PROTECTIVE COVER SYSTEM

Abstract

Provided is a protective cover system including a first protective cover and a second protective cover, both include a polymer and being pre-formed into a curved shape so as to accommodate at least a part of a wind turbine blade to be protected, each of the first and second protective covers has a tip end and a root end, wherein the first protective cover includes a first overlap portion at the root end, and the second protective cover includes a second overlap portion at the tip end, wherein the shape of the first overlap portion is substantially complementary to the shape of the second overlap portion such that when overlapping the first and second overlap portions, the resulting cross section of the overlapped overlap portions substantially corresponds to the cross sections of the first or second protective covers outside the overlap portions.

Claims

1. Protective cover system (10) for protecting a leading edge (59) of a wind turbine rotor blade (55) from erosion, the system (10) comprising a first protective cover (1) and a second protective cover (2), both comprise a polymer and being pre-formed into a curved shape so as to accommodate at least a part of a wind turbine rotor blade (55) to be protected, each of the first and second protective covers (1, 2) has a tip end (3) and a root end (4), wherein the first protective cover (1) comprises a first overlap portion (4a) at the root end (4), and the second protective cover (2) comprises a second overlap portion (3a) at the tip end (3), wherein the shape of the first overlap portion (4a) is substantially complementary to the shape of the second overlap portion (3a) such that when overlapping the first and second overlap portions (4a, 3a), the resulting cross section of the overlapped overlap portions (4a, 3a) substantially corresponds to the cross sections of at least one of the first and second protective covers (1, 2) outside the overlap portions (4a, 3a).

2. The protective cover system (10) according to claim 1, wherein the first overlap portion (4a) tapers at least partly towards the root end (4) of the first protective cover (1), and the second overlap portion (2) tapers at least partly towards the tip end (3) of the second protective cover (2).

3. The protective cover system (10) according to claim 1 or claim 2, wherein each of the first overlap portion (1) and the second overlap portion (2) comprises at least one step (5).

4. The protective cover system according to claim 3, wherein the step (5) is at least partly rounded.

5. The protective cover system (10) according to one of claims 1-4, wherein one of the first and second protective covers (1, 2) comprises a protruding element (6) in the respective first or second overlap portion (4a, 3a), and wherein the other one of the first and second protective covers (1, 2) comprises a recess (7) in the other respective first or second overlap portion (4a, 3a), wherein the recess (7) is arranged to accommodate the protruding element (6).

6. The protective cover system (10) according to claim 5, wherein the recess (7) is a hole and the protruding element (6) is nipple-shaped.

7. The protective cover system (10) according to one of the preceding claims, wherein at least one of the protective covers (1, 2) comprise an elastomer, e.g. comprising Polyurethane, Polyethylene, polyaspartic (proposed by Covestro) (?).

8. The protective cover system (10) according to one of the preceding claims, wherein each of the first and second protective covers (1, 2) comprises four corners (8), wherein at least one of these corners (8) is rounded.

9. The protective cover system according to one of the preceding claims, wherein the first and second protective covers (1, 2) are pre-formed into a curved shape in a lateral direction and extend from their tip end (3) to their root end (4) in a longitudinal direction, wherein at least one of the first and second protective covers (1, 2) has a centerline (C) running in the longitudinal direction, the at least one of the first and second protective covers (1, 2) further comprises an outer edge (9), the outer edge (9) running in parallel to and being shorter than the respective centerline (C).

10. The protective cover system (10) according to one of the preceding claims, wherein the first and second protective covers (1, 2) are pre-formed into a curved shape in a lateral direction and extend from their tip end 3) to their root end (4) in a longitudinal direction, wherein each of the first and second protective covers (1, 2) has a centerline (C) running in the longitudinal direction, and a first outer edge (9a) and a second outer edge (9b), both running in parallel to the centerline (C), wherein the first and second protective covers (1, 2) have a thickness along their centerline (C), wherein the thickness tapers off towards the respective first and second outer edges (9a, 9b).

11. The protective cover system (10) according to one of the preceding claims, wherein the first and second protective covers (1, 2) are pre-formed into a curved shape in a lateral direction and extend from their tip end (3) to their root end (4) in a longitudinal direction, wherein at least one of the first and second protective covers (1, 2) is curved in the longitudinal direction and/or tapers in the longitudinal direction, preferably towards its tip end (3). Advantage: avoid shell wrinkle tapering: avoiding peel-off, continuous transition between shells

12. The protective cover system (10) according to one of the preceding claims, wherein a length of at least one of the first and second protective cover (1, 2) amounts to about 2000 mm at maximum, preferably to about 1000 mm.

