Wind Turbine Blade Component Mounting via Bushing Load Distribution
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Solution Overview
Problem
Conventional methods for mounting components to the internal structure of wind turbine rotor blades, such as deicing components, often cause damage to the sandwich construction by compressive loads that crush the foam core and lead to premature delamination of the biax laminate panels.
Innovation Solution
A mounting system that uses through-holes with bushings and adhesive, reinforced by plates and spacers, to distribute loads away from the core material, preventing damage to the foam core and ensuring secure attachment of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If bolts are passed through the webs to mount components, then component mounting is achieved, but the foam core is crushed and delamination occurs
Solution Approach 1:
A bushing is introduced as an intermediary component between the bolt and the sandwich web. The bushing is embedded in adhesive within a through-hole in the web, and the bolt passes through the bushing rather than directly through the web. This intermediary structure distributes the compressive load from the bolt over a larger area of the adhesive and web panels, preventing the foam core from being crushed while still enabling secure component mounting.
2Strength
If additional fiberglass layers are added to reinforce the mounting location, then structural strength is increased, but foam core collapse is not prevented
Solution Approach 1:
The bushing acts as a load-distributing intermediary that prevents direct transmission of compressive forces to the foam core. By embedding the bushing in adhesive within a through-hole, the load path is redirected through the adhesive and panel laminates rather than through the foam core, thereby preventing foam collapse while providing the necessary structural strength at the mounting location.
Solution Approach 2:
The mounting system utilizes a composite construction combining the bushing material, adhesive, and sandwich web structure. The adhesive acts as a bonding composite that transfers loads between the bushing and the web panels, creating a integrated load-path that protects the foam core while maintaining structural integrity at the mounting location.
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
The system effectively distributes compressive and shear loads, preventing damage to the foam core and ensuring reliable attachment of components like deicing units without causing delamination, thereby enhancing the durability and maintenance efficiency of wind turbine rotor blades.
Implementation Method 1
A bushing is located within the through-hole and is encased within an adhesive applied between the bushing and a wall of the through-hole
Implementation Method 2
a plate is attached to each of the opposite panels at the first mounting location against an end face of the bushing
Data Source
AI summary
A system and method for mounting a component to an internal web of a wind turbine blade includes, at a first mounting location on the internal web, at least one through-hole defined through the internal web. A bushing is located within the through-hole and is encased within an adhesive applied between the bushing and a wall of the through-hole. A plate is attached to each of the opposite panels of the internal web at the mounting location against an end face of the bushing, with each plate having a hole therein that is aligned with the through-hole. For mounting the component at the mounting location, a bolt is passed completely through the plates and bushing for attachment of a frame of the component to one of the plates.