Dynamic Hardener Control for Wind Turbine Composite Infusion
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Solution Overview
Problem
Composite moulding processes for wind turbine components, such as VARTM, face challenges with long infusion and curing cycle times due to the viscosity changes of the resin mixture as it cures, leading to increased risks of leaks, defects, and decreased manufacturing throughput.
Innovation Solution
A method involving a mould with multiple zones, where a resin mixture with varying proportions of slower and faster hardeners is supplied to each zone based on monitored process parameters, allowing for real-time control of the hardener speed and resin mixture viscosity to optimize infusion and curing times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a resin mixture with a long cure time is used, then the resin mixture remains sufficiently fluid during infusion, but the infusion and curing cycle time increases
Solution Approach 1:
The patent applies dynamics by transitioning from a static hardener composition to a dynamic one. The resin mixture initially contains a first hardener that provides slow curing for complete infusion, then a second hardener is introduced to accelerate curing in later stages. This dynamic adjustment of hardener composition allows the system to adapt its curing speed to different process stages, resolving the contradiction between maintaining fluidity and reducing cycle time.
Solution Approach 2:
The patent changes the chemical composition parameter of the hardener mixture during the process. By switching from a first hardener (slow-acting) to a second hardener (fast-acting), the curing rate parameter is dynamically adjusted. This parameter change allows optimization of both infusion completeness and cycle time by matching the hardener reactivity to the specific stage of the molding process.
2Productivity
If the resin mixture cures faster, then the cycle time decreases, but the viscosity increases prematurely causing blockages and incomplete infusion
Solution Approach 1:
The system dynamically selects hardeners based on process stage. During the infusion phase, a first hardener with slower reactivity is used to maintain low viscosity and ensure complete resin penetration. After infusion completion, a second hardener with faster reactivity is introduced to accelerate curing and improve throughput. This dynamic switching prevents premature viscosity increase while maximizing productivity.
Solution Approach 2:
The patent applies preliminary action by first ensuring complete infusion with the slow-acting first hardener before introducing the fast-acting second hardener. This sequential approach ensures that the resin mixture remains fluid long enough to fully penetrate the fibrous material, then accelerates curing only after infusion is complete, avoiding blockages while improving cycle time.
3Device complexity
If a single hardener is used, then the process is simple, but the cycle time cannot be optimized for both complete infusion and rapid curing
Solution Approach 1:
The patent transitions from a static single-hardener system to a dynamic dual-hardener system. The control system monitors infusion progress and automatically switches between the first hardener (for complete infusion) and the second hardener (for rapid curing). This dynamic control optimizes manufacturing throughput while maintaining process simplicity through automation, resolving the contradiction between complexity and productivity.
Solution Approach 2:
The system uses feedback control to determine when to switch between hardeners. Sensors monitor the infusion process, and when infusion completion is detected, the control system automatically transitions from the first hardener to the second hardener. This feedback mechanism optimizes cycle time and throughput while keeping the operational complexity manageable through automated decision-making.
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 infusion and curing cycle times, minimizes the risk of defects, and increases manufacturing throughput by maintaining optimal resin mixture viscosity and flow throughout the process.
Implementation Method 1
The resin mixture typically comprises resin and a hardener, which chemically react to cure the resin mixture
Implementation Method 2
supplying the resin mixture to the layup during an infusion process
Data Source
AI summary
In a first aspect of the invention there is provided a method of making a wind turbine component, the method comprising supporting a layup (14) of fibrous reinforcing material in a mould (12); providing a supply of resin (16); providing a supply of hardener (20) comprising at least a first hardener (20a) and a second hardener (20b), the second hardener being faster than the first hardener; mixing resin with the first and/or second hardener to create a resin mixture (24); supplying the resin mixture (24) to the layup (14) during an infusion process; monitoring one or more process parameters of the infusion process; and controlling the speed of the hardener (20) by varying the relative proportions of the first and second hardeners (20a, 20b) in the resin mixture (24) during the course of the infusion process in dependence upon the one or more process parameters.