Wind Turbine Rotor Blade Segment Coupling via Tapered Mounting Elements
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Solution Overview
Problem
Large wind turbines face challenges in securely connecting rotor blade segments due to high static and dynamic forces, leading to stress concentrations at connection points which can result in failure and damage.
Innovation Solution
A rotor blade design featuring mounting elements with non-linearly decreasing contact surfaces, which taper in the longitudinal direction, providing a secure and easy connection by reducing stress at the tip and increasing force transmission through a reinforcing structure made of unidirectional fabric, integrated with adhesive bonding for optimal force distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If mounting elements are dimensioned to absorb high loads, then connection strength is improved, but rotor blade weight increases significantly
Solution Approach 1:
The mounting elements feature a non-linearly decreasing distance between contact surfaces, creating locally optimized geometry where the wider base provides load-bearing capacity while the tapered tip reduces stress concentration. This local geometric variation allows the connection to handle high loads without requiring uniformly thick mounting elements throughout, thereby reducing overall weight while maintaining strength.
2Reliability
If high safety factors are applied at connection points, then reliability is improved, but stress concentrations increase leading to potential failure
Solution Approach 1:
The mounting elements utilize a non-linear geometric parameter variation where the distance between contact surfaces decreases non-linearly from base to tip. This parameter change creates a gradient structure that distributes stress more evenly, with the wider base absorbing initial loads and the tapered tip gradually transitioning forces, thereby reducing stress concentrations while maintaining high safety factors for reliable operation.
3Length of moving object
If rotor blades are manufactured in segments, then transportability is improved, but connection complexity increases
Solution Approach 1:
The rotor blade is divided into multiple segments that can be manufactured and transported separately. Each segment incorporates mounting elements with standardized non-linear geometry, allowing for modular assembly. The consistent mounting element design across segments simplifies the connection process despite the segmented structure, reducing overall connection complexity while enabling transportable blade lengths.
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 design reduces stress concentrations at connection points, enhances the secure coupling of rotor blade segments, and prevents failure by distributing forces effectively, ensuring the structural integrity of the wind turbine.
Implementation Method 1
integrated with adhesive bonding for optimal force distribution
Data Source
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AI summary
The invention relates to a rotor blade (108) for a wind turbine (100), having a longitudinal direction (L) in which the rotor blade (108) extends, at least one first rotor blade segment (10, 10') with a first end face (12), and at least one second rotor blade segment (20) with a second end face (22), wherein the first rotor blade segment (10, 10') is coupled to the second rotor blade segment (20) at the end face in the longitudinal direction (L), and the first and second rotor blade segment (10, 10', 20) each comprise: a blade laminate (14, 24) with a plurality of laminate layers (16) which are stacked in a profile thickness direction (D); and a plurality of assembly elements (30a, 30b, 30c, 30a', 30b', 30'c, 30.1, 30.2, 40a, 40b, 40c, 40a', 40b', 40'c) which are arranged on the end face for coupling the first rotor blade segment (10, 10') to the second rotor blade segment (20). Each assembly element (30a, 30b, 30c, 30a', 30b', 30'c, 30.1, 30.2, 40a, 40b, 40c, 40a', 40b', 40'c) extends in the longitudinal direction (L) and has two contact surfaces (32a, 32b, 32c, 32'a, 32'b, 32'c, 34a, 34b, 34c, 34'a, 34'b, 34'c) which are arranged at a distance to one another transversely, in particular orthogonally to the longitudinal direction (L), said distance decreasing at the end face in a nonlinear manner.