Wind Turbine Blade Segment Assembly for Higher-Wind Installation
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Solution Overview
Problem
The installation of wind turbine blades poses challenges due to extreme torsional moments and loads on the gearbox and other components during the mounting process, limiting the size of wind turbines and increasing costs, as conventional methods require low wind speeds and specialized tools to manage these stresses.
Innovation Solution
A method involving blades with root and extension segments, where the root segment is mounted first, followed by the extension segment, reducing torsional moments and allowing for higher wind speed installations, using cranes efficiently to connect the segments while minimizing the weight and cost of the driving tool and gearbox components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional blade installation methods are used (mounting complete blades requiring multiple rotor rotations), then blades can be installed, but extreme torsional moments are imposed on the gearbox and other components
Solution Approach 1:
The blade is divided into a root segment and an extension segment. The root segment is mounted to the rotor hub first, then the extension segment is attached later using a crane, eliminating the need for multiple rotor rotations and extreme torsional moments during installation.
2Ease of manufacture
If conventional blade installation methods are used, then blades can be mounted, but a specialized driving tool capable of handling extreme loads is required
Solution Approach 1:
By segmenting the blade into root and extension portions, the installation process no longer requires a specialized driving tool capable of handling extreme loads. The root segment is mounted conventionally, then the extension segment is attached using standard crane equipment.
3Ease of manufacture
If conventional blade installation methods are used, then blades can be installed, but installation is limited to very low wind conditions
Solution Approach 1:
The segmented blade installation method allows the root segment to be mounted when wind conditions are favorable, then the extension segment is attached later using a crane. This eliminates the constraint of requiring very low wind speeds throughout the entire installation process, extending the available weather window.
4Productivity
If larger wind turbine sizes are used to increase energy production, then energy efficiency improves, but extreme loads during blade installation increase
Solution Approach 1:
The segmented installation method allows larger blades to be installed without proportionally increasing extreme loads on components. The root segment is mounted using conventional methods, then the extension segment is attached using crane equipment, avoiding the extreme torsional moments that would otherwise be required for complete large-blade installation.
5Productivity
If larger wind turbine sizes are used to increase energy production, then energy efficiency improves, but installation costs increase
Solution Approach 1:
By segmenting the blade installation process, the method avoids the need for expensive specialized driving tools and extreme load handling equipment. The root segment is installed conventionally, then the extension segment is attached using standard crane equipment, reducing overall installation costs for larger turbines.
Data Source
AI summary
A method (100) of mounting blades (22) to a rotor hub (20) of a wind turbine (10), the wind turbine (10) comprising a tower (12), a nacelle (16) mounted on the tower (12), the rotor hub (20) being coupled to the nacelle (16), and blades (22), each blade (22) comprising a blade root segment (56) and a blade extension segment (66), the method (100) comprising mounting a first blade root segment (50) to the rotor hub (20), mounting a second blade (72) to the rotor hub (20) after mounting the first blade root segment (50), the second blade (72) comprising a second blade root segment (52) and a second blade extension segment (62), and connecting a first blade extension segment (60) to the first blade root segment (50) after mounting the second blade (72).