The present invention relates to wind turbine rotor blade comprising a lightning protection system. In particular, the invention relates to a lightning protection system comprising lightning receptors for capturing lightning strikes. The receptors are arranged in the rotor blade. Moreover, the invention relates to a wind turbine generator with a lightning protection system, to a lightning receptor, and to a method of fabricating a wind turbine rotor blade with a lightning protection system.
Wind turbine generators are tall protruding constructions placed in the open and are therefore typically exposed to lightning strikes. To protect the wind turbine generators from the strikes, the wind turbine rotor blades are normally provided with a lightning protection system. Such systems are generally known and include lightning receptors of an electrically conducting material. Lightning receptors are often mounted in the rotor blades, where they are placed near the tip or other exterior surface. The lightning receptor may capture a strike of lightning and conduct the current through a lightning down-conductor extending in the longitudinal direction of the blade and being earthed via the wind turbine hub.
It is a known problem that the charge involved in a strike is so large that the resulting heating may cause the material of the lightning receptors to vaporize and be removed. This leads to increased inspection of the lightning receptors and increased maintenance in order to repair or replace worn out receptors and possible repair of damages of the rotor blades as well. This leads to unwanted down-time of the wind turbine generators.
The inventors of the present invention have appreciated that an improved lightning protection system of a wind turbine rotor blade would be of benefit, and have in consequence devised the present invention.
The present invention seeks to provide an improved wind turbine rotor blade with respect to wear resistance from lightning strikes of the lightning receptors. It may be seen as an object of the present invention to provide a wind turbine generator with low down-time, or even no down-time, due to lightning strikes. Preferably, the invention alleviates, mitigates or eliminates one or more problems of the prior art.
According to a first aspect of the invention there is provided a wind turbine rotor blade comprising a lightning protection system, wherein the lightning protection system comprises a lightning receptor arranged in the rotor blade, and wherein the lightning receptor comprises carbon nanotubes.
The inventors of the present invention have realized that in connection with lightning strikes a number of factors may be of importance, one factor relates to providing a material with a sufficiently high vaporizing point (latent energy of vaporization), melting point (latent heat of fusion) and/or chemical and thermal stability to sustain the heating arising from the lightning discharge, a second factor relates to providing a material with a high electrical conductance to efficiently lead the currents from the impact area and into the bulk of the receptor, and the third factor relates to a material with a high heat conductance and/or heat capacity to efficiently drain generated heat away from the impact area, and/or to be able to sustain the heat generated from the strike. It is an advantage of the present invention that lightning receptors comprising carbon nanotubes, supports these factors, since carbon nanotubes possess a vaporizing point, chemical and thermal stability, conductivity and thermal properties which are superior to most metals.
In the context of the present invention, a lightning receptor is to be construed as a dedicated or specified region for capturing a strike of lightning and remove the induced currents away from the impact area. This region being a dedicated and/or separate part of the rotor blade typically fabricated separately and intended for mount in the rotor blade.
The carbon nanotubes may be provided at an exterior surface in the form of a layer of carbon nanotubes and/or encapsulated in the lightning receptor so that at least part of the lightning receptor is of a carbon nanotube metal composite material. Carbon nanotubes provided at the surface or in the surface region may have a field enhancing effect whereas the presence of carbon nanotube in the metal composite material can further improve the characteristics of material with respect to increased wear resistance to lightning strikes, such as erosion resistance, e.g. arc erosion resistance, as compared to lightning receptors of a metal composite materials without carbon nanotubes.
The carbon nanotubes may be single-walled carbon nanotubes (SWNT), multi-walled carbon nanotubes (MWNT) or a combination of the two.
Single-walled carbon nanotubes are superior to multi-walled carbon nanotubes with respect to electrical and heat conductivity, however MWNT may be superior to SWNT with respect to resistance to chemical influences from the surrounding environment. It may therefore be an advantage to use a combination of SWNT and MWNT.
