WIND TURBINE ROTOR BLADE JOINT CONSTRUCTED OF DISSIMILAR MATERIALS

Abstract

A rotor blade for a wind turbine includes a first blade segment and a second blade segment extending in opposite directions from a chord-wise joint. Each of the first and second blade segments includes at least one shell member defining an airfoil surface. The rotor blade also includes one or more pin joints for connecting the first and second blade segments at the chord-wise joint. The pin joint(s) includes one or more pin joint tubes received within the pin joint slot(s). The pin joint slot(s) are secured within a load bearing block. Further, a gap is defined between the pin joint slot(s) and the load bearing block. Moreover, the rotor blade includes a shim within the gap between the pin joint slot(s) and the load bearing block so as to retain the pin joint slot(s) within the load bearing block. In addition, the shim is constructed of a liquid material that hardens after being poured into the gap.

Claims

1. A rotor blade for a wind turbine, comprising: a first blade segment and a second blade segment extending in opposite directions from a chord-wise joint, each of the first and second blade segments comprising at least one shell member defining an airfoil surface; and, one or more pin joints for connecting the first and second blade segments at the chord-wise joint, the one or more pin joints comprising one or more pin joint tubes received within the one or more pin joint slots, the one or more pin joint slots secured within a load bearing block, wherein the one or more pin joint slots are constructed of a first material having a first coefficient of thermal expansion, the load bearing block constructed of a second material having a second coefficient of thermal expansion, the first and second coefficients of thermal expansion being substantially equal so as to maintain contact between the one or more pin joint slots and the load bearing block during operational temperature changes of the wind turbine.

2. The rotor blade of claim 1, wherein the first material comprises a metal material and the second material comprises a composite material.

3. The rotor blade of claim 1, wherein the one or more pin joint slots comprise one or more bushings.

4. The rotor blade of claim 1, wherein the operational temperature changes of the wind turbine comprise temperature changes ranging from about −40 degrees Celsius (° C.) to about 60° C.

5. The rotor blade of claim 2, wherein the composite material comprises at least one of a thermoset resin or a thermoplastic resin.

6. The rotor blade of claim 5, wherein the composite material is optionally reinforced with one or more fiber materials to achieve a predetermined fiber content.

7. The rotor blade of claim 6, wherein the predetermined fiber content is greater than about 55%.

8. The rotor blade of claim 6, wherein the one or more fiber materials comprising at least one of glass fibers, carbon fibers, polymer fibers, wood fibers, bamboo fibers, ceramic fibers, nanofibers, metal fibers, or combinations thereof

9. The rotor blade of claim 2, wherein the metal material comprises steel, aluminum, or titanium.

10. The rotor blade of claim 1, wherein the first and second coefficients of thermal expansion are substantially equal plus or minus 20%.

11. A method for manufacturing a load bearing block assembly of a jointed rotor blade of a wind turbine, the method comprising: providing one or more pin joint slots of a first material having a first coefficient of thermal expansion; forming at least one load bearing block of a second material such that a second coefficient of thermal expansion of the load bearing block is substantially equal to the first coefficient of thermal expansion so as to maintain contact between the one or more pin joint slots and the load bearing block during operational temperature changes of the wind turbine, the load bearing block having one or more openings; and, securing the one or more pin joint slots within the one or more openings of the load bearing block.

12. The method of claim 11, wherein the first material comprises a metal material and the second material comprises a composite material.

13. The method of claim 11, wherein the one or more pin joint slots comprise one or more bushings.

14. The method of claim 11, wherein forming the load bearing block of the second material to have the second coefficient of thermal expansion further comprises reinforcing the second material with a fiber content that will either increase or decrease an original coefficient of thermal expansion of the composite material by a predetermined percentage.

15. The method of claim 14, wherein the fiber content is greater than about 55%.

16. The method of claim 11, wherein the operational temperature changes of the wind turbine comprise temperature changes ranging from about −40 degrees Celsius (° C.) to about 60° C.

17. The method of claim 12, wherein the composite material comprises at least one of a thermoset resin or a thermoplastic resin, and wherein the metal material comprises steel, aluminum, or titanium.

