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    • 专利摘要:
    system and method of manufacturing a wind turbine blade method of manufacturing a wind turbine blade (10), in particular a method of joining components (110, 112) of a wind turbine blade (10). the method involves the use of an adhesive collecting chute (126, 226, 326) positioned on the side of a joining surface (114) of a first member (112) of a wind turbine blade (10), the chute (126, 226, 326) arranged to form an acute angle to a second opposing joining surface (116) of a second member (110) of a wind turbine blade (10). the adhesive chute (126, 226, 326) acts to retain the flowable adhesive (118) in the bonding area between two bonding surfaces (114, 116), ensuring that a full and complete bond is provided between the paddle members (110, 112). the chute (126, 226, 326) provides a valve action, deflecting to allow excess adhesive (118) to expel past the chute (126, 226, 326), which indicates that the bonding area between the surfaces of union (114, 116) was filled with adhesive (118). in addition, the angled arrangement of the chute (126, 226, 326) results in a tapered edge of the adhesive bonding layer (128) between two members (110, 112), which has been found to provide a reduced probability of crack formation. substantial in the adhesive bonding layer (128).
    公开号:BR112015011848B1
    申请号:R112015011848-8
    申请日:2013-12-02
    公开日:2021-07-27
    发明作者:Lars Nielsen
    申请人:Lm Wp Patent Holding A/S；
    IPC主号:
    专利说明:

    Field of Invention
    [0001] The present invention relates to a method for manufacturing a wind turbine blade, in particular a manufacturing method to ensure adequate adhesive connections between the members of a wind turbine blade. Background of the Invention
    [0002] Modern utility scale wind turbines use relatively large sized wind turbine blades, often exceeding 40 meters in length. Such paddles are mainly manufactured from fiber composite materials, which comprise a fiber, eg, glass fiber, carbon fibers, held in a cured resin. A common manufacturing process used in the construction of these blades is to mold the separate sections or covers of a wind turbine blade into separate molds, the different sections or covers subsequently assembled together to form a complete wind turbine blade.
    [0003] Often, these blade sections will be assembled with an internal mast element, for example, a mast box or a shear web, which extends between opposite blade sections, the mast element providing shear strength and reinforcement for the structure of wind turbine blades.
    [0004] Referring to Fig. 1, a cross-sectional illustration is provided of a joint between a portion of a blade section or cover 110 and an inner mast element, in this case an I-shaped shear web 112. The web 112 comprises a mating surface 114 which is arranged to mate with a mating mating surface 116 provided on the blade cover 110. A portion of the resin or adhesive 118 is provided on the mating surface 114, and web 112 is applied against surface 116 of blade cover 110 such that adhesive 118 is spread between the two surfaces 114,116 to bond shear web 112 of blade cover 110.
    [0005] However, this approach can often present subsequent problems during the operation of the blade. Referring to Fig. 2, an example is illustrated of the system of Fig. 1 after the adhesive 118 has cured in an adhesive bonding layer 120 between the web 112 and the blade cover 110. bond 120 is one of the most likely sites for subsequent blade failure, due to the increased possibility of cracking at the interface between adhesive bonding layer 120 and the blade cover denoted 122.
    [0006] Another disadvantage of the approach taken in Fig. 1 is that it is difficult to ensure that the adhesive 118 spreads evenly between the bonding surfaces 114,116. This can be as a result of an initial uneven application of the adhesive to the first joining surface 114, and/or the first joining surface being pressed towards the second joining surface 116 at an angle, resulting in an uneven distribution of forces. depression.
    [0007] In the example shown in Fig. 2, the adhesive 118 is not fully spread between the joining surfaces 114,116, resulting in the formation of an adhesive bonding layer 120 that does not extend the entire length of the space between the joining surfaces 114,116 , indicated by the void 124 defined between the joining surfaces 114,116. As a result, the strength of the adhesive bond between the bonding surfaces 114,116 is reduced, which can lead to bond failure between the blade components 110,112.
    [0008] To avoid this type of failure, depa designers often adopt at least one of the following approaches. First, the adhesive 118 can be applied in a considerably greater amount than is sufficient to fill the space between the joining surfaces 114,116, with the hope that such an excess amount will ensure that the area between the joining surfaces 114,116 is filled with the adhesive. However, this approach leads to a waste of adhesive during the manufacture of the paddle. In addition, any excess adhesive that cures outside the area between the bonding surfaces 114,116 will often break up some time after curing, which results in loose debris inside a wind turbine blade. Finally, the use of an excess amount of such adhesive does not completely guarantee that the area between the joining surfaces 114,116 will be filled with adhesive, with additional factors such as the direction in which pressure is applied to the web 112 when adhering to the blade cover 110 can further result in an uneven application of adhesive between the mating surfaces 114,116.
    [0009] A second approach is that blade components, in particular mast elements, such as the I 112 web, are intended to be oversized in such a way that the structural integrity of the wind turbine blade is not significantly compromised in the case that the adhesive layer 120 does not extend over the entire extent of the area between the joining surfaces 114,116. However, this oversizing approach results in inefficient use of resources and increases the cost and weight of the wind turbine blade.
    [0010] Finally, wind turbine manufacturers may decide to evaluate the adhesive layer 120 between the bonding surfaces 114,116 after the cure of the adhesive 118, to ensure that there is an adequate bond between the components 110,112. In case of an incomplete bond, a subsequent repair operation can be carried out by applying additional adhesive to the affected area. However, this approach can be relatively costly and time-consuming, particularly when it has to be carried out in a closed wind turbine structure, where lifting and subsequent repair operations must be carried out from outside the blade, for example, using ultrasonic detection to identify the size of adhesive bonding layers 120, pumping resin or additional adhesive from the outside of the paddle to the inside to provide adequate adhesion.
    [0011] U.S. Patent Application Publication No. US 2012/0114497 describes the use of a resin barrier applied to a mating surface between the members of a wind turbine blade to define a cavity between the blade members . Resin can be pumped into said cavity to ensure that the adhesive fully fills the cavity defined between the members. However, this approach requires considerable additional preparation during paddle fabrication, precise placement of the barrier resin, as well as further pumping of adhesive into the defined cavity, thereby increasing the complexity and time of the fabrication process. Furthermore, this system does not solve the problem of bond failure at the interface of the adhesive joints between the blade members.
