Multi-Component Shear Web Joint Assembly for Wind Turbine Blades
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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 decreased strength, particularly in sections where repair is not feasible.
Innovation Solution
A multi-component shear web configuration with a joint assembly featuring H-shaped connecting members and a flexible material, where the shear web components are infused directly with spar caps, reducing the number of bonded joints and using an adhesive or fasteners for secure bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a rigid flange is used to achieve desired bond width with bond paste, then bond width dimension is improved, but blade weight increases and bond paste may break off causing rattling
Solution Approach 1:
The shear web is divided into multiple discrete components (first shear web component, second shear web component, third shear web component) instead of using a single continuous shear web with rigid flange. This segmentation eliminates the need for excess bond paste while maintaining precise bond width dimensions through the modular structure of individual components.
2Manufacturing precision
If excess bond paste is used to achieve desired bond width, then bond width dimension is improved, but bond strength decreases due to air voids and unpredictable squeeze-out
Solution Approach 1:
The shear web is divided into multiple discrete components (first shear web component, second shear web component, third shear web component) instead of using a single continuous shear web with rigid flange. This segmentation eliminates the need for excess bond paste while maintaining precise bond width dimensions through the modular structure of individual components.
3Stability of the object's composition
If a continuous shear web spans between spar caps, then structural continuity is improved, but the juncture between shear web and spar cap becomes time-consuming and tedious to manufacture
Solution Approach 1:
The shear web is divided into multiple discrete components (first shear web component, second shear web component, third shear web component) that can be manufactured and assembled separately. This segmentation simplifies the manufacturing process at the junctures between shear web and spar caps while maintaining structural continuity through the interconnected modular components.
Solution Approach 2:
The invention changes the structural parameters of the shear web from a single continuous element to multiple discrete components with specific geometries (including H-shaped cross-sections with flanges and webs). This parameter change enables easier manufacturing through standardized modular components while preserving the structural continuity needed for load transfer.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration enhances bond strength, reduces weight, and simplifies the manufacturing process by eliminating the need for excess bond paste, while allowing for flexible movement with the rotor blade, thereby improving the structural integrity and operational reliability of wind turbine blades.
Implementation Method 1
The connecting structure is infused and integral with the first component of the shear web. Further, the connecting structure is bonded with the second component of the shear web.
Data Source
AI summary
A wind turbine rotor blade joint assembly and method of manufacturing same is disclosed. The rotor blade includes an upper shell member having a spar cap configured on an internal face thereof and a lower shell member having a spar cap configured on an internal face thereof. A shear web extends between the spar caps along a longitudinal length of the blade. The shear web includes first and second longitudinally aligned components that extend from and are integral with respective spar caps. A joint assembly is configured between facing transverse ends of the first and second components of the shear web. The joint assembly includes a connecting structure configured to receive the transverse ends of the first and second components. The connecting structure is infused and integral with the first component of the shear web and bonded with the second component of the shear web.