Segmented Wind Turbine Rotor Head with Intersecting Axis Joints
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Solution Overview
Problem
As wind turbines increase in size, traditional cast metal rotor heads become difficult to mold and transport due to weight and size constraints, and existing segmented designs face reliability issues with joint strength and size reduction limitations.
Innovation Solution
A rotor head formed by joining segments with joint parts in planes intersecting the axis, allowing for reliable production and transportation, and reducing the cross-sectional area between wind turbine blade attaching openings to enhance compactness and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the rotor head is formed as a single component from cast metal, then strength and reliability are improved, but manufacturing difficulty and transportation cost increase significantly with larger sizes
Solution Approach 1:
The rotor head is divided into multiple segments that can be manufactured separately and then assembled. This segmentation allows each segment to be produced within feasible casting size limits, improving manufacturing ease while maintaining overall structural integrity through proper joint design
2Ease of manufacture
If the rotor head is divided into segments, then manufacturing and transportation are improved, but joint strength and long-term reliability deteriorate
Solution Approach 1:
The joint parts are designed with localized structural features including recesses and protrusions that create interlocking connections. The joint geometry is optimized locally to distribute loads and enhance connection strength, ensuring that the jointed structure achieves reliability comparable to integral structures
3Strength
If joint parts are provided around the entire circumference, then structural strength is improved, but the cross-sectional area for molten metal flow increases, limiting size reduction
Solution Approach 1:
The joint parts are positioned in planes intersecting the rotation axis rather than being distributed around the entire circumference. This dimensional repositioning allows the joints to be located where they can effectively resist loads while minimizing the cross-sectional area required for molten metal flow paths, enabling compact core portion design
4Power
If the rotor head size is increased for higher power generation, then power output is improved, but transportation difficulty and manufacturing complexity increase
Solution Approach 1:
The rotor head is segmented into manageable sections that can be manufactured and transported separately, then assembled at the installation site. This segmentation enables the construction of large-scale, high-power rotor heads without being constrained by transportation and manufacturing limitations of monolithic structures
Data Source
AI summary
A pitch drive device of a wind power generator capable of preventing the loss of reliability of the pitch drive device with a simple structure and a wind power generator are provided. A rotor head of a wind power generator in which a plurality of wind turbine blades are radially attached around a rotation axis is formed by joining a plurality of separately formed front rotor head and rear rotor head, and joint portions of the front rotor head and the rear rotor head are formed in a plane intersecting the rotation axis.