Wind Turbine Blade Shear Web Stabilizer Join-Up
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Solution Overview
Problem
The existing methods for manufacturing wind turbine blades with a single main shear web are hindered by the need for complex and expensive jigs that occupy significant space, have long lead times, and are bespoke for specific blade types, making them inefficient and costly.
Innovation Solution
A method involving a one-stage join-up process where a shear web is supported by stabilisers attached to the web, allowing simultaneous bonding to both half shells without the need for external jigs, using removable and permanently attached stabilisers to maintain vertical orientation and alignment, and bond spacers to ensure precise adhesive distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a jig is used to support the shear web during the join-up process, then the shear web remains stable and aligned, but the equipment becomes very large, complicated and expensive
Solution Approach 1:
The support function is segmented from a single complex jig into multiple simple stabilisers distributed along the shear web. Each stabiliser is a simple L-shaped component with a foot, replacing the need for one large complicated jig structure.
Solution Approach 2:
The stabilisers are extracted from the traditional jig concept and attached directly to the shear web itself. This removes the need for external jig equipment and integrates the support function into the blade components.
2Manufacturing precision
If a jig is used to support the shear web, then consistent results are achieved, but manufacturing costs increase
Solution Approach 1:
The stabilisers are simple, inexpensive components that can be easily manufactured and discarded or reused. They replace expensive, custom-made jigs with simple L-shaped brackets that have feet, significantly reducing tooling costs.
3Reliability
If a jig is used to support the shear web, then alignment is maintained, but installation and configuration time increases
Solution Approach 1:
The stabilisers are attached to the shear web before the join-up process begins. This preliminary attachment ensures the shear web is pre-positioned and supported correctly, eliminating the need for time-consuming jig installation and configuration during the join-up process.
4Area of stationary object
If stabilisers are attached to the shear web, then the need for large jigs is eliminated, but the stabilisers occupy space within the blade structure
Solution Approach 1:
The stabilisers are nested within the blade structure during manufacturing. The L-shaped brackets with feet fit into the blade's internal geometry, and the feet contact the inner surface of the half shell, efficiently using the available space without requiring external jig equipment.
Data Source
AI summary
A method of making a wind turbine blade is described. The wind turbine blade comprises first and second half shells joined together and a shear web bonded between inner surfaces of the respective half shells. The blade is made in a one-stage join up process, which involves supporting the half shells in respective mould halves, and arranging one of the half shells on top of the other half shell with the shear web arranged between the two half shells. Adhesive is provided between the shear web and the inner surfaces of the respective half shells. During the join-up process, the shear web is supported by stabilisers. The use of stabilisers avoids the need for a jig to support the shear web. Stabilisers attached to an inboard end of the shear web may remain accessible after the join-up and can be removed.