Wind Turbine Blade Flatback Assembly Alignment
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Solution Overview
Problem
The challenge in manufacturing wind turbine blades with a flatback profile is the complexity of assembling webs within the structure, particularly aligning inner webs and the flatback web with the shell parts without misalignment, which complicates bonding and increases production time.
Innovation Solution
A method involving a flatback assembly where the flatback profile component is connected with at least one shear web using distance elements like bolts, allowing for precise alignment and simultaneous bonding with the shell parts, facilitating faster and less complex assembly by lifting the assembly into a mould for bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If webs and flatback profile component are assembled separately and then bonded to shell parts, then bonding can be performed in multiple steps, but assembly complexity increases and alignment accuracy decreases
Solution Approach 1:
The patent combines the flatback profile component with the web structure into a single integrated assembly that is bonded to the shell parts simultaneously. This merging eliminates the need for separate bonding operations, reduces alignment complexity, and ensures high precision because all components are positioned and bonded together in one operation rather than being assembled and bonded separately in multiple steps.
2Productivity
If multiple separate components are bonded in multiple steps, then each component can be precisely positioned, but production time increases
Solution Approach 1:
The flatback profile component is pre-assembled with the web structure before being bonded to the shell parts. This preliminary assembly action allows the components to be prepared and positioned in advance, and then the entire assembly is bonded in a single operation, significantly reducing the total production time compared to bonding each component separately in multiple sequential steps.
3Reliability
If inner webs and flatback web are bonded separately to shell parts, then bonding control can be maintained, but the risk of misalignment increases
Solution Approach 1:
The patent merges the bonding operations for inner webs and flatback web into a single simultaneous bonding process. The entire assembly including all webs and the flatback profile component is bonded to the shell parts in one operation, which eliminates the risk of misalignment between separate bonding steps while maintaining full control over the bonding process through a single controlled 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
This method simplifies the manufacturing process, ensures high accuracy in component alignment, reduces production time, and lowers tooling costs by allowing the entire assembly to be bonded in fewer steps, resulting in an economically improved production of wind turbine blades with enhanced aerodynamic properties.
Implementation Method 1
an upwind side shell part and a downwind side shell part are assembled and bonded with an adhesive
Data Source
AI summary
Disclosed is a wind turbine blade and a method for its manufacture. A lower shell part and an upper shell part are provided, each shell part having a leading edge end and a trailing edge end. A flatback profile component and web for connecting an inner surface of the lower side shell part with an inner surface of the upper side shell part are connected. The assembly which comprises the flatback profile component and the at least one web are placed on the lower shell part and the upper shell part is mounted. The wind turbine blade comprises a flatback profile component being arranged at the trailing edge, wherein the flatback profile component is coupled by at least one distance holder with at least one web, wherein the web couples the interior surface of the upwind side shell part with the interior surface of the downwind side shell part.