Patent Grant
10961982
The present subject matter relates generally to wind turbines, and more particularly to segmented rotor blades for wind turbines and methods of manufacturing the same.
Wind power is considered one of the cleanest, most environmentally friendly energy sources presently available, and wind turbines have gained increased attention in this regard. A modern wind turbine typically includes a tower, a generator, a gearbox, a nacelle, and one or more rotor blades. The rotor blades capture kinetic energy of wind using known airfoil principles and transmit the kinetic energy in the form of rotational energy so as to turn a shaft coupling the rotor blades to a gearbox, or if a gearbox is not used, directly to the generator. The generator then converts the mechanical energy to electrical energy that may be deployed to a utility grid.
The construction of a modern rotor blade generally includes skin or shell components, opposing spar caps, and one or more shear webs extending between the opposing spar caps. The skin is typically manufactured from layers of fiber composite and a lightweight core material and forms the exterior aerodynamic airfoil shape of the rotor blade. Further, the spar caps provide increased rotor blade strength by providing structural elements along the span of the rotor blade on both interior sides of the rotor blade. Moreover, spar caps are typically constructed from glass fiber reinforced composites, though spar caps for some larger blades may be constructed from carbon fiber reinforced composites. The shear web(s) generally include structural beam-like components that extend essentially perpendicular between the opposing spar caps and across the interior portion of the rotor blade between the outer skins.
The size, shape, and/or weight of rotor blades are factors that contribute to energy efficiencies of wind turbines. An increase in rotor blade size increases the energy production of a wind turbine, while a decrease in weight also furthers the efficiency of a wind turbine. Furthermore, as the size of wind turbines increases, particularly the size of the rotor blades, so do the respective costs of manufacturing, transporting, and assembly of the wind turbines. The economic benefits of increased wind turbine sizes must be weighed against these factors.
One known strategy for reducing the costs of pre-forming, transporting, and erecting wind turbines having rotor blades of increasing sizes is to manufacture the rotor blades in blade segments. As such, the blade segments may be assembled to form the rotor blade after, for example, the individual blade segments are transported to an erection location. For example, some rotor blades include either bonded or bolted joints. One such bolted joint includes a chord-wise extending pin securing a male shear web member or spar member within a female shear web member so as to join adjacent blade segments.
Various structural bonds may be used to join blade segments. First, elements of the structural ‘I’ beam, such as the skins of the shear web and the spar caps, may be used to join blade segments. Further, fasteners may be used to join longitudinal bulkheads and/or similar structures. Moreover, the outer skin and/or aerodynamic fairings may be joined using a shell-to-shell connection.
In addition, the outer skin typically forms the exterior aerodynamic airfoil shape of the rotor blade. In some turbine blades, the outer skin does not form a complete enclosure. More specifically, gaps and spaces may be left between the blade segments. As such, aerodynamic fairings can be used to cover the gaps and/or spaces between the blade segments to reduce form drag and interference drag. Such fairings may also improve the performance of the turbine blade. Moreover, the fairings can be joined together and/or to the outer skin using shell-to-shell connections.
A number of challenges may be involved in achieving the aforementioned connections, particularly with the outer skin bond. For example, the outer skin may be joined along scarf joints using adhesives, thermoplastics, and/or pre-preg film. Such methods often require internal and external pressures applied at the joint simultaneously. Such pressures maintain segments together and can allow for the formation of a strong bond at the joint.
The internal pressure, however, can be difficult to achieve and maintain on the mating surfaces during the bond process. Of particular concern is the internal consolidation pressure in areas of the turbine blade that are inaccessible. For instance, the portion of the rotor blade at the tip is often smaller and cannot be easily reached using conventional methods. The internal consolidation pressure necessary at these inaccessible areas is generally referred to as blind pressure.
Structural requirements must also be considered, such as, adequate transfer of the load (especially through 0° direction fibers). For example, the joint should be able to successfully transfer the load across the inner and outer skins on either side of the structural core. In addition, the surface bonds and sub-component bonds must be accurately aligned with smooth transitions to ensure suitable aerodynamic shape and performance. Further, in order to achieve a stronger bond using thermoplastics, separate mechanical and/or chemical adhesion are critical via controlled heat and pressure.
