Modular Wind Turbine Blade Segmented Design

Solution Overview

Problem

The existing manufacturing process of wind turbine blades is bottlenecked by the long mold occupancy time, which hinders efficient production and increases the cycle time.

Innovation Solution

A modular wind turbine blade design featuring a segmented structure with a blade root, intermediate portion, and blade tip, where the intermediate portion consists of multiple modular blades connected via first and second connecting portions, allowing for efficient assembly and reduced mold occupancy time.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional integral blade molding is used, then blade structural integrity is maintained, but mold occupancy time increases significantly

Engineering Contradiction:

Improveblade structural integrityVSAvoidmold occupancy time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The blade is divided into multiple modular segments (root module, intermediate modules, tip module) that can be manufactured separately and assembled later. Each module contains specific structural components (leading edge, trailing edge, main beam, web) that are pre-fabricated and then connected through standardized interfaces, enabling parallel production and reducing mold occupancy time while maintaining overall structural integrity through precise connection designs

Inventive Principle:

Principle #1Segmentation

2Loss of time

If modular blade design is implemented, then mold occupancy time is reduced, but connection complexity between modules increases

Engineering Contradiction:

Improvemold occupancy timeVSAvoidconnection structure complexity

Core Design Contradiction:

Loss of timeVSDevice complexity

Solution Approach 1:

Standardized connection interfaces (including positioning structures, fastening mechanisms, and sealing systems) are designed to be universal across all blade modules. The same connection principles and components are applied throughout the blade assembly, allowing for repeatable, modular construction that reduces overall system complexity despite the increased number of modules

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

Multiple connection functions (positioning, fastening, sealing, load transfer) are integrated into unified connection structures at each module interface. This consolidation reduces the number of separate components and assembly steps required, simplifying the overall connection system while enabling efficient modular assembly

Inventive Principle:

Principle #5Merging (Combining)

3Productivity

If modular blades are manufactured separately, then production efficiency is improved, but transportation and assembly logistics become more complex

Engineering Contradiction:

Improveproduction efficiencyVSAvoidassembly logistics complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The blade is divided into multiple modular segments (root module, intermediate modules, tip module) that can be manufactured separately and assembled later. Each module contains specific structural components (leading edge, trailing edge, main beam, web) that are pre-fabricated and then connected through standardized interfaces, enabling parallel production and reducing mold occupancy time while maintaining overall structural integrity through precise connection designs

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Standardized connection interfaces (including positioning structures, fastening mechanisms, and sealing systems) are designed to be universal across all blade modules. The same connection principles and components are applied throughout the blade assembly, allowing for repeatable, modular construction that reduces overall system complexity despite the increased number of modules

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

The modular design significantly reduces mold occupancy time, shortens the production cycle, and enhances molding efficiency, while also improving the blade's ability to withstand shear loads and reducing production costs.

Implementation Method 1

the first connecting portion at the edge of the trailing edge shell and the leading edge shell being fixedly connected to the second connecting portion at the edge of the main beam

Methodology Applied

Scientific EffectMechanical interlocking: Mechanical Fastener

Implementation Method 2

the boss being embedded in the recess and fixedly connected by means of structural adhesive

Methodology Applied

Scientific EffectAdhesive bonding: Adhesive

Data Source

PatentUS12311627B2Modular wind turbine blade and manufacturing method thereof

Publication Date: 2025.05.27 NEWTECH GRP CO LTD

AI summary

A modular wind turbine blade includes a blade root, an intermediate portion and a blade tip. The intermediate portion includes a plurality of modular blades, two adjacent modular blades being provided at edge thereof with a first connecting portion and a second connecting portion that cooperate with each other, and wherein the plurality of modular blades includes a trailing edge shell, a leading edge shell and a main beam, respectively, the first connecting portion at the edge of the trailing edge shell and the leading edge shell being fixedly connected to the second connecting portion at the edge of the main beam. The wind turbine blade according to the present invention adopts segmented modular structural design, which effectively reduces the mold occupancy time of the blade, shortening the production cycle and improving the molding efficiency.