Variable Moulding Surface for Wind Turbine Blade Preforms

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Solution Overview

Problem

The manufacturing of wind turbine blade preforms is complex and costly due to the need for various shapes and sizes, requiring significant floor space and multiple moulding techniques, which limits efficiency and flexibility.

Innovation Solution

A method using a preform mould structure with a variable moulding surface and actuators to change the shape, allowing the same mould structure to produce preforms of different shapes, such as concave and convex configurations, for both upwind and downwind blade halves, reducing the need for multiple moulds and space.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple preforms of different shapes and sizes are manufactured using separate moulds, then the required variety of preform shapes is achieved, but the complexity and cost of manufacturing increases and significant floor space is required

Engineering Contradiction:

Improvevariety of preform shapesVSAvoidnumber of moulds required

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent applies universality by designing a single preform mould that can produce multiple different preform shapes (concave, convex, and flat) through programmable control of the robotic arm. The mould structure includes a programmable positioning system that adjusts the position and orientation of the mould relative to the fibre reinforcement material, enabling one mould to perform the functions of multiple dedicated moulds, thereby reducing manufacturing complexity and space requirements

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent implements dynamics by introducing a programmable positioning system with a robotic arm that can dynamically adjust the mould's position and orientation during the manufacturing process. This dynamic adaptability allows the same mould structure to produce different preform shapes by changing its configuration through programmed movements, rather than requiring static, dedicated moulds for each shape

Inventive Principle:

Principle #15Dynamics

2Manufacturing precision

If multiple dedicated moulds are used for different preform shapes, then manufacturing precision for each shape is maintained, but the cost and floor space requirements increase significantly

Engineering Contradiction:

Improvepreform shape accuracyVSAvoidfloor space for moulds

Core Design Contradiction:

Manufacturing precisionVSArea of stationary object

Solution Approach 1:

The patent reduces floor space by consolidating multiple dedicated moulds into a single universal preform mould that can be programmatically reconfigured to produce different preform shapes. The programmable positioning system ensures that despite using one mould, the manufacturing precision for various shapes (concave, convex, flat) is maintained through controlled positioning and orientation adjustments

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of manufacture

If traditional moulding methods are used for each preform shape, then the manufacturing process is straightforward for each shape, but the overall manufacturing complexity and cost increase

Engineering Contradiction:

Improvesimplicity of moulding processVSAvoidnumber of moulding techniques required

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent reduces the number of required moulding techniques by using a single programmable positioning system that can accommodate different fibre reinforcement materials and adjust to various mould configurations. This universal approach maintains ease of manufacture for each shape while reducing the overall complexity of having multiple dedicated moulding setups

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent changes the parameters of the positioning system (position, orientation, configuration) to produce different preform shapes using the same basic moulding process. By programmatically adjusting these parameters, the system maintains process simplicity while achieving shape variety, avoiding the need for fundamentally different moulding techniques for each shape

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS11607826B2Method of manufacturing at least two preforms for moulding a wind turbine blade

Publication Date: 2023.03.21 LM WIND POWER INT TECH II APS

AI summary

The present invention relates to a method and a mould system (66) for manufacturing at least two preforms for moulding a wind turbine blade. The preforms include at least one preform of a first shape and at least one preform of a second shape. The preform mould structure (68) has a moulding surface (70) of variable shape such that the shape of the moulding surface (70) can be varied at least between a first and a second configuration by using actuators.