• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    A method for making a rotor blade panel of a wind turbine includes placing one or more fiber-reinforced outer shells in a mold of the rotor blade panel. The method also includes printing and depositing, via a computer numerical control device (CNC), a plurality of rib elements that form at least one three-dimensional (3-D) reinforcement grid structure on an internal surface of one or more external coatings reinforced with fiber. In addition, the grid structure attaches to one or more fiber-reinforced outer coatings as the grid structure is deposited. In addition, the method includes printing at least one additional feature on the grid structure.
    公开号:BR112020009406A2
    申请号:R112020009406-4
    申请日:2018-11-05
    公开日:2020-11-03
    发明作者:James Robert Tobin；Alan M. Walker；Todd Anderson；Norman Arnold Turnquist；Stephen Bertram Johnson；Don Conrad Johnson；Thomas Merzhaeuser；Peggy Lynn Baehmann；Stefan Herr；Murray Fisher；Andrew McCalip
    申请人:General Electric Company；
    IPC主号:
    专利说明:

    [001] [001] The present invention relates in general to wind turbine rotor blades, and more particularly to methods of manufacturing wind turbine rotor blade panels with printed grid structures. BACKGROUND OF THE INVENTION
    [002] [002] Wind energy is considered one of the cleanest and most environmentally friendly energy sources currently available, and wind turbines have gained greater attention in this regard. A modern wind turbine typically includes a tower, a generator, a gearbox, a nacelle and one or more rotor blades. Rotor blades capture the kinetic energy of the wind using known aluminum foil principles. The rotor blades transmit kinetic energy in the form of rotational energy, so as to rotate an axis that couples the rotor blades to a gearbox or, if a gearbox is not used, directly to the generator. The generator then converts mechanical energy into electrical energy that can be implanted in an electrical network.
    [003] [003] The rotor blades, in general, include a lateral suction housing and a pressure side housing typically formed using molding processes that are connected together in connecting lines along the front and rear ends of the blade. In addition, the pressure and suction shells are relatively light and have structural properties (for example, rigidity, strength and warping force) that are not configured to withstand the bending moments and other loads exerted on the rotor blade during operation. Thus, to increase stiffness, warp resistance and rotor blade strength, the body housing is typically reinforced using one or more structural components (for example, opposing spar caps) with a configured shear net between them) that engage the internal pressure and suction side surfaces of the coating halves.
    [004] [004] Stringer crowns are typically constructed of various materials, including, but not limited to, laminated fiberglass composites and / or laminated carbon fiber composites. The rotor blade lining is generally built around the spar stringer crowns by stacking layers of fiber fabric in a lining mold. The layers are then typically infused together, for example, with a thermosetting resin. Accordingly, conventional rotor blades generally have a sandwich panel configuration. As such, conventional manufacture of large rotor blade blades involves high labor costs, slow production and low use of expensive mold tools. In addition, paddle molds can be expensive to customize.
    [005] [005] Thus, methods for making rotor blades can include the formation of rotor blades in segments. The blade segments can then be assembled to form the rotor blade. For example, some modern rotor blades, such as those described in US Patent Application: 14 / 753,137 filed on June 29, 2015 and entitled “Modular blades for wind turbine rotors and similar assembly methods”, which are incorporated here by reference in its entirety, it has a modular panel configuration. Thus, the various components of the modular blade can be constructed with different materials based on the function and / or location of the blade component.
    [006] [006] In view of the above, the state of the art is continually looking for improved methods for the manufacture of wind turbine rotor blade panels. DESCRIPTION OF THE INVENTION
    [007] [007] Achievements and advantages of the invention will be presented in part in the description below, or they can be obvious from the description, or they can be learned through the practice of the invention.
    [008] [008] In one embodiment, the present invention is directed to a method for making a rotor blade panel. The method includes placing a rotor blade panel mold in relation to a computer numerical control (CNC) device. The method also includes forming one or more fiber-reinforced outer coatings in the mold. The method also includes printing and depositing, via the CNC device, a plurality of rib elements that form at least one three-dimensional (3-D) reinforcement grid structure on an internal surface of one or more external fiber-reinforced coatings one or more fiber-reinforced outer coatings are cooled by the formation.
    [009] [009] In another embodiment, the present invention is directed to a method for making a rotor blade panel. The method includes placing one or more fiber-reinforced outer coatings in a rotor blade panel mold. The method also includes printing and depositing, via a computer numerical control device (CNC), a plurality of rib elements that intersect in a plurality of nodes to form at least one three-dimensional (3-D) reinforcement grid structure. on an internal surface of one or more fiber-reinforced outer coatings. In addition, the grid structure attaches to one or more fiber-reinforced outer coatings as the grid structure is deposited.
    [010] [010] In yet another embodiment, the present invention is directed to a method for making a rotor blade panel. The method includes placing a rotor blade panel mold in relation to a computer numerical control (CNC) device. In addition, the method includes forming one or more fiber-reinforced outer coatings in the mold. The method also includes printing and depositing, via the CNC device, at least one three-dimensional (3-D) reinforcement grid structure on an internal surface of one or more fiber-reinforced outer coatings before the one or more outer coatings reinforced with fiber cooled from the formation. Thus, the grid structure attaches to one or more fiber-reinforced outer coatings as the grid structure is being deposited. In addition, the grid structure includes at least one curved rib element.
    [011] [011] In yet another embodiment, the present invention is directed to a method for making a rotor blade panel. The method includes placing one or more fiber-reinforced outer coatings in a rotor blade panel mold. The method also includes printing and depositing, via a computer numerical control device (CNC), a plurality of rib elements that form at least one three-dimensional (3-D) reinforcement grid structure on an internal surface of one or more external coatings reinforced with fiber. In addition, the grid structure attaches to one or more fiber-reinforced outer coatings as the grid structure is deposited. In addition, the method includes printing at least one additional feature on the grid structure.
