Wind Turbine Shear Web Pultrusion with In-Line Shaping
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manufacturing of wind turbine blade components, such as shear webs, faces challenges due to increased complexity and material waste in producing structures with varying geometries, which are not easily accommodated by existing methods.
Innovation Solution
A method involving pultrusion with in-line shaping using an adjustable die and guide flange to create parts with varying cross-sectional profiles, allowing for precise adjustment of the pultrusion path and orientation to match the complex internal surfaces of wind turbine blades, reducing material waste and enabling accurate geometry control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If traditional pultrusion method is used to manufacture shear web components, then the manufacturing process is simple, but the geometry is limited and cannot accommodate complex varying cross-sections
Solution Approach 1:
The patent applies dynamics by making the pultrusion die aperture adjustable during the manufacturing process. The die aperture can be dynamically changed to produce different cross-sectional profiles along the length of the component, allowing complex varying geometries to be manufactured in a single continuous pultrusion operation without requiring multiple dies or post-processing operations.
Solution Approach 2:
The patent introduces an additional degree of freedom to the traditional pultrusion process by enabling the die aperture shape and orientation to vary along the longitudinal axis of the component. This dimensional variation allows the cross-sectional profile to change continuously, transforming the static geometry limitation into a dynamic multi-dimensional shaping capability.
2Manufacturing precision
If machining or cutting is used to adjust web foot height, then the geometry can be adjusted, but material waste increases
Solution Approach 1:
The patent applies preliminary action by pre-configuring the die aperture to the required shape and orientation before the pultrusion process begins. The correct cross-sectional geometry is built into the component during manufacturing rather than being created through subsequent machining or cutting operations, thereby eliminating material waste associated with removal processes.
Solution Approach 2:
The patent utilizes parameter changes by varying the die aperture dimensions and orientation parameters along the length of the component. This allows the cross-sectional profile to be precisely controlled to match the required geometry, eliminating the need for material removal and ensuring near 100% material utilization.
3Productivity
If existing pultrusion methods are used, then the process is efficient, but the components do not match the complex internal surfaces of modern wind turbine blades
Solution Approach 1:
The patent maintains manufacturing efficiency by using a continuous pultrusion process while incorporating dynamic adjustments to the die aperture. This allows the component geometry to adapt to complex blade internal surfaces without interrupting the production flow, achieving both high productivity and precise geometry control in a single continuous operation.
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 allows for the efficient and accurate manufacturing of wind turbine blade components with varying geometries, minimizing waste and ensuring a secure bond with the blade's internal surfaces, facilitating the production of complex structures with reduced defects and improved quality control.
Implementation Method 1
pultruding composite material through at least one die to form a part of a wind turbine blade having a cross-sectional profile
Implementation Method 2
providing a guide flange having a profile to define the direction of a pultrusion path downstream of said at least one die
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A method for manufacturing a part for a wind turbine blade (10), and in particular a part of a shear web (70) for a wind turbine blade (10), is described. The method comprises pultruding the part, wherein an in-line shaping of the part is performed, to provide a part having a cross-sectional profile which varies in the longitudinal length of the part. Providing a shear web (70) having a portion which varies in cross-sectional profile results in production of a wind turbine blade (10) part which can be accurately controlled to have precise geometrical profile corresponding to a desired blade profile, with minimal waste of materials.