Patent Application
20150143696
The present subject matter relates to an apparatus for assembling blade sections for forming a blade for a wind turbine rotor. In particular, the apparatus for assembling blade sections according to the present subject matter enables an advantageous operation for assembling blades for large-scale wind turbines.
Further, the present subject matter relates to a method of operating the apparatus which provides a simplified and enhanced procedure for assembling blades for large-scale wind turbines.
In a commonly known wind turbine, a plurality of blades is mounted to a hub. The hub is connected to a generator system. The generator systemgenerates electricity based on the rotational power caused by wind energy exerted on the blades. In commonly known wind turbine installations, the hub is rotatably mounted with the axis being aligned substantially horizontally, such an installation is referred to as a horizontal axis wind turbine.
In recent years, the length of wind turbine blades has increased in order to provide wind turbine installations with an output of as much as 1 MW (el) or more in a single turbine. Consequently, specific restrictions relating to the transportation of elements of such wind turbine installations are introduced. However, large wind turbine installations provide an increased output, an enhanced efficiency and, besides others, several economic improvements.
Conventional rotor systems are set up with single part blades which are mounted to the hub at the construction site of the wind turbine installation. Due to the fact that large-scale wind turbine installations are frequently set up at remote locations, restrictions with respect to transportation of blades having a length of 50 m or more introduce a limitation on the power output of the single wind turbine and consequently decrease the economic and energetic efficiency.
Wind turbine blades which comprise two blade sections are known in the state of the art. Said blade sections are joined longitudinally in order to enable the transportation to the construction site of the wind turbine installation as the single blade sections meet the requirements of transportability. The blade sections are assembled to form the complete blade at the construction site and the blade is mounted to the hub of the wind turbine in order to complete the rotor. Special apparatuses for assembling such multi-section blades have not been developed yet.
According to the basic concept of the present subject matter, an apparatus for assembling blade sections for forming a blade is provided. The apparatus comprises at least two members movable with respect to each other, said members having respective opposing surfaces forming a pressing space, said pressing space being adapted to receive respective joining end portions of said blade sections to be assembled, moving means for moving said members with respect to each other, controlling means for controlling said moving means, supplying means for supplying a fluid into a boundary portion between said blade sections when received in said pressing space, wherein said control means controls said moving means to exert a predetermined pressure to at least one of the joining end portions of said blade sections when received in said pressing space.
The apparatus for assembling blade sections for forming a blade according to the present subject matter is applicable to blade sections which are joinable to each other in a longitudinal direction. The apparatus for assembling blade sections according to the present subject matter is arranged with said at least two members which are movable with respect to each other. The at least two members of the apparatus for assembling blade sections can be moved in order to exert a force or a pressure to specific portions of said blade sections to be joined. Consequently, the apparatus for assembling blade sections is advantageous for joining blade sections which require a specific force or pressure to predetermine portions for joining.
In the apparatus for assembling blade sections according to the present subject matter, supply means for injecting a fluid, such as adhesive fluid, into a boundary portion between said blade sections are provided. In cooperation with the force or pressure exerted by the at least two members to the blade sections, the supply means can supply a fluid into the boundary portion between said blade sections when received in said pressing space which is formed by respective opposing surfaces of said at least two members.
The fluid which can be supplied by said supply means can be a joining fluid for forming a joint between the blade sections in order to form the blade.
According to an embodiment of the present subject matter, said members are movable with respect to each other in order to close or open said pressing space. When said members are moved with respect to each other such that said pressing space is open, no pressure or force is exerted to the blade sections, whereas a pressure or force can be exerted to the blade sections when said members are moved with respect to each other such that the pressing space is closed. Consequently, the pressing space can be brought to an operative position to enable a pressing operation of the blade sections, and can be brought to an inoperative position, i.e., an open position in order to release the blade sections.
According to an embodiment of the present subject matter, said opposing surfaces are provided with a profile which substantially corresponds to an outer profile of said joining end portions of said blade sections when assembled, when said pressing space is closed. According to this embodiment, the at least two members are provided with predefined surfaces which are adapted to the outer appearance or shape of the blade sections in the area of the joining end portions thereof in order to optimize the application of pressure or force to the blade section when said pressing space is closed, i.e., is in an operative position.
