Wind Turbine Blade Trailing Edge Assembly Without Laminate Trimming
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Solution Overview
Problem
The manufacturing process of wind turbine rotor blades is laborious due to the need for manual trimming of laminate layers extending over the trailing edge, which complicates the formation of the desired edge contour.
Innovation Solution
The trailing edge of the wind turbine rotor blade is formed by an adhesive joint between two spar caps, eliminating the need for manual trimming of laminate layers, and ensuring a precise, stable edge contour through the design and thickness of the spar caps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If laminate layers are arranged underneath or on top of the spar cap extending over the mould edge, then the trailing edge can be formed with sufficient stiffness and strength, but manual trimming operations are required which are laborious and time-consuming
Solution Approach 1:
The trailing edge structure is segmented into distinct functional components: the spar cap provides structural stiffness while the laminate layers are positioned only where needed for aerodynamic contouring. This segmentation allows the spar cap to be manufactured independently with precise thickness control, eliminating the need for trimming operations on extending laminate layers.
Solution Approach 2:
The spar cap is manufactured in advance with its final thickness and contour precisely defined before assembly. By pre-forming the trailing edge structure to the exact required dimensions, the need for post-manufacturing trimming operations is eliminated, significantly improving manufacturing efficiency.
2Shape
If laminate layers extend over the mould edge to form the trailing edge, then the desired edge contour can be achieved, but the trimming process becomes complex and labor-intensive
Solution Approach 1:
The trailing edge contour is predetermined by the spar cap design and manufacturing process. The spar cap is fabricated with the exact required thickness profile and contour before assembly, eliminating the need for complex trimming operations to achieve the desired edge shape.
Solution Approach 2:
The spar cap acts as an intermediary element between the aerodynamic requirements and the structural requirements. It provides the precise trailing edge contour needed for aerodynamics while simultaneously providing the structural stiffness required, without requiring extending laminate layers that would need trimming.
3Adaptability or versatility
If the trailing edge is formed by laminate layers extending over the mould edge, then sufficient material is available for shaping, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The trailing edge geometry is predetermined during spar cap manufacturing rather than being formed through post-assembly trimming. The spar cap is fabricated with the exact required thickness and contour, eliminating time-consuming trimming operations while maintaining the flexibility to achieve various edge shapes through the manufacturing process itself.
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 by eliminating or reducing the need for trimming operations, while providing a stable and aerodynamically efficient trailing edge.
Implementation Method 1
The first spar cap and the second spar cap are connected to each other by an adhesive joint
Data Source
Figure 1
Figure 2~3
Figure 4~7
AI summary
The invention relates to a wind turbine rotor blade (110) comprising a suction side half shell (132) and a pressure side half shell (133), wherein the suction side half shell (132) comprises a first spar cap (141), wherein the pressure side half shell (133) comprises a second spar cap (142), wherein the first spar cap (141) and the second spar cap (142) are connected to each other by an adhesive joint (146), wherein, at least in a section between a root end (126) of the wind turbine rotor blade (110) and a tip end (127) of the wind turbine rotor blade (110), a trailing edge (135) of the wind turbine rotor blade (110) is formed by the first spar cap (141), the second spar cap (142) and the adhesive joint (146). The invention also concerns a method of manufacturing a wind turbine rotor blade.