Shifting Layup for Composite Blades
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Solution Overview
Problem
The manual layup process in wind turbine blade manufacturing is labor-intensive, error-prone, and costly due to the need for human interaction and specialized training, especially when dealing with non-prismatic geometries and complex fiber draping, which results in out-of-plane distortions and reduced fatigue life of the components.
Innovation Solution
A semi-automated system that uses a shifting method involving rollers with arcuate surfaces to continuously feed and shift non-crimp fabric, synchronized with a linear axis drive, to conform the fabric to complex mold geometries, reducing human interaction and allowing for predictable in-plane distortions, thereby improving the structural integrity and fatigue life of wind turbine blades.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual layup process is used, then flexibility in handling complex geometries is maintained, but labor intensity and error rate increase significantly
Solution Approach 1:
The patent replaces manual mechanical manipulation of fabric with an automated system consisting of a mandrel, formers, and positioning mechanisms. The automated system uses controlled mechanical forces to conform fabric to complex geometries, eliminating manual labor while maintaining geometric flexibility through programmable control of the positioning mechanisms.
Solution Approach 2:
The automated layup system is designed to self-adjust and self-position fabric layers through feedback control mechanisms. The system automatically detects fabric position and adjusts positioning mechanisms accordingly, eliminating the need for continuous manual intervention while maintaining precision in complex geometry fabrication.
2Adaptability or versatility
If manual layup process is used, then adaptability to different geometries is maintained, but manufacturing cost and variability increase
Solution Approach 1:
The patent employs dynamically adjustable mandrels and formers that can be reconfigured through programmable control to accommodate different geometries. The positioning mechanisms feature real-time adjustment capabilities with feedback control, allowing precise adaptation to varying geometric requirements while eliminating manual variability through automated control.
Solution Approach 2:
The automated layup system incorporates feedback control mechanisms that continuously monitor fabric position and adjust positioning mechanisms accordingly. Sensors detect fabric location and tension, and the control system makes real-time adjustments to maintain precise positioning, eliminating variability inherent in manual operations.
3Productivity
If automated shifting method is used, then labor cost is reduced, but device complexity increases
Solution Approach 1:
The automated layup system is divided into distinct functional modules: mandrel assembly, former assembly, positioning mechanisms, and control system. Each module performs a specific function and can be independently adjusted or replaced, reducing overall system complexity while maintaining automation capabilities. The segmentation allows for easier maintenance and reconfiguration.
Data Source
AI summary
Shifting is a method for manipulating unidirectional non-crimp fabrics that allows for a curved fiber path along with compound surface geometry. The bases for shifting is understanding unidirectional (UD) non-crimp-fabrics (NCFs) as a semi-flexible prismatic linkage and planning manipulations such that the array of linkages can conform to the surface geometry and path plan within allowable manufacturing tolerances. This has applications in structural composite components such as the current trailing edge prefabricated unidirectional components for wind turbine blades, and for future wind turbine blade designs including a curve-linear spar cap.