According to an embodiment of the present subject matter, said supply means is arranged to supply said fluid, i.e., said adhesive fluid, into an inlet of a flow path which is provided in said boundary portion between said blade sections when received in said pressing space, wherein said apparatus further comprises discharge means which is arranged to discharge said fluid from an outlet of said flow path. The operation of the apparatus according to the present subject matter is based on the cooperation of the at least two members which are movable with respect to each other and said supply means for supplying said fluid, i.e., said adhesive fluid, into a boundary portion between said blade sections when said blade sections are received in said pressing space. Consequently, providing an inlet of a flow path for supplying said fluid and discharge means for discharging said fluid from an outlet provides a specific advantage in the operation of the apparatus for assembling blade sections as the fluid, i.e., the adhesive fluid, can be led through the flow path from the inlet to the outlet in order to optimize the joining of said blade sections.
According to an embodiment of the present subject matter, the apparatus further comprises supply monitoring means for monitoring an amount of fluid supplied by said supply means and/or discharge monitoring means for monitoring an amount of fluid discharge from said discharge means. According to this embodiment, the joining operation of said apparatus is optimized due to the information derivable from said supply monitoring means and/or said discharge monitoring means which provides an indication of the state of said fluid in said flow path. In particular, the current state of said fluid can be determined based on the information which is derivable from this embodiment such that the joining operation can be optimized.
According to an embodiment of the present subject matter, the apparatus further comprises a metering device for metering said amount of fluid supplied by said supply means. According to this embodiment, the amount of fluid supplied to said supply means can be adjusted or controlled by said metering device.
According to an embodiment of the present subject matter, said metering device is controllable based on information obtained from said supply monitoring means and/or based on information obtained from said discharge monitoring means. According to this embodiment, the amount of fluid supplied to said supply means can be adjusted or controlled by said metering device, wherein said amount of fluid can be optimized based on the current state of the fluid in said flow path.
According to an embodiment of the present subject matter, the apparatus further comprises heating means for applying heat to said joining end portions of said blade sections when received in said pressing space. The fluid supplied to the boundary portion between said blade sections can be an adhesive fluid which can be curable, e.g., by heat.
According to an embodiment of the present subject matter, said fluid is a resin, preferably a thermosetting resin. Such a fluid is advantageous for providing a permanent joint between the blade sections. In particular, in cooperation with the heating means for applying heat to said joining end portions of said blade sections, the use of a thermosetting resin provides advantages with respect to the strength of the joint between the blade sections.
According to an embodiment of the present subject matter, said moving means is formed as at least one threaded spindle connecting said at least two members. The threaded spindle can be driven by any means or even by a manual operation.
According to an embodiment of the present subject matter, a spindle drive is provided for driving said at least one threaded spindle. The spindle drive for driving said at least one threaded spindle is a simple means for providing the required movement of said at least two members with respect to each other. Such a system is accurately controllable and the threaded spindle having such a spindle drive is highly responsive for exerting the required force or pressure to the joining end portions of the blade sections. Moreover, such an arrangement is highly reliable.
According to an embodiment of the present subject matter, said moving means is formed as at least one hydraulic actuator. A hydraulic actuator is applicable for providing a specific movement of the members with respect to each other and can be accurately controlled for exerting a specific pressure.
According to an embodiment of the present subject matter, one of said at least two members is provided with a guide arrangement which is engageable with a rail arrangement for moving said apparatus along said rail arrangement. Due to the fact that the apparatus according to the present subject matter is applicable to a joining operation for joining blade sections for forming a blade for a large-scale wind turbine, it is convenient and advantageous to provide an option of moving said apparatus in relation to the blade sections to be joined rather than moving the blade sections while the apparatus is stationary. Based on the arrangement of this embodiment, a disassembling operation of said apparatus is not required in case that the apparatus is to be positioned at a specific longitudinal position of the blade section to be joined. Further, the sliding arrangement facilitates the assembling operation of a multi-section blade which includes more than one joint.
