Modular Wind Turbine Blade Spar Cap Bending Transport
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Solution Overview
Problem
The increasing size of wind turbine blades for maximizing energy capture complicates transportation and adds significant weight due to the need for larger materials and extra fastening materials to ensure structural stiffness and resistance, particularly in modular designs where separate parts are coupled together.
Innovation Solution
The design of primary and secondary blade modules with spar caps and shear webs allows for compact transportation by bending spar cap portions during transport and easy assembly at the site, reducing the need for excessive reinforcement materials, thus minimizing weight and using shorter transport vehicles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If blades are constructed as modular parts to be coupled together, then transportation complexity and cost are reduced, but structural stiffness and resistance are negatively affected requiring additional reinforcement material
Solution Approach 1:
The blade is divided into multiple modular sections that can be transported separately and assembled on-site. Each module contains complete structural elements (spar caps, shear webs, blade shells) that maintain structural integrity independently while allowing flexible transportation routing and assembly configurations.
Solution Approach 2:
The blade modules utilize composite material construction with integrated spar caps and shear webs that provide high strength-to-weight ratio. The composite structure allows for optimized material distribution that maintains structural stiffness while reducing overall weight and reinforcement requirements.
2Strength
If blade parts are made thicker and heavier with larger amounts of material, then structural stiffness and resistance are improved, but blade weight increases significantly
Solution Approach 1:
The blade structure implements local quality optimization where material thickness and reinforcement are concentrated specifically at coupling regions and high-stress areas. The majority of the blade structure uses optimized thin-walled composite construction, providing structural resistance only where needed rather than uniform reinforcement throughout.
Solution Approach 2:
The blade modules are pre-assembled with integrated structural elements (spar caps, shear webs, and blade shells) before transportation. This preliminary assembly ensures proper structural configuration and eliminates the need for additional reinforcement during on-site assembly, reducing overall material requirements.
3Strength
If extra fastening material is added to couple thicker blade parts together, then structural ability to withstand loads is improved, but blade weight increases by approximately one tonne or more
Solution Approach 1:
The structural elements (spar caps, shear webs, and blade shells) are merged into integrated modular units that function as complete structural components. The coupling interfaces between modules are designed to connect these integrated units directly, eliminating the need for separate fastening materials and reinforcement elements.
Solution Approach 2:
The design replaces traditional mechanical fastening systems (bolts, flanges, welds) with integrated composite coupling interfaces. The modular blade sections are joined through interlocking composite structures that distribute loads across the coupling region without requiring additional fastening materials.
Data Source
AI summary
Primary blade modules for a wind turbine blade are provided comprising a first blade shell, two opposed spar caps, and at least one shear web. The first blade shell has a root end and a first coupling end configured to be coupled with a secondary blade module. The two opposed spar caps have respective first spar cap portions extending along the first blade shell substantially from the root end to the first coupling end of the first blade shell, and respective second spar cap portions extending beyond the first coupling end. The at least one shear web extends between the opposed spar caps at least partially along the respective first spar cap portions. Secondary blade modules, systems for transporting primary blade modules, and methods of assembling (in situ) wind turbine blades having a primary blade module and a secondary blade module are also provided in the present disclosure.