Wind Turbine Rotor Assembly Cable System Design
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Solution Overview
Problem
Existing wind turbine rotor assemblies face issues with complex cable systems that interfere with wing shapes, leading to undesirable peak loads and vibrations, increased weight, and manufacturing complexities, particularly due to non-uniform twists in extruded wings.
Innovation Solution
A rotor assembly design featuring a central hub with vanes having a central and radial vane part, where the radial vane part includes a wing with an internal cavity for secure attachment, and a simplified cable system with a pair of cables per vane, minimizing interference and allowing for efficient deformation absorption, along with a manufacturing process using a twisted extrusion die for uniform twist and reduced complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a cable system is used to connect intermediate points of vanes to the central hub, then structural support is provided, but the cables interfere with the wing shape of the vanes causing peak loads and vibrations
Solution Approach 1:
The patent removes the intermediate cable connections between vanes and the central hub, eliminating the source of interference with the wing shape. The cables are extracted from the system entirely, allowing the vanes to operate without the harmful peak loads and vibrations caused by cable-wing interference.
Solution Approach 2:
The vane structure is divided into a central hub portion and radial vane parts that are independently connected. This segmentation allows each component to function independently without the need for intermediate cable connections, reducing structural complexity and eliminating vibration sources.
2Reliability
If multiple cables per vane are used to provide structural support, then reliability is improved, but device complexity increases
Solution Approach 1:
The patent eliminates the complex multi-cable system per vane by removing intermediate cable connections. Instead, the vanes are directly supported through their attachment to the central hub, significantly reducing device complexity while maintaining structural reliability through the streamlined design.
3Stability of the object's composition
If a big ring connection is used to connect intermediate points of vanes, then structural stability is improved, but weight and complexity increase
Solution Approach 1:
The patent removes the big ring connection entirely, eliminating the additional weight and complexity it introduces. The vanes are directly attached to the central hub, providing structural stability without the need for intermediate connecting rings.
4Productivity
If a twisted shape is applied to the wing to improve aerodynamics, then wind energy conversion is improved, but manufacturing complexity increases due to non-uniform twist
Solution Approach 1:
The patent applies a uniform twist parameter along the length of the extruded wing, changing the geometric parameter from non-uniform to uniform. This uniform twist is achieved through controlled extrusion processes, improving manufacturing consistency and reducing complexity while maintaining aerodynamic performance.
5Force
If the cable system is aligned with the longitudinal axis of the vane, then cable load is reduced, but the cables still interfere with the wing shape
Solution Approach 1:
The patent removes the cable system entirely from the intermediate connections, eliminating both the cable load issue and the wing-cable interference problem simultaneously. The direct attachment of vanes to the central hub provides support without requiring intermediate cables.
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
The design results in a lightweight, simpler construction with reduced air resistance, minimized peak loads, and improved wind energy conversion efficiency, while the manufacturing process ensures uniform twist and mechanical properties for the wings.
Implementation Method 1
The wing (35) is rotatably attached to the tube (34) of the radial vane part (30)
Implementation Method 2
the wing (35) is produced as a twisted extruded profile, that is twisted about its longitudinal axis
Data Source
Figure 1
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Figure 3
AI summary
There is provided a rotor assembly for a wind turbine having vanes and an advantageous cable system.