Integral Vortex Generators in Wind Turbine Blades
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional wind turbine blade manufacturing processes face challenges with the integration of vortex generators, including high costs, time-consuming manual application, and vulnerability to damage during shipping and extreme weather conditions, due to the difficulty in demolding and positioning of small, plate-shaped vortex generators on long blades.
Innovation Solution
A molding apparatus and method that integrate vortex generators directly into the wind turbine blade during manufacturing, using a mold with recessed cavities and removable insert members to form three-dimensional prism-type vortex generators, composed of different materials for structural robustness and durability, allowing for simultaneous demolding of blades and vortex generators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If vortex generators are applied after blade manufacturing using adhesive materials, then the blade can be produced using conventional molding processes, but the manufacturing time and cost increase due to manual positioning and adherence
Solution Approach 1:
The vortex generators are integrated directly into the blade molding process by forming them as integral features of the blade structure. The molding apparatus includes a mold body with a cavity that defines the vortex generator geometry, allowing the vortex generators to be formed simultaneously with the blade in a single manufacturing step, eliminating separate application processes
Solution Approach 2:
The vortex generator geometry is pre-defined in the mold cavity before blade manufacturing begins. The mold is prepared with the precise vortex generator shape and positioning built-in, so that when the blade is molded, the vortex generators are automatically formed in their correct locations and orientations without requiring subsequent manual intervention
2Ease of manufacture
If vortex generators are applied after blade manufacturing using adhesive materials, then the blade can be produced using conventional molding processes, but the manufacturing cost increases due to manual labor requirements
Solution Approach 1:
The vortex generators are integrated directly into the blade molding process by forming them as integral features of the blade structure. The molding apparatus includes a mold body with a cavity that defines the vortex generator geometry, allowing the vortex generators to be formed simultaneously with the blade in a single manufacturing step, eliminating separate application processes
Solution Approach 2:
The mold cavity automatically forms the vortex generators with the correct geometry and positioning through the molding process itself. The system is self-sufficient in creating the vortex generators without requiring external manual operations for positioning, shaping, or attaching the vortex generators to the blade
3Ease of manufacture
If conventional plate-shaped vortex generators are used, then they can be easily manufactured, but they are vulnerable to damage during shipping and from repeated extreme weather conditions
Solution Approach 1:
The vortex generators are integrated directly into the blade molding process by forming them as integral features of the blade structure. The molding apparatus includes a mold body with a cavity that defines the vortex generator geometry, allowing the vortex generators to be formed simultaneously with the blade in a single manufacturing step, eliminating separate application processes
Solution Approach 2:
The vortex generators are formed as integral features of the composite blade structure, using the same composite materials and manufacturing processes as the blade itself. This integration provides the vortex generators with the same structural strength and environmental resistance as the blade, eliminating the vulnerability of separately attached generators
4Ease of operation
If vortex generators are manually adhered to the blade, then they can be positioned on the blade surface, but the positioning accuracy and consistency are difficult to ensure
Solution Approach 1:
The vortex generator geometry is pre-defined in the mold cavity before blade manufacturing begins. The mold is prepared with the precise vortex generator shape and positioning built-in, so that when the blade is molded, the vortex generators are automatically formed in their correct locations and orientations without requiring subsequent manual intervention
Solution Approach 2:
The vortex generators are integrated directly into the blade molding process by forming them as integral features of the blade structure. The molding apparatus includes a mold body with a cavity that defines the vortex generator geometry, allowing the vortex generators to be formed simultaneously with the blade in a single manufacturing step, eliminating separate application processes
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 reduces manufacturing time and costs, enhances the lift coefficient of wind turbine blades by delaying boundary layer separation, and minimizes damage risks during demolding, resulting in increased blade efficiency and power generation with reduced drag and noise.
Implementation Method 1
vortex generators are positioned within the boundary layer to create vortices downstream of the vortex generators. The flow vortices force increased mixing of air from the boundary layer and air outside the boundary layer, thereby delaying the boundary layer separation
Implementation Method 2
the thickness of a boundary layer tends to increase away from the leading edge of a wind turbine blade. The increased thickness of the boundary layer tends to promote turbulent flow within the boundary layer
Data Source
Figure 1
Figure 2
Figure 3~5B
AI summary
A wind turbine for generating electrical energy may include a wind turbine blade including a plurality of vortex generators integrally formed in the outer surface of the blade. The vortex generator includes a first component that defines a portion of the outer surface of the blade and a second component defining the shape of the vortex generator and at least partially surrounded by the first component. A method of manufacturing the wind turbine blade includes disposing a first plurality of layers of structural material over a mold main body and a removable insert member with a shaped cavity. A shaped plug is then pressed into the shaped cavity, and a second plurality of layers of structural material is disposed over the plug and the mold main body to complete manufacture of a wind turbine blade with a vortex generator.