Modular Winding Core for Variable Rotor Blade Ends
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Solution Overview
Problem
The production of rotor blades for wind turbines with increasing rotor diameters is time-consuming and costly, requiring significant effort and resources, especially in adapting blade designs for different diameters and transporting longer blades to installation sites.
Innovation Solution
A modular winding core with interchangeable sections allows for the production of blade ends suitable for various rotor diameters by varying the longitudinal extent and diameter of the core, enabling the creation of blade ends with different longitudinal extents, thus facilitating the production of rotor blades for wind turbines with different rotor diameters using the same core and reducing production and transportation costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If rotor blade production is adapted to different rotor diameters by creating new molds and tools for each diameter, then manufacturing precision and product suitability are improved, but device complexity and production costs increase significantly
Solution Approach 1:
The winding core is divided into multiple detachable sections that can be selectively assembled. Each section corresponds to a specific diameter range, allowing the core to be configured for different rotor diameters by combining appropriate sections rather than creating entirely new molds for each diameter.
Solution Approach 2:
A single universal winding core design can produce blade ends for multiple rotor diameters through selective assembly of its sections. This multi-functional approach eliminates the need for separate dedicated molds for each rotor diameter, reducing equipment complexity while maintaining adaptability.
2Manufacturing precision
If new molds and production tools are developed for each rotor diameter, then manufacturing precision is improved, but production time and development costs increase
Solution Approach 1:
The winding core sections are pre-manufactured with precise geometries for specific diameter ranges, and standardized connection interfaces are pre-designed. This allows rapid assembly and disassembly without requiring time-consuming new mold creation for each production run or diameter change.
Solution Approach 2:
The winding core configuration is made dynamic and adjustable rather than fixed. Sections can be added or removed based on the required rotor diameter, allowing the production system to adapt quickly to different specifications without lengthy retooling processes.
3Power
If longer rotor blades are produced to increase rotor diameter, then power generation capacity is improved, but transportation difficulty and logistical costs increase
Solution Approach 1:
The blade end production is segmented into modular sections that can be independently manufactured and then assembled. This allows the final blade assembly to be optimized for transportation by producing components that can be efficiently transported and connected on-site, rather than transporting complete long blades.
Data Source
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AI summary
The invention relates to a wound core (100) for producing blade ends for rotor blades of wind turbines, and to a mold for producing trailing edge segments. The invention also relates to a method for producing a blade end, for producing a trailing edge segment and for producing a rotor blade, and also to a rotor blade and a rotor blade series. The wound core (100) comprises a first section (110) having a first end (111) for forming a hub connection geometry for connecting the blade end to a rotor hub, and a second section (120) having a second end (122) for forming an outer blade connection geometry for connecting the blade end to an outer blade, wherein by replacing or completely or partially removing the first section it is possible to vary a longitudinal extent of the wound core and/or a diameter of the first section and/or a shape of the first section such that blade ends produced therewith are suitable for wind turbines having different rotor diameters. The mold for producing trailing edge segments for rotor blades of wind turbines, in particular for blade ends of rotor blades of turbines, is characterized in that by replacing and/or removing and/or adding one or more mold segments, it is possible to vary a longitudinal extent of the mold and/or a shape of the mold and/or a maximum extent of the mold orthogonal to the longitudinal extent such that trailing edge segments produced therewith are suitable for rotor blades of wind turbines having different rotor diameters.