Modular Mould System for Composite Shell Parts
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Solution Overview
Problem
The manufacturing of large oblong composite structures, such as wind turbine blades, is space-consuming and requires separate molds for minor changes, leading to inefficiencies in mold usage and increased production costs due to the need for complete molds for each variation.
Innovation Solution
A modular mould system comprising flexible mould sections that can be assembled to fit various contours, allowing for separate manufacturing of mould sections and compensation for manufacturing tolerances, reducing the need for multiple molds and enabling reuse of identical parts for different blade varieties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a complete separate mould is used for each structure variation, then manufacturing precision is maintained, but device complexity and production costs increase
Solution Approach 1:
The mould system is divided into multiple independent mould sections that can be assembled together. Each section can be manufactured separately with standard tolerances, and the segmented design allows different combinations of sections to produce various structure variations without requiring complete separate moulds for each variation.
Solution Approach 2:
The mould sections are designed to be universal and interchangeable, where a single set of mould sections can be assembled in different configurations to produce multiple structure variations. This multi-functional capability eliminates the need for dedicated complete moulds for each variation, reducing overall system complexity.
2Adaptability or versatility
If multiple complete moulds are manufactured for different variations, then adaptability is improved, but space requirements and manufacturing costs increase
Solution Approach 1:
By segmenting the mould system into reusable sections, the same physical space can accommodate a versatile set of mould sections that can be reconfigured for different variations, rather than requiring separate complete moulds for each variation stored in different locations.
Solution Approach 2:
The universal mould sections can be assembled in different configurations to produce multiple structure variations, providing high adaptability while occupying minimal storage space compared to multiple complete moulds.
3Manufacturing precision
If rigid mould sections are used, then manufacturing precision is maintained, but ease of manufacture and assembly are worsened due to tight tolerances
Solution Approach 1:
The segmentation allows each mould section to be manufactured with more relaxed tolerances since the overall precision is achieved through the modular assembly interface rather than requiring each individual section to meet tight tolerance requirements.
Solution Approach 2:
The end segments incorporate flexible elements that can deform to compensate for manufacturing tolerances and ensure smooth transitions between sections, maintaining surface precision while simplifying the assembly process and reducing tolerance 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 modular system minimizes space requirements, reduces production costs, and allows for efficient manufacturing of wind turbine blades with varying dimensions and contours, improving surface smoothness and adaptability to different hub connections.
Implementation Method 1
the end segment of the first moulding surface being at least partially flexible
Implementation Method 2
By generating a vacuum, typically 80% to 95% of the total vacuum, in the mould cavity between the inner side of the mould part and the vacuum bag, the liquid polymer can be drawn in and fill the mould cavity with the fibre material contained herein
Data Source
AI summary
A modular mold system for manufacturing a shell part of an oblong composite structure having a longitudinal direction from a fiber reinforced matrix material. The modular mould system includes a number of mold sections, which are adapted to being assembled to an assembled mold part. The number of mold sections includes a first mold section having a first molding surface with a contour that defines a surface of a first longitudinal part of the shell part and a first end section; and a second mold section having a second molding surface with a contour that defines a surface of a second longitudinal part of the shell part and a second end section; which, when the modular mold system is assembled to the assembled mold, the second end section of the second mold section abuts the first end section of the first mold section.