Wind Turbine Blade Segmentation with Flow Altering Devices
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Solution Overview
Problem
The traditional method of designing wind turbine blades is complex and time-consuming, requiring initial design of the outer shape and aerodynamic performance, followed by manufacturing, which results in high development costs and long time-to-market for new blade types due to the complexity of manufacturing and mould production.
Innovation Solution
A method where a first blade design is used as a base for a second blade, with flow altering devices applied to adjust the aerodynamic properties to meet target induction factors, allowing for a simpler base part profile and modular design, enabling reuse of base parts across different blade lengths and types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional aerodynamic design methods are used to design wind turbine blades with complex double-curved contours and multiple airfoil shapes, then the aerodynamic performance and target loading are optimized, but the manufacturing process and mould production become quite complex and time-consuming
Solution Approach 1:
The blade is divided into a base part with simplified geometry and separate flow altering devices. This segmentation allows the base part to be manufactured using simple moulds, while the flow altering devices (such as flaps, slats, or vortex generators) are added subsequently to achieve the desired aerodynamic performance without requiring complex double-curved contours in the main blade structure
Solution Approach 2:
Instead of changing the complex geometric parameters of the base blade profile, the invention changes aerodynamic parameters by adding flow altering devices. These devices modify the flow characteristics over the blade surface, effectively changing the aerodynamic behavior without requiring complex manufacturing of the base part itself
2Reliability
If traditional aerodynamic design methods are used to design wind turbine blades with complex double-curved contours and multiple airfoil shapes, then the aerodynamic performance and target loading are optimized, but the development time from initial design to product launch becomes long
Solution Approach 1:
The base part of the blade is designed and manufactured in advance with simplified geometry using standard moulds. The flow altering devices are then added in a subsequent step to achieve the final aerodynamic performance. This preliminary action with the base part allows for faster initial production while maintaining the ability to optimize aerodynamics through the added devices
Solution Approach 2:
By separating the blade into a base part and flow altering devices, the development process is accelerated. The base part can be designed once and reused, while only the flow altering devices need to be modified for different aerodynamic requirements, significantly reducing the overall development time from design to product launch
3Reliability
If traditional aerodynamic design methods are used to design wind turbine blades with complex double-curved contours, then the target axial induction factor is achieved, but the manufacturing costs and production costs become high
Solution Approach 1:
The blade is segmented into a base part with simple geometry that is easy and cheap to manufacture, and separate flow altering devices that provide the necessary aerodynamic performance. This segmentation eliminates the need for expensive moulds required for complex double-curved contours, significantly reducing both manufacturing and production costs while maintaining the target axial induction factor
Solution Approach 2:
The flow altering devices can be made as separate, potentially disposable components that are added to the base part. These devices achieve the required aerodynamic performance without requiring expensive, complex moulds for the entire blade, making the overall manufacturing process more cost-effective
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 design and manufacturing process, reduces production costs, and shortens the time from design to market by using flow altering devices to compensate for non-ideal aerodynamic characteristics, enabling efficient production of blades with near-optimum performance.
Implementation Method 1
the first longitudinal segment of the second blade is provided with first flow altering devices so as to adjust the aerodynamic properties of the first longitudinal segment
Data Source
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AI summary
A method of manufacturing a wind turbine blade by using the design of a longitudinal segment of a first wind turbine blade for the design of a second wind turbine blade is described. The first wind turbine blade and the second wind turbine blade each comprise a longitudinally extending base part having a profiled contour comprising a pressure side and a suction side as well as a leading edge and a trailing edge with a chord extending between the leading edge and the trailing edge, the profiled contour generating a lift when being impacted by an incident airflow, the profiled contour in the radial direction being divided into a root region with a substantially circular or elliptical profile closest to the hub, an airfoil region with a lift generating profile furthest away from the hub, and preferably a transition region between the root region and the airfoil region, the transition region having a profile gradually changing in the radial direction from the circular or elliptical profile of the root region to the lift generating profile of the airfoil region. The method comprises the steps of a) taking a first blade design of a first base part of a first longitudinal section of the airfoil region of a first blade, b) using the first blade design for the first base part on a first longitudinal section of the airfoil region of a second blade, so that an induction factor of the first base part on the second blade without flow altering devices at a rotor design point deviates from a target induction factor, and c) providing the first longitudinal section of the second blade with first flow altering devices so as to adjust the aerodynamic properties of the first longitudinal segment to substantially meet the target induction factor at the design point on the second blade. The first longitudinal segment extends along at least 20% of a longitudinal extent of the airfoil region of the second blade.