    [012] [012] In yet another embodiment, the present invention is directed to a rotor blade panel. The rotor blade panel includes an outer surface with one or more fiber-reinforced outer coatings. In addition, the rotor blade panel includes a printed grid structure attached to an inner surface of one or more fiber-reinforced outer linings. The grid structure includes a plurality of rib elements and at least one additional feature printed on the grid structure. In addition, the plurality of rib elements includes at least one first rib element that extends in a first direction and a second rib element that extends in a different second direction. In addition, the first rib element has a variable height along its length.
    [013] [013] These and other features, aspects and advantages of the present invention will be better understood with reference to the following description and appended claims. The attached drawings, which are incorporated and form part of the specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention. BRIEF DESCRIPTION OF THE FIGURES
    [014] [014] A complete and enabling description of the present invention, including the best mode, directed to a technician in the subject, is presented in the specification, which makes reference to the attached Figures, in which: - Figure 1 illustrates a perspective view of an embodiment of a wind turbine according to the present invention; Figure 2 illustrates a perspective view of an embodiment of a rotor blade of a wind turbine according to the present invention;
    [015] [015] Reference will now be made in detail to the embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided as an explanation of the invention, not as a limitation of the invention. Indeed, it will be apparent to those skilled in the art that various modifications and variations can be made to the present invention without departing from the scope of the invention. For example, features illustrated or described as part of one embodiment can be used with another embodiment to produce an even more further embodiment. Thus, it is intended that the present invention covers the modifications and variations included in the scope of the attached claims and their equivalents.
    [016] [016] In general, the present invention is directed to methods for the manufacture of grid structures for wind turbine rotor blades using automated material deposition using technologies such as 3D printing, additive manufacturing, automated fiber deposition, as well as other techniques that use CNC control and multiple degrees of freedom to deposit material. As such, the grid structures of the present invention are useful for reinforcing an outer cover for a wind turbine rotor blade. The shape of the grid can be optimized to maximize warp load factor versus print weight and speed. In addition, additive manufacturing allows for more personalized reinforcement compared to conventional sandwich panels.
    [017] [017] Thus, the methods described here provide many advantages not present in the prior art. For example, the methods of the present invention provide the ability to easily customize blade structures with various curvatures, aerodynamic features, forces, stiffness, etc. As such, the printed structures of the present invention can be designed to correspond to the rigidity and / or warp resistance of the existing sandwich panels for the rotor blades. More specifically, the rotor blades and components of the present invention can be more easily customized based on the required local warp resistance. In addition, other advantages include the ability to bend locally and temporarily to reduce loads and / or adjust the resonant frequency of the rotor blades to avoid problematic frequencies. In addition, the grid structures described in this document allow torsion-curve coupling of the rotor blade.
    [018] [018] In addition, the methods of the present invention provide a high level of automation, faster productivity and reduced tool costs and / or increased tool usage. In addition, the rotor blade components of the present invention may not require adhesives, especially those produced with thermoplastic materials, thereby eliminating costs, quality problems and extra weight associated with the adhesive paste.
    [019] [019] Referring now to the drawings, Figure 1 illustrates an embodiment of a wind turbine (10) according to the present invention. As shown, the wind turbine (10) includes a tower (12) with a nacelle (14) mounted on it. A plurality of rotor blades (16) are mounted on a rotor hub (18), which in turn is connected to a main flange that rotates a main rotor shaft. The components of wind power generation and control are housed inside the nacelle (14). The view in Figure 1 is provided for illustrative purposes only to place the present invention in an exemplary use field. It should be noted that the invention is not limited to any particular type of wind turbine configuration. In addition, the present invention is not limited to use with wind turbines, but can be used in any application with rotor blades. In addition, the methods described here can also apply to the manufacture of any similar structure that benefits from printing a structure directly on the coatings within a mold before the coatings have cooled, in order to take advantage of the coatings heat, provide a adequate connection between the printed structure and the coatings. As such, the need for additional adhesive or additional curing is eliminated.
    [020] [020] With reference now to Figures 2 and 3, several views of a rotor blade (16) according to the present invention are illustrated. As shown, the illustrated rotor blade (16) has a segmented or modular configuration. It should also be understood that the rotor blade (16) can include any other suitable configuration now known or later developed in the art. As shown, the modular rotor blade (16) includes a main blade structure (15) constructed, at least in part, from a thermosetting and / or thermoplastic material and at least one blade segment
    [021] [021] The components and / or materials of the thermoplastic rotor blade, as described herein, generally comprise a plastic material or polymer that is reversible in nature. For example, thermoplastic materials usually become malleable or moldable when heated to a certain temperature and return to a more rigid state after cooling. In addition, thermoplastic materials can include amorphous thermoplastic materials and / or semi-crystalline thermoplastic materials. For example, some amorphous thermoplastic materials can generally include, but are not limited to, styrenes, vinyls, cellulosics, polyesters, acrylics, polysulfones and / or imides. More specifically, exemplary amorphous thermoplastic materials may include polystyrene, acrylonitrile butadiene styrene (ABS), polymethyl methacrylate (PMMA), glycol modified polyethylene terephthalate (PET-G), polycarbonate, polyvinyl acetate, amorphous polyamide, polyvinyl chlorides (PVC ), polyvinylidene chloride, polyurethane or any other suitable amorphous thermoplastic material. In addition, exemplary semicrystalline thermoplastic materials can generally include, but are not limited to, polyolefins, polyamides, fluropolymers, ethyl methyl acrylate, polyesters, polycarbonates and / or acetals. More specifically, exemplary semicrystalline thermoplastic materials can include polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polypropylene, polyphenyl sulfide, polyethylene, polyamide (nylon), polyether ketone or any other suitable semicrystalline thermoplastic material.
    [022] [022] In addition, components and / or thermosetting materials as described herein generally encompass a plastic or polymer material that is non-reversible in nature. For example, thermosetting materials, once cured, cannot be easily remodeled or returned to a liquid state. Thus, after initial formation, thermosetting materials are generally resistant to heat, corrosion and / or creep. Examples of thermosetting materials can generally include, but are not limited to, some polyesters, some polyurethanes, esters, epoxies or any other suitable thermosetting material.