18. The method of claim 16, wherein the fiber content is achieved by adding one or more fiber materials, the one or more fiber materials comprising at least one of glass fibers, carbon fibers, polymer fibers, wood fibers, bamboo fibers, ceramic fibers, nanofibers, metal fibers, or combinations thereof

19. The method of claim 10, wherein the first and second coefficients of thermal expansion are substantially equal plus or minus 20%.

20. A bearing block assembly, comprising: a bearing block defining one or more openings; and, one or more pin joint slots received within the one or more openings of the bearing block, wherein the one or more pin joint slots are constructed of a metal material having a first coefficient of thermal expansion, the bearing block constructed of a composite material having a second coefficient of thermal expansion, the first and second coefficients of thermal expansion being substantially equal so as to maintain contact between the one or more pin joint slots and the bearing block during operational temperature changes of the bearing block assembly.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:

[0017] FIG. 1 illustrates a perspective view of one embodiment of a wind turbine according to the present disclosure;

[0018] FIG. 2 illustrates a plan view of one embodiment of a rotor blade having a first blade segment and a second blade segment according to the present disclosure;

[0019] FIG. 3 illustrates a perspective view of a section of one embodiment of the first blade segment according to the present disclosure;

[0020] FIG. 4 illustrates a perspective view of one embodiment of a section of the second blade segment at the chord-wise joint according to the present disclosure;

[0021] FIG. 5 illustrates an assembly of one embodiment of the rotor blade of the wind turbine having the first blade segment joined with the second blade segment according to the present disclosure;

[0022] FIG. 6 illustrates an exploded perspective view of one embodiment of the multiple supporting structures of the assembly of the rotor blade of the wind turbine according to the present disclosure;

[0023] FIG. 7 illustrates a cross-sectional view of one embodiment of a bearing block of a rotor blade of a wind turbine at a chord-wise joint according to the present disclosure;

[0024] FIG. 8 illustrates a perspective view of one embodiment of a pin joint slot of a bearing block of a rotor blade of a wind turbine at a chord-wise joint according to the present disclosure;

[0025] FIG. 9 illustrates a perspective view of another embodiment of a bearing block of a rotor blade of a wind turbine at a chord-wise joint according to the present disclosure; and

[0026] FIG. 10 illustrates a flow chart of one embodiment of a method for manufacturing a bearing block assembly of a jointed rotor blade of a wind turbine according to the present disclosure.

DETAILED DESCRIPTION

[0027] Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.

[0028] Referring now to the drawings, FIG. 1 illustrates a perspective view of one embodiment of a wind turbine 10 according to the present invention. In the illustrated embodiment, the wind turbine 10 is a horizontal-axis wind turbine. Alternatively, the wind turbine 10 may be a vertical-axis wind turbine. In addition, as shown, the wind turbine 10 may include a tower 12 that extends from a support surface 14, a nacelle 16 mounted on the tower 12, a generator 18 positioned within the nacelle 16, a gearbox 20 coupled to the generator 18, and a rotor 22 that is rotationally coupled to the gearbox 20 with a rotor shaft 24. Further, as shown, the rotor 22 includes a rotatable hub 26 and at least one rotor blade 28 coupled to and extending outward from the rotatable hub 26. As shown, the rotor blade 28 includes a blade tip 17 and a blade root 19.

[0029] Referring now to FIG. 2, a plan view of one of the rotor blades 28 of FIG. 1 is illustrated. As shown, the rotor blade 28 may include a first blade segment 30 and a second blade segment 32. Further, as shown, the first blade segment 30 and the second blade segment 32 may each extend in opposite directions from a chord-wise joint 34. In addition, as shown, each of the blade segments 30, 32 may include at least one shell member defining an airfoil surface. The first blade segment 30 and the second blade segment 32 are connected by at least an internal support structure 36 extending into both blade segments 30, 32 to facilitate joining of the blade segments 30, 32. The arrow 38 shows that the segmented rotor blade 28 in the illustrated example includes two blade segments 30, 32 and that these blade segments 30, 32 are joined by inserting the internal support structure 36 into the second blade segment 32. In addition, as shown, the second blade segment includes multiple spar structures 66 (also referred to herein as spar caps) that extend lengthwise for connecting with a blade root section 35 of the rotor blade 28 (which is shown in more detail in FIG. 7) and with the beam structure 40 of the first blade segment 30 (which is shown in more detail in FIG. 5).

