Reconfigurable Wind Turbine Blade Mould With Modular Skin Sections
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Solution Overview
Problem
The manufacturing of modern utility-scale wind turbine blades is challenged by the high cost, space requirements, and logistical constraints of large and complex moulds, which are often damaged during reconfiguration for different blade designs, leading to material wastage and increased capital expenditure.
Innovation Solution
A reconfigurable mould assembly comprising a mould skin with interchangeable sections and a modular main frame, allowing for easy exchange and addition of components to accommodate blades of varying dimensions, reducing the need for new moulds and minimizing downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a blade manufacturer changes or adjusts an existing mould to manufacture a different blade, then the mould can be reused for different blade designs, but this typically involves permanently damaging the existing mould through grinding and/or welding operations and results in material wastage
Solution Approach 1:
The mould is divided into multiple interchangeable sections (first section, second section, third section) that can be independently replaced. This segmentation allows the mould to be reconfigured for different blade designs without permanently damaging the entire structure, as only specific sections need to be exchanged rather than modified through damaging operations.
Solution Approach 2:
The mould is designed with universal interfaces and standardized connection mechanisms that allow different blade sections to be mounted on the same base structure. The first mould section can accommodate multiple blade configurations through interchangeable components, enabling one mould assembly to serve multiple blade design purposes without permanent modification.
2Manufacturing precision
If multiple blade moulds are manufactured to accommodate different blade designs, then each blade geometry can be produced with optimal precision, but the capital expenditure and storage space requirements increase significantly
Solution Approach 1:
The mould system is segmented into standardized sections that can be independently configured. This allows precise blade geometries to be achieved by assembling appropriate sections in specific arrangements, rather than manufacturing entirely different moulds for each blade design. The modular approach maintains precision while reducing overall system complexity.
Solution Approach 2:
A universal base mould structure is designed with standardized interfaces that can accommodate multiple blade geometries through interchangeable sections. This multi-functional design enables a single mould system to produce various blade configurations with optimal precision, eliminating the need for multiple specialized moulds and reducing capital expenditure.
3Productivity
If large wind turbine blade moulds are manufactured at the blade manufacturing facility, then the moulds can be immediately used for production, but this requires specialist mould manufacturing tools and equipment to be stored and used at the facility, placing an additional constraint on the location
Solution Approach 1:
The mould is segmented into transportable sections that can be manufactured separately using standard equipment and then assembled at the blade manufacturing facility. This segmentation allows mould production to occur at specialized facilities using conventional equipment, with the modular sections transported and quickly assembled on-site, reducing the need for extensive specialist equipment at the blade manufacturing location.
Solution Approach 2:
Mould sections are pre-manufactured and prepared at specialized facilities before being transported to the blade manufacturing facility for assembly. This preliminary manufacturing action allows the use of dedicated mould-making equipment at specialized locations, while the blade manufacturing facility only requires assembly capabilities, thereby reducing the constraint on facility location and equipment requirements.
Data Source
AI summary
According to an aspect of the invention there is provided a method of making a mould assembly for a wind turbine blade half shell. The method comprises providing an elongate mould plug at a first location. The mould plug has a profile corresponding to part of a profile of a wind turbine blade half shell. The method further comprises forming a mould skin section on the mould plug. The method comprises providing a frame structure on top of the mould skin section on the plug and attaching the frame structure to the mould skin section to form a sub-assembly comprising the mould skin section and the frame structure. The method further comprises removing the sub-assembly from the mould plug and transporting the sub-assembly from the first location to a blade manufacturing facility. The method further comprises arranging the sub-assembly end to end with one or more further sub-assemblies at the blade manufacturing facility to form a mould assembly for a wind turbine blade half shell having a first geometry.