A parameterized cutting and differentiated functional partitioning recycling method for decommissioned wind turbine blades

Abstract

The application discloses a kind of parameterization cutting and differentiated function partition recycling methods of decommissioned wind power blade.The method is obtained or reconstructed by digitizing to decommissioned wind power blade, extracts the spatial distribution characteristics of the internal core load-bearing skeleton and the geometric parameters based on the shape of fluid mechanics;Based on the parameters, a multi-dimensional parameterized evaluation model is established, the blade is functionally partitioned along the axial direction to obtain sections with different mechanical properties and structural potential;On this basis, the cutting path is planned according to the principle of maximum continuity of the core load-bearing skeleton, avoiding the stress-sensitive area to perform cutting, obtaining segmented components with axial continuity of the internal skeleton;Further based on the cross-sectional mechanical parameters and material aging characteristics, the carrying capacity of the segmented components is quantified, and the corresponding engineering recycling role is defined according to its functional partition.The application realizes the parameterization and regularization of cutting decision and function output in the engineering recycling process of decommissioned wind power blade.

Description

Technical Field

[0001] This invention relates to the field of structured reuse and engineering remanufacturing of decommissioned wind power equipment. Specifically, it relates to a method for parametric segmentation and differentiated functional zoning reuse of decommissioned wind turbine blades based on point sampling logic, digital parameter identification, structural constraint analysis and functional output rules. This method is applicable to converting decommissioned wind turbine blades into structural units of buildings or municipal structures with clear load-bearing levels and engineering roles. Background Technology

[0002] Decommissioned wind turbine blades are typically made of glass fiber reinforced composite materials or carbon fiber reinforced composite materials. During their service life, they must simultaneously meet the requirements of complex aerodynamic shapes and long-term cyclic loads. As a result, wind turbine blades exhibit significant geometric variability, wall thickness gradients, and structural functional heterogeneity in the axial direction: their cross-sectional shape gradually transitions from an approximate circle to an airfoil, while internally they form a multi-layered load-bearing skeleton system composed of a sparsity cap, shear web, and shell.

[0003] The aforementioned structural features make wind turbine blades essentially composite structural components with continuously varying axial functions. Among them, the spar cap and shear web regions have a decisive influence on longitudinal load-bearing capacity, and their fiber continuity and structural integrity directly determine the mechanical usability of the component.

[0004] Current methods for handling decommissioned wind turbine blades mainly include crushing and landfilling, pyrolysis, or downgrading and recycling. These methods generally destroy the high-value continuous fiber structure of composite materials, resulting in high energy consumption, low material utilization efficiency, and difficulty in preserving the original engineering structural value of the blades.

[0005] Some technical solutions attempt to use retired blades directly as engineering components after cutting them up. However, these solutions often employ cutting methods based on experience or dimensional requirements, typically segmenting only according to external dimensions or service length, without systematically identifying and constraining the spatial distribution of the core load-bearing skeleton inside the blade, areas of abrupt changes in axial performance, and stress-sensitive areas. This results in the severing of critical load-bearing fibers such as the wing spars during the cutting process, leading to abrupt changes in the mechanical properties of the components after cutting, making it difficult to quantify and assess their engineering applicability and safety.

[0006] Furthermore, existing technologies generally lack a systematic method to transform the axial heterogeneity of retired blades into a clear engineering functional output. They have failed to establish a complete technical chain from structural feature identification and segmentation path planning to the definition of the engineering role of components, resulting in vague application scenarios and low standardization of reused components, making it difficult for them to enter the building or municipal engineering system.

[0007] Therefore, there is an urgent need for a parameterized segmentation method based on the point sampling logic, which can realize the calculability of the engineering performance of the segmented components and the regularization of their functional positioning while preserving the continuity of the core load-bearing skeleton to the greatest extent possible, so as to solve the problem of uncontrollable performance of the structured reuse of retired wind turbine blades in the existing technology. Summary of the Invention

[0008] The purpose of this invention is to provide a point sampling method for parametric segmentation and differentiated functional zoning reuse of retired wind turbine blades. By discretely sampling, parametrically evaluating and regularly constraining the structural features of the blade, a deterministic mapping relationship between the segmentation path and the functional output is established, so that the segmented components have quantifiable load-bearing capacity and clear engineering application roles, thereby realizing the safe, controllable and high-value engineering reuse of retired wind turbine blades.

