Rotor Blade Mold Spacer Design for Shape Stability
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Solution Overview
Problem
Large rotor blade mold shells are prone to twisting and bending due to their considerable dimensions, leading to aerodynamic shape deviations and laminate tears under adjustment forces, which compromises their durability and aerodynamic performance.
Innovation Solution
The introduction of spacers between the inner and outer shells, connected via fastening means to adjustment devices, creates a torsionally and flexurally stable sandwich construction, distributing tensile and compressive loads across both shells to prevent laminate tears, while allowing air circulation and heat retention for uniform curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If adjustment devices are used to correct the shape of large molded shells, then the aerodynamic shape precision is improved, but laminate tears occur within the molded shell due to the forces applied
Solution Approach 1:
The patent introduces a reinforcement element (such as a metal plate or composite patch) as an intermediary between the adjustment device and the molded shell laminate. This intermediary distributes the concentrated forces from the adjustment device over a larger area, preventing stress concentration that would cause laminate tears. The reinforcement element acts as a mediator that transfers forces safely without damaging the delicate laminate structure.
2Productivity
If the molded shell dimensions are increased to produce larger rotor blades, then the productivity and power output are improved, but the shell becomes prone to twisting and bending due to its considerable dimensions
Solution Approach 1:
The patent employs composite materials, specifically a sandwich construction with the molded shell laminate combined with a core material (such as foam or honeycomb structure). This composite structure provides high stiffness and stability relative to the weight, enabling large dimensions without excessive twisting or bending. The composite design maintains structural integrity while allowing the production of larger rotor blades for increased productivity.
3Stability of the object's composition
If the molded shell is made thicker to prevent twisting and bending, then the structural stability is improved, but the weight of the molded shell increases significantly
Solution Approach 1:
The patent uses a sandwich construction with thin laminate shells separated by a lightweight core material (foam, honeycomb, or balsa wood). This composite structure achieves high structural stability and resistance to twisting and bending without increasing the weight of the shell laminates themselves. The core material provides structural rigidity while remaining lightweight, avoiding the need to thicken the actual molded shell layers.
4Device complexity
If adjustment devices are applied directly to the outer shell, then the device complexity is reduced, but the forces act only on the outer shell causing laminate tears
Solution Approach 1:
The patent introduces a reinforcement element as an intermediary structure between the adjustment device and the outer shell. The fastening means connects to this reinforcement element rather than directly to the outer shell laminate. This intermediary distributes the forces over a larger area and transfers them to both the inner and outer shells, preventing laminate tears while maintaining a relatively simple adjustment device structure.
Data Source
Figure 1
Figure 2a~2c
Figure 3
AI summary
The invention relates to a manufacturing device with a base frame (2) and a molded part shell (3) arranged on the base frame (2), the molded part shell having an inner shell (14) and an outer shell (16), which is connected to the base frame (2) by at least one adjustment device (4), wherein at least one spacer (17) is arranged between the inner shell (14) and the outer shell (16), and at least one fastening means (22) is fixedly connected to the at least one spacer (17) and projects through the outer shell (16) to the base frame (2), and the at least one fastening means (22) is connected to each of the at least one adjustment device (4).