Carbon nanotubes may exhibit semiconducting conductivity or metallic conductivity based on the structure of the nanotube. From electrical considerations alone it may therefore be advantageous to use carbon nanotubes with metallic conductivity. However, all types of carbon nanotubes are superior over most metals with respect to thermal conductivity as well as chemical and thermal stability. Improved lightning receptors may therefore be provided from use of carbon nanotubes exhibiting metallic or semiconducting conductivity, or a mixture/combination of the two.
In embodiments the lightning receptor may comprise carbon nanotubes as a surface layer supported by the lightning receptor, encapsulated in a metal matrix composite material, i.e. to form a carbon nanotube metal matrix composite material, or as a surface layer supported by a carbon nanotube metal matrix composite material. The receptor material may comprise a metallic part, however additional non-metal components may be provided as well. In embodiments, the lightning receptor comprises a material selected from the group of: Cu, Co, Cr, W, V, Ag, Ni, Au, Al, Pb, Mg, Sn, Zn, Ti, Mo, Zr, Mn, Fe, In, Ir, Nb, Ta, Re, Pd, Os, Rh, Ir, Pt, Ru, C, CuW, CuWAg, CuSn, CuNi, CuBe, CuZn, CuAg, CuCd, CuCr, CuZr, CuCrZr, CuTe, CuC, AgCdO, AgSnO2, AgSnO2, AgSnO2In2O3, AgZnO, AgCdOSnO2, AgMgONiO, AgW, AgWC, AgWO2, AgWO3, AgMo, AgC, AgNi, AgPd, AgCuNi, ReW, metal-matrix composites of Cu, Ag, W, Mo, Ni, Cr, Ti, V, Zr, Mn, Ta, Fe or Nb with additions of oxides, Inconel, Constantan, Monel, Invar, Hastelloy, Cu—Al2O3 (e.g. GlidCop), stainless steel, steel, or any alloy or composite thereof.
The lightning receptor may be provided with one or more electric field enhancing protrusions to the exterior surface of the receptor to further improve the lightning receptors, since the electric field strength may be increased in the vicinity of a protrusion extending outwards from the exterior surface of the receptor. Upon lightning strike, edges of the lightning receptors are prone to loose more material than central parts of the lightning receptors. When material is removed at the edge of the receptor, this may have an electric field enhancing effect which further increases the probability of lightning strike in the edge area. It is however desirable to remove the impact area away from the edge due to a risk of damaging the rotor blade itself from the strike, and thereby further increasing the maintenance requirement. It may therefore be advantageous to provide field enhancing protrusions to the exterior surface, to remove the impact area away from the edge area. As a further advantage even if material is removed from the lightning strike, the material is removed in an area which is distanced from the edge, and thereby diminish the probability of affecting the rotor blade itself from a lightning strike.
The dependent claims define advantageous embodiments of specific electric field enhancing geometries.
In embodiments, the carbon nanotubes are provided in the form of a surface layer at an exterior surface of the receptor. The carbon nanotubes of such a surface layer may themselves function as electric field enhancing protrusions. To further improve the field enhancing effect, the layer of carbon nanotubes may be patterned in accordance with a pattern mask. In embodiments, a patterned carbon nanotube layer may be provided onto an exterior surface with a surface topography comprising field enhancing protrusions.
In embodiments, the carbon nanotubes may be substantially vertically aligned along directions being normal to a surface plane of the exterior surface or substantially vertically aligned along a normal direction of a reference surface plane. The reference surface plane may e.g. be the surface plane of the blade abutting the receptor. Carbon nanotubes possess superior heat and electrical properties along the tube axis of the nanotubes. It is therefore advantageous to align the nanotubes so that the impact area of the lightning strikes is substantially at ends of the tubes, and that the tube axes extend along a direction extending from the impact area to the exterior surface of the receptor. Such alignment may be obtained using substantially vertically aligned carbon nanotubes.
