METHOD OF INTRODUCING A ROTOR BLADE SPAR CAP INTO A ROTOR BLADE SHELL, A SPAR CAP MOLD, A ROTOR BLADE, AND A WIND ENERGY INSTALLATION

Abstract

A method of introducing a rotor blade spar cap into a rotor blade shell for a rotor blade of a wind energy installation, a spar cap mold for manufacturing a rotor blade spar cap, a rotor blade comprising such a spar cap, and a wind energy installation including such a rotor blade. At least two strip-shaped spar cap elements are arranged on at least one substantially flat spar cap forming surface of the spar cap mold. The at least one spar cap forming surface extends along a longitudinal direction of the spar cap mold which corresponds to a longitudinal axis of the rotor blade. The spar cap elements are arranged on the at least one spar cap forming surface along the longitudinal direction and are connected to one another so as to form the rotor blade spar cap. The spar cap elements connected to one another are removed from the spar cap mold, are introduced into the rotor blade shell, and are connected to the rotor blade shell.

Claims

1. A method of introducing a rotor blade spar cap into a rotor blade shell (4) for a rotor blade of a wind energy installation, which rotor blade has a rotor blade longitudinal axis which extends from a rotor blade root to a rotor blade tip, wherein at least two strip-shaped spar cap elements (3) are arranged on at least one substantially flat spar cap forming surface (2) of a spar cap mold (1), wherein the at least one spar cap forming surface (2) extends along a longitudinal direction of the spar cap mold (1) which corresponds to the longitudinal axis of the rotor blade, the spar cap elements (3) which are arranged on the at least one spar cap forming surface (2) are connected to one another so as to form a rotor blade spar cap, and the spar cap elements (3) connected to one another are removed from the spar cap mold (1), are introduced into the rotor blade shell (4), and are connected to the rotor blade shell (4).

2-11. (canceled)

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0029] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate exemplary embodiments of the invention and, together with a general description of the invention given above, and the detailed description given below, serve to explain the principles of the invention.

[0030] FIG. 1 shows a cross section of an example of a spar cap mold for the manufacture of a rotor blade spar cap for a rotor blade of a wind energy installation; and

[0031] FIG. 2 shows an example of a rotor blade shell into which a rotor blade spar cap of spar cap elements which are connected to one another is introduced.

DETAILED DESCRIPTION

[0032] FIG. 1 shows an example of a spar cap mold 1 for the manufacture of a rotor blade spar cap for a rotor blade of a wind energy installation in a cross section along a transverse direction Q of the spar cap mold 1. The spar cap mold 1 comprises three substantially flat spar cap forming surfaces 2 which are located next to each other in the transverse direction Q. In this context, each of the spar cap forming surfaces 2 is arranged to receive, and/or to support, a strip-shaped spar cap element 3 of the rotor blade spar cap. In this context, the spar cap elements 3 placed on the spar cap forming surfaces 2 extend along a longitudinal direction of the spar cap mold 1, which longitudinal direction of the spar cap mold 1 runs perpendicular to the transverse direction Q and thus perpendicular to the drawing plane. This longitudinal direction corresponds to a rotor blade longitudinal axis which runs from a rotor blade root to a rotor blade tip, so that the spar cap elements 3 arranged on the spar cap forming surfaces 2 can be connected to each other, can be removed from the spar cap mold 1 and can be arranged in the rotor blade as a rotor blade spar cap along the rotor blade longitudinal axis.

[0033] In this context, the spar cap forming surfaces 2 are formed, for example, by a surface of the spar cap mold 1, which surface of the spar cap mold 1 is segmented in accordance with the spar cap forming surfaces 2. The spar cap forming surfaces 2 are inclined with respect to each other, so that, in the cross section shown, the surface follows a polygonal chain which replicates or approximates a curvature of the rotor blade or of a rotor blade shell of the rotor blade along a rotor blade transverse axis perpendicular to the rotor blade longitudinal axis. Therefore, the spar cap mold 1 causes the spar cap elements 3 to be arranged in an arrangement which corresponds to the curvature of the rotor blade, so that spar cap elements 3 which are connected to each other in the spar cap mold 1 by, for example, a resin infusion process do not need to be deformed and thus do not need to be placed under tension in order to conform to the shape of the rotor blade.

[0034] FIG. 2 shows an example of a rotor blade shell 4 of a rotor blade, into which a rotor blade spar cap made up of three spar cap elements 3 which are connected to each other, in particular using the spar cap mold shown in FIG. 1, is introduced. Here, the arrangement of the spar cap elements 3 substantially corresponds to the curvature of the rotor blade shell 4, so that the spar cap elements 3 are substantially free of tension. The tension in the spar cap elements 3 can also be reduced by stacking further spar cap elements 3 or further stiffening materials (not shown) on top of the three spar cap elements 3 and connecting them to each other, since the bending stiffness is increased in this way.

[0035] The rotor blade shell 4 is manufactured in a rotor blade mold 5, which has a top surface the shape of which defines the curvature of the rotor blade shell along a rotor blade transverse axis q which extends from a rotor blade leading edge (nose) to a rotor blade trailing edge.

[0036] A deformable filling material 6 is arranged between the spar cap elements 3, which are connected to one another, and the rotor blade shell 4, which filling material 6 adapts, in the direction of the transverse axis q of the rotor blade, to the shape of the rotor blade shell 4 and/or the spar cap elements 3, which are connected to one another. In particular, the deformable filling material 6 fills the space between the spar cap elements 3, which are connected to one another, and the rotor blade shell 4, which space arises because the curvature replicated by the spar cap elements 3, which are arranged next to each other and which are inclined with respect to each other, only approximates the actual curvature of the rotor blade shell 4.

[0037] The spar cap elements 3, which are connected to one another, are preferably joined to the rotor blade shell 4 with the aid of a resin infusion process. As part of this, the deformable filling material 6 is impregnated with resin and forms a solid fiber-reinforced plastics material in the space between the spar cap elements 3 and the rotor blade shell 4.

[0038] While the present invention has been illustrated by a description of various embodiments, and while these embodiments have been described in considerable detail, it is not intended to restrict or in any way limit the scope of the appended claims to such de-tail. The various features shown and described herein may be used alone or in any combination. Additional advantages and modifications will readily appear to those skilled in the art. The invention in its broader aspects is therefore not limited to the specific details, representative apparatus and method, and illustrative example shown and described. Accordingly, departures may be made from such details without departing from the spirit and scope of the general inventive concept.