Rotor Blade Segmentation and Thermoplastic Welding
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Solution Overview
Problem
Current methods for assembling rotor blades are logistically difficult, time-consuming, and expensive due to the challenges of transporting long blades and assembling them at erection sites, with a high risk of catastrophic failures at bond lines.
Innovation Solution
A method involving the use of a fixture system with cradle assemblies supported on transportation vehicles to align and connect spar caps and blade segments of rotor blade portions at the erection site, utilizing thermoplastic resin for welding, which reduces transportation and assembly complexities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire rotor blade is assembled at the manufacturing site and then transported to the erection site, then the blade structure is complete and ready for installation, but transportation becomes logistically difficult, time-consuming and expensive due to the length of the rotor blades
Solution Approach 1:
The rotor blade is divided into multiple transportable portions (e.g., root portion, intermediate portions, tip portion) that can be manufactured separately and transported independently to the erection site, where they are subsequently assembled using the fixture system and welding process
2Reliability
If the entire rotor blade is assembled at the manufacturing site and then transported to the erection site, then the blade structure is complete and ready for installation, but transportation becomes logistically difficult, time-consuming and expensive due to the length of the rotor blades
Solution Approach 1:
The rotor blade is divided into multiple transportable portions (e.g., root portion, intermediate portions, tip portion) that can be manufactured separately and transported independently to the erection site, where they are subsequently assembled using the fixture system and welding process
3Device complexity
If portions of the rotor blade are assembled separately and then connected at the erection site using bonding paste, then transportation complexity is reduced, but the assembly process becomes difficult and time-consuming
Solution Approach 1:
The conventional bonding paste application process is replaced with a welding process that uses thermoplastic resin to join blade portions. The fixture system positions portions for welding, and the thermoplastic resin is heated to melt and bond the portions together, eliminating the time-consuming bonding paste application and curing process
Solution Approach 2:
The joining method changes from chemical bonding (bonding paste) to thermal bonding (welding with thermoplastic resin). The thermoplastic resin is heated to its melting point, allowing the blade portions to be welded together quickly and strongly, significantly reducing assembly time
4Ease of manufacture
If bonding paste is applied along the bond line with minimum designed bond width, then the blade can be assembled, but the bond line becomes a critical failure point with significant number of turbine blade field failures occurring there
Solution Approach 1:
The conventional bonding paste application process is replaced with a welding process that uses thermoplastic resin to join blade portions. The fixture system positions portions for welding, and the thermoplastic resin is heated to melt and bond the portions together, eliminating the time-consuming bonding paste application and curing process
Solution Approach 2:
The blade portions are joined using thermoplastic resin composite material that provides both structural strength and bonding functionality. The thermoplastic resin creates a unified composite structure between blade portions, eliminating the weak interface created by bonding paste and significantly improving bond line reliability
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 decreases the time and expense associated with rotor blade transportation and assembly, enhances structural integrity by using thermoplastic resin for bonding, and minimizes the risk of catastrophic failures by improving the assembly process efficiency and reliability.
Implementation Method 1
welding a spar cap of the first portion and a spar cap of the second portion together at the erection site, the spar cap of the first portion and the spar cap of the second portion each including a thermoplastic resin
Data Source
AI summary
Methods for assembling rotor blades are provided. A method includes receiving a first portion of a rotor blade at an erection site. The method further includes receiving a second portion of the rotor blade at the erection site. The method further includes aligning the first portion and the second portion at the erection site, the first portion and the second portion supported on a fixture system when aligned. The method further includes connecting a blade component of the first portion and a blade component of the second portion together at the erection site.