Wind Turbine Blade Add-On Mounting for Low-Drag Adhesive Bonding
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Solution Overview
Problem
Existing aerodynamic add-on elements on wind turbine rotor blades face a trade-off between structural and aerodynamic requirements due to the thickness of the adhesive bond line, which can cause flow separation and drag, affecting overall performance.
Innovation Solution
The design incorporates a baseplate with an inclined bottom side relative to the rotor blade surface, forming a gap that increases in thickness downstream, allowing for a structurally sufficient adhesive thickness while minimizing aerodynamic disturbances, using spacers or barriers to enhance stability and reduce adhesive material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thicker adhesive bond line is used to meet structural requirements, then the structural strength and reliability are improved, but the aerodynamic performance deteriorates due to increased drag and flow separation
Solution Approach 1:
The baseplate is designed with non-uniform thickness, having a greater thickness at the upstream end and a smaller thickness at the downstream end. This local variation in geometry allows the adhesive bond line to be thicker at the upstream end where structural strength is most critical, while maintaining a thinner profile at the downstream end to minimize aerodynamic drag and flow separation. This resolves the contradiction by optimizing the adhesive bond line thickness spatially rather than uniformly.
2Ease of manufacture
If a uniform adhesive bond line thickness is used, then the manufacturing process is simplified, but the aerodynamic performance deteriorates due to flow separation at the leading edge
Solution Approach 1:
The baseplate incorporates a non-uniform thickness profile where the upstream end has a greater thickness than the downstream end. This creates a varying adhesive bond line thickness that is thicker at the leading edge to prevent flow separation and maintain smooth airflow, while being thinner at the trailing edge. This local differentiation resolves the contradiction by prioritizing aerodynamic performance at critical locations while maintaining manufacturability through a relatively simple geometric transition.
3Object-generated harmful factors
If the aerodynamic add-on element is mounted closer to the rotor blade surface, then the aerodynamic performance is improved by reducing drag, but the structural reliability deteriorates due to insufficient adhesive bond line thickness
Solution Approach 1:
The baseplate is designed with non-uniform thickness, providing a greater thickness at the upstream end to accommodate a thicker adhesive bond line for structural strength, while having a smaller thickness at the downstream end to allow the add-on element to be mounted closer to the blade surface for reduced drag. This spatial variation in baseplate thickness resolves the contradiction by optimizing both structural and aerodynamic requirements at different locations along the add-on element.
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
This design optimizes both structural and aerodynamic performance by reducing drag, improving airflow, and lowering energy costs, while allowing for standard adhesives and easier finish, thus enhancing production quality and reducing maintenance costs.
Implementation Method 1
Adhesive is provided in the gap to bond the aerodynamic add-on element to the outer surface of the wind turbine rotor blade
Data Source
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AI summary
The invention relates to a wind turbine rotor blade (110), comprising an aerodynamic add-on element (132) comprising a baseplate (134), the baseplate (134) having an upper side (136) and a bottom side (138), wherein the aerodynamic add-on element (132) is mounted with the bottom side (138) of the baseplate (134) to an outer surface (130) of the wind turbine rotor blade (110), at least a section of the bottom side (138) is inclined relative to the outer surface (130) of the wind turbine rotor blade (110) along a downstream direction (148) of an operational wind flow, such that a gap (144) is formed between the at least one section and the outer surface (130) in which a distance (146) between the outer surface (130) and the bottom side (138) increases along the downstream direction (148), and adhesive (150) is provided in the gap (144) to bond the aerodynamic add-on element (132) to the outer surface (130) of the wind turbine rotor blade (110). The invention also relates to an aerodynamic add-on element (132) .