Wind Blade Monolithic Structure via Single Infusion
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Solution Overview
Problem
Current wind turbine blade manufacturing processes are complex, time-consuming, and prone to errors, resulting in high costs and structural weaknesses due to the use of multiple components glued together, which can lead to stress-related issues and waste generation.
Innovation Solution
A method involving the use of a single infusion process with composite materials, where fibre sheets and core elements are integrated within a hollow structure to form a single, integral piece without gluing, using reusable moulds to produce a wind blade with enhanced strength and reduced weight, while minimizing waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple components are glued together to form the support frame, then the structural resistance to stresses is improved, but the manufacturing complexity and production time increase
Solution Approach 1:
The patent merges multiple separate components (slabs and webs) into a single monolithic support frame structure. Instead of manufacturing separate slabs and webs that require gluing, the invention uses a single mould to create an integrated support frame with the same structural functionality, eliminating the need for assembly operations and reducing manufacturing complexity.
Solution Approach 2:
The invention segments the manufacturing process by using a single mould that can produce the entire support frame in one operation. The mould is designed with specific features (such as removable cores) that allow the complex monolithic structure to be manufactured through a simplified, segmented production approach rather than assembling multiple components.
2Strength
If multiple components are glued together to form the support frame, then the structural resistance to stresses is improved, but the production time increases
Solution Approach 1:
The patent applies preliminary action by pre-forming the entire support frame structure in a single moulding operation. The mould is designed with predetermined geometric features and removable cores that allow the complex monolithic structure to be created in one step, eliminating subsequent assembly operations and reducing total production time.
Solution Approach 2:
The invention combines multiple manufacturing operations into a single moulding process. By integrating the production of what would otherwise be separate slabs and webs into one monolithic structure created in a single operation, the total production time is significantly reduced while maintaining structural integrity.
3Strength
If multiple components are glued together to form the support frame, then the structural resistance to stresses is improved, but the risk of manufacturing defects increases
Solution Approach 1:
The patent eliminates the gluing process by merging separate components into a single monolithic support frame. This integration removes the interface between components where bonding defects could occur, thereby improving manufacturing reliability and structural consistency throughout the entire support frame.
4Strength
If numerous components and gluing steps are used, then the structural resistance is improved, but the manufacturing cost increases
Solution Approach 1:
The invention reduces manufacturing cost by merging multiple components into a single monolithic structure produced in one operation. This eliminates the need for purchasing, storing, and applying adhesives, as well as reducing labor costs associated with assembly operations, while maintaining the structural resistance through the integrated design.
Solution Approach 2:
The patent extracts the gluing process from the manufacturing sequence by creating a monolithic structure that requires no adhesive bonding. This removal of the gluing step eliminates associated costs including adhesive materials, application equipment, and quality inspection of bonded joints.
5Productivity
If a single infusion process with integrated fibre sheets and core elements is used, then the production time and costs are reduced, but the manufacturing precision requirements increase
Solution Approach 1:
The patent applies preliminary action by designing the mould with pre-configured geometric features, including removable cores and precise cavity dimensions, that accommodate the single infusion process. This preliminary preparation of the mould ensures that the integrated structure can be manufactured with high precision in one operation, meeting the increased precision requirements through proactive mould design.
Data Source
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AI summary
A method for manufacturing a blade of a wind turbine, wherein the blade (1) extends along a given axis (A) and is made of a composite material comprising filaments arranged according to at least two directions, in particular fibre of a material; the method comprising the steps of: laying on a first mould (100) a plurality of sheets (101) of fibre of a material; laying second moulds (102), preferably stiff, above the plurality of sheets (101) of a fibre material previously laid down; laying on the second moulds (102) sheets (101) of a fibre material; laying a third mould (130) on the first mould (100) to create at least one closed volume (200) between the first mould (100) and the third mould (130) inside of which the plurality of sheets (101) of fibre laid down and the second moulds (102) are housed; the method comprising the step of injecting fluid material, preferably liquid, comprising resin to impregnate the plurality of sheets (101) of fibre material; removing the first (100) and third moulds (130) from the outside of the blade (1) thus formed, and removing the second moulds (102) from the inside of the blade (1) through a cavity of the blade (100).