Multi-part Casting Mould for Wind Turbine Rotor Hub
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Solution Overview
Problem
Modern wind turbines with multiple rotor leaf connections face challenges in achieving sufficient rigidity while minimizing weight and production costs, particularly due to the difficulty in manufacturing large-scale rotor components with stable, thin-walled structures and the need for efficient separation of molding boxes during the casting process.
Innovation Solution
A multi-part cast shape design featuring an upper and lower shape box with a core, where the leaf flanges and stiffening levels are angled relative to the central rotor axis, allowing for simpler vertical separation of the shape boxes and facilitating the production process by reducing the need for complex threading and alignment, using materials like spherical graphite for the cast iron.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the rotor hub is designed with thin walls to reduce weight, then the weight decreases, but the structural rigidity and manufacturing difficulty worsen
Solution Approach 1:
The patent applies local quality by positioning stiffening elements at specific locations within the rotor hub structure. These stiffening elements are strategically placed in areas requiring enhanced rigidity while maintaining thin walls in other regions, thus achieving weight reduction without compromising overall structural strength.
Solution Approach 2:
The patent utilizes composite material structures by combining base hub material with integrated stiffening elements. This creates a composite structure where different regions have different mechanical properties - thin-walled areas for weight savings and reinforced areas for structural integrity, effectively resolving the contradiction between weight and strength.
2Volume of moving object
If the rotor hub size increases to accommodate larger turbines, then the power capacity increases, but the manufacturing complexity and mold closing difficulty worsen
Solution Approach 1:
The patent applies segmentation by dividing the rotor hub into multiple separable mold sections. The hub is manufactured in segments that can be independently formed and then assembled, allowing large-volume hubs to be produced without requiring excessively large or complex single-piece molds. This segmentation enables manageable mold sizes even for large turbine applications.
Solution Approach 2:
The patent utilizes dimensional changes by introducing a parting plane that divides the mold into upper and lower sections. This allows the mold to be opened and closed vertically rather than requiring horizontal separation, simplifying the manufacturing process for large-volume hubs and enabling easier mold operation.
3Ease of manufacture
If the blade connection stiffeners are aligned with the blade flange end planes, then the manufacturing alignment is simplified, but the structural effectiveness in absorbing deformation loads worsens
Solution Approach 1:
The patent applies asymmetry by deliberately misaligning the blade connection stiffeners relative to the blade flange end planes. The stiffeners are positioned at optimized angles that differ from the flange orientation, creating an asymmetric configuration that enhances deformation load absorption while maintaining acceptable manufacturing complexity through defined angular relationships.
Data Source
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AI summary
The invention relates to a multi-part casting mould (1) for a rotor hub (50) of a wind turbine with two or more rotor blade connections (20, 20', 20''), said casting mould comprising an upper moulding box (2), a lower moulding box (3) and a core (4), wherein, in the assembled state, in which the upper moulding box (2) and the lower moulding box (3) lie one on the other in a partition plane (7) and surround the core (4), the casting mould (1) encloses a cavity (10) having the shape of the rotor hub (50) to be produced, wherein a central rotor axis (8) is oriented in the casting mould (1) vertically and perpendicular in relation to the partition plane (7), wherein each rotor blade connection (20, 20', 20'') has a blade flange (22, 22', 22'') and a blade connection brace (24, 24', 24'') arranged inside the rotor blade connection (20, 20', 20''), wherein terminating planes (23) of the blade flanges (22, 22', 22'') are each at a first angle in relation to the central rotor axis (8) and are traversed by the rotor axis (8) below or above the partition plane (7). The invention further relates to a production method, to a rotor hub (50) and to a wind turbine. The casting mould according to the invention is distinguished by the fact that the blade connection braces (24, 24', 24'') span bracing planes (25) arranged at a second angle, which differs from the first angle, in relation to the central rotor axis (8).