Wind Turbine Rotor Blade Reinforcement Assembly
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Solution Overview
Problem
Existing rotor blades face challenges in maintaining structural integrity and aerodynamics when increasing size, particularly due to stress concentrations and weight issues associated with adding inserts or glass plies, which can compromise efficiency and require inefficient manufacturing processes.
Innovation Solution
A rotor blade assembly featuring a shell with an inner and outer skin, a core, and a bonded reinforcement assembly that includes a reinforcement core, providing structural reinforcement while maintaining aerodynamic design and minimizing weight increase.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the thickness of the aerodynamic design is increased to reinforce rotor blades, then structural strength is improved, but weight substantially increases and manufacturing becomes more complex
Solution Approach 1:
The reinforcement assembly is divided into discrete components including a reinforcement core and reinforcement skins that can be separately manufactured and then bonded to the rotor blade. This allows the reinforcement to be applied only where needed rather than increasing the overall blade thickness uniformly.
Solution Approach 2:
The reinforcement assembly is positioned within the existing rotor blade structure, with the reinforcement core disposed between the inner and outer skins of the rotor blade shell. This nested configuration provides structural reinforcement without substantially increasing the external dimensions or weight of the rotor blade.
2Strength
If glass plies are applied to existing rotor blade shells to reinforce them, then structural integrity is improved, but weight significantly increases and manufacturing efficiency decreases
Solution Approach 1:
The reinforcement assembly is provided as a pre-fabricated unit consisting of a reinforcement core and reinforcement skins that can be manufactured separately and then bonded to the rotor blade as a single assembly operation, improving manufacturing efficiency compared to applying multiple layers of glass plies.
Solution Approach 2:
The reinforcement assembly uses composite material construction with a reinforcement core and reinforcement skins that provide high structural integrity-to-weight ratio, avoiding the excessive weight gain associated with traditional glass ply applications.
3Use of energy by moving object
If rotor blade size is increased to improve energy production, then energy efficiency is improved, but structural integrity becomes more difficult to maintain due to stress concentrations
Solution Approach 1:
The reinforcement assembly is strategically positioned at specific locations on the rotor blade where stress concentrations are most likely to occur, such as between blade segments or at critical structural transitions. This localized reinforcement maintains structural integrity without requiring uniform thickening of the entire blade.
Solution Approach 2:
The reinforcement assembly is nested within the existing rotor blade structure, with the reinforcement core disposed between the inner and outer skins. This configuration provides internal structural support that helps the blade withstand increased loads from larger blade sizes.
4Length of moving object
If inserts are added between blade segments to increase rotor blade length, then energy production is improved, but stress concentrations increase and structural integrity is compromised
Solution Approach 1:
The reinforcement assembly merges the reinforcement core with the reinforcement skins to create a unified structural element that is bonded to the rotor blade shell. This combined structure provides continuous reinforcement across the insert region, distributing stresses and preventing concentration at the segment joints.
Solution Approach 2:
The reinforcement assembly is specifically positioned at or near the insert locations between blade segments, providing targeted reinforcement where the greatest stress concentrations occur due to the joint between segments. This localized approach maintains structural integrity without adding weight to the entire blade.
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 solution enhances the structural integrity and aerodynamic performance of rotor blades, particularly when formed from multiple segments or lengthened through inserts, by distributing reinforcement effectively, reducing buckling and stress concentrations, and optimizing weight and manufacturing efficiency.
Implementation Method 1
a reinforcement assembly bonded to the shell, the reinforcement assembly comprising a reinforcement core
Data Source
AI summary
Rotor blade assembly and methods for forming rotor blade assemblies are provided. A rotor blade assembly includes a rotor blade including a shell and defining a pressure side, a suction side, a leading edge and a trailing edge each extending between a tip and a root. The rotor blade further defines a span and a chord. The shell includes an inner skin, an outer skin, and a core disposed between the inner skin and the outer skin. The rotor blade assembly further includes a reinforcement assembly bonded to the shell, the reinforcement assembly comprising a reinforcement core.