Wind Turbine Blade Shear Web Support Bars
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for manufacturing wind turbine blades with a single main shear web are hindered by the need for large, complex, and expensive jigs to support the shear web during bonding, which are not adaptable for different blade types or sizes, occupy significant space, and result in high production costs and long lead times due to misalignment issues.
Innovation Solution
A method and apparatus where a shear web is supported by a plurality of bars attached to its surface, which are engaged with mounts to maintain vertical orientation, allowing the shear web to be accurately positioned between half shells before bonding, eliminating the need for large jigs and enabling a one-stage join-up process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a large jig is used to support the shear web during bonding, then the shear web remains stable and correctly positioned, but the equipment complexity and cost increase significantly
Solution Approach 1:
The single large jig is segmented into multiple smaller support elements (bars or struts) that can be independently positioned and adjusted. These segmented supports are distributed along the length of the shear web, providing stability without requiring one complex monolithic structure. This segmentation reduces manufacturing complexity while maintaining positioning accuracy.
Solution Approach 2:
The support system transitions from a two-dimensional planar jig to a three-dimensional framework using vertical bars or struts that extend through the bonding interface. By adding the vertical dimension, the shear web is stabilized in space without requiring a large horizontal footprint, reducing the overall complexity of the support apparatus.
2Manufacturing precision
If a custom jig is designed for a specific blade type, then the shear web support is optimized for that blade, but the equipment cannot be reused for different blade types or sizes
Solution Approach 1:
The support bars or struts are designed to be movable and adjustable rather than fixed in position. Each support element can be repositioned along the blade length and adjusted in height or angle to accommodate different blade geometries. This dynamic adjustability allows the same support system to be used across multiple blade types while maintaining precise shear web alignment.
Solution Approach 2:
The support system is designed as a universal apparatus that can function with multiple blade types and sizes. The bars or struts are made adjustable through mechanisms such as telescopic sections, repositionable clamps, or variable-angle mounting, enabling a single support system to serve multiple functions across different blade configurations without requiring custom tooling for each blade type.
3Manufacturing precision
If a large jig is used to support the shear web, then positioning stability is achieved, but significant factory floor space is occupied
Solution Approach 1:
The support system utilizes the vertical dimension by employing bars or struts that extend upward and downward through the bonding interface. This vertical support approach provides the necessary shear web stability without requiring a large horizontal footprint, thereby reducing the factory floor space occupied by the support apparatus while maintaining positioning accuracy.
Solution Approach 2:
The support structure uses thin, minimally-invasive bars or struts rather than bulky rigid frameworks. These slender support elements provide the necessary mechanical stability with minimal spatial occupation, allowing the shear web to remain correctly positioned without consuming significant factory floor space.
4Manufacturing precision
If a complex jig assembly is used, then the shear web is securely supported, but installation and configuration time increases
Solution Approach 1:
The support system is divided into multiple independent, modular bar or strut elements that can be quickly installed and removed individually. This segmentation eliminates the need to assemble and disassemble a single complex jig structure, significantly reducing installation and configuration time while maintaining the same level of shear web support accuracy through the distributed modular supports.
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 solution reduces production costs, simplifies the manufacturing process, and allows for consistent and accurate bonding of the shear web to the half shells, improving efficiency and reducing the need for bespoke equipment, thus enabling more efficient use of factory space and faster production times.
Implementation Method 1
a first shear web mounting region is defined on an inner surface of the first half shell and a second shear web mounting region is defined on an inner surface of the second half shell... adhesive being provided between the first mounting flange and the inner surface of the first half shell... adhesive being provided between the second mounting flange and the inner surface of the second half shell
Data Source
AI summary
A method of making a wind turbine blade is described. The blade comprises first (12) and second (14) half shells bonded together and a shear web (16) bonded inside the shells. Prior to joining the shells together, the shear web is positioned in one of the shells. A plurality of bars (70) are attached to the shear web and engaged with a plurality of mounts (80) in order to support and stabilise the shear web relative to that shell. The shells are then arranged one above the other whilst the bars remain attached to the shear web. The bars continue to support the shear web whilst the shear web is aligned with the other shell. The bars are then detached from the shear web and the shells are brought together to bond the shells to each other and to bond the shear web between the shells.