Moving Mold Control for Balanced Wind Blade Production
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Solution Overview
Problem
The conventional manufacturing method for wind turbine blades is logistically demanding, requires significant overhead due to the need for multiple workshops and expensive molds, and can compromise quality due to the involvement of highly skilled human labor and the complexity of managing large molds in a moving mold system.
Innovation Solution
A computer-implemented method for controlling the manufacturing of wind turbine blades using a moving mold system, which involves monitoring and coordinating operations across different workstations through sensors and a central control system to maintain line balancing, quality, and cycle time, thereby optimizing resource use and reducing delays.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manufacturing method with multiple workshops and molds is used, then wind turbine blades can be manufactured with high quality, but it requires significant overhead, occupies lot of space, and is logistically demanding
Solution Approach 1:
The patent combines multiple manufacturing operations (mold preparation, fiber placement, resin infusion, curing) into a single integrated moving mold system. The mold travels through different workstations rather than having separate workshops for each operation, thereby reducing the number of molds and workshops needed while maintaining quality control through centralized monitoring.
Solution Approach 2:
The moving mold system serves multiple functions across different workstations. The same mold is used for fiber placement, resin infusion, and curing operations at different locations, making it a universal tool that performs multiple manufacturing tasks rather than requiring dedicated molds for each operation.
2Device complexity
If moving mold system is implemented, then resource overhead is reduced, but it requires sophisticated control systems to maintain line balancing and quality
Solution Approach 1:
The patent implements a control system that receives data from sensors at different workstations and uses this feedback to monitor and adjust the manufacturing process. The system tracks cycle times, quality metrics, and operational status of the moving mold to maintain line balancing and ensure quality standards are met throughout the manufacturing process.
Solution Approach 2:
The patent replaces manual coordination and mechanical synchronization of the moving mold system with an automated control system. Instead of relying on mechanical timing and manual operations, the system uses sensors, data processing, and automated control to coordinate the mold's movement through different workstations and maintain process precision.
3Adaptability or versatility
If conventional manufacturing method is used, then each workshop can be independently operated, but it occupies lot of space and increases logistical demands
Solution Approach 1:
The patent segments the manufacturing process into discrete workstations (mold preparation, fiber placement, resin infusion, curing) that the moving mold visits sequentially. This segmentation allows each workstation to be compact and specialized rather than requiring large independent workshops, reducing total space while maintaining operational flexibility.
Data Source
Figure 1
Figure 2A~2B
Figure 2C~3
AI summary
The present disclosure relates to a computer-implemented method (100) for controlling a manufacturing method of a wind turbine blade. The method comprises receiving first data (102) related to one or more first operations carried out in a first workstation obtained by one or more first sensors arranged with the first workstation; receiving second data (104) related to one or more second operations carried out in a second workstation obtained by one or more second sensors arranged with the second workstation; analyzing the first and second data (106) to determine a quality and/or a cycle time of one or more of the first and second operations; and determining (108) a deviation in the quality and/or cycle time of the one or more of the first and second operations.