Segmented Composite Screw Turbine Blades for Easier Shipping
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Solution Overview
Problem
The manufacture and deployment of steel screw turbines are labor-intensive and costly, with significant challenges in shipping and installation due to their large and heavy nature, limiting their flow capacity and power output.
Innovation Solution
The development of composite screw systems with removably attachable blade segments made of composite materials, using a closed mold formation process for consistency and reduced labor costs, and a shaft with helical holes for easy assembly, allowing for unassembled shipping and field assembly, reducing deployment time and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional steel turbines are fabricated using welded annular sections, then structural strength is achieved, but manufacturing time and labor costs increase significantly
Solution Approach 1:
The turbine is divided into multiple removable blade segments that can be manufactured separately and assembled later, eliminating the need for time-consuming welding operations while maintaining structural integrity through mechanical attachment mechanisms
Solution Approach 2:
The patent employs composite materials for blade segments that provide high strength-to-weight ratio, achieving structural strength requirements without the need for extensive welding and post-processing operations required by conventional steel construction
2Ease of operation
If steel turbines are fully assembled before shipping, then installation readiness is improved, but shipping costs and transportation difficulty increase
Solution Approach 1:
The turbine components are segmented into modular blade sections that can be shipped separately in compact configurations, reducing shipping weight and costs, while maintaining installation readiness through standardized attachment mechanisms that enable quick field assembly
Solution Approach 2:
Blade segments are pre-manufactured and pre-positioned with attachment features, allowing for preliminary preparation without complete assembly, so that final assembly can be efficiently completed at the installation site
3Quantity of substance
If the turbine diameter is increased to improve flow capacity, then power output increases, but transportation and installation difficulty increase
Solution Approach 1:
Large-diameter turbines are constructed from multiple smaller blade segments that can be manufactured and shipped with manageable dimensions, then assembled to achieve the required large diameter for high flow capacity, effectively bypassing transportation size constraints
Solution Approach 2:
The turbine design transitions from a solid large-diameter structure to a segmented modular configuration, allowing components to be transported in compact forms and assembled in three-dimensional space to achieve the required operational dimensions
4Strength
If conventional steel construction methods are used, then structural integrity is maintained, but corrosion resistance and maintenance requirements are worsened
Solution Approach 1:
The patent utilizes composite materials for blade segments that inherently provide superior corrosion resistance compared to conventional steel, while maintaining structural integrity through carefully engineered composite structures and attachment mechanisms
Data Source
AI summary
A screw system including a plurality of segmented blades. Each blade segment of the plurality of blade segments including a mounting portion and a vane portion. The mounting portion, having a helical length, for removably attaching the blade segment. The vane portion extending from the mounting portion along the helical length thereof. The vane portion having a front surface that is not parallel to a back surface from the mounting portion to a tip of the blade segment, along the helical length.