Wind Turbine Blade Shell Alignment Marks for Vortex Generator Positioning
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Solution Overview
Problem
The precise positioning of vortex generators on wind turbine blades is challenging due to the circular cross-sectional shape and potential blade deformation, leading to uncertainties in measurement and aerodynamic performance.
Innovation Solution
Incorporating alignment marks and marking means during the casting process of wind turbine blade shells using a mould, allowing for precise positioning of additional components like vortex generators by projecting alignment marks or using distinct marking materials that remain embedded in the blade, facilitating accurate alignment without additional measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual measurement methods are used to position vortex generators on the blade surface, then the process is simple to perform, but the positioning precision deteriorates due to measurement uncertainties and blade deformation
Solution Approach 1:
Alignment marks are integrated into the blade shell during the casting process itself, before the blade is removed from the mould. This preliminary action ensures that reference points are established when the blade is still in its ideal geometric state within the mould, avoiding subsequent measurement problems on the finished blade surface.
Solution Approach 2:
The alignment marks serve as an intermediary element between the mould geometry and the final component positioning. These marks are transferred to the blade shell during casting and then used as reference points for positioning vortex generators, mediating the transfer of precise geometric information from the mould to the final assembly.
2Ease of operation
If reference points are measured on the outer surface of a painted wind turbine blade, then the measurement process is straightforward, but measurement accuracy deteriorates due to blade bending and circular cross-section shape
Solution Approach 1:
Alignment marks are established during the casting process while the blade is still in the mould, before the blade is removed and subjected to gravitational bending. This timing ensures that reference points are created when the blade maintains its intended geometric configuration.
Solution Approach 2:
The alignment marks effectively copy the precise geometric reference system from the mould directly onto the blade shell. This copying process transfers the mould's accurate geometry to the blade without requiring subsequent measurement and calculation on the finished blade surface.
3Manufacturing precision
If alignment marks are provided during the casting process, then positioning precision of components is improved, but the complexity of the manufacturing process increases
Solution Approach 1:
The alignment mark creation process is merged with the existing casting process. Alignment marks are formed using the same mould cavity and casting materials already in place, combining two functions (blade shell formation and alignment mark creation) into a single integrated manufacturing step.
Solution Approach 2:
The alignment marks serve multiple functions: they provide positioning references for vortex generators, serve as quality control indicators, and can be used for future maintenance and repair activities. This multi-functionality justifies the additional step by providing ongoing value beyond the initial manufacturing phase.
Data Source
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AI summary
Method for fabricating a wind turbine blade shell, wherein the wind turbine blade shell is fabricated in a casting process using a mould (1) and a plurality of shell components (6), comprising the steps: - providing the mould (1) and the plurality of shell components (6), - providing at least one alignment mark (3) at the mould (1) and/or at one or more shell components (6) placed in the mould, - providing at least one marking means at the position of the at least one alignment mark (3), - arranging the or further shell components in the mould and casting the wind turbine blade shell.