    [023] [023] Furthermore, as mentioned, the thermoplastic and / or thermoset material, as described here, can optionally be reinforced with a fiber material, including, but not limited to, glass fibers, carbon fibers, polymer fibers, fibers of wood, bamboo fibers, ceramic fibers, nanofibers, metallic or similar fibers or combinations thereof. In addition, the direction of the fibers may include multiaxial, unidirectional, biaxial, triaxial or any other suitable direction and / or combinations thereof. In addition, the fiber content may vary depending on the required stiffness in the corresponding blade component, the region or location of the blade component in the rotor blade (16) and / or the desired weldability of the component.
    [024] [024] More specifically, as shown, the main blade structure (15) can include any or a combination of the following: a root section of the preformed blade (20), a tip section of the preformed blade ( 22), one or more one or more continuous stringer crowns (48, 50, 51, 53), one or more shear nets (35) (Figures 6-7), an additional structural component (52) attached to the cross section blade root (20) and / or any other suitable structural component of the rotor blade (16). In addition, the root section of the blade (20) is configured to be mounted or otherwise attached to the rotor (18) (Figure 1). In addition, as shown in Figure 2, the rotor blade (16) defines an extension (23) that is equal to the total length between the root section of the blade (20) and the tip section of the blade (22). As shown in Figures 2 and 6, the rotor blade (16) also defines a rope (25) that is equal to the total length between a leading edge (24) of the rotor blade (16) and a trailing edge (26 ) of the rotor blade (16). As is generally understood, the rope (25) can generally vary in length with respect to the extension (23), when the rotor blade (16) extends from the root section of the blade (20) to the tip section of the blade ( 22).
    [025] [025] Referring particularly to Figures 2-4, any number of blade segments (21) or panels of any suitable size and / or shape can generally be arranged between the root section of the blade (20) and the section of blade tip (22) along a longitudinal axis (27) in a direction generally in the direction of extension. Thus, the blade segments (21) generally serve as the outer covering / cover of the rotor blade (16) and can define a substantially aerodynamic profile, such as defining a symmetrical or curved airfoil cross section. In additional embodiments, it is to be understood that the blade segment part of the blade (16) can include any combination of the segments described in this document and is not limited to the embodiment as shown. In addition, the blade segments (21) can be constructed of any suitable material, including, but not limited to, a thermoset material or a thermoplastic material optionally reinforced with one or more fiber materials. More specifically, in certain embodiments, the paddle panels (21) can include any one, or combination of the following: side pressure and / or suction segments (44, 46), (Figures 2 and 3), edge segments of attack and / or escape (40, 42) (Figures 2-6), a non-articulated segment, a single articulation segment, a blade segment with several joints, a J-shaped blade segment or similar.
    [026] [026] More specifically, as shown in Figure 4, the leading edge segments (40) can have a forward pressure side surface (28) and a forward suction side surface (30). Likewise, as shown in Figure 5, each of the trailing edge segments (42) can have a rear side pressure surface (32) and a rear side suction surface (34). Thus, the forward pressure side surface (28) of the leading edge segment (40) and the rear pressure side surface (32) of the trailing edge segment (42) generally define a side pressure surface of the blade. rotor (16). Likewise, the forward suction side surface (30) of the leading edge segment (40) and the rear side suction surface (34) of the trailing edge segment (42) generally define a lateral suction surface of the leading edge. rotor blade (16). In addition, as shown in Figure 6, the leading edge segment (s) (40) and trailing edge segment (s) (42) can be joined at a side pressure joint (36) and a lateral suction joint (38). For example, the blade segments (40, 42) can be configured to overlap at the side pressure joint (36) and / or at the side suction joint (38). In addition, as shown in Figure 2, the adjacent blade segments (21) can be configured to overlap at a joint (54). Thus, where the blade segments (21) are constructed, at least partially, from a thermoplastic material, the adjacent blade segments (21) can be welded together along the joints (36, 38, 54), which will be discussed in more details here. Alternatively, in certain embodiments, the various segments of the rotor blade (16) can be fixed together by means of an adhesive (or mechanical fasteners) configured between the overlapping leading and trailing edge segments (40, 42) and / or the adjacent overlapping leading or trailing edge segments (40, 42).
    [027] [027] In specific embodiments, as shown in Figures 2-3 and 6-7, the root section of the blade (20) may include one or more longitudinally extending stringer crowns (48, 50) infused with the same. For example, the blade root section (20) can be configured according to US patent application 14 / 753,155, filed on June 29, 2015, entitled “Blade Root Section for a Modular Rotor Blade and Method of Manufacturing Same ”, Which is incorporated herein by reference in its entirety.
    [028] [028] Likewise, the tip section of the blade (22) may include one or more longitudinally extending stringer crowns (51, 53) infused with it. More specifically, as shown, the stringer crowns (48, 50, 51, 53) can be configured to fit against opposite internal surfaces of the blade segments (21) of the rotor blade (16). In addition, the stringer crowns (48, 50) of the blade root can be configured to align with the stringer crowns (51, 53) of the blade tip.
    [029] [029] In addition, stringer crowns (48, 50, 51, 53) can be constructed with any suitable material, for example, a thermoplastic or thermoset material or combinations thereof. In addition, stringer crowns (48, 50, 51, 53) can be pultruded from thermoplastic or thermosetting resins. As used herein, the terms "pultrudado", "pultrusões" or similar generally encompass reinforced materials (for example, fibers or braided threads or fabrics) that are impregnated with a resin and pulled through a stationary matrix, so that the resin cures or undergo polymerization. As such, the manufacturing process of pultruded elements is typically characterized by a continuous process of composite materials that produces composite parts with a constant cross section. Thus, pre-cured composite materials can include pultrusions constructed of thermosetting materials or reinforced thermoplastics. In addition, stringer crowns (48, 50, 51, 53) can be formed by the same pre-cured composites or different pre-cured composites. In addition, pultruded components can be produced from preliminary spinning (rovings), which generally encompass long, narrow bundles of fibers that are not combined until joined by a cured resin.