In embodiments, the carbon nanotubes are provided in the form where they are encapsulated into the bulk material of the lightning receptor, so that at least part of the lightning receptor is of a carbon nanotube metal composite material. It may be advantageous that the carbon nanotubes are substantially homogeneously distributed in the metal matrix material over at least a substantial part of the entire thickness of the metal matrix material, thereby providing a lightning receptor at least substantially without weak areas. By homogeneously distributing the carbon nanotubes in the metal matrix a material is provided which can be worked with standard metalworking techniques, such as extrusion, forging, rolling, machining, etc., even though special tools suitable for hard materials may be required.
In an embodiment, the carbon nanotubes are substantially randomly oriented in a metal matrix material. In a fabrication process it may be simpler to provide the nanotubes in a substantial randomly oriented manner.
In an embodiment, at least an ensemble of the carbon nanotubes is oriented along a direction extending along a thickness of the receptor. Carbon nanotubes possess superior heat and electrical properties along the tube axis of the nanotubes. It may therefore be advantageous to align the nanotubes so that heat and current are directed away from the receptor and thereby avoiding dispersion of the heat and current in the bulk of the lightning receptor. The direction of the orientation may be controlled by application of electric or magnetic field in connection with the fabrication of the carbon nanotube metal composite.
In an embodiment, the carbon nanotubes are dispersed in a continuous metal matrix, thereby providing a lightning receptor with increased strength. In a continuous metal matrix there is a metal path through the matrix to any point in the material. Moreover, in a continuous metal matrix impurities and cavities, such as air bubbles, are avoided or at least only present to a very low extend.
In an embodiment, at least a portion of the carbon nanotubes are in physical contact with each other, thereby increasing the probability of directing heat and current away from the receptor instead of dispersing the heat and current in the bulk of the lightning receptor.
In an embodiment, the volume fraction of the carbon nanotubes is in the range of 5% to 75%, such as 10% to 60%, such as 15% to 50%, such as 20% to 40%, such as 30%.
Such factors as degree of alignment of the carbon nanotubes, or no alignment (randomness) of the carbon nanotubes, the degree of physical contact between the carbon nanotubes, or no physical contact between the carbon nanotubes and the specific volume fraction of the carbon nanotubes, may be varied in order to tailor the specific properties of the lightning receptor.
According to a second aspect of the present invention there is provided, a wind turbine generator comprising one or more rotor blades, wherein the one or more rotor blades comprise a lightning protection system, wherein the lightning protection system comprises a lightning receptor arranged in the rotor blade, and wherein the lightning receptor comprises carbon nanotubes. A wind turbine generator with improved lightning protection may thereby be provided.
According to a third aspect of the present invention there is provided, a lightning receptor for a wind turbine rotor blade, wherein the lightning receptor comprises carbon nanotubes.
The lightning receptors according to the second and third aspects may be provided in accordance with the lightning receptor described in connection with the first aspect of the invention.
According to a fourth aspect of the invention there is provided a method of fabricating a wind turbine rotor blade with a lightning protection system, the method comprising:
The lightning receptors may be fabricated prior to mounting the receptor in a receptor location on the rotor blade. Thereby rendering it possible for an owner of a wind turbine generator to update an existing lightning protection system with a protection system in accordance with the present invention.
In embodiments, the carbon nanotubes may be grown onto the exterior surface of the lightning receptors by providing islands or particles of catalytic material, e.g. Ni or Mo or other catalyst particles, to the exterior surface and growing the carbon nanotubes from the catalytic material, e.g. by use of such techniques as chemical vapour deposition (CVD), plasma-enhanced CVD (PE-CVD), physical vapour deposition (PVD) and arc discharge. Catalytic growth of carbon nanotubes onto the surface plane of a substrate is a versatile and well-known method of growing carbon nanotubes.
The carbon nanotubes may be grown vertically aligned along an orientation direction. The direction of the orientation may be controlled by use of masking or by application of electric or magnetic fields in connection with the growth as is known in the art. Techniques for growing vertically aligned carbon nanotubes are known in the art.
