Modular Wind Turbine Blade Assembly Using Segmented Airfoils
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Solution Overview
Problem
The increasing size of wind turbine blades poses challenges in manufacturing and transportation due to the need for larger production facilities and higher logistics costs, as well as the difficulty in handling and replacing full blade shells.
Innovation Solution
A method of manufacturing wind turbine blades using a spar and airfoil sections with an outer surface forming part of the aerodynamically active surface, where the spar is not completely encapsulated within shell parts, allowing for easier transport and assembly, using a support structure and clamps for precise positioning and adhesion, and enabling the use of smaller, interchangeable parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the blade is manufactured as a complete large shell structure, then the structural integrity is maintained, but the transportation cost and facility requirements increase significantly
Solution Approach 1:
The blade is divided into multiple airfoil sections that can be manufactured separately and assembled later. Each section includes a spar cap and skin forming a structural unit, allowing modular transportation and reduced facility requirements while maintaining overall blade integrity through precise assembly processes
2Strength
If the spar is completely encapsulated within shell parts, then the aerodynamic performance is optimized, but the handling and transport difficulty increases
Solution Approach 1:
The blade structure is segmented into airfoil sections where the spar runs continuously through multiple sections but is accessible at segment boundaries. This allows the spar to provide structural reinforcement while enabling easier handling and transport of individual sections compared to a fully encapsulated design
Solution Approach 2:
The skin acts as an intermediary element that connects the spar cap to the aerodynamic shell. This intermediate structure allows the spar to be partially exposed or accessible while still providing the necessary aerodynamic enclosure, balancing structural performance with handling ease
3Reliability
If damaged parts are replaced in traditional blade structures, then the blade functionality is restored, but the replacement complexity increases due to large shell parts
Solution Approach 1:
The blade is divided into replaceable airfoil sections that can be independently removed and replaced. If damage occurs in one section, only that specific module needs to be replaced rather than the entire blade shell, significantly reducing repair complexity and time while restoring blade functionality
Solution Approach 2:
Damaged airfoil sections can be discarded and replaced with new or refurbished sections. The modular design allows for efficient recovery and replacement of individual units, maintaining blade reliability without requiring complex repairs to large integrated shell structures
Data Source
AI summary
The invention provides a method of manufacturing a wind turbine blade comprising a spar and at least one airfoil section, where both the spar and the airfoil section comprise an outer surface which forms part of an aerodynamically active surface of the blade. The method comprises steps of providing a support structure, placing the spar at the support structure, providing a clamp adapted to be fixed to the outer surface of both the spar and the airfoil section, arranging the airfoil section relative to the spar, fixing the clamp to the outer surface of the spar and the airfoil section, and assembling the at least one airfoil section an the spar by a process including adhesion.