Variable Flow Rate Vacuum Infusion for Composite Rotor Blades
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Solution Overview
Problem
The existing methods for manufacturing fiber composite components for wind turbine rotor blades, particularly those with varying thicknesses, face issues with improper impregnation leading to resin accumulations and air pockets, which affect the durability and resilience of the components.
Innovation Solution
The method involves adjusting the matrix material flow rates based on the thickness of the fiber material by using a production mold with a sprue channel having variable cross-sectional areas, ensuring uniform impregnation by optimizing the flow rate according to the thickness variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a constant flow rate of matrix material is used during vacuum infusion, then the production process is simple, but improper impregnation occurs leading to resin accumulations and air pockets in thicker regions
Solution Approach 1:
The patent applies dynamics by transitioning from a static constant flow rate to a dynamic variable flow rate system. The matrix material supply is adjusted in real-time based on the local thickness of the fiber material, allowing the flow rate to change continuously throughout the impregnation process to match the varying absorption needs of different regions.
Solution Approach 2:
The patent implements local quality by providing different matrix material flow rates to different regions of the fiber material based on their specific thickness requirements. Thicker regions receive higher flow rates while thinner regions receive lower flow rates, ensuring each area receives the appropriate amount of matrix material for proper impregnation.
2Manufacturing precision
If the vacuum infusion process is optimized for uniform thickness, then impregnation is consistent, but components with varying thickness cannot be properly manufactured
Solution Approach 1:
The patent applies parameter changes by modifying the flow rate parameter of matrix material supply based on the thickness parameter of the fiber material. A thickness map or sensor data is used to adjust the flow rate parameter dynamically, allowing the same vacuum infusion process to handle components with varying thickness while maintaining consistent impregnation quality.
Solution Approach 2:
The patent implements feedback by using thickness information (from mapping or sensing) to control the matrix material supply rate. The system continuously monitors or references the thickness distribution and adjusts the flow rate accordingly, creating a closed-loop control system that adapts to varying thickness conditions in real-time.
3Reliability
If resin accumulations and air pockets are prevented through uniform impregnation, then component durability improves, but the production process becomes more complex
Solution Approach 1:
The patent introduces an intermediary system (flow rate control mechanism based on thickness data) that mediates between the vacuum infusion process and the fiber material. This intermediary layer processes thickness information and translates it into appropriate flow rate commands, preventing resin accumulations and air pockets while managing the complexity through a structured control approach.
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 ensures uniform impregnation and enhanced durability and resilience of the fiber composite components by adapting the matrix material flow rates to the thickness variations, preventing resin accumulations and air pockets.
Implementation Method 1
The molding device with the semi-finished fiber product is then sealed, for example by means of a vacuum film, and placed under a vacuum or negative pressure. Liquid resin is fed in via hoses or channels, which flows into the mold under the effect of the vacuum
Data Source
Figure 1~3c
Figure 4a~5
AI summary
The invention relates to a method for manufacturing a composite fiber component, in particular a composite fiber component for a rotor blade of a wind turbine, comprising the following method steps: Introducing a fiber material (40) for the fiber composite component into a manufacturing mold (10); supplying a flowable matrix material for the fiber composite component via a longitudinally extending runner (20) of the manufacturing mold (10), using a vacuum infusion method, such that the fiber material (40) in the manufacturing mold (10) is soaked with matrix material exiting the runner (20), said matrix material running transversely to the longitudinal extension of the runner (20), a first region (42, 42', 42'') of the fiber material (40) being substantially soaked with matrix material from a first section (22, 22', 22'') of the runner (20) and a second region (42, 42', 42'') of the fiber material (40) being substantially soaked with matrix material from the second section (22, 22', 22'') of the runner (20); and setting a first matrix material flow rate for the first section (22, 22', 22'') of the runner (20) depending on a thickness of the fiber material (40) in the first region (42, 42', 42'') and setting a second matrix material flow rate for the second section (22, 22', 22'') of the runner (20) depending on a thickness of the fiber material (40) in the second region (42, 42', 42'').