Wind Turbine Mold B-Surface Heating and Cooling via Fluid Channels
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Solution Overview
Problem
Conventional heating systems for wind turbine blade manufacturing are limited to heating the mold surface only, leading to inefficient and uncontrolled heating and cooling of the composite surface, especially in regions with varying thickness, resulting in slow cure processes and non-uniform temperature distribution.
Innovation Solution
Incorporating fluid channels into vacuum bags that overlay the composite part, allowing for direct heating and cooling on the manufactured surface, with controlled fluid circulation to manage temperature distribution and accelerate the cure process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional heating systems are used to heat the mold surface, then the heating process can be implemented, but the heating and cooling of the composite surface becomes inefficient and uncontrolled, resulting in slow cure processes and non-uniform temperature distribution
Solution Approach 1:
The heating/cooling system is segmented into multiple independent fluid channels distributed across the vacuum bag, allowing different regions of the composite part to be heated or cooled independently and simultaneously, achieving uniform temperature distribution and accelerating the cure process
Solution Approach 2:
A thermal fluid acts as an intermediary medium circulating through the fluid channels to transfer heat directly to the composite surface, enabling controlled and efficient heating/cooling that overcomes the limitations of conventional mold surface heating
2Ease of operation
If heating elements are disposed proximate the mold surfaces, then heating can be provided, but the heating and cooling control is limited and cannot directly manage the composite surface temperature
Solution Approach 1:
The vacuum bag with integrated fluid channels serves as an intermediary between the heating/cooling system and the composite part, enabling direct thermal contact and precise temperature control of the composite surface while maintaining uniform temperature distribution
Solution Approach 2:
The conventional mechanical heating elements proximate the mold surface are replaced with a fluid-based thermal transfer system integrated into the vacuum bag, providing superior temperature control and uniformity through direct thermal contact with the composite surface
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
The system provides active heating and cooling on the composite surface, ensuring uniform temperature distribution, reducing cure time, and improving manufacturing efficiency and quality by minimizing non-uniformity and glass transition temperature violations.
Implementation Method 1
circulating a thermal fluid through the first series of fluid channels and the second series of fluid channels
Implementation Method 2
circulating a thermal fluid through the first series of fluid channels and the second series of fluid channels
Implementation Method 3
a first vacuum bag disposed above the first turbine blade shell; and a second vacuum bag disposed above the second turbine blade shell
Data Source
Figure 1
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AI summary
Devices, systems, and methods of improving heat transfer between a composite wind turbine blade surface are provided to reduce cure time. The assembly includes molds having heating wires disposed proximate the mold surface for delivering heat to the composite blade during layup and/or resin cure. Additionally, the vacuum bag disposed on top of the composite part includes a plurality of fluid channels for distributing a thermal fluid (e.g. heated/cooled water, air or oil) across the composite surface (opposite the mold surface).