Modular Rotorblade Segmentation for Surface Quality and Transport
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Solution Overview
Problem
Current rotorblade construction methods, involving large pre-bonded blade halves, lead to surface abnormalities at aerodynamically critical points, inefficient tooling costs, and high transportation expenses due to lengthy structures.
Innovation Solution
A modular rotorblade construction method using multiple sections bonded along lines away from the leading and trailing edges, with an internal blade frame and subassemblies for improved alignment and transportation, reducing the length of bonding lines and allowing for interchangeable sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If blades are molded in large sections (halves) and bonded continuously along leading and trailing edges, then structural integrity is maintained, but surface abnormalities and defects occur at aerodynamically critical points
Solution Approach 1:
The blade is divided into multiple sections that are bonded together through intermediate bonding lines positioned away from the leading and trailing edges. This segmentation allows each section to be molded separately with higher precision, avoiding the surface abnormalities that occur when bonding continuously along the aerodynamically critical edges.
2Strength
If blades are molded in large sections (halves), then structural integrity is maintained, but tooling costs become inefficient and turn-around time increases
Solution Approach 1:
By dividing the blade into smaller sections rather than molding large halves, each section can be produced using more efficient, less expensive tooling. The segmented approach reduces the complexity and cost of each individual mold while maintaining overall structural integrity through the bonding of sections.
3Strength
If blades are molded in large sections, then structural integrity is maintained, but transportation costs increase due to difficulty in hauling lengthy structures
Solution Approach 1:
The blade is segmented into smaller sections that can be easily transported by conventional means. These smaller sections are then assembled at the installation site through bonding, eliminating the need to transport lengthy, difficult-to-haul blade halves while maintaining the overall structural integrity of the completed blade.
4Strength
If bonding lines are positioned continuously along leading and trailing edges, then structural integrity is maintained, but erosion resistance at aerodynamically critical points deteriorates
Solution Approach 1:
The bonding lines are repositioned to intermediate locations away from the leading and trailing edges, creating a segmented bonding pattern. This positioning removes the bonding lines from the aerodynamically critical areas where erosion occurs, thereby improving reliability and erosion resistance while maintaining structural integrity through the distributed bonding of sections.
Data Source
AI summary
Disclosed is a modularly constructed rotorblade including a leading and a trailing edge, including a plurality of rotorblade sections in bonded association, and at least one bonding line disposed away from continuous contact with the leading edge and the trailing edge.