Turbine Blade Segmentation for Remote Assembly
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Solution Overview
Problem
Shipping large turbine blades for applications like wind turbines is inconvenient and expensive due to their size, necessitating a method to join sections together at a remote location without excessive complexity and expense.
Innovation Solution
A method involving the integration of an integral bulkhead with a blade shell to form a blade, which is then separated into segments, allowing each segment to include a portion of the bulkhead and shell, enabling easier assembly and shipment, with the bulkhead being fabricated as a one-piece component or composite parts integrated using locking elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If turbine blades are manufactured as large integral structures, then structural strength and integrity are improved, but shipping cost and convenience deteriorate
Solution Approach 1:
The turbine blade is divided into multiple segments that can be manufactured separately and assembled at the installation site. The bulkhead is designed with integrated attachment features that enable mechanical connection between segments, maintaining structural integrity while allowing separate transportation of smaller components.
2Ease of manufacture
If turbine blades are divided into segments for shipping, then shipping cost and convenience are improved, but assembly complexity at remote location worsens
Solution Approach 1:
The bulkhead integrates multiple functions into a single component: it provides structural support, incorporates attachment features for joining blade segments, and includes mechanisms for securing the joint. This merging of functions reduces the number of separate parts and simplifies the assembly process at remote locations.
3Manufacturing precision
If bulkhead is fabricated as one-piece component, then manufacturing precision and structural integrity are improved, but material usage and cost worsen
Solution Approach 1:
The bulkhead is divided into multiple parts that can be manufactured separately using optimized material quantities for each section, then joined using locking elements. This segmentation allows for more efficient material usage while maintaining the structural integrity and precision of the complete bulkhead assembly.
4Adaptability or versatility
If blade is assembled from multiple parts, then adaptability for remote assembly is improved, but device complexity worsens
Solution Approach 1:
The bulkhead combines multiple functional elements into integrated features, including attachment surfaces, locking mechanisms, and structural support elements. This reduces the total number of separate parts required while maintaining the adaptability for remote assembly of blade segments.
Data Source
AI summary
A method includes joining an integral bulkhead and a blade shell to form a blade and separating the blade into two blade segments at a location including the integral bulkhead such that each blade segment comprises a portion of the integral bulkhead and a portion of the blade shell.