According to an embodiment of the present subject matter, the apparatus is operated to contract a cavity provided in the joining end portion of one of said blade sections by pressing said joining portion when received in said pressing space. As stated above, the apparatus for assembling blade sections is applicable for blade sections having specific properties. The specific operation for assembling said applicable blade sections includes the requirement of contracting the cavity which is provided in the joining end portion of one of said blade sections. Consequently, the apparatus is applicable to such blade sections which are designed such that a cavity is present in a joining end portion of at least one blade section which is contractible and expandable.
According to an embodiment of the present subject matter, the apparatus for assembling blade sections is applicable to blade sections, wherein said cavity is contractible based on the elasticity or deformability of the material of said blade section having said cavity and/or wherein said cavity is contractible based on the form or shape of the joining end portion having said cavity.
According to an embodiment of the present subject matter, the apparatus is applicable to blade sections, wherein at least one slit is provided in a joining end portion having said cavity, said at least one slit extending from said cavity to an outer surface of the joining end portion. Consequently, the apparatus according to the present subject matter is applicable to blades sections which are joined by a joining operation in which a cavity which is provided in at least one of said blade sections can be contracted due to the presence of at least one slit which extends from said cavity to the outer surface of the joining end portion. Therefore, the apparatus according to the present subject matter is preferably applicable to blade sections, wherein at least one of said blade sections comprises a cavity which has an inner dimension or shape which is variable in response to a pressure which is exerted to the outer surface of said blade section having said cavity. This variable property with respect to the inner shape of said cavity is created by providing at least one slit as stated above.
According to an embodiment of the present subject matter, the apparatus is applicable to blade sections having at least one slit which is provided in the joining end portion of one of said blade sections. Said apparatus is operated to close said at least one slit by pressing said joining end portion of the respective blade section having said cavity when received in said pressing space. As a consequence, the apparatus is operative for specific blade sections which are joined by pressing outer surfaces of at least one of said blade sections, thereby closing at least one slit and thus contracting the cavity in order to join the blade sections to each other.
According to an embodiment of the present subject matter, an inner shape of the said cavity is adjustable or variable by pressing said joining end portion having said cavity to an outer shape of a protrusion which is formed at the joining end portion of the other of said blade sections and which is inserted in said cavity. In the course of operation of the apparatus, the apparatus is applied to the blade sections which are preassembled and received in the pressing space. The apparatus is applicable to blade sections in which one blade section comprises a least one cavity and the other of said blade sections comprises at least one protrusion which is insertable into said at least one cavity. In the applicable operation of the apparatus, the preassembled blade sections are arranged such that the protrusion is inserted into the cavity when expanded or enlarged such that the apparatus is adapted to join such blade sections by pressing the outer surface of at least the blade section having the cavity in order to contract the cavity. By such an operation, the cavity is contracted in order to approach to the outer shape of the protrusion which is formed at the joining end portion of the other of said blade sections and which is inserted in said cavity.
According to an embodiment of the present subject matter, the apparatus further comprises a power supply connector for supplying the required power for operating said apparatus. The power supply connector is connectable to a disconnectable external power line. Consequently, the apparatus is movable to the required position and can be supplied by the required power through said power connector when connected to said power line after the apparatus is positioned at the predetermined site or location. The power supply connector can be provided for supplying power to said heating means, to said spindle drive or hydraulic drive means as well as to the supply means and any control or detection means provided in said apparatus.
According to an embodiment of the present subject matter, a pressure controlling means is arranged to control the pressure exerted by said at least two members. The pressure which is exerted by said at least two members is applicable to the blade section having the cavity and can be controlled to a predetermined pressure for bringing the cavity to the contracted position which enhances the operation for joining the blade sections. The pressure control means can include a pressure or force detecting means and can be associated with the moving means.
According to an embodiment of the present subject matter, a temperature controlling means is arranged to control a temperature of said fluid or resin or adhesive fluid supplied by said supply means.
According to an embodiment of the present subject matter, a heat controlling means is arranged to control said heating means for curing said resin and/or to determine a curing time.
Thus, controlling means is provided for control the above mentioned subjects. As a consequence, it is possible to optimize the operation of the apparatus with respect to temperature, time, pressure, and the like which is standardized for a specific operation, type and which can be predefined by experience or based on empiric information or experiments.
