3D Reinforcement Grid for Wind Turbine Blade Panels
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Solution Overview
Problem
Conventional wind turbine rotor blade manufacturing methods are labor-intensive, costly, and inefficient, with high labor costs, slow throughput, and low utilization of expensive mold tooling, and they struggle to customize structural properties like stiffness and buckling resistance effectively.
Innovation Solution
The method involves using a CNC device to print and deposit a 3-D reinforcement grid structure onto the inner surface of fiber-reinforced outer skins within a mold before they cool, allowing for customized reinforcement and bonding without the need for additional adhesives, enabling optimized buckling load factors and reduced tooling costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional molding processes with stacked fiber fabrics and resin infusion are used, then structural reinforcement is achieved, but labor costs increase and throughput decreases
Solution Approach 1:
The patent replaces manual stacking and resin infusion processes with automated 3D printing technology. The CNC-controlled 3D printer deposits reinforcement material layer by layer to form the grid structure directly within the mold, eliminating the need for manual labor and traditional resin infusion while maintaining structural reinforcement.
Solution Approach 2:
The invention changes the state of the reinforcement material from pre-cut fabric layers requiring manual assembly to a 3D-printable material that can be automatically deposited. The material is deposited in a semi-solid or viscous state that allows for automated extrusion and immediate bonding, transforming the manufacturing parameters to enable automation.
2Strength
If conventional molding processes with multiple layers and resin infusion are used, then structural reinforcement is achieved, but manufacturing time increases
Solution Approach 1:
The 3D printer deposits reinforcement material directly into the final grid structure configuration without requiring preliminary cutting, stacking, or alignment of fabric layers. The material is deposited in its final position and orientation, eliminating preparatory steps and reducing manufacturing time.
Solution Approach 2:
The 3D printing process operates continuously, depositing reinforcement material layer by layer without interruption. The material is deposited and bonds immediately, eliminating the downtime associated with manual assembly and resin infusion cycles, thereby reducing total manufacturing time.
3Manufacturing precision
If expensive mold tooling is used for conventional manufacturing, then precision molding is achieved, but tooling utilization decreases
Solution Approach 1:
The mold design is adapted to serve multiple functions: it provides the forming cavity for the outer skin, contains the 3D printing process, and facilitates the bonding of the printed grid structure. This multi-functional mold increases utilization by eliminating the need for separate tooling for different manufacturing steps.
Solution Approach 2:
The invention merges the molding process with the reinforcement deposition process. The 3D printing occurs within the same mold cavity used for forming the outer skin, combining two previously separate operations into one integrated process, thereby increasing tooling utilization.
4Strength
If adhesive bonding is used to attach reinforcement structures, then structural integrity is achieved, but additional curing time is required
Solution Approach 1:
The 3D-printed reinforcement structure bonds to the outer skin through self-adhesion as the material is deposited. The deposited material inherently adheres to the mold and outer skin surface without requiring separate adhesive application or curing steps, as the printing process itself provides the bonding mechanism.
Solution Approach 2:
The invention uses composite material properties where the 3D-printed reinforcement material contains bonding agents or adhesion-promoting characteristics embedded within the material itself. This allows the reinforcement to bond directly to the outer skin as part of the deposition process, eliminating the need for separate adhesive layers and curing time.
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 approach enhances the stiffness and buckling resistance of rotor blades, reduces manufacturing costs, and allows for faster production with higher tooling utilization, while eliminating the need for adhesives and curing time, resulting in more efficient and customizable wind turbine blades.
Implementation Method 1
printing and depositing, via the CNC device, a plurality of rib members that form at least one three-dimensional (3-D) reinforcement grid structure
Implementation Method 2
the grid structure bonds to the fiber-reinforced outer skin(s) as the structure is deposited
Data Source
AI summary
A method for manufacturing a rotor blade panel of a wind turbine includes placing a mold of the rotor blade panel relative to a computer numeric control (CNC) device. The method also includes forming one or more fiber-reinforced outer skins in the mold. The method also includes printing and depositing, via the CNC device, printing and depositing, via the CNC device, a plurality of rib members that intersect to form at least one three-dimensional (3-D) reinforcement grid structure onto an inner surface of the one or more fiber-reinforced outer skins before the one or more fiber-reinforced outer skins have cooled from forming. Further, the grid structure bonds to the fiber-reinforced outer skin(s) as the structure is deposited. In addition, the plurality of rib members include, at least, a first rib member extending in a first direction and a second rib member extending in a different, second direction. Moreover, the first rib member has a varying height along a length thereof.