Modular Wind Turbine Blade Assembly With Mobile Factory Alignment
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Solution Overview
Problem
Current methods for assembling large wind turbine blades are inefficient due to handling and transportation challenges, requiring more precise and robust assembly techniques to ensure consistent strength across sectional joints.
Innovation Solution
A method and system involving a mobile factory with a platform and support cradles to level and align blade sections, using actuators for precise positioning and joining, allowing for the assembly of modular wind turbine blades at or near the wind turbine site, reducing transportation costs and ensuring strong joints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If wind turbine blades are made in one piece, then the blade structure is simple and strong, but the blade becomes very long (over 80 meters) making it challenging to handle during manufacturing and transportation
Solution Approach 1:
The blade is divided into multiple sections (root section, intermediate sections, tip section) that can be manufactured separately and transported individually. Each section is then assembled at the installation site to form the complete blade, resolving the transportation challenge while maintaining structural integrity through proper joining techniques.
2Manufacturing precision
If a fixed assembly plant is used to assemble blade sections, then the assembly process is well-controlled, but the plant must be located far from wind turbine sites and transportation costs increase
Solution Approach 1:
The assembly plant is transformed from a fixed structure to a mobile factory that can be transported to locations near wind turbine sites. The mobile factory includes movable support structures and positioning systems that maintain assembly precision while reducing transportation distances for blade sections.
Solution Approach 2:
A mobile factory serves as an intermediary between the blade section manufacturing locations and the final wind turbine installation sites. It provides a controlled assembly environment close to the installation site, reducing transportation costs while maintaining assembly quality through its equipped workspace.
3Ease of manufacture
If blade sections are assembled with simple support on ground, then the assembly process is simple, but the alignment precision and joint strength are insufficient
Solution Approach 1:
A platform is introduced as an intermediary support structure between the ground and the blade sections. The platform provides a stable, level working surface with integrated positioning systems that enable precise alignment of blade sections while maintaining relative simplicity in the assembly process.
Solution Approach 2:
Traditional ground-based mechanical alignment methods are replaced with a platform system that uses controlled positioning mechanisms. The platform can be adjusted and leveled precisely, providing better alignment control without significantly complicating the overall assembly process.
4Loss of energy
If a mobile factory is moved to the wind turbine site, then transportation costs are reduced, but the site access may be limited (especially for off-shore turbines)
Solution Approach 1:
The mobile factory is designed with flexible positioning capabilities that allow it to be deployed in various locations, including near coastlines for off-shore projects. The factory can be positioned optimally based on site-specific constraints while still providing reduced transportation distances compared to fixed inland assembly plants.
Data Source
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AI summary
The invention relates to a method for establishing a sectional or modular wind turbine blade. The method comprises the steps of transporting at least two blade sections of said wind turbine blade and a mobile factory for joining blade sections to a location at or in proximity of a wind turbine site, positioning said blade sections with two blade section ends facing each other and supported on a platform in said mobile factory, moving said platform in relation to the ground at the location for levelling said platform, aligning said blade section ends in relation to each other, and establishing said sectional or modular wind turbine blade by joining blade sections in an area of connection at said blade section ends. The invention also relates to a system for establishing a sectional or modular wind turbine blade and a mobile factory for joining sections of a wind turbine blade.