Wind Turbine Rotor Blade Segment Connection
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Solution Overview
Problem
The existing connection methods for wind turbine rotor blades are costly, time-consuming, and prone to damage due to unfavorable force conditions, requiring expensive machinery and complex post-processing, especially when dealing with large rotor blades.
Innovation Solution
A wind turbine rotor blade design featuring a connecting device with an inner and outer insert made of fiber-reinforced plastic, where the connecting element is integrated during manufacturing, reducing force redirection and allowing for automated production, and featuring a screw or bolt connection that minimizes local bending moments and simplifies assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If connecting devices are located on protruding webs to join inner and outer blade sections, then the blade sections can be connected, but unfavorable force distribution is created leading to local bending moments and potential damage
Solution Approach 1:
The connecting device is divided into two separate inserts (inner insert and outer insert) that are integrated into different blade sections during manufacturing. These inserts are then connected by connecting elements, distributing the connection function across multiple components rather than concentrating it on protruding webs.
Solution Approach 2:
The inner and outer inserts are pre-integrated into the inner and outer blade sections respectively during the manufacturing process before assembly. This preliminary integration ensures proper force distribution is built into the structure from the beginning, avoiding the need for protruding webs that create unfavorable force conditions.
2Ease of operation
If connecting devices are attached after blade section manufacturing, then blade sections can be joined, but material removal is required and expensive machinery is needed
Solution Approach 1:
The connecting inserts are integrated into the blade sections during the manufacturing process itself, rather than being attached afterward. This preliminary integration eliminates the need for post-manufacturing material removal and expensive machining equipment.
Solution Approach 2:
The connection device integration is merged with the blade section manufacturing process. The inserts are placed and secured within the blade sections during composite layup and curing, combining two operations (connection device installation and blade manufacturing) into one.
3Ease of manufacture
If connecting devices are installed after blade section manufacturing, then blade sections can be connected, but considerable time is required for retrofitting
Solution Approach 1:
The connecting inserts are pre-installed during blade section manufacturing, eliminating the time-consuming retrofitting process. The inserts are positioned and secured while the blade sections are being constructed, so no additional time is needed for installation after manufacturing.
Solution Approach 2:
The connection device installation is merged with the blade section manufacturing timeline. Both operations occur simultaneously during production, eliminating sequential processing and reducing total time required.
4Productivity
If rotor blades are made longer to increase efficiency, then wind turbine efficiency improves, but manufacturing and transport become increasingly difficult
Solution Approach 1:
The rotor blade is divided into multiple sections (inner blade section and outer blade section) that can be manufactured separately and then connected. This segmentation allows each section to be manufactured at manageable lengths, avoiding the difficulties of manufacturing and transporting single-piece ultra-long blades.
Solution Approach 2:
The blade sections are pre-manufactured with integrated connecting inserts during their fabrication process. This preliminary preparation allows sections to be manufactured independently and then quickly assembled, streamlining the overall manufacturing process for long blades.
Data Source
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AI summary
The invention relates to a rotor blade for a wind turbine. The rotor blade comprises at least one rotor blade inner section (3) with a region for connecting to the rotor blade hub and at least one rotor blade outer section (2) with a rotor blade tip, wherein the rotor blade inner section (3) and the rotor blade outer section (2) are both made predominantly from a fiber-reinforced plastic, and wherein the rotor blade inner section (3) and the rotor blade outer section (2) are connected to one another by means of a connection device (4). In that context, the connection device (4) comprises an inner insert (5) at least partially enveloped in the fiber-reinforced plastic of the rotor blade inner section (3), and an outer insert (6) at least partially incorporated into the fiber-reinforced plastic of the rotor blade outer section (2), wherein the inner insert (5) and the outer insert (6) are connected to one another by means of a connection element (7).