Wind Turbine Rotor Blade Segment Joints Using Non-Uniform Bolts
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Solution Overview
Problem
Existing connection methods for wind turbine rotor blade segments are inefficient, using unnecessary material, compromising structural integrity, and preventing disassembly for inspection, maintenance, or upgrading, due to the use of standardized bolts and difficulties in applying bonding materials.
Innovation Solution
The use of non-uniformly sized bolts with varying lengths and cross-sectional areas, strategically positioned and spaced to provide optimal structural support while minimizing material usage, along with alternating bolt directions and threaded inserts for secure and efficient connection of blade segments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If standardized connection pieces (uniformly sized bolts) are used to connect blade segments, then the connection process is simplified, but unnecessary material is used and the structure of the rotor blade is compromised by removing composite material to accommodate oversized bolts
Solution Approach 1:
The patent applies local quality by varying the bolt sizes according to the specific requirements of each connection location. Instead of using uniform bolts throughout, the connection pieces are customized to match the local structural needs, allowing smaller bolts where less strength is required and preserving more composite material, while using larger bolts only where structurally necessary.
Solution Approach 2:
The patent changes the parameter of bolt size from a constant value to a variable value based on location. The connection pieces have different dimensions, materials, and configurations optimized for their specific positions in the blade segment assembly, allowing optimization of both material usage and structural performance.
2Ease of manufacture
If standardized connection pieces are used to connect blade segments, then manufacturing is simplified, but structural integrity is compromised by removing composite material
Solution Approach 1:
The connection pieces are designed with local quality by tailoring each bolt's size, material, and configuration to the specific structural requirements of its location. This ensures that structural integrity is maintained at each connection point without unnecessarily removing composite material from areas that don't require large standardized bolts.
Solution Approach 2:
The patent optimizes structural integrity by varying connection piece parameters (size, material composition, thread configuration) to match the local stress and load conditions at each blade segment interface, rather than applying a one-size-fits-all standardized approach that compromises strength.
3Productivity
If known connection devices are used, then blade segments can be connected, but disassembly is prevented after rotor blade formation, blocking inspection, maintenance, replacement, or upgrading
Solution Approach 1:
The patent applies dynamics by making the connection pieces reversible rather than permanently fixed. The threaded connection design allows the blade segments to be assembled efficiently during manufacturing while also enabling disassembly for future inspection, maintenance, or upgrading, thus adapting to different operational phases.
Solution Approach 2:
The connection system is designed as separable segments that can be independently removed and reinstalled. This segmentation allows the rotor blade to be disassembled into individual blade segments for maintenance purposes while maintaining efficient assembly capability when reconfigured.
4Productivity
If known connection devices are used, then blade segments can be connected, but application and inspection of bonding material is difficult
Solution Approach 1:
The patent introduces an intermediary approach by using threaded connection pieces that create accessible channels and pathways for bonding material application. The connection design allows bonding material to be easily injected or applied at the blade segment interfaces, and the threaded structure provides access points for inspection of the bonding material distribution.
Data Source
Figure 1
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AI summary
Joints 100 for connecting a first blade segment 101 to a second blade segment 102 of a wind turbine rotor blade 16 include a first bolt 120 comprising a first proximal end connected to the first blade segment 101 and a first distal end connected to the second blade segment 102, a second bolt 120 comprising a second proximal end connected to the first blade segment 101 and a second distal end connected to the second blade segment 102, and a third bolt 120 comprising a third proximal end connected to the first blade segment 101 and a third distal end connected to the third blade segment. At least two of the first bolt 120, the second bolt 120 and the third bolt 120 differ in size, and a first distance between the first bolt 120 and the second bolt 120 is different than a second distance between the second bolt and the third bolt.