Wind Turbine Blade Root Flange Design for Fastener Alignment
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Solution Overview
Problem
Wind turbine blades experience deformation and ovalization of the blade root portion due to weight-induced forces during storage and curing, leading to alignment issues and a less secure connection to the rotor hub, which complicates the mounting process and may result in misalignment of fasteners.
Innovation Solution
A wind turbine blade assembly design featuring a blade root flange coupled to the blade root portion through embedded receptacles, reducing the thickness and weight of the blade root and ensuring direct alignment with hub fasteners, thereby minimizing deformation and misalignment during mounting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the blade root portion is made thicker to provide structural integrity for secure fastening, then the strength and reliability of the connection to the rotor hub is improved, but the overall weight of the blade increases, leading to greater weight-induced deformation and ovalization during storage
Solution Approach 1:
The blade root flange utilizes composite material construction with optimized fiber orientation and resin distribution to achieve high strength-to-weight ratio. The composite structure provides necessary structural integrity for secure fastening while minimizing overall weight, thereby reducing weight-induced deformation during storage.
Solution Approach 2:
The blade root flange incorporates localized reinforcement zones at critical stress points (fastener attachment areas) while maintaining thinner sections in non-critical areas. This local quality approach ensures structural integrity where needed most without unnecessarily increasing overall blade weight.
2Productivity
If the blade is removed from the mould quickly to increase productivity, then the manufacturing cycle time is reduced, but the resin is not fully cured and the blade root portion deforms due to softness and weight forces
Solution Approach 1:
The blade root flange incorporates pre-formed reinforcement structures and geometric features during the moulding process that maintain structural integrity even when the resin is not fully cured. These preliminary structural measures prevent deformation during the critical early storage period before full curing.
Solution Approach 2:
The patent utilizes controlled modification of resin formulation and curing parameters to achieve adequate structural stability at reduced cure times. By adjusting chemical composition and curing conditions, the blade achieves sufficient rigidity for handling and storage earlier in the curing process, enabling faster production cycles without sacrificing geometric accuracy.
3Ease of manufacture
If the blade root portion is left circular to simplify manufacturing, then the ease of manufacture is improved, but the alignment with the rotor hub during mounting is compromised due to deformation
Solution Approach 1:
The blade root assembly is segmented into the blade root portion and the separate blade root flange. This segmentation allows the blade root portion to maintain a simple circular cross-section for easy manufacturing, while the attached flange provides the precise geometric features and reinforcement needed for accurate fastener alignment with the rotor hub.
Solution Approach 2:
The blade root flange acts as an intermediary element between the blade root portion and the rotor hub. It transfers and aligns the connection, providing precise geometric reference surfaces and reinforcement that ensure accurate fastener alignment, while allowing the blade root portion itself to remain simple and easy to manufacture.
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 reduces weight-induced deformation and ensures secure alignment of fasteners, facilitating a more efficient and secure connection between the blade and rotor hub, improving the mounting process and structural integrity.
Implementation Method 1
long period of blade storage leads to large and sustained forces acting on the blade due to the blade's own weight
Data Source
AI summary
The present invention discloses a blade root assembly for a wind turbine, the assembly comprising a blade with a root portion and a blade root flange. The blade root portion comprising a plurality of receptacles configured to receive fasteners to couple the blade root portion with a wind turbine rotor hub.