Magnetic Retention for Wind Turbine Blade Composite Impregnation
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Solution Overview
Problem
The manufacturing of large wind turbine blades using fibre reinforced polymer materials faces challenges such as incomplete impregnation of fibre materials with resin, leading to dry spots and air pockets, which are difficult to remove and can cause structural weaknesses and increased curing times, especially in complex blade designs.
Innovation Solution
The use of magnet means to retain fibre materials against the mould forming surface during the manufacturing process, allowing for non-intrusive securing and preventing damage, thereby ensuring complete impregnation and reducing manufacturing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fibre material is retained against the mould forming surface using traditional mechanical means, then the fibre material can be secured during manufacturing, but the fibre material may be damaged and local weaknesses may be caused
Solution Approach 1:
The patent replaces traditional mechanical retention means (clamps, weights, or mechanical fixtures) with a magnetic field generated by magnet means to retain the fibre material against the mould forming surface. This substitution eliminates mechanical contact that could damage the fibres while maintaining effective retention during resin infusion and curing, thereby improving structural integrity without causing fibre damage.
2Reliability
If vacuum pressure is increased to remove air pockets, then air removal may be improved, but the impregnation time increases and manufacturing efficiency decreases
Solution Approach 1:
The patent applies magnetic retention of fibre material before and during the resin infusion process to ensure complete fibre impregnation from the outset. By securing the fibres firmly against the mould surface, the resin can flow through and impregnate the fibres uniformly without trapping air pockets, eliminating the need for extended vacuum cycles or repeated impregnation attempts, thus maintaining high manufacturing efficiency while ensuring complete impregnation.
3Manufacturing precision
If staff manually repair dry spots by puncturing the vacuum bag, then dry spots can be addressed, but the process is time-consuming and may cause deformations
Solution Approach 1:
The patent employs magnetic retention of fibre material during the initial resin infusion process to prevent dry spots from forming in the first place. By maintaining firm contact between the fibres and the mould forming surface throughout the impregnation process, the resin flows uniformly through all fibre layers, ensuring complete saturation and eliminating the formation of dry spots that would require time-consuming manual repairs.
4Object-generated harmful factors
If larger vacuum outlets are used to improve air removal, then air evacuation may be enhanced, but the resin distribution becomes less uniform
Solution Approach 1:
The patent uses magnetic retention to secure the fibre material against the mould forming surface before resin infusion begins. This preliminary action ensures that the fibres remain in optimal position and maintain uniform contact with the mould surface throughout the process, allowing resin to distribute evenly through the fibre layers regardless of vacuum outlet configuration, thus maintaining manufacturing precision while enabling effective air removal.
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 method ensures complete resin distribution and curing of large composite structures like wind turbine blades without causing local weaknesses, reducing manufacturing time and improving the structural integrity of the blades.
Implementation Method 1
the fibre material is retained against the first forming surface by use of magnet means during step b) and/or step c)
Data Source
AI summary
A method of manufacturing a wind turbine blade shell part comprising fiber material impregnated with cured resin is described. The method comprises the steps of: a) providing a first mold part having a first forming surface with a contour that defines at least a part of an outer surface of turbine blade shell part, b) arranging fiber material in the first mold part, the fiber material comprising fibers of a magnetizable material, c) providing a resin in the first mold part simultaneous with and/or subsequent to step b), and d) curing the resin in order to form the wind turbine blade shell part or wind turbine blade. The fiber material is retained against the first forming surface by use of magnet means during step b) and/or step c).