According to the basic concept of the present subject matter, a method of operating an apparatus for assembling blade sections is provided. The apparatus which is operatable by this method is discussed above. The method comprises the following steps:
The method of operating the apparatus is applicable to the above discussed blade sections having specific properties. According to the above indicated method of operating the apparatus, the apparatus is moved to the joining end portion to enable that said moving means can exert a pressure from said at least two members to said joining end portions. According to the basic concept of the present subject matter, the pressure is exerted to the outer surface of said blade sections. Consequently, the method is applicable to such blade sections which include at least one cavity which have a variable shape or in which the cavity is contractible. Further, the method includes supplying resin to the boundary portion between said blade sections which forms a permanent joint between the blade section after curing the resin.
According to an embodiment of the present subject matter, the amount of resin discharged from said discharge means is monitored and the supply means is controlled based on the monitored amount of discharged resin. Due to the fact that the flow path provided in the boundary between the blade sections has a predetermined volume and the amount of supplied resin is predefined, the amount of discharged resin can provide information on the complete filling of the flow path from said resin. Consequently, this procedure enhances the quality of the joint between the blade sections.
According to an embodiment of the present subject matter, the amount of resin discharged from said discharge means is monitored and the amount of resin supplied by said supply means is monitored. Further, according to this embodiment, a correct operation of said apparatus is confirmed based on the monitored amount of supplied and discharged resin. Due to the fact that the flow path provided in the boundary between the blade sections is predefined, there is a specific correlation between the amount of supplied resin and the amount of discharged resin. In case that the correlation is not met, this information can be employed to obtain information of an incorrect operation, e.g., based on a leakage of resin from the flow path or the like. In case that the correlation is met, it is confirmed that the filling process has been completed properly.
According to an embodiment of the present subject matter, the resin is a thermosetting resin, wherein the method further comprises a step of applying heat to said joining end portions for curing said thermosetting resin. Thermosetting resin has a high strength and can provide an optimum joint between the blade sections after curing said thermosetting resin based on the application of heat. According to the basic concept of the present subject matter, a method of assembling two blade segments for forming a blade for a wind turbine rotor using the above discussed apparatus is provided. The method of assembling two blade segments comprises the following steps:
According to an embodiment of the present subject matter, the method of assembling two blade segments comprises the step of contracting said cavity by pressing said members.
According to an embodiment of the present subject matter, the method of assembling two blade segments comprises closing at least one slit by the step of pressing, wherein said at least one slit is provided in said blade section having said cavity and extends from an inner surface of said cavity to an outer surface of said blade section having said cavity.
In the following, an embodiment of the present subject matter is explained based on the drawings. It is noted that the drawings show a specific embodiment as explained below and blade sections to which the apparatus is applicable. Further alternative modifications of the embodiment which are at least in part not illustrated are specified in the following description:
The apparatus shown in
As shown in
The bottom member 2 is formed as box-shaped member with the sheet metal portion forming the surface 2A on top. The top member 1 is formed as similar box-shaped member comprising the sheet metal forming the surface 1A which is oriented to a bottom and, as such, towards the surface 2A of the bottom member 2.
The top member 1 is attached to the bottom member 2 by spindles 3 which are rod-shaped members and which are provided with an outer thread on the outer circumference which is engaged to an inner threat in order to form a screw mechanism. In the example shown in
An inner thread is provided in the bottom member 2 corresponding to each of the spindle 3. The inner thread is not shown and is embodied as nut member which is fixedly mounted to the bottom member 2 and engaged to the outer thread of the respective spindle 3. Upon rotating the spindle 3 in response to an operation of the spindle drive 30, the distance between the top member 1 and the bottom member 2 is adjustable.
On top of the top member 1, lid members 40 are provided in order to close the space in which the spindle drives 30 are provided. In the present embodiment, two lid members 40 are provided which are linked to the top member 1 via hinge members such that the lid members 40 are tiltable in order to open or close the space in which the spindle drives 30 are arranged.
