Wind Turbine Spar Cap Edge Member Integration

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Solution Overview

Problem

The manufacturing of spar caps for wind turbine rotor blades is inefficient due to the need for labor-intensive edge planning to remove sharp edges, which generates dust and increases production costs, especially when using carbon fibers.

Innovation Solution

Incorporating edge members made of foam, wooden, or honeycomb materials, such as balsa wood, adjacent to the fiber-reinforced members, which eliminates the need for edge planning by providing a smooth surface and serving as a molding form, allowing precise fitting into the rotor blade skin without extensive finishing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If traditional manufacturing method without edge members is used, then the spar cap can be manufactured with fiber-reinforced material, but sharp edges are generated requiring labor-intensive edge planning

Engineering Contradiction:

Improveedge planning processVSAvoidproduction time

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The edge members are integrated into the mold before the fiber-reinforced material is placed, so that the edges are pre-formed with smooth surfaces during the molding process itself, eliminating the need for subsequent edge planning operations

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Edge members made of foam, wooden, or honeycomb materials serve as intermediary elements between the mold and the fiber-reinforced material, providing a smooth edge surface that prevents direct contact between the sharp edges of the fiber material and the external environment

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-generated harmful factors

If edge planning is performed to remove sharp edges, then the spar cap can be prepared for subsequent processes, but high amount of dust is generated especially with carbon fibers

Engineering Contradiction:

Improvedust generationVSAvoidedge preparation process

Core Design Contradiction:

Object-generated harmful factorsVSEase of manufacture

Solution Approach 1:

The invention converts the potentially harmful sharp edges into a beneficial smooth surface by using edge members that are inherently smooth, thereby eliminating dust generation while maintaining structural integrity

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The edge members can be made from inexpensive materials like foam or wooden materials that are easier to work with and do not generate harmful dust, serving as a sacrificial or permanent protective element at the edges

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Device complexity

If traditional manufacturing method is used, then the spar cap structure can be kept simple, but extensive edge planning increases production costs

Engineering Contradiction:

Improvespar cap structureVSAvoidproduction cost

Core Design Contradiction:

Device complexityVSEase of manufacture

Solution Approach 1:

The spar cap is segmented into distinct components: the fiber-reinforced member and the edge members, allowing each to be optimized independently and manufactured separately before assembly, thereby reducing overall manufacturing complexity and cost

Inventive Principle:

Principle #1Segmentation

Data Source

PatentEP2716904B1Method of manufacturing a composite spar cap for a rotor blade of a wind turbine

Publication Date: 2018.08.29 AREVA BLADES

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AI summary

A spar cap (24), a rotor blade (4), a wind turbine (2) and a method of manufacturing a spar cap is provided. A spar cap for a rotor blade of a wind turbine comprises a fiber-reinforced member (26) and at least a first edge member (28). The fiber-reinforced member comprises a first side (72) which is arranged towards a leading edge of the rotor blade and the second side (34) which is arranged towards a trailing edge of the rotor blade. The at least first edge member is arranged adjacent to the first side or adjacent to the second side of the fiber-reinforced member. The first edge member projects towards a leading edge of the rotor blade or towards a trailing edge of the rotor blade.