Wind Turbine Blade Mould Pre-Heating Zones
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Solution Overview
Problem
The resin infusion process in wind turbine blade manufacturing is inefficient due to heat loss, leading to incomplete infusion and the formation of voids, which weaken the structure and increase manufacturing time.
Innovation Solution
A method involving a mould with pre-heated zones to maintain elevated temperatures of fibrous material layers before resin infusion, ensuring consistent heat transfer and reduced viscosity throughout the infusion process, particularly by heating the second zone to a higher temperature than the first zone to account for varying thicknesses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If resin is heated to reduce viscosity for faster infusion, then infusion speed is improved, but heat is quickly lost to the surrounding fibrous material and mould components acting as heat sinks
Solution Approach 1:
The mould and fibrous material layers are pre-heated to a temperature close to the resin infusion temperature before resin injection. This preliminary heating action reduces the temperature differential between the resin and surrounding materials, minimizing heat loss during infusion and maintaining resin流动性 throughout the process
Solution Approach 2:
The fibrous material layers and mould components that previously acted as heat sinks (harmful) are intentionally pre-heated to become heat sources that maintain resin temperature (beneficial). By converting these heat-absorbing elements into pre-heated structures, the system transforms the harmful heat loss into a beneficial temperature-maintaining mechanism
2Reliability
If resin infusion time is extended to ensure complete penetration throughout structural layers, then infusion completeness is improved, but total manufacturing time increases
Solution Approach 1:
The mould and fibrous material structures are pre-heated before resin infusion to eliminate cold spots that would otherwise slow resin penetration. This preliminary thermal preparation ensures that resin maintains its流动性 throughout the entire infusion process, enabling complete penetration in a shorter time without creating voids or incomplete regions
Solution Approach 2:
The temperature parameter of the mould and fibrous material is changed from ambient to elevated (close to resin infusion temperature) before resin injection. This parameter change reduces the temperature gradient between resin and surrounding materials, significantly improving resin flow rate and penetration speed while ensuring complete infusion
3Stability of the object's composition
If mould zones with varying thickness are heated to the same temperature, then heating uniformity is improved, but thicker zones do not reach sufficient temperature due to acting as larger heat sinks
Solution Approach 1:
Different zones of the mould are heated to different temperatures based on their thermal characteristics. Thicker zones that act as larger heat sinks are heated to higher temperatures to compensate for their greater heat capacity and ensure they reach the required temperature for effective resin infusion
Solution Approach 2:
The heating temperature parameter is varied across different mould zones according to their thickness and heat sink characteristics. By adjusting the heating parameter locally rather than uniformly, the system ensures that all zones reach appropriate temperatures for the resin infusion process
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 results in faster, more complete resin infusion, reducing voids and manufacturing time while maintaining structural integrity and efficiency.
Implementation Method 1
The mould 25 may be heated by external heating means, or alternatively heating means may be integrated in the mould, for example the mould may include embedded electric heating elements
Implementation Method 2
Heating the resin to an infusion temperature of approximately 30 °C prior to infusion. At this infusion temperature, the viscosity of the resin is lower than it would be at ambient temperature, allowing the resin to flow more quickly
Implementation Method 3
The sealed region is evacuated and a supply of liquid resin is connected to the sealed region
Implementation Method 4
The resin is introduced into the mould half 25 and infused through and between the elements in a resin infusion process
Implementation Method 5
The resin is introduced into the mould half 25 and infused through and between the elements
Implementation Method 6
Heat in the resin is quickly lost to the surroundings as the resin infuses between the elements of the shell, in particular to the layers of fibrous material and the other components in the mould which act as heat sinks
Data Source
Figure 1~2
Figure 3A~3C
Figure 4A~5
AI summary
A method of making a wind turbine blade (10) having a shell (14, 16) of varying thickness. The method comprises providing a blade mould (30), the mould defining first (32) and second zones (34); arranging layers of fibrous material (42) for forming a first part of the shell having a first thickness in the first zone (32) of the mould; arranging layers of fibrous material for forming a second part of the shell having a second thickness greater than the first thickness in the second zone (34) of the mould; and supplying resin (41) to the mould (30). The method further comprises pre-heating the mould in the first zone (32) to a first temperature, and pre-heating the mould in the second zone (34) to a second temperature greater than the first temperature before supplying the resin (41) to the mould (30).