The apparatus shown in
As shown in
In the present embodiment shown in
Both the bottom member 2 and the top member 1 are provided with a heating means 7. In particular, the heating means comprises a bottom heating arrangement 72 provided for the bottom member 2 which is arranged at or in close connection to the member forming the surface 2A of the bottom member 2, and a top heating arrangement 71 provided at or close to the member forming the surface 1A of the top member 1. In particular, the heating arrangements 71, 72 are embodied as electrical heating, i.e., as resistant-based heating which are arranged on the backside of the sheet metal which form the respective surfaces 1A, 2A of the top member 1 and the bottom member 2. Consequently, by supplying energy to the respective heating arrangements 71, 72, the surfaces 1A, 2A can be brought to a predetermined temperature to be applied to the outer surface of the blade to be formed by the apparatus.
In the embodiment shown in
The bottom member 2 is provided with a guide arrangement which is formed by guides 16 which are provided on the bottom side of the bottom member 2. In the present embodiment shown in
The guides 16 can be brought into engagement with rails (not shown in the drawings) in order to enable that the apparatus can be shifted by sliding the guides 16 on the rails in a longitudinal direction. The specific purpose of this arrangement is discussed below.
On top of the top member 1, in particular, in the area of the corners of the top member 1, transport members 17, such as hooks or rings are provided. A crane or the like can be connected to the transport members 17 such that the apparatus having a remarkable weight can be positioned to a predetermined location, such as on the rails in order to be shifted by sliding the apparatus with the guide 16 being in sliding engagement with the rails.
In the following, the operation of the apparatus according to the present embodiment is explained in detail. It is noted that the first and second forms of blade sections shown in
Blade sections 100, 200 which are adapted to be assembled by the apparatus shown in
Furthermore, the blade sections should be adapted to be glued by resin, such as a thermosettable resin which is introducible into the boundary region between the blade sections.
For assembling blade sections for forming a blade of the above mentioned first and second forms, the blade sections are preassembled by inserting the protrusion 201 of one of the blade sections into the cavity 101 of the other of the blade sections. In this state, the cavity 101 of the blade section 100 of the above mentioned type is in the expanded or enlarged condition.
The expanded or enlarged condition and the resulting contractibility can be achieved by providing at least one interruption of material in the joining end portion 110 of the first form of the blade section 100 having the cavity 101. The interruption of material can be formed as two slits 102, 103 as shown in
The expanded or enlarged condition and the resulting contractibility can be achieved without the interruption of material in the second form of the blade section 100 as shown in
As consequence, at least the above mentioned forms of the blade sections shown in
When the blade sections are preassembled and aligned to each other, the apparatus shown in
As the rails are aligned to the longitudinal direction of the preassembled blade section, the apparatus can be shifted along the rails with the preassembled blade section being sandwiched by the top member 1 and the bottom member 2. The apparatus is shifted to the transition between the blade sections such that the boundary or transition in the longitudinal direction of the preassembled blade sections is positioned inside the pressing space formed by surfaces 1A, 2A. When this condition is achieved, the spindle drives 30 are operated to close the pressing space such that the surfaces 1A, 2A press the outer surface of the preassembled blade sections. During this operation, the cavity provided in one of the blade sections is brought to the contracted position such that the inner dimension of the cavity is changed in order to approach the outer dimension of the protrusion of the other of the blade sections.
With the blade sections shown in
With the blade sections 100, 200 shown in
In this condition, in which the outer surface of the blade sections are pressed by the top member 1 and the bottom member 2, resin is supplied to the supply duct 5 and pressed through the flow path provided in the boundary area between the blade sections such that the resin is pressed out of the discharge duct 6 after the complete filling of the flow path.
In this situation, the resin can be cured. As the resin is cured, the pressing space is kept closed by maintaining the force exerted from the top member 1 and the bottom member 2 to the outer surface of the blade sections for a predetermined time period.
In the present embodiment, thermosetting resin is used which is cured in response to the application of heat. As discussed above, heating arrangements 71, 72 are provided which can be operated to apply heat to the outer surfaces of the blade section in this state wherein this heat is transferred by conduction towards the boundary area between the blade sections which includes the flow path which is filled by the thermosetting resin.
