Segmented Wind Turbine Blade Assembly for Local Manufacturing
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Solution Overview
Problem
Conventional wind turbine blade manufacturing is costly due to high capital investment, extensive manual labor, and transportation challenges, particularly for large blades that require long-distance transport to remote installation sites.
Innovation Solution
A system and method for manufacturing wind turbine blades using modular shell core sections and strengthening elements, where each section is formed by additive manufacturing or moulding, allowing assembly and curing near the installation site, reducing the need for long-distance transport of finished blades.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional centralized blade manufacturing is used, then manufacturing precision and structural integrity are improved, but transportation cost and difficulty increase significantly
Solution Approach 1:
The blade is divided into multiple modular segments (root segment, intermediate segments, tip segment) that can be manufactured separately at a centralized facility and then assembled on-site. Each segment includes integrated strengthening elements and connection interfaces, allowing the blade to be transported in manageable pieces rather than as a single massive structure.
2Manufacturing precision
If large-scale moulds are used for blade production, then manufacturing precision is improved, but capital investment and facility requirements increase
Solution Approach 1:
Instead of using one or two enormous moulds, the system employs multiple smaller moulds that each form individual blade segments. This segmentation of the moulding process reduces the size and complexity of each mould while maintaining manufacturing precision through standardized mould designs and processes.
Solution Approach 2:
The blade segments are pre-manufactured with integrated strengthening elements and connection interfaces already incorporated during the moulding process. This preliminary action eliminates the need for complex post-assembly operations and reduces the complexity of the overall manufacturing system.
3Adaptability or versatility
If manual labor is used in blade production, then manufacturing flexibility is improved, but labor cost increases
Solution Approach 1:
The blade manufacturing process is segmented into standardized modules that can be produced using automated moulding and assembly techniques. This segmentation enables the use of automation and robotics in segment production while maintaining flexibility through modular design, reducing both labor costs and improving consistency.
4Adaptability or versatility
If finished blades are transported long distances, then installation flexibility is improved, but transportation cost and damage risk increase
Solution Approach 1:
The blade is segmented into multiple smaller sections that can be transported individually to the installation site. These segments are then assembled on-site to form the complete blade, reducing transportation costs and damage risk while maintaining installation flexibility through the modular assembly process.
Solution Approach 2:
The blade segments are pre-manufactured and prepared with connection interfaces and strengthening elements before transport. This preliminary action allows the segments to be shipped in a ready-to-assemble state, reducing on-site construction time and maintaining installation flexibility without requiring long-distance transport of the finished blade.
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 minimizes human labor costs and transportation expenses by enabling local assembly and manufacturing of wind turbine blades, making wind energy technology more accessible and cost-effective for remote installations.
Implementation Method 1
The outer surface material layer and the plurality of strengthening elements are consolidated together by curing of the outer surface material layer
Data Source
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AI summary
A system (24) and method are described herein for manufacturing a wind turbine blade (22) proximate to the final installation site of a wind turbine (10). The system (24) includes a creel (72) of feeders (74) configured to apply strengthening elements (62) onto a plurality of shell core sections (26) coupled together and fed through the creel (72). The shell core sections (26) include an external surface (56) with a plurality of external grooves (58) recessed into the external surface (56) such that the strengthening elements (62) are laid into the external grooves (58). The system (24) also includes a deposition station (78) configured to apply an outer surface material layer (82) in fluid form to cover the external surface (56) and the plurality of strengthening elements (62). A curing station (86) heats and consolidates the shell core sections (26), the strengthening elements (62), and the outer surface material layer (82) together into a final consolidated part, with the outer surface material layer (82) defining an external profile of the blade (22) following curing.