Segmented Wind Turbine Rotor Blade Mould Reducing Overhead Clearance
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Solution Overview
Problem
The manufacturing of long wind turbine rotor blades with large root ends is hindered by the need for excessive overhead clearance, requiring high ceilings and potentially necessitating the construction of new facilities, which is costly.
Innovation Solution
A segmented upper mould for wind turbine rotor blades, comprising a root end mould section and multiple airfoil mould sections, allows for sideways displacement and longitudinal movement, reducing the required overhead clearance and enabling the use of existing facilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a one-piece upper mould half is used, then the mould structure is simple, but the required overhead clearance increases to more than 3 m at the root end
Solution Approach 1:
The upper mould half is divided into multiple sections: a root end mould section and one or more airfoil mould sections. This segmentation allows each section to be positioned and moved independently, reducing the overhead clearance required during assembly and disassembly while maintaining the structural integrity needed for manufacturing large rotor blades.
2Ease of manufacture
If the root end mould section is positioned directly at the root end, then the mould assembly is straightforward, but the required overhead clearance increases
Solution Approach 1:
The root end mould section is designed to be movable in the longitudinal direction along the rotor blade axis. This allows the section to be temporarily positioned above an airfoil region (using airfoil mould sections as intermediaries) and then moved longitudinally to its final position at the root end, effectively using longitudinal movement to reduce vertical clearance requirements.
3Length of stationary object
If a segmented upper mould is used, then the required overhead clearance is reduced, but the mould structure becomes more complex
Solution Approach 1:
The segmented upper mould design incorporates mobility into the mould structure, allowing sections to be moved independently during assembly and disassembly. This dynamic capability enables the use of smaller, more manageable sections that can be positioned sequentially, reducing the overhead clearance needed while the complexity is managed through standardized section designs and movement mechanisms.
4Length of stationary object
If the root end mould section is moved longitudinally, then the overhead clearance is reduced, but the handling complexity increases
Solution Approach 1:
Airfoil mould sections serve as intermediaries during the assembly process. The root end mould section is first positioned above an airfoil region using the airfoil mould sections as temporary support structures, and then moved longitudinally to its final position. This intermediary approach simplifies handling by providing stable reference points and support during the movement process.
Data Source
AI summary
The invention describes a method of manufacturing a wind turbine rotor blade (4), which method comprises at least the steps of providing a rotor blade mould (1) comprising a lower mould (11) and a segmented upper mould (12), the segmented upper mould (12) comprising a root end mould section (120) and a number of airfoil mould sections (121, 122); and arranging a composite material layup (2) in the lower mould (11). The inventive method comprises further steps of arranging the upper mould (12) over the composite layup (11) by: placing the root end mould section (120) at the position of an airfoil mould section (121); moving the root end mould section (120) in a longitudinal direction (Dz) to its intended position at the root end (20) of the composite layup (2); and placing the airfoil mould sections (121, 122) in their positions on the composite layup (2).