Wind Turbine Frame With Decoupled Cross Structure

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Solution Overview

Problem

Wind turbine frames face challenges in reducing weight and stress fatigue while maintaining structural integrity, particularly due to the dynamic loading induced by wind energy, which existing designs struggle to address efficiently.

Innovation Solution

A frame design featuring a cross-shaped structure decoupled from the load-bearing beams, allowing for reduced stress transfer and enabling the cross-shaped structure to be designed exclusively for tension, using materials like cables or ropes, and allowing for sliding or rotational joints with low friction materials to prevent deformation and fatigue.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If the cross-shaped structure is rigidly connected to the load-bearing beams, then structural stability is improved, but stress and fatigue on the beams increase

Engineering Contradiction:

Improvestructural stabilityVSAvoidstress and fatigue on beams

Core Design Contradiction:

Stability of the object's compositionVSStrength

Solution Approach 1:

The frame is divided into functionally independent segments: the load-bearing third beam and the cross-shaped structure. The decoupling allows each segment to perform its specific function without transferring stress to the other, reducing fatigue on the beams while maintaining structural stability through geometric arrangement.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The cross-shaped structure is extracted from the load-bearing function and positioned independently alongside the third beam. This extraction removes the stress-inducing connection while preserving the geometric and visual stability provided by the cross-shaped configuration.

Inventive Principle:

Principle #2Taking out (Extraction)

2Strength

If additional stiffening components are added to the frame, then structural strength is improved, but frame weight increases

Engineering Contradiction:

Improvestructural strengthVSAvoidframe weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The frame design allows dynamic movement between the cross-shaped structure and the third beam through the opening. This dynamic arrangement provides structural adaptability that maintains strength while using less material, reducing overall frame weight compared to rigid stiffening components.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The cross-shaped structure uses slender, cable-like elements that provide structural functionality with minimal material. These flexible, thin elements maintain geometric stability without the weight penalty of traditional rigid stiffening beams.

Inventive Principle:

Principle #30Flexible shells and thin films

3Adaptability or versatility

If the cross-shaped structure is designed to withstand both tension and compression, then structural versatility is improved, but component complexity increases

Engineering Contradiction:

Improvestructural versatilityVSAvoidcomponent complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The cross-shaped structure is designed with local quality optimization: each leg is specifically configured for its local stress conditions (tension or compression) based on its position and function. This localized design approach provides versatility without requiring the entire structure to be over-engineered for all possible load conditions.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

Instead of designing the cross-shaped structure to withstand all types of loads universally, the design inverts the approach by allowing the structure to be optimized for specific load types (tension or compression) based on its geometric configuration and position, achieving versatility through specialized design rather than general-purpose design.

Inventive Principle:

Principle #13The other way round (Inversion)

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 design achieves weight reduction, increased flexibility, and cost efficiency by decoupling the cross-shaped structure from the load-bearing beams, allowing for a focus on tension resistance without compression, thereby enhancing the structural integrity and reducing stress and fatigue in wind turbine components.

Implementation Method 1

a joint with a low friction material facilitating the movement between the cross-shaped structure and the third beam

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentEP3475562B1A frame for carrying a load in a wind turbine

Publication Date: 2021.02.24 VESTAS WIND SYSTEMS AS

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Figure 3A~4
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AI summary

The invention is a frame for carrying a load in a wind turbine. The frame comprises a first and a second beam extending in a lengthwise direction, a third beam extending in a transverse direction between a first joint on the first beam and a second joint on the second beam. The third beam is configured for carrying the load. The frame further comprises a stress-inducing cross-shaped structure forming four legs joined at an intersection and extending therefrom towards four ends, where two of the four ends are attached on opposite sides of the joint on the first beam and the other two of the four ends are attached on opposite sides of the joint on the second beam. To prevent excessive deflection of the third beam and of the cross- shaped structure, the cross-shaped structure is decoupled from the third beam and therefore allowed to move e.g. without touching the third beam.