    [030] [030] With reference to Figures 6-7, one or more shear nets (35) can be configured between one or more stringer crowns (48, 50, 51, 53). More particularly, the shear net (s) (35) can be configured to increase stiffness in the root section of the blade (20) and / or in the tip section of the blade (22). In addition, the shear nets (35) can be configured to close the root section of the blade (20).
    [031] [031] In addition, as shown in Figures 2 and 3, the additional structural component (52) can be attached to the root section of the blade (20) and extend in a direction generally towards the extension, in order to provide support additional to the rotor blade (16). For example, the structural component (52) can be configured according to US order 14 / 753,150, filed on June 29, 2015, entitled “Structural Component for a Modular Rotor Blade”, which is incorporated here by reference in its entirety .
    [032] [032] With reference now to Figures 8 to 19, the present invention is directed to methods for the manufacture of rotor blade panels (21) that have at least one printed reinforcement grid structure (62) formed via 3D printing, for example such as the blade segments shown in Figures 2 to 7. As such, in certain embodiments, the rotor blade panel (21) may include a side pressure surface, a side suction surface, a segment of the trailing edge, a leading edge segment or combinations thereof. 3D printing, as used here, is generally understood to encompass processes used to synthesize three-dimensional objects in which successive layers of material are formed under computer control to create the objects. As such, objects of almost any size and / or shape can be produced from digital model data. It should also be understood that the methods of the present invention are not limited to 3D printing, but can also cover more than three degrees of freedom, so that printing techniques are not limited to printing stacked two-dimensional layers, but are also capable of to print curved shapes.
    [033] [033] Referring particularly to Figure 10, an embodiment of the method includes placing a mold (58) of the rotor blade panel (21) in relation to a CNC device (60). More specifically, as shown in the illustrated embodiment, the method may include placing the mold (58) on a bed (61) of the CNC device (60). Alternatively, the method may include placing the mold (58) under the CNC device (60) or adjacent to the CNC device (60). In addition, as shown in Figures (8 and 10), the method of the present invention further includes the formation of one or more fiber-reinforced outer coatings (56) in the mold (58) of the rotor blade panel (21). In certain embodiments, the outer shell (s) (56) may include one or more outer thermoplastic or thermosetting outer linings reinforced with continuous multiaxial (e.g., biaxial) fibers. In addition, in particular embodiments, the method of forming the fiber-reinforced outer coatings (56) can include at least one of injection molding, 3D printing, 2D pultrusion, 3D pultrusion, thermoforming, vacuum forming, forming pressure, bladder formation, automated deposition of fibers, automated deposition of fiber tapes or vacuum infusion.
    [034] [034] In addition, as shown, the outer casing (s) (56) of the rotor blade panel (21) can (b) be curved. In such embodiments, the method may include forming the curvature of the fiber-reinforced outer linings (56). Such forming may include providing one or more generally flat fiber-reinforced outer coatings, forcing the outer coatings (56) into a desired shape corresponding to a desired contour and maintaining the outer coatings (56) in the desired shape during printing and deposition. As such, the outer linings (56) generally retain their desired shape when the outer linings (56) and the grid structure (62) printed on them are released. In addition, the CNC device (60) can be adapted to include a tool path that follows the contour of the rotor blade panel
    [035] [035] The method also includes printing and depositing the grid structure (62) directly on the fiber-reinforced outer coating (s) (56) via the CNC device (60) . More specifically, as shown in Figures 9, 10, 12 and 15, the CNC device (60) is configured to print and deposit a plurality of rib elements (64) that intersect in a plurality of nodes (74) to form the grid structure (62) on an internal surface of the one or more fiber-reinforced outer linings (56). Alternatively, as shown in Figure 20, the CNC device (60) can also print and deposit curved rib elements (64), which do not intersect to form the grid structure (62).
    [036] [036] For example, in one embodiment, the CNC device (60) is configured to print and deposit the rib elements (64) on the inner surface of one or more fiber-reinforced outer linings (56) after the ( s) formed coating (s) (56) reach (in) a desired state that allows the connection of the printed rib elements (64) to it, that is, based on one or more parameters of temperature, time and / or hardness. Therefore, in certain embodiments, where the liner (s) (56) and the grid structure (62) are formed from a thermoplastic matrix, the CNC device (60) can immediately print the rib elements (64) at the same time as the formation temperature of the coating (s) (56) and the desired printing temperature to allow welding / thermoplastic bonding can be the same. More specifically, in particular embodiments, before the coating (s) (56) have cooled from the formation (that is, while the coatings are still hot or heated), the CNC device (60) is configured to print and deposit the rib elements (64) on the inner surface of one or more fiber-reinforced outer linings (56). For example, in one embodiment, the CNC device (60) is configured to print and deposit the rib elements (64) on the inner surface of the outer liners (56) before the liners (56) have cooled completely.
    [037] [037] For example, in one embodiment, a thermoset material can be infused into the fiber material in the mold (58) to form the outer linings (56) using vacuum infusion. As such, the vacuum bag is removed after curing and one or more thermosetting grid structures (62) can then be printed on the inner surface of the outer linings (56). Alternatively, the vacuum bag can be left in place after curing. In such embodiments, the material of the vacuum bag can be chosen so that the material does not detach easily from the cured thermosetting fiber material. Such materials, for example, can include a thermoplastic material, such as poly methyl methacrylate (PMMA) or polycarbonate film. Thus, the thermoplastic film that is left in place allows the connection of thermoplastic grid structures (62) to the thermosetting coatings with the film in the middle.