[0030] Referring now to FIG. 3, a perspective view of a section of the first blade segment 30 according to the present disclosure is illustrated. As shown, the first blade segment 30 includes a beam structure 40 that forms a portion of the internal support structure 36 and extends lengthwise for structurally connecting with the second blade segment 32. Further, as shown, the beam structure 40 forms a part of the first blade segment 30 having an extension protruding from a spar section 42, thereby forming an extending spar section. The beam structure 40 includes a shear web 44 connected with a suction side spar cap 46 and a pressure side spar cap 48.

[0031] Moreover, as shown, the first blade segment 30 may include one or more first pin joints towards a first end 54 of the beam structure 40. In one embodiment, the pin joint may include a pin that is in a tight interference fit with a bush. More specifically, as shown, the pin joint(s) may include at least one pin tube 52 located on the beam structure 40. Thus, as shown, the pin tube 52 may be oriented in a span-wise direction. It should be understood that the pin tubes described herein may include any suitable pin, bolt, fastener, or similar.

[0032] Further, the first blade segment 30 may also include a pin joint slot 50 located on the beam structure 40 proximate to the chord-wise joint 34. Moreover, as shown, the pin joint slot 50 may be oriented in a chord-wise direction. In one example, there may be a bushing within the pin joint slot 50 arranged in a tight interference fit with a pin tube or pin (shown as pin 53 in FIG. 6). Further, the first blade segment 30 may include multiple second pin joint tubes 56, 58 located at the chord-wise joint 34. Thus, as shown, the second pin joint tubes 56, 58 may include a leading edge pin joint tube 56 and a trailing edge pin joint tube 58. Further, each of the second pin joint tubes 56, 58 may be oriented in a span-wise direction. In addition, as shown, each of the second pin joint tubes 56, 58 may include multiple flanges 55, 57, respectively, that are configured to distribute compression loads at the chord-wise joint 34.

[0033] It is to be noted that the pin tube 52 located at the first end of the beam structure 40 may be separated span-wise with the multiple second pin joint tubes 56, 58 located at the chord-wise joint 34 by an optimal distance D. This optimal distance D may be such that the chord-wise joint 34 is able to withstand substantial bending moments caused due to shear loads acting on the chord-wise joint 34. In another embodiment, each of the pin joints connecting the first and second blade segments 30, 32 may include an interference-fit steel bushed joint.

[0034] Referring now to FIG. 4, a perspective view of a section of the second blade segment 32 at the chord-wise joint 34 according to the present disclosure is illustrated. As shown, the second blade segment 32 includes a receiving section 60 extending lengthwise within the second blade segment 32 for receiving the beam structure 40 of the first blade segment 30. The receiving section 60 includes the spar structures 66 that extend lengthwise for connecting with the beam structure 40 of the first blade segment 30. As shown, the second blade segment 32 may further include pin joint slots 62, 64 for receiving pin tubes 56, 58 (shown in FIG. 3) of the first blade segment 30 and forming tight interference fittings. In one example, each of the multiple pin joint slots 62, 64 may include multiple flanges 61, 63, respectively, that are configured to distribute compression loads at the chord-wise joint 34.

[0035] Referring now to FIG. 5, an assembly 70 of the rotor blade 28 having the first blade segment 30 joined with the second blade segment 32 according to the present disclosure is illustrated. As shown, the assembly 70 illustrates multiple supporting structures beneath outer shell members of the rotor blade 28 having the first blade segment 30 joined with the second blade segment 32. Further, as shown, the receiving section 60 includes the multiple spar structures 66 extending lengthwise and supports the beam structure 40. The receiving section 60 also includes a rectangular fastening element 72 that connects with the pin tube 52 of the beam structure 40 in the span-wise direction. Further, the first and the second blade segments 30, 32 may also include chord-wise members 74, 76 respectively at the chord-wise joint 34. Further, as shown, the chord-wise members 74, 76 may include leading edge pin openings 78 and trailing edge pin openings 80 that allows pin joint connections between the first and second blade segments 30, 32. For example, as shown, the chord-wise members 74, 76 are connected by pin tubes 56 and 58 that are in tight interference fit with bushings located in the leading edge pin openings 78 and the trailing edge pin openings 80. In another embodiment, each of the spar structures 66, the rectangular fastening element 72, and the chord-wise members 74, 76 may be constructed of glass reinforced fibers. In this example, the assembly 70 may also include multiple lightening receptor cables 73 that are embedded between the multiple pin tubes or pins 56, 58 and the bushing connections attached to the chord-wise members 74, 76.

