Bonded Window Cover Joint Assembly for Wind Turbine Rotor Blades
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional tip extensions for wind turbine rotor blades require significant length to accommodate increased loads, leading to high manufacturing and transportation costs, and laminated window covers can cause undesirable bumps at the leading edge when bonded.
Innovation Solution
A bonded window cover with a unique joint assembly that transitions from two sets of inner skin layers to one, using a bonding agent and a window cover with tapered sections to minimize bumps and machining requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a bonded window cover is used without a transition from two sets of inner skins to a single set, then the window cover is securely bonded in place, but an undesirable bump is created at the leading edge of the rotor blade
Solution Approach 1:
The joint assembly acts as an intermediary component between the window cover and the blade structure. It includes a first portion that bonds to the window cover and a second portion that integrates with the single set of inner skins, providing a smooth transition that eliminates the bump while maintaining secure bonding through the bonding agent
Solution Approach 2:
The joint assembly creates a localized transition zone with varying skin layer configurations. The first portion area has two sets of inner skins for bonding, while the second portion area has a single set of inner skins for aerodynamic smoothness, with the bonding agent providing structural continuity between these different local configurations
2Strength
If conventional tip extensions are made significantly longer to accommodate increased loading, then the structural strength is sufficient, but the manufacturing and transportation costs become prohibitively expensive
Solution Approach 1:
The rotor blade is divided into segments with a tip extension that is significantly shorter than conventional designs. The joint assembly with its complex bonding structure and skin layer transitions enables this segmentation, allowing the tip extension to be optimized for minimal length while maintaining structural integrity through the bonded connection and distributed load paths
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 effectively eliminates leading edge bumps and reduces manufacturing complexity, enhancing the aerodynamic profile and reducing costs associated with tip extensions.
Implementation Method 1
bonding, via a bonding agent, the window cover within the access window
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A method for assembling a rotor blade assembly 200 having a blade insert 206 and a first blade segment 202, the blade insert 206 including a top side 220 extending between a forward edge 228 and an aft edge 230 and a bottom side 222 extending between a forward edge 232 and an aft edge 234, includes securing a forward end 216 of the blade insert 206 adjacent to a first joint end of the first blade segment 202, at least a portion of the forward edge 228 of the top side 220 being offset relative to the forward edge 232 of the bottom side 222 such that an access window 240, 241 is defined between the blade insert 206 and the first blade segment 202, positioning a window cover 284a, 284b so as to cover at least a portion of the access window 240, 241, and bonding, via a bonding agent, the window cover 284a, 284b within the access window 240, 241.