By applying heat to a thermosetting resin, the same is cured. After a predetermined curing time while the temperature of the heating arrangements 71, 72 is maintained as a preset value, the curing is completed.
After the completion of the curing of the thermosetting resin, the joint between the blade sections is made permanent and the pressing space is opened. By opening the pressing space, the outer appearance of the blade thus assembled is released which corresponds to a target appearance. That is, the contracted state of the cavity formed in the respective blade section is maintained. With the blade sections of
The apparatus according to the present embodiment can be equipped with sensors for measuring temperature of the resin as supplied to the supply duct 5, for measuring or detecting the pressure exerted by the spindle drives 30 in cooperation with the spindles 3, temperature detecting means for detecting the temperatures at the surfaces 1A, 2A of the top member 1 and the bottom member 2 respectively and control means for controlling the respective operations, such as temperature control means for controlling the heating means 71, 72 in order to maintain a predetermined temperature and pressure control means for controlling the operation of the spindle drives 30 in order to maintain a predetermined pressure or force to the preassembled blade section or to open/close the pressing space.
Furthermore, a metering device (not shown in the drawings) can be provided at the supply duct 5 in order to detect the amount of resin supplied to the supply duct 5. In this context, a detecting means (not shown in the drawings) for detecting the amount of resin discharged from the discharge duct 6 can be provided and the detecting results of the metering device and the detecting means for detecting the amount of discharge can be employed as follows.
In the course of supplying resin to the supply duct 5, the amount of resin as introduced into the supply duct 5 is known. Furthermore, the amount of resin for completely filling the flow path provided in the boundary area between the blade sections is known for a specific blade assembly. In the course of supplying the resin to the supply duct 5, the flow path is filled and an overflow of resin is discharged from the discharge duct 6. The discharged resin is detected and the amount of discharged resin is compared to a target discharge amount which is predefined based on known data regarding the specific blade assembly.
In case that the detected discharge amount at the end of the filling operation for filling the flow path is in conformity with the target amount, the correct filling of the flow path is confirmed. In case that less than the target discharge amount is detected at the discharge duct 6, a leakage of resin can be determined. Further, in case that more than the target discharge amount is detected at the discharge duct 6, an additional problem in the flow path, such as a clogging or the like, can be determined.
The present embodiment can be modified as follows.
The spindle drives 30 can be embodied as hydraulic means driven by hydraulic pressure or other suitable mean as long as the movable property of the top member 1 with respect to the bottom member 2 is achieved. The spindle drives 30 can be optionally operated manually.
The heating arrangements 71, 72 can be replaced by another concept, such as a fluid heating using heat transfer members or a radiation heating using radiation for heating the surfaces 1A, 2A of the top member 1 and the bottom member 2, respectively.
The metering and detection of the supply and discharge of the resin is not required but leads to a preferable embodiment enhancing the quality of the assembled blade sections.
The resin is a thermosetting resin in the present embodiment. However, it is possible to employ a resin which is cured without the influence of an increased temperature.
The blade sections and the structures of the joining end portions thereof are not limited to the above application. As further application, the protrusion and/or the cavity provided in the respective blade sections can be formed with engagement means, such as serrations, which are engageable to each other by contracting the cavity provided in one of the blade sections.
In this case, by contracting the cavity, a locked joint between the inner surface of the cavity and the outer surface of the protrusion is achieved which enhances the strength of the joint between the blade section.
Further, the blade sections can be provided with more than one cavity and more than one protrusion.
The shape of the surfaces 1A and 2A provided in the top member 1 and the bottom member 2, respectively in
It is possible to apply the apparatus to blade sections which achieve the contracted position when no force is exerted to the joining end portion of the blade section having the cavity, as stated above. As modification, the blade section having the cavity can be arranged to achieve an intermediate position when no force is exerted, which is between the contracted and the non-contracted or expanded position. The complete expansion of the cavity can be achieved by introducing the protrusion of the other blade section. As further alternative, the expansion can be achieved by applying a corresponding force to the non-contracted cavity.
| Number | Date | Country | Kind |
|---|---|---|---|
| 12170099.1 | May 2012 | EP | regional |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2013/060950 | 5/28/2013 | WO | 00 |
