Wind Turbine Blade Lightning Protection Recess Integration

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Solution Overview

Problem

Current wind turbine blades with lightning protection systems are cumbersome to manufacture and can disrupt the aerodynamic design due to the need for an additional conducting layer and protrusions that affect efficiency.

Innovation Solution

A method of integrating an electrically conductive layer into the wind turbine blade mold, with a protruding element and connecting member housed in a recess, ensuring the connecting element does not protrude from the outer surface, and using a pre-formed component with a protective layer to maintain aerodynamic efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a conducting layer is added over the outer surface of the blade shell to increase lightning capture area, then the effectiveness of the lightning protection system is improved, but the manufacturing process becomes more complex and time-consuming

Engineering Contradiction:

Improvelightning protection effectivenessVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The conducting layer is integrated into the blade shell manufacturing process itself, combining the lightning protection layer application with the structural shell formation into a single consolidated process. This eliminates the need for separate post-manufacturing steps to apply the conducting layer.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The conducting layer is applied and integrated during the initial blade shell manufacturing stage rather than as a subsequent addition. This preliminary integration ensures the conducting layer is properly positioned and bonded before final blade assembly, simplifying the overall manufacturing sequence.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If a conducting layer is added over the outer surface of the blade shell, then the lightning capture area is increased, but the manufacturing time is significantly extended

Engineering Contradiction:

Improvelightning protection effectivenessVSAvoidmanufacturing speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The conducting layer integration is merged with the blade shell manufacturing process, allowing both components to be produced simultaneously in one operation rather than sequentially. This consolidation maintains production throughput while ensuring lightning protection effectiveness.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of manufacture

If connecting members protrude from the outer surface of the blade to connect the conducting layer, then the electrical connection is simplified, but the aerodynamic performance is degraded

Engineering Contradiction:

Improveelectrical connection easeVSAvoidaerodynamic efficiency

Core Design Contradiction:

Ease of manufactureVSLoss of energy

Solution Approach 1:

The connecting members are nested within recesses formed in the blade shell surface, with the conducting layer extending into these recesses to establish electrical contact. This nesting arrangement allows electrical connections to be made without external protrusions that would disrupt the blade's aerodynamic contours.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The blade shell surface is modified with localized recesses only where connecting members are needed, maintaining the smooth aerodynamic profile across the majority of the surface. This localized modification approach preserves overall aerodynamic performance while enabling necessary electrical connections.

Inventive Principle:

Principle #3Local quality

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 method simplifies the manufacturing process and maintains aerodynamic performance by embedding the conductive layer within the blade shell, effectively routing electrical connections without disrupting the blade's surface, thus enhancing lightning protection without reducing electricity generation efficiency.

Implementation Method 1

The lightning is discharged from the lightning receptor to the down cable and then to a ground potential via conductors that extend inside the blade, nacelle and tower of the wind turbine

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

consolidating the layers under vacuum to form a blade shell

Methodology Applied

Scientific EffectVacuum pressure: Vacuum

Data Source

PatentUS10427363B2Wind turbine blade having a lightning protection system and method of making the same

Publication Date: 2019.10.01 VESTAS WIND SYSTEMS AS

AI summary

A method of making a wind turbine blade incorporating a lightning protection system includes providing a blade mold; arranging a protruding element in the mold; arranging an electrically conductive layer over the protruding element; arranging one or more structural layers and/or structural components over the conductive layer; consolidating the layers under vacuum to form a blade shell having the conductive layer proximate an outer surface of the shell; separating the protruding element from the blade shell to define a recess with the conductive layer extending into the recess; providing an electrical component adjacent an inner surface of the shell; and electrically connecting the conductive layer to the component. An end portion of the connecting member is housed in the recess such that a surface of the connecting member abuts the conductive layer inside the recess.