Flexible Vortex Generator for Wind Turbine Blades
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Solution Overview
Problem
Conventional vortex generators for wind turbine blades are custom-designed and costly due to their rigidity, making them inflexible and specific to particular blade shapes, which increases manufacturing costs and limits their universal application.
Innovation Solution
A universal vortex generator with airflow modifying elements featuring discontinuities such as openings, apertures, or tine bundles that allow flexibility for attachment to various blade surfaces, reducing part count and tooling costs, and enabling installation at multiple locations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional rigid vortex generators are custom-designed for specific blade shapes, then aerodynamic performance is optimized for that specific application, but manufacturing cost increases and versatility decreases
Solution Approach 1:
The vortex generator employs a flexible rib structure that can change its geometric parameters (curvature, orientation) to adapt to different blade surfaces. The flexibility allows the same basic design to conform to various blade shapes by physically deforming to match the surface curvature, eliminating the need for custom rigid designs for each application.
Solution Approach 2:
The flexible vortex generator design serves multiple functions: it can be applied to different blade types (horizontal and vertical axis turbines), different positions on blades, and different blade curvatures using a single universal component design, replacing the need for multiple custom-designed variants.
2Reliability
If conventional rigid vortex generators are custom-designed for each blade location, then precise aerodynamic optimization is achieved, but manufacturing cost increases due to higher part count and tooling costs
Solution Approach 1:
The flexible material allows the vortex generator to adapt its shape parameters to different blade geometries and locations while maintaining the same manufacturing process. This eliminates the need for custom tooling and molds for each application, significantly reducing manufacturing costs while preserving aerodynamic optimization.
Solution Approach 2:
A single universal vortex generator design can be manufactured in large quantities using standardized processes and then applied to multiple different blade types and locations, reducing part count, tooling requirements, and overall manufacturing complexity.
3Stability of the object's composition
If rigid vortex generators are used, then structural stability is maintained, but flexibility to conform to blade curvature is lost
Solution Approach 1:
The vortex generator uses a flexible rib structure that can bend and deform to conform to the curved surface of the blade while maintaining its structural integrity. The flexibility allows adaptation to blade curvature without sacrificing the structural stability needed to withstand operational forces.
Solution Approach 2:
The flexible design allows the vortex generator to dynamically adapt its shape to match the blade surface geometry it is applied to, while the material properties ensure it maintains sufficient structural stability to function effectively in the aerodynamic environment.
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 flexible design of the vortex generator reduces manufacturing and installation costs, allows for easier adaptation to different blade shapes, and improves aerodynamic performance by prolonging the attached flow region and reducing drag.
Implementation Method 1
These structures are often referred to as 'vortex generators' and serve to create one or more vortexes that enhance the momentum of the flow to overcome an adverse pressure gradient and prevent separation
Implementation Method 2
The airflow modifying element includes one or more discontinuities configured therein so as to increase flexibility of the vortex generator
Data Source
Figure 1
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AI summary
Universal vortex generators 32 for wind turbine rotor blades 16 and methods of manufacturing same are disclosed. The vortex generator 32 includes a base portion 36 configured for attachment to at least one of a suction side surface 20 or a pressure side surface 22 of the rotor blade 16 and at least one airflow modifying element 34 extending from the base portion 36. In addition, the airflow modifying element 34 includes one or more discontinuities 38 configured therein so as to increase flexibility of the vortex generator 32.