In embodiments, the layer of carbon nanotubes may be patterned. Patterning of the carbon nanotube layer may be achieved by patterning of the catalyst material. Catalyst material patterning may be obtained by lithography techniques, liquid dispersion techniques, etching, etc. Patterning methods are known in the art.
In embodiments, the carbon nanotube metal composite is fabricated by a liquid state fabrication method, a vapour state fabrication method or a powder-metallurgical method.
A number of liquid state fabrication methods exist. Such methods include, but are not limited to electroplating or electroforming methods where a solution containing metal ions loaded with carbon nanotubes is co-deposited forming a composite material, and stir casting methods where carbon nanotubes are stirred into molten metal, which is allowed to solidify.
An example of vapour state fabrication include, but is not limited to physical vapour deposition methods, where the carbon nanotubes are passed through a thick cloud of vaporized metal, coating it.
In a powder-metallurgical fabrication, the material components in powder form are provided into a mould where the powder is exposed to high pressure and high temperature. In order to provide a material with a sufficient strength, it may be necessary to apply such high temperatures and pressures that the material reorders to a certain degree.
In general, the individual aspects of the present invention may each be combined with any of the other aspects. These and other aspects of the invention will be apparent from the following description with reference to the described embodiments.
Embodiments of the invention will be described, by way of example only, with reference to the drawings, in which
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In embodiments, the size of the lightning receptor may be in the centimetre (cm) range, such as possessing a diameter or other relevant width in the range of 0.5 to 5 cm, such as 1.5 cm.
In embodiments, the height of the field enhancing protrusions may be in the range between some millimetre (mm) to a few centimetres, such as a between 1 mm to 10 mm, or larger.
The receptor is schematically illustrated as being connected to a down-conductor 43 for leading away any induced currents from a lightning strike. The lightning receptor may be connected to a down-conductor in any suitable way. Moreover, the lightning receptor may be fixed in the rotor blade by any suitable means. In an embodiment, the lightning receptor is secured in a holder unit 44.
The carbon nanotubes may be substantially homogeneously distributed in the receptor, and the carbon nanotubes may be substantially randomly oriented in the entire thickness 51 of the receptor. In the illustrated embodiment, at least a portion of the carbon nanotubes are in physical contact with each other 52.
The scope of the invention is not limited to the embodiment shown in the
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Carbon nanotubes may be provided with a large variety of lengths. In different embodiments, the carbon nanotubes may be of different lengths, as well as the layer of carbon nanotubes and/or the carbon nanotube metal composite may be provided with carbon nanotubes exhibiting a length distribution.
The lightning receptors may be provided 91 in a separate fabrication process. In an embodiment of the fabrication process of the lightning receptors, the receptors are first provided 91, e.g. in a moulding, casting or powder-metallurgical process. The process may in embodiments comprise processing steps 92 to ensure that at least part of the lightning receptor is of a carbon nanotube metal composite material and/or the process may in embodiments comprise processing steps which provides a layer of carbon nanotubes 93 onto an exterior surface of the receptor. The receptors are mounted 94 in the receptor location on the rotor blade and electrical contact from the lightning receptors to an electrical down-conductor is established 95.
Although the present invention has been described in connection with the specified embodiments, it should not be construed as being in any way limited to the presented examples. The scope of the present invention is set out by the accompanying claim set. In the context of the claims, the terms “comprising” or “comprises” do not exclude other possible elements or steps. Also, the mentioning of references such as “a” or “an” etc. should not be construed as excluding a plurality. Furthermore, individual features mentioned in different claims, may possibly be advantageously combined, and the mentioning of these features in different claims does not exclude that a combination of features is not possible and advantageous.
Number | Date | Country | Kind |
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PA 2007 01840 | Dec 2007 | DK | national |
PA 2007 01860 | Dec 2007 | DK | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/DK2008/050328 | 12/19/2008 | WO | 00 | 9/16/2010 |
Number | Date | Country | |
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61009053 | Dec 2007 | US | |
61008701 | Dec 2007 | US |