Wind Turbine Rotor Blade Surface Feature Attachment

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Solution Overview

Problem

Conventional methods for attaching surface features to wind turbine rotor blades are time-consuming, expensive, and hazardous due to the need for custom tooling and hazardous adhesives, particularly for field installations, and are inefficient for small features.

Innovation Solution

A method involving a mold to form and attach surface features directly onto the rotor blade using materials like thermoset or thermoplastic compounds, with optional pressure application and removal of excess material, and using flexible molds or attachment layers like double-sided tape for secure bonding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional attachment methods using fixtures and adhesives are used, then surface features can be attached to rotor blades, but the installation process becomes time-consuming and expensive

Engineering Contradiction:

Improveattachment process efficiencyVSAvoidinstallation time

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

The mold is pre-positioned at the desired location on the rotor blade before any attachment operations begin. The adhesive is applied to the mold itself rather than to individual surface features, allowing multiple features to be attached simultaneously in a single operation, dramatically reducing installation time and eliminating the need for complex fixtures

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Multiple surface features are attached simultaneously through a single adhesive application process. The mold holds multiple cavities that form multiple surface features, allowing them to be positioned and attached in one operation rather than individually, reducing both time and cost

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If conventional attachment methods using hazardous adhesives are used, then surface features can be secured to rotor blades, but safety risks and protective measures increase

Engineering Contradiction:

Improveattachment securityVSAvoidhazardous material exposure

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The mold serves as an intermediary carrier that holds the adhesive in a controlled manner. By applying adhesive to the mold rather than directly to individual surface features or the blade, the system gains better control over adhesive distribution and reduces the need for extensive protective measures during application

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The adhesive is applied once to the mold and then automatically distributed to multiple surface features simultaneously as they are formed in the mold cavities. This self-distributing mechanism reduces manual handling of hazardous adhesive and minimizes exposure risks for workers

Inventive Principle:

Principle #25Self-service

3Manufacturing precision

If custom tooling is used for each location on the rotor blade, then accurate attachment of surface features is achieved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improveattachment accuracyVSAvoidtooling complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

A single mold design can be used to attach multiple surface features at various locations on the rotor blade. The mold is simply repositioned to different locations rather than requiring custom tooling for each position, maintaining precision while eliminating the need for multiple specialized fixtures

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The mold can be adapted to different locations on the rotor blade by changing its position and orientation parameters rather than changing the mold itself. This allows the same tooling to achieve accurate attachment at multiple locations by adjusting where and how it is applied

Inventive Principle:

Principle #35Parameter changes

4Ease of manufacture

If conventional methods are used for small surface features, then attachment is achieved, but the process becomes tedious and inefficient

Engineering Contradiction:

Improveattachment efficiencyVSAvoidinstallation speed

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

Multiple small surface features are attached simultaneously through a single adhesive application and curing process. The mold holds multiple cavities that form multiple small features at once, making the process efficient rather than tedious despite the small size and numerous quantity of the features

Inventive Principle:

Principle #5Merging (Combining)

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 method reduces installation time and costs, enhances safety by minimizing hazardous material exposure, and allows for efficient attachment of small features, improving the aerodynamic performance of wind turbine blades.

Implementation Method 1

an adhesive layer is applied between a blade-side surface of each of the plurality of surface features and either of the suction side or the pressure side

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS11274650B2Attachment methods for surface features of wind turbine rotor blades

Publication Date: 2022.03.15 GE INFRASTRUCTURE TECH LLC

AI summary

The present disclosure is directed to methods for attaching a plurality of surface features to a rotor blade of a wind turbine. Such methods may include direct molding of the surface features to the rotor blade, bonding arrays of connected components to the rotor blade and subsequently removing connections between components, as well as using a flexible template with or without a tinted adhesive.