Wind Turbine Blade Flexible Trailing Edge Manufacturing
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Solution Overview
Problem
Existing wind turbine blades face challenges in reducing operational noise and securely attaching noise-reducing trailing edge devices, which require complex bonding techniques and additional manufacturing adjustments.
Innovation Solution
A method of manufacturing wind turbine blades where a portion of fibre layers is kept resin-free to form a flexible fibre portion projecting from the trailing edge, integrated into the blade structure during moulding, using vacuum-assisted resin transfer moulding to ensure secure anchoring and simplify the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If trailing edge devices (serrated panels, bristles, flexible rods) are attached to reduce operational noise, then noise reduction is improved, but device complexity and manufacturing difficulty increase due to required bonding techniques and loading force distribution
Solution Approach 1:
The patent merges the trailing edge noise-reducing device with the blade structure itself by forming both from the same fibre-reinforced resin composite in a single moulding process. The flexible trailing edge device and the rigid blade structure become an integrated unit, eliminating the need for separate attachment processes and bonding techniques.
Solution Approach 2:
The patent performs preliminary action by pre-positioning the fibre layers in the mould to form both the blade structure and the flexible trailing edge device before resin infusion. This allows the trailing edge device to be built into the blade during the initial manufacturing process rather than requiring post-manufacturing attachment.
2Object-affected harmful factors
If separate trailing edge devices are attached to the blade, then noise reduction is achieved, but manufacturing time increases due to post-moulding attachment operations
Solution Approach 1:
The patent combines the manufacturing of the blade structure and the trailing edge noise-reducing device into a single moulding operation. Both components are formed simultaneously from fibre layers and resin in the same mould, eliminating the need for separate post-moulding attachment operations and reducing total manufacturing time.
Solution Approach 2:
The trailing edge device is prepared and positioned in advance within the mould along with the blade structure fibres. This preliminary arrangement allows both components to be manufactured together in one process, avoiding time-consuming post-manufacturing attachment operations.
3Object-affected harmful factors
If separate trailing edge devices are attached to the blade, then noise reduction is achieved, but reliability decreases due to potential failure at bonding interfaces during turbine operation
Solution Approach 1:
The patent merges the trailing edge device and blade structure into a single integrated composite component manufactured in one moulding process. This integration eliminates bonding interfaces and potential attachment failure points, significantly improving reliability while maintaining the noise-reducing functionality of the flexible trailing edge device.
4Shape
If reinforced fibre strips are laminated into the trailing edge during assembly, then flexible trailing edge is formed, but manufacturing complexity increases due to process adjustments required
Solution Approach 1:
The patent combines the formation of the flexible trailing edge and the rigid blade structure into a single moulding process using the same fibre-reinforced resin composite material. This approach eliminates the need for separate lamination operations and process adjustments, simplifying manufacturing while achieving the desired flexible trailing edge shape.
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 reduces operational noise effectively and eliminates the need for post-moulding attachment of trailing edge devices, enhancing the durability and ease of manufacturing while maintaining the structural integrity of the blade.
Implementation Method 1
infusing said plurality of fibre layers with a resin
Implementation Method 2
curing said resin to form at least a portion of a fibre-composite blade structure
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A manufacturing method is described for a wind turbine blade (10), where layers of fibre material (72) are laid up in a mould to form a portion of the blade structure. The fibre layers are infused with a resin which is subsequently cured to form the hardened blade structure. Some of the layers of fibre material are arranged so that a portion (72a) of the layers are kept resin-free during the infusion and curing steps, so that the fibre layer extends freely out from the external surface of the blade, preferably at the blade trailing edge, to provide a flexible blade trailing edge (70b) to reduce blade operational noise.