Wind Turbine Rotor Blade Connecting Flanges for Torsional Rigidity
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Solution Overview
Problem
The existing methods for connecting wind turbine rotor blade segments are labor-intensive, require precise assembly, and struggle with force transmission in the torsion plane, leading to high assembly effort, accessibility issues, and a large number of parts.
Innovation Solution
The use of two connecting flanges with positive engagement, where one flange is mounted on each rotor blade segment and connected via fasteners, allowing for self-centering and simplified preload measurement, while providing a torsion-resistant connection with a reduced number of parts and improved accessibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional mechanical connections with multiple fasteners are used to connect rotor blade segments, then the connection can transmit forces, but the assembly effort increases and precision requirements become tighter
Solution Approach 1:
The patent combines multiple separate fastening elements into a single integrated connecting flange structure. The connecting flange integrates the functions of multiple bolts, washers, and alignment features into one monolithic component that attaches to the rotor blade segment, thereby reducing part variety and assembly complexity while maintaining force transmission capability
Solution Approach 2:
The connecting flange incorporates self-aligning features such as tapered surfaces and complementary geometric profiles that automatically position the connection elements correctly during assembly. This self-service mechanism eliminates the need for precise pre-positioning and reduces assembly effort by allowing the components to self-center and self-align
2Reliability
If precise positioning and preloading of multiple fasteners is required for connecting rotor blade segments, then connection reliability improves, but assembly time and labor increase significantly
Solution Approach 1:
The connecting flange incorporates self-aligning features such as tapered surfaces and complementary geometric profiles that automatically position the connection elements correctly during assembly. This self-service mechanism eliminates the need for precise pre-positioning and reduces assembly effort by allowing the components to self-center and self-align
Solution Approach 2:
The connecting flange is pre-designed with integrated alignment features and pre-loaded fastening mechanisms that automatically establish correct positioning and force distribution during assembly. This preliminary design of the alignment geometry ensures reliable connection without requiring time-consuming measurement and adjustment operations
3Strength
If multiple connecting elements and fasteners are used to join rotor blade segments, then the connection can withstand high forces, but the degree of accessibility to components decreases
Solution Approach 1:
The patent combines multiple separate fastening elements into a single integrated connecting flange structure. The connecting flange integrates the functions of multiple bolts, washers, and alignment features into one monolithic component that attaches to the rotor blade segment, thereby reducing part variety and assembly complexity while maintaining force transmission capability
4Ease of manufacture
If traditional connection methods are used for split rotor blades, then the segments can be connected, but torsional rigidity at the segmentation point is insufficient
Solution Approach 1:
The patent combines multiple separate fastening elements into a single integrated connecting flange structure. The connecting flange integrates the functions of multiple bolts, washers, and alignment features into one monolithic component that attaches to the rotor blade segment, thereby reducing part variety and assembly complexity while maintaining force transmission capability
Data Source
Figure 1
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AI summary
The invention relates to a wind turbine rotor blade (110) formed by a first rotor blade segment (132) and a second rotor blade segment (134), wherein: - the first rotor blade segment (132) has a first connection end (136) with first connecting elements (140), - the second rotor blade segment (134) has a second connection end (138) with second connecting elements (142), - a first connecting flange (154) is mounted to the first rotor blade segment (132) by means of the first connecting elements (140), - a second connecting flange (174) is mounted to the second rotor blade segment (134) by means of the second connecting elements (142), and - the two connecting flanges (154, 174) are positively engaged with one another, so that the two rotor blade segments (132, 134) are torsionally rigidly connected to one another. The invention also relates to a method.