13. The protective cover system (1, 2) according to one of the preceding claims, wherein at least one of the first and second protective cover (1, 2) comprises a printed centerline (C) on its outer surface (11) to facilitate the mounting onto a leading edge (59) of a wind turbine blade (55).

14. Wind turbine blade (55) comprising a protective cover system (10) according to one of the preceding claims, wherein the protective cover system (10) is connected to the wind turbine blade (55) along a leading edge (59) of the blade (55).

15. Method for mounting a protective cover system (10) according to one of claims 1-13 to a leading edge (59) of a wind turbine blade (55), the method comprises the steps of: Providing a wind turbine blade (55), the protective cover system (10) according to one of claims 1-13 and an adhesive; Applying the adhesive on the wind turbine blade (55) and/or on an inner surface (12) of the first and the second protective covers (1, 2); Placing the first and the second protective covers (1, 2) onto the wind turbine blade (55), wherein the first and the second overlap portions (4a, 3a) of the protective covers (1, 2) are arranged such that the first and the second overlap portions (3a, 4a) overlap; Optionally, applying further adhesive between the first and the second overlap portions (4a, 3a); and Allowing the adhesive to firmly connect the first and the second protective covers (1, 2) to the wind turbine blade (55).

16. The protective cover system (10) according to claim 1 further comprising a first set of protective covers, each of the protective covers of the first set of protective covers corresponds to a true copy of said first protective cover (1), a second set of protective covers, each of the protective covers of the second set of protective covers corresponds to a true copy of said second protective cover (2), a protective tip cover (?), and a protective root cover (??).

17. The protective cover system according to claim 16, wherein the LE radius of the first protective cover (1) is different from the LE radius of the second protective cover (2).

18. The protective cover system according to claim 16 or 17, wherein the first protective cover (1) has a chord length between 0.5 (2 m from tip/1 m-3 m) and 1.3 (12 m from tip/pref. 9-24 m/more pref. 10-14 m) meters and the second protective cover (2) has a chord length of about 1.3 meters or more.

19. The protective cover system according to claim 16 or 17, wherein the first protective cover (1) has a chord length between 0.5 and 1.3 meters and the second protective cover (2) has a chord length of about 1.3 meters or more.

20. The protective cover system according to anyone of claims 16 to 19, wherein the protective tip cover (?) has a swept end to cover and fit the blade tip.

21. The protective cover system according to anyone of claims 16 to 20, wherein the protective root cover (??) features a smooth transition towards the leading edge on the root side.

Description

[0079] FIG. 1 shows a wind turbine (prior art)

[0080] FIG. 2 shows a plan view of a wind turbine blade (prior art)

[0081] FIG. 3 shows the profile of a wind turbine blade together with the protective cover system according to the invention

[0082] FIG. 4 shows a cross-sectional view of a protective cover according to the invention

[0083] FIG. 5 to 22 showing further embodiments of the invention.

[0084] FIG. 23 shows how flexible the protective covers 1 and 2 may be

[0085] A “wind turbine rotor blade” may also be referred to as “wind turbine blade”. A “protective cover” for protecting a leading edge of a wind turbine blade from erosion may also be referred to as “shell” or “shield”.

[0086] The “protective cover” according to the present invention is preformed. The protective cover is brought into a curved shape before being mounted. It may be machined. Preferably, it is pre-casted. The term “preformed” may also be referred to as pre-shaped. According to the present invention, the “protective cover” is pre-shaped into a curved shape so as to accommodate at least a part of a wind turbine blade (55). The “curved shape” referred to in claim 1 may also be described as a channel-like shape or as a substantially parabolic channel.

[0087] It is known in the art to cast a male part on the blade by use of a male mould. The resulting bond may be of superior quality. In contrast to this concept, a female mould may be used in addition to the male mould to pre-cast the first and second protective covers (1, 2) instead of casting over the blade (55) with one or more protective covers (1, 2).

[0088] Covers of an Elastomeric Polyurethane are preferred. This may be a rubbery, elastic and flexible material to allow the protective shell to be easily form-fitted to a wind turbine blade surface and to provide it with sufficient elasticity so as to dampen the impact of erosive influences.

