Segmented Wind Turbine Blade Mounting for Lower Torsional Loads
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Solution Overview
Problem
The installation of large rotor blades in wind turbines is hindered by extreme loads and torsional moments, requiring specialized tools and limiting operations to low wind conditions, increasing costs and complexity.
Innovation Solution
A method involving the mounting of blade root segments first, followed by extension segments, reduces torsional moments by orienting segments at specific angles and using smaller cranes, allowing installation at higher wind speeds and minimizing gearbox stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional blade installation methods are used with complete blades, then the blades can be mounted to the rotor hub, but extreme torsional moments are generated on the gearbox and other components during installation
Solution Approach 1:
The blade is divided into two segments: a blade root segment that is mounted to the rotor hub first, and a blade extension segment that is connected afterward. This segmentation allows the installation process to proceed in stages, with the rotor hub rotated to appropriate positions between segments, thereby reducing the torsional moments and rotor imbalance experienced during installation compared to mounting complete blades.
2Reliability
If conventional blade installation methods are used, then blades can be mounted to the rotor hub, but a driving tool capable of handling extreme loads is required
Solution Approach 1:
By segmenting the blade into root and extension portions that are installed at different times, the rotor imbalance during installation is significantly reduced. This eliminates the need for complex, high-capacity driving tools, as the lighter blade root segment creates much smaller unbalanced forces that can be handled by standard equipment.
3Reliability
If conventional blade installation methods are used, then blades can be mounted, but installation is limited to very low wind conditions to prevent increased rotor imbalance
Solution Approach 1:
The segmented installation approach reduces rotor imbalance during the installation process, allowing operations to proceed at higher wind speeds than would be safe with complete blades. This expands the acceptable weather window for installation operations, improving project scheduling flexibility and reducing weather-related delays.
4Productivity
If increasing wind turbine size or blade size is pursued to increase energy production, then energy efficiency improves, but the extreme loads increasingly drive up the design and costs of the gearbox and other components
Solution Approach 1:
The segmented blade installation method reduces the extreme torsional moments and loads experienced during installation, making it feasible to install larger blades without proportionally increasing the size and cost of the gearbox and supporting components. The reduction in installation loads allows existing component designs to support larger turbine configurations.
5Productivity
If increasing wind turbine size or blade size is pursued, then energy production increases, but the costs of manufacturing, transporting, assembly or repair increase
Solution Approach 1:
By reducing the extreme loads during installation, the segmented approach allows for the use of smaller, less expensive cranes and installation equipment. This reduces the overall assembly cost and makes the installation of large blades more economically viable, improving the cost-benefit ratio of increasing turbine size for higher energy production.
Data Source
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Figure 3~4B
AI summary
A method (100) of mounting blades (22) to a rotor hub (20) of a wind turbine (10), the wind turbine (10) comprising a tower (12), a nacelle (16) mounted on the tower (12), the rotor hub (20) being coupled to the nacelle (16), and blades (22), each blade (22) comprising a blade root segment (56) and a blade extension segment (66), the method (100) comprising mounting a first blade root segment (50) to the rotor hub (20), mounting a second blade (72) to the rotor hub (20) after mounting the first blade root segment (50), the second blade (72) comprising a second blade root segment (52) and a second blade extension segment (62), and connecting a first blade extension segment (60) to the first blade root segment (50) after mounting the second blade (72).