Tapered Box Adhesive Joint for Wind Turbine Blades
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for joining long turbine blades, such as those used in wind turbines, are complex, costly, and risky due to the use of metallic fasteners and other techniques, which are not suitable for high-power wind turbines with blades exceeding 50 meters in length.
Innovation Solution
A system and method involving tapered outer and inner boxes supported by bulkheads, which are adhesively bonded to facilitate the insertion and coupling of blade segments without metallic fasteners, using composite materials tolerant to harsh environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metallic fasteners and traditional joining techniques are used to join long turbine blade sections, then the structural strength is improved, but the device complexity and manufacturing cost increase significantly
Solution Approach 1:
The patent replaces traditional mechanical fastening systems (metallic fasteners, spliced structures, dowel pins) with an adhesive bonding system. The adhesive is applied between the outboard and inboard blade segments to create a strong chemical bond, eliminating the need for complex mechanical fasteners and significantly reducing assembly complexity while maintaining joint strength.
Solution Approach 2:
The patent employs composite materials in the adhesive bonding system to achieve strong joints between blade segments. The adhesive acts as a composite material that bonds the structural components together, providing both structural integrity and simplifying the joining process compared to traditional metallic fastening methods.
2Reliability
If traditional joining methods with metallic fasteners are used, then reliable connection is achieved, but the manufacturing expense and assembly risk increase
Solution Approach 1:
The adhesive bonding system replaces complex mechanical fastening operations with a simpler application process. The adhesive is applied between blade segments and cured to create a reliable bond, eliminating the need for precise alignment and installation of multiple metallic fasteners, thereby improving ease of manufacture while maintaining connection reliability.
3Strength
If blade sections are joined using conventional techniques, then structural integrity is maintained, but the assembly process becomes costly and time-consuming
Solution Approach 1:
The adhesive bonding process replaces time-consuming mechanical fastening operations. The adhesive can be applied continuously along the joint interface and cures to form strong bonds, significantly reducing assembly time and improving productivity while maintaining structural integrity of the joined blade sections.
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 approach simplifies the assembly process, reduces complexity and cost, and provides a strong, efficient joint for long turbine blades, enabling the construction of high-power wind turbines with reduced assembly risks.
Implementation Method 1
A system and method involving tapered outer and inner boxes supported by bulkheads, which are adhesively bonded to facilitate the insertion and coupling of blade segments without metallic fasteners
Data Source
AI summary
A blade assembly including an outboard blade segment is provided. The outboard blade segment includes an outboard blade shell, first and second outboard bulkheads situated within the outboard blade shell, and an outer box supported by and aligned by the outboard bulkheads. The blade assembly also includes an inboard blade segment including an inboard blade shell, first and second inboard bulkheads situated within the inboard blade shell, and an inner box supported by and aligned by the inboard bulkheads. Further, the inner and the outer boxes are tapered to facilitate insertion of the inner box into the outer box and coupling of the inner and outer boxes.