Segmented Wind Turbine Blade Structure for Strength and Aerodynamics
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Solution Overview
Problem
The increasing size of wind turbine blades poses challenges in manufacturing, transportation, and installation due to larger moulds, heavier components, and higher logistical demands, while existing designs compromise between aerodynamic performance and structural strength, and the root region of current blades contributes to drag and reduced energy production.
Innovation Solution
A wind turbine blade design combining an inboard blade part with a load-carrying structure optimized for strength and an outboard part optimized for aerodynamics, allowing separate manufacturing and assembly, with the outboard part being pitchable to reduce pitching system demands and enhance energy yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the wind turbine blade is made longer to increase energy production, then the energy yield increases, but the manufacturing complexity, transportation difficulty, and installation challenge increase significantly
Solution Approach 1:
The blade is divided into multiple sections (root section, intermediate sections, tip section) that can be manufactured separately and assembled together. This allows each section to be produced in smaller, more manageable moulds and transported more easily, while still achieving the total blade length needed for high energy production
Solution Approach 2:
The intermediate blade sections are designed to be nested within each other during transportation, with smaller sections fitting inside larger ones. This reduces the transportation volume and logistical complexity while maintaining the ability to assemble a long blade for high energy yield
2Strength
If the blade root region is made wider to strengthen mounting, then the mounting strength improves, but the drag increases and energy production decreases
Solution Approach 1:
The blade root section has a circular cross-section optimized for strong mounting to the hub, while the blade tip and intermediate sections have airfoil cross-sections optimized for aerodynamic performance. This local differentiation allows each part to have the quality needed for its specific function without compromising the other
Solution Approach 2:
The blade is segmented into a root section with circular cross-section for strength and intermediate/tip sections with airfoil cross-sections for aerodynamics. The transition region connects these different geometries, allowing the strong root design without the penalty of circular cross-section drag across the entire blade
3Productivity
If the blade is designed as a single piece for optimal aerodynamics, then the aerodynamic performance is maximized, but the manufacturing and transportation costs increase
Solution Approach 1:
The blade is divided into multiple manufacturable sections that can be produced separately in smaller facilities with smaller moulds, then assembled into a complete blade that maintains optimal aerodynamic performance across all sections including the transition regions
4Adaptability or versatility
If the pitching system is made more powerful to handle larger blades, then the control capability improves, but the system weight and cost increase
Solution Approach 1:
The pitching system is segmented so that only the outer blade sections containing the airfoil profiles require pitching capability, while the inner root section remains fixed. This reduces the mass that needs to be pitched compared to traditional designs where the entire blade must be pitched, thereby reducing pitching system weight and power requirements
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 design facilitates easier and cheaper transportation, reduces manufacturing costs, and improves aerodynamic performance by optimizing both structural strength and energy production, while minimizing the weight and complexity of the pitching system.
Implementation Method 1
When the wind turbine blade is impacted by incident airflow, the profiled contour generates a lift. When the wind turbine blade is mounted on a wind turbine, the wind turbine hub begins to rotate due to the lift.
Data Source
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AI summary
A blade (10) for a rotor of a wind turbine (2) is disclosed. The blade is assembled from an inboard blade part (50) closest to the hub and an outboard blade part (110) farthest from the hub of the wind turbine. The inboard part (50) comprises a load carrying structure (60) with a first aerodynamic shell (70) fitted to the load carrying structure (60), and the outboard part (110) comprises a blade shell (141, 143) with a load carrying structure (142, 144) integrated in the blade shell (141, 143).