[0089] The protective cover may be flexible. In other words, it may have some flexibility. That means the protective cover may be flexible in such a way that it is less flexible than a tape but more flexible than a stiff component. The advantage of a preformed but flexible protective cover is on the one hand a curved shape which facilitates handling of the cover and provides for a good fit to a curved surface, and on the other hand the fact that the protective cover may easily adapt to a range of differently curved surfaces, e.g. at different locations along a leading edge of a wind turbine blade. In other words, a preformed and flexible protective cover, e.g. made of a Polyurethane based Elastomer, may adapt to different curved surfaces having a range of different bending rates (angle) in a predetermined range of bending rates.

[0090] In order to keep the protective covers (1, 2) on the blade 55 even after being struck by a relatively large foreign object, such as a bird or an ice fragment, without a protective cover (1, 2) peeling off, the protective cover system (10) is bonded to the blade (55), e.g. by means of a heat-activatable adhesive. In so doing, the adhesive may be heated, e.g. by a heating blanket or a vacuum heating blanket.

[0091] FIG. 1 shows a typical wind turbine (51) comprising a tower (52), a nacelle (53), a generator (56), and blades (55). The blades (55) are attached to a hub (54). They capture the energy of the wind, spinning a generator (56) in the nacelle (53). The tower (52) comprises the electrical conduits, supports the nacelle (53), and provides access to the nacelle (53) for maintenance.

[0092] FIG. 2 shows a plan view of a wind turbine rotor blade (55) comprising a tip (57) and a root (58), a leading edge (59) and a trailing edge (60). The rotor blade (55) further comprises a shoulder (61) near the blade root (58) and an airfoil portion (62).

[0093] FIG. 3 shows the profile of a wind turbine rotor blade (55) including a leading edge (59), a trailing edge (60) as well as the suction and the pressure sides (65, 64) between the leading and the trailing edges (59, 60). The profile shown in FIG. 3 further comprises a protective cover system (10) according to the present invention which is positioned along the leading edge (59) of the rotor blade (55).

[0094] FIG. 4 The protective cover system (10) for protecting a leading edge (59) of a wind turbine blade (55) from erosion comprises a first protective cover (1) and a second protective cover (2). The first and the second protective covers (1, 2) comprise a polymer material. The covers (1, 2) are pre-formed into a curved shape so as to accommodate at least a part of a wind turbine blade (55), especially along the leading edge (59) of the blade (55).

[0095] FIG. 5 Each of the first and second protective covers (1, 2) has a tip end (3) and a root end (4). The first protective cover (1) comprises a first overlap portion (4a) at the root end (4) and the second protective cover (2) comprises a second overlap portion (3a) at the tip end (3a). The shape of the first overlap portion (4a) at the root end (4) of the first protective cover (1) is substantially complementary to the shape of the second overlap portion (3a) at the tip end (3) of the second protective cover (2) such that when overlapping these first and second overlap portions (4a, 3a), the resulting cross section of the overlapped overlap portions (4a, 3a) substantially correspond to the cross sections of at least one of the first and second protective covers outside the overlap portions.

[0096] The wind turbine blade comprises a protective cover system according to the invention, wherein the protective cover system is connected to the wind turbine blade along a leading edge of this blade.

[0097] The method for mounting a protective system to a leading edge 59 of a wind turbine rotor blade 55 from erosion,

[0098] the method comprises the steps of: [0099] Providing a wind turbine blade, a first and a second protective covers according to the invention, and an adhesive; [0100] Applying the adhesive on the wind turbine blade and/or on an inner surface of the first and second protective covers; [0101] Placing the first protective cover onto the wind turbine blade; [0102] Placing the second protective cover onto the wind turbine blade, wherein the step of placing the second protective cover onto the wind turbine blade involves arranging the first and second overlap portions such that these first and second overlap portions overlap; [0103] Optionally, applying further adhesive between the first overlap portion and the second overlap portion; and [0104] Allowing the adhesive to firmly connect the first and second protective covers to the wind turbine blade.

[0105] The invention is directed towards having a plastic shell 1, 2 that is bonded to the outer surface of the blade 55, more specific of the leading edge 59. The shell 1, 2 is referred herein to as protective cover 3. It may have a width W of +/−100 mm with respect to the leading edge 59 of the wind turbine blade 55, see FIG. 3.

