Segmented Wind Turbine Rotor Blade Dovetail Joint Assembly
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Solution Overview
Problem
Existing methods for joining large rotor blade segments in wind turbines face challenges such as increased weight, manufacturing difficulties, and the need for dedicated facilities, particularly with bolted and scarf joint connections.
Innovation Solution
A segmented rotor blade design utilizing a dovetail connection with a joint assembly that includes a receiving section and a joining structure, secured by a securement assembly, which can be formed integrally with the blade segments and uses pre-tensioned bolts and thermoplastic resin to maintain contact and transmit loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bolted joint connections are used to join rotor blade segments, then the connection strength and reliability are improved, but the overall weight of the blade increases and maintenance requirements increase
Solution Approach 1:
The patent replaces the traditional bolted mechanical connection system with a scarf joint system that uses friction and surface area to transmit loads. This substitution eliminates the need for heavy bolts and connection hardware, reducing blade weight while maintaining connection reliability through optimized joint geometry and surface treatment.
Solution Approach 2:
The patent employs composite material construction for the blade segments, allowing the scarf joint interface to be integrated into the composite structure itself. This enables the joint to be as strong as or stronger than the blade material, eliminating the need for additional heavy fastening components while maintaining or improving connection strength.
2Weight of moving object
If scarf joint connections are used to join rotor blade segments, then the blade weight is reduced compared to bolted joints, but the manufacturing complexity increases and dedicated facilities are required
Solution Approach 1:
The patent divides the blade into modular segments with standardized scarf joint interfaces that can be manufactured independently and then assembled. This segmentation allows each segment to be manufactured using conventional techniques in existing facilities, reducing the need for specialized dedicated facilities while maintaining the weight advantages of scarf joints.
Solution Approach 2:
The patent incorporates the scarf joint surfaces and alignment features directly into the blade segment manufacturing process itself, rather than requiring separate post-manufacturing operations. This preliminary integration of joint preparation into the molding process eliminates the need for dedicated assembly facilities and complex field manufacturing operations.
3Power
If rotor blade size is increased to improve power generation efficiency, then the amount of power generation increases, but the difficulties with manufacturing, transportation, and handling increase
Solution Approach 1:
The patent divides large rotor blades into smaller manageable segments that can be manufactured using existing facility capabilities, transported with available equipment, and handled with standard cranes and machinery. The segments are then joined using scarf joints to create the full-scale high-power blade, effectively scaling up power generation without proportionally increasing manufacturing and handling difficulties.
Solution Approach 2:
The patent designs the segmented blade structure where smaller segments nest together through the scarf joint interfaces to form progressively larger blade assemblies. This nested approach allows large power-generating blades to be constructed from smaller components that individually have manageable sizes for manufacturing, transportation, and handling.
4Power
If rotor blade size is increased to improve power generation efficiency, then the amount of power generation increases, but the transportation and handling difficulties increase
Solution Approach 1:
The patent segments large rotor blades into smaller sections that fit within standard transportation dimensions and can be handled by conventional cranes and equipment. The segments are transported separately to the assembly location and then joined on-site using scarf joint technology, eliminating the need for specialized heavy-lift transportation infrastructure while enabling the deployment of large power-generating blades.
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 dovetail connection provides a lightweight, efficient, and field-friendly method for joining rotor blade segments, reducing manufacturing complexity and facilitating easier assembly without the need for specialized equipment.
Implementation Method 1
The joint assembly may also include a securement assembly securing the joining structure within the at least one receiving section so as to secure the dovetail connection
Implementation Method 2
uses pre-tensioned bolts and thermoplastic resin to maintain contact and transmit loads
Data Source
AI summary
A segmented rotor blade for a wind turbine. The segmented rotor blade including at least a first blade segment and a second blade segment extending in opposite directions from a joint. Each of the first and second blade segments including at least one shell member defining an airfoil surface. A joint assembly coupling the first blade segment to the second blade segment via a dovetail connection at the joint. The joint assembly including at least one receiving section defining a receiving cavity, a joining structure received within the at least one receiving section to establish a dovetail connection, and a securement assembly securing the joining structure within the at least one receiving section so as to secure the dovetail connection.