[0009] The technical solution provided by this invention mainly includes the following steps: S1. Steps for Digital Characterization and Core Supporting Framework Identification Using the Point Sampling Method: The decommissioned wind turbine blade undergoes at least three-dimensional digital acquisition and non-destructive testing to support the point sampling method, acquiring original geometric and structural data covering the blade's axial range. Discrete feature sampling points are deployed along the blade's axial direction and key cross-sectional locations to parametrically extract the blade's outline, cross-sectional geometric parameters, wall thickness distribution, and internal cavity features. Through parameter analysis of the sampling points, the spatial location and axial continuous segments of the core supporting framework, such as the spar cap and shear web, are identified, and a blade axial parameter database is established accordingly. The point sampling method includes acquiring structural parameters in the form of discrete sampling points, or equivalently obtaining discretizable parameter sampling results through continuous curve or surface fitting. S2. Parametric evaluation steps for structural heterogeneity: Based on the sampling point parameter database, construct a parametric evaluation model that reflects the axial structural variation characteristics of the blade. The model includes at least structural parameters such as the rate of change of cross-sectional moment of inertia, wall thickness gradient, skeleton eccentricity, and cavity ratio, which are used to identify the structural stability zone, performance mutation zone, and stress-sensitive zone within the axial range of the blade. S3. The differentiated functional zoning generation step is based on the calculation results of the parametric evaluation model, and performs axial functional zoning on the blade according to the preset structural constraint rules. The functional zoning is the parametric output result driven by sampling points, rather than a manually preset type. The functional zoning includes at least: a high-rigidity zone suitable for use as a high-rigidity connection or compression member, a structural bearing zone suitable for use as a main bearing member, and a lightweight covering zone suitable for use as an enclosure or covering member. S4. Parametric Segmentation Path Planning Step: Based on the functional zoning, and in accordance with the principle of maximizing the continuity of the core load-bearing skeleton, the axial segmentation position of the blade is parametrically planned based on sampling point constraints. The segmentation path must meet the following constraints: the segmentation section avoids the continuous area of ​​the wing cap and the stress-sensitive area, and is located in a stable section where the geometric change rate of the section and the wall thickness gradient are lower than the preset threshold. S5. Precise Segmentation and Component Generation Step: Perform precise segmentation on the decommissioned wind turbine blades along the segmentation path to obtain at least one single-segment component with axial continuity of the internal core load-bearing frame; if necessary, adjust the shape or process the boundary of the single-segment component to form a standardized component unit that meets the engineering installation requirements. S6. Engineering performance quantification and functional role definition steps: Based on the cross-sectional parameters, skeleton integrity and material service life of the segmented components, an aging reduction factor is introduced to calculate the engineering performance of the components and obtain the effective load-bearing level of the components; according to the load-bearing level and stability parameters, the functional roles of the components that can be allowed or prohibited in engineering applications are defined according to preset rules, including but not limited to compression columns, bending beams or self-supporting shell components.

[0010] Compared with existing technologies, this invention has at least the following beneficial effects: It achieves the standardization and calculability of decommissioned wind turbine blade segmentation decisions through parametric identification and structural constraint analysis driven by the point sampling method, avoiding the uncontrollable performance problems caused by empirical segmentation; it maximizes the preservation of the axial continuity of the blade's core load-bearing skeleton during the segmentation process, significantly enhancing the engineering structural value of the segmented components; it transforms the axial heterogeneity of the blade into a clear engineering functional output, enabling reused components to have clear load-bearing levels and application boundaries; and it constructs a complete technical chain from point sampling, structural feature identification, segmentation path planning to engineering role definition, improving the standardization and safety of decommissioned wind turbine blades in building and municipal engineering. Attached Figure Description

[0011] Figure 1 This diagram illustrates the sampling point distribution and axial parameter extraction of a decommissioned wind turbine blade using a point sampling method. As shown, multiple types of sampling points (3) are arranged within the axial range of the wind turbine blade (1), including axial reference sampling points (3a) for establishing axial parameter sequences, cross-sectional feature sampling points (3b) arranged on the cross-sectional profile, skeleton-related sampling points (3c) associated with the longitudinal skeleton inside the blade, and change-triggered sampling points (3d) for identifying the location of structural parameter changes. These sampling points are used to obtain the geometric and structural parameters of the blade at different axial positions to support subsequent axial functional zoning and segmentation path planning.

