Wind Turbine Blade Segment Joining via Resin Infusion
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Solution Overview
Problem
The transportation of large wind turbine blades poses logistical challenges due to their size, and existing assembly methods using bolted joints are not as durable as cast blades, while conventional manufacturing techniques face precision and tolerance control issues.
Innovation Solution
A method of forming wind turbine blade segments with fiber reinforcement partially infused with thermoset resin up to a controlled boundary, using techniques such as vacuum-assisted liquid molding, resistive heating, and physical stops to control the resin flow and curing, allowing for in-situ joining of segments at the assembly location.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If large wind turbine blades are manufactured as single pieces, then blade strength and durability are improved, but transportation logistics become difficult due to size constraints
Solution Approach 1:
The blade is divided into multiple segments that can be manufactured separately and transported independently. These segments are then joined in-situ at the installation location using fiber reinforcement and resin infusion, creating a monolithic structure that combines the advantages of segmented transportation with continuous blade strength.
2Length of moving object
If blades are assembled using bolted joints, then transportation logistics are improved by dividing blades into smaller pieces, but joint durability deteriorates compared to cast blades
Solution Approach 1:
The traditional mechanical bolted joint system is replaced with a chemical bonding system using fiber reinforcement and thermoset resin. The fiber provides structural continuity while the cured resin creates a monolithic bond between segments, eliminating weak mechanical connection points and achieving cast-blade-level durability.
Solution Approach 2:
A composite joining system is used combining fiber reinforcement (such as carbon fiber or glass fiber) with thermoset resin. This composite material system provides both structural strength through the fiber and durable bonding through the cured resin, creating joints that are as strong as or stronger than the blade material itself.
3Ease of manufacture
If conventional manufacturing techniques are used for blade segments, then ease of manufacture is improved, but manufacturing precision and tolerance control deteriorate
Solution Approach 1:
The resin infusion process parameters are controlled and optimized to achieve precise boundary formation. By controlling resin flow rate, pressure, temperature, and fiber preform permeability, the resin front can be precisely positioned at the desired boundary location, achieving high manufacturing precision while maintaining the simplicity of segmented manufacturing.
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 method enables the production of durable wind turbine blades with improved precision and tolerance control, reducing transportation logistics issues and enhancing the durability of blade assemblies by forming a monolithic blade from segments with a controlled resin boundary.
Implementation Method 1
using a fiber of the fiber reinforcement as a resistive heating element to heat the thermoset resin proximate the desired boundary location to cause the cure of the flow front of the flow
Implementation Method 2
wherein the fiber comprises a carbon fiber
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
A method of forming a wind turbine component, the method including forming a segment (10, 12) by impregnating a portion (18, 20) of a fiber reinforcement (50) with a thermoset resin (60) up to a boundary (56), curing the thermoset resin, and leaving unimpregnated fiber reinforcement (22) extending from the boundary. The component may then be assembled by impregnating and joining the unimpregnated fiber reinforcement of two such segments.