Wind Blade Bonding Fixture for Uniform Force Application
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for assembling flatback components in wind turbine blades result in uneven force application, leading to paste voids and unreliable structural integrity due to manual handling.
Innovation Solution
A fixture system with interconnected struts, arms, legs, and actuators is used to precisely position and apply consistent force to the trailing edge of the blade, ensuring even bonding of flatback inserts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual force is used to lift and push the flatback component against the bond surface, then the assembly process is simple, but the force application is uneven resulting in paste voids and unreliable structural integrity
Solution Approach 1:
The patent introduces a fixture system with arms, legs, and actuators as an intermediary device between the operator and the flatback component. This mediator applies force uniformly across multiple points of the component, eliminating the uneven force application that occurs with direct manual handling while maintaining operational simplicity through the automated fixture system
Solution Approach 2:
The fixture system divides the force application into multiple discrete points through separate arms and legs that contact different locations on the flatback component. Each actuator independently controls force at its contact point, ensuring uniform distribution of force across the entire component rather than concentrated manual pressure at a single point
2Device complexity
If manual handling is used for flatback assembly, then the device complexity is low, but the reliability of bonding is poor due to paste voids
Solution Approach 1:
The fixture system serves as a reliable intermediary that ensures consistent and uniform force application during bonding. By mediating between the flatback component and the bonding process, it eliminates the variability and inconsistency of manual handling, thereby preventing paste voids and ensuring reliable bonding integrity without requiring excessively complex equipment
3Productivity
If larger rotor blade sizes are used to increase energy production, then the energy capture improves, but the structural integrity requirements become more stringent and difficult to maintain
Solution Approach 1:
The fixture system acts as a reliable intermediary during the assembly of flatback components in large rotor blades. By ensuring uniform force application and preventing bonding defects, it maintains high structural integrity standards even as blade sizes increase to achieve greater energy production, allowing the structural requirements to be met without compromising the integrity improvements needed for larger blades
Data Source
Figure 1
Figure 2
Figure 3
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.