METHOD FOR MANUFACTURING A STRUCTURAL COMPONENT OF A BLADE SEGMENT FOR A ROTOR BLADE OF A WIND TURBINE
20220063216 ยท 2022-03-03
Inventors
- Scott Jacob Huth (Greenville, SC, US)
- Xu Chen (Simpsonville, SC, US)
- Louis Rondeau (Greenville, SC, US)
- Andrew Mitchell Rodwell (Greenville, SC, US)
- Scott Iverson Shillig (Greenville, SC, US)
Cpc classification
F05B2240/302
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B29C70/84
PERFORMING OPERATIONS; TRANSPORTING
Y02P70/50
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
F03D1/0675
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B29C70/48
PERFORMING OPERATIONS; TRANSPORTING
B29C70/446
PERFORMING OPERATIONS; TRANSPORTING
F05B2230/50
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05B2280/6013
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05B2280/6015
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02E10/72
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
International classification
B29C70/48
PERFORMING OPERATIONS; TRANSPORTING
B29C70/44
PERFORMING OPERATIONS; TRANSPORTING
B29C70/84
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A method for manufacturing a structural component of a blade segment for a segmented rotor blade of a wind turbine includes providing a mold of the structural component. The mold has an outer wall that defines an outer surface of the structural component. The method also includes securing at least one tooling pin to the outer wall for defining a pin joint slot in the structural component. Further, the method includes laying up one or more outer fiber layers in the mold so as to at least partially cover the outer wall. The outer fiber layer(s) has at least one hole that receives the tooling pin(s). As such, the outer fiber layer(s) form the outer surface of the structural component. Moreover, the method includes placing one or more structural features atop the outer fiber layer(s) in the mold. In addition, the method includes infusing the outer fiber layer(s) and the structural feature(s) together via a resin material so as to form the structural component.
Claims
1. A method for manufacturing a structural component of a blade segment for a segmented rotor blade of a wind turbine, the method comprising: providing a mold of the structural component, the mold having an outer wall that defines an outer surface of the structural component; securing at least one tooling pin to the outer wall for defining a pin joint slot in the structural component; laying up one or more outer fiber layers in the mold so as to at least partially cover the outer wall, the one or more outer fiber layers having at least one hole that receives the at least one tooling pin, the one or more outer fiber layers forming the outer surface of the structural component; placing one or more structural features atop the one or more outer fiber layers in the mold; and, infusing the one or more outer fiber layers and the one or more structural features together via a resin material so as to form the structural component.
2. The method of claim 1, wherein the structural component comprises at least one of a beam structure or a receiving section of the blade segment.
3. The method of claim 1, wherein placing the one or more structural features atop the one or more outer fiber layers in the mold further comprises placing a first layer of one or more pultrusions atop the one or more outer fiber layers.
4. The method of claim 1, wherein placing the one or more structural features atop the one or more outer fiber layers in the mold further comprises placing one or more shear webs atop the one or more outer fiber layers, the one or more shear webs comprising a web hole that receives the at least one tooling pin.
5. The method of claim 1, further comprising placing one or more bushings to the outer wall within the mold and securing the at least one tooling pin within the one or more bushings.
6. The method of claim 4, wherein securing the at least one tooling pin to the outer wall for defining the pin joint slot in the beam structure further comprises securing a single tooling pin from a leading edge end of the mold to a trailing edge end of the mold.
7. The method of claim 4, wherein securing the at least one tooling pin to the outer wall for defining the pin joint slot in the beam structure further comprises securing a leading edge tooling pin at a leading edge end of the mold and securing a separate trailing edge tooling pin at a trailing edge end of the mold, the leading and trailing edge tooling pins being coaxially aligned in a chord-wise direction of the beam structure.
8. The method of claim 7, wherein placing the one or more shear webs atop the one or more outer fiber layers and the first layer of one or more pultrusions further comprises placing at least one leading edge shear web at the leading edge end of the mold such that a leading edge hole of the at least one leading edge shear web receives the leading edge tooling pin and placing a trailing edge shear web at the trailing edge end of the mold such that a trailing edge hole of the at least one trailing edge shear web receives the trailing edge tooling pin.