[0106] The shell may be made of a polymer comprising polyurethane and a further component. The shell is a curved protective plate in the shape of a parabolic channel. It is designed to be mounted lengthwise along the leading edge of a wind turbine blade. The shell is moulded in a moulding process. The shell is pre-moulded but still pliable enough to provide a tight fit to the turbine blade.

[0107] The shell system comprises a first shell and a second shell. Each shell has two short edges, herein also referred to as tip end and root end (3, 4) and two long edges, herein also referred to as outer edges. The long edges are longer than the short edges. The first short edge 4 is located at one end of the parabolic channel, and the second short edge 3 is located at the opposite end of the parabolic channel. The two long edges 9 are perpendicular to the two short edges 3, 4.

[0108] The shell has a centerline C running lengthwise along the substantially parabolic channel in parallel to the long edges 9. The thickness Tn of the shell is greatest along the centerline C and gradually diminishes toward the two long edges 9. The thickness Tn may be 3 mm at the centerline C, see FIG. 4

[0109] Overlap section: A shell system comprises at least two of above-mentioned shells 1, 2 touching one another at their short edges 3, 4. The shells may be connected to each other or interconnected by various means, e.g. by edge chamfer and guiding nipple 6, see FIG. 5.

[0110] The overlap portions 3a, 4amay have a length Lo of 30 mm in longitudinal direction of the protective cover 1, 2. The protrusion 6 may have a diameter Dp of 2 mm and the recess 7 may also have diameter Dr of 2 mm. The length Lp of the protrusion may be 3 mm, see FIG. 7.

[0111] The shells may be interconnected by means of connecting elements 5, 20, 21 that serve for a guiding/connecting of the two shells 1, 2. Mechanical Interlocking between the shells 1, 2 is achieved by having connecting elements 5, 20, 21 that have a nipple shape. This shape reduces stress concentration for the connecting element 5, 20, 21.

[0112] Transition consideration: Camfered interna—no exposure for the blade. Stepwise decline transition—provide thickness and strength which prolong the lifetime.

[0113] Different decline transitions at different positions of the leading edge are possible, e.g. step-like connecting elements 5 at the leading edge (that means at the Centerline C) of the shell 1, 2), step-like connecting elements 20 having rounded edges onto a width of the shell of +/−50 mm from the Leading edge (Centerline C) and tapered connecting elements 21 from +/−50 mm on to a width of +/−100 m (that means until the outer edges 9, 9a, 9b), see FIG. 5 and FIG. 6.

[0114] The blade chord length is decisive of the aerodynamic property—therefore it needs to be as thin as possible. The thickness Tne at an end 4 of the shell may be around 0.05 mm. Corner rounding of corner 8 with a radius R5 help avoiding peeling off of the shell, see FIG. 7a

[0115] At an end 3, 4 in lengthwise direction of the shell, the overlap area 3a, 4amay have a length of 20-40 mm, preferably 30 mm. The thickness of the shell may diminish in the overlap area to a very small thickness in the range of 0.03 mm to 0.07 mm, preferably to about 0.05 mm.

[0116] The shell may have a peel height Hp, referred to in Danish language as Peelhejde (in English language Sagitta height). That means the shell 1, 2 may be curved with a radius R2, that means the centerline C is curved. see FIG. 8.

[0117] It is from other technology to extrude plastic elements. This invention is directed towards overcoming the disadvantage of having an extrude element.

[0118] Having a sagitta height Hp enables the shells to be drapable. The height difference between an outer end of the shell and a position at the centerline in the middle of the shell may be 3 to 7 mm, preferably about 5 mm.

[0119] The sagitta height Hp is achieved during the manufacturing of the shell. Each of the shells will be moulded as one piece. Another advantage of casting the shells is that each shell can be tailored.

[0120] The protective cover system 10 comprising a first and a second protective cover 1, 2 (first and second shell) may have an open angle at the Overlap OV. That means the angle between centerline C and root or tip end 3, 4 is smaller than 90 degrees and the angle between outer edge 9 and root or tip end 3, 4 is greater than 90 degrees. At the outer edge 9 the distance Dd may be 3 mm, see FIG. 9.

[0121] Each overlap influences the aerodynamic performance of the blade. It is import to avoid excess overlap and thereby material. Therefore the overlap is less than 30 mm.