Accordingly, some outer skin bonds utilize adhesives at the joint locations. However, certain adhesive bonds provide additional challenges. For example, wet adhesives can be difficult to apply without air bubbles and/or may provide uneven coverage with slide-in assemblies, thereby requiring rectification of the aerodynamic surface. Additionally, adhesive squeeze-out can cause parasitic weight, undesirable spills, a subpar bond, and/or undesirable clean-up. Further, the ability to reposition the surfaces can be limited due to the risk of introducing air and/or air pockets in the adhesive.
Still further outer skin bonds use injection bonding or pre-preg film. Injection bonding, however, can present challenges with the internal seal and consolidation. In addition, pre-preg film can increase cost as extreme accuracy is required for the sealing and consolidation. Further, these processes may require vacuum sealing, which can increase costs and production time.
Accordingly, the art is continuously seeking new and improved joint technologies for joining blade segments of rotor blades. More specifically, there is a need for a joint assembly for rotor blade segments that simplifies and expedites the assembly thereof.
Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.
In one aspect, the present disclosure is directed to a method for joining rotor blade segments of a rotor blade. The method includes placing at least one inflatable internal bladder at least partially within at least one of a first blade segment or a second blade segment. Another step includes arranging a first joint end of the first blade segment with a second joint end of the second blade segment at a joint. Each of the first and second joint ends includes at least one thermoplastic material. Another step includes arranging the first and second joints ends in an end-to-end orientation with the at least one thermoplastic material of each of the first and second joint ends contacting each other. Yet another step includes inflating the at least one internal bladder so as to provide an internal pressure at the joint from within the first and second blade segments. The method also includes applying heat to the thermoplastic materials at the first and second joint ends so as to join the first and second rotor blade segments.
In one embodiment, the method may include placing at least one core material within the first and second blade segments at the joint. In another embodiment, the method may include placing the internal bladder between an upper portion of the core material and a lower portion of the core material. In other embodiments, the method may include placing the internal bladder around the core material. In a further embodiment, the method may include supplying external pressure at an outer surface of the joint. Still, in a further embodiment, the method may include deflating the internal bladder and leaving the internal bladder within the rotor blade. In one embodiment, inflating the internal bladder so as to provide pressure at the joint from within the first and second blade segments may include applying pressure to the internal bladder of about one (1) to about two (2) pounds per square inch (lbs./in.2).
In additional embodiments, the method may include wrapping at least one of an outer surface or an inner surface of each of the first and second joint ends with the at least one thermoplastic material. In other embodiments, the method may include applying heat to the at least one thermoplastic material at the first and second joint ends via at least one of an external mat or a convection source.
In another aspect, the present disclosure is directed to a method for joining closed rotor blade segments of a rotor blade. The method includes placing at least one inflatable internal bladder at least partially within at least one of a first blade segment or a second blade segment. Another step includes arranging a first joint end of the first blade segment with a second joint end of the second blade segment at a joint. Yet another step includes inflating the at least one internal bladder so as to provide an internal pressure at the joint from within the first and second blade segments. The method also includes supplying external pressure to the joint via an external pressure source. In a further step, the method includes joining the first and second joint ends while the joint is under internal and external pressure so as to join the first and second rotor blade segments. Another step includes deflating the at least one internal bladder within the first and second blade segments. As such, the at least one internal bladder remains in place after the first and second joint ends are joined.
In one embodiment, the method may include encapsulating at least one of a first joint end of a first rotor blade segment or a second joint end of a second rotor blade segment in at least one thermoplastic material. In another embodiment, joining the first and second joint ends while the joint is under internal and external pressure so as to join the first and second rotor blade segments may include supplying heat to the joint. As such, the heat supplied to the joint may cause the at least one thermoplastic material of each of the first and second joint ends to join the first blade segment to the second blade segment at their respective joint ends.
In yet another aspect, the present disclosure is directed to a segmented rotor blade for a wind turbine. The segmented rotor blade includes a first rotor blade segment, a second rotor blade segment, at least one thermoplastic material, and an internal pressure source. The first rotor blade segment includes a first joint end. The second rotor blade segment includes a second joint end. The first and second joint ends are arranged together in an end-to-end orientation so as to form at least one scarf joint. The at least one thermoplastic material is arranged at each of the first and second joint ends. The first and second joint ends of the first and second rotor blade segments are bonded together via thermoplastic welding of the at least one thermoplastic material. The internal pressure source provides pressure to the scarf joint during the thermoplastic welding. The internal pressure source remains within the rotor blade after thermoplastic welding is complete.
