Layered Wind Turbine Covers for Large Curved Composite Parts
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Solution Overview
Problem
Existing manufacturing processes for producing larger components and/or additional components that are attachable to the wind turbine in order to enhance their performance become cumbersome and/or more difficult. In addition to the size of the components, also the loads acting on the components during operation of the wind turbine increase so that the manufacturing process has to be adapted taking into account the increasing loads.
Innovation Solution
A wind turbine component comprising a main body formed by a layer stack with at least two layers of different materials, allowing for adapting the properties of the component to expected external loads during operation, and fabricated using a vacuum forming process that facilitates the fabrication of larger components with a continuous and at least partly curved surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If extrusion or vacuum injection is used to manufacture larger components, then the components can be produced, but the manufacturing process becomes costly and requires larger component thickness
Solution Approach 1:
The patent uses a layer stack comprising multiple layers of different materials (e.g., thermoplastic layers, reinforcement layers with fibers) to create composite structures that achieve the required strength and stiffness with reduced thickness. This allows larger components to be manufactured without requiring excessive thickness while maintaining structural integrity under increased loads.
Solution Approach 2:
The component is divided into multiple thin layers stacked together, where each layer can be manufactured separately and then bonded. This segmentation allows for easier manufacturing of large components compared to creating a single thick component through extrusion or vacuum injection, reducing manufacturing complexity and cost.
2Strength
If component thickness is increased to match higher loads, then structural strength is improved, but aerodynamic performance deteriorates due to steps in height
Solution Approach 1:
The layer stack creates a composite structure that achieves high strength-to-weight ratio, allowing the component to maintain aerodynamic shapes with thinner walls. The combination of thermoplastic layers and reinforcement layers provides structural strength without the need for thick sections that would disrupt airflow.
Solution Approach 2:
The reinforcement layers can be strategically positioned within the layer stack to provide localized strength where loads are highest, while other areas maintain thinner profiles for aerodynamic efficiency. This allows optimization of both strength and aerodynamic performance in different regions of the component.
3Strength
If component thickness is increased, then structural strength is improved, but component mass increases which negatively affects attachment process and wind turbine performance
Solution Approach 1:
The patent employs composite materials in the layer stack, combining thermoplastic polymers with reinforcement fibers (glass, carbon, or organic fibers). This creates a lightweight yet strong structure that provides the necessary structural strength while minimizing component mass, thereby improving the attachment process and overall wind turbine performance.
Solution Approach 2:
By dividing the component into multiple thin layers rather than using a single thick section, the overall mass is reduced while maintaining structural integrity. The layered composite structure distributes loads efficiently across layers, achieving strength requirements with less material.
4Productivity
If larger components are manufactured using conventional processes, then the components can be produced, but the manufacturing process becomes cumbersome and difficult
Solution Approach 1:
The manufacturing process divides the large component into multiple manageable layers that can be prepared, handled, and processed separately. Each layer can be cut to size, reinforced, and stacked before final forming, making the manufacturing of large components (with surfaces larger than 0.2 m²) much easier and less cumbersome than conventional single-step processes.
Solution Approach 2:
The patent uses thermoplastic materials that can be heated to become formable and then cooled to set the shape. This parameter change (temperature) allows large components to be formed after assembly of the layer stack, simplifying the manufacturing process for large-scale wind turbine components.
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 layer stack design enables the production of stronger, cost-effective components with improved aerodynamic performance and attachment capabilities, while integrating sensing and active layers for load monitoring and adjustment.
Implementation Method 1
a main body comprising a continuous and at least partly curved surface formed from a layer stack comprising a plurality of layers may be fabricated advantageously using a stack of multiple layers and a vacuum forming process
Data Source
AI summary
A wind turbine component adapted to be attached to a wind turbine, wherein the component is a cover element adapted to cover at least one part of a wind turbine or an aerodynamic element adapted to be attached to a rotor blade of a wind turbine, wherein the component includes a main body with a continuous and at least partly curved surface, wherein the main body is formed by a layer stack including a plurality of layers, wherein at least two of the layers are of a different material.