Segmented Composite Wind Turbine Blade On-Site Assembly

Solution Overview

Problem

Existing wind turbine blade constructions face limitations in length and material usage due to transportation constraints and the need for lighter, stronger materials, with prior methods being uneconomical for on-site fabrication and often not optimized for specific wind regimes, leading to inefficiencies and increased maintenance costs.

Innovation Solution

A composite wind turbine blade design utilizing longitudinal composite members with fiber and resin layers, including braided sleeves and a continuous outer skin, allowing for assembly into a majority airfoil shape without large molds, enabling on-site assembly and customization for specific wind conditions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If longer wind blades are used to increase swept area and energy capture, then energy generation efficiency is improved, but blade weight increases making transportation difficult

Engineering Contradiction:

Improveenergy generation efficiencyVSAvoidblade weight

Core Design Contradiction:

ProductivityVSWeight of moving object

Solution Approach 1:

The patent employs composite materials consisting of a foam core with embedded fiber-reinforced polymer layers. This composite construction provides high strength-to-weight ratio, enabling longer blades to be manufactured with reduced weight while maintaining structural integrity and aerodynamic performance

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The blade is divided into multiple segments that can be manufactured separately and assembled on-site. This segmentation allows each segment to be transported individually using existing infrastructure, eliminating transportation constraints while achieving the total blade length needed for increased energy capture

Inventive Principle:

Principle #1Segmentation

2Productivity

If blade length is increased to capture more wind energy, then return on investment improves, but transportation constraints prevent delivery to remote locations

Engineering Contradiction:

Improvereturn on investmentVSAvoidblade length

Core Design Contradiction:

ProductivityVSLength of moving object

Solution Approach 1:

The blade is divided into multiple segments that can be manufactured separately and assembled on-site. This segmentation allows each segment to be transported individually using existing infrastructure, eliminating transportation constraints while achieving the total blade length needed for increased energy capture

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Blade segments are pre-manufactured at fabrication facilities near existing infrastructure, then transported to remote sites for assembly. This preliminary manufacturing action enables deployment in remote locations without requiring transportation of complete long-blade assemblies

Inventive Principle:

Principle #10Preliminary action

3Strength

If traditional mold-based construction is used for composite blades, then structural integrity is achieved, but large expensive molds are required that cannot be transported to remote sites

Engineering Contradiction:

Improvestructural integrityVSAvoidmold size and cost

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The blade is divided into multiple segments that can be manufactured separately and assembled on-site. This segmentation allows each segment to be transported individually using existing infrastructure, eliminating transportation constraints while achieving the total blade length needed for increased energy capture

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Blade segments are pre-manufactured at fabrication facilities near existing infrastructure, then transported to remote sites for assembly. This preliminary manufacturing action enables deployment in remote locations without requiring transportation of complete long-blade assemblies

Inventive Principle:

Principle #10Preliminary action

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 enables longer, lighter wind turbine blades that can be efficiently transported and assembled on-site, optimizing structural properties for specific installations while reducing material usage and maintenance needs, thus enhancing cost-effectiveness and performance across varying wind regimes.

Implementation Method 1

each having a fiber and resin layer around a core

Methodology Applied

Scientific EffectComposite materials: Composite Materials

Implementation Method 2

including braided sleeves

Methodology Applied

Scientific EffectBraided structure:

Data Source

PatentUS9169732B1Composite wind turbine blade and method for manufacturing same

Publication Date: 2015.10.27 A&P TECH

AI summary

A wind turbine blade may include a plurality of longitudinal composite members each having a fiber and resin layer around a predetermined cross-sectional shape and each comprising at least one longitudinal outer surface and at least one longitudinal mounting surface, each of the outer surfaces of the plurality of longitudinal composite members corresponding to a different portion of a desired airfoil shape, the plurality of longitudinal composite members assembled such that the outer surfaces of the composite members form at least a majority of the airfoil shape. An outer skin may be provided. The composite members may be made up of transportable segments. A method of assembly may include transporting the segments to a desired location such as an installation site for assembly of the wind turbine blade at the installation site.