Wind Turbine Blade Heating Connector for Simple Electrical Joining
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Solution Overview
Problem
Existing wind turbine rotor blades with electrical heating elements are complex and costly to manufacture due to the challenges in creating secure and efficient electrical connections within the limited space of the rotor blade.
Innovation Solution
A wind turbine rotor blade with an electrical heating element that features a connector with an outer thread screwed directly into the fiber reinforced composite material and electrical supply line, providing a secure and efficient electrical connection without the need for additional nuts or clamping forces, allowing for easy assembly and reduced manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional connection methods (bolts, nuts, clamping forces) are used to connect the heating element to the electrical supply line, then secure electrical connection is achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The connector combines multiple functions into a single integrated component: the threaded outer surface provides both mechanical anchoring in the composite material and electrical contact with the supply line. The head section integrates the electrical contact surface and the threaded connection body, eliminating the need for separate nuts, bolts, or clamping mechanisms. This merging of functions reduces device complexity while maintaining reliable electrical and mechanical connection.
Solution Approach 2:
The connector serves multiple purposes simultaneously: it provides mechanical fastening through threading into the composite material, establishes electrical contact through its conductive body and head section, and applies controlled clamping force through its head geometry. This multi-functionality eliminates the need for multiple specialized components, reducing overall connection structure complexity while ensuring reliable electrical connection.
2Reliability
If traditional connection methods with multiple components are used, then secure electrical connection is achieved, but manufacturing cost increases
Solution Approach 1:
By combining the fastening function and electrical contact function into a single connector component, the number of parts to be manufactured, inventoried, and assembled is reduced. This eliminates costs associated with multiple components (nuts, bolts, washers, clamps) and reduces assembly operations, directly lowering manufacturing cost while maintaining connection reliability.
Solution Approach 2:
The connector's outer thread automatically engages with the composite material and electrical supply line during installation, creating both mechanical anchoring and electrical contact without requiring additional fastening operations or separate electrical connection steps. This self-service capability simplifies the manufacturing process and reduces labor costs while ensuring reliable connection.
3Strength
If limited space within the rotor blade is considered, then structural integrity is maintained, but connection options are restricted
Solution Approach 1:
The connector is designed with distinct functional segments: a head section for electrical contact and a threaded body for mechanical anchoring. This segmentation allows each portion to be optimized for its specific function while keeping the overall component compact. The threaded portion can engage with the composite material at a precise location, minimizing space requirements while maintaining structural integrity.
Solution Approach 2:
The connector utilizes the thickness dimension of the rotor blade shell by threading into the composite material along the blade's thickness direction. This allows the electrical connection to be made through the blade shell structure rather than requiring additional lateral space, maintaining structural integrity while providing a viable connection method in the constrained three-dimensional space of the rotor blade.
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 solution enables easier and more cost-effective production of wind turbine rotor blades with reliable electrical connections, ensuring effective heating for anti-icing and de-icing while maintaining structural integrity and electrical conductivity.
Implementation Method 1
an electrical heating element arranged on an outer surface of the wind turbine rotor blade shell structure, the electrical heating element having an electrical heating conductor with an end section
Data Source
AI summary
A wind turbine rotor blade including a wind turbine rotor blade shell structure including a fiber reinforced composite material; an electrical heating element arranged on an outer surface of the wind turbine rotor blade shell structure, the electrical heating element having an electrical heating conductor with an end section; an electrical supply line running along a longitudinal direction of the wind turbine rotor blade; and, a connector connecting the end section of the heating conductor electrically to the electrical supply line wherein the connector includes an outer thread screwed directly into the fiber reinforced composite material and into the electrical supply line.