    [0012] Therefore, it is an object of the invention to provide a method of manufacturing a wind turbine blade, in particular a method of connecting two components of wind turbine blades, which provides for the strengthening of the reliable connection between components balanced with an implementation relatively simple compared to prior art systems. Brief Description of the Invention
    [0013] Therefore, there is provided a method of manufacturing a wind turbine blade, the method comprising the steps of: providing a first member having a first joining surface; providing a second member having a second joining surface; at least one adhesive chute on a first side of said first joining surface of said first member; providing an amount of adhesive capable of flowing between said first and second joining surfaces; pressing said first and second members together to spreading said amount of flowable adhesive to form an adhesive layer between said first and second mating surfaces; curing said adhesive layer to bond said first member to said second member, wherein said at least one adhesive chute is formed of a relatively flexible material, such that during said pressing step, said at least one adhesive chute is arranged to deflect to allow excess flowable adhesive to be extruded after said at least one adhesive chute.
    [0014] Preferably, said depressing step is carried out until an excess amount of flowable adhesive is extruded past said at least one adhesive chute, to indicate that said flowable adhesive substantially fills the space between the said first and second joining surfaces on said first side.
    [0015] As the components are pressed together, when excess adhesive is extruded beyond the adhesive chute, an operator can deduce that the bonding area between the components is filled with adhesive at least for the portion. adjacent, where excess adhesive has extruded past the gutter. This therefore provides a clear indication that sufficient adhesive has been applied to the area of joint between the components such that the area up to the gutter is filled with adhesive. It should be understood that the rigidity or strength of the gutter can be chosen such that the gutter resists the passage of excess adhesive out of the gutter until the area behind the gutter has been filled with adhesive, thus eliminating gaps or air pockets in the adhesive layer between the surfaces.
    [0016] Preferably, the method comprises the steps of: providing a first adhesive chute to a first side of said first joining surface; and providing a second adhesive chute to a second opposite side of said first mating surface, such that an adhesive channel is defined by said first and second mating surfaces, and said first and second adhesive chutes after said step of pressing.
    [0017] Having the first and second rails to define a channel means that the entire connection area between the members can be easily defined. It will be understood that one of said first or second runners may be formed of a resilient material or harder than the other such that excess adhesive is initially at least just extruded past one of the runners.
    [0018] Preferably, said second adhesive chute is formed from a relatively flexible material, and wherein said pressing step is carried out until an excess amount of flowable adhesive is extruded past said first and second chutes adhesive collectors, to indicate that said flowable adhesive substantially fills the adhesive channel between said first and second members.
    [0019] Preferably, said step of providing an amount of adhesive comprises selecting an amount of adhesive to be applied such that the adhesive layer will substantially fill said adhesive channel after said pressing step.
    [0020] Preferably, said selection step comprises selecting an amount of adhesive having a greater volume per unit length than the volume per unit length closed by said adhesive channel, such that said adhesive channel is filled by adhesive, after said pressing step.
    [0021] Preferably, said selection step comprises selecting an amount of adhesive of at least 105% volume per unit length of said adhesive channel, even more preferably at least 110% volume per unit length of said adhesive channel. Such values ensure that the adhesive channel will be filled with adhesive, with minimal waste of excess adhesive extruded beyond the adhesive chute(s).
    [0022] Preferably, said at least one adhesive chute is arranged at an angle not orthogonal to the second joining surface of said second member, such that said adhesive layer comprises a substantially tapered profile on said first side of said first joining surface.
    [0023] Preferably, the method comprises the step of providing said at least one adhesive chute with a securing flange provided on a second free end of said at least one adhesive chute, said retaining flange arranged to retain any excess of extruded adhesive past said second free end of said at least one adhesive chute.
    [0024] The retaining flange may have a curved profile, or it may comprise a planar flange projection.
    [0025] Preferably, said first member is provided with at least a portion of a mast element of a wind turbine blade, preferably a web I, alternatively a web C, a mast box.
    [0026] In one aspect, said at least one adhesive chute is connected to said at least a portion of a mast element of a wind turbine blade. The gutter can be bonded using adhesives or mechanical connections, for example, a clasp fastening arrangement, screws, rivets, etc.
    [0027] In a further aspect, the at least one adhesive chute is removed after said curing step. This can allow the gutter to be reused in the manufacturing process. It should be understood that the gutter can be provided with a suitable release primer or release coating for this purpose.
    [0028] Alternatively, it is to be understood that said at least one adhesive chute can be left in situ.
    [0029] In an alternative aspect, said at least one adhesive chute is formed integrally with said at least a portion of a mast element of a wind turbine blade. The gutter can be formed as part of the mast element using any suitable process, e.g. pultrusion, extrusion, as part of a resin-infused fiber composite structure, etc.
    [0030] Preferably, the method comprises the step of forming said at least one adhesive chute from a relatively resilient material, such that, during said pressing step, said at least one adhesive chute is arranged to deflect for expelling said overflow adhesive past said at least one adhesive drip chute, and wherein said at least one adhesive drip chute is arranged to return to an undeflected state after the overflow adhesive has been expelled by passing at least one adhesive chute to said chute.
    [0031] Preferably, said at least one adhesive collecting chute is provided so that a first end of said chute is connected to said first member adjacent to said first joining surface, wherein after said step of pressing a the second free end of said runner is located adjacent to said second mating surface of said second member.
    [0032] Preferably, said at least one adhesive collecting chute is provided in such a way that after said step of pressing said second free end of said chute is disposed at an acute angle to said second joining surface of said second member.
    [0033] Preferably, the method comprises the step of providing said at least one adhesive chute having a curved cross-sectional profile, such that after said pressing step, said adhesive layer assumes a cross-sectional profile curved corresponding to said first side of said first joining surface.
    [0034] Preferably, said at least one adhesive chute comprises a substantially sine wave-shaped profile.
    [0035] Preferably, said second member is provided as at least a portion of a cover of a wind turbine blade.
