Modular Wind Turbine Blade Structure for Efficient Manufacturing
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Solution Overview
Problem
Existing modular wind power blades face challenges in achieving improved structural strength and processing efficiency due to complex production and connection methods, particularly with sandwich structures.
Innovation Solution
A modular wind turbine blade structure comprising a windward and leeward shell, T-shaped ribs, and support members formed through automated tape laying and pultruded profiles, with enhanced connections using trailing edge beams, flanging structures, and reinforcement layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If sandwich structure with inner core and reinforcement layer is used to increase blade size, then structural strength is improved, but production complexity increases and processing efficiency decreases
Solution Approach 1:
The blade is divided into modular segments that can be manufactured separately and assembled. The support members are integrated into the shell structure, eliminating the need for separate sandwich structure assembly. This segmentation allows for simplified production while maintaining structural strength through the integrated support members and shell configuration.
Solution Approach 2:
The support members and shell structure are merged into a single integrated component manufactured through automated tape laying. This combines the functions of the inner core, reinforcement layer, and shell into one unified structure, reducing production complexity while maintaining the structural strength benefits of the sandwich configuration.
2Strength
If sandwich structure with inner core and reinforcement layer is used, then structural strength is improved, but manufacturing time and processing efficiency are reduced
Solution Approach 1:
The manual or semi-manual assembly process for sandwich structures is replaced with automated tape laying technology. This automated system deposits reinforcement layers and matrix material in a continuous process, significantly improving manufacturing efficiency while producing the same structural strength benefits through the integrated support members and shell configuration.
Solution Approach 2:
The support members and shell structure are designed to be manufactured as an integrated preliminary unit through automated tape laying. This preliminary action of creating the integrated structure eliminates subsequent assembly steps, reducing total manufacturing time while ensuring the structural strength requirements are met through the optimized integrated design.
3Adaptability or versatility
If modular assembly of windward and leeward shells is used, then manufacturing flexibility is improved, but connection structural strength may be compromised
Solution Approach 1:
The support members are nested within the shell structure, with the windward and leeward shells assembled around the integrated support members. This nesting configuration ensures that the connection between modular segments occurs at strategically located support points, maintaining structural strength while preserving manufacturing flexibility through the modular assembly approach.
Data Source
AI summary
A modular wind power blade structure and a manufacturing method thereof are disclosed. The structure includes a windward shell, a leeward shell, a T-shaped rib and a support member. The windward shell and leeward shell are assembled relative to each other to form a complete cross-sectional structure of the blade, the T-shaped rib is fixed on the windward shell and leeward shell along length direction of the blade and a plurality of the T-shaped ribs is provided at an interval in width direction of the blade, and the support member comprises a web and spar caps connected at both ends of the web, the two spar caps respectively fixedly connected to the inner wall of the windward shell and the leeward shell, and the T-shaped rib and the spar cap are pultruded profiles, and the windward shell and the leeward shell are formed through an automatic tape laying process.