Wind Turbine Blade Pre-Form Manufacturing With Integrated Adhesive Heating
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Solution Overview
Problem
The manufacturing of longer wind turbine blades is challenged by the need for more expensive infrastructure, longer production times, and increased complexity, which affects the production costs and return on investment, necessitating a more efficient method for pre-form parts fabrication.
Innovation Solution
A method involving the use of an adhesive that is heated by an electric current to locally stiffen mat-like components, allowing for point-wise fixation and integration of pre-form parts without the need for additional heating means, using mat-like components or additional heating means as actively heated layers to facilitate the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional heating methods are used to heat adhesive, then heating can be achieved, but additional heating means and complex infrastructure are required
Solution Approach 1:
The mat-like component serves dual purposes: it is both the structure being manufactured and the heating element. By applying electric current to the mat-like component itself, it generates heat to melt the adhesive without requiring separate heating infrastructure, thus simplifying the manufacturing process
Solution Approach 2:
The mat-like component performs multiple functions simultaneously: structural reinforcement, heating element, and adhesive carrier. This multi-functionality eliminates the need for dedicated heating means and reduces overall device complexity
2Productivity
If longer wind turbine blades are manufactured, then energy generation increases, but production time and costs increase
Solution Approach 1:
The blade is divided into smaller pre-form parts that can be manufactured independently using the simplified heating method. These pre-forms can be produced in parallel and then assembled, reducing total production time while enabling longer blade lengths
Solution Approach 2:
The mat-like component is pre-heated and the adhesive is pre-melted before assembly operations. This preliminary heating action eliminates the need for time-consuming on-site heating during blade assembly, accelerating production
3Ease of manufacture
If more heating means are used to heat adhesive, then adhesive heating is effective, but equipment complexity increases
Solution Approach 1:
The mat-like component generates its own heat through electrical resistance when current is applied, eliminating the need for external heating equipment. The component itself is the heat source for melting the adhesive
Solution Approach 2:
The heating function is merged with the structural component. The mat-like component that provides structural reinforcement also serves as the heating element, combining two functions into one element and reducing equipment complexity
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 reduces production costs and time by enabling efficient fabrication of pre-form parts with enhanced process flexibility and reduced equipment complexity, allowing for easier handling and integration into wind turbine blades.
Implementation Method 1
Heating the adhesive by providing an electric current to at least one actively heated layer
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
Method for manufacturing of a pre-form part (1) for a wind turbine blade comprising one or more components (2) and an adhesive (3), wherein the component (2) or at least one of the components (2) is a mat-like component (4, 5) comprising fibres, comprising the steps: - Arranging the adhesive (3) at one or more positions on the component (2) or arranging the components (2) in a stack (8), wherein the adhesive (3) is arranged at one or more positions between the components (2), and - Heating the adhesive (3) by providing an electric current to at least one actively heated layer (10), wherein the mat-like component (4) is used as actively heated layer (10) and/or wherein at least one additional mat-like heating means (9) provided and arranged on top of or below the component (2) or the stack (8) of components (2) is used as actively heated layer (10).