Flexible Mold Element for Wind Turbine Blade Preform Manufacturing
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Solution Overview
Problem
The existing mold arrangement for producing preform elements of wind turbine blades is cumbersome, expensive, and has low productivity due to the complexity of the mold setup, the need for extensive heating and cooling systems, and the time-consuming process of heating and cooling the preform within the mold.
Innovation Solution
A mold arrangement featuring a flexible, plate-like mold element that adapts to the three-dimensional geometry of the receiving surface, allowing the preform building material to be arranged and fixed on the mold element, which is then removed and processed separately for heating and cooling, thereby simplifying the mold design and increasing productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If heating and cooling systems are integrated into the mold, then the preform can be processed completely within the mold, but the mold becomes very complicated and expensive
Solution Approach 1:
The manufacturing process is segmented into separate stages: the mold is used only for forming the preform building material into the desired shape, while heating and cooling operations are performed separately after the preform is removed from the mold. This segmentation eliminates the need for complex heating and cooling systems within the mold itself, significantly reducing mold complexity and cost.
2Ease of manufacture
If heating and cooling treatments are performed with the preform in the mold, then the preform can be processed completely within the mold, but the mold is occupied during these long-lasting procedures, reducing productivity
Solution Approach 1:
The mold performs the preliminary action of forming the preform building material into the desired shape and then releases it. Subsequent heating and cooling treatments are performed as separate preliminary actions before the final product is completed. This allows the mold to be reused immediately for the next preform, eliminating idle time and significantly increasing productivity.
3Manufacturing precision
If the mold geometry is designed for a specific preform geometry, then the preform can be produced with precise geometry, but extensive reworking of the mold is necessary when preform geometry changes
Solution Approach 1:
The mold incorporates adjustable and reconfigurable elements that allow its geometry to be dynamically changed to match different preform requirements. Instead of being fixed for a single geometry, the mold can be adapted to various preform shapes and sizes, maintaining manufacturing precision while significantly improving versatility and reducing reworking requirements.
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 proposed mold arrangement significantly simplifies the mold design by eliminating the need for heating and cooling systems within the mold, increases productivity by allowing continuous use of the mold, and reduces the time required for each manufacturing cycle.
Implementation Method 1
a flexible, plate-like mold element that adapts to the three-dimensional geometry of the receiving surface
Implementation Method 2
Afterwards heat is supplied to the building material in order to activate or melt a binding material
Implementation Method 3
After this heating operation the preform needs to be cooled to room temperature, whereafter it is sufficiently stable to be handled by crane equipment
Data Source
AI summary
A Mold arrangement for producing a preform element of a wind turbine blade is provided, including a mold carrier with a receiving section having a three-dimensional receiving surface for receiving a mold element and at least one transferable and flexible plate-like mold element adapted to receive preform building material and arrangeable on the receiving surface, which flexible mold element adapts to the three-dimensional geometry of the receiving surface when positioned on the receiving surface.