Wind Turbine Blade Root Manufacturing via Integrated Molding
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Solution Overview
Problem
The manufacturing of wind turbine blade root-end sections is challenging due to high loads and forces during operation, requiring multiple pre-cast segments that increase cycle time and mold usage, leading to inefficiencies and operational risks.
Innovation Solution
A method involving fabric material cutting, consolidation, resin injection, and curing, using automated tools to reduce cycle time and mold requirements, enabling efficient and high-quality production of wind turbine blade components with improved ergonomics and reduced operational risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple pre-cast blade-root segments are manufactured separately using open molding processes, then the mechanical stability of the root-end portion is ensured, but the cycle time increases and the number of molds required increases to six to twelve
Solution Approach 1:
The patent combines multiple separate blade-root segments into a single integrated root structure that is manufactured as one piece using a single mold. This merging eliminates the need to produce and assemble six to twelve separate segments, thereby reducing the number of molds required and shortening the overall cycle time while maintaining the necessary mechanical stability through the unified structural design
Solution Approach 2:
The patent applies segmentation in reverse by designing the root structure to be manufactured as a single integrated component rather than dividing it into multiple segments. This approach eliminates the assembly process and reduces the number of molds needed, directly addressing the productivity issue while ensuring structural integrity through continuous material flow throughout the root structure
2Quantity of substance
If six to twelve molds are used in parallel to produce blade-root segments daily, then the required quantity of segments is met, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent designs a universal single mold that can produce complete blade roots with integrated segmentation features. This multi-functional mold replaces the need for multiple specialized molds, reducing device complexity while maintaining the capability to produce the required quantity of root segments through optimized molding cycles and design
3Strength
If multiple separate casting processes are used for blade-root segments, then the required mechanical properties are achieved, but the manufacturing precision and quality consistency decrease due to assembly variations
Solution Approach 1:
The patent merges the manufacturing process into a single casting operation that produces the complete blade root as one piece. This eliminates assembly variations and joining interfaces that could compromise quality consistency, while the integrated design ensures uniform material properties and consistent mechanical performance throughout the root structure
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 significantly reduces the number of molds needed, increases output, and lowers costs by streamlining the manufacturing process, enhancing repeatability and safety while facilitating digital integration and modular production.
Implementation Method 1
at least one binding agent is arranged in and/or in between the stacked fabric sheets... Consolidating the stack of fabric sheets, wherein the stack of consolidated fabric sheets forms a preform part
Implementation Method 2
Injecting resin into the preform part... Curing the resin
Data Source
AI summary
A method for manufacturing of a wind turbine blade component is provided, including the steps: providing a fabric material and at least one binding agent, cutting the fabric material into a plurality of fabric sheets using a fabric cutting tool and arranging at least one stack of the cut fabric sheets on at least one preform mold tool, wherein the binding agent is arranged in and/or in between the stacked fabric sheets, consolidating the stack of fabric sheets, wherein the stack of consolidated fabric sheets forms a preform part, arranging at least one preform part inside a resin injection mold tool, injecting resin into the preform part, curing the resin, arranging the cured part on a holding means, and treating the cured part using at least one treatment tool for forming the wind turbine blade component.