Adjustable Root Plate Attachment for Wind Turbine Blade Molds
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Solution Overview
Problem
Existing wind turbine blade manufacturing techniques require labor-intensive assembly processes and heavy equipment for attaching root plates due to high stresses, necessitating a need for an efficient and safe method for an axially adjustable, rigid connection between a metallic root plate and a composite root flange without specialized tools.
Innovation Solution
A root plate assembly system featuring a root plate with apertures, a sealing collar, washers, a threaded collar, and fasteners that allow for axial adjustment by turning the threaded collar, enabling secure coupling with a composite root flange using threaded engagement and locking mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional root plate attachment methods are used, then the connection can support high stresses, but the assembly process becomes labor intensive and requires heavy equipment
Solution Approach 1:
The root plate attachment system is divided into modular components including the root plate itself, multiple root inserts with threaded holes, and separate fastening mechanisms. This segmentation allows each component to be independently positioned and secured, enabling assembly without heavy equipment while maintaining the structural strength needed to support high blade loads
Solution Approach 2:
Root inserts serve as intermediary elements between the composite root flange and the metallic root plate. These inserts are embedded in the composite structure and provide threaded engagement points, allowing the root plate to be securely attached through standardized fasteners rather than requiring direct attachment to the composite material, thus simplifying the assembly process
2Strength
If the root plate is made larger to support increasing blade sizes, then the load capacity increases, but the assembly process requires even heavier equipment
Solution Approach 1:
The attachment system uses multiple root inserts distributed across the root plate surface, allowing the load to be distributed across multiple attachment points. This enables larger root plates to support increased blade sizes and loads while being assembled using the same straightforward fastening process, avoiding the need for progressively heavier equipment as blade sizes increase
Solution Approach 2:
The root insert design provides universal attachment capability across different root plate sizes and configurations. The standardized threaded inserts and fastening mechanism can be used regardless of the specific blade size or root plate dimensions, allowing the same assembly process to accommodate scaling to larger turbine sizes without requiring specialized heavy equipment
3Manufacturing precision
If adjustment of the root plate is needed, then the fit can be optimized, but complete removal and remachining is required
Solution Approach 1:
The attachment system incorporates adjustable features that allow the root plate position to be modified by simply removing and repositioning the root plate or adjusting the root inserts, rather than requiring complete disassembly and remachining. This dynamic adjustment capability maintains precise alignment while significantly reducing the time and effort required for modifications
Solution Approach 2:
Multiple root inserts are provided as interchangeable components that can be positioned at different locations or orientations. If adjustment is needed, equivalent inserts can be relocated or replaced to achieve the desired alignment, avoiding the need for time-consuming remachining operations while maintaining manufacturing precision
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
Facilitates efficient and safe adjustment of the root plate relative to the root flange without specialized equipment, reducing labor intensity and enabling precise alignment and secure attachment, thus improving manufacturing efficiency and safety.
Implementation Method 1
a threaded collar, the threaded collar having a longitudinally extending channel and threads on inner and outer surfaces thereof
Implementation Method 2
a fastener disposed at least partially within the longitudinally extending channel of the threaded collar
Implementation Method 3
a locknut disposed above the fastener, the locknut abutting the fastener
Implementation Method 4
a sealing collar, the sealing collar disposed within the aperture in the root plate
Data Source
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AI summary
The present disclosure provides for a root plate assembly system, an axially adjustable, rigid connection between a metallic (e.g. steel) root plate and a composite root flange of a wind turbine blade mold. The system includes a root plate including a flange portion with at least one aperture disposed therein. The system includes a sealing collar disposed within the aperture in the root plate. The system includes at least one washer having a larger diameter than the aperture in the root plate. The system includes a threaded collar having a longitudinally extending channel and threads on an outer surfaces thereof. The system includes a fastener disposed at least partially within the longitudinally extending channel of the threaded collar. The system includes a locknut disposed above the fastener abutting the fastener and a bolt cover disposed over the locknut, the bolt cover abutting the collar