In one embodiment, the at least one thermoplastic material may wrap around at least one of an outer surface or an inner surface of at least one of the first and second rotor blade segments. In a further embodiment, the internal pressure source may include an inflatable internal bladder. In yet another embodiment, the internal pressure source may further include at least one core material arranged between the first and second joint ends. In an additional embodiment, the core material may be arranged around the internal bladder. Still, in a further embodiment, the internal bladder is arranged around the core material.
In some embodiments, the first and second joint ends may form a double scarf joint. In another embodiment, the at least one thermoplastic material extends between the at least one core material and the inner surface of at least one of the first rotor blade segment or the second rotor blade segment. Such that, the at least one core material may be welded to the inner surface of at least one of the first rotor blade segment or the second rotor blade segment via the thermoplastic material.
These and other features, aspects, and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:
Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.
Generally, the present subject matter is directed to a segmented rotor blade for a wind turbine and methods of manufacturing the same. For example, in one embodiment, the segmented rotor blade includes a first rotor blade component, a second rotor blade component, at least one thermoplastic material, and a disposable, internal pressure source (e.g. such as an inflatable internal bladder). The first rotor blade segment includes a first joint end, and the second rotor blade segment includes a second joint end. As such, the first and second joint ends are arranged together in an end-to-end orientation so as to form at least one scarf joint. The thermoplastic material(s) is arranged at each of the first and second joint ends. Thus, the first and second joint ends of the first and second rotor blade segments are bonded together via thermoplastic welding of the thermoplastic material(s). In addition, the internal pressure source provides internal pressure to the scarf joint during the thermoplastic welding. Moreover, the internal pressure source remains within the rotor blade after thermoplastic welding is complete. The internal pressure sources can be part bonded in the process to prevent them from becoming mobile.
The present disclosure provides many advantages not present in the prior art. For example, the use of a disposable bladder to supply internal pressure for a thermoplastic bond between the rotor blade segments is configured to reduce the labor hours required to form the joint. Accordingly, such bladders can be used in otherwise inaccessible, internal (blind) areas of the wind turbine blade. Thus, the joint of the present disclosure requires minimal to no rectification of the aerodynamic surface bond. Further, thermoplastic bonding occurs quickly and can be achieved in a wide variety of atmospheric conditions.
It should be appreciated that, although the present subject matter will generally be described herein with reference to components of a wind turbine, the disclosed method may be generally used to bond any two or more composite parts along a joint.
Referring now to the drawings,
Referring now to
In general, the rotor blade 16, and thus each blade segment 20, may include a pressure side 32 and a suction side 34 extending between a leading edge 36 and a trailing edge 38. Each blade segment 20 may include a first end 50 and a second end 52 defining the end points of each blade segment 20. Additionally, the rotor blade 16 may have a span 42 extending along a span-wise axis 43 and a chord 44 extending along a chord-wise axis 45. Further, as shown, the chord 44 may change throughout the span 42 of the rotor blade 16. Thus, a local chord may be defined at any span-wise location on the rotor blade 16 or any blade segment 20 thereof.
The rotor blade 16 may, in exemplary embodiments, be curved. Curving of the rotor blade 16 may entail bending the rotor blade 16 in a generally flapwise direction and/or in a generally edgewise direction. The flapwise direction is a direction substantially perpendicular to a transverse axis through a cross-section of the widest side of the rotor blade 16. Alternatively, the flapwise direction may be construed as the direction (or the opposite direction) in which the aerodynamic lift acts on the rotor blade 16. The edgewise direction is perpendicular to the flapwise direction. Flapwise curvature of the rotor blade 16 is also known as pre-bend, while edgewise curvature is also known as sweep. Thus, a curved rotor blade 16 may be pre-bent and/or swept. Curving may enable the rotor blade 16 to better withstand flapwise and edgewise loads during operation of the wind turbine 10, and may further provide clearance for the rotor blade 16 from the tower 12 during operation of the wind turbine 10.
Referring now to
In exemplary embodiments, and as discussed in detail below, the rotor blade segments 20 may be joined together through a joint 58, more particularly the joint 58 may be a scarf joint. Thus, a portion of each of the rotor blade segments 20 may be scarfed (i.e. angled or tapered), to form a joint face with an adjacent blade segment 20 scarfed to have a corresponding joint end. More specifically, one joint end 64 may generally correspond to a male half of a scarf joint that is secured into an opposite joint end 62 that corresponds to a female half of a scarf joint. As such, the joint ends 62, 64 may be connected and fastened together to form the scarf joint, which will be described in more detail herein.
