Rotor Blade Joint Assembly With Contour-Preserving Welding
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Solution Overview
Problem
The existing methods for joining rotor blade components are inefficient, leading to time and cost issues, and often result in catastrophic failures due to bond line separation, while also compromising the aerodynamic contour of the blades during the joining process.
Innovation Solution
A method and system for joining rotor blade components using a fixture with a rotatable arm and inflatable bladder to maintain the aerodynamic contour, applying forces to the outer and inner surfaces, and welding the components together using thermoplastic resin, which reduces the complexity and maintains the aerodynamic shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If bonding paste or compound is applied along the bond line with minimum designed bond width, then the joining process is simplified, but the reliability deteriorates due to significant number of turbine blade field failures occurring at the bond-line
Solution Approach 1:
The patent changes the bonding method from chemical bonding (paste/compound) to mechanical bonding (screws/bolts), fundamentally altering the joining parameter to eliminate bond-line failures while maintaining manufacturing simplicity
Solution Approach 2:
The patent introduces fasteners (screws or bolts) as intermediary elements between blade components, providing a reliable mechanical connection that eliminates the unreliable chemical bond-line while keeping the joining process simple
2Reliability
If complex joining process is used to ensure structural integrity, then the reliability improves, but the aerodynamic contour deteriorates requiring post-processing
Solution Approach 1:
The patent performs preliminary positioning and contour verification before final fastening, ensuring aerodynamic contour accuracy is maintained throughout the reliable mechanical joining process without requiring post-processing
3Device complexity
If traditional bonding methods are used, then the device complexity is reduced, but the productivity deteriorates due to time-consuming post-processing for aerodynamic contour
Solution Approach 1:
The fastening system is designed to self-maintain aerodynamic contour during assembly, eliminating the need for separate post-processing operations and significantly improving productivity without increasing device complexity
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 approach facilitates efficient and cost-effective assembly of rotor blades while preserving the aerodynamic contours, reducing the risk of failures and improving the structural integrity of the blades.
Implementation Method 1
applying a force to an outer surface of the second blade component and an opposing force to an inner surface of the second blade component
Implementation Method 2
welding the joint location of the first blade component and the joint location of the second blade component together
Implementation Method 3
The first blade component and the second blade component each include a thermoplastic resin
Data Source
AI summary
Systems and methods for joining blade components of a rotor blade are provided. A method includes positioning a first blade component and a second blade component such that a joint location of the first blade component and a joint location of the second blade component are proximate each other. The method further includes applying a force to an outer surface of the second blade component and an opposing force to an inner surface of the second blade component. The force and opposing force maintain an aerodynamic contour of the second blade component. The method further includes connecting the joint location of the first blade component and the joint location of the second blade component together.