Composite Flange Trimming Guides for Precise Blade Post-Processing
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Solution Overview
Problem
The existing methods for post-mould processing of wind turbine blades lack efficient tools for separating the flange section, transferring datum points, and performing surface treatment, leading to inconsistent trims, damage to the aerodynamic shape, and increased manual skill requirements, which affect the quality and efficiency of the manufacturing process.
Innovation Solution
A method and device involving an assistance tool with a cutting element and datum point indicator, allowing for precise separation of the flange section and transfer of datum points, and a guiding device for surface inspection and processing, which can be used to streamline the post-mould processing of composite structures like wind turbine blades.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual flash trimming is used to separate the flange section, then the process is simple and flexible, but the trimming consistency is poor and the aerodynamic shape may be damaged
Solution Approach 1:
A template device is introduced as an intermediary tool between the manual cutting tool and the flange section. The template provides a predefined cutting path that ensures consistent trimming while protecting the aerodynamic shape. The template acts as a guide that mediates between the flexibility of manual operation and the precision required for consistent results.
Solution Approach 2:
The template device creates a copy or replica of the desired final shape by providing a physical guide that defines the cutting path. By following the template's geometry, the cutting process reproduces the intended shape consistently across multiple operations, ensuring trimming consistency without requiring high skill levels.
2Adaptability or versatility
If manual surface treatment is performed on the composite structure, then the process can be adapted to complex geometries, but the treatment consistency is poor and requires high skill levels
Solution Approach 1:
A guiding device is introduced as an intermediary that provides a predefined path for the surface treatment tool. This guide ensures consistent movement along the surface, maintaining uniform treatment quality while accommodating complex geometries. The guiding device mediates between the need for manual adaptability and the requirement for consistent results.
Solution Approach 2:
The guiding device provides more constraint than strictly necessary for simple geometries, ensuring consistent surface treatment by over-constraining the tool path. This excessive guidance ensures that even operators with varying skill levels can achieve consistent results on complex surfaces by following the predetermined path.
3Productivity
If no template or engineering control is used for flash trimming, then the process is fast and requires minimal equipment, but the trimming consistency is poor and rework is required
Solution Approach 1:
The template device is prepared in advance with the predefined cutting path, allowing the actual trimming operation to proceed quickly without requiring complex measurements or adjustments during the process. The preliminary preparation of the template ensures that the subsequent cutting operation is both fast and consistent, eliminating the need for rework.
4Reliability
If clamping tongs are used to secure the blade shell part during mould turning, then the blade part can be prevented from falling out, but the flange section requires subsequent removal
Solution Approach 1:
The flange section is extracted or separated from the main blade structure after serving its protective function during handling. The cutting path defined by the template allows for clean removal of the flange section, converting a potentially problematic feature into a easily removable component that fulfilled its security function during the critical handling phase.
Data Source
AI summary
The present invention relates to methods and devices for post mould processing of a composite structure, wherein the composite structure extends along a longitudinal direction and comprising a main composite part, and a flange section extending around a perimeter of the main composite part. The flange section comprises an upper surface having a first mating part with a specific shape in a cross-sectional plane perpendicular to the longitudinal direction, the first mating part being located at a fixed position relative to the main composite part. The method may comprise attaching a guiding device to the outer surface of the composite structure and inspecting and/or processing the surface area with a tool fitted to the guiding device.