Pre-bent Wind Turbine Blade Resin Distribution Segmentation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
During the manufacturing of pre-bent wind turbine blades using fibre-reinforced resin, the fibre/resin ratio becomes uneven due to gravity, leading to a higher ratio at the highest mould areas and a lower ratio at the lowest areas, which negatively affects the fatigue strength of the composite material, especially in the upwind shell half that faces high loads during operation.
Innovation Solution
The method involves dividing the resin feed channel and distribution layer into segments with transverse flow barriers to control resin flow, ensuring a desired fibre/resin ratio by adjusting the resin supply through strategically placed feed channels and flow barriers, and using additional feed channels for faster and more reliable resin impregnation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the mould is arranged with the centre line horizontal for manufacturing blade shell halves, then the manufacturing process is simplified, but the fibre/resin ratio becomes uneven due to gravity, with higher ratio at highest mould areas and lower ratio at lowest areas
Solution Approach 1:
The distribution layer is divided into multiple segments separated by transverse flow barriers. This segmentation allows independent control of resin flow in different longitudinal zones, enabling the resin to be distributed uniformly throughout the mould cavity despite the gravitational effects during vertical resin injection.
Solution Approach 2:
Transverse flow barriers are introduced as intermediary elements within the distribution layer. These barriers act as mediators that redirect resin flow laterally, preventing resin from concentrating at the highest mould areas and ensuring more uniform fibre/resin ratio distribution throughout the composite structure.
2Strength
If multiple fibre layers are placed on top of each other in the lowest area of the mould to form load-bearing structure, then the structural strength is improved, but the fibre/resin ratio becomes too high due to gravity acting on the resin
Solution Approach 1:
The distribution layer is segmented into multiple sections with transverse flow barriers. This allows the resin flow to be controlled independently in different zones, ensuring that even in areas with multiple fibre layers, the resin is distributed uniformly to achieve the desired fibre/resin ratio while maintaining structural strength.
Solution Approach 2:
The flow barriers create different flow conditions in different longitudinal zones of the mould. In areas with higher fibre layer density, the resin flow is adjusted locally to ensure proper impregnation, while in areas with fewer fibre layers, the resin flow is optimized accordingly, achieving uniform fibre/resin ratio throughout.
3Ease of manufacture
If resin is supplied continuously to the mould cavity, then the manufacturing process is simple, but resin surplus accumulates at the highest positioned areas due to gravity
Solution Approach 1:
The distribution layer is divided into segments by transverse flow barriers. This segmentation allows the continuous resin supply to be distributed uniformly across multiple zones, preventing resin accumulation at the highest areas while maintaining a simple continuous injection process.
Solution Approach 2:
The flow barriers redirect resin flow from a purely vertical gravity-driven pattern to a multi-dimensional flow pattern that includes lateral movement. This changes the resin distribution from concentration at highest points to more uniform distribution throughout the mould cavity.
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 achieves a uniform fibre/resin ratio across the blade shell halves, enhancing the fatigue strength and performance of pre-bent wind turbine blades by minimizing resin surplus and optimizing resin distribution, particularly in the load-bearing structures.
Implementation Method 1
due to the gravity acting on the resin, a too high fibre/resin ratio tends to be formed at the highest positioned areas of the mould
Implementation Method 2
by means of vacuum-assisted resin transfer moulding (VARTM)
Data Source
Figure 1
Figure 2~3
Figure 4~6
AI summary
In a method of manufacturing a blade shell half of a pre-bent wind turbine blade by means of vacuum-assisted resin transfer moulding (VARTM), a fibre lay-up (16) is placed on a mould surface (14) and a distribution layer (24) is placed above the fibre lay-up (16). At least one segmentation area is provided in the distribution layer by providing at least one transversely extending flow barrier in the distribution layer (24) preventing or restricting longitudinal resin flow to the distribution layer. A longitudinally extending first feed channel (27) is placed above the distribution layer (24). The first feed channel (27) is divided into at least two feed channel sections, a feed channel section being arranged in each distribution layer segment. A vacuum bag (43) is arranged on top of the mould part (13) to define a mould cavity. The mould cavity (44) is evacuated and liquid resin is supplied to each feed channel section through a resin inlet to fill the mould cavity and impregnate the fibre lay-up.