    [0036] In one aspect, said depressing step is carried out until an excess flowable amount of adhesive is extruded past a free end of said at least one adhesive chute, along substantially the entire longitudinal length of said by minus one adhesive chute.
    [0037] Also provided is a method of manufacturing a wind turbine blade, the method comprising the steps of: providing a first member having a first joining surface; providing a second member having a second mating surface; providing at least one adhesive chute to a first side of said first mating surface of said first member, said at least one adhesive chute having a first end disposed on said first member and an opposite second free end; providing an amount of flowable adhesive between said first and second mating surfaces; pressing said first and second members together to spread said amount of flowable adhesive to form an adhesive layer between said first and second joining surfaces; curing said adhesive layer to attach said first member to said second member, wherein said at least one adhesive chute is provided with a retaining flange at said second free end of said at least one adhesive chute, said flange retainer arranged to retain any excess adhesive that may be extruded past said second end of said at least one adhesive chute.
    [0038] By providing an adhesive chute with an adhesive retaining flange at the free end of the chute, this ensures that if excess adhesive is pushed out of the chute, it will be retained substantially in situ adjacent to the chute. Therefore, after curing, excess adhesive will not tend to break up inside a wind turbine blade as debris inside the blade.
    [0039] It should be understood that the retaining flange may be arranged such that the retaining flange abuts a surface of the second member, thus forming a substantially closed channel for retaining any excess adhesive. Alternatively, the retaining flange may be arranged to extend adjacent the second member, providing a gutter channel or pickup arm for any excess adhesive.
    [0040] Additionally or alternatively, there is provided a method of manufacturing a wind turbine blade, comprising the steps of: providing a first member having a first joining surface; providing a second member having a second joining surface; providing an amount of flowable adhesive between said first and second joint surfaces; pressing said first and second members together to spread said amount of flowable adhesive to form an adhesive layer between said first and second joint surfaces. unity; curing said adhesive layer to bond said first member to said second member, wherein, prior to said pressing step, the method comprises the step of providing at least one adhesive chute to a first side of said first joining surface of the said first member, said adhesive chute disposed at an angle not orthogonal to the second joining surface of said second member, wherein a portion of said flowable adhesive is pushed against said adhesive chute through said pressing step, such that said adhesive layer comprises a substantially tapered profile on said first side of said first joining surface.
    [0041] The use of an adhesive chute on the side of the joining surfaces acts to keep the adhesive able to flow between the joining surfaces as the first and second members are pressed together. The taper profile is defined by the adhesive chute. The angular arrangement of the trough acts to force the adhesive layer to assume a tapered profile along the edge of the adhesive layer. Therefore, the height of the adhesive layer above the member surfaces is reduced at the edge of the layer. As the energy release rate of the adhesive layer is found to be related to the height of the adhesive layer over the member surface, the tapered edge profile of the adhesive layer results in a reduction in crack formation in the adhesive layer of the turbine blade. finished wind. Preferably, said at least one adhesive chute comprises a substantially flat element.
    [0042] Preferably, said first member comprises at least a portion of a mast element of a wind turbine blade.
    [0043] A mast element may comprise any element used in strengthening a wind turbine blade, generally an inner member that extends along at least a portion of the longitudinal extent of the blade. The mast element may, for example, comprise a mast box, a shear web such as a web I, a web C, etc.
    [0044] Preferably, said second member comprises at least a portion of a cover of a wind turbine blade.
    [0045] The outer body of a wind turbine blade can be formed from a plurality of blade covers, which are formed in a blade mold, and which are subsequently assembled to form the outer body of the blade. For example, the blade covers can form substantially respective upstream and downstream sides of a wind turbine blade.
    [0046] It will be understood that the first and/or second members may comprise subsections of a larger wind turbine blade structure, preferably by a longitudinally extending portion of a wind turbine blade. For example, the second member may comprise a subsection of a cover for a wind turbine blade, the first member comprising a portion of a mast element for connecting to said subsection of a cover for a wind turbine blade.
    [0047] Preferably, said at least one adhesive track is provided along substantially the entire length of the first and second members. However, this implementation can result in additional work on the manufacturing process.
    [0048] The at least one adhesive chute may be provided along those areas of the wind turbine blade most susceptible to the bonding interface failing. In one aspect, said at least one adhesive chute is provided on said first and second members within 0 to 75% of the longitudinal extent of the wind turbine blade, measured from a root end of said blade to an end of tip of said paddle. In an alternative aspect, the gutter can be provided within 25 to 75% of the longitudinal extension. In another alternative, the gutter can be provided within 0 to 25% of the longitudinal extension.
    [0049] In one aspect, said at least one adhesive chute is provided on said first and second members within 0 to 15% of the longitudinal extent of the wind turbine blade, measured from a root end of said blade to a tip end of said blade.
    [0050] For example, for a 40 meter long shovel, in such modality the adhesive chute is provided in the area between 0 to 6 meters from the root end of the shovel.
    [0051] Preferably, said at least one adhesive chute is provided on said first and second members, up to the maximum chord location of the wind turbine blade.
    [0052] Preferably, said at least one adhesive collecting chute is provided so that a first end of said chute is connected to said first member adjacent to said first adhesion surface, wherein after said step of pressing a the second end of said runner is located adjacent to said second mating surface of said second member.
    [0053] The gutter is arranged so that the shape and length of the gutter are configured to extend between the first and second members when the members are pressed together to join the members together.
    [0054] Preferably, said at least one adhesive collecting chute is provided in such a way that after said step of pressing said second end of said chute is disposed at an acute angle with said second joining surface of said second member.
    [0055] The gutter protrudes at an angle from the first member, so that the gutter forms an acute angle with the surface of the second member when the first and second members are pressed together. This sharp angle creates a cross-sectional profile tapering to the adhesive layer between the members when the flowable adhesive is pressed against the chute during the pressing step.
    [0056] In a preferred aspect, said at least one adhesive chute comprises a curved cross-sectional profile, such that after said step of pressing said adhesive layer assumes a curved cross-sectional profile corresponding to said first side of the said first joining surface.
