Wind Turbine Blade Preform Segmentation for Lay-up Efficiency
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Solution Overview
Problem
The manufacturing of large wind turbine blades is hindered by the difficulty in handling and arranging heavy glass fiber mats, which increases production time and requires extensive safety equipment, leading to decreased output due to the cumbersome lay-up process and high material thickness requirements.
Innovation Solution
The method involves using preform elements, which are layers of glass fiber fabric locally adhered with a binder, arranged in a mold to facilitate the lay-up process, allowing for easier handling and reduced manufacturing time by providing a modular, adjustable, and adaptable solution for forming wind turbine blades, potentially reducing the need for heavy lifting and specialized equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If glass fiber mats are used to achieve high material thickness in the blade root section, then the structural strength is improved, but the handling and arrangement becomes difficult and time-consuming
Solution Approach 1:
The glass fiber mats are divided into multiple smaller pieces instead of using large continuous mats. This segmentation makes the fiber material easier to handle and arrange in the mold, particularly in the root section where high material thickness is required, while still achieving the necessary structural strength through proper layering of the segmented pieces
Solution Approach 2:
The glass fiber mats are pre-cut into smaller pieces before being placed in the mold. This preliminary action of cutting and preparing the fiber material in advance simplifies the lay-up process and reduces the time and effort required for arrangement during manufacturing
2Strength
If large pieces of fiber glass fabric are used to achieve required material thickness, then the structural integrity is improved, but the manufacturing time increases and output decreases
Solution Approach 1:
The fiber glass fabric is segmented into smaller pieces that can be more quickly and easily arranged in the mold. This segmentation maintains the structural integrity through proper distribution and layering of the smaller pieces, while significantly reducing the time required for the lay-up process and increasing manufacturing output
Solution Approach 2:
The size parameter of the fiber glass pieces is changed from large to small. This parameter change enables faster handling and arrangement during manufacturing while the structural integrity is maintained through the cumulative effect of multiple smaller pieces arranged in the required pattern
3Strength
If large glass fiber mats are used to achieve high material thickness, then the structural strength is improved, but safety equipment like fall lines are required due to large work height
Solution Approach 1:
The glass fiber mats are segmented into smaller pieces that can be handled and arranged at lower work heights. This segmentation eliminates or reduces the need for safety equipment like fall lines, making the manufacturing process safer while maintaining structural strength through proper arrangement of the smaller pieces
4Volume of moving object
If the blade mold size is increased to accommodate larger blade dimensions, then the blade capacity is improved, but the lay-up process becomes more challenging and time-consuming
Solution Approach 1:
The fiber material is segmented into smaller pieces that can be more easily managed and arranged even in large blade molds. This segmentation makes the lay-up process less challenging and time-consuming, while the large blade capacity is achieved through the cumulative arrangement of these smaller pieces in the required patterns
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 reduces the complexity and time required for the lay-up process, improves packing quality, and decreases the risk of wrinkles, enabling more efficient production with smaller, easier-to-handle preform elements that can be manufactured in separate facilities, thus enhancing the overall efficiency and safety of wind turbine blade manufacturing.
Implementation Method 1
The preform elements comprise for instance several layers of glass fiber fabric that are placed on top of each other and locally adhered to each other by application of binder in between the layers of fiber fabric
Implementation Method 2
the preform elements are at least partly infused with a resin for casting of the blade part
Data Source
AI summary
A method for manufacturing at least a part of a wind turbine blade in a resin-based casting process using a mold is provided, wherein at least one preform element, at least one further preform element and at least one laminate supporting element are arranged in the mold, wherein the preform element is arranged on a molding surface of the mold and extends over a section of the circumference of the blade part to be manufactured, wherein the laminate supporting element is arranged on the preform element and the further preform element is arranged on the laminate supporting element, wherein the preform element and the further preform element extend over the entire circumference of the blade part to be manufactured, wherein the preform elements are at least partly infused with a resin for casting of the blade part.