Curved Blade Coupling Pocket for Durable Shaft Attachment
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Solution Overview
Problem
Existing methods for attaching curved structures, such as wind turbine blades, to central shafts often result in weak spots, reduced durability, and increased complexity due to mismatched thicknesses and perpendicular forces, leading to premature blade failure under high winds.
Innovation Solution
A coupling system featuring a coupling member with a pocket and flange portion that maintains the thickness of the blade, allowing for perpendicular attachment without compromising the curvature, using a rod or bolt with washers and nuts for secure fastening, and minimizing aerodynamic interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing methods for attaching curved structures to central shafts are used, then the attachment is achieved, but weak spots and reduced durability occur due to mismatched thicknesses and perpendicular forces
Solution Approach 1:
The invention applies local quality by creating a pocket with a flat bottom portion that has a specific thickness matching the curved structure, while the rest of the curved structure maintains its original curvature and thickness. This localized modification provides a suitable attachment surface without compromising the overall structural integrity or aerodynamic properties of the curved structure.
Solution Approach 2:
The invention transitions from a two-dimensional curved surface to a three-dimensional pocket structure by removing material to create a depression with a flat bottom. This dimensional change allows the coupling member to be attached perpendicularly to the curved structure's tangent, distributing forces more effectively and eliminating weak spots caused by thickness mismatches.
2Ease of manufacture
If existing attachment methods are used, then the curved structure is attached to the shaft, but increased complexity and premature failure occur due to mismatched thicknesses
Solution Approach 1:
The pocket is pre-formed in the curved structure during manufacturing, creating a ready-made receptacle for the coupling member. This preliminary action eliminates the need for complex field assembly operations, as the coupling member simply needs to be inserted and fastened to the pre-prepared pocket rather than adapting to an irregular curved surface.
3Productivity
If existing attachment methods are used, then the connection is made, but aerodynamic efficiency is reduced due to interference from the attachment structure
Solution Approach 1:
The flat bottom portion of the pocket is designed with a thickness equal to the curved structure's wall thickness, creating a smooth transition that minimizes aerodynamic interference. The coupling member is embedded within this localized flat region, keeping the attachment hardware concealed and reducing turbulence and drag on the curved structure's surface.
Data Source
AI summary
A coupling system for coupling a curved object to a central shaft, the curved object includes an inner surface facing the central shaft and an outer surface. The system includes a coupling member for coupling the curved object to the central shaft; at least one pocket integrally formed on a curved surface of the curved object and defined as a depression with respect to at least one of the inner and outer surfaces. The pocket includes: a flat portion having an aperture for holding the coupling member; and a flange portion which merges continuously from the flat portion to the curved object and is shaped such that the flat portion is disposed perpendicularly to the coupling member; a fastening member for fastening the coupling member to the flat portion. The thickness of the flat portion and flange portion is the thickness of the curved object.