Wind Turbine Blade Trailing Edge Bonding Without Surface Steps

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Solution Overview

Problem

The challenge in forming wind turbine blades with serrations at the trailing edge is the difficulty in joining main blade and separate edge modules during manufacturing, due to the complex geometry and delicate materials, which can lead to turbulence and noise from steps at the attachment points.

Innovation Solution

A method involving the use of mating features such as tongues and recesses, with an adhesive applied to bond the modules together using a pressure force created by removing air from or injecting air into an air-sealed region, utilizing inflatable airbags or a deformable vacuum bag to ensure a smooth transition and prevent damage to the trailing edge.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If a separate serrated trailing edge part is attached to the blade surface, then serrations can be provided to reduce noise, but a step is created at the attachment point which generates turbulence and noise

Engineering Contradiction:

Improvenoise reductionVSAvoidturbulence from step

Core Design Contradiction:

Object-affected harmful factorsVSObject-generated harmful factors

Solution Approach 1:

The blade is divided into a main blade module and a separate edge module, allowing the serrated trailing edge to be manufactured and attached separately while maintaining aerodynamic continuity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Mating features (tongue and recess) act as intermediaries between the main blade module and edge module, enabling precise alignment and flush attachment that eliminates steps at the interface

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If the main blade and separate edge modules are moved to bring them together, then assembly can be achieved, but difficulty arises due to scale, complex geometry, and delicate materials

Engineering Contradiction:

Improveassembly feasibilityVSAvoidhandling complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The mating features are designed with complementary geometries (tongue and recess) that guide the modules into proper alignment during assembly, reducing the complexity of positioning and handling

Inventive Principle:

Principle #12Equipotentiality

Solution Approach 2:

The tongue and recess mating features enable self-alignment and self-location of the edge module relative to the main blade module during assembly, reducing the need for complex external alignment equipment

Inventive Principle:

Principle #25Self-service

3Object-generated harmful factors

If modules are joined to achieve smooth transition, then noise and turbulence are reduced, but manufacturing complexity increases due to precise joining requirements

Engineering Contradiction:

Improvenoise from transition pointVSAvoidjoining process complexity

Core Design Contradiction:

Object-generated harmful factorsVSDevice complexity

Solution Approach 1:

The mating features are pre-formed during module manufacturing, so that alignment and positioning are built into the components themselves rather than requiring complex alignment procedures during assembly

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The mechanical alignment and positioning functions are replaced by the geometric complementarity of the tongue and recess features, which automatically guide proper positioning when brought together

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 effectively bonds the modules without creating steps, reducing noise and turbulence, and allows for the precise alignment and secure attachment of serrated trailing edge modules, enhancing the aerodynamic efficiency and reducing manufacturing complexities.

Implementation Method 1

applying an adhesive to at least one of the first mating feature and the second mating feature

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

locating a pressure distributor against the separate edge module to distribute the pressure force that is applied to the first and second mating features

Methodology Applied

Scientific EffectPressure distribution: Pressure Gradient

Implementation Method 3

providing a consolidator at an interface between the main blade module and the separate edge module at an outer surface of the blade

Methodology Applied

Scientific EffectMechanical constraint: Mechanical Force

Data Source

PatentUS11927172B2Method of forming a wind turbine blade

Publication Date: 2024.03.12 VESTAS WIND SYSTEMS AS

AI summary

The invention provides a method of forming a wind turbine blade. The blade has a main blade module that defines a main body of the blade and includes a first mating feature, e.g. a tongue. The blade also includes a separate edge module that defines at least part of a trailing edge of the blade and includes a second mating feature, e.g. a recess. The method includes applying an adhesive to at least one of the first mating feature and the second mating feature. The method includes arranging the separate edge module relative to the main blade module such that the first and second mating features are mutually adjacent. The method includes applying a pressure force to squeeze the adhesive to bond the first and second mating features together. The pressure force is caused by removing air from, or injecting air into, an air sealed region.