    [0057] The use of a curved gutter acts to form a curved cross-sectional profile of the edge of the adhesive layer. Such a curved contour acts to evenly distribute forces around the adhesive layer, further reducing the possibility of adhesive failure during wind turbine blade operation.
    [0058] Preferably, said at least one adhesive collecting gutter comprises a convex profile between said first and second ends, such that after said step of pressing said adhesive layer assumes a concave profile in cross section on said first side of said first joining surface.
    [0059] Preferably, said at least one adhesive collecting trough is in the form of a sine wave.
    [0060] In the preferred embodiment, said at least one adhesive chute is provided so that after said pressing step, said second end of said adhesive chute is provided in contact with said second joining surface.
    [0061] By arranging the contact chute with the surface of the second member, when the flowable adhesive is pressed against the chute, the contour or end of the subsequent adhesive layer will fully taper to the surface of the second member. Such adhesive layer which tapers fully to the surface of the second member has a considerably reduced energy release rate compared to the contours of the prior art adhesive layer, leading to a reduction in the possibility of contour failure during paddle operation.
    [0062] Preferably, said at least one adhesive chute is formed from a relatively flexible material, such that during said pressing step, said at least one adhesive chute is arranged to deflect to allow excess of flowable adhesive extruded from said second end of said chute.
    [0063] By having a flexible adhesive collecting gutter, the gutter can act as a simple valve, which allows excess adhesive to exit the adhesive channel defined by the union surfaces and the at least one gutter. Therefore, the amount of adhesive that is supplied can be selected to ensure that the volume of adhesive will fill the desired area between the bonding surfaces, with the possibility of providing an adhesive volume of more than an excess amount, for example, 110% adhesive volume required. In such a case, the action of pressing the members together will ensure that the adhesive will fill the area between the joining surfaces, with any excess adhesive passed through the action of the chute valve.
    [0064] Still preferably, said at least one adhesive chute is formed from a relatively resilient material, such that, during said pressing step, said at least one adhesive chute is arranged so as to return to a undeflected state after excess flowable adhesive has extruded past said second end of said chute.
    [0065] By having a resilient gutter, the gutter will return to a position of contact with the surface of the second member, such that the height of the adhesive layer over the surface of the second member will taper to 0 at the edge of the adhesive layer, maintaining a low possibility of adhesive failure during operation.
    [0066] In one aspect, said at least one collecting gutter is formed from a plastic material, for example, pultruded plastic. In another aspect, said at least one chute is formed from a composite fiber material, cured in a mold, for example, a fiberglass material. In a preferred aspect, the adhesive chute is formed from 450 g/m2 biax, preferably using two layers per chute.
    [0067] Additionally or alternatively, said step of providing at least one adhesive collecting chute comprises providing a second end of said chute having a serrated edge.
    [0068] The use of a serrated edge can allow an extrusion of the adhesive able to flow past the second end of the gutter. In such a case, the gutter can be formed from an inflexible rigid element, eg rigid plastic, metal, etc., or from a flexible medium, as described above.
    [0069] Alternatively, said at least one adhesive chute is provided so that after said pressing step, said second end of said adhesive chute is spaced from said second joining surface by a distance D, where D < 5mm.
    [0070] The gutter can be arranged in such a way that when the first and second members are pressed together on both sides of a desired height of the adhesive layer, the gutter will project from the first member to a height spaced from the surface of the second member. In this case, the edge of the adhesive layer will be formed by the chute to have a tapered profile to the second end of the chute, which has a reduced height with respect to the surface of the second member. Such reduced height will reduce the possibility of failure of the adhesive layer compared to prior art systems.
    [0071] In a further aspect, said at least one adhesive chute comprises a retaining flange provided at the second end of said at least one adhesive chute, said retaining flange arranged to retain any excess past adhesive extruded to said second the end of said at least one adhesive collecting chute.
    [0072] As the gutter is molded beyond the second end to have a retaining flange, this acts to hold excess adhesive in place adjacent to the surface of the second element. This prevents excess adhesive from coming off the second member, and loose debris from forming inside the wind turbine blade.
    [0073] In one aspect, said at least one adhesive chute is provided as an integral part of said first member.
    [0074] In this aspect, the first member can be formed with an integral sump chute. For example, the first member can be formed using a pultrusion process, have a profile with an integrated chute, for example a pultruded web having integrated chute.
    [0075] In an alternative aspect, the method comprises the step of assembling said at least one adhesive chute to said first member adjacent to said first joining surface.
    [0076] In this case, a preformed first member, for example a preformed mast box, web I, etc., can be provided, where the chutes can be attached to the first member so that the chutes are located adjacent to the relevant mating surfaces of the first member. For example, the chute can be attached to the first member using adhesives, the chute can be bolted to the first member and/or a clip or snap fit can be used where the chute and the first member have coupling elements with -operating for connection.
    [0077] Preferably, the method comprises the steps of: providing a first adhesive chute to a first side of said first joining surface; and providing a second adhesive chute to a second opposite side of said first mating surface, such that an adhesive channel is defined by said first and second mating surfaces, and said first and second adhesive chutes after said step of pressing.
    Preferably, said step of providing an amount of adhesive comprises selecting an amount of adhesive to be applied such that the adhesive layer will substantially fill said adhesive channel after said pressing step.
    [0079] Preferably, said selection step comprises selecting an amount of adhesive having a greater volume per unit length than the volume per unit length closed by said adhesive channel, such that said adhesive channel is filled by adhesive, after said pressing step.
    [0080] The definition of an adhesive channel between the first and second members allows an assembly area to be filled by the adhesive, to ensure a satisfactory connection between the elements of the wind turbine blade. It should be understood that the adhesive channel may be defined by a portion of the longitudinal extent of the first and second members where it is desirable to ensure that the adhesive layer fills the area defined by the adhesive channel, in particular for the areas of the wind turbine blade, wherein failure of the adhesive layer is most likely during blade operations, for example for the portion of the first and second members up and around the maximum chord of the wind turbine blade.
