Wind Turbine Preform Mould Segmentation for Complex Geometries
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Solution Overview
Problem
The manufacturing of wind turbine blade preforms is costly and time-consuming, especially when producing preforms of various shapes and sizes, due to the complexity and expense of creating molds for different geometries.
Innovation Solution
A method using a combination of support elements with planar members and strips to create flexible and cost-effective preform molds, allowing for the production of preforms with complex geometries by arranging steel or composite strips on the support elements, which can be heated with a binding agent to form consolidated fibre arrangements for use in blade manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional molds for preforms of various shapes and sizes are manufactured, then preforms with complex geometries can be produced, but the manufacturing process becomes tedious and costly
Solution Approach 1:
The mold is divided into multiple separate components: a first mold part with a first cavity and a second mold part with a second cavity. These separate parts can be manufactured independently using standard molding techniques and then assembled together to form the complete preform mold with complex geometries, thereby reducing the complexity of manufacturing each individual mold component.
Solution Approach 2:
The mold components are designed to be reusable and adaptable. The first and second mold parts can be used to produce different preform shapes and sizes by adjusting the positioning and configuration of the cavities, making the mold system versatile for manufacturing various preform geometries without requiring completely different molds for each product.
2Adaptability or versatility
If multiple preforms of different shapes and sizes are manufactured, then various blade requirements can be met, but production time and manufacturing costs increase
Solution Approach 1:
The mold is pre-assembled with all necessary cavities and tooling components in the correct positions before production begins. This preliminary configuration allows for rapid production of multiple preforms with different geometries without requiring time-consuming adjustments or reconfigurations during the manufacturing process, thereby improving productivity.
Solution Approach 2:
Multiple preform production capabilities are merged into a single mold system by combining the first and second mold parts with their respective cavities in one assembly. This allows for the simultaneous or sequential production of different preform types in a single manufacturing cycle, reducing overall production time and improving efficiency.
3Reliability
If preforms are preconsolidated to reduce repairs, then blade quality improves, but the consolidation process becomes more complex and time-consuming
Solution Approach 1:
The mold design incorporates self-aligning features and pre-configured cavity positions that automatically ensure proper positioning and consolidation of preform layers during the molding process. This self-service approach eliminates the need for complex external consolidation equipment or procedures, achieving preconsolidation through the mold structure itself while maintaining simplicity.
Data Source
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AI summary
The present invention relates to a method of manufacturing a preform for a wind turbine blade and to a preform mould. The method involves providing a plurality of support elements (70), each support element (70) comprising a planar member (72), arranging a plurality of strips (88) on the top surface (78) of the planar member (72) of each support element (70), wherein the strips (88) are arranged in juxtaposition. Subsequently, a fibre material and a binding agent may be laid on at least part of the strips (88) for forming the preform.