Wind Turbine Rotor Blade Segments with Variable Gap
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Solution Overview
Problem
The existing rotor blades in wind turbines face issues with structural integrity due to differing stiffnesses between beam structures and receiving sections, leading to uneven loading and potential direct contact at connection locations, which can cause stress concentration and reduced durability.
Innovation Solution
The rotor blade design incorporates a variable-size gap between the beam structure and the receiving section, with a varying thickness in the span-wise direction, secured by pin joints, bolts, or adhesives, allowing for optimal deflection and stress distribution, and optionally filled with a filler material to enhance structural support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the beam structure and receiving section are directly coupled at connection locations, then structural support is provided, but stress concentration and indefinite loading occur due to differing stiffnesses
Solution Approach 1:
A gap is introduced between the beam structure and receiving section to act as an intermediary element. This gap prevents direct contact and the associated stress concentration at connection locations, allowing the differing stiffnesses of the beam structure and receiving section to be accommodated without causing indefinite loading on the components.
Solution Approach 2:
The gap serves as a pre-established cushioning space that accommodates the differential deflection between the beam structure and receiving section before direct contact occurs. This beforehand cushioning prevents the harmful effect of stress concentration from occurring in the first place.
2Ease of manufacture
If the beam structure and receiving section are directly coupled, then connection is achieved, but uneven loading occurs due to distinct deformations from differing stiffnesses
Solution Approach 1:
The gap acts as an intermediary that decouples the direct mechanical interaction between the beam structure and receiving section. This allows each component to deform according to its own stiffness characteristics without transmitting uneven loads to the other, while still maintaining the necessary connection through the gap.
3Reliability
If a constant gap thickness is maintained, then stress distribution is optimized, but manufacturing precision requirements increase
Solution Approach 1:
The gap thickness is designed to vary locally along the span-wise direction rather than being uniformly constant. This local variation in gap thickness allows optimization of stress distribution at different locations while accommodating manufacturing tolerances, as the critical stress areas can be targeted with specific gap dimensions.
Data Source
AI summary
A rotor blade for a wind turbine including a first blade segment and a second blade segment extending in opposite directions from a chord-wise joint. Each of the first and second blade segments include one or more shell members and an internal support structure. The internal support structure of the first blade segment includes a beam structure extending between a receiving end and a second end. The internal support structure of the second blade segment includes a receiving section that receives the receiving end of the beam structure of the first blade segment. The rotor blade further includes one or more connection locations where the first and second blade segments are secured together. Moreover, when the beam structure is received within the receiving section, a gap including a varying thickness is defined and maintained between the beam structure and the receiving section in a span-wise direction of the rotor blade.