    [0081] The amount of adhesive that is supplied in the adhesive channel can be selected to ensure that the volume of adhesive will fill the desired area between the bonding surfaces. When providing an adhesive volume plus an excess amount, eg 110% adhesive volume required, it must be ensured that the adhesive channel will be completely filled with adhesive, with any excess adhesive or extruded past the second end of the gutters, as described above, or forced further along the length of the adhesive channel, past the gutters.
    [0082] Preferably, said step of providing an amount of adhesive comprises applying an amount of adhesive to said first joining surface or to said second joining surface.
    [0083] In another aspect, said at least one adhesive chute is provided with a marker element, which allows the location of the position of the marker element to determine when the adhesive chute is installed on a wind turbine blade.
    [0084] For example, the adhesive chute may comprise a reflection element that is operable to reflect optical, radio-frequency, or ultrasonic signals from test apparatus, for example, from an ultrasonic detector used on the outer surface of a wind turbine blade. Such a reflective element can act to assist in locating the gutter within the interior of the blade, and may act accordingly to define the contour of adhesive layers, replacement elements, etc., within a blade during non-testing procedures. destructive.
    [0085] In another aspect, the method comprises the step of, after said pressing step, removing said at least one adhesive chute.
    [0086] In some cases, the gutter may be removed after the members have been pressed together, and the flowable adhesive settles on the adhesive layer between the two joining surfaces. The chute can then be re-used in the manufacture of subsequent blades. It should be understood that the gutter can be removed after said curing step has taken place.
    [0087] It will be understood that the method provides an element comprising said first and second members connected together through said adhesive layer, wherein said element can be used as components for manufacturing a wind turbine blade. While the embodiments illustrated herein show the connection between the blade cover and a mast element of a wind turbine blade, it will be understood that the method can be used to provide a better connection between any elements of a wind turbine blade.
    [0088] It should be understood that the characteristics described in relation to the above methods, and the associated advantages of each, are interchangeable between the methods, without undue modification of the underlying processes.
    [0089] An adhesive chute for use in any aspect of the methods as described above is also provided.
    [0090] Also provided is a wind turbine blade manufactured in accordance with any of the aspects of the methods described above. Description of the Invention
    [0091] The embodiments of the invention will now be described, by way of example only, with reference to the attached drawings, in which:
    [0092] Fig. 1 shows a part of a cross-sectional view of a prior art method of assembling components of a wind turbine blade;
    [0093] Fig. 2 shows the section illustrated in Fig. 1 after assembly;
    [0094] Fig. 3 shows a wind turbine;
    [0095] Fig. 4 shows a schematic view of a wind turbine blade;
    [0096] Fig. 5 shows a schematic view of an airfoil profile of a wind turbine blade;
    [0097] Figs. 6 and 7 show a portion of a cross-sectional view of a method of assembling components of a wind turbine blade according to an embodiment of the invention, before and after assembly;
    [0098] Figs. 8 and 9 show a portion of a cross-sectional view of a method of assembling components of a wind turbine blade according to a second embodiment of the invention, before and after assembly; and
    [0099] Figs. 10 and 11 show a portion of a cross-sectional view of a method of assembling components of a wind turbine blade according to a third embodiment of the invention, before and after assembly.
    [0100] It should be understood that the elements of the designs that are replicated between the modalities are designated with the same reference numbers.
    [0101] Fig. 3 illustrates a modern conventional wind turbine against wind according to the so-called "Danish concept" with a tower 4, a nacelle 6 and a rotor with an essentially horizontal rotor shaft. The rotor includes a hub 8 and three blades 10 extending radially from the hub 8, each having a root blade 16 closest to the hub and a blade tip 14 furthest from the hub 8. The rotor has an indicated radius. A.
    [0102] Fig. 4 shows a schematic view of a first embodiment of a wind turbine blade 10, which can be used according to an embodiment of the invention. The wind turbine blade 10 is shaped like a conventional wind turbine blade and comprises a root region 30 closer to the hub, an airfoil or profile region 34 further from the hub, and a transition region 32 between the root region. 30 and the airfoil region 34. Blade 10 comprises a leading edge 18 facing the direction of rotation of blade 10 when the blade is mounted on the hub, and a trailing edge 20 facing the opposite direction of the leading edge. 18.
    [0103] The airfoil region 34 (also called the profiled region) has an ideal or near-ideal blade shape with respect to elevation generation, where the root region 30 due to structural considerations has a substantially circular or cross-section. elliptical, for example, which makes it easier and safer to mount the 10 paddle to the hub. The diameter (or chord) of root region 30 is typically constant over the entire root area 30. Transition region 32 has a transition profile 42 gradually changing from the circular or elliptical shape of root region 30 of the airfoil profile 50, as shown in Fig. 3, of the airfoil region 34. The chord length of the transition region 32 typically substantially increases linearly with increasing distance r from the cube.
    [0104] The airfoil region 34 has an airfoil profile 50 with a chord that extends between the leading edge 18 and the trailing edge 20 of the blade 10. The width of the chord decreases with increasing distance r from the center.
    [0105] It should be noted that the strings from different sections of the blade do not normally rest in a common plane, as the blade may be twisted and/or curved (i.e., pre-bent), thus providing the chord plane. with a correspondingly twisted and/or curved course, this being the most frequent case, in order to compensate for the local blade speed being dependent on the radius from the hub.
    [0106] Fig. 5 shows a schematic view of an airfoil profile 50 of a typical wind turbine blade represented with the various parameters that are typically used to define the geometric shape of an airfoil. The airfoil profile 50 has a pressure side 52 and a suction side 54, which during use - i.e. during rotation of the rotor - normally faces to the windward (or downwind) side and to the wind side. leeward (or downwind), respectively. Airfoil 50 has a chord 60 of chord length c that extends between a leading edge 56 and a trailing edge 58 of the blade. The airfoil 50 has a thickness t, which is defined as the distance between the pressure side 52 and the suction side 54. The thickness t of the airfoil varies along the chord 60. The deviation from a symmetrical profile is given by a line of curvature 62, which is a midline through the aerophilic profile 50. The midline can be found by selecting inscribed circles from the leading edge 56 to the trailing edge 58. The midline follows the centers of said inscribed circles and the deviation or the distance from chord 60 is called the curvature f. Asymmetry can also be defined by using parameters called upper curvature and lower curvature, which are defined as the distances from the chord 60 and the suction side 54 and the pressure side 52, respectively.
