Modular Wind Turbine Blade Spar With Overlapping Shear Webs
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Solution Overview
Problem
The current manufacturing methods for wind turbine blades are labor and capital intensive, leading to high costs and increased probability of defects, especially with larger blades, which are difficult to transport and require over-engineering, resulting in higher material and installation costs. Additionally, existing modular designs face issues with structural integrity and aerodynamic performance at connections.
Innovation Solution
A modular wind turbine blade design featuring a spar composed of multiple beams arranged side by side, with longitudinal webs and flanges, allowing for standardized, cost-effective production and assembly. The beams can be of different types, such as closed or open sections, and are connected via mechanical fixings or adhesives, with overlapping shear webs to transmit loads in shear, reducing material usage and maintaining structural integrity while allowing for tapered and curved configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If blades are made larger to capture more wind energy, then power generation capability is improved, but transportation difficulty and cost increase
Solution Approach 1:
The blade is divided into multiple modular sections (root section, intermediate sections, tip section) that can be manufactured separately and transported independently. Each section contains a complete spar structure with beams, webs, and flanges, allowing the blade to be assembled on-site without requiring transportation of the entire blade structure.
2Power
If blades are made larger to capture more wind energy, then fewer turbines are needed for the same power generation, but manufacturing cost and defect probability increase
Solution Approach 1:
The blade is segmented into multiple sections that can be manufactured using standardized processes and then assembled. This allows for better quality control in each section and reduces the complexity of manufacturing a single large blade.
Solution Approach 2:
Different beam configurations (closed box sections vs. open I-sections) are used in different sections of the blade based on local structural requirements. The spar cap depth and beam arrangement are optimized for each specific section's load conditions.
3Ease of operation
If traditional modular designs are used with box section reinforcements, then transportation is facilitated, but structural complexity and material usage increase
Solution Approach 1:
The blade is divided into transportable sections while using efficient open-section beam structures rather than heavy box sections throughout. The segmentation allows for simplified beam designs in each section.
Solution Approach 2:
Closed box section beams are used only where structurally necessary (such as in the root section or high-load areas), while open I-section beams are used in other sections to reduce material usage and complexity.
4Strength
If blade sections are connected with traditional joining methods, then structural integrity may be compromised, but aerodynamic performance at connections deteriorates
Solution Approach 1:
The spar structure is designed with overlapping webs and pre-positioned bearing blocks that facilitate smooth load transfer between sections. The bearing blocks are precisely positioned to maintain the aerodynamic profile while enabling mechanical connection.
Solution Approach 2:
Bearing blocks serve as intermediary elements between adjacent blade sections, providing a smooth transition for load transfer while maintaining the aerodynamic contour. These blocks are integrated with the spar cap structure to minimize disruption to the aerodynamic shape.
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 design reduces material wastage, transportation costs, and maintains structural integrity and aerodynamic performance by transmitting loads through overlapping shear webs, enabling the use of expensive materials only where necessary and allowing for flexible blade configurations without increasing weight or cost.
Implementation Method 1
Overlapping shear webs are provided to transmit loads in shear
Implementation Method 2
The flanges and webs are preferably adhered together
Data Source
AI summary
A spar (30) for a wind turbine blade. The spar comprises a plurality (typically three or more) beams (33) arranged side-by-side. Each beam has a longitudinal web (32), a flange (31) at either longitudinal edge. The spar may be made up of a number of modules connected to one another primarily via overlapping shear webs.