It should be recognized that though the illustrated embodiments depict a rotor blade 16 with a monolithic shell, other types of shells can be used. For example, one or more portions of the shell may be configured as a layered construction and may include a core material, formed from a lightweight material such as wood (e.g., balsa), foam (e.g., extruded polystyrene foam) or a combination of such materials, disposed between layers of laminate composite material.
Referring now to
More specifically, as shown in
Further, as shown, the internal pressure source 54 is configured to provide pressure to the scarf joint 58 during thermoplastic welding. Moreover, the internal pressure source 54 is designed to remain within the rotor blade 16 after thermoplastic welding is complete. More specifically, the internal pressure source 54 may include at least one of an inflatable internal bladder 56 or a core material 55. Further, in particular embodiments, the internal bladder(s) 56 of the present invention may be formed from plastic or aerospace-type films. As such, the core material(s) 55 may position and orient the internal bladder(s) 56 in proximity to its desired location. Such placement can remove the necessity of using high pressure to inflate the internal bladder(s) 56, allowing a thinner walled, lighter bladder. Such internal bladders 56 can be manufactured cheaper than other bladders known in the art, such as those made from silicon. For instance, the internal bladder(s) 56 may be left inside the rotor blade 16 where it may be cost prohibitive to leave bladders made from materials such as silicon.
For example, as shown in
Referring particularly to
Referring now to
Pressure may be supplied to the internal bladder(s) 56 via a tube or multiple tubes supplying a pressurized fluid, such as air. In certain embodiments, the tube may be approximately a quarter inch in diameter and be fed to the internal bladder 56 through a small corresponding hole in the turbine blade 16. Once the thermoplastic material 60 has set, the tube may be cut. Further, the remaining tube end may be pushed inside the rotor blade 16. As such, the remaining hole may be left open or may be filled with a plug.
Referring now to
Referring particularly to
Referring particularly to
Referring particularly to
Referring particularly to
The thermoplastic material 60 as described herein generally encompasses a plastic material or polymer that is reversible in nature. For example, thermoplastic materials typically become pliable or moldable when heated to a certain temperature and solidify upon cooling. Further, thermoplastic materials may include amorphous thermoplastic materials and/or semi-crystalline thermoplastic materials. For example, some amorphous thermoplastic materials may generally include, but are not limited to, styrenes, vinyls, cellulosics, polyesters, acrylics, polysulphones, and/or imides. More specifically, exemplary amorphous thermoplastic materials may include polystyrene, acrylonitrile butadiene styrene (ABS), polymethyl methacrylate (PMMA), glycolised polyethylene terephthalate (PET-G), polycarbonate, polyvinyl acetate, amorphous polyamide, polyvinyl chlorides (PVC), polyvinylidene chloride, polyurethane, aliphatic polyurethane, or any other suitable amorphous thermoplastic material. In addition, exemplary semi-crystalline thermoplastic materials may generally include, but are not limited to polyolefins, polyamides, fluropolymer, ethyl-methyl acrylate, polyesters, polycarbonates, and/or acetals. More specifically, exemplary semi-crystalline thermoplastic materials may include polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polypropylene, polyphenyl sulfide, polyethylene, polyamide (nylon), polyetherketone, or any other suitable semi-crystalline thermoplastic material.
The present disclosure is also directed to methods for joining the rotor blade segments 20 of the rotor blade 16. For example, as shown in
As shown at 106, the method 100 also includes inflating the at least one internal bladder 56 so as to provide an internal pressure at the joint 58 from within the first and second blade segments 21, 23. More specifically, in one embodiment, the method 100 may include inflating the internal bladder 56 to apply pressure thereto ranging from about one (1) to about fifteen (15) pounds per square inch (lbs./in.2). In another embodiment, pressure may be applied to the internal bladder 56 ranging from about one (1) to about (2) pounds per square inch (lbs./in.2).
In addition, in some embodiments, the method 100 may include placing at least one core material 55 within the first and second blade segments 21, 23 at the joint 58. In another embodiment, the method 100 may include placing the internal bladder 56 between an upper portion of the core material 57 and a lower portion of the core material 59. In other embodiments, the method 100 may include placing the internal bladder 56 around the core material 55.
Referring still to
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.
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