Wind Turbine Spar Cap Manufacturing via 3D Pultrusion
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Solution Overview
Problem
The manufacturing process for spar caps in wind turbine rotor blades faces challenges such as difficulty in transporting pultruded plates to molds and shifting during the resin infusion process, leading to inefficiencies and material waste.
Innovation Solution
A method involving forming an outer frame via 3D pultrusion, thermoforming, or 3D printing with a varying cross-section, arranging structural materials within the frame, and infusing them with resin to create the spar cap, eliminating the need for conventional molds and reducing material consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If pultruded plates are used in conventional VARTM process, then spar caps can be manufactured, but transportation of plates to molds becomes difficult and plates may shift during infusion
Solution Approach 1:
The spar cap is divided into two functional components: a pultruded outer frame (made via 3D pultrusion) and separate structural materials (plies or pultruded plates). The outer frame serves as a rigid container that maintains its shape during manufacturing, while the structural materials are placed inside it. This segmentation allows the outer frame to be transported and positioned easily, while the structural materials are contained within it, preventing shifting during resin infusion.
Solution Approach 2:
The outer frame is pre-formed via 3D pultrusion to the final spar cap geometry before the resin infusion process. This preliminary formation of the outer frame establishes the precise positioning and shape requirements upfront, eliminating the need to transport and position large pultruded plates during the infusion process. The frame acts as a pre-positioned structure that guides subsequent material placement.
2Productivity
If conventional VARTM process is used with pultruded plates, then spar caps can be manufactured, but material waste increases due to shifting and rework
Solution Approach 1:
By separating the structural function into the outer frame and internal structural materials, the design eliminates the need to handle large pultruded plates during infusion. The frame structure contains the structural materials in place, preventing shifting that would cause material waste and rework, thereby improving manufacturing efficiency.
Solution Approach 2:
The manufacturing process transitions from using conventional pultruded plates to using a pultruded outer frame with internal structural materials. This parameter change in the structural configuration allows for better material containment and reduced shifting during the resin infusion process, minimizing material waste.
3Ease of manufacture
If pultruded plates are transported to spar cap molds, then manufacturing can proceed, but transportation difficulty increases
Solution Approach 1:
The spar cap manufacturing is segmented into: (1) forming the outer frame via 3D pultrusion, (2) placing structural materials inside the frame, and (3) infusing resin through the frame. This segmentation allows the outer frame to be manufactured and transported independently in a controlled state, simplifying logistics while maintaining manufacturing capability.
Solution Approach 2:
The pultruded outer frame serves multiple functions: it provides the external shape of the spar cap, acts as a container for structural materials, serves as a mold for resin infusion, and provides structural support. This multi-functionality eliminates the need for separate molds and handling of multiple large components, simplifying the overall manufacturing process.
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 method simplifies the manufacturing process, reduces material transport difficulties, and allows for easier integration with existing rotor blade manufacturing processes, enhancing efficiency and reducing material requirements.
Implementation Method 1
infusing the plurality of structural materials and the outer frame together via a resin material so as to form the spar cap
Implementation Method 2
forming an outer frame of the spar cap via at least one of three-dimensional (3D) pultrusion
Data Source
AI summary
The present disclosure is directed methods for manufacturing spar caps for wind turbine rotor blades. In certain embodiments, the method includes forming an outer frame or tray of the spar cap via at least one of three-dimensional (3D) pultrusion, thermoforming, or 3D printing. As such, the outer frame has a varying cross-section that corresponds to a varying cross-section of the rotor blade along a span thereof. The method also includes arranging a plurality of structural materials (e.g. layers of pultruded plates) within the pultruded outer frame of the spar cap and infusing the structural materials and the outer frame together via a resin material so as to form the spar cap. The resulting spar cap can then be easily incorporated into conventional rotor blade manufacturing processes and/or welded or bonded to an existing rotor blade.