[0036] Referring now to FIG. 6, an exploded perspective view of the multiple supporting structures of the assembly 70 towards the receiving section 60 of the rotor blade 28 is illustrated. As shown, a pair of spar structures 66 is configured to receive the beam structure 40 and includes pin joint slots 82, 84 that are aligned with the pin joint slot 50 of the beam structure 40 through which a pin tube or pin 53 may be inserted. Further, the pin 53 is configured to remain in a tight interference fit within the aligning pin joint slots 82, 50, 84 such that spar structures 66 and the beam structure 40 are joined together by during assembling. Further, FIG. 6 also illustrates the rectangular fastening element 72 that includes a pin joint slot 86 configured for receiving the pin tube 52 of the beam structure 40. As such, the pin tube 52 is configured to form a tight interference fit pined joint. Further, the pair of spar structures 66 may be joined together at one end 88 using any suitable adhesive material or an elastomeric seal.

[0037] Referring to FIGS. 7 and 9, the pin joint slot(s) 62, 64 may be installed and retained within one or more openings 65, 67 of a bearing block 68 (similar to or synonymous with the chord-wise members 74, 76). In one embodiment, as shown in FIGS. 8 and 9, the pin joint slot(s) 62, 64 described herein may include one or more bushings. As such, in certain embodiments, the bushings 62, 64 may be constructed of a metal material having a first coefficient of thermal expansion. In contrast, the bearing block 68 may be constructed of a composite material having a second coefficient of thermal expansion. In conventional bearing blocks, however, the coefficients of thermal expansion of the metal and composite materials would be substantially different, thereby causing thermally-induced stresses between the pin joint slot(s) 62, 64 and the bearing block 68. In addition, in such situations, the different coefficients of thermal of expansion between the dissimilar materials may compromise the structural integrity of the joint.

[0038] In the present disclosure, however, the first and second coefficients of thermal expansion of the dissimilar materials are substantially equal so as to maintain contact between the pin joint slot(s) 62, 64 and the bearing block 68 during operational temperature changes of the wind turbine 10. In several embodiments, the first and second coefficients of thermal expansion may be substantially equal, e.g. plus or minus 20%. In other words, the bearing block 68 of the present disclosure may be custom designed for the operational temperature of the wind turbine 10 to avoid the aforementioned issues. In one embodiment, the operational temperature changes of the wind turbine 10 may include temperature changes ranging from about −40 degrees Celsius (° C.) to about 60° C. Thus, the bearing block 68 may be designed to withstand the entire ranges of potential temperatures.

[0039] For example, in one embodiment, the composite material of the bearing block 68 may include a thermoset resin or a thermoplastic resin. In addition, the composite material of the bearing block 68 may optionally be reinforced with one or more fiber materials to achieve a predetermined fiber content. For example, in such embodiments, the predetermined fiber content may be greater than about 55%, such as from about 56% to about 60%. Thus, by increasing the fiber content of the composite material, the coefficient of thermal expansion of the composite material is reduced. Accordingly, by knowing the coefficient of thermal expansion of the metal material of the pin joint slot(s) 62, 64, the materials of the bearing block 68 can be specifically chosen such that the coefficient of thermal expansion therefore substantially matches the metal.

