Segmented Wind Turbine Rotor Blade Connection for Flapwise Load Transfer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Manufacturing very long wind turbine rotor blades is constrained by manufacturing errors, transportation, installation, and structural limitations, particularly in segmented blades, which face challenges in transferring flapwise loads and require complex assembly for lightning protection.
Innovation Solution
A connecting interface using double-end stud bolts with aligned bores and threaded nuts, embedded in precast spar caps, effectively transfers flapwise and edgewise loads, and facilitates seamless assembly with integrated lightning protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rotor blades are manufactured as one piece, then manufacturing precision and structural integrity are improved, but manufacturing complexity and cost increase significantly for very long blades
Solution Approach 1:
The rotor blade is divided into multiple segments that can be manufactured separately and then connected. This segmentation allows each segment to be manufactured with controlled complexity while the overall blade achieves the required length and structural integrity through proper connection interfaces.
2Ease of manufacture
If rotor blades are segmented, then transportation and installation costs are reduced, but the ability to transfer flapwise loads is limited
Solution Approach 1:
Connection elements such as bolts, keys, or interlocking features are pre-integrated into the blade segment designs during manufacturing. This preliminary integration ensures that when segments are assembled, the load transfer paths are already established, enabling effective flapwise load transfer without requiring complex field assembly operations.
3Ease of operation
If conventional connection methods are used for segmented blades, then assembly is simplified, but complex assembly measures are required for lightning protection systems
Solution Approach 1:
The connection interface between blade segments is designed to serve multiple functions: mechanical load transfer, structural alignment, and integration of lightning protection conductors. By incorporating conductor connection capabilities directly into the mechanical connection elements, the system eliminates separate assembly steps for lightning protection while maintaining structural integrity.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention describes a wind turbine rotor blade (2) comprising at least a first rotor blade segment (21) and a second rotor blade segment (22) connected by means of a connecting interface (1), which connecting interface (1) comprises a plurality of bores (11) formed in a connecting face (21F, 22F) of each rotor blade segment (21, 22), each bore (11) extending in a longitudinal direction (L) of the rotor blade (2) and terminating in a cavity (12) dimensioned to accommodate a threaded nut (13); a threaded nut (13) arranged in each of the plurality of cavities (12); and a plurality of double-end stud bolts (10), wherein a double-end stud bolt (10) comprises a shaped portion (100) formed between a first threaded end (101) and a second threaded end (102), which shaped portion (100) is shaped to engage with a bolt tightening means; and wherein the first threaded end (101) of each double-end stud bolt (100) is screwed into a threaded nut (13) held in a cavity (12) of the first rotor blade segment (21), and the second threaded end (102) of each double-end stud bolt (100) is screwed into a threaded nut (13) held in a cavity (12) of the second rotor blade segment (22). The invention further describes a method of manufacturing such a wind turbine rotor blade (2); a method of assembling a wind turbine rotor blade (2); and a wind turbine (3) comprising a number of such rotor blades (2).