Wind Turbine Hub Space Frame Design

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Solution Overview

Problem

Monolithic shell structures used in wind turbine hubs are structurally inefficient due to material wastage and stress concentrations caused by large cutouts, leading to excessive weight and increased manufacturing costs.

Innovation Solution

A space frame with truss members configured to carry primary torsion, bending, and direct loading, combined with a shell to stabilize and carry shear loading, which reduces material usage and eliminates stress concentrations, using either metal or composite materials for the shell and attachment methods like welding, bolting, or bonding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a monolithic shell structure is used for the hub, then the hub can be manufactured as a single piece, but the structure becomes structurally inefficient and excessively heavy due to material wastage and stress concentrations from large cutouts

Engineering Contradiction:

Improvesingle-piece manufacturingVSAvoidhub weight

Core Design Contradiction:

Ease of manufactureVSWeight of moving object

Solution Approach 1:

The hub is divided into multiple components: a space frame structure with truss members and a separate shell. This segmentation allows each component to be optimized independently - the space frame provides structural efficiency while the shell provides aerodynamic surfaces, eliminating the need for excessive material in a monolithic design.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention combines different structural elements (space frame with truss members and shell) to create a composite hub structure. This composite approach allows the structure to achieve both strength and lightness by using materials and configurations optimized for their specific functions rather than using a single monolithic material.

Inventive Principle:

Principle #40Composite materials

2Adaptability or versatility

If large cutouts are made in the monolithic shell for blade and shaft attachments, then component interfaces can be created, but stress concentrations occur and structural efficiency decreases

Engineering Contradiction:

Improvecomponent interface capabilityVSAvoidstructural strength

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

By separating the hub into a space frame and shell, attachment interfaces can be created at the joints and connections of the space frame structure rather than through large cutouts in a shell. This segmentation allows for localized attachment points that maintain overall structural integrity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The space frame structure acts as an intermediary between the shell and the components to be attached (blades, shafts). Instead of directly cutting into the shell, attachments are made to the space frame members, which then transmit loads to the shell, distributing stresses more evenly.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If extensive machining is performed on the hub to create component interfaces, then multiple attachments can be made, but manufacturing costs and material waste increase

Engineering Contradiction:

Improvemultiple component attachmentsVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The hub is segmented into a space frame structure where multiple component attachments can be made at the joints and connection points. This eliminates the need for extensive machining of a monolithic structure, as the segmented design naturally provides attachment interfaces at the frame members.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The space frame structure is designed with pre-configured attachment points and connection interfaces built into the truss members. This preliminary design of attachment locations eliminates the need for extensive post-manufacturing machining operations.

Inventive Principle:

Principle #10Preliminary action

4Strength

If a monolithic hub structure is used, then the structure can support heavy loads, but the supporting tower must be designed with increased capacity to support the excess weight

Engineering Contradiction:

Improveload bearing capacityVSAvoidtower weight capacity requirement

Core Design Contradiction:

StrengthVSWeight of stationary object

Solution Approach 1:

The segmented space frame structure distributes loads through multiple truss members and connection points, maintaining load-bearing capacity while reducing overall weight. This allows the hub to support heavy operational loads without requiring the supporting tower to be designed for excessive weight capacity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

By changing the structural parameters from a solid monolithic design to a segmented space frame with optimized truss members, the strength-to-weight ratio is improved. The hub maintains adequate load-bearing capacity through the geometric configuration and material distribution of the space frame rather than through excessive material mass.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS7740450B2Lightweight hub for rotors

Publication Date: 2010.06.22 GENERAL ELECTRIC CO

AI summary

A structure for a hub of a rotor includes a space frame having truss members configured to carry primary torsion, bending, and direct loading. The structure also includes a shell on the space frame configured to stabilize the space frame and carry shear loading.