[0040] The metal material of the bushing(s) 62, 64 described herein may include, for example, steel, aluminum, titanium, or any other suitable metal or metal alloy. The thermoplastic materials described herein may generally encompass a plastic material or polymer that is reversible in nature. For example, thermoplastic materials typically become pliable or moldable when heated to a certain temperature and returns to a more rigid state upon cooling. Further, thermoplastic materials may include amorphous thermoplastic materials and/or semi-crystalline thermoplastic materials. For example, some amorphous thermoplastic materials may generally include, but are not limited to, styrenes, vinyls, cellulosics, polyesters, acrylics, polysulphones, and/or imides. More specifically, exemplary amorphous thermoplastic materials may include polystyrene, acrylonitrile butadiene styrene (ABS), polymethyl methacrylate (PMMA), glycolised polyethylene terephthalate (PET-G), polycarbonate, polyvinyl acetate, amorphous polyamide, polyvinyl chlorides (PVC), polyvinylidene chloride, polyurethane, or any other suitable amorphous thermoplastic material. In addition, exemplary semi-crystalline thermoplastic materials may generally include, but are not limited to polyolefins, polyamides, fluropolymer, ethyl-methyl acrylate, polyesters, polycarbonates, and/or acetals. More specifically, exemplary semi-crystalline thermoplastic materials may include polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polypropylene, polyphenyl sulfide, polyethylene, polyamide (nylon), polyetherketone, or any other suitable semi-crystalline thermoplastic material.

[0041] Further, the thermoset materials as described herein may generally encompass a plastic material or polymer that is non-reversible in nature. For example, thermoset materials, once cured, cannot be easily remolded or returned to a liquid state. As such, after initial forming, thermoset materials are generally resistant to heat, corrosion, and/or creep. Example thermoset materials may generally include, but are not limited to, some polyesters, some polyurethanes, esters, epoxies, or any other suitable thermoset material.

[0042] In addition, the fiber materials described herein may include but are not limited to glass fibers, carbon fibers, polymer fibers, wood fibers, bamboo fibers, ceramic fibers, nanofibers, metal fibers, or combinations thereof. In addition, the direction or orientation of the fibers may include quasi-isotropic, multi-axial, unidirectional, biaxial, triaxial, or any other another suitable direction and/or combinations thereof

[0043] Referring now to FIG. 10, a flow chart 100 of a method for manufacturing a bearing block assembly of a jointed rotor blade of a wind turbine according to the present disclosure is illustrated. In general, the method 100 will be described herein with reference to the wind turbine 10 and the rotor blade 28 shown in FIGS. 1-9. However, it should be appreciated that the disclosed method 100 may be implemented with rotor blades having any other suitable configurations. In addition, although FIG. 10 depicts steps performed in a particular order for purposes of illustration and discussion, the methods discussed herein are not limited to any particular order or arrangement. One skilled in the art, using the disclosures provided herein, will appreciate that various steps of the methods disclosed herein can be omitted, rearranged, combined, and/or adapted in various ways without deviating from the scope of the present disclosure.

[0044] As shown at (102), the method 100 may include providing the pin joint slot(s) 62, 64 of a metal material having a first coefficient of thermal expansion. As shown at (104), the method 100 may include forming the bearing block 68 of a composite material such that a second coefficient of thermal expansion of the bearing block 68 is substantially equal to the first coefficient of thermal expansion so as to maintain contact between the pin joint slot(s) and the bearing block 68 during operational temperature changes of the wind turbine 10. Further, the bearing block 68 has one or more openings 65, 67. For example, in one embodiment, the bearing block 68 may be formed by reinforcing the composite material with a fiber content that will either increase or decrease an original coefficient of thermal expansion of the composite material by a predetermined percentage. Thus, the resulting coefficient of thermal expansion of the composite material substantially matches that of the metal material of the pin joint slot(s) 62, 64. As shown at (106), the method 100 may include securing the pin joint slot(s) 62, 64 within the openings 65, 67 of the bearing block 68.

[0045] The skilled artisan will recognize the interchangeability of various features from different embodiments. Similarly, the various method steps and features described, as well as other known equivalents for each such methods and feature, can be mixed and matched by one of ordinary skill in this art to construct additional systems and techniques in accordance with principles of this disclosure. Of course, it is to be understood that not necessarily all such objects or advantages described above may be achieved in accordance with any particular embodiment. Thus, for example, those skilled in the art will recognize that the systems and techniques described herein may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other objects or advantages as may be taught or suggested herein.

[0046] While only certain features of the invention have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention.

[0047] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.