Wind Turbine Blade Tool Hinge Layout for Flexible Manufacturing
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Solution Overview
Problem
The conventional manufacturing method for wind turbine blades is logistically demanding, requires significant overhead, and is costly due to the need for multiple workstations equipped with various tools and molds, leading to inefficiencies and quality risks as the industry scales to meet increasing demand.
Innovation Solution
The use of a set of hinge devices in multiple blade manufacturing operations, which allows for the releasable connection of different tools, provides increased flexibility and precision in manufacturing processes, reducing the need for overhead cranes and simplifying logistics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple workstations are equipped with various tools and molds for conventional manufacturing, then manufacturing capacity is increased, but device complexity and overhead costs increase significantly
Solution Approach 1:
A single workstation is designed to perform multiple manufacturing operations by sequentially mounting different tools and molds. The workstation serves universal functions including molding blade shells, attaching shear webs, and curing, eliminating the need for multiple specialized workstations and reducing overall system complexity.
Solution Approach 2:
The system dynamically reconfigures the workstation by mounting and dismounting different tools and molds as needed for each manufacturing step. This dynamic adaptability allows one workstation to replace multiple static workstations, reducing device complexity while maintaining productivity.
2Productivity
If multiple molds are maintained at different workstations for conventional manufacturing, then production throughput is improved, but manufacturing cost increases due to production and maintenance expenses
Solution Approach 1:
A single mold is designed to be reused across multiple manufacturing steps and operations. The mold is mounted at the workstation, used for forming blade shells, then reused for subsequent operations, eliminating the need to manufacture and maintain multiple identical molds while maintaining production throughput.
Solution Approach 2:
Instead of discarding or maintaining multiple molds simultaneously at different workstations, the system recovers and reuses the same mold repeatedly. The mold is dismounted after use, stored, and remounted when needed, reducing manufacturing and maintenance costs while preserving productivity.
3Adaptability or versatility
If all materials are transported to every workstation in conventional manufacturing, then manufacturing flexibility is maintained, but logistical complexity and time consumption increase
Solution Approach 1:
Multiple manufacturing steps that were previously distributed across separate workstations are merged into a single workstation. This consolidation eliminates the need to transport materials between multiple locations, reducing logistical time consumption while maintaining flexibility through sequential tool mounting.
Solution Approach 2:
Materials and components are prepared and staged in advance at the single workstation location. By consolidating all operations at one location, the system performs preliminary positioning and preparation, eliminating repeated transport cycles and reducing overall logistical time while maintaining adaptability.
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 enhances control and precision in manufacturing operations, facilitates automation, and improves safety by minimizing working under suspended loads, while also reducing costs and increasing the efficiency of wind turbine blade production.
Implementation Method 1
a set of hinge devices in the first workstation, the hinge devices having a static member and a movable member, the movable member being configured to rotate with respect to the static member about a pivot axis
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
The present disclosure relates to methods for manufacturing a wind turbine blade. The methods comprise providing a first blade mold (100) in a first workstation (51), and providing a set of hinge devices (300) in the first workstation (51), the hinge devices (300) comprising a static member (302) and a movable member (301). Furthermore, the method comprises coupling a first tool (200) to the movable members (301) of the hinge devices (300) and rotating the movable members (301) with respect to the static members (302) to carry out one or more first operations with the first tool (200). The method also comprises coupling a second tool (400) to the movable members (301) of the hinge devices (300) and rotating the movable members (301) with respect to the static members (302) to carry out one or more second operations with the second tool (400). The present disclosure further comprises a system for use during manufacturing of a wind turbine blade (10).