WIND TURBINE ROTOR BLADE

Abstract

A wind turbine rotor blade having a flatback trailing edge. The flatback trailing edge has at least one insert which has a flat outside and a curved inside.

Claims

1. A wind turbine rotor blade, comprising: a flatback trailing edge, wherein the flatback trailing edge has at least one insert having a flat outside surface and a curved inside surface; a preform or an outer laminate placed at an inside of the insert; and a core material and an inner laminate on the preform or the outer laminate.

2. The wind turbine rotor blade according to claim 1 comprising a body portion, wherein the curved inside surface of the at least one insert corresponds to a curvature of the body portion.

3. The wind turbine rotor blade according to claim 1 wherein the at least one insert is a foam insert, an insert of balsa wood, or an insert of PET, PVC or PU.

4. (canceled)

5. A wind turbine comprising at least one wind turbine rotor blade according to claim 1.

6. A method comprising: producing a half-shell of a wind turbine rotor blade having a flatback profile, wherein producing comprises: placing at least one insert in a mold for the production of the half-shell of the wind turbine rotor blade, wherein the at least one insert has a flat outside surface and a curved inside, surface; placing a preform or an outer laminate on the curved inside surface of the at least one insert; placing core material and inner laminate on the preform or the outer laminate; and carrying out a vacuum infusion method to thereby produce the half-shell for the wind turbine rotor blade.

7. The wind turbine rotor blade according to claim 2 wherein the body portion is a half shell.

8. The wind turbine rotor blade according to claim 1 wherein the at least one insert is a plurality of inserts.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0020] Advantages and embodiments by way of example of the invention are described in greater detail hereinafter with reference to the drawing.

[0021] FIG. 1 shows a diagrammatic view of a wind turbine according to the invention,

[0022] FIG. 2 shows a diagrammatic view in section of a wind turbine rotor blade according to an aspect of the present invention,

[0023] FIG. 3 shows a diagrammatic view in section of a wind turbine rotor blade according to a first embodiment,

[0024] FIG. 4 shows a diagrammatic view in section of a part of a wind turbine rotor blade according to an embodiment,

[0025] FIG. 5 shows a diagrammatic view in section of a wind turbine rotor blade according to an embodiment in production of the rotor blade, and

[0026] FIG. 6 shows a perspective view in section of foam inserts or a wind turbine rotor blade according to an aspect of the present invention.

DETAILED DESCRIPTION

[0027] FIG. 1 shows a diagrammatic view of a wind turbine. FIG. 1 shows a wind turbine 100 comprising a tower 102 and a nacelle 104. Arranged on the nacelle 104 is a rotor 106 having three rotor blades 200 and a spinner 110. In operation the rotor 106 is caused to rotate by the wind and thereby drives a generator in the nacelle 104.

[0028] The wind turbine rotor blade 200 is typically formed by two half shells, wherein one half shell represents the pressure side and the other half shell represents the suction side. The wind turbine rotor blade also has a flatback profile, that is to say the rotor blade trailing edge is at least partially straight.

[0029] FIG. 2 shows a diagrammatic view in section of a wind turbine rotor blade according to an aspect of the present invention. In this case the rotor blade 200 has a flatback profile 210, that is to say a flattened trailing edge.

[0030] FIG. 3 shows a diagrammatic view in section of a wind turbine rotor blade according to a first embodiment. FIG. 3 shows in particular the end edge or the flatback 210 of the rotor blade. In FIG. 3 the insert is shown as extending circumferentially. However by virtue of the production method the insert can also be of a divided configuration. FIG. 3 further shows an insert 220 (for example an end edge insert), a laminate layer 230 and a preform 240. As an alternative to a preform it is also possible to introduce fixed parts (infused and tempered).

[0031] The insert 220 can be made from different materials like for example balsa wood, PET (Polyethylene Terephthalate), PVC (polyvinyl chloride) or PU (polyurethane) foam.

[0032] FIG. 4 shows a diagrammatic view in section of a part of a wind turbine rotor blade according to a further embodiment. Cover layers 221 can be provided over the insert 220 or on the insert. The inside 220b of the insert 220 is of a curved configuration. The outer laminate can follow the insert. The preform 260 can then be placed. That can be followed by the core material 250 and then the inner laminate 230 can be applied.

[0033] The inserts 220 are typically prefabricated and at their first side 220a have a flat end which then determines or shapes or constitutes the flatback profile of the rotor blade 200. At its second side 220b the foam inserts 220 have a curved profile which is of such a configuration that the fiber mats (fiber fabric or weave) can be fitted in with the fibers substantially in the correct relationship. The foams used can represent for example PET foams. The foam inserts 220 can be milled to the correct shape. As an alternative thereto it is also possible to carry out alternative production methods like for example a foamed geometry or a layer-wise structure.

[0034] FIG. 5 shows a diagrammatic view in section of a wind turbine rotor blade according to an aspect in production of the rotor blade. To produce the rotor blade 200 the foam inserts 220 are placed in a mold 300, then optionally an outer laminate, a preform 260, core material 250 and an inner laminate 230 can be placed. A half-shell is then produced for example by means of the vacuum assisted transfer molding (VATM) method.

[0035] That is advantageous because tolerances or inaccuracies in the inserts 220 can be compensated therewith. Optional cover layers 221 can be provided over the inserts 220 in production of the rotor blade, which cover layers can then represent the outer surface of the rotor blade 200 at least in the region of the flatback 210.

[0036] The inserts are incorporated during the normal process of producing the rotor blade so that no additional separate parts have to be subsequently fitted.

[0037] FIG. 6 shows a perspective view in section of the insert 220 for a wind turbine rotor blade according to an aspect. The inserts 220 have an outside 220a and an inside 220b. The outside 220a is preferably smooth or flat while the inside is of a curved configuration in order in that way to permit laying of the fiber mats in the correct fiber orientation.