Wind Turbine Blade Internal Web Pre-Curing
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Solution Overview
Problem
Conventional methods for assembling wind turbine blades with internal webs face issues due to thermal distortions during the curing process, leading to potential delamination or adhesive voids that compromise the structural integrity of the blades.
Innovation Solution
A method and apparatus that involves pre-curing the adhesive bonds between the internal web and the outer shell portions using localized heat energy before full curing, ensuring the adhesive bond can withstand thermal deformations and stresses, thereby maintaining bond integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive bonds are cured using heated mould and heated air during the bond line curing step, then the adhesive material is cured and elements are bonded together, but thermal distortions occur in the outer shell portions causing delamination or adhesive voids
Solution Approach 1:
The patent applies preliminary action by pre-positioning and pre-curing the internal web to the first outer shell portion before the final assembly with the second outer shell portion. This preliminary bonding creates a stable structural core that resists thermal distortions during subsequent curing operations, preventing delamination and adhesive voids that would occur if all elements were bonded simultaneously during high-heat curing.
Solution Approach 2:
The curing process is segmented into multiple stages: first, the internal web is bonded to the first outer shell portion and cured; then the second outer shell portion is added and bonded. This segmentation allows each bonding operation to be optimized independently, with the first bond established under controlled conditions before thermal curing begins, thereby preventing thermal distortions from compromising bond integrity.
2Strength
If internal webs are added to strengthen the wind turbine blade, then the blade rigidity and strength are improved, but the assembly complexity and manufacturing difficulty increase
Solution Approach 1:
The internal web is pre-positioned and pre-cured to the first outer shell portion before final assembly. This preliminary action simplifies the overall manufacturing process by creating a stable intermediate structure that is easier to handle and align during subsequent steps, reducing assembly complexity while maintaining the strength benefits of the internal web reinforcement.
Solution Approach 2:
The patent applies local quality by providing structural reinforcement (internal web) only where needed within the blade structure, rather than uniformly throughout. This allows the blade to achieve necessary rigidity and strength in critical areas while keeping the overall design and assembly process manageable and cost-effective.
3Reliability
If the second outer shell portion is closed over the internal web and first outer shell portion during curing, then the blade structure is finalized, but thermal distortions compromise the adhesive bond between the internal web and second outer shell portion
Solution Approach 1:
The internal web is pre-positioned and pre-cured to the first outer shell portion with high precision before the second outer shell portion is added. This preliminary bonding establishes accurate positioning and creates a stable reference structure that maintains bond positioning accuracy even when thermal distortions occur during final curing with the second shell portion.
Solution Approach 2:
The pre-cured internal web acts as a cushioning element that absorbs and compensates for thermal distortions occurring during final curing. By establishing the first bond beforehand under controlled conditions, the structure is cushioned against subsequent thermal stresses, maintaining bond integrity and positioning accuracy despite thermal expansion and contraction during final assembly.
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
The pre-curing process enhances the reliability of the adhesive bond between the internal web and the outer shell portions, reducing the risk of delamination and adhesive voids, resulting in a more structurally reliable wind turbine blade.
Implementation Method 1
A localized heating device is provided for pre-curing an adhesive material at a top end of the internal web with application of thermal energy
Implementation Method 2
pre-curing an adhesive material at a top end of the internal web with application of thermal energy to bond the top end of the internal web to one of the first and second outer shell portions
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
A method and apparatus for assembling a wind turbine blade (10) including first and second outer shell portions (16, 18) and an internal web (12) are provided. An adhesive material (42) is applied to a top end (30) of the internal web (12) as well as the edges (62, 64) of the first outer shell portion (16) for connection to the second outer shell portion (18). Localized heat energy is applied to pre-cure the adhesive material (42) at the top end (30) of the internal web (12) before applying heat energy to fully cure all of the adhesive material (42) in the wind turbine blade (10). The pre-curing is performed by a removable localized heater device (72), and it assures that the integrity of the bond between the internal web (12) and the second outer shell portion (18) is maintained during the full curing of the blade (10), when temporary thermal deformation of the outer shell (14) sometimes occurs.