Composite Blade Layer Segmentation for Profile Accuracy
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Solution Overview
Problem
The existing method for manufacturing composite blades, as described in Patent Literature 1, faces challenges in securing the accuracy of the profile and thickness due to difficulties in preparing and coupling thin composite layers, leading to decreased manufacturing yield and increased costs.
Innovation Solution
The composite blade is formed by laying up composite layers with reinforced fibers impregnated with resin, where relatively thin layers are used in the surface area and relatively thick layers in the deep area, with a larger surface layer area compared to the deep layer area, and the layers are bonded at a neutral surface to improve accuracy and reduce costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a massive amount of thin composite layers are coupled to secure the accuracy of the profile and thickness, then the accuracy of the profile and thickness is improved, but the manufacturing complexity and cost increase significantly
Solution Approach 1:
The blade is divided into two distinct regions: a surface layer area with thinner composite layers for profile accuracy, and a deep layer area with thicker composite layers for structural integrity. This segmentation allows each region to be optimized independently, reducing the overall manufacturing complexity while maintaining high precision where needed.
Solution Approach 2:
Different composite layer thicknesses are applied to different regions of the blade based on local requirements. The surface layer area uses thinner layers (smaller median thickness) to achieve high profile accuracy, while the deep layer area uses thicker layers (larger median thickness) to reduce manufacturing complexity and cost. This local differentiation resolves the contradiction between precision and complexity.
2Manufacturing precision
If thin composite layers are used to secure profile accuracy, then the profile accuracy is improved, but the manufacturing yield decreases and cost increases
Solution Approach 1:
Thin composite layers are applied only in the surface layer area where profile accuracy is critical, rather than throughout the entire blade. This localized application maintains high profile accuracy while reducing the overall number of layers required, thereby improving manufacturing yield and reducing costs.
Solution Approach 2:
The blade structure is segmented into surface layer and deep layer areas with different layer thickness specifications. This segmentation allows the use of thin layers only where necessary for accuracy, while thicker layers are used in the deep area to reduce total layer count, thus improving productivity without sacrificing profile accuracy.
3Manufacturing precision
If the number of composite layers is changed depending on places to respond to thickness changes, then the thickness accuracy is improved, but the manufacturing complexity increases
Solution Approach 1:
The composite layer thickness is locally optimized based on the blade's thickness requirements in different regions. The surface layer area uses a smaller number of thinner layers to achieve accurate thickness control, while the deep layer area uses a larger number of thicker layers to simplify manufacturing. This local differentiation improves thickness accuracy without uniformly increasing manufacturing complexity.
Solution Approach 2:
The blade is segmented into regions with different layer configurations: surface layer area with fewer, thinner layers for precision thickness control, and deep layer area with more, thicker layers for simplified manufacturing. This segmentation resolves the contradiction by allowing thickness accuracy to be achieved only where critical, while reducing complexity in other regions.
Data Source
AI summary
A composite blade is formed by laying up composite layers in which reinforced fibers are impregnated with resin. The composite layers are laid up in a blade thickness direction that is a direction connecting a suction side and a pressure side of the composite blade. The composite blade includes a thick part that has a surface layer area from a surface of the thick part to a predetermined depth in the blade thickness direction and a deep layer area at a depth larger than the predetermined depth from the surface in the blade thickness direction. A median value in a predetermined range of thicknesses of each composite layer in the surface layer area is smaller than a median value in a predetermined range of thicknesses of each composite layer in the deep layer area.