Wind Turbine Rotor Blade Mold Heating Zones
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Solution Overview
Problem
Existing rotor blade molds for wind turbines are complex and inefficient in heating, leading to uneven temperature distribution and potential overheating during the curing process of resin-based rotor blades, which can result in instability and weight issues.
Innovation Solution
A rotor blade mold with multiple electrical resistance heating elements and separate supply units allows for dynamic and localized heating, enabling precise temperature control through independent heating zones and a central control system, reducing the complexity of the heating system and enhancing temperature uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a pipe system with hot water circulation is used for heating the mold, then the heating function is provided, but the system becomes complex and sluggish
Solution Approach 1:
The patent replaces the mechanical water circulation system with an electrical heating system. Electrical resistance heating elements are embedded in the mold, allowing direct heating without complex fluid circulation infrastructure. This substitution eliminates pumps, pipes, and water heating infrastructure, significantly reducing system complexity while maintaining heating capability.
Solution Approach 2:
The patent extracts the heating function from the complex water circulation system and implements it through independent electrical heating elements. Each heating zone can be independently controlled, allowing the heating function to be separated from the mold structure and controlled precisely without requiring a centralized complex system.
2Temperature
If hot water circulation is used for heating, then heating is provided, but the system is sluggish and cannot respond dynamically
Solution Approach 1:
The patent replaces the thermal inertia-prone water circulation system with electrical resistance heating elements that can be switched on and off instantly. Electrical heating responds immediately to control signals, eliminating the thermal inertia and delay associated with heating and circulating water, thus achieving dynamic and rapid temperature control.
3Temperature
If a single heating system is used for the entire mold, then heating is provided, but temperature distribution becomes uneven and overheating occurs
Solution Approach 1:
The patent divides the mold into multiple independently controllable heating zones, each with its own heating elements and control system. This segmentation allows different regions of the mold to be heated at different rates and to different target temperatures, preventing overheating in any single area while ensuring uniform overall temperature distribution during curing.
Solution Approach 2:
The patent implements localized heating control where each heating zone can be independently adjusted according to the specific thermal requirements of different mold regions. This allows non-uniform heating patterns to be intentionally created to compensate for varying thermal conductivity and heat loss rates in different areas of the mold, achieving uniform final temperature distribution.
4Productivity
If resin curing is allowed to proceed, then the rotor blade is produced, but exothermic heat causes unwanted overheating
Solution Approach 1:
The patent implements temperature monitoring and control systems in each heating zone that provide feedback on actual temperature conditions during resin curing. This feedback mechanism allows the control system to detect exothermic heat generation and automatically adjust or shut off heating elements to prevent overheating, while still allowing the curing process to proceed productively.
Solution Approach 2:
The patent applies preliminary cooling measures through the same heating elements that can rapidly switch from heating to cooling mode, or through pre-positioned cooling channels, to counteract exothermic heat generation before it causes harmful overheating. This preliminary anti-action prevents the harmful effect while allowing the beneficial curing process to continue.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution provides a more efficient and controlled heating process, reducing the risk of overheating, allowing for a lighter and more stable rotor blade with improved thermal management, and enabling the production of larger blades with enhanced mechanical properties.
Implementation Method 1
at least two heating elements, each with at least one electrical resistance heating element
Implementation Method 2
The heat spreads from this heated piping system through the body of the rotor blade mold to its surface to the material to be cured
Implementation Method 3
The resin gives off heat to the environment during curing, which can lead to unwanted and uncontrolled heating
Data Source
AI summary
The invention relates to a rotor blade mold (1) for producing a rotor blade of a wind power plant or a part thereof, having a heatable mold section having a shaping surface for shaping the rotor blade surface, and wherein the heatable mold section comprises at least two heating sections (Bi) and each heating section comprises at least one electrical resistance heating element disposed at or below the shaping surface, and a supply unit (vi) for supplying electrical power to the at least one resistance heating element for heating.