9. The method of claim 7, further comprising placing one or more inner fiber layers so as to cover the one or more shear webs and the first layer of one or more pultrusions.
10. The method of claim 9, further comprising placing at least one mandrel atop the one or more inner fiber layers so as to provide a base shape for shaping the structural component thereon, the mandrel comprising a compressible material.
11. The method of claim 10, further comprising folding ends of the one or more inner fiber layers around the at least one mandrel.
12. The method of claim 11, wherein placing the one or more structural features atop the one or more outer fiber layers in the mold further comprises placing a second layer of one or more pultrusions atop the folded ends of the one or more inner fiber layers.
13. The method of claim 12, further comprising folding ends of the one or more outer fiber layers around the second layer of the one or more pultrusions.
14. The method of claim 1, wherein the mold comprises a first mold portion and a second mold portion, the method further comprising placing the second mold portion atop the first mold portion that contains the one or more outer fiber layers and the one or more structural features and subsequently infusing the one or more outer fiber layers and the one or more structural features together so as to form the structural component.
15. The method of claim 1, further comprising removing the leading edge tooling pin and the trailing edge tooling pin, after infusing the one or more outer fiber layers and the one or more structural features together to partially form the pin joint slot.
16. A molding kit for manufacturing a beam structure of a blade segment for a segmented rotor blade of a wind turbine, the kit comprising: a first mold portion comprising an outer wall that defines an outer surface of the beam structure; at least one tooling pin secured to the outer wall for defining a pin joint slot in the beam structure; and, a second mold portion configured to fit with the first mold portion after one or more materials are placed therein to form the beam structure so as to create a vacuum that can draw a resin material within the first and second mold portions for infusing the one or more materials together.
17. The molding kit of claim 16, wherein the one or more materials comprise at least one of one or more outer fiber layers, one or more layers of pultrusions, one or more shear webs, or one or more inner fiber layers, and wherein the resin material comprises at least one of a thermoset resin or a thermoplastic resin.
18. The molding kit of claim 16, wherein at least one of the one or more materials comprise a pre-cut hole that receives the at least one tooling pin when placed into the first mold portion.
19. The molding kit of claim 16, further comprising one or more bushings for securing to the outer wall within the first mold portion.
20. The molding kit of claim 16, wherein the at least one tooling pin further comprises a leading edge tooling pin and a trailing edge tooling pin.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] 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:
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DETAILED DESCRIPTION
[0040] 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.
[0041] Referring now to the drawings,
[0042] Referring now to
[0043] Referring now to
[0044] 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 bushing. More specifically, as shown, the pin joint(s) may include 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. 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
[0045] 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.
[0046] Referring now to
[0047] Referring now to
[0048] Referring now to
[0049] Referring now to
[0050] As shown at (102), the method 100 may include providing a mold 150 of the beam structure 40. As shown at (104), the method 100 may include securing at least one tooling pin to the outer wall 156 of the mold 150 for defining the pin joint slot 50 in the beam structure 40. For example, as shown in
[0051] Referring back to
[0052] Referring back to
[0053] Referring now to
[0054] Referring back to
[0055] After the components of the beam structure 40 are infused together and cured, the method 100 may also include removing the beam structure 40 from the mold 150 and/or removing the leading edge tooling pin 162, the trailing edge tooling pin 164, and/or the mandrel 184 from within the beam structure 40 so as to form the pin joint slot 50, as shown in
[0056] Referring now to
[0057] In such embodiments, as shown in
[0058] The resin material described herein may include, for example, a thermoset material or a thermoplastic material. The thermoplastic materials as 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, fluoropolymer, 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.
[0059] 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.
[0060] In addition, the fiber layers described herein may include, for example, 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.
[0061] 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.
[0062] 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.
[0063] 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.