Wind Turbine Blade Airflow Devices With 3D Printing
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Solution Overview
Problem
Conventional methods for integrating airflow modifying devices with complex aerodynamic profiles into wind turbine blades are complex, time-consuming, and costly, often compromising structural integrity and requiring specialized molds.
Innovation Solution
Manufacture airflow modifying devices with complex profiles using three-dimensional printing and machining, allowing for separate production and attachment to the wind turbine blade, eliminating the need for intricate lay-up processes and molds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional lay-up techniques are used to integrate airflow modifying devices with complex aerodynamic profiles, then the devices can be integrated into the wind turbine blade, but the manufacturing process becomes very complex and time-consuming
Solution Approach 1:
The patent uses a positive master tool to create a negative mould, which then forms the positive airflow modifying device. This copying process allows complex aerodynamic profiles to be reproduced accurately without requiring complex lay-up techniques. The master tool defines the precise geometry, and this geometry is copied through the moulding process to create the final device with complex profile.
Solution Approach 2:
The manufacturing process is segmented into distinct stages: creating a master tool, forming a negative mould from the master, and then using the negative mould to produce the final device. This segmentation allows each stage to be optimized independently, avoiding the need for complex integrated lay-up processes while maintaining the ability to produce devices with complex aerodynamic profiles.
2Productivity
If conventional lay-up techniques are used to integrate airflow modifying devices, then the devices can be manufactured, but the manufacturing time increases significantly
Solution Approach 1:
The negative mould is prepared in advance from a positive master tool before the actual device production. This preliminary action allows the complex geometry to be pre-defined in the mould, so that when production occurs, the complex profile is formed automatically during the moulding process rather than requiring time-consuming lay-up operations for each device.
Solution Approach 2:
The master tool serves as a template that copies its geometry into the negative mould, which then copies it again into the final device. This multi-stage copying process efficiently reproduces complex aerodynamic profiles without requiring repeated manual lay-up operations, significantly reducing manufacturing time while maintaining geometric fidelity.
3Adaptability or versatility
If recesses are formed by removing material from the finished outer surface, then the airflow modifying devices can be placed in the recesses, but the structural integrity of the blade shell is reduced
Solution Approach 1:
The recesses are formed during the blade shell manufacturing process itself, before the outer surface is finished. By preparing the recesses in advance during the lay-up and curing stages, the blade shell structure can be designed to accommodate the devices from the outset, maintaining structural integrity while providing the necessary adaptability for device installation.
4Manufacturing precision
If templates are used to form recesses, then the airflow modifying devices can be placed in the recesses, but the placement requires high precision and adds extra manufacturing steps
Solution Approach 1:
The template function is merged into the negative mould itself. The negative mould incorporates the precise geometry and positioning features that would otherwise require a separate template. This merging eliminates the need for separate template placement steps while maintaining high manufacturing precision, as the mould directly defines both the recess shape and the device positioning during a single moulding operation.
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
Facilitates a cost-effective and efficient method for producing devices with advanced aerodynamic profiles, reducing manufacturing time and maintaining structural integrity while enhancing airflow performance.
Implementation Method 1
said device is manufactured by three-dimensional printing and/or by three-dimensional machining of a base element of said device
Implementation Method 2
said at least one layer of fibre material is infused or injected with a thermoplastic binder or a thermoset resin
Implementation Method 3
said at least one layer of fibre material is infused or injected with a thermoplastic binder or a thermoset resin, wherein said at least one device comprises a first sub-device (19a) and a second sub-device (19b)
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
This invention relates to a method and a wind turbine blade, wherein one or more air-flow modifying devices are attached to a wind turbine blade having a base aerodynamic profile. The base aerodynamic profile is configured to substantially carry the structural loading of this modified wind turbine blade. The airflow modifying device is manufactured via 3D-printing and/or via 3D-machining and optionally coated or laminated before attachment. Once attached, the airflow modifying device may further be coated or laminated before working the outer surfaces into their finished shape.