    [038] [038] In yet other embodiments, the outer coatings (56) can be formed of a thermoplastic resin reinforced with the grid structure (62) being formed of a thermoset resin with optional fiber reinforcement. In such embodiments, depending on the thermosetting chemistry involved - the grid structure (62) can be printed on the outer coatings (56) while the coatings (56) are still hot, warm, partially cooled or completely cooled.
    [039] [039] In addition, the method of the present invention may include treating the outer coatings (56) to promote the bond between the outer coatings (56) and the grid structure (62). More specifically, in certain embodiments, the outer coatings (56) can be treated using flame treatment, plasma treatment, chemical treatment, chemical attack, mechanical abrasion, embossing, raising a temperature of at least areas to be printed in external coatings (56) and / or any other suitable treatment method to promote said bond. In additional embodiments, the method may include forming the outer coatings (56) with more (or even less) matrix resin material on the inner surface to promote said bonding. In additional embodiments, the method may include varying the thickness of the outer coating and / or the fiber content, as well as the orientation of the fiber.
    [040] [040] Furthermore, the method of the present invention includes varying the design of the grid structure (62) (for example, materials, width, height, thickness, shapes etc., or combinations thereof). As such, the grid structure (62) can define any suitable shape, so as to form any suitable structure component, such as the stringer crown (48, 50), the shear net (35) or additional structural components ( 52) of the rotor blade (16). For example, as shown in Figure 11, the CNC device (60) can start printing the grid structure (62) by first printing an outline of the structure (62) and building the grid structure (62) with the rib elements (64) in several passages. As such, the extruders (65) of the CNC device (60) can be designed to have any suitable thickness or width in order to disperse a desired amount of resin material to create rib elements (64) with heights and / or variable thickness. In addition, the size of the grid can be designed to allow the local warping of the cover sheet between the rib elements (64), which can influence the aerodynamic shape as an extreme load mitigation device (blast).
    [041] [041] More specifically, as shown in Figures 9 to 15, the rib elements (64) can include at least a first rib element (66) extending in a first direction (76) and a second rib element rib (68) extending in a different second direction (78). In various embodiments, as shown in Figure 15, the first direction (76) of the first set (70) of rib elements (64) can generally be perpendicular to the second direction (78). More specifically, in certain embodiments, the first direction (76) can generally be parallel to a chord-like direction of the rotor blade (16) (i.e., a direction parallel to the chord (25) (Figure 2)) , while the second direction (78) of the second set (72) of rib elements (64) can generally be parallel with an extension direction of the rotor blade (16) (i.e., a direction parallel to the extension ( 23) (Figure 2)). Alternatively, in an embodiment, an off-axis orientation (for example, from about 20 ° to about 70 ° or to the second axis (202)) can be provided in the grid structure (62) to introduce flexion-coupling torsion to the rotor blade (16), which can be beneficial as a passive load mitigation device.
    [042] [042] In addition, as shown in Figures 13 and 14, one or more of the first and second rib elements (66, 68) can be printed to have a variable height along a length (84, 85) of the same. In alternative embodiments, as shown in Figures 16 and 17, one or more of the first and second rib elements (66, 68) can be printed to have a uniform height (90) over a length (84, 85 ) the same. In addition, as shown in Figures 9, 12 and 15, the rib elements (64) can include a first set (70) of rib elements (64) (containing the first rib element (66)) and a second set (72) of rib elements (64) (containing the second rib element (68)).
    [043] [043] In such embodiments, as shown in Figures 13 and 14, the method may include printing a maximum height (80) of one or both of the first set (70) of rib elements (64) or the second set (72) of rib elements (64) at a location substantially at (i.e., +/- 10%) a maximum bending moment in the rotor blade panel (21) that occurs. For example, in one embodiment, the maximum bending moment can occur at a central location (82) of the grid structure (62), although not always. As used herein, the term "central location" refers, in general, to a location of the rib element (64) that contains the center plus or minus a predetermined percentage of a total length (84) of the rib element (64) ). For example, as shown in Figure 13, the central location (82) includes the center of the rib element (64) about 10%. Alternatively,
    [044] [044] Furthermore, as shown, the first and second sets (70, 72) of the rib elements (64) can also include at least one tapered end (86, 88) that tapers from the maximum height (80 ). More specifically, as shown, the tapered end (s) (86, 88) can taper towards the inner surface of the fiber-reinforced outer linings (56). Such a taper can correspond to certain locations of the blade that require more or less structural support. For example, in one embodiment, the rib elements (64) may be shorter at or near the tip of the blade and may increase as the grid structure (62) approaches the root of the blade.
    [045] [045] In additional embodiments, one or more heights of the intersecting rib elements (64) at the nodes (74) may be different. For example, as shown in Figure 16, the heights of the second set (72) of the rib elements (64) are different from the first intersecting rib element (66). In other words, the rib elements (64) can have different heights for different directions at their crossing points. For example, in one embodiment, the extending direction rib elements (64) may be twice as high as the height of the rope direction rib elements (64). In addition, as shown in Figure 16, the second set (72) of rib elements (64) may each have a different height from the adjacent rib elements (64) in the second set (72) of rib elements (64). 64). In such embodiments, as shown, the method may include printing each of the second set (70) of rib elements (64) so that structures (64) with higher heights are located towards the central location ( 82) of the grid structure (62). In addition, the second set (70) of rib elements (64) can be tapered along a length (85) thereof, so that the rib elements (64) are tapered shorter as the elements of rib approach the tip of the shovel.
    [046] [046] In other embodiments, as mentioned, the rib elements (64) can be printed with varying thicknesses. For example, as shown in Figure 15, the first set (70) of rib elements (64) defines a first thickness (94) and the second set (72) of rib elements (64) defines a second thickness (96) . More specifically, as shown, the first and second thicknesses (94, 96) are different. In addition, as shown in Figures 18 and 19, the thicknesses of a single rib element (64) can vary along its length.
