Wind Turbine Shear Web Backing Plate Resin Infusion
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Solution Overview
Problem
Existing methods for manufacturing shear webs for wind turbine blades often result in unsatisfactory resin flow patterns and structural properties, leading to a higher risk of structural failure and increased costs.
Innovation Solution
A method and mould system where fibre layers are arranged on an elongated lower web mould part with diverging side parts, and backing plates with channels or grooves are used to supply resin, allowing for improved flow patterns and structural stability, with the option of using magnetic materials for quick plate mounting and a vacuum-assisted resin transfer process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If resin is infused into the mould cavity at the centre of the web body, then the manufacturing process is simple, but the resin flow pattern is unsatisfactory and structural properties are poor
Solution Approach 1:
The invention divides the resin infusion process into multiple entry points by providing first and second resin infusion channels at opposite ends of the backing plate, rather than a single central infusion point. This segmentation of the resin flow path improves both flow pattern and structural properties while maintaining manufacturing simplicity
Solution Approach 2:
The invention transitions from a single-point (0D) or linear (1D) resin infusion approach to a distributed multi-point infusion system across the width of the mould cavity. The first and second channels are positioned at opposite ends, creating a two-dimensional resin flow distribution that enhances structural properties
2Reliability
If complex mould structures are used to achieve good resin flow patterns, then structural properties improve, but manufacturing complexity and costs increase
Solution Approach 1:
The complex resin flow distribution is achieved through segmentation of the infusion system into multiple simple channels in the backing plate, rather than using a complex three-dimensional mould structure. This keeps the device complexity low while achieving good structural properties
Solution Approach 2:
The backing plate serves as an intermediary component that simplifies the resin infusion system. Instead of complex internal mould structures, the backing plate with its channels acts as a mediator to distribute resin evenly, reducing overall device complexity
3Manufacturing precision
If expensive and complex mould systems are used, then manufacturing precision improves, but manufacturing costs increase
Solution Approach 1:
The backing plate is designed as a relatively simple, potentially disposable or reusable component that provides precise resin flow control without requiring expensive mould structures. This achieves manufacturing precision at lower cost
Solution Approach 2:
The invention changes the parameter of resin infusion from single-point to multi-point distribution, achieving better flow control and manufacturing precision through this parameter modification rather than through expensive equipment
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 results in better structural stability, reduced risk of repairs, and a cost-effective, time-efficient process suitable for various blade types, with the added benefit of using reusable, non-costly backing plates made of polymers.
Implementation Method 1
a channel or groove extending between at least one of the outer surfaces and the inner moulding surface of the backing plate
Implementation Method 2
supplying resin to the mould cavity via the respective channel or groove
Implementation Method 3
vacuum-assisted resin transfer process
Implementation Method 4
using magnetic materials for quick plate mounting
Implementation Method 5
curing or hardening the resin in order to form the shear web
Data Source
Figure 1
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Figure 4~5
AI summary
A method and a mould system (70) for manufacturing a shear web for a wind turbine blade as well as a backing plate (66) for such method and mould system. The method involves arranging one or more fibre layers on top of a web mould part (61), arranging backing plates (66) at each end to create a mould cavity between the first and second backing plate (66, 68) and the web mould part (61). Each backing plate (66, 68) comprises an inner moulding surface (80), outer surfaces (98, 100) and a channel (82) or groove (83) extending between at least one of the outer surfaces (98, 100) and the inner moulding surface (80). Resin is supplied to the mould cavity via each channel or groove of the first and second backing plate (66, 68), and subsequently the resin is cured or hardened to form the shear web.