Lightweight Wind Turbine Construction

Automated manufacturing method for wind turbine towers using additive printing to build the tower layer by layer, with integrated reinforcement. The method involves using a movable frame assembly with platforms that are raised vertically. As the platforms move, reinforcement bars are dispensed automatically from a separate assembly under tension. Then, cementitious material is printed onto the platforms to embed the bars. This allows continuous reinforcement as the tower grows. The printed layers are repeated to build the tower. The additive printing assembly has multiple printer heads for outer/inner walls and filler material.

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A wind turbine blade with a shear web that has improved strength-to-weight properties and load distribution compared to traditional blade designs. The shear web uses an open lattice structure made by 3D printing instead of solid materials. This allows customization based on load conditions and reduces weight. The lattice structure connects the flanges of the shear web to the blade spar caps. It provides better load distribution since the lattice spindles intersect at nodes instead of just at the flange edges. This reduces peak stresses and allows a more detailed design for specific loads. The 3D printing method also enables nested connection of blade sections for assembly.

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Abstract This study explores the development and optimization of polymer composite-based wind turbine blades, integrating glass fiber reinforced plastic (GFRP) with shape memory alloy (SMA) to enhance performance in energy harvesting. Advances materials science, aerodynamics, computational modelling, structural analysis have been leveraged improve blade efficiency, durability, self-adaptive capabilities. The research employs finite element (FEA) artificial neural networks (ANN) evaluate mechanical behaviour composite blades under varying loads. A graded beam model was developed assess effects ply drop-off material distribution on integrity. Experimental validation confirmed that SMA integration enhances deformation recovery, mitigating stress accumulation improving aerodynamic stability. results demonstrate GFRP-SMA achieve a coefficient approaching Betz limit (0.5923), reducing deflections load response. Despite these advancements, challenges remain optimizing wire placement, adhesion, actuation efficiency. Future work should focus refining interfaces, developing adaptive control me... Read More

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To bridge the mechanical performance gap between polyethylene terephthalate (PET) foam cores and balsa wood in wind turbine blades, this study proposes a hierarchical groove-perforation design for structural optimization. A finite element model integrating PET epoxy resin was developed validated against experimental shear modulus data ( < 0.5%). Machine learning combined with multi-island genetic algorithm (MIGA) optimized groove parameters (spacing: 7.5-30 mm, width: 0.9-2 depth: 0-23.5 perforation angle: 45-90) under constant infusion. The optimal configuration (width: 1 spacing: 15 65) increased by 9.2% (from 125 MPa to 137.1 MPa) enhanced compressive/tensile 10.7% compared conventional designs, without increasing core mass. Stress distribution analysis demonstrated that secondary grooves improved infiltration uniformity interfacial stress transfer, reducing localized strain concentration. Further integration of machine MIGA parameter optimization enabled reach 150 while minimizing weight gain, achieving balance material efficiency. This strategy offers cost-effective lightw... Read More

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Wind turbine component design for towers and blades that allows prefabrication, easier transportation, and faster assembly compared to traditional towers. The component has a wall element with a corrugated structural element attached to it. The corrugated shape reduces weight and allows compression during transportation. The component segments can be prefabricated and connected together at the tower or blade site. This allows preassembly of larger sections offsite, simplifies transportation, and speeds up installation compared to traditional tower assembly. The corrugated shape also provides strength and stiffness.

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Fiber reinforcement fabric for wind turbine components like blades and spar caps that allows easier and more efficient impregnation of resin during manufacturing. The fabric has tapered edges where the thickness gradually reduces towards the edge. This eliminates dry spots and air pockets by providing a smooth transition of resin fill as the fabric conforms to the tapered mold shapes. The fabric also enables easier layup of tapered fiber layers for components like spar caps by stitching together layers with terminated edges instead of manually arranging terminated plies.

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Floating wind turbine foundation design that reduces manufacturing cost while meeting anti-typhoon requirements. The floating foundation has a main body with an enclosed compartment. During normal conditions, the compartment is filled with water. During typhoons, the water level in the compartment is lowered to provide extra buoyancy to counteract the increased wind loads on the turbine. This allows using a lighter, less expensive foundation compared to traditional hardened foundations for anti-typhoon resistance.

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A system and method for recycling wind turbine blades into usable materials. The system involves scalping, shattering, breaking, screening, and grinding the shredded blade pieces to produce progressively finer fibers and strands. This allows recycling the fiberglass composite into reinforcement fibers and micro-fibers that can be used in new composites. The process stages include scalping off balsa wood, shattering the chips, breaking the fiber clusters, screening the strands, and grinding to micro-fiber size.

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Additive manufacturing (3D printing) technique for reinforcing large-scale structures like wind turbine towers using coiled polymer reinforcement members instead of conventional steel rings. The method involves printing the tower structure layers, unwinding continuous rolls of pultruded polymer reinforcement material into coils, placing the coils on the printed layers, and then printing more layers on top. This allows reinforcing the structure with lightweight, corrosion-resistant polymer instead of heavy steel rings. The coiled polymer members are wound and secured using fixtures to maintain shape during printing.

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Wind turbine blade made from environmentally-friendly material obtained from date palm trees. The blades are manufactured using natural material from date palm trees as an alternative to traditional blade materials. This reduces waste and environmental impact compared to conventional blades that are non-recyclable at the end of their life. The method involves extracting the date palm material and processing it into the blade structure.

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3D printed mold tool for making composite ducts that avoids the hazards and disadvantages of traditional eutectic salt methods. The tool has a sparse infill structure that allows fluid to flow through it. The tool is made of multiple 3D printed parts that assemble into a mold. Fluid is introduced into the sparse infill areas. This fluid permeates through the mold to partially cure a sacrificial fill material. The cured sacrificial mold is then used as a mandrel to shape the composite ducts. The 3D printed mold tool eliminates the need for destructive removal of salt molds and provides a lighter, faster, and safer alternative.

