Wind Turbine Blade Manufacture Using Interchangeable Tip Sections
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Solution Overview
Problem
The existing methods for manufacturing wind turbine blades are costly and inefficient, as they require multiple large moulds of different sizes to produce blades optimized for specific wind conditions, which is impractical due to the expense and space requirements.
Innovation Solution
A method involving a main blade mould assembly with interchangeable tip sections of varying lengths, allowing the same mould to produce blades of different overall lengths tailored to site-specific wind conditions, using a combination of laminate structures and adhesive bonding to ensure robust connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple large moulds of different sizes are used to produce blades of different lengths, then blades can be optimized for specific wind conditions, but tooling costs and factory space requirements increase significantly
Solution Approach 1:
The blade mould is divided into a main blade mould and interchangeable tip sections. The main blade mould remains constant while only the tip sections need to be changed to produce different blade lengths. This segmentation allows optimization for different wind conditions without requiring multiple complete moulds, significantly reducing tooling costs.
Solution Approach 2:
The main blade mould is designed to be universal and can produce different blade lengths by accepting various tip sections. This multi-functionality allows a single main mould to serve multiple purposes across different wind conditions, eliminating the need for multiple specialized moulds and reducing both tooling costs and factory space requirements.
2Adaptability or versatility
If multiple large moulds of different sizes are used to produce blades of different lengths, then blades can be optimized for specific wind conditions, but factory floor space occupation increases
Solution Approach 1:
By segmenting the mould system into a permanent main blade mould and interchangeable tip sections, the factory only needs space for one main mould rather than multiple complete moulds. The tip sections are small components that occupy minimal space, dramatically reducing the total factory floor space required while maintaining the ability to produce different blade lengths.
Solution Approach 2:
The universal main blade mould can produce various blade lengths by accepting different tip sections, meaning the factory needs only one large mould space rather than multiple large mould spaces. This multi-functionality directly reduces the factory floor space occupation while preserving adaptability to different wind conditions.
3Ease of manufacture
If a single mould is used to produce blades of different lengths, then tooling costs and space requirements are reduced, but the complexity of the manufacturing process increases
Solution Approach 1:
The tip sections are pre-manufactured to precise specifications before being attached to the main blade mould. This preliminary preparation ensures that when assembly is required, the components are ready to be precisely positioned and bonded, reducing the complexity and time of the actual assembly process while maintaining cost-effectiveness.
Solution Approach 2:
The tip sections act as intermediaries between the standard main blade mould and the requirement for different blade lengths. By introducing this intermediate component, the system achieves variability in blade length without requiring complex modifications to the main mould itself, simplifying the overall manufacturing process while maintaining adaptability.
4Productivity
If blades are manufactured with optimized lengths for specific sites, then annual energy production increases, but manufacturing flexibility decreases
Solution Approach 1:
The segmentation of the blade into main section and interchangeable tip sections maintains manufacturing flexibility by allowing quick changes between different tip lengths. This enables the production of blades optimized for different wind conditions at various sites, thereby increasing annual energy production while preserving the ability to adapt to different manufacturing requirements.
Solution Approach 2:
The universal main blade mould with interchangeable tips provides multi-functionality that supports both site-specific optimization and manufacturing flexibility. The same main mould can produce different blade lengths for different wind farm locations, ensuring each turbine is optimized for its specific conditions while maintaining a flexible, cost-effective manufacturing system.
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 enables cost-effective production of wind turbine blades optimized for specific sites, reducing tooling costs and factory space while maintaining structural integrity and efficiency.
Implementation Method 1
bonding the first and second half shells together and simultaneously bonding the inboard end of the tip section to the outboard ends of the first and second half shells
Data Source
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AI summary
Improvements relating to wind turbine blade manufacture A method of making wind turbine blades of variable length is described. The method involves forming first and second half shells of a main blade section in a main blade mould assembly. A pre-manufactured tip section is selected from a plurality of tip sections of different lengths according to a total length requirement for the wind turbine blade. The tip section is supported adjacent to the main blade mould assembly such that an inboard end of the tip section overlaps with an outboard end of one of the half shells of the main blade section. The main mould assembly is then closed to bond the two main half shells together and to bond the tip section to the main blade half shells. The invention allows blades of different overall length to be produced using a common main blade mould assembly.