Automated Production for Wind Turbines

The geometric structure design of three-layer hollow fan blades is extremely complex, which not only directly related to the blade quality and manufacturing cost but also has a significant impact on engine performance. Based algorithms combined with rules process constraints, an intelligent method for proposed: A new cross-section curve based non-equidistant offset presented enable rapid wall plate structure. An innovative parametric corrugation in cross-sections driven by constraints such as diffusion bonding angle thresholds put forward. spanwise rib smoothing optimization realized minimum energy change term. densification carried out improve accuracy wireframe achieve solid modeling blades. Finally, proposed methods are seamlessly integrated into NX software (version 12), system developed, enables automated complex under aerodynamic shape large number constraints.

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Digital 3D measurement of bondline thickness during wind turbine blade assembly using a 3D laser scanner to accurately determine the gaps between blade components where bonding paste is applied. This involves scanning the blade shell, shear webs, and mold flanges before and after paste application, aligning the scans, and measuring the bondline thickness. Retroreflective targets are used for registration and volume extension accelerates scanning large parts. This provides high precision component positioning to avoid quality issues from incorrect paste thickness.

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A lifting device for rotating and moving preform building elements used in wind turbine blade manufacturing. The lifting device is a yoke with pivoting attachment points that can rotate a building element between top and bottom attachment positions. This allows the preform to be flipped over without manual rotation, reducing damage. The yoke has multiple pivoting attachment devices mounted on a beam that can all be pivoted simultaneously by an actuator. The beam can be clamped onto the building element using a bracket that pivots underneath to secure it. This enables rotating and moving multiple preforms at once. The yoke can also have adjustable counterweights to keep the center of gravity constant during rotation.

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Method to manufacture wind turbine blades faster by tailoring the cure time of the resin during infusion based on process parameters. The method involves using two hardeners, one faster than the other, to create a resin mixture. The hardener speed is adjusted by varying the relative proportions of the fast and slow hardeners during infusion. This allows optimizing the cure time and open time of the resin as it infuses the blade layup. By speeding up the hardener as infusion progresses, the cure time and open time can be reduced compared to using just a single hardener. This enables faster infusion cycles with less risk of defects.

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Manufacturing wind turbine rotor blades with segmented upper molds that can be assembled around the lower mold without needing excessive overhead clearance. The rotor blade molds consist of a lower mold and a segmented upper mold. The segmented upper mold has a root end section and multiple airfoil sections. The root end section is placed next to an airfoil section, then slid into position at the root. The airfoil sections are then positioned. This allows the upper mold to be assembled around the lower mold without needing the entire height of the blade length. The segmented upper mold sections can be handled sideways for assembly/disassembly.

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A cost-effective and rapid method for forming large-diameter, thick-walled tubular structures like wind turbine towers using thinner material. The method involves winding thin strips of material around a curved base and joining them together in spirals. This allows forming thick-walled tubes without the need for expensive rolling and welding of thick steel plates. The spirally wound layers provide structural strength similar to solid-walled tubes while being faster and cheaper to manufacture.

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Method to manufacture large wind turbine blades with improved curing uniformity to reduce defects. The method involves impregnating the reinforcement preform with a curing promoter before placing it in the mold. This allows the promoter concentration to vary spatially in the preform, with lower amounts near the edges and higher in the center. This helps prevent overcure and shrinkage differences when curing thicker areas versus the edges. The promoter can be a curing accelerator like a transition metal salt.

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A method to manufacture wind turbine blades that improves alignment and bonding of shear webs between the inner shell surfaces. The method involves attaching the shear web to one shell half, then bringing the other half together while guiding the shear web over pairs of angled guide members on the inner surface of the second shell half. This prevents rotation and twisting during bonding. The guide members form a funnel shape that aligns the shear web as it's inserted into the other shell half. The guide members are removable spacers during assembly that are later removed. The guide members can be extruded or injection molded parts with hollow bodies and angled surfaces.

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A method to manufacture preforms for wind turbine blades that reduces wrinkles and improves quality compared to conventional methods. The preform layers are arranged in a stack with some layers made of a fabric treated with binding agent. The fabric has an alternating pattern of sections with untreated fiber and sections with fiber treated with binding agent. This allows the fabric to conform better to curved surfaces during heating and avoid wrinkling compared to using untreated fabric. The preform is then formed by heating the stack, transferred to the blade mold, and infused with resin.