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Carbon fiber-reinforced polyetheretherketone (CF/PEEK) composite offer lightweight, high strength and toughness by combining benefits of resin fiber materials. However, current shaping methods face challenges such as forming difficulties, inconsistent shapes, significant mechanical damage. Herein, a CF/PEEK thermoforming device were designed. Thermoforming employs two heating molds (crimping mold at 310C roll pipe 400C) coiling roller operating 45 rpm to enable automatic efficient continuous production pipes with diameters ranging from 3 5 mm. High-strength retain excellent thermal stability during shaping, commendable properties-tensile 1467 N (decrease 8.8 %) specific stiffness 1.61 10 6 Nm/kg, 35-fold increase. Furthermore, stronger braided winding points introduced into hollow truss enhance their strengths, radial compression node-reinforced structure is 550 (improved 151 % compared that single pipe). This truss, its ultra-lightweight tensile/compressive strength, significantly expands application potential

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Lightweight, high-strength covered foam for applications like wind turbine blades, boats, cars, and buildings that use a renewable and sustainable material for the foam core. The foam is made from a copolymer containing ethylene furanoate and ethylene terephthalate units. It uses blowing agents like HFO-1234ze(E) to expand the polymer into a foam. The foam is covered with a separate material to provide strength and protection. This allows using a lighter foam for weight savings while maintaining strength in critical areas. The foam can be extruded into shapes like wind turbine blade cores, boat hulls, car underbody panels, or building insulation.

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Lightweight, high-strength closed-cell foam made from renewable and sustainable materials like polyethylene furanoate (PEF) that can be used in applications like wind turbine blades, sports equipment, transportation, and construction. The foam is extruded from a composition containing PEF polymers, tannins, and a select group of blowing agents. The foam has low density and good mechanical properties like strength and stiffness. The PEF cells contain a mixture of ethylene furanoate and ethylene terephthalate moieties. The foam can be face-sheeted with other materials for applications like wind turbine blades, or used as a standalone foam article.

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Lightweight, high-strength covered foam used in applications like transportation devices, building structures, and wind turbine blades. The foam has closed cell structure made from a polyethylene furanoate copolymer containing furanoate moieties. The foam is covered with a facing material like glass fiber reinforced polymer. The furanoate polymer provides strength and low density, while the covering provides additional strength. The blowing agent used is hydrofluoroolefin (HFO).

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This review investigates interlayer hybrid fiber composites for wind turbine blades (WTBs), focusing on their potential to enhance blade damage tolerance and maintain structural integrity. The objectives of this are: (I) assess the effect different lay-up configurations failure analysis (II) identify combinations WTBs supplement or replace existing glass fibers. Our method involves comprehensive qualitative quantitative analyses literature. Qualitatively, we tolerance-with an emphasis impact load-and under operational load six distinct configurations. Quantitatively, compare tensile flexural properties-essential integrity-of composites. reveals that placing high elongation (HE)-low stiffness (LS) fibers, e.g., glass, impacted side reduces size improves residual properties Placing low (LE)-high (HS) carbon, in middle layers, protects them during equips with mechanisms delay various conditions. A sandwich HE-LS fibers outermost LE-HS innermost layers provides best balance between integrity post-impact properties. benefits from synergistic effects, including bridging, enhanced buckling ... Read More

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ABSTRACT Carbon fiberreinforced polymer composites (CFRPs) are extensively employed in engineering applications owing to their exceptional strengthtoweight ratio and outstanding fatigue resistance. Nevertheless, when utilized critical components such as aircraft wings, wind turbine blades, structural elements, performance durability frequently degraded by harsh environmental conditions. To address these challenges, thermoplastic polyurethane (TPU) nonwoven fabric was introduced an interlayer carbon fiber/epoxy (CF/EP) improve both erosion resistance interlaminar fracture toughness. Experimental investigations revealed remarkable enhancements mechanical properties: the CF/TPU/EP exhibited a 28.6% increase maximum load, 11.8% improvement tensile strength, substantial 45.3% augmentation bending load compared conventional CF/EP composites. Moreover, demonstrated progressive enhancement with increasing impact angles (30 90), showing improvements of 58%, 130%, 185%, 227%, 292%, respectively. These results clearly demonstrate that TPUmodified achieve superior toughness while... Read More

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Carbon fiber-reinforced composite (CFRP) material with improved lightning strike resistance without adding conductive particles. The CFRP has a structure that reduces the risk of edge glow during lightning strikes. The key feature is a specific layer with carbon fibers closely packed together to form conductive paths between layers. The layer has a unique fiber orientation distribution with low void content in the fiber direction. This forces the fibers to contact each other and provides direct conduction between layers. The CFRP also has high overall conductivity in the thickness direction.

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A panel with alternating connected and unconnected regions between skins and an intermediate portion. The panel provides reduced weight with improved strength compared to solid intermediate sections. The connected regions have protrusions in one skin and recesses in the other, alternating with unconnected regions. The sizes in the connected regions gradually change perpendicular to the direction of alternation. This allows localized connection and prevents concentration of forces. It also allows controlled cooling without sudden temperature drops.

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Additively manufactured aerospace panels with integrated truss structures to eliminate joints and reduce weight. The panels have a single monolithic structure formed by printing the skins and truss members together. The skins have lattice regions to eliminate support during printing. The truss members connect the skins and extend between intersections of the lattice grids. This allows complex shapes and features like closeout walls to be printed in one step. The panels have optimized truss angles and truss density variations for strength and thermal management.

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