Wind Blade Bonding Fixture for Uniform Flatback Insert Assembly
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Solution Overview
Problem
The existing methods for assembling wind turbine blade components, particularly flatback inserts, face challenges such as uneven force application leading to paste voids and inefficiencies in manufacturing, which affect the structural integrity and aerodynamic performance of large commercial wind turbines.
Innovation Solution
A system comprising a fixture with interconnected struts, arms, legs, and actuators that precisely positions and applies consistent force to flatback inserts within a mold, ensuring even bonding and reducing manual handling, thereby enhancing the assembly process and structural integrity of wind turbine blades.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual force is used to lift and push flatback components against the bond surface, then assembly simplicity is maintained, but force uniformity deteriorates resulting in paste voids
Solution Approach 1:
A fixture system acts as an intermediary between the operator and the flatback component. The fixture includes a support structure that holds the component and an actuator that applies force through a guide mechanism, mediating the force application to ensure uniformity while maintaining ease of operation through automated control
Solution Approach 2:
The manual mechanical pushing action is replaced with an automated actuator system. The actuator, controlled by a controller, substitutes human manual force application with a mechanical system that can precisely control force magnitude and distribution, eliminating paste voids while maintaining operational simplicity
2Reliability
If larger actuators are used to apply sufficient bonding force, then bonding reliability improves, but device complexity increases
Solution Approach 1:
The actuator system is segmented into multiple components: an actuator that generates force, a guide mechanism that directs the force, and a fixture structure that supports the operation. This segmentation allows each component to be optimized independently, maintaining bonding reliability while managing overall device complexity through modular design
Solution Approach 2:
The fixture system is designed with multi-functionality to reduce overall complexity. The support structure serves multiple purposes: holding the flatback component, providing a reference frame for the actuator, and guiding the force application. This universal design consolidates multiple functions into a single integrated system rather than requiring separate components for each function
Data Source
AI summary
The disclosed subject matter provides a system and method for facilitating bonding of various turbine blade components, including trailing edge inserts, or flatbacks, to the trailing edge of a wind turbine blade. The system disclosed herein ensures a consistent force is applied from root to top thereby preventing defects, e.g. paste voids, from forming. Additionally, a consistent bonding gap can be achieved due to the consistent application of force from the root to tip of the blade.