[0012] Figure 1A for Figure 1A magnified isometric cross-sectional view of region I. As shown in the figure, the blade includes a composite material shell (7) and a longitudinal skeleton (4) located inside the shell and continuously arranged along the axial direction. The longitudinal skeleton includes a spar cap (4a) and a shear web (4b). Section feature sampling points (3b) are arranged on the section profile to extract the section geometry and wall thickness related parameters at the corresponding positions, so as to characterize the structural features at the sampling point positions.

[0013] Figure 2 This is a schematic diagram of the axial functional zoning of a decommissioned wind turbine blade based on the parameter evaluation results of the sampling method. As shown in the figure, based on the geometric and structural parameters obtained along the axial direction of the wind turbine blade (1), the blade is functionally divided into multiple functional sections with different engineering load-bearing characteristics. The functional sections include a high-rigidity connection area (F1), a structural load-bearing area (F2), and a lightweight covering area (F3). The boundaries of each functional section are determined according to the parameter changes, which is used to guide the selection of the segmentation strategy and the differentiated engineering reuse method of the decommissioned wind turbine blade.

[0014] Figure 3 This is a schematic diagram of the splitting path planning for decommissioned wind turbine blades based on functional zoning and parameter constraints. As shown in the figure, multiple decision regions based on parameter evaluation results are sequentially set along the axial direction of the decommissioned wind turbine blade (1). Among them, the region located at the root of the blade is set as the NC region, which is a prohibited splitting region and does not participate in the splitting path planning; the structural bearing region located in the middle of the blade is set as the AC region, which is a permitted splitting region and is used to indicate the optional splitting paths; BK regions are set on both sides of the AC region as avoidance regions, which are used to limit the boundary position of the splitting path away from the adjacent region; no splitting decision rules are set for the remaining sections of the blade, which are non-active planning regions. Through the above splitting path planning method, the controllable splitting of the decommissioned wind turbine blade is realized under the conditions of functional zoning and parameter constraints.

[0015] Figure 4 This diagram illustrates the quantification of engineering performance and functional role definition of components based on the parametric segmentation method for retired wind turbine blades. As shown, retired wind turbine blade components obtained through the aforementioned point sampling parametric analysis, functional zoning, and segmentation path planning methods are classified into different types of engineering components and distinguished by numbers according to their source sections and corresponding parameter evaluation results. Component 10 is a connection or support component formed by segmentation from a high-rigidity connection zone; component 20 is a structural component formed by segmentation from a structural load-bearing zone, possessing high load-bearing capacity; and component 30 is an enclosure or non-load-bearing component formed by segmentation from a lightweight cover zone. By quantifying the engineering performance of different components and defining their functional roles, differentiated reuse of retired wind turbine blade components in buildings or structures can be achieved.

[0016] In this manual, NC indicates No Cutting, AC indicates AllowCutting, and BK indicates Buffer Keep-out. Detailed Implementation

[0017] Taking a 40m long decommissioned wind turbine blade as an example. In step S1, discrete sampling points are set up along the axial direction and at key cross-section locations to obtain its full-length cross-sectional parameters and internal skeleton distribution information. In step S2, it is calculated that the 0–5m section at the root has a large moment of inertia and a low wall thickness gradient, and is identified as the structurally stable zone; the 10–25m section has a continuous wing cap and a regular cross-sectional shape, and is identified as the main load-bearing potential zone; the blade tip section is identified as a lightweight zone due to the significant reduction in wall thickness.

