I-Shaped Shear Web Mould for Wind Turbine Blades
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Solution Overview
Problem
Existing methods for manufacturing wind turbine blade shear webs, such as those with I- or C-shaped cross-sections, face challenges including complex fibre layup processes, the need for removable inserts, and increased risk of structural faults due to resin-infused fibre flanges, which complicate the manufacturing process and may lead to wrinkles and structural issues.
Innovation Solution
A method and mould system for manufacturing I-shaped shear webs using an elongated lower web mould part with diverging side parts and an upper web mould part with converging side parts, allowing fibre layers to be draped and cured without folding, eliminating the need for removable inserts and external side mould flanges, and enabling a more straightforward and efficient resin infusion process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If removable inserts are used to enable I-web removal from the mould system, then the I-web can be removed from the system, but the layup becomes complicated and wrinkles are formed in the fibre layup
Solution Approach 1:
The patent removes the removable insert from the mould system entirely. Instead of using an insert that requires removal, the invention uses the mould walls themselves to define and form the flanges directly, eliminating the need for separate insert components and simplifying the overall process.
Solution Approach 2:
The patent merges the function of the removable insert with the mould walls. The mould walls are designed to directly receive and form the flanges, combining what were previously separate components (insert and mould walls) into a unified system that eliminates the need for insert removal and simplifies the layup process.
2Shape
If fibre layers are folded around inserts to form flanges, then the flanges can be formed, but wrinkles are created in the fibre layup
Solution Approach 1:
Instead of folding fibre layers around inserts to form flanges, the patent inverts the approach by having the mould walls directly form the flanges from the fibre layers. The fibre layers are laid up flat against the mould walls, and the mould walls themselves create the flange shape, eliminating the folding action that causes wrinkles.
3Strength
If resin is infused into fibre-infused flanges, then the flanges gain structural integrity, but the risk of structural faults and cracks increases
Solution Approach 1:
The patent converts the potential harm of resin infusion into fibre-infused flanges (which causes structural faults) into a benefit by using the mould walls to directly form the flanges without requiring separate resin infusion steps. The flanges are formed as integral parts of the moulding process, eliminating the risks associated with post-infusion structural faults.
4Device complexity
If a simple U-shaped mould is used for C-web manufacturing, then the mould structure is simple, but the I-web requires more complex moulding with flexible support members and adjustable channels
Solution Approach 1:
The patent segments the mould into distinct functional zones: a central support area and side wall areas. This segmentation allows the simple U-shaped mould structure to effectively form I-webs by dividing the moulding function into separate regions that can independently form different parts of the web structure.
Solution Approach 2:
The patent makes the simple U-shaped mould multi-functional by designing it to accommodate both C-web and I-web manufacturing. The mould structure can form different web shapes (C-shaped or I-shaped) depending on the fibre layer arrangement, eliminating the need for separate complex moulds for different web types.
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 approach simplifies the manufacturing process, reduces the risk of structural failures, and enhances the ease of producing wind turbine blade components by eliminating the need for complex fibre layup and removable inserts, resulting in a more reliable and efficient method for producing shear webs.
Implementation Method 1
supplying a resin to the mould cavity, and curing or hardening the resin in order to form said wind turbine blade component
Data Source
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AI summary
A method and mould system for manufacturing I-shaped shear webs for wind turbine blades are described. The mould system comprises a lower web mould part having a concave shape with diverging side parts for manufacturing first sides of I-web foot flanges, and an upper mould part having a concave shape with converging side parts for manufacturing other sides of the I-web foot flanges.