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The presented manuscript is devoted to the consideration of design features elements power equipment, in particular rotor and its elements: spider varieties, rim poles rotor. analysis requirements for parameters depending on swing moment was carried out. situation failure turbine regulator directly during load shedding considered. operational characteristics hydraulic unit, which affect reliability operation, were also outlines materials used manufacture equipment. Such modern production technologies these as stamping laser cutting are considered detail. peculiarities assembly unit a whole outlined, well assembly, pressing wedging charged focused tension reduction.

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The blades of wind turbines constitute key components for converting energy into electrical energy, and modifications to blade airfoil geometry can effectively enhance aerodynamic performance turbine. trailing edge flap enables load control on the through adjustments its motion geometric parameters, thereby overcoming limitations inherent in conventional pitch systems. However, current research primarily emphasizes isolated parametric effects performance, with limited exploration interactions between multiple design variables. This study adopts a numerical simulation approach based FFA-W3-241 DTU 10 MW. Geometric deformations are achieved by manipulating influence is analyzed using computational fluid dynamics methods. Investigations conducted lengths deflection angles characteristics. results show existence an optimal length angle combination. Specifically, when 0.1c 10, lift-to-drag ratio demonstrates significant improvement under defined operational conditions. These findings offer practical guidance optimizing turbine designs.

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System and method for accurately identifying misaligned holes in components during manufacturing using tool force data. The method involves comparing the forces exerted by a tool as it drills into a component to form a hole with reference force data for aligned holes. If the forces differ, indicating deformation, it indicates the hole is out of tolerance. This allows detecting misaligned holes during drilling without manual inspection.

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Automated method and apparatus for forming a kink in a composite laminate during pick and place operations. The method involves using a specialized end effector on a robot or gantry to pick up the composite laminate, clamp portions on either side of the intended kink location, and bend the central vacuum plates to form the kink while the laminate is held in tension. This allows automated kinking of composite laminates without manual labor.

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Automated fiber placement assembly for forming composite components with improved fiber cutting capabilities during the fabrication process. The assembly has a movable cutter head that can change shape to allow customized fiber cutting profiles for complex component geometries. Multiple independent cutter heads can be used to simultaneously cut fibers in different shapes. This enables better fiber management around overhangs and other features compared to fixed cutter shapes.

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Automated method and apparatus for forming composite structures with bends and flanges using a mandrel and cutting technique to reduce wrinkling. The method involves bending a flat composite laminate over a mandrel with kinks in the web surface. The laminate is then placed into a forming assembly where overhanging sections are bent into contact with the mandrel sides to form the final composite structure with the desired bend and flanges. The key is using discontinuous zero degree plies near the kinks to mitigate tension during forming.

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A method and system to accurately place internal components like spar caps during wind turbine blade manufacturing. It uses retractable/extendable pins in the mold surface that can pierce through the layup segments. The pins have drivers to move them between retracted and extended positions. This provides precise geometric references for component placement during molding. The pins also prevent component movement during resin infusion. The pins can have rotational motion to reduce wrinkling during piercing. This improves blade quality and repeatability by ensuring proper component placement without impacting the structure.

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Using data analytics to improve composite manufacturing by optimizing process parameters like temperature, pressure, and cure time based on historical observations and machine learning. The method involves classifying localized inconsistencies on composite structures, identifying potential causes from process parameters, and modifying the geometry, layup, or parameters to address the causes. It leverages historical data from prior composites to optimize parameters for current composites.

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System for manufacturing large scale composite structures like wind turbine blades using molds that provide precise placement and assembly of internal components like spar caps. The molds have apertures for pins to extend into the molded layers. The pins engage the internal components during layup to hold them in place. After layup, the pins can extend beyond the molded section to be trimmed. This prevents internal component misalignment during mold closure. Additional features like studs, cams, and actuators enable further component positioning and measurement.

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A method for assembling wind turbine components to reduce assembly time and costs by allowing personnel to remain in the tower during lifts instead of evacuating and repositioning. The method involves lowering the component to overlap the mounting interface vertically with a threshold separation. If the separation exceeds the threshold, an indicator alerts. This ensures the component can be connected without needing to evacuate and reposition personnel between lifts. The indicator uses a transmitter/receiver to verify separation during overlapping.

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Molding method for wind turbine blade shells that eliminates the need for clamps on the molds during rotation and joining of the shell halves. The method involves using fastening elements attached to the mold flange to secure the shell during rotation. A measurement arrangement tracks displacement of the shell flange relative to the mold flange during rotation to monitor shell-mold alignment. This allows accurate joining of the shell halves without clamps.

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