Composite Wing Section Connection via Bonded Boxes and Tie Rods
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Solution Overview
Problem
Current mechanical connections for composite wind turbine blades face issues of non-homogeneous force distribution, local stress overflows, and difficulty in ensuring structural optimization and reliability, particularly due to the use of metal fasteners that are discontinuous and difficult to dismantle.
Innovation Solution
The solution involves assembling wind turbine blade sections using composite boxes glued between skins and a network of tie rods, where the tie rods are tightened on ribs to compress the boxes, ensuring a continuous force transfer without drilling or misalignment, and allowing for a simplified assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If metal fasteners (screws, pins) are used for discontinuous mechanical connection, then the connection can be dismantled, but the force distribution becomes non-homogeneous causing local stress overflows
Solution Approach 1:
The patent replaces the traditional mechanical fastener system (screws, pins) with a bonding system using adhesive layers. This substitution maintains the dismantlability through thermal or chemical separation while achieving homogeneous force distribution across the entire bonding surface, eliminating local stress concentrations.
Solution Approach 2:
The patent changes the connection mechanism from discrete mechanical fasteners to a continuous bonding interface by controlling adhesive layer parameters (thickness, viscosity, curing properties). This parameter change enables uniform stress distribution while maintaining the ability to dismantle through controlled adhesive failure or thermal separation.
2Ease of manufacture
If multiple metal parts are used for connection, then the connection can be assembled mechanically, but the structure complexity increases and mass optimization is reduced
Solution Approach 1:
The patent merges multiple discrete metal connection parts into a single continuous bonding layer applied between composite surfaces. This consolidation reduces the number of components while maintaining assembly capability through adhesive application and curing processes, thereby simplifying the overall structure.
Solution Approach 2:
The patent uses composite bonding materials (adhesives) that combine the functions of multiple metal parts into a single material system. This composite approach reduces part count and structural complexity while maintaining the mechanical connection functionality through the bonded interface.
3Strength
If drilling is performed for mechanical fasteners, then the connection can be secured, but additional reinforcement plies are required increasing mass and complexity
Solution Approach 1:
The patent replaces the drilling and fastening mechanical system with a bonding system that applies adhesive layers to the composite surfaces. This substitution eliminates the need for drilling holes and installing reinforcement plies, thereby reducing the overall mass of the blade structure while maintaining connection strength through the bonded interface.
4Reliability
If continuous fitting or closed frame is used for force transfer, then the force passage is ensured, but the assembly process becomes complex and costly
Solution Approach 1:
The patent achieves continuous force transfer by controlling the parameters of the adhesive layer (continuity, thickness, coverage area) rather than using complex continuous fittings or closed frames. This parameter-based approach ensures force transfer continuity while maintaining structural simplicity and reducing assembly complexity.
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 approach achieves a mechanically optimized connection that is cost-effective, removable, and maintains the aerodynamic profile continuity without additional reinforcement, enhancing the structural reliability and ease of assembly and disassembly.
Implementation Method 1
The clamping forces stress the clamping rods in tension and the boxes in compression
Implementation Method 2
the bending forces pass through the bonded connections between the box sections and the skins
Data Source
Figure 1
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Figure 4
AI summary
The subject matter of the invention is a device for the connection of sections of wings such as wind turbine blades which include, at the ends of the facing sections, central boxes arranged end to end and clamped against each other by clamping rods, and a method of producing sections of wings such as wind turbine blades which includes a step of producing devices for the connection of said sections in the form of central junction boxes.