Wind Turbine Blade Adhesive Bonding Spar Assembly

Solution Overview

Problem

Conventional wind power generator blades face challenges in achieving lightweight construction, reducing manufacturing costs, and ensuring a smooth surface for efficient wind flow due to the use of rivets and mold-based methods, which complicate the manufacturing process and hinder weight reduction and aerodynamic performance.

Innovation Solution

The design incorporates a main spar with protruded flanges and webs, coupled with adhesive steps, and additional structural elements like C-type spars and curved ribs, eliminating the need for rivets and allowing for a smooth surface by bonding these components together, thereby simplifying assembly and reducing weight and manufacturing costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If rivets and rivet holes are used to join components, then the structural strength is improved, but the blade weight increases and the manufacturing cost increases

Engineering Contradiction:

Improvestructural strengthVSAvoidblade weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent replaces the mechanical fastening system (rivets and rivet holes) with a chemical bonding system (adhesive). The adhesive is applied to the bonding surfaces of the skin and spar, creating a strong chemical bond that joins the components without requiring physical fasteners. This substitution eliminates the weight of rivets and the material removed by rivet holes while maintaining structural integrity through the adhesive bond.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Strength

If rivets and rivet holes are used to join components, then the structural strength is improved, but the manufacturing process becomes more complicated and manufacturing cost increases

Engineering Contradiction:

Improvestructural strengthVSAvoidmanufacturing process complexity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent replaces the mechanical fastening system (rivets and rivet holes) with a chemical bonding system (adhesive). The adhesive is applied to the bonding surfaces of the skin and spar, creating a strong chemical bond that joins the components without requiring physical fasteners. This substitution eliminates the weight of rivets and the material removed by rivet holes while maintaining structural integrity through the adhesive bond.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent extracts and eliminates the rivet fastening system from the blade structure. By removing the rivets and rivet holes, the design simplifies the manufacturing process by eliminating the steps required to drill, countersink, and install rivets. The adhesive bonding system requires only surface preparation and adhesive application, significantly reducing manufacturing complexity.

Inventive Principle:

Principle #2Taking out (Extraction)

3Strength

If rivet holes are formed in the blade surface, then the components can be joined together, but the blade surface becomes non-smooth and aerodynamic performance deteriorates

Engineering Contradiction:

Improvecomponent joiningVSAvoidblade surface smoothness

Core Design Contradiction:

StrengthVSShape

Solution Approach 1:

The patent replaces the mechanical fastening system (rivets and rivet holes) with a chemical bonding system (adhesive). The adhesive is applied to the bonding surfaces of the skin and spar, creating a strong chemical bond that joins the components without requiring physical fasteners. This substitution eliminates the weight of rivets and the material removed by rivet holes while maintaining structural integrity through the adhesive bond.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent extracts and eliminates the rivet fastening system from the blade structure. By removing the rivets and rivet holes, the design simplifies the manufacturing process by eliminating the steps required to drill, countersink, and install rivets. The adhesive bonding system requires only surface preparation and adhesive application, significantly reducing manufacturing complexity.

Inventive Principle:

Principle #2Taking out (Extraction)

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 enables weight reduction, lowers manufacturing costs, and enhances aerodynamic performance by eliminating the need for rivets and simplifying the assembly process, leading to improved wind power generation efficiency.

Implementation Method 1

the steps and the pair of main spar flanges are coupled together with an adhesive

Methodology Applied

Scientific EffectAdhesive bonding: Adhesive

Data Source

PatentUS10393090B2Blade for wind power generator

Publication Date: 2019.08.27 IND UNIV COOPERATION FOUND OF KOREA AEROSPACE UNIV

AI summary

Provided is a blade for a wind power generator comprising: a main spar including: an upper main spar flange and a lower main spar flange whose both ends are protruded towards the front and rear side respectively; a front main spar web and a rear main spar web which are connecting the upper main spar flange and the lower main spar flange; a first body, located in the front side of the main spar, including an inverted D-type rib; and a second body, located in the rear side of the main spar, including a curved rib. The inverted D-type rib includes: a vertical frame; and a block frame extendedly formed from the upper side and the lower side of the vertical frame respectively and convexly formed towards the front side.