Segmented Mounting Ring for Wind Turbine Blade Root Bushing Alignment
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Solution Overview
Problem
The existing methods for manufacturing wind turbine rotor blades using a mounting ring arrangement are complex and costly due to the need for precise alignment of ring halves, which can lead to fibre compression or shifting during the blade mould joining process, resulting in defective root ends.
Innovation Solution
A mounting ring arrangement comprising a mounting ring segment and a partial mounting ring, where the partial mounting ring has a recess to accommodate the segment, ensuring accurate geometrical alignment and embedding of root bushings, allowing for a more straightforward and cost-effective manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a circular or one-piece mounting ring is used, then the alignment of root bushings is simplified, but the complexity of arranging fibre material between the root bushings increases
Solution Approach 1:
The mounting ring is divided into two separate ring segments that are placed in different blade mould halves. This segmentation allows fibre material to be arranged freely between the root bushings in each mould half without the obstruction of a complete circular ring, while still providing the alignment function through the distributed bushing arrangement.
2Ease of manufacture
If two ring segments are used to avoid fibre material arrangement complexity, then fibre placement is easier, but the alignment accuracy between ring segments becomes critical and difficult to achieve
Solution Approach 1:
Instead of requiring precise alignment of the ring segments themselves, the invention applies local quality by ensuring that each root bushing is individually positioned with high precision in its respective mould half. The alignment function is distributed to the individual bushing locations rather than requiring global ring segment alignment.
Solution Approach 2:
The root bushings are pre-positioned and fixed to the ring segments before the mould halves are joined. This preliminary action ensures that when the moulds are assembled, the bushings are already in their correct positions, eliminating the need for precise ring segment alignment during the joining process.
3Device complexity
If conventional mounting ring halves are used, then the structure is simple, but the manufacturing cost increases due to high effort required for accurate placement and alignment
Solution Approach 1:
The mounting ring is segmented into two parts that can be independently prepared and placed in separate mould halves. This allows parallel preparation of fibre layups and bushing arrangements in both mould halves simultaneously, improving manufacturing efficiency while maintaining the simple ring structure concept.
Solution Approach 2:
The ring segments serve themselves by having the root bushings directly attached to them, eliminating the need for separate alignment fixtures or complex joining mechanisms. The segments are self-contained units that can be independently positioned and secured.
Data Source
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AI summary
The invention describes a mounting ring arrangement (1S, 1P) realised for the alignment of root bushings (4) in a rotor blade root end (70) during a rotor blade assembly step, which mounting ring arrangement (1S, 1P) comprises a mounting ring segment (1S); and a partial mounting ring (1P), which partial mounting ring (1P) is realised as a closed annular component (1P) and comprises a recess (10) dimensioned to accommodate the mounting ring segment (1S). The invention also describes a method of manufacturing a rotor blade (7), which method comprises the steps of (A) arranging a fibre layup (3) in a first blade mould (M1) and arranging a fibre layup (3) in a second blade mould (M2); (B) arranging the partial mounting ring (1P) of a mounting ring arrangement (1P, 1S) according to any of claims 1 to 9 in the first blade mould (M1) and arranging the mounting ring segment (1S) of the mounting ring arrangement (1P, 1S) in the second blade mould (M2); and (C) joining the first and second blade moulds (M1, M2) such that the partial mounting ring (1P) and the mounting ring segment (1S) join to form a full mounting ring (1P, 1S).