[0018] In step S3, the system generates functional zones—a high-rigidity zone, a structural load-bearing zone, and a lightweight covering zone—based on the sampling point parameter output results. In step S4, the segmentation algorithm automatically avoids the continuous zone and high-stress zone of the wing cap based on the sampling points, selecting the section location located within the stable zone as the segmentation point. After segmentation in step S5, a middle section member with a continuous internal skeleton is obtained.

[0019] In step S6, the aging reduction factor is introduced in combination with the cross-sectional parameters and service life of the component to calculate its effective bending stiffness. Based on this, the component is defined as being able to be used as a self-supporting shell or a large-span beam, while it is prohibited from being used as a high compression ratio column. The root component is defined as being able to be used as a compression column component due to its high cross-sectional stability.

Claims

1. A parameterized segmentation method for decommissioned wind turbine blades, characterized in that, Includes the following steps: S1. Digital Characterization and Skeleton Recognition: Digital acquisition or reconstruction of retired wind turbine blades, identification and location of their internal core load-bearing skeleton, including the spar cap and shear web, and extraction of digital feature parameters of the blade along the entire axis; the feature parameters include, but are not limited to, cross-sectional shape gradient, wall thickness distribution characteristics and internal cavity geometry characteristics based on hydrodynamic shape, to provide data support for subsequent partitioning and segmentation. S2. Differentiated Functional Zoning Planning: Based on the characteristic parameters described in step S1, a parametric evaluation model is established to divide the blade into multiple functional zones along the axial direction. Each functional zone has different mechanical properties and geometric adaptability. The functional zones may include, but are not limited to, high-rigidity connection zones, structural load-bearing zones, and lightweight covering zones. The functional zones are calculated based on the characteristic parameters and are not manually preset. S3. Parametric Segmentation Path Planning: Based on the reuse objectives of each functional zone and the principle of maximizing the continuity of the core load-bearing skeleton, plan the axial segmentation path, determine the cut-off position, and ensure that the cut-off position avoids the stress-sensitive area and geometric diameter change area of ​​the core load-bearing skeleton, while considering the geometric regularity of the cross section, fiber continuity, and the adaptability of standardized connection nodes. S4. Precise Segmentation Execution: Perform segmentation according to the planned path in step S3 to obtain segmented structural units containing an axially continuous core load-bearing skeleton. Optionally, the step includes boundary treatment of the non-load-bearing shell to form profile units with high stiffness-to-weight ratio. S5. Performance Quantification and Application Empowerment: Extract the core skeleton section modulus of the segmented structural unit, combine it with the material aging characteristics to conduct a quantitative assessment of the load-bearing capacity, and define its differentiated application role in building engineering according to its functional zoning, including but not limited to compression columns, bending beams or self-supporting shell units.

2. The method according to claim 1, characterized in that: In step S2, the high-rigidity connection area is located in the circular thick-walled area at the root of the blade, the structural bearing area is located in the airfoil section area in the middle section of the blade, and the lightweight covering area is located in the tip area of ​​the blade, but is not limited to this partitioning method.

3. The method according to claim 1, characterized in that: In step S5, the differentiated application roles include: configuring the high-rigidity connection area as an engineering compression member, configuring the structural load-bearing area as an engineering bending member or a self-supporting shell member, and configuring the lightweight covering area as a non-load-bearing functional covering unit.

4. The method according to claim 1, characterized in that: In step S3, the constraints of the split path planning include, but are not limited to, cross-sectional geometric regularity, fiber orientation continuity and adaptability of standardized connection nodes, and the aging gradient of the blade and local strength decay can also be considered.

5. The method according to claim 1, characterized in that: The longitudinal contouring and cutting step can optionally involve peeling off the non-load-bearing shell along the longitudinal edge of the core load-bearing frame to obtain profile units with a high stiffness-to-weight ratio. This step can be adjusted according to specific engineering requirements.

6. A decommissioned wind turbine blade engineering component obtained by the method described in any one of claims 1-5, characterized in that: The core load-bearing skeleton inside the component maintains axial fiber continuity and has a quantified physical load-bearing capacity after material aging correction, and the load-bearing capacity can be used for engineering application decisions.

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