Fiber Mat Rolling Mechanism for Uniform Wind Turbine Blade Spacers
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Solution Overview
Problem
Existing methods for manufacturing fiber mats as spacers in wind turbine rotor blades are manual and inconsistent, leading to potential safety issues and suboptimal fiber distribution, which can result in areas with low fiber concentration.
Innovation Solution
A device and method for rolling a fiber mat into a coil using a shaft that slides and rotates in reverse to a film, allowing for automated and consistent production of spacers for wind turbine rotor blades.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual manufacturing of fiber mat spacers is used, then flexibility and adaptability are maintained, but manufacturing precision and consistency deteriorate
Solution Approach 1:
The device enables the fiber mat to be rolled automatically through a self-contained mechanism where the shaft rotates to wind the film and fiber mat into a coil, eliminating the need for complex external equipment while achieving consistent manufacturing precision
Solution Approach 2:
The manual mechanical rolling process is replaced with an automated shaft rotation mechanism that systematically winds the fiber mat, transforming inconsistent manual operations into a controlled mechanical process that ensures uniform fiber distribution and consistent coil formation
2Productivity
If manual fiber mat rolling is performed, then adaptability to different shapes is maintained, but productivity and safety deteriorate
Solution Approach 1:
The device performs the rolling operation automatically through its shaft and film mechanism, significantly improving productivity while requiring minimal operator intervention beyond placing the fiber mat and initiating the rolling action
Solution Approach 2:
The device controls critical rolling parameters such as coil diameter, fiber mat thickness, and winding tension through the shaft dimensions and film properties, enabling consistent production of spacers with varying specifications without complicating the operational process
3Manufacturing precision
If manual fiber mat handling is used, then flexibility in shaping is maintained, but manufacturing precision and fiber distribution consistency deteriorate
Solution Approach 1:
The manual handling and shaping process is replaced with a controlled mechanical rolling system where the shaft rotation automatically ensures uniform fiber distribution and consistent coil formation, eliminating the variability introduced by manual operations while keeping the overall manufacturing process simple
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 device ensures consistent quality and safety in the manufacturing process by replacing manual work, reducing safety risks and improving fiber distribution in rotor blade connections.
Implementation Method 1
the shaft is rotatable in the opposite direction to the sliding direction, wherein with respect to the working surface the shaft rotates as if the shaft were rolling backwards against the sliding direction
Data Source
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AI summary
The invention relates to a device (150) for rolling a fiber mat (148) for a wind turbine rotor blade (110), the device (150) comprising - a working surface (156), - a shaft (176) being slidably and rotatably supported, wherein - the shaft (176) is slidable in a sliding direction (170) between a start position (172) and an end position (174) along the working surface (156), and - the shaft (176) is rotatable in the opposite direction to the sliding direction (170), and - a film (184) covering the working surface (156) and being fixedly connected to the shaft (176) with a first end (186), such that upon rotation of the shaft (176) the film (184) is wound up on the shaft (176). The invention also relates to a corresponding method for rolling a fiber mat (148) to a coil (216).