    [0107] Airfoil profiles are often characterized by the following parameters: the length of the chord c, the maximum curvature f, the position df of the maximum curvature f, the maximum thickness of airfoil t, which is the largest diameter of the inscribed circles along the line of median curvature 62, the position dt of the maximum thickness T, and a tip radius (not shown). These parameters are typically defined as ratios for chord length c.
    [0108] Wind turbine blades are generally formed from fiber reinforced plastic material, for example, glass fibers and/or carbon fibers, which are placed in a mold and cured with a resin to form a solid structure. Modern wind turbine blades can often be in excess of 30 to 40 meters in length, with blade root diameters of several meters.
    [0109] Generally, wind turbine blades are manufactured as separate cover pieces, which are then assembled together to form the structure of wind turbine blades. In preferred techniques, the wind turbine blade is assembled from at least one cover member substantially forming an upward flowing or pressure-side surface of a wind turbine blade profile, and at least one member. of cover substantially forming a downwind surface or pressure side surface of a wind turbine blade profile, and at least one cover member substantially forming a downwind surface or a wind turbine blade profile.
    [0110] Referring to Fig. 6, a cross-section of a portion of a new method of manufacturing a wind turbine blade according to the invention is illustrated. The invention relates to the joining of the first and second members of a wind turbine blade, in this case a blade section or cover 110 and a mast element 112. In Fig. 6, the mast element 112 comprises a web I , but it will be understood that any suitable mast reinforcing element may be used, for example a mast box, a shear web, for example a C-shaped web, etc.
    [0111] A first mating surface 114 is provided on the mast element 112, the mating surface 114 arranged to be mated with an opposing second mating surface 116, defined on the blade cover 110. It should be understood that said surfaces may be pretreated to improve the adhesive bonding properties of the surfaces, for example the surfaces can be scored or undulated to provide a stronger mechanical adhesive bond.
    [0112] The first and second adhesive chutes 126 are provided on the mast element 112, on each side of the first joining surface 114. The adhesive chutes 126 extend from the mast element 112 to the blade cover 110, the rails 126 arranged such that they form a non-orthogonal angle with the second joining surface 116 of the blade cover 110. Preferably, the rails 126 project from the mast element 112 to form a flared or other collar on the side of the blade. said first joining surface 114, forming an acute angle with said second joining surface 116.
    [0113] An amount of flowable adhesive 118 is applied to said first joint surface 114, the amount of adhesive approximately equal to the amount of adhesive required to ensure a secure bond between the first and second joint surfaces 114,116.
    [0114] Therefore, when the demasted element 112 is pressed towards the blade cover 110, an adhesive channel is defined between the first and second opposing mating surfaces 114,116 and side walls provided by the first and second adhesive chutes 126, the side walls of the adhesive channel being tapered towards the second mating surface 116. Furthermore, with reference to Fig. 7, the adhesive 118 provided on the first mating surface 114 is pinched or pressed by the opposite first and second mating surfaces 114,116 to spread to fill the adhesive channel, with the chutes 126 acting to retain the flow of adhesive 118 within the channel. As a result, the adhesive 118 is guaranteed to fill the space between the first and second mating surfaces 114,116, regardless of the initial distribution of adhesive over the first surface 114 and/or the angle at which the mast element 112 is pressed towards of the paddle cover 110. The flowable adhesive 118 is then cured by forming an adhesive layer 128 which connects the respective first and second mating surfaces 114,116.
    [0115] As an additional advantage, the use of chutes 126 provided on each side of the first joining surface 114 provides a suitable receiving platform to receive an amount of flowable adhesive 118 during the assembly and manufacturing process, thus increasing simplicity manufacturing process for operators and reducing the possibility of adhesive waste spills 118.
    [0116] It was found that the probability of substantial cracks or the formation of flaws at the interface between an adhesive layer and the inner surface of a blade cover is directly related to the energy release rate (ERR) of the adhesive layer. The higher ERR results in a reduced likelihood of substantial crack formation in the wind turbine blade. Therefore, it is desirable to reduce the ERR of the adhesive bonding layer 128 formed between the mating surfaces 114,116 to improve the reliability of the joint between the blade layer 110 and the mast element 112.
    [0117] Crack formation is more likely to occur at the edges of the adhesive bonding layer 128, at the interface of the second bonding surface 116. As the ERR the adhesive bonding layer 128 at one point is directly related to the cross-sectional area of the layer at that point, consequently reducing the height of the adhesive bonding layer 128 above the surface of the second joining surface 116 with the edges of the layer 128 will result in a reduction in ERR to these limits, consequently providing a considerable reduction in possibility of formation of substantial cracks in these boundary contours.
    [0118] Arranging the adhesive chutes 126 in angled projection from the mast element 112 towards the blade cover 110, to form sharp angles with the second joining surface 116 of the blade cover 110, results in the formation of a blade profile. tapering at the edges of the adhesive bonding layer 128. This provides an adhesive layer 128 with a reduced ERR when compared to prior art systems, resulting in a reduction in the possibility of cracking over the lifetime of the wind turbine blade. Thus, the system of the invention provides a considerable advantage over prior art methods for joining wind turbine blade components.
    [0119] Preferably, the adhesive collected chutes126 are substantially flat members, preferably formed from a composite molded fiber material, for example, 450 g/m2 biaxial, preferably using two layers per chute. The chutes can be formed from a pultrusion process.
    [0120] The rails 126 protrude from a first end 126a located on the mast element 112, to a second end 126b, which is located adjacent the second joining surface 116 of the blade cover 110, since the mast element 112 and the paddle cover 110 are pressed together. Preferably, the second end 126b abuts the second joining surface 116, as the mast element 112 and the blade cover 110 are pressed together, forming a barrier or wall between the first and second surfaces 114,116, but it is to be understood that the second end 126b may rest a short distance from the second surface 116 after the pressing step. Preferably, second end 126b is at most 5 millimeters away from second surface 116 after said pressing step. Such a small distance will result in a relatively low height of adhesive layer 128 above second surface 116, maintaining a relatively low ERR at the boundary of adhesive layer 128 defined by adhesive chutes 126.
