Automated Rotor Blade Adhesive Application System
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Manual application of adhesive for large wind turbine rotor blades is inefficient, leading to uneven application, air inclusions, and reduced adhesive effectiveness due to exposure to ambient air, resulting in increased production time and costs.
Innovation Solution
An automated gantry robot device with a feed unit and application unit that applies adhesive evenly along the surface of rotor blade halves, minimizing exposure to air and ensuring consistent adhesive coverage, using a feed system that supplies adhesive directly to the application area and adjusts according to the surface contour.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If adhesive is applied manually using a spatula, then the application process is simple and requires minimal equipment, but the adhesive is exposed to ambient air causing it to dry before bonding, reducing adhesive effectiveness
Solution Approach 1:
The patent implements a closed application system where adhesive is applied within a controlled environment that limits exposure to ambient air. The application device creates a localized environment that protects the adhesive from premature drying, maintaining its bonding properties throughout the application process and ensuring reliable adhesive effectiveness.
Solution Approach 2:
The patent introduces an automated application device as an intermediary between the adhesive container and the bonding surface. This device includes controlled dispensing mechanisms and positioning systems that ensure precise adhesive application while minimizing air exposure, thereby maintaining adhesive effectiveness without requiring manual intervention.
2Device complexity
If adhesive is applied manually with a spatula, then equipment complexity is low, but air inclusions are introduced into the adhesive, impairing bonding quality
Solution Approach 1:
The patent replaces the manual mechanical spatula application method with an automated dispensing system. This system uses controlled mechanical mechanisms to apply adhesive in a precise, bubble-free manner, eliminating the air inclusions that occur with manual spatula application while maintaining reasonable equipment complexity through modular design.
3Device complexity
If adhesive is applied manually, then equipment costs are low, but application is uneven requiring post-processing and causing adhesive waste
Solution Approach 1:
The patent incorporates feedback mechanisms in the automated application system, including sensors that monitor adhesive flow and application quality in real-time. This feedback enables the system to adjust dispensing parameters dynamically, ensuring uniform adhesive application and preventing both under-application and over-application, thereby minimizing adhesive waste.
Solution Approach 2:
The patent implements dynamic control of the adhesive application process, where the dispensing rate and application parameters are automatically adjusted based on the specific geometry and requirements of the bonding surface. This dynamic adaptation ensures optimal adhesive coverage without excess material, reducing waste while maintaining application quality.
4Ease of manufacture
If adhesive is applied manually, then setup is simple, but production time is increased due to manual handling and rework
Solution Approach 1:
The patent implements preliminary positioning and preparation functions in the automated application system, where the bonding surfaces are pre-positioned and the adhesive dispensing parameters are pre-configured before the actual application begins. This preliminary action eliminates the need for manual handling and rework during production, significantly reducing production time while maintaining ease of setup through programmable parameters.
5Device complexity
If manual adhesive application is used, then equipment investment is low, but adhesive exposure to air reduces bonding strength
Solution Approach 1:
The patent creates a protected environment within the automated application device that minimizes adhesive exposure to ambient air. This localized controlled environment maintains adhesive bonding strength by preventing premature drying and chemical degradation, ensuring strong bonds without requiring expensive comprehensive environmental control systems.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The device has an application unit (10), which is guided over a surface that is provided with adhesive and to apply the adhesive on the surfaces (44,45) during a movement and a feed unit, which is provided to feed adhesive in an area, which is limited by the application unit. The application unit has a side with an opening and the opening is formed to give a predetermined contour to the adhesive applied on the surface. An independent claim is also included for a method for manufacturing a rotor blade of a wind turbine.