Rotor Blade Connection Parts With Removable Cavities for Fiber Integrity
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Solution Overview
Problem
Existing methods for manufacturing wind turbine rotor blade connection parts with integrated joining elements often compromise the integrity of reinforcing fibers due to drilling holes or require complex integration processes, making anchoring of joining elements unreliable and time-consuming.
Innovation Solution
A method involving the use of placeholders embedded in a fibrous composite material, which are removable to create cavities for joining elements, allowing for simple and reliable integration of bolts or sleeves without damaging the reinforcing fibers, and enabling separate, controlled insertion of joining elements after the composite material has cured.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If joining elements are integrated when forming the fibrous composite material in a manufacturing mould, then the integrity of the reinforcing fibres can be maintained, but the process becomes complex and time-consuming
Solution Approach 1:
The placeholder is positioned and embedded in the fibrous composite material before curing, preparing the structure in advance for subsequent joining element insertion without compromising fiber integrity during the forming process
Solution Approach 2:
The integration process is divided into separate stages: first embedding the placeholder during composite formation, then removing it after curing, and finally inserting the joining element. This segmentation allows each step to be optimized independently
2Ease of manufacture
If holes are drilled in the joining surface after manufacturing the wind turbine rotor blade part, then joining elements can be inserted, but the integrity of the reinforcing fibres is compromised
Solution Approach 1:
The placeholder is positioned and embedded in the fibrous composite material before curing, preparing the structure in advance for subsequent joining element insertion without compromising fiber integrity during the forming process
Solution Approach 2:
The placeholder serves as an intermediary element that occupies the space where the joining element will eventually be inserted. It allows the composite material to cure undisturbed while maintaining the precise positioning needed for later joining element installation
3Reliability
If placeholders are embedded in the fibrous composite material and removed after curing, then joining elements can be reliably anchored, but an additional process step is required
Solution Approach 1:
The placeholder is positioned and embedded in the fibrous composite material before curing, preparing the structure in advance for subsequent joining element insertion without compromising fiber integrity during the forming process
Solution Approach 2:
The placeholder is a temporary, disposable element that serves its purpose during manufacturing and is then removed. It is replaced by the permanent joining element that performs the actual fastening function
Data Source
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AI summary
A method of manufacturing a wind turbine rotor blade connection part having a joining surface, the method comprising the following steps: • providing a mould, • placing a first layer of reinforcing fibres in the mould, • providing a placeholder comprising a front end and a longitudinal direction, • positioning the placeholder in the mould on top of the first layer of reinforcing fibres so that the front end is arranged at the joining surface, • embedding the first layer of a reinforcing fibres and the placeholder in a matrix material, • curing of the matrix material, so that the placeholder is embedded in a fibrous composite material, • removing the wind turbine rotor blade connection part from the mould, • wherein the placeholder is removable from the fibrous composite material, so that at the position of the placeholder a cavity can be formed.