Modular Thermoplastic Wind Turbine Rotor Blade Segments
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional wind turbine rotor blades face issues with bond-line failures, complex manufacturing processes, and increased weight due to complex joint designs, particularly when manufactured in larger sizes, leading to increased labor and assembly time.
Innovation Solution
The development of modular rotor blades constructed from a combination of thermoset and thermoplastic materials, with pre-formed main blade structures and segments reinforced with fiber materials, using welding or mechanical fasteners for assembly, and additional composite layers for improved bonding and reduced joint complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If rotor blades are manufactured in larger sizes, then energy capture capability is improved, but manufacturing complexity and assembly difficulty increase
Solution Approach 1:
The rotor blade is divided into multiple modular segments that can be manufactured separately using standardized processes and then assembled together. This segmentation allows each segment to be produced with controlled complexity while the overall blade achieves the required large size for enhanced energy capture.
2Ease of manufacture
If conventional bonding methods are used, then assembly is simplified, but reliability decreases due to bond-line failures
Solution Approach 1:
The patent replaces chemical bonding methods with mechanical connection systems such as interlocking joints, pins, or friction-fit interfaces. This substitution eliminates bond-line failures while maintaining assembly simplicity through standardized mechanical connection procedures.
3Strength
If complex joint designs are used to connect blade segments, then structural integrity is improved, but weight increases
Solution Approach 1:
The joint design implements local quality by concentrating structural reinforcement only at critical connection points rather than throughout the entire blade. This allows the joints to achieve necessary structural integrity while minimizing additional weight through targeted material placement.
4Strength
If complex joint designs are used to connect blade segments, then structural integrity is improved, but assembly time and labor increase
Solution Approach 1:
The joint components are pre-assembled or pre-positioned during the manufacturing phase, allowing for quick final assembly in the field. Alignment features and pre-installed connection elements are prepared in advance to minimize assembly time while maintaining structural integrity.
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
This approach simplifies the manufacturing process, reduces weight, and decreases assembly time and labor costs by using modular designs with improved bonding techniques, enhancing the structural integrity and efficiency of wind turbine rotor blades.
Implementation Method 1
The blade segment(s) is/are constructed, at least in part, of a thermoplastic material
Implementation Method 2
thermoplastic material reinforced with at least one of fiber material
Data Source
AI summary
The present disclosure is directed to a modular rotor blade constructed of thermoset and/or thermoplastic materials for a wind turbine and methods of assembling same. The rotor blade includes a pre-formed main blade structure constructed, at least in part, from a thermoset material. The rotor blade also includes at least one blade segment configured with the main blade structure. The blade segment(s) is constructed, at least in part, of a thermoplastic material reinforced with at least one fiber material.