Wind Turbine Blade Root Replacement With Beveled Composite Joint
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Solution Overview
Problem
Existing methods for repairing wind turbine blade roots are inadequate as they do not address the root cause of damage, leading to costly and frequent repairs, potential accidents, and environmental waste, while existing replacement blades are unavailable or excessively costly.
Innovation Solution
A method involving the complete cutting of the damaged root section, redesigning and manufacturing a new root section, and joining it to the blade using single or double bevels, with reinforcement layers and composite materials, ensuring a strong and durable connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If localized repairs are performed by replacing individual inserts or bolts, then repair costs increase and maintenance complexity increases, but the root cause of damage is not addressed leading to repeated failures
Solution Approach 1:
The blade root assembly is divided into modular components (blade, root assembly, hub) that can be independently replaced. The root assembly itself is segmented into multiple inserts that can be individually replaced without affecting the entire structure, enabling targeted repairs rather than complete blade replacement.
Solution Approach 2:
The damaged root assembly is extracted and replaced with a new one while keeping the blade and hub in place. Individual damaged inserts are extracted and replaced separately. This selective extraction approach repairs only the problematic components rather than replacing the entire blade structure.
2Strength
If the entire blade root assembly is replaced, then structural integrity is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The root assembly is designed as a segmented structure with multiple interchangeable inserts rather than a monolithic component. This segmentation allows manufacturing of smaller, more manageable components that can be produced using standard composite manufacturing processes, reducing overall manufacturing complexity.
Solution Approach 2:
The root assembly is designed as a universal interface between the blade and hub that can accommodate different blade types and hub configurations. The standardized root assembly design with multiple inserts provides multi-functionality, serving both structural support and damage tolerance functions while simplifying manufacturing through standardization.
3Ease of operation
If conventional repair methods are used, then immediate repair is achieved, but long-term reliability deteriorates due to repeated repairs
Solution Approach 1:
The root assembly is designed with preliminary protective features including multiple redundant inserts and a structure that prevents single-point failures. The design anticipates potential damage locations and incorporates preventive measures, allowing quick replacement of individual inserts before catastrophic failure occurs.
Solution Approach 2:
The root assembly incorporates built-in redundancy with multiple inserts that provide cushioning against failure. If one insert is damaged, the other inserts continue to provide structural support, preventing catastrophic failure and allowing time for scheduled maintenance rather than emergency repairs.
4Reliability
If blades are frequently replaced due to root damage, then operational reliability is maintained, but environmental waste increases and costs increase
Solution Approach 1:
Instead of discarding entire blades with damaged roots, the invention allows recovery and reuse of the blade and hub components. Only the specific damaged root assembly or individual inserts are replaced and discarded, while the valuable blade airfoil sections and hub structures are retained and continue to serve their function.
Solution Approach 2:
The blade system is segmented into replaceable root assemblies and permanent blade/hub components. This segmentation enables selective replacement of only the damaged portion (root assembly or inserts) while preserving the majority of the blade structure, significantly reducing material waste compared to complete blade replacement.
Data Source
AI summary
A method of replacing the root part from a wind turbine blade by attaching a new fabricated root part consisting of utilizing a new root part manufactured specifically for the blade to be repaired, which does not use the same materials as the original. To separate the original root segment from the original blade the cut line with single or double bevels is prepared, both in the new, pre-fabricated root assembly and in the region to be cut of the original blade. The next step is joining the new root assembly with the original blade using layers of structural fiber fabric, initially utilizing reconstruction layers and subsequently with internal and external reinforcement layers on the blade and, optionally, apply resin preferably through vacuum infusion and optionally through hand layup, to complete the joint between the new root and the original blade.