Wind Turbine Spar Assembly Segmented Joint Design
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Solution Overview
Problem
Conventional wind turbine rotor blades have insufficient structural properties to withstand bending moments and loads, and existing spar assemblies are difficult to install and costly, especially as blade sizes increase, necessitating improved structural integrity and assembly methods.
Innovation Solution
A spar assembly for wind turbine rotor blades comprising multiple spar cap segments joined by dowel pins, with a structural web and adhesive for enhanced stiffness, allowing for reduced shell thickness and cost-effective assembly of blade segments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional spar caps are used to reinforce the shell, then structural integrity is improved, but device complexity and difficulty of installation increase
Solution Approach 1:
The spar cap is divided into multiple segments that can be separately manufactured and then joined together using scarf joints. This segmentation allows the spar assembly to maintain high structural integrity while reducing the complexity of handling and installing large single-piece spar caps, as smaller segments are more manageable during installation processes.
Solution Approach 2:
Adhesive bonding is introduced as an intermediary method to join the spar cap segments together. This adhesive intermediary allows for strong structural connections between segments while simplifying the assembly process compared to mechanical fastening methods, thereby maintaining strength while reducing installation complexity.
2Ease of manufacture
If blade segments are used to reduce manufacturing and transportation costs, then cost is reduced, but assembly time and complexity increase
Solution Approach 1:
The rotor blade is divided into multiple blade segments that can be manufactured separately and transported independently. This segmentation enables cost-effective manufacturing and transportation of smaller components, while the segments are designed with matching scarf joint interfaces that facilitate relatively quick assembly at the installation site.
Solution Approach 2:
The spar cap segments are pre-assembled and pre-bonded together in a controlled manufacturing environment before the blade segments are final assembled. This preliminary action ensures proper alignment and bonding conditions are met, reducing the time and complexity of final field assembly.
3Stability of the object's composition
If scarf joints are used to join blade segments, then structural continuity is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The spar cap is segmented into multiple sections with scarf joint interfaces. These segmented sections are designed to be joined using scarf joints that provide structural continuity, while the segmentation allows for more manageable manufacturing and assembly processes compared to creating one large continuous spar cap.
Solution Approach 2:
Adhesive is used as an intermediary material in the scarf joint connection between blade segments. This adhesive intermediary fills the scarf joint interface and provides strong bonding that ensures structural continuity, while the bonding process is simpler and more cost-effective than alternative mechanical joining methods.
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
The solution provides increased load-carrying capacity and deflection control, reducing material and mass while simplifying the installation process, thereby enhancing energy efficiency and reducing costs for larger rotor blades.
Implementation Method 1
The plurality of pins are inserted into the plurality of holes in the second spar cap segment to form a chord-wise joint. In one embodiment, an adhesive is used to bond the spar cap segments together.
Implementation Method 2
A spar assembly for wind turbine rotor blades comprises multiple spar cap segments joined by a plurality of dowel pins
Data Source
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AI summary
A spar assembly 50 for a rotor blade 16 of a wind turbine 10 is disclosed. The spar assembly 50 includes a first spar cap segment 53 and a second spar cap segment 55. The first spar cap segment 53 is configured on an interior surface 63 of a first blade segment 62 and the second spar cap segment 55 is configured on an interior surface 63 of a second blade segment 64. Each spar cap segment 53, 55 includes an end having a joint section 57, 59 that is joinable at a chord-wise joint. Each of the first and second joint sections 57, 59 includes a plurality of holes 68 formed therein. Further, the spar assembly 50 includes a plurality of pins 66 inserted into the plurality of holes 68 of the first and second joint sections 57, 59 to join the first and second blade segments 62, 64 so as to improve stiffness of the rotor blade 16.