Connected Rotor Blade Test Rig for Long-Blade Load Testing
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Solution Overview
Problem
Existing test rigs for wind turbine rotor blades are expensive, unsuitable for blades longer than 70-100 meters, and require high investment costs to expand, delaying and increasing the cost of implementing new designs, while current solutions do not efficiently handle the static and dynamic loads of larger blades.
Innovation Solution
A test device for simultaneously testing two rotor blades or segments, comprising adapter elements connected to a support structure, which applies loads via an excitation device, minimizing bending moments and allowing for efficient testing of blades up to 100 meters in length, with reduced hardware and foundation requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If existing test rigs are expanded to accommodate rotor blades longer than 70-100 meters, then the testing capability for long blades is improved, but the investment costs and equipment complexity increase extremely high
Solution Approach 1:
The test rig is divided into modular adapter elements (first adapter element, second adapter element) that can be independently configured and connected. Each adapter element handles specific functions (attaching rotor blades, applying loads), allowing the system to be scaled for different blade lengths without redesigning the entire test rig.
Solution Approach 2:
The adapter elements are designed to perform multiple functions: attaching rotor blades to the support structure, applying static and cyclic loads, and supporting blades of various lengths. This multi-functionality eliminates the need for specialized test rigs for each blade length category.
2Length of moving object
If existing test rigs are expanded to accommodate rotor blades longer than 70-100 meters, then the testing capability for long blades is improved, but the investment costs increase extremely high
Solution Approach 1:
The test rig uses segmented adapter elements that can be independently manufactured and assembled, reducing the need for expensive custom-built monolithic structures. This modular approach lowers manufacturing costs and allows for easier maintenance and upgrades.
Solution Approach 2:
The adapter elements are designed with adjustable parameters (connection points, load application positions) that can be modified to accommodate different blade lengths and testing requirements, eliminating the need to purchase multiple specialized test rigs for different blade sizes.
3Reliability
If rotor blades are tested on traditional test rigs, then fatigue strength and material reliability can be verified, but the testing time and implementation cost are significantly delayed and increased
Solution Approach 1:
The test rig enables continuous application of both static extreme loads and cyclic fatigue loads simultaneously on multiple rotor blades. This parallel testing capability reduces the total testing time compared to sequential testing on traditional single-blade rigs.
Solution Approach 2:
The adapter elements are pre-configured with connection interfaces and load application points, allowing rapid setup and transition between different testing scenarios. This preliminary preparation reduces the time required for test setup and blade changes.
4Weight of stationary object
If the test device minimizes bending moments in the support structure, then the equipment and foundation requirements are reduced, but the structural design complexity increases
Solution Approach 1:
The adapter elements are designed with asymmetric connection configurations where the first and second adapter elements are connected in a specific arrangement that creates force cancellation. This asymmetric design minimizes bending moments in the support structure while maintaining simple overall architecture.
Solution Approach 2:
The connection between the first and second adapter elements creates a counterbalancing effect where loads on one side are offset by equivalent loads on the other side. This counterweight principle minimizes the net bending moments transmitted to the support structure, allowing for lighter and simpler foundation requirements.
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 significantly reduces investment costs and testing time by minimizing bending moments, enabling efficient testing of long blades with lower equipment and infrastructure needs, and allowing for on-site testing to reduce transport and certification delays.
Implementation Method 1
an excitation device (30a, b; 130a) for applying a static and/or cyclic load to the first and/or second rotor blade (108) or rotor blade segment (108')
Data Source
Figure 1
Figure 2a
Figure 2b
AI summary
The invention relates to a test device for simultaneously testing two rotor blades and/or two rotor blade segments for a wind turbine, a method for simultaneously testing two rotor blades and/or two rotor blade segments for a wind turbine, a method for testing one rotor blade and/or one rotor blade segment for a wind turbine, and the use of a test device for testing one rotor blade and/or one rotor blade segment for a wind turbine and/or for simultaneously testing two rotor blades and/or two rotor blade segments for a wind turbine.The test device comprises a first adapter element for attaching a first rotor blade or rotor blade segment to it, a second adapter element for attaching a second rotor blade or rotor blade segment to it, a support structure to which the first and second adapter elements are rotatably attached about a common axis of rotation, and an excitation device configured to apply a static and/or cyclic load to the first and/or second rotor blade or rotor blade segment, wherein the first and second adapter elements are connected to each other.