    [047] [047] Referring particularly to Figure 15, the first set (70) of rib elements (64) and / or the second set (72) of rib elements (64) can be evenly spaced. In alternative embodiments, as shown in Figures 18 and 19, the first set (70) of rib elements (64) and / or the second set (72) of rib elements (64) can be unevenly spaced. For example, as shown, the additive methods described herein allow for complex internal structures that can be optimized for loads and / or geometric constraints of the general shape of the rotor blade panel (21). As such, the grid structure (62) of the present invention may have shapes similar to those that occur in nature, such as organic structures (for example, bird bones, leaves, trunks or the like). Accordingly, the grid structure (62) can be printed to have an internal paddle structure that optimizes rigidity and strength, while also minimizing weight. In yet another embodiment, as shown in Figure 20, the grid structure (62) can include at least one curved rib element (64). More specifically, as shown, the grid structure (62) includes a plurality of curved rib elements (64). In addition, as shown, the curved rib element (s) can form a waveform.
    [048] [048] In various embodiments, the printing cycle time of the rib elements (64) can also be reduced using a rib pattern that minimizes the amount of directional change. For example, 45 degree angular grids can probably print faster than 90 degree grids in relation to the rope direction of the proposed printer, for example. As such, the present invention minimizes the acceleration and deceleration of the printer whenever possible while still printing quality rib elements (64).
    [049] [049] In another embodiment, as shown in Figures 8 and 12, the method may include printing a plurality of grid structures (62) on the inner surface of the fiber-reinforced outer linings (56). More specifically, as shown, the plurality of grid structures (62) can be printed in separate and distinct locations on the inner surface of the outer linings (56).
    [050] [050] Certain advantages associated with the grid structure (62) of the present invention can be better understood in relation to the Figure
    [051] [051] With reference now to Figures 22 to 24, several additional features of the grid structure (62) of the present invention are illustrated. More specifically, Figure 22 illustrates a partial top view of an embodiment of the printed grid structure (62), particularly illustrating one of the nodes (74) thereof. As shown, the CNC device (60) can form at least a substantially 45 degree angle (95) for a short distance on one or more of the plurality of nodes (74). As such, the 45 degree angle (95) is configured to increase the amount of support or connection in the corners. In such embodiments, as shown, there may be a slight overlap in this corner knot.
    [052] [052] Referring particularly to Figure 23, a partial top view of an embodiment of the printed grid structure (62) is illustrated, particularly illustrating an initial print location and a final print location of the grid structure (62 ). This helps in starting and stopping the ribbing. When the CNC device (60) starts to print the rib elements (64) and the process speeds up, the extruders may not extrude the resin material perfectly. Thus, as shown, the CNC device (60) can start the printing process with a curve or twist to provide a guide for the rib structure (64). By extruding this twist in the initial location, the extruders (65) are given time to increase / decrease their pressure more slowly, instead of being forced to start instantly over an independent, narrow starting point. As such, the twist allows the grid structures (65) of the present invention to be printed at higher speeds.
    [053] [053] In certain cases, however, this start curve can create a small void (99) (that is, the area within the torsion) in the starting region, which can create problems as the void (99) propagates through the layers in progress. Therefore, the CNC device (60) is also configured to terminate one of the rib elements (64) within the twist of the starting region, in order to prevent the void (99) from developing. More specifically, as shown, the CNC device (60)
    [054] [054] Referring particularly to Figure 24, an elevation view of an embodiment of one of the rib elements (64) of the printed grid structure (62) is illustrated, particularly illustrating a base section (55) of the rib elements (64) having a wider first layer W and thinner T, in order to improve the connection of the grid structure (62) to the outer coverings (56) of the rotor blade panel (21).
    [055] [055] Referring now to Figures 25 to 30, the CNC device (60) described here is also configured to print at least one additional feature (63) directly on the grid structure (s) (62), in that the heat of printing connects the additional features (63) to the frame (62). As such, the additional resource (s) (63) can be printed directly in 3D on the grid structure (62). This printing allows the additional resource (s) (63) to be printed on the grid structure (62) using undercuts and / or negative draft angles, as needed. In addition, in certain cases, the hardware for various paddle systems can be mounted within the grid structure (62) and then printed to encapsulate / protect these components.
    [056] [056] For example, as shown in Figures 25 to 28, additional feature (s) (63) may include auxiliary features (81) and / or mounting features (69). More specifically, as shown in Figures 25 and 26, the mounting feature (s) (69) can include one or more alignment structures (73), at least one handling or lifting feature (71), one or more more adhesive clearances or gaps (95) or one or more adhesive containment areas (83). For example, in one embodiment, the CNC device (60) is configured to print a plurality of handling features (71) on the grid structure (62) to provide multiple grip locations for removing the rotor blade panel (21) of the mold (58). In addition, as shown in Figure 25, one or more adhesive containment areas (83) can be formed in the grid structure (62), for example, so that another blade component can be attached to it or in this way.
    [057] [057] In particular embodiments, as shown in Figures 26 and 27, the alignment or orientation in the structure (s) (73) may include any alignment features of the stringer crown and / or the shear net . In such embodiments, as shown, the grid structure (s) (62) can be printed so that an angle of the plurality of rib elements (64) is displaced from a location of stringer crown to create an adhesive containment area (83). More specifically, as shown, the adhesive containment areas (83) are configured to prevent compression of an adhesive (101). It should also be understood that these adhesive containment areas (83) are not limited to stringer crown locations, but can be provided at any suitable location on the grid structure (62), including, but not limited to, locations adjacent to the edge of attack (24), to the escape board (26) or to any other connection point.
    [058] [058] In other embodiments, the alignment structure (s) (73) may correspond to support alignment features (for example, support structure (52)), alignment features paddle joint, panel alignment features (75) or any other suitable alignment feature. More specifically, as shown in Figure 28, the panel alignment features (75) can include a male alignment feature (77) or a female alignment feature (79) that fits with a male alignment feature (77) or a female alignment feature (79) of an adjacent rotor blade panel (21).
