Wind Turbine Shear Web Installation Without Gantry Fixtures
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Solution Overview
Problem
The existing methods for manufacturing large-scale composite structures like wind turbine blades face challenges with shear web installation, including sub-optimal positioning due to movement during mold closure and the need for complex gantry fixtures, which increase costs and design complexity.
Innovation Solution
The system employs support elements, specifically bulkheads attached to the shear web, which serve as installation guides and ensure stability without requiring a gantry, allowing for precise positioning and simultaneous bonding to both mold skins during mold closure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a gantry fixture is used to support and position the shear web during mold closure, then positioning accuracy is improved, but device complexity and cost increase
Solution Approach 1:
The patent removes the gantry fixture from the system entirely and replaces it with bulkhead supports that are integrated into the mold structure. The shear web is supported directly by bulkheads attached to the mold halves, eliminating the need for complex external positioning equipment while maintaining positioning accuracy through the bulkhead design.
Solution Approach 2:
The bulkhead acts as an intermediary element between the mold and the shear web. Instead of using a complex gantry system, the bulkhead provides a simple intermediate support structure that guides and positions the shear web during mold closure, transferring the positioning function from external equipment to an integrated component.
2Stability of the object's composition
If a gantry fixture is used to install the shear web, then positioning stability is improved, but production cycle time increases
Solution Approach 1:
The bulkheads are pre-attached to the mold halves before the shear web installation. This preliminary preparation ensures that the support structure is already in place and properly positioned, allowing the shear web to be installed directly onto the prepared supports without requiring time-consuming gantry positioning operations.
Solution Approach 2:
By removing the gantry fixture entirely and using integrated bulkhead supports, the patent eliminates the time-consuming operations associated with gantry setup, positioning, and operation. The simplified support system allows for faster shear web installation while maintaining stability through the bulkhead design.
3Productivity
If the shear web is bonded to the mold skin during mold closure, then manufacturing efficiency is improved, but positioning accuracy deteriorates due to web movement
Solution Approach 1:
The bulkhead supports are installed beforehand to prevent shear web movement before bonding occurs. By providing preliminary mechanical support and positioning through the bulkheads, the system counteracts the tendency of the shear web to shift during the bonding process, ensuring accurate positioning is maintained throughout mold closure.
Solution Approach 2:
The bulkhead serves as an intermediary support structure that maintains shear web position during the bonding process. It acts as a mediator between the shear web and the mold, providing continuous positional control from initial placement through bonding completion, thereby ensuring manufacturing efficiency without sacrificing positioning accuracy.
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 eliminates the need for gantry fixtures, reduces production cycle time, and lowers costs by enabling efficient shear web installation and curing while maintaining structural integrity.
Implementation Method 1
heating includes directing fluid from the blade root through a bulkhead towards the blade tip with the fluid circulating around the shear web
Data Source
AI summary
A method of forming a wind turbine blade is provided which includes upper and lower blade mold halves, and a shear web having at least one aperture formed therein. A plurality of bulkheads are attached to the shear web and the shear web can be lifted and rotated, without need for a complex gantry/galactica apparatus, to be placed inside the lower blade mold. The upper mold half can then be closed with the shear web and bulkhead(s) disposed within the blade interior. A heating fluid can be pumped into the interior to pass through the bulkheads, circulating around the shear web and exiting the blade root with the assistance of a sump to pull the cold air outside the blade.