Rotor Blade Edge Seal Shaping for Smooth Add-On Transitions
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Solution Overview
Problem
The aerodynamic performance of wind turbine rotor blades is adversely affected by surface imperfections such as steps or obstacles that lie in close proximity to the leading edge of the rotor blade, such as the leading edge of the rotor blade, which are not effectively addressed by existing technologies, especially when a step or an obstacle is present on the rotor blade, for example following the application of a leading edge protection (LEP) cover and/or a vortex generator (VG) panel, a trailing edge (TE) panel, etc. These imperfections cause turbulence and noise, impacting annual energy production (AEP) and turbine noise.
Innovation Solution
A method of shaping an edge seal along a longitudinal edge of an add-on part mounted on the rotor blade, involving an initial edge seal application, machining to remove a top layer, and grinding to form a wedge transition, with a sealing agent and adhesive to ensure a smooth finish, optimizing the edge seal ratio and viscosity to minimize aerodynamic impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sealant material is applied to form an edge seal along the longitudinal edge of an add-on part, then the aerodynamic performance is improved by reducing turbulence, but the sealant material may shrink or detach during hardening, creating steps that worsen aerodynamic performance
Solution Approach 1:
The method applies masking tape to the add-on part before sealant application to predefine the exact boundary and overlap region. This preliminary action ensures that the sealant is applied only where needed and prevents shrinkage or detachment from creating steps, as the masking tape acts as a physical constraint during the hardening process
Solution Approach 2:
The masking tape serves as an intermediary element between the add-on part and the sealant material. It controls the sealant application width and prevents the sealant from shrinking or detaching during hardening, thereby maintaining a smooth edge seal that preserves aerodynamic performance
2Reliability
If the edge seal width is increased to compensate for sealant shrinkage, then aerodynamic performance is maintained, but the device complexity and material usage increase
Solution Approach 1:
By applying masking tape before sealant application, the method pre-defines the exact sealant width and overlap region. This eliminates the need to over-compensate for potential shrinkage, as the masking tape physically constrains the sealant during hardening, maintaining a precise width without requiring additional structural complexity
3Manufacturing precision
If machining is used to remove the top layer of the initial edge seal, then a smooth wedge transition is achieved, but manufacturing time and cost increase
Solution Approach 1:
The method extracts and removes only the excess top layer of sealant that extends beyond the masking tape boundary, rather than machining the entire edge seal. This selective removal achieves a smooth wedge transition while minimizing machining time and material waste
Solution Approach 2:
The masking tape is applied before sealant application to pre-define the final boundary. This preliminary action ensures that after sealant hardening, only a thin excess layer needs to be removed by machining, significantly reducing machining time compared to machining a larger excess sealant application
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 method significantly reduces turbulence and noise, ensuring the aerodynamic performance of rotor blades is maintained or improved, making add-ons like LEP shells more effective and reducing manufacturing costs by allowing thicker edges, thus enhancing AEP and reducing non-conformance costs.
Implementation Method 1
forming an edge seal and hardening or curing the sealant
Implementation Method 2
an adhesive material having a viscosity and an adhesion to surfaces
Data Source
Figure 1~3
Figure 4~5
AI summary
Method of shaping an edge seal for a rotor blade add-on The invention describes a method of shaping an initial edge seal (S1) along a longitudinal edge step (3E) of an add-on part (3) mounted on the outer surface (2) of a rotor blade (1), which method comprises the steps of - providing an initial edge seal (S1) along a longitudinal edge step (3E) of an add-on part (3) mounted on an outer surface (2) of a rotor blade (1), - removing a top layer (L) of the initial edge seal (S1). The invention further describes an according wind turbine rotor blade.