Wind Turbine Blade Assembly Using Gravity Alignment
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Solution Overview
Problem
The assembly of wind turbine blades from long and flexible blade elements poses challenges in correct alignment and joining, as existing methods lack robustness and efficiency, especially for blades exceeding 40 meters in length.
Innovation Solution
The method involves using pre-bent and/or pre-twisted alignment members inserted at defined positions within the blade elements, which align along a longitudinal axis due to gravity, facilitating the joining of root-end and tip-end elements through over-lamination and anchoring, allowing for accurate alignment and assembly of wind turbine blades from separate components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If wind turbine blades are made longer to reduce energy cost, then energy production efficiency is improved, but transportation difficulty and assembly complexity increase
Solution Approach 1:
The wind turbine blade is divided into multiple detachable elements (first element, second element, etc.) that can be manufactured separately and transported easily. These segments are then joined together during assembly to form the complete long blade, resolving the contradiction between blade length and transportation difficulty.
Solution Approach 2:
Alignment members are introduced as intermediary components between blade elements to facilitate precise alignment during assembly. These alignment members include alignment features that guide the positioning of segments, reducing assembly complexity while enabling longer blade construction.
2Device complexity
If wind turbine blades are assembled from shorter elements, then transportation difficulty is reduced, but alignment precision and joining reliability deteriorate
Solution Approach 1:
Alignment members serve as intermediary components that ensure precise alignment between blade elements. These members include alignment features such as alignment pins, alignment slots, or alignment surfaces that guide the positioning of segments, maintaining high alignment precision even when assembling shorter elements.
Solution Approach 2:
The alignment members are pre-installed in the blade elements before assembly, or alignment features are pre-formed during manufacturing. This preliminary preparation ensures that when elements are joined, precise alignment is achieved without requiring complex real-time adjustment procedures.
3Manufacturing precision
If alignment members are used to ensure precise alignment, then assembly precision is improved, but device complexity and assembly time increase
Solution Approach 1:
The alignment members are designed to be self-aligning, utilizing features such as tapered alignment surfaces, spherical alignment heads, or interference-fit alignment pins that automatically position blade elements correctly without requiring external alignment tools or complex adjustment procedures. This self-service approach improves precision while minimizing added complexity.
Solution Approach 2:
The alignment members are designed to perform multiple functions: alignment, positioning, and sometimes even temporary mechanical connection during assembly. This multi-functionality reduces the need for separate alignment tools and procedures, improving precision while limiting the increase in overall assembly complexity.
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 precise and efficient assembly of wind turbine blades, reducing transportation costs and complexities associated with long blades, while ensuring robust and accurate alignment of blade elements, thereby enhancing the assembly process for longer blades.
Implementation Method 1
the one or more members align along a longitudinal axis of at least one of the first element and the second element due to gravity
Data Source
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AI summary
A method for assembling a wind turbine blade is disclosed. The method includes providing a root end element 70 of the wind turbine blade 10, providing a tip end element 72 of the wind turbine blade 10, and inserting one or more alignment members 82 at pre-defined positions in at least one of the root end elements 70 and the tip end element 72, The one or more alignment members 82 is of a pre-defined shape. The method further includes aligning the one or more members 82 with a receiver portion of at least one of the root end elements 70 and the tip end element 72 in which the one or more alignment members 82 is not inserted, along a joining portion. Then, joining the root end element 70 and the tip end element 72 wherein, during joining, the one or more alignment members 82 align along a longitudinal axis of at least one of the root end elements 70 and the tip end element 72.