Method for manufacturing a structural component of a blade segment for a rotor blade of a wind turbine
11840030 ยท 2023-12-12
Assignee
Inventors
- Andrew Mitchell Rodwell (Greenville, SC, US)
- Xu Chen (Simpsonville, SC, US)
- Julie Ann Shepherd (Liberty, SC, US)
- Scott Iverson Shillig (Greenville, SC, US)
Cpc classification
F05B2240/302
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F03D80/30
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F03D13/30
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B29C70/885
PERFORMING OPERATIONS; TRANSPORTING
F03D1/0675
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F03D1/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B29C70/88
PERFORMING OPERATIONS; TRANSPORTING
F03D13/30
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
A method for manufacturing a structural component of a blade segment for a rotor blade includes providing a mold of the structural component having an outer wall that defines an outer surface of the structural component. The method also includes laying up one or more fiber layers in the mold so as to at least partially cover the outer wall. As such, the fiber layer(s) form the outer surface of the structural component. Further, the method includes providing one or more metal mesh layers having one or more ends. Moreover, the method includes providing a cover material to the end(s) of the metal mesh layer(s). In addition, the method includes placing the metal mesh layer(s) with the covered end(s) atop the fiber layer(s). Thus, the method includes infusing the fiber layer(s) and the metal mesh layer(s) together via a resin material so as to form the structural component.
Claims
1. A method for preventing manufacturing defects in a manufacturing process of a structural component of a blade segment of a rotor blade of a wind turbine, the method comprising: providing one or more metal mesh layers having one or more ends; covering the one or more ends of the one or more metal mesh layers with a cover material; placing the one or more metal mesh layers with the one or more covered ends adjacent to one or more fiber layers within a mold; forming the structural component with the one or more metal mesh lavers having the one or more covered ends and the one or more fiber layers; and wherein the cover material is disposed completely around a periphery of the metal mesh layer without covering at least a portion of an interior region of the metal mesh layer bordered by the cover material prior to placing the metal mesh layers with the covered ends adjacent to the fiber layers in the mold.
2. The method of claim 1, wherein the cover material comprises at least of a composite fabric material, a prefabricated composite part, an adhesive, or a resin.
3. The method of claim 1, wherein the one or more metal mesh layers are constructed, at least in part, of copper.
4. The method of claim 1, further comprising infusing the one or more metal mesh layers having the one or more covered ends and the one or more fiber layers together within the mold via a resin material.
5. The method of claim 4, wherein forming the structural component with the one or more metal mesh layers having the one or more covered ends and the one or more fiber layers further comprises placing one or more shear webs into the mold and infusing the one or more shear webs with the one or more metal mesh layers having the one or more covered ends and the one or more fiber layers together via the resin material.
6. 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.
7. The method of claim 4, wherein the resin material comprises at least one of a thermoset resin or a thermoplastic resin.
8. The method of claim 1, wherein the one or more metal mesh layers are configured to provide at least one of lightning protection to the structural component during operation of the wind turbine or structural support to the structural component.
9. A method for preventing manufacturing defects in a manufacturing process of a structural component of a blade segment of a rotor blade of a wind turbine, the method comprising: providing one or more metal mesh layers having one or more ends; covering the one or more ends of the one or more metal mesh layers with a cover mated al; placing the one or more metal mesh layers with the one or more covered ends adjacent to one or more fiber layers; forming the structural component with the one or more metal mesh layers having the one or more covered ends and the one or more fiber layers; and further comprising tensioning the one or more fiber layers after placing the one or more metal mesh layers with the one or more covered ends adjacent to the one or more fiber layers.
10. A method for manufacturing a structural component of a blade segment for a rotor blade of a wind turbine, the method comprising: providing a mold of the structural component; laying up one or more fiber layers on or in the mold, the one or more fiber layers forming a surface of the structural component; providing one or more metal mesh layers having one or more ends; providing a cover material completely around a periphery of the meal mesh layers so as to cover the one or more ends of the one or more metal mesh layers without covering at least a portion of an of an interior region of the metal mesh layers bordered by the cover material; placing the one or more metal mesh layers with the one or more covered ends atop the one or more fiber layers; and, infusing the one or more fiber layers and the one or more metal mesh layers together via a resin material so as to form the structural component.
