Wind Turbine Rotor Blade Welded Joint Design

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Solution Overview

Problem

Conventional wind turbine rotor blades face issues with bond-line failures, complex and labor-intensive manufacturing, and increased weight due to segmented designs, which affect their structural integrity and assembly efficiency.

Innovation Solution

The use of fiber-reinforced composite materials with varying fiber density regions, where thermoplastic resin materials are welded at joint interfaces to form a secure and efficient connection between blade components, reducing the need for complex interconnecting components and enhancing structural properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional adhesive bonding is used to join blade segments, then the joint strength can be adequate, but the manufacturing complexity and labor intensity increase significantly

Engineering Contradiction:

Improvejoint strengthVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent replaces adhesive bonding (chemical system) with mechanical interlocking through tapered spigot and socket joints. The mechanical connection provides both structural strength and alignment functionality, eliminating the need for separate bonding processes and reducing manufacturing complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The blade is divided into multiple segments that can be manufactured separately and assembled on-site. Each segment includes integrated joining features (spigot and socket structures) that simplify the assembly process and reduce the need for complex external joining mechanisms.

Inventive Principle:

Principle #1Segmentation

2Strength

If blade segments are assembled using complex interconnecting components, then the joint strength can be sufficient, but the assembly time increases

Engineering Contradiction:

Improvejoint strengthVSAvoidassembly time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

The spigot and socket joining features are pre-formed as integral parts of the blade segments during manufacturing. This preliminary integration of joining mechanisms eliminates the need for complex assembly operations and reduces on-site assembly time significantly.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The joining features (spigot and socket structures) are merged with the blade segment structures themselves rather than being separate components. This integration combines the structural elements with the joining mechanism, simplifying both the number of parts and the assembly process.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of manufacture

If segmented blade design is used to reduce manufacturing complexity, then the assembly process can be simplified, but the blade weight increases due to additional joints and parts

Engineering Contradiction:

Improvemanufacturing easeVSAvoidblade weight

Core Design Contradiction:

Ease of manufactureVSWeight of moving object

Solution Approach 1:

The patent uses simple, lightweight spigot and socket components rather than heavy, complex interconnecting structures. These simplified joining elements provide adequate strength while minimizing additional weight, making the segmented design more attractive despite the presence of multiple joints.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

4Strength

If conventional molding processes are used for rotor blade shells, then the structural properties can be adequate, but the bond lines become failure points

Engineering Contradiction:

Improvestructural strengthVSAvoidbond line reliability

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent replaces adhesive bonding (chemical system) with mechanical interlocking through tapered spigot and socket joints. This mechanical connection eliminates the bond lines that serve as failure points in conventionally bonded structures, significantly improving joint reliability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 improves the structural integrity and assembly efficiency of wind turbine rotor blades by creating a secure welded joint with reduced weight and complexity, addressing bond-line failures and manufacturing challenges.

Implementation Method 1

thermoplastic resin materials are welded at joint interfaces to form a secure and efficient connection between blade components

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentUS10400745B2Rotor blade components having varying fiber density regions

Publication Date: 2019.09.03 GE INFRASTRUCTURE TECH LLC

AI summary

A rotor blade for a wind turbine may generally include a first blade component formed from a first fiber-reinforced composite including a first thermoplastic resin material and a second blade component configured to be coupled to the first blade component at a joint interface. The second blade component may be formed from a second fiber-reinforced composite including a second thermoplastic resin material. The second fiber-reinforced composite may include a low fiber region and a high fiber region, with the low fiber region having a fiber-weight fraction that is less than a fiber-weight fraction of the high fiber region. In addition, the first thermoplastic resin material of the first fiber-reinforced composite may be welded to the second thermoplastic resin material contained within the low fiber region of the second thermoplastic composite to form a welded joint at the joint interface between the first blade component and the second blade component.