Wind Turbine Blade Shear Web Intermediate Connection Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional wind turbine blade shear web configurations face challenges in achieving precise bond dimensions and strength between spar caps, leading to excess weight, bond paste issues, and reduced durability due to air voids and unpredictable squeeze-out, which complicates the manufacturing process and can result in blade rattling during operation.
Innovation Solution
A multi-component shear web configuration with intermediate connection assemblies, including retaining structures such as transversely extending flange members or longitudinally extending wall members, to confine bond paste and achieve a strong, uniform bond between shear web components and spar caps, optimizing bond width and thickness dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a rigid flange is used to achieve desired bond width between shear web and spar cap, then bond width is improved, but excess bond paste is used which increases blade weight
Solution Approach 1:
The shear web is divided into multiple discrete components (first component, second component, and intermediate component) rather than using a single continuous member. This segmentation allows for precise control of bond dimensions at each interface, enabling adequate bond width without requiring excessive bond paste that would increase blade weight.
Solution Approach 2:
An intermediate component is introduced between the first and second shear web components to achieve the desired bond width. This intermediary element provides a larger bonding surface area without requiring excess bond paste, as the intermediate component itself structurally defines the bond geometry and provides mechanical interlocking.
2Stability of the object's composition
If continuous shear web spans between spar caps, then structural continuity is improved, but manufacturing precision becomes difficult and time-consuming
Solution Approach 1:
The continuous shear web is segmented into discrete components that can be manufactured separately with controlled tolerances. Each component has defined dimensions and bonding surfaces that are easier to manufacture precisely compared to a single continuous piece requiring complex in-situ bonding.
Solution Approach 2:
The shear web components are pre-manufactured with precise dimensions and bonding surfaces before assembly. This preliminary fabrication allows for quality control and dimensional precision to be achieved during manufacturing rather than during the complex assembly process between spar caps.
3Quantity of substance
If excess bond paste is used to achieve desired bond width, then bond coverage is improved, but blade rattling occurs due to paste break-off
Solution Approach 1:
The segmented shear web components create multiple discrete bonding interfaces rather than one large continuous bond. This distribution of bonding surfaces reduces the total quantity of bond paste required while maintaining adequate bond strength, eliminating the paste break-off that causes blade rattling.
Solution Approach 2:
The intermediate component acts as a mediator that provides structural support and mechanical interlocking at the bonding interface. This reduces dependence on large quantities of bond paste for structural integrity, allowing for minimal paste application that won't break off during operation.
4Strength
If bond paste is applied between spar caps and shear web, then bonding is achieved, but air voids and unpredictable squeeze-out reduce bond strength
Solution Approach 1:
Segmenting the shear web into discrete components creates multiple smaller bonding zones that are easier to control during assembly. Each interface can be bonded with consistent paste application and proper consolidation, reducing air void formation and ensuring predictable squeeze-out behavior for consistent bond quality.
Data Source
AI summary
A wind turbine blade has upper and lower shell members with a respective spar cap configured on an internal face of the shell members. A shear web extends between the spar caps along a longitudinal length of the blade and includes first and second components extending from a respective spar cap. An intermediate connection assembly is provided between facing transverse ends of the first and second components, and includes bond paste retaining structure configured relative to the transverse ends to achieve a bond between the transverse ends having desired width and thickness dimensions.