Wind Turbine Rotor Blade Web Recess Manufacturing
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Solution Overview
Problem
The existing methods for manufacturing wind turbine rotor blades require machining a recess into the web, resulting in significant manpower and material waste, as well as potential stress concentrations due to abrupt geometry changes.
Innovation Solution
The method involves arranging a core member with a pre-machined parabolic or semicircular recess within the mold, which is then covered by fiber material layers, eliminating the need for post-curing machining and ensuring smooth load transfer by tapering web tips towards the blade root.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the recess is machined into the cured web, then the web geometry can be adjusted, but substantial manpower and material waste are required
Solution Approach 1:
The recess geometry is predetermined in the core member before the web is manufactured. The core member is designed with the recess shape already incorporated, so when fiber material is laid up against it, the web automatically acquires the desired recess geometry without requiring post-curing machining operations.
Solution Approach 2:
The recess geometry is copied from the core member to the web through the fiber material layup process. The fiber material conforms to the core member's recess shape, creating an accurate geometric copy without material removal.
2Shape
If the recess is machined into the cured web, then the web geometry can be adjusted, but substantial manpower is required
Solution Approach 1:
The recess geometry is predetermined in the core member before the web is manufactured. The core member is designed with the recess shape already incorporated, so when fiber material is laid up against it, the web automatically acquires the desired recess geometry without requiring post-curing machining operations.
3Shape
If the recess is machined into the cured web, then the web geometry can be adjusted, but stress concentrations occur due to abrupt geometry changes
Solution Approach 1:
The recess features smooth curved transitions with specific radius values (e.g., R10, R20) at critical locations where geometry changes occur. This local optimization of the recess shape ensures smooth stress flow paths and avoids abrupt transitions that would create stress concentrations.
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 approach reduces manpower and waste by integrating the recess into the core member, allowing for efficient resin impregnation and curing without additional machining, while enhancing load transfer and reducing stress concentrations.
Implementation Method 1
curing a resin impregnating the fiber material of the first and second layup to form the rotor blade
Implementation Method 2
vacuum applied from beneath. Then, mold cores are covered in vacuum bags
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A method for manufacturing a rotor blade (5) for a wind turbine is provided. The method comprises: a) arranging a first layup (39) of fiber material inside a mold (40), the first layup (39) corresponding to an airfoil (7) of the rotor blade, b) arranging a second layup (34) of fiber material on a core member (17) before and/or after arranging the core member (17) in the mold (40), the second layup (34) including the core member (17) corresponding to a web (9) of the rotor blade, the core member (17) comprising a recess (22) configured to ensure a smooth transfer of loads into and out of the web (9), and c) curing a resin impregnating the fiber material of the first (39) and second layup (34) to form the rotor blade (5). The method is advantageous in that there is no need anymore to machine the recess into the cured web, thus saving man power and avoiding waste.