Fiber Mat Joule Heating for Wind Turbine Blade Preforms
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Solution Overview
Problem
The manufacturing of longer wind turbine blades is challenged by the need for more expensive infrastructure, longer production times, and increased complexity, which affects the production costs and time to market.
Innovation Solution
A method for manufacturing pre-form parts using a mat-like component as an actively heated layer, with an adhesive that is heated by an electric current, allowing local stiffening and fixation of components, reducing the need for additional heating means and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional heating methods are used to heat adhesive in pre-form part manufacturing, then the adhesive can be heated, but additional heating means and complex equipment are required
Solution Approach 1:
The mat-like component serves dual functions: as a structural element of the pre-form part and as a heating element for the adhesive. This multi-functionality eliminates the need for separate heating equipment, reducing device complexity while maintaining ease of manufacture.
Solution Approach 2:
The mat-like component heats the adhesive using its own inherent properties (electrical resistance heating), without requiring external heating means. The component essentially serves itself by using its own structure to perform the heating function needed for adhesive activation.
2Temperature
If additional mat-like heating means are provided, then the adhesive can be heated effectively, but the device complexity increases
Solution Approach 1:
The heating function is merged with the structural mat-like component. Instead of adding separate heating means, the structural element itself is utilized as the heating element, combining structure and heating functions into a single integrated component.
Solution Approach 2:
The mat-like component performs both structural and heating functions simultaneously, eliminating the need for additional dedicated heating equipment and reducing overall device complexity.
3Length of moving object
If longer wind turbine blades are manufactured, then energy generation increases, but production time and infrastructure cost increase
Solution Approach 1:
The blade manufacturing process is segmented into pre-form part production and final blade assembly. Pre-form parts are manufactured separately using simplified processes, then assembled into the complete blade. This segmentation allows for reduced production time in the pre-form stage while accommodating longer blade lengths.
Solution Approach 2:
Pre-form parts are fabricated in advance before final blade assembly. This preliminary action allows for parallel processing and reduces the overall production time for longer blades, as the pre-form components can be prepared while the final assembly process is organized.
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
This method facilitates the production of pre-form parts with reduced equipment complexity and cost, enabling faster and more efficient assembly of wind turbine blades with improved process flexibility and mechanical properties.
Implementation Method 1
Heating the adhesive by providing an electric current to at least one actively heated layer
Data Source
AI summary
A method for manufacturing of a pre-form part for a wind turbine blade including one or more components and an adhesive, wherein the component or at least one of the components is a mat-like component including fibres, includes the steps: arranging the adhesive at one or more positions on the component or arranging the components in a stack, wherein the adhesive is arranged at one or more positions between the components, and heating the adhesive by providing an electric current to at least one actively heated layer, wherein the mat-like component is used as actively heated layer and/or wherein at least one additional mat-like heating means provided and arranged on top of or below the component or the stack of components is used as actively heated layer.