    [059] [059] Furthermore, as shown in Figure 29, the additional feature (s) (63) can include at least one auxiliary feature (81) of the rotor blade panel (21). For example, in one embodiment, auxiliary resources (81) can include a balance box (67) of the rotor blade (16).
    [060] [060] In addition, the step of printing the additional resource (s) (63) on the grid structure (s) (62) may also include closing an area between the elements of the rib (64) to surround said area. In general, 3D printing technologies tend to print layers on top of layers, however, the present invention also encompasses printing a layer on top of the air using certain typically amorphous polymers, for example, acrylonitrile-butadiene-styrene (ABS ). In such embodiments, the coating can be printed over a limited distance without support underneath. Although these structures may experience some degree of slope or fall, the structures allow the impression of a surface structure to cover the rib elements (64), in addition to providing additional rigidity to the grid structure (62).
    [061] [061] In additional embodiments, the auxiliary resource (s) (81) may include housings (87), pockets, supports or enclosures, for example, for an active aerodynamic device, a damping system friction or a load control system, conduit (89), channels or passages, for example for defrost systems, one or more valves, a support (91), tubing or channel around an orifice location of the outer linings fiber-reinforced, a sensor system with one or more sensors (103), one or more heating elements (105) or wires (105), rods, conductors or any other printed resource. In one embodiment, for example, the supports for the friction damping system can include sliding interface elements and / or free locking structures. For example, in one embodiment, the 3D printed grid structure (62) offers the opportunity to easily print channels on it to provide heated air from heat source (s) at the root of the blade or cube to have an effect thaw or prevent the formation of ice.
    [062] [062] In particular embodiments, the sensor system can be incorporated in the grid structure (s) (62) and / or in the external coatings (56) during the manufacturing process. For example, in one embodiment, the sensor system can be a surface pressure measurement system arranged with the grid structure (62) and / or directly incorporated into the linings (56). As such, the printed frame and / or liners (56) are manufactured to include the series of piping / channels required to easily install the sensor system. In addition, the printed structure and / or linings (56) can also provide a series of holes in it to receive connections from the system. Thus, the manufacturing process is simplified by printing several structures in the grid structure (62) and / or in the coatings (56) to house the sensors, act as the static pressure port and / or act as the piping that runs directly to the outer padding. Such systems may also allow the use of pressure taps for closed circuit control of the wind turbine (10).
    [063] [063] In still other embodiments, the mold (58) may include certain marks (such as a positive mark) that are configured to create a small dimple in the coating during manufacture. Such marks allow easy machining of the holes in the exact location required for the associated sensors. In addition, additional sensor systems can be incorporated into the grid structures and / or the outer layers of the liner (56) to provide aerodynamic or acoustic measurements, to allow closed-loop control or prototype measurements.
    [064] [064] In addition, the heating elements (105) described herein can be heating elements mounted on the level surface distributed around the leading edge of the blade. Such heating elements (105) allow the determination of the angle of attack on the blade, correlating the temperature / heat transfer by convection with the flow speed and the stagnation point. This information is useful for turbine control and can simplify the measurement process. It is to be understood that these heating elements (105) can also be incorporated into the outer covering layers (56) in additional ways and need not be flush mounted thereon.
    [065] [065] Referring again to Figure 25, the method according to the present invention may include placing a filler material (98) between one or more of the rib elements (64). For example, in certain embodiments, the filler material (98) described herein can be constructed of any suitable materials, including, but not limited to, low density foam, cork, compounds, balsa wood, composites or the like. Suitable low-density foam materials may include, but are not limited to, polystyrene foams (eg expanded polystyrene foams), polyurethane foams (eg closed cell polyurethane foam), polyethylene terephthalate (PET) foams ), other resin-based foam / foam rubbers and various other open and closed cell foams. In such embodiments, the method (100) can also include printing an upper surface on the filler material (98), which eliminates the tilt or sagging effect described above.
    [066] [066] Referring again to Figure 28, the method may also include printing one or more features (93) on the outer coatings (56), for example, on the trailing and / or leading edges of the paddle panels. rotor (21). For example, as shown in Figure 28, the method may include printing at least one lightning protection feature (93) on at least one of the one or more fiber-reinforced outer coatings (56). In such embodiments, the lightning protection feature (93) can include a cooling fin or trailing edge feature having less fiber content than the fiber-reinforced outer coatings (56). More specifically, the cooling fins can be printed directly on the inner surface of the outer coatings (56) and optionally loaded with fillers to improve thermal conductivity, but below a certain threshold to address lightning concerns. As such, the cooling fins are configured to improve the thermal transfer from the heated air flow to the external linings (56). In additional embodiments, these features (93) can be configured to overlap, for example, such as interlaced edges or pressure fittings.
    [067] [067] Referring now to Figures 30 and 31, the additional resource (s) (63) may include an adhesive gap (95) or spacing, which can be incorporated into the grid structures ( 62). These spacings (95) provide a specified gap between two components when connected together, to minimize adhesive tightness. As such, the spacings (95) provide the desired bonding clearance for optimized bonding strength based on the adhesive used.
    [068] [068] This written description uses examples to reveal the invention, including the best mode, and to allow any person skilled in the art to make the invention, including the construction and use of any devices or systems and the execution of any built-in 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. These 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 non-substantial differences from the literal languages of the claims.
    权利要求:
    Claims (20)
    [1]
    1. METHOD FOR MANUFACTURING A ROTOR PADDLE PANEL (21) FROM A WIND TURBINE (10), the method comprising: placing one or more fiber-reinforced outer linings (56) in a mold (58) of the blade panel rotor (21); print and deposit, using a computer numerical control device (CNC) (60), a plurality of rib elements (64) that form at least one three-dimensional reinforcement grid structure (3-D) (62) on a surface internal of one or more fiber-reinforced outer coatings (56), the grid structure (62) attaching to one or more fiber-reinforced outer coatings (56) as the grid structure (62) is being deposited; and, printing at least one additional feature (63) on the grid structure (62).
