Deformable Wind Turbine Blade Root Mould for Wrinkle-Free Fibre Layup
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Solution Overview
Problem
The increasing length of wind turbine blades poses challenges in manufacturing blade shell parts without errors, such as fibre material wrinkles, which can compromise the mechanical strength and necessitate scrapping of the blades, especially in the root region where fibre layup distribution is critical.
Innovation Solution
A blade mould with a deformation assembly that adjusts the root end mould part to accommodate a root insert, ensuring proper fibre distribution and reducing the risk of wrinkles, while allowing for higher fibre weight ratios and improved strength properties in the root region.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If larger moulds are used to manufacture longer wind turbine blades, then the blade length increases, but the manufacturing precision deteriorates due to formation of wrinkles in the fibre material
Solution Approach 1:
The mould shell is made dynamically adjustable through deformation assemblies that can change the mould geometry during manufacturing. This allows the mould to adapt to different fibre mat configurations and apply optimized pressure distributions, preventing wrinkle formation even in large-scale moulds for long blades
Solution Approach 2:
The invention changes physical parameters of the mould system by introducing deformable mould shells with adjustable geometry. The deformation assemblies modify the mould cavity shape and pressure distribution parameters dynamically, enabling precise control over fibre mat impregnation processes to eliminate wrinkles while manufacturing longer blades
2Adaptability or versatility
If the root end mould part is made deformable to accommodate root insert, then the adaptability improves, but the device complexity increases
Solution Approach 1:
The mould shell is segmented into multiple independent parts, with the root end mould part being separable and deformable. This segmentation allows the root end section to be independently adjusted to accommodate root inserts, while the rest of the mould shell remains structurally simple and rigid
Solution Approach 2:
The root end mould part is designed with dynamic deformation capabilities through integrated deformation assemblies. This localized dynamism allows the specific region needing adaptability to be flexible while maintaining overall mould structure simplicity, avoiding the need to make the entire mould complex
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 solution reduces the risk of fibre layup errors in the root region, facilitates better fibre distribution, and enhances the strength properties of the blade shell part, particularly for longer blades, by enabling precise positioning and insertion of the root insert, thus improving the manufacturing quality and reducing scrap rates.
Implementation Method 1
a deformation assembly/first deformation device for deforming the root end mould part of the mould shell
Implementation Method 2
the mould cavity is evacuated via the vacuum outlets so as to form an underpressure in the mould cavity
Implementation Method 3
The resin is forced into the mould cavity due to the pressure differential and impregnates the fibre material of the fibre mats
Implementation Method 4
The resin is forced into the mould cavity due to the pressure differential and impregnates the fibre material of the fibre mats
Data Source
AI summary
A blade mould and a method for manufacturing a blade shell part of a wind turbine blade is disclosed. The blade mould comprises a first mould frame; a mould shell supported by the first mould frame and provided with a moulding surface that defines an outer shape of the blade shell part, wherein the mould shell has a longitudinal direction and comprises a root end mould part at a first end thereof; and a first deformation device for deforming the root end mould part of the mould shell. The method comprises arranging reinforcement material on the moulding surface of the root end mould part; deforming the root end mould part to a receiving configuration; inserting the root end insert in the root end mould part; and bringing the root end mould part to a moulding configuration.