Wind Turbine Split Blade Joining via Embedded Composite Laminates
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Solution Overview
Problem
The existing manufacturing methods for split blades of wind turbines with joining elements are complex, limiting the efficiency and cost-effectiveness of the process.
Innovation Solution
A manufacturing method involving the creation of joint laminates with embedded joining elements, which are then used as preforms to manufacture inboard and outboard shells or spars, allowing for centralized quality control and decentralized production, using composite materials like Carbon Fibre Reinforced Plastic (CFRP) or Glass Fiber Reinforced Plastic (GFRP).
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If joining elements are incorporated into components during their manufacture, then the integration of joining elements is improved, but the manufacturing complexity increases
Solution Approach 1:
The blade is divided into multiple sections (inboard section and outboard section) that can be manufactured separately and then joined together using joining elements. This segmentation allows each section to be manufactured independently with simpler processes, while the joining elements provide the necessary integration between sections.
Solution Approach 2:
Joining elements are incorporated into components during their manufacture as a preliminary action, so that when the sections are assembled, the joining elements are already in place and properly integrated. This eliminates the need for separate installation steps and ensures proper integration from the start.
2Power
If blade length is increased to increase power output, then energy production is improved, but transportation and infrastructure requirements worsen
Solution Approach 1:
The blade is divided into multiple transportable sections that can be manufactured separately and assembled at the wind turbine site. This allows the final blade to achieve the length necessary for high power output while each individual section remains within transportation constraints.
Solution Approach 2:
The joining elements are embedded within the blade sections themselves, with the joining means integrated into the structure of the inboard and outboard sections. This nested integration allows the blade to achieve its full length and structural integrity without requiring external infrastructure for joining.
3Length of moving object
If blade is divided into multiple sections for transportation, then transportation problems are solved, but the number of joining operations increases
Solution Approach 1:
The joining elements are combined with the blade sections during their manufacture, merging the joining function with the structural components. This integration reduces the number of separate joining operations needed during assembly, as the joining elements are already incorporated into the sections themselves.
Data Source
AI summary
The invention provides a manufacturing method of a component of a split blade of a wind turbine (such as an inboard shell or an inboard spar) having joining elements with its complementary component (i.e. an outboard shell or an outboard spar). The method comprises the following steps: a) manufacturing a joint laminate of a composite material having embedded into it the joining elements, said joint laminate being configured for becoming a part of the component; b) manufacturing the component using as a preform said joint laminate. The invention also refers to a split blade comprising components manufactured by said manufacturing method.