Wind Turbine Blade Mould Gas Flow Thermal Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for moulding wind turbine blade outer shells using epoxy resin face challenges such as high temperature requirements leading to health and safety hazards, corrosion, and uneven curing due to temperature gradients, particularly with large moulds.
Innovation Solution
The use of a gas flow system within the mould, with external heat exchangers to control temperature, minimizing gradients and enabling local temperature control, and the reuse of heat energy through liquid circulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If water is heated to high pressure to achieve curing temperature above 100°C, then the curing time becomes commercially acceptable, but health and safety hazards increase
Solution Approach 1:
The patent introduces gas as an intermediary medium to transfer heat to the mould. Instead of directly heating water to high pressure, the system uses gas heated by heat exchangers to indirectly heat the mould, avoiding the safety hazards of pressurized hot water while achieving the necessary curing temperatures
Solution Approach 2:
The patent replaces the mechanical pressurization system (pumps and high-pressure water delivery) with a thermal field system using heat exchangers and gas flow. This substitution eliminates the need for high-pressure mechanical systems while achieving the same thermal effect for curing
2Temperature
If serpentine channel is formed in the mould to control temperature, then the area of contact between water and mould is optimized, but the complexity of manufacture increases
Solution Approach 1:
The patent extracts the temperature control function from the mould structure itself and relocates it to external heat exchangers. Instead of embedding channels within the mould, the system uses external equipment to heat gas that then flows through or around the mould, simplifying mould manufacturing while maintaining temperature control capability
Solution Approach 2:
The patent introduces gas as an intermediary medium that carries thermal energy from external heat exchangers to the mould. This eliminates the need for complex internal water channels in the mould, as the gas medium can be delivered through simpler external piping and distribution systems
3Temperature
If serpentine channel is formed in the mould, then temperature contact area is maximized, but temperature gradients along the channel length increase
Solution Approach 1:
The patent segments the temperature control system into multiple independent zones, each with its own heat exchanger and gas supply. This allows different regions of the mould to be controlled independently, eliminating the temperature gradients that occur in long serpentine channels and ensuring uniform curing across the entire mould
Solution Approach 2:
The patent transitions from a one-dimensional serpentine channel approach to a multi-dimensional gas distribution system. Gas can flow through the mould in multiple directions and dimensions, allowing more uniform heat distribution throughout the mould volume rather than following a single linear path
4Temperature
If pressurized water is used to heat the mould, then the desired temperature is achieved, but corrosion of the mould occurs
Solution Approach 1:
The patent introduces gas as an intermediary heating medium that does not come into direct contact with the mould surface in the same way water does. The gas transfers heat through conduction and convection without causing corrosion, while still achieving the desired mould temperatures for curing
Solution Approach 2:
The patent uses gas (such as air or inert gases) to create an inert thermal environment around the mould. This gas atmosphere provides the necessary heat for curing without the corrosive chemical reactions that occur with pressurized water, thereby protecting the mould from degradation
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 allows for safe, uniform heating and cooling of large wind turbine blade moulds, reducing energy consumption and extending the lifespan of equipment by reusing heat energy.
Implementation Method 1
a plurality of heat exchangers located externally to the mould, each heat exchanger being arranged to transfer heat between the gas flowing from at least one of the exhaust ports to at least one of the supply ports and a supply of liquid
Implementation Method 2
supply gas to the mould at a plurality of supply ports and to cause the gas to flow through the mould so as to control the temperature of the article in the mould
Data Source
AI summary
A mold for forming a wind turbine blade is formed in two halves, each half 1a comprising a sandwich structure of a perforated outer layer, an inner aluminum honeycomb structure and an inner impermeable heat-conducting layer. An article in the form of a mat of glass fiber impregnated with epoxy resin is placed in the mold. A supply chamber 6 supplies heated pressurized air to the mold which passes into the honeycomb core of the mold through the perforated outer layer, and back through the outer layer into two exhaust chambers 7. A row of supply conduits 13 and exhaust conduits 16 connect the exhaust chambers 7 to the supply chamber 6. The air in each conduit 13, 16 is heated by a respective heat exchanger 18 supplied with heated water 9. The heated air cures the epoxy resin, and the mold is then cooled by supplying cold water to the heat exchangers 18, which, in turn cools the air supplied to the mold. The water used to cool the mold is then re-used for the subsequent heating of another article placed in the mold, in order to save energy. Alternatively, the article in the mold may be cooled using a separate supply of air which is not cooled in the heat exchangers 18.