    [0121] Although the embodiment of Figs. 6 and 7 illustrate adhesive chutes 126 with a linear planar profile, it should be understood that other transverse chute profiles may be used. For example, with reference to Figs. 8 and 9, a second embodiment of the invention is illustrated.
    [0122] The modality of Fig. 8 is similar to the modality of Fig. 6, with the distinction that the chutes having a curved cross-section profile 226 are used. The rails 226 curve between the first end 226a provided adjacent the first mating surface 114 and the second end 226b arranged to abut the opposing second mating surface 116. In this embodiment, the rails 226 are arranged to flare outwardly from the adjacent first joining surface 114, having a convex face opposite the second joining surface 116. The flowable adhesive application method 118, pressing together the paddle element 112 and the paddle cover 110 to spread the adhesive 118 between the chutes 226, and subsequently curing the adhesive 118 into the adhesive layer 128 (Fig. 9) is carried out as described above with respect to the first embodiment.
    [0123] This curved shape of the adhesive chute226 results in a more uniform distribution of forces on the subsequently cured adhesive bonding layer 128, as seen in Fig. 9. Such force distribution further provides a further reduction in the probability of cracking or formation of cracks. failures in adhesive bonding layer 128.
    [0124] In a further preferred aspect of the invention, at least one adhesive chute can be provided as a relatively flexible member. In such a case, the gutter flexibility is selected to deflect under pressure if an excess amount of flowable adhesive is applied between the joint surfaces. In such a case, any excess adhesive can be squeezed past the second end of the chute.
    [0125] Preferably, flexibility is further chosen such that the gutter is resilient enough to return to a rest position in contact with, or in close proximity to, the opposite second joining surface, since excess adhesive has squeezed past the second end of the gutter. In this case, the sump chute acts as a valve in a simple way, in that it can deflect to allow excess adhesive to pass outside the channel defined between the joining surfaces and the adhesive sump, and can subsequently return to a in-rest position that defines a tapered edge of the adhesive bonding layer.
    [0126] Another modality of the invention is illustrated in Figs. 10 and 11, wherein the adhesive chutes 326 comprise a substantially sinusoidal waveform profile. The runners 326 are disposed on adjacent opposite sides of the first joining surface 114, which has a first end 326a provided on the first joining surface 114 and a second notional end 326b disposed towards the opposite second joining surface 116. The first and second joining surfaces 116. ends 326a, 326b are disposed approximately at successive minimum and maximum points of the sine wave profile, so that the trough 326 will provide a curved sidewall profile of the adhesive channel created when the mast element 112 is pressed against the cover of shovel 110.
    [0127] As the chute 326 is formed from a relatively flexible material, it is arranged to deflect when an excess amount of adhesive is supplied in the adhesive channel defined between the first and second mating surfaces 114,116 and the opposing chutes 326 Once the excess is squeezed out of the adhesive channel, the chute 326 can return to an at-rest position in contact with the second mating surface 116. Referring to Fig. 11, the excess adhesive subsequently cures in portions of an adhesive layer adjacent the second notional end 326b of runners 326, indicated at 330.
    [0128] The chute 326 is molded to continue beyond said second notional end 326b to effectively provide a retaining flange 332 for any excess adhesive 330 that can be extruded past the second notional ends 326b of the sump chutes 326. The retaining flanges 332 may act to prevent excess adhesive able to flow from dripping past the flange 332, and/or in the case of excess adhesive that has cured into a layer 330 of the flange 332 may act to keep the excess in place adjacent to the overlay of spade cover 110. If the excess layer of 330 fits out from the blade cover 110, the flange 332 can retain the cured adhesive pieces 332 next to the blade cover 110, and prevent such debris from falling onto the larger interior. of wind turbine blade.
    [0129] It should be understood that several other technical features may be combined with the features of the modalities described above. For example, while the second end 126b, 226b, 326b of the chute 126,226,326 is preferably a straight edge so as to form a solid or wall barrier against the second joining surface 116, it will be appreciated that in some embodiments the second end 126b of the chute 126 may be profiled or molded, for example a serrated or wavy edge, in order to facilitate the passage of excess adhesive beyond said second end 126b, 226b, 326b. This feature can be used in combination with, or in place of, the relatively flexible adhesive collector feature 126,226,326.
    [0130] It should be understood that the arrangement of the adhesive chutes in relation to the first and second joining surfaces may be interchangeable. For example, adhesive chutes extending from the second joining surface defined on the blade cover towards the first surface defined on the mast element. Furthermore, while the above-described embodiments relate to joining a mast element to a blade cover, providing adhesive capable of flowing over a surface of the mast element, it will be understood that the invention is equally applicable to the case where the flowable adhesive is applied to the surface of the blade cover, with the mast element subsequently bonded to this surface.
    [0131] The adhesive chutes can be mounted or adhered to the mast element or blade cover. For example, the mast element may be provided with a plurality of snap-in fitting elements, with corresponding elements providing at said first end of the chute, allowing a relatively simple mounting of the adhesive chute to the mast element. In a preferred embodiment, the adhesive chutes are formed integrally with the mast element, for example, as part of a pultruded shear web profile.
    [0132] In one aspect, the adhesive chutes can be removed from the mast element either while the adhesive bonding layer is curing, or after curing is complete.
    [0133] Although adhesive chutes can be applied along the entire length of the wind turbine blade, in one aspect, the chutes are only applied along the length of the blade where it is most desired to prevent failure of adhesive bonding between members of shovel. In a preferred aspect, sump troughs are provided along a portion of the inner section of the wind turbine blade, towards the root end of the blade. Preferably, the chutes are applied in the area between the end of the root and the point along the length of the blade which has the maximum length of the wind turbine blade's chord.
