Segmented Rotor Blade Bonding Device for Complex Geometries
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Solution Overview
Problem
Conventional rotor blade manufacturing methods face challenges in producing geometries with undercuts and strong torsions, limiting the complexity and efficiency of rotor blade production, especially for offshore wind turbines.
Innovation Solution
A gluing device and method for segmented rotor blades that allows for the precise alignment and bonding of prefabricated nose shell, middle part segment, and trailing edge segment, enabling the production of complex geometries with increased torsion and undercut features, using a system with movable receiving areas and automated positioning for efficient assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional two-molecule technology is used for manufacturing rotor blades, then the manufacturing process is simple, but the ability to produce complex geometries with undercuts and torsions is limited
Solution Approach 1:
The rotor blade is divided into multiple separately manufacturable segments (leading edge segment, trailing edge segment, and intermediate segments) that can be produced using conventional two-molecule technology and then joined together. This segmentation allows each segment to be manufactured with simpler processes while the final assembled blade achieves complex geometries including undercuts and torsions that would be impossible with a single-piece construction.
2Reliability
If rotor blade half-shells are glued together after fitting ribs and webs, then the manufacturing process is straightforward, but achieving durable bonds in complex geometries with undercuts and torsions is significantly more difficult
Solution Approach 1:
Ribs and webs are pre-fitted to the inner surfaces of blade shell segments before the bonding process. This preliminary action ensures that load-bearing components are properly positioned and secured prior to applying adhesive, allowing for durable bonds even in complex geometries with undercuts and torsions. The pre-assembly of these components facilitates subsequent bonding operations by establishing proper alignment and access.
3Adaptability or versatility
If novel rotor blade geometries with pronounced helical twist and strong torsions are constructed, then the aerodynamic performance is improved, but the joining and bonding of rotor blade halves becomes significantly more complicated
Solution Approach 1:
The rotor blade is segmented into multiple sections that can be manufactured with simplified geometries and then joined to achieve the final complex helical and twisted configuration. This approach allows each segment to be produced more easily while the overall blade achieves the desired aerodynamic performance through proper assembly of segments with appropriate bonding areas.
4Productivity
If traditional manufacturing methods are used, then the manufacturing process is well-established, but the manufacturing time and logistical challenges for large rotor blades are significant
Solution Approach 1:
The rotor blade is divided into multiple segments that can be manufactured separately and simultaneously, reducing overall manufacturing time. The segments are designed with bonding areas that facilitate efficient assembly. This segmentation also reduces logistical challenges by allowing segments to be transported and stored more easily than a complete large rotor blade, while the bonding device enables rapid assembly of the segmented components.
Data Source
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AI summary
The invention relates to an adhesive device (10) for constructing segmented rotor blades (5) comprising at least three prefabricated rotor blade parts (1, 2, 3), having: a first accommodating region (11) for receiving a first prefabricated rotor blade part (1), a second accommodating region (12) for receiving a second prefabricated rotor blade part (2) and a third accommodating region (13) for receiving a third prefabricated rotor blade part (3), wherein the first accommodating region (11), the second accommodating region (12) and the third accommodating region (13) can be moved relative to each other so that, following successful receiving of the three prefabricated rotor blade parts (1, 2, 3) in the proper accommodating regions (11, 12, 13) in an open position of the adhesive device (10), said rotor blade parts (1, 2, 3) can be brought into direct or indirect contact with each other via predetermined adhesion regions (21, 22) and thus transferred into an adhesion position.