    [2]
    METHOD according to claim 1, characterized in that at least one additional feature (63) comprises at least one auxiliary feature (81) of the rotor blade panel (21) or at least one mounting feature (69) of the rotor blade panel (21).
    [3]
    METHOD, according to claim 2, characterized in that at least one auxiliary resource (81) comprises at least one of a balance box (67), a support, housing (87) or compartment for an active aerodynamic device (60 ), ducts or channels for defrost systems, one or more supports for a friction damping system, one or more supports or bags for a load control system, one or more passages, one or more valves, supports, piping or channels around a hole location of the fiber-reinforced outer linings (56), one or more sensors, one or more heating elements, a wire, a rod, a conductor or a lifting device.
    [4]
    4. METHOD according to claim 1, characterized by the printing of at least one additional feature (63) on the grid structure (62) further comprising enclosing at least a portion of the grid structure (62).
    [5]
    METHOD according to claim 2, characterized in that at least one mounting feature (69) comprises at least one of one or more alignment structures (73), at least one handling feature (71) or one or more adhesive containment areas (83).
    [6]
    6. METHOD according to claim 5, characterized in that it further comprises printing a plurality of handling resources (71) on the grid structure (62) to provide various gripping locations for removing the rotor blade panel (21) from the mold (58).
    [7]
    7. METHOD according to claim 1, characterized in that it further comprises printing at least one additional feature (63) on the grid structure (62) using at least one within a lowered or negative inclination angle.
    [8]
    METHOD, according to claim 1, characterized in that it further comprises printing at least one lightning protection feature (93) on at least one of the one or more external fiber-reinforced coatings (56).
    [9]
    METHOD according to claim 1, characterized in that it further comprises printing a first layer of the grid structure (62) to form individual base sections of the plurality of rib elements (64), each of the individual base sections defining a cross section that is wider and thinner than a remainder of the plurality of rib elements (64).
    [10]
    10. METHOD, according to claim 1, characterized in that it also comprises, through the computerized numerical control device (60), a curve at the initial location of a first rib element (66) and fills the curve with a final location of a second rib element (68).
    [11]
    11. METHOD according to claim 1, characterized in that it also comprises at least a 45 degree angle in one or more nodes of the grid structure (62).
    [12]
    12. ROTOR BLADE PANEL (21) FOR A WIND TURBINE ROTOR BLADE (10), characterized by the rotor blade panel (21) comprising: an outer surface comprising one or more fiber-reinforced outer coatings (56) ; and, a printed grid structure (62) attached to an internal surface of one or more fiber-reinforced outer linings (56), the grid structure (62) comprising a plurality of rib elements (64) and at least one feature additional (63) printed on the grid structure (62), the plurality of rib elements (64) comprising at least a first rib element (66) extending in a first direction and a second rib element (68) which extends in a different second direction, the first rib element (66) having a variable height along a length thereof.
    [13]
    13. ROTOR PADDLE PANEL (21) according to claim 12, characterized in that the rotor paddle panel (21) comprises at least one of a lateral pressure surface, a lateral suction surface, a trailing edge, a leading edge or combinations thereof.
    [14]
    14. ROTOR PADDLE PANEL (21) according to claim 12, characterized by at least one additional feature (63)
    comprise at least one auxiliary feature or at least one assembly feature (69).
    [15]
    15. ROTOR PADDLE PANEL (21), according to claim 14, characterized in that the auxiliary feature (81) comprises at least one of a balance box (67), a support, housing (87) or compartment for a device aerodynamic active (60), ducts or channels for defrost systems, one or more supports for a friction damping system, one or more supports or bags for a load control system, one or more passages, one or more valves, a support or channels around a hole location of the fiber-reinforced outer linings (56), a wire, a rod, a conductor, or a lifting feature.
    [16]
    16. ROTOR PADDLE PANEL (21) according to claim 15, characterized in that one or more supports for the friction damping system comprise at least one of the sliding interface elements or free interlocking structures.
    [17]
    17. ROTOR PADDLE PANEL (21) according to claim 14, characterized in that at least one assembly feature comprises at least one of one or more alignment structures, at least one handling feature or one or more areas of alignment adhesive restraints, wherein the one or more alignment structures comprise at least one of one or more spar cap alignment features, one or more shear alignment features, one or more alignment features bracket, one or more paddle alignment features or one or more panel alignment features.
    [18]
    18. ROTOR PADDLE PANEL (21) according to claim 17, characterized in that one or more panel alignment features comprise at least one of a male alignment feature or a female alignment feature that fits with a feature alignment feature or a female alignment feature of an adjacent rotor blade panel.
    [19]
    19. ROTOR PADDLE PANEL (21), according to claim 12, characterized in that it further comprises at least one lightning protection feature (93) printed on at least one of the one or more fiber-reinforced outer coatings, wherein the lightning protection feature comprises at least one of a cooling fin or a trailing end feature containing less fiber content than fiber-reinforced outer coatings (56).
    [20]
    20. ROTOR PADDLE PANEL (21), according to claim 12, characterized in that it further comprises a filling material positioned between one or more among the plurality of rib elements.
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    同族专利:
    公开号 | 公开日
    WO2019103830A2|2019-05-31|
    EP3713750A4|2021-08-11|
    WO2019103830A3|2019-07-18|
    CA3082594A1|2019-05-31|
    CN111601703A|2020-08-28|
    US10865769B2|2020-12-15|
    EP3713750A2|2020-09-30|
    US20190153994A1|2019-05-23|
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    法律状态:
    2021-12-07| B350| Update of information on the portal [chapter 15.35 patent gazette]|
    优先权:
    申请号 | 申请日 | 专利标题
    US15/818,957|US10865769B2|2017-11-21|2017-11-21|Methods for manufacturing wind turbine rotor blade panels having printed grid structures|
    US15/818,957|2017-11-21|
    PCT/US2018/059184|WO2019103830A2|2017-11-21|2018-11-05|Methods for manufacturing wind turbine rotor blade panels having printed grid structures|
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