Reconfigurable Rotor Blade Mold System for Rapid Shape Adaptation

Solution Overview

Problem

The construction of molds for rotor blades in wind turbines is a time-consuming and expensive process, requiring separate molds for each individual rotor blade shape, making it difficult to modify or redesign rotor blades efficiently.

Innovation Solution

A reconfigurable mold system with a frame assembly and alternatable mold material that allows for the formation of multiple rotor blades with different shapes by modifying the bed and using a plug to create a cavity, eliminating the need for separate molds for each shape.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a separate mold is constructed for each rotor blade shape, then the desired shape precision is achieved, but the manufacturing time and cost increase significantly

Engineering Contradiction:

Improverotor blade shape precisionVSAvoidmold construction time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The mold is divided into multiple adjustable segments or modules that can be reconfigured independently. Each segment can be adjusted to different positions and angles, allowing the same mold structure to produce various rotor blade shapes without requiring complete reconstruction of the entire mold for each design variation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The mold incorporates dynamic and adjustable components rather than fixed structures. Elements such as adjustable support frames, movable formers, and reconfigurable tooling fixtures enable the mold to adapt its geometry dynamically, allowing rapid transition between different rotor blade configurations without time-consuming reconstruction.

Inventive Principle:

Principle #15Dynamics

2Manufacturing precision

If a separate mold is constructed for each rotor blade shape, then the desired shape precision is achieved, but the manufacturing cost increases significantly

Engineering Contradiction:

Improverotor blade shape precisionVSAvoidmold construction cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The mold is designed as a universal system capable of producing multiple rotor blade shapes and sizes. By incorporating adjustable and reconfigurable components, a single mold structure can serve multiple functions and produce various blade geometries, eliminating the need to invest in separate expensive molds for each design, thereby reducing overall manufacturing costs.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The mold utilizes adjustable parameters such as positioning mechanisms, variable geometry fixtures, and reconfigurable support structures that can be modified to match different rotor blade design specifications. This allows the same physical mold to accommodate varying blade shapes, sizes, and aerodynamic profiles without requiring costly reconstruction, maintaining precision while reducing manufacturing expenses.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If traditional molds are used, then rotor blades can be formed, but any shape modification requires construction of a new tool

Engineering Contradiction:

Improverotor blade production efficiencyVSAvoidmold adaptability to shape changes

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The mold incorporates dynamic and adjustable components rather than fixed structures. Elements such as adjustable support frames, movable formers, and reconfigurable tooling fixtures enable the mold to adapt its geometry dynamically, allowing rapid transition between different rotor blade configurations without time-consuming reconstruction.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The mold utilizes adjustable parameters such as positioning mechanisms, variable geometry fixtures, and reconfigurable support structures that can be modified to match different rotor blade design specifications. This allows the same physical mold to accommodate varying blade shapes, sizes, and aerodynamic profiles without requiring costly reconstruction, maintaining precision while reducing manufacturing expenses.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentEP2712718B1Method for forming a rotor blade

Publication Date: 2017.05.17 GENERAL ELECTRIC CO

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AI summary

Frame assemblies 110, molds 100, and methods for forming rotor blades 16 are provided. A frame assembly 110 for a rotor blade mold 100 includes a plurality of frames 112, at least one of the plurality of frames 112 movable relative to the others of the plurality of frames 112, and a bed 114 supported by the plurality of frames 112. Movement of the at least one of the plurality of frames 112 causes a modification of the bed 114 along a width-wise axis 118. A mold 100 for forming a rotor blade 16 includes a frame assembly 110 and a mold material 150 disposed in the bed 114 of the frame assembly 110.