Wind Blade Cable Installation via Extraction and Sealing
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Solution Overview
Problem
The installation of cables in wind blades for sensor communication poses challenges, including structural integrity issues with large manholes, increased manufacturing lead time with external sensor placement, and the limitations of wireless sensors requiring frequent battery replacements and costly energy harvesting systems.
Innovation Solution
A method and system involving a cable with a sheath and flexible layer, where the cable is laid inside the wind blade during manufacturing and accessed externally through a narrow path after manufacture, allowing easy extraction and routing with a protection pipe and sealing, avoiding the need for large manholes and reducing battery reliance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If large manholes or access panels are created on the wind blade surface to access cables, then cable accessibility is improved, but structural integrity of the wind blade deteriorates
Solution Approach 1:
The cable is extracted from the internal cavity through a small access hole and routed externally along the wind blade surface using a protection pipe, eliminating the need for large manholes while maintaining structural integrity
Solution Approach 2:
A protection pipe serves as an intermediary component that guides the cable from the internal cavity to the external surface, allowing cable access through a minimal opening while preserving the wind blade's structural strength
2Device complexity
If sensors are positioned outside the wind blade during manufacturing phase, then cable routing complexity is reduced, but manufacturing lead time increases
Solution Approach 1:
The cable is preliminarily disposed inside the wind blade during manufacturing, and the access hole is created after manufacturing is complete, allowing parallel processing that reduces overall manufacturing lead time
Solution Approach 2:
The cable installation process is segmented into two independent phases: internal cable disposal during manufacturing and external routing after manufacturing, allowing these operations to occur at different times without increasing total lead time
3Strength
If wireless sensors are used to avoid holes in the wind blade surface, then structural integrity is maintained, but system cost increases due to expensive sensors and energy harvesting systems
Solution Approach 1:
The patent replaces wireless sensors with wired sensors connected through a protection pipe, substituting an expensive electronic system with a simpler mechanical cable routing solution that maintains structural integrity while reducing system cost
4Duration of action of stationary object
If wireless sensors with energy harvesting systems are used, then continuous operation is achieved, but power availability is limited and battery replacement frequency increases
Solution Approach 1:
The cable is extracted and routed externally, enabling wired power and data connection that eliminates batteries entirely, achieving continuous operation without any replacement frequency issues
Data Source
AI summary
A method of installing a cable in an elongated structure, wherein the cable includes one or more lines is disclosed. The method includes a) enclosing the one or more lines of the cable using a sheath, b) coupling one end of the sheath to a flexible layer, c) disposing the flexible layer at a defined location at an inner surface of elongated structure, d) creating an access path extending from an outer surface of the elongated structure, opposite to the defined location, and e) extracting at least one of the flexible layer, the one or more lines, and the sheath from inside the elongate structure via the access path. Further, a system for installation of a cable in an elongated structure is also disclosed.