Segmented Wind Turbine Rotor Blade Sections
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Solution Overview
Problem
Current manufacturing and assembly techniques for large wind turbine rotor blades face challenges with bonding line control, edge contour control, reparability, weight reduction, and handling of components, particularly in assembling and transporting blade sections of increasing sizes.
Innovation Solution
The rotor blade section is designed with a plurality of ribs extending in a chord-wise direction, each with an aerodynamic outer surface, and cross-members between ribs, along with an outer body that matches the aerodynamic contour, allowing for independent management and assembly of sections, facilitating easier transportation and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If rotor blade size is increased to increase energy production, then energy production is improved, but manufacturing and transportation costs increase
Solution Approach 1:
The rotor blade is divided into multiple blade sections that can be manufactured separately and assembled on-site. Each blade section includes ribs, cross-members, and outer bodies that can be produced in controlled environments and transported more easily than a complete large blade, reducing manufacturing and transportation costs while enabling larger overall blade sizes for increased energy production.
2Power
If rotor blade size is increased to increase energy production, then energy production is improved, but structural integrity becomes more difficult to maintain
Solution Approach 1:
Dividing the blade into sections with internal structural elements (ribs, cross-members, spar caps) allows each section to be optimized for structural integrity independently while maintaining overall blade strength through controlled assembly connections.
Solution Approach 2:
The blade sections utilize composite materials including fiber-reinforced polymers for the outer bodies and structural elements, providing high strength-to-weight ratio and maintaining structural integrity across large blade sizes while enabling energy production increases.
3Productivity
If rotor blade weight is decreased to improve efficiency, then efficiency is improved, but structural strength is reduced
Solution Approach 1:
The rotor blade sections employ composite materials such as fiber-reinforced polymers and lightweight core materials that provide high strength-to-weight ratios, enabling weight reduction for improved efficiency while maintaining necessary structural strength through optimized material distribution and structural design.
Solution Approach 2:
Different sections of the blade utilize materials and structural configurations optimized for their specific functional requirements, with varying material densities and structural reinforcements placed where needed to maintain strength while minimizing overall weight for improved efficiency.
4Ease of manufacture
If blade sections are manufactured separately to reduce transportation costs, then transportation costs are reduced, but bonding line control and edge contour control become more difficult
Solution Approach 1:
Standardized bonding surfaces, alignment features, and pre-formed structural elements are incorporated into each blade section during manufacturing, enabling precise assembly connections and consistent edge contours when sections are joined on-site, thereby maintaining manufacturing precision while benefiting from reduced transportation costs of segmented components.
Data Source
AI summary
A rotor blade section and a method for assembling a rotor blade for a wind turbine are disclosed. The rotor blade section includes a plurality of ribs each extending in a generally chord-wise direction. Each of the plurality of ribs includes an outer surface. The outer surface has a generally aerodynamic contour. The rotor blade section further includes at least one cross-member extending between adjacent ribs of the plurality of ribs, and an outer body mounted to the plurality of ribs. The outer body has an aerodynamic contour generally corresponding to the aerodynamic contour of the plurality of ribs.