Automated Rotor Blade Preform Production via Scrim Portal
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Solution Overview
Problem
The manual laying process for producing rotor blades from structured mats is labor-intensive and difficult to automate, limiting quality management and process optimization, and existing automated methods are not suitable for large components like wind turbine rotor blades.
Innovation Solution
An automated method and device that uses a scrim portal to roll out and apply structured mats to a molded part, with a rolling tool holder and gluing tool holder for automated unrolling and adhesive application, allowing for efficient production of preforms for rotor blades.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual laying method is used to produce preforms from structured mats, then flexibility and adaptability are maintained, but labor intensity increases and automation becomes difficult
Solution Approach 1:
The patent replaces manual mechanical laying operations with an automated robotic system. A robot arm equipped with a picking device automatically picks up structured mats from a storage magazine, transports them to the mold, and places them in predetermined positions. This substitution eliminates manual labor while maintaining precise placement capability through programmable robot motion control.
Solution Approach 2:
The system implements self-service through automated material handling. The robot automatically retrieves structured mats from the magazine, positions them according to the preform design, and prepares them for impregnation without human intervention. The process includes automatic coordination between the robot, mold positioning system, and subsequent vacuum infusion equipment.
2Extent of automation
If existing automated methods are used for fiber composite materials, then automation is achieved, but they cannot be applied to large components like rotor blades
Solution Approach 1:
The patent creates a universal automated system that can handle various sizes and types of composite structures. The robotic arm with adjustable workspace, programmable picking device, and flexible magazine system can accommodate different structured mat sizes, mold configurations, and preform designs. This multi-functionality enables the same automated system to produce everything from small composite parts to large rotor blade preforms.
Solution Approach 2:
The system addresses the scale challenge by extending the automation into three-dimensional space with a robot arm that has sufficient workspace envelope and positioning capability. The magazine is configured to store and supply large structured mats, and the mold positioning system accommodates large component geometries. This dimensional extension allows automated handling of rotor blade-sized components while maintaining precision.
3Manufacturing precision
If structured mats are manually placed in mold, then quality control is possible, but process optimization is limited
Solution Approach 1:
The automated system incorporates feedback mechanisms through programmable robot control that ensures consistent picking, transporting, and placing operations. The system can be programmed with precise motion trajectories, positioning accuracy requirements, and process parameters that maintain quality while optimizing cycle time. Feedback from sensors and controllers ensures repeatable placement accuracy and enables systematic process optimization through parameter adjustment and monitoring.
Data Source
Figure 1(A)~1(B)
Figure 2
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AI summary
The invention relates to a method for producing a rotor blade (201), according to which a preform is produced as a semi-finished textile product from a number of material sheets of textured laid scrim mats, preferably for use in a subsequent vacuum infusion. The method comprises the steps: provision of a mould (200) for the preform in a laying frame (100), provision of a textured laid scrim mat in the form of a roll of the material sheet on a laying roll, automatic rolling out of the textured laid scrim mat and automatic application of an adhesive to the textured laid scrim mat in the mould in the laying frame.