Wind Turbine Spar Caps with Defined Joint Surfaces
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Solution Overview
Problem
Traditional methods for manufacturing wind turbine spars face challenges in achieving a well-defined outer geometry and sufficient strength while minimizing weight, as the inner geometry of tubular elements is well-defined by mandrels or cores, but the outer geometry is less precise, leading to variations and potential mismatch with blade shells.
Innovation Solution
A method involving the use of at least two caps and two webs, where the caps and webs are moulded to form a tubular configuration with well-defined joint surface portions, allowing for a spar with a non-uniform shape that can be precisely matched to wind turbine blade shells, using different materials for intermediate and end portions to optimize strength and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If composite materials are used to increase spar strength, then the strength increases, but the manufacturing complexity and precision control become more difficult
Solution Approach 1:
The spar is segmented into multiple discrete components (spar caps and webs) that are manufactured separately using moulds. This segmentation allows each component to be optimized independently for both strength and geometric precision, with the final assembly achieving the required overall strength while maintaining control over each part's geometry through dedicated moulding processes.
2Ease of manufacture
If a tubular element is made from two separately moulded elements, then manufacturing flexibility increases, but achieving the right size and fit requires additional height adjustment elements
Solution Approach 1:
The invention uses parameter changes in the mould design to directly control the final dimensions of the spar caps. By incorporating adjustable or variable geometry features in the moulds themselves, the correct size and fit are achieved during the moulding process, eliminating the need for additional adjustment elements or complex assembly procedures.
Data Source
AI summary
The invention provides a method of manufacturing a spar (1) for a wind turbine blade steps of providing at least two caps (2a, 2b), each cap forming an intermediate portion (4) between two end portions (5), where the end portions each forms a cap joint surface portion (6) along a longitudinal extending edge of the end portion and the intermediate portion forms an outer surface portion (7) of the spar, providing at least two webs (3a, 3b), each web being provided with web joint surface portions (8) along opposite and longitudinally extending edges, and connecting the joint surface portions of the caps with the joint surface portions of the webs to form a tubular configuration of the spar. The at least two caps are configured for attachment to a blade shell so that the intermediate portion of one of the caps faces towards or forms part of a windward surface of the blade and the other one of the caps faces towards or forms part of a leeward surface of the blade.