Wind Turbine Structural Web Heel Bond Inspection Design
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Solution Overview
Problem
Existing methods for forming adhesive bonds in wind turbine blades are inadequate for ensuring robust integrity, particularly at the heel region, and current non-destructive testing techniques cannot reliably assess bond quality, leading to potential crack propagation and failure risks.
Innovation Solution
The method involves integrating a flange extender with the web member, ensuring adequate adhesive coverage at the heel region through a flange extender and filler material, allowing for visual and ultrasonic inspection to verify bond integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional wind turbine blades are manufactured, then production cost and time are reduced, but manufacturing precision and quality consistency deteriorate due to manual layup processes
Solution Approach 1:
The patent uses digital twins and virtual models to replicate the physical blade manufacturing process. Computer-aided design (CAD) models and finite element analysis (FEA) simulations create virtual copies of the blade structure and manufacturing process, allowing precise control and monitoring without requiring complex manual operations. This digital copying approach enables high manufacturing precision while simplifying the overall process control.
Solution Approach 2:
The patent replaces manual mechanical layup processes with automated fiber placement systems and computer-controlled manufacturing equipment. Instead of manual hand layup or traditional mechanical processes, the system uses automated robotic arms, computer-controlled rollers, and digital monitoring systems to deposit and position fibers and resins, thereby improving precision and consistency.
2Manufacturing precision
If manual layup processes are used, then device complexity is reduced, but manufacturing precision and quality consistency deteriorate
Solution Approach 1:
The patent employs digital twin technology to create virtual replicas of the layup process. Computer-aided design models simulate the exact fiber placement paths, angles, and patterns, allowing automated systems to replicate these digital instructions with high precision. The digital twin continuously monitors and adjusts the automated layup process to maintain optimal fiber placement without requiring complex manual intervention.
Solution Approach 2:
The patent substitutes manual mechanical fiber placement with automated computer-controlled systems. Robotic arms, computer-guided rollers, and digitally programmed deposition equipment replace manual operator skills and physical dexterity, enabling consistent fiber placement precision through programmable control rather than manual operation.
3Manufacturing precision
If traditional manufacturing methods are used, then production time is reduced, but manufacturing precision and quality control worsen
Solution Approach 1:
The patent replaces traditional manual and semi-automated manufacturing methods with fully automated computer-controlled systems. Fiber placement, resin injection, and curing processes are all managed by computer programs that can operate continuously without interruption, maintaining high production speed while ensuring consistent geometric precision through digital control and real-time monitoring.
Solution Approach 2:
The patent implements real-time feedback systems using sensors and monitoring equipment that continuously measure blade geometry, fiber placement accuracy, and manufacturing parameters. This feedback is fed back to the control system, which automatically adjusts process parameters to maintain precision while operating at optimal production speeds, eliminating the trade-off between speed and accuracy.
Data Source
Figure 1
Figure 2a~2b
Figure 3a~3b
AI summary
: A method of forming a structural web for a wind turbine blade comprises providing a web member having a web portion and a flange portion extending away from each other, where 5 a heel of substantially curvilinear form is located between the web portion and the flange portion. A planar flange extender comprising a cured composite material is arranged together with the web member with the flange extender positioned adjacent to the flange portion so that a portion of the flange extender projects past the heel and away from the web portion. The flange extender is integrated with the web member in a resin matrix, or 10 with an adhesive, to form the structural web. A structural web and a wind turbine blade comprising the web is disclosed. [Figure 5a to accompany abstract]