Wind Turbine Rotor Blade Section Casting for Faster Manufacturing
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Solution Overview
Problem
The manufacturing of large wind turbine rotor blades is time-consuming and costly due to the need for extensive preparation of thicker inboard regions and the large floor space required for one-piece moulds, with existing methods not optimizing the use of different casting techniques to reduce these inefficiencies.
Innovation Solution
The method involves manufacturing wind turbine rotor blades as separate inboard and outboard sections using different casting processes, allowing for optimized workflow scheduling and reduced resource wastage by separating time-intensive and less time-intensive sections, with the inboard section manufactured using an open-mould process and the outboard section using a closed-mould process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If one-piece moulding is used to manufacture rotor blades, then structural integrity is maintained, but manufacturing time and floor space requirements increase significantly
Solution Approach 1:
The rotor blade is divided into two separate sections: an inboard section and an outboard section. Each section is manufactured independently using different casting processes, then joined together. This segmentation allows the inboard section to be made using open-mould casting (faster for thick regions) while the outboard section uses closed-mould casting (better for surface quality), resolving the contradiction between structural integrity and manufacturing time by combining the benefits of both approaches.
2Strength
If one-piece moulding is used to manufacture rotor blades, then structural integrity is maintained, but floor space requirements increase
Solution Approach 1:
By segmenting the blade into inboard and outboard sections manufactured separately, smaller moulds can be used instead of one large mould. This reduces the floor space footprint of the manufacturing facility while still achieving a structurally integrated final product through the joining of sections.
3Productivity
If different casting processes are used for inboard and outboard sections, then manufacturing efficiency is improved, but process complexity increases
Solution Approach 1:
Different casting processes are applied to different sections of the blade based on their specific requirements: open-mould casting for the inboard section (where thickness and speed are priorities) and closed-mould casting for the outboard section (where surface quality is prioritized). This local differentiation optimizes manufacturing efficiency for each region while managing overall process complexity through a structured approach.
4Loss of time
If the blade is manufactured in sections, then manufacturing time is reduced, but joining requirements and structural complexity increase
Solution Approach 1:
The inboard and outboard sections are manufactured separately in parallel using optimized casting processes for each section, reducing overall manufacturing time. The sections are then joined using a standardized interface with load-bearing connections that integrate the spar cap and shear web structures, managing the complexity of joining through pre-planned connection details.
Data Source
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AI summary
The invention describes a method of manufacturing wind turbine rotor blades (1), wherein each rotor blade (1) comprises an inboard section (1A) and an outboard section (1B), and wherein an inboard blade section (1A) comprising a root end (10) and a transition region (11) is manufactured using a first casting process (P1); and an outboard blade section (1B) comprising an airfoil region (12) is manufactured using a second casting process (P2), which second casting process (P2) is different from the first casting process (P1). The invention further describes a wind turbine rotor blade manufactured using such a method.