    [0134] In one aspect, chutes may comprise a marker or a tracer element (not shown) that acts to highlight the location of the chutes during a survey operation, for example, a non-destructive test operation such as a sweep image of a wind turbine blade. Such a marker or tracer may be a material that has a different density, preferably an increase in density, relative to the rest of the collection chute, such that the tracer or tracer can easily be detected during such a surveying or scanning operation. . This allows a worker to easily identify the location of adhesive bonding layers on an assembled wind turbine blade, and can help determine if the blade components are sufficiently bonded together. Preferably, the marker or tracer comprises a strip of relatively dense material provided at said second end of the chute, thus defining the boundaries of the cured adhesive bonding layer provided in the adhesive channel described above defined between the opposing joining surfaces and the adhesive gutters.
    [0135] It will be understood that the method of the invention can further provide for the case where a single adhesive chute is used, on a first side of the joining surface. In this case, the flowable adhesive can be applied adjacent to the single chute, in which the action of pressing the two members together will result in the adhesive touching the chute, and being squeezed in an outward direction of the chute to substantially fill the area between the two joining surfaces.
    [0136] The use of adhesive chutes as described above in the method of the invention provides for the assembly of wind turbine components having an improved adhesive connection. Such bonded components can later be mounted on a larger wind turbine blade structure having greater reliability and requiring a reduction in the number of repair operations.
    [0137] The invention is not limited to the modalities described herein, which can be modified or adapted, without departing from the scope of the present invention.
    权利要求:
    Claims (11)
    [0001]
    1. Method of manufacturing a wind turbine blade (10), characterized in that it comprises the steps of: providing a first member (112) having a first joining surface (114); providing a second member (110) having a second mating surface (116); providing at least one adhesive chute (126, 226, 326) on a first side of said first mating surface of said first member; providing an amount of flowable adhesive (118 ) between said first (114) and second (116) mating surfaces; pressing said first (112) and second (110) members together to spread said amount of flowable adhesive (118) to form a layer adhesive (128) between said first and second joining surfaces; curing said adhesive layer to bond said first member to said second member, wherein said at least one adhesive collecting chute is formed of a flexible material, such that during said pressing step, said at least one chute The adhesive collector is arranged to bypass to allow excess flowable adhesive to be extruded after said at least one adhesive collector chute, wherein said pressing step is carried out until an excess amount of flowable adhesive is extruded past said at least one adhesive chute, to indicate that said flowable adhesive substantially fills the space between said first and second joining surfaces on said first side, and wherein the method comprises the step of providing said by at least one adhesive chute with a marker element, wherein said marker element allows for locating the position of the link. marker element to be determined after binding the first member to the second member.
    [0002]
    2. Method, according to claim 1, characterized in that it comprises the steps of: providing a first adhesive chute to a first side of said first joining surface; and providing a second adhesive drip chute to a second opposite side of said first adhesion surface, such that an adhesive channel is defined by said first and second mating surfaces, and said first and second adhesive drip chutes after said step of pressing.
    [0003]
    3. Method according to claim 2, characterized in that said second adhesive chute is formed from a flexible material, and wherein said pressing step is carried out until an amount of adhesive is able to flow excess is passed extruded to said first and second adhesive chutes to indicate that said flowable adhesive substantially fills the adhesive channel between said first and second members.
    [0004]
    4. Method according to any one of the preceding claims, characterized in that it comprises the step of providing said at least one adhesive chute with a retaining flange provided at a second free end of said at least one adhesive chute said retaining flange arranged to retain the amount of extruded adhesive capable of overflowing past said second free end of said at least one adhesive chute.
    [0005]
    5. Method according to any one of the preceding claims, characterized in that said first member is provided as at least a portion of a wind turbine blade mast element, and wherein said at least one sump chute adhesive is attached to said at least a portion of a wind turbine blade mast element.
    [0006]
    6. Method according to any one of the preceding claims, characterized in that said first member is provided as at least a portion of a wind turbine blade mast element, and wherein said at least one sump chute adhesive is formed integrally with said at least a portion of a wind turbine blade mast element.
    [0007]
    7. Method according to any one of the preceding claims, characterized in that a resilience of said resilient material is selected such that during said pressing step, said at least one adhesive chute is arranged to deflect to extrude said amount of excess flowable adhesive past said at least one adhesive drip chute, and wherein said at least one adhesive drip chute is arranged to return to an undeflected state after the amount of flowable adhesive in excess has passed said at least one adhesive collecting chute extruded.
    [0008]
    8. Method according to any one of the preceding claims, characterized in that said at least one adhesive chute is provided so that a first end of said at least one adhesive chute is connected to said first member in a manner adjacent to said first mating surface, wherein after said step of pressing a second free end, said at least one adhesive chute is located adjacent to said second mating surface of said second member.
    [0009]
    9. Method according to claim 8, characterized in that said at least one adhesive drip chute is provided in such a way that after said step of pressing said second free end, said at least one adhesive chute is disposed at an acute angle with said second joining surface of said second member.
    [0010]
    10. Method according to any one of the preceding claims, characterized in that it comprises the step of providing said at least one adhesive chute having a curved cross-sectional profile, such that after said step of pressing , said adhesive layer assumes a corresponding curved cross-sectional profile on said first side of said first joining surface.
    [0011]
    11. Method according to any one of the preceding claims, characterized in that said at least one adhesive chute comprises a substantially sine wave-shaped profile.
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    同族专利:
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    WO2014086703A1|2014-06-12|
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    EP2931498B1|2019-08-28|
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    法律状态:
    2018-03-06| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2018-03-13| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2018-03-20| B06I| Publication of requirement cancelled [chapter 6.9 patent gazette]|Free format text: ANULADA A PUBLICACAO CODIGO 6.6.1 NA RPI NO 2462 DE 13/03/2018 POR TER SIDO INDEVIDA. |
    2019-12-10| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|
    2021-02-23| B06A| Notification to applicant to reply to the report for non-patentability or inadequacy of the application [chapter 6.1 patent gazette]|
    2021-06-22| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2021-07-27| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 02/12/2013, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    EP12195249|2012-12-03|
    EP12195249.3|2012-12-03|
    PCT/EP2013/075213|WO2014086703A1|2012-12-03|2013-12-02|A system and method of manufacturing a wind turbine blade|
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