locations within the mold. This segmentation allows resin to be supplied simultaneously to multiple regions of the fiber lay-up, parallelizing the infusion process and significantly reducing the total time required to complete saturation of large blade cross-sections
Solution Approach 2:
The patent employs sensors to detect the position of the resin flow front during infusion. This real-time monitoring enables preliminary identification of regions that require additional resin supply, allowing the system to proactively adjust inlet activation to ensure complete and timely wetting of the entire fiber lay-up
3Manufacturing precision
If resin is provided through upper resin inlets to improve wetting, then dry areas can be prevented, but the device complexity increases with additional sensors and control systems
Solution Approach 1:
The patent incorporates sensors that detect the position of the resin flow front during infusion and provide real-time feedback to the control system. This feedback mechanism enables dynamic adjustment of resin supply, ensuring uniform distribution throughout the fiber lay-up while maintaining manufacturing precision even as blade size increases
Solution Approach 2:
The sensor system automatically detects resin position and triggers activation of appropriate resin inlets without requiring external intervention. This self-service capability allows the system to autonomously ensure complete wetting, reducing the need for complex external monitoring and control while maintaining uniform resin distribution
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 resin infusion efficiency, reduces manufacturing time, and prevents dry areas in the blade, enabling the production of large blades with improved strength and robustness.
Implementation Method 1
applying vacuum to a space between the upper and lower molds
Implementation Method 2
applying vacuum to a space between the upper and lower molds, and infusing the dry fiber lay-up
Implementation Method 3
a resin flow of the resin provided through the at least one upper resin inlet is supported in a downward direction by the gravitational force
Data Source
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AI summary
A method for manufacturing a wind turbine blade (3), comprising the steps of: - arranging (S2, S2') an upper mold (10, 10') on a lower mold (9, 9'), wherein a dry fiber lay-up (11, 11') is arranged in the upper mold (10, 10') or in the upper mold (10, 10') and the lower mold (9, 9'), - applying (S3, S3') vacuum to a space (15, 15') between the upper and lower molds (10, 10', 9, 9'), and - infusing (S5, S8) the dry fiber lay-up (11, 11') in the upper and/or lower molds (10, 10', 9, 9') with resin (17), wherein the resin (17) is at least partially provided (S4, S7') through at least one upper resin inlet (16, 16', 37, 38) arranged at an upper portion (29, 29') of the upper mold (10, 10'). Having the at least one upper resin inlet of the upper mold allows to improve the vacuum-assisted resin infusion. For example, resin provided through the at least one upper resin inlet has to be raised by a smaller height to reach the top of the mold. For example, a resin flow of the resin provided through the at least one upper resin inlet is supported in a downward direction by the gravitational force.