11. The method of claim 10, wherein the cover material comprises at least of a composite fabric material, a prefabricated composite part, an adhesive, or a resin.
12. The method of claim 10, wherein the structural component comprises at least one of a beam structure or a receiving section of the blade segment.
13. The method of claim 10, wherein the one or more metal mesh layers are constructed, at least in part, of copper.
14. The method of claim 10, further comprising placing one or more structural features into the mold and infusing the one or more structural features with the one or more fiber layers and the one or more metal mesh layers together via the resin material.
15. A method for manufacturing a structural component of a blade segment for a rotor blade of a wind turbine, the method comprising: providing a mold of the structural component; laying up one or more fiber layers on or in the mold, the one or more fiber layers forming a surface of the structural component; providing one or more metal mesh layers having one or more ends; providing a cover material to the one or more ends of the one or more metal mesh layers; placing the one or more metal mesh layers with the one or more covered ends atop the one or more fiber layers; infusing the one or more fiber layers and the one or more metal mesh layers together via a resin material so as to form the structural component; and further comprising tensioning the one or more fiber layers after placing the one or more metal mesh layers with the one or more covered ends adjacent to one or more fiber layers.
16. A structural component for a blade segment of a rotor blade of a wind turbine, the structural component comprising: one or more metal mesh layers having one or more ends; a cover material covering the one or more ends of the one or more metal mesh layers; one or more fiber layers adjacent to the one or more metal mesh layers; a resin material securing the one or more metal mesh layers, the cover material, and the one or more fiber layers together; and wherein the cover material is disposed completely around a periphery of the metal mesh layer without covering at least a portion of an interior region of the metal mesh layer bordered by the cover material.
17. The structural component of claim 16, further comprising one or more structural features secured within the resin material.
18. The structural component of claim 17, wherein the one or more structural features comprise at least one of one or more layers of pultrusions, one or more shear webs, or a core material.
19. The structural component of claim 16, wherein the cover material comprises at least of a composite fabric material, a prefabricated composite part, an adhesive, or a resin, the one or more metal mesh layers being constructed, at least in part, of copper.
20. The structural component of claim 16, wherein the structural component comprises at least one of a beam structure or a receiving section of the blade segment.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) 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
(15) 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.
(16) Referring now to the drawings,
(17) Referring now to
(18) Referring now to
(19) 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
(20) 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.
(21) Referring now to
(22) Referring now to
(23) Referring now to
(24) Referring now to
(25) As shown at (102), the method 100 includes providing a mold 150 of the beam structure 40. For example, as shown in
(26) As shown at (106), the method 100 includes providing one or more metal mesh layers 156 having one or more ends 158. Thus, the metal mesh layer(s) 156 are configured to provide lightning protection to the beam structure 40 during operation of the wind turbine 10 and/or structural support to the beam structure 40. For example, as shown in
(27) Thus, referring back to
(28) As shown at (110), the method 100 includes placing the metal mesh layer(s) 156 with the covered end(s) 158 atop the fiber layer(s) 154. For example, as shown in
(29) In one embodiment, the method 100 may include tensioning the fiber layer(s) 154 after placing the metal mesh layer(s) 156 with the covered end(s) 158 adjacent to the fiber layer(s) 154. In such embodiments, the cover material 160 is configured to prevent snagging or tearing of the fiber layer(s) 154 against the metal mesh layer(s) 156.
(30) Referring back to
(31) In certain embodiments, the resin material 162 may include a thermoset resin or a thermoplastic resin. 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, 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.
(32) 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.
(33) 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.
(34) Referring now to
(35) As shown at (202), the method 200 may include providing one or more metal mesh layers 156 having one or more ends 158. As shown at (204), the method 200 may include covering the end(s) 158 of the metal mesh layer(s) 156 with a cover material 160. As shown at (206), the method 200 may include placing the metal mesh layer(s) 156 with the covered end(s) 158 adjacent to one or more fiber layers 154. As shown at (208), the method 200 may include forming the beam structure 40 with the metal mesh layer(s) 156 having the covered end(s) 158 and the fiber layer(s) 154.
(36) 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.
(37) 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.
(38) 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.