Beveled Rotor Blade Layer System for Detachment Prevention
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing rotor blade components for wind turbines face challenges in achieving optimal load-bearing capacity and reducing the risk of detachment, particularly due to residual thickness at the ends of pultruded layers during manufacturing.
Innovation Solution
A method for producing rotor blade components, specifically a rotor blade belt, by creating a layer system with a first layer made of a high-modulus material and a second layer made of a lower-modulus material. The layer system is beveled at one end so that the second layer projects beyond the first layer, and multiple such layer systems are joined to form the rotor blade component, thereby reducing stiffness jumps and enhancing load-bearing capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the ends of pultruded layers are beveled by milling, grinding or sawing to reduce thickness, then the risk of detachment is reduced, but a residual thickness remains which cannot be reduced to zero due to technical constraints
Solution Approach 1:
Instead of beveling the high-modulus first layer to reduce detachment risk, the patent inverts the approach by beveling the low-modulus second layer. This allows the second layer to be completely removed at the ends, achieving zero residual thickness and eliminating the detachment risk that plagues conventional designs where the first layer must retain some thickness.
Solution Approach 2:
The patent changes the material parameter selection by using a low-modulus material for the second layer that is easier to remove completely during beveling. This parameter change enables complete removal at the beveled ends, achieving zero residual thickness while maintaining structural integrity through the combination with the high-modulus first layer.
2Strength
If multiple pultruded layers are stacked to increase load-bearing capacity, then the strength increases, but stiffness jumps occur at layer ends which create stress concentrations
Solution Approach 1:
The patent applies local quality by creating a spatial variation in layer composition: the first layer (high-modulus) extends along the longitudinal direction for structural strength, while the second layer (low-modulus) is present only in the inner region and is beveled at the ends. This local differentiation allows the first layer to provide continuous load-bearing capacity while the beveled second layer eliminates stiffness jumps and stress concentrations at the layer ends.
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a method for producing a rotor blade component for a rotor blade of a wind turbine, to a rotor blade component, and to a wind turbine having such a rotor blade component. A layer system (10), consisting of a first layer (1) made of a first material and a second layer (2) made of a second material, is produced. The second material has a lower modulus of elasticity than the first material, and at least part of the second layer (2) runs along the first layer (1). The layer system (10) is chamfered, at least at one end, by means of at least one cutting method in such a way that the second layer (2) protrudes beyond the first layer (1) at the at least one end of the layer system (10). Furthermore, the layer system (10) is joined to at least one other such layer system (10) to form the rotor blade component.