[0122] Bondline Features: Indentation, e.g with 20 mm spacing inbetween the indentations, on the inner surface ensure a better bonding due to the fact that the indentation entrap glue, see FIG. 10

[0123] A tailored tip as shown in FIG. 11 may have a length Lt in the range of around 530 mm to 630 mm, a width Wt1 of around 50 mm at the tip end 3 of the shell 1 and a width Wt1 of around 100 mm at the root end 4 of the shell 1. In addition, at the tip end 3 of the shell 1 Wt1 may be slightly greater such that a Radius R30 is generated at the outer edge of the shell. So, the tip of the blade is very good enclosed and thus protected from erosion, see FIG. 11 showing a tip shell (soft tip shell)

[0124] Enclosing the tip of the blade is an option, as also shown in FIG. 12. Better transition of the tip. One unique shell could be used for the tip end.

[0125] As an alternative, the tip shell 1, may be designed to leave the tip of the blade 30 blank, that means not covered, see FIG. 12.

[0126] Advantages [0127] Compared to coating and tape solutions this invention offers a method that can be done in one working step [0128] Having a peel height enables the shells to be drapable. The peel height is achieved during the manufacturing of the shell. Each shell will be moulded as one piece. [0129] Another advantage of casting the shells is that each shell can be tailored [0130] Cost and repair reduced

[0131] Further Aspects of Invention

[0132] The length of at least one of the first and second protective cover (1, 2) may amount to about 2000 mm at maximum, preferably to about 1000 mm.

[0133] Advantage: good length blade, in view of operational window (1.7 m). w/o repositioning worker himself

[0134] Method for mounting a protective cover system (10) according to one of claims 1-4 to a leading edge (59) of a wind turbine blade (55),

[0135] the method comprises the steps of: [0136] Providing a wind turbine blade (55), the protective cover system (10) according to one of claims 1-13 and an adhesive; [0137] Applying the adhesive on the wind turbine blade (55) and/or on an inner surface (12) of the first and the second protective covers (1, 2); [0138] Placing the first and the second protective covers (1, 2) onto the wind turbine blade (55), wherein the first and the second overlap portions (4a, 3a) of the protective covers (1, 2) are arranged such that the first and the second overlap portions (3a, 4a) overlap; [0139] Optionally, applying further adhesive between the first and the second overlap portions (4a, 3a); and [0140] Allowing the adhesive to firmly connect the first and the second protective covers (1, 2) to the wind turbine blade (55).

[0141] The protective cover system (10) according to claim 1 further comprising [0142] a first set of protective covers, each of the protective covers of the first set of protective covers corresponds to a true copy of said first protective cover (1), [0143] a second set of protective covers, each of the protective covers of the second set of protective covers corresponds to a true copy of said second protective cover (2), [0144] a protective tip cover, and [0145] a protective root cover.

[0146] Possible for some blades—first set true copy of second set!—Depending on shape and/or shorter length;

[0147] depending on repair length

[0148] The protective cover system according to claim 6, wherein the LE radius of the first protective cover (1) is different from the LE radius of the second protective cover (2).

[0149] bending rate->LE radius

[0150] more open curvature vs., more closed curvature

[0151] only 4 diff cover types->

[0152] The protective cover system according to claim 6 or 7, wherein the first protective cover (1) has a chord length between 0.5 (2 m from tip/1 m-3 m) and 1.3 (12 m from tip/pref. 9-24 m/more pref. 10-14 m) meters and the second protective cover (2) has a chord length of about 1.3 meters or more.

[0153] Outer ⅓ (−½ to) of the length of LE −50%/50% for diff sets of shells

[0154] The protective cover system according to claim 6 or 7, wherein the first protective cover (1) has a chord length between 0.5 and 1.3 meters and the second protective cover (2) has a chord length of about 1.3 meters or more.

[0155] The protective cover system according to anyone of claims 6 to 8, wherein the protective tip cover has a swept end to cover and fit the blade tip.

[0156] Pre-bend—more curved than other shells

[0157] not exact copy of blade tip but more curved—so it is stretched when mounted to the blade

[0158] Valid for all shells, but more exaggerated for tip shell

[0159] Tip covered or not covered/

[0160] open tip—easier fit to all variations of blade tips, but less erosion protection performance than closed one

[0161] close tip—better protection, but requires little variance in blade tips therefore more shell variants are needed

[0162] The protective cover system according to anyone of claims 6 to 9, wherein the protective root cover features a smooth transition towards the leading edge on the root side. [0163] root end w/o overlap portion, w/o pin hole

[0164] smooth transition towards the leading edge on the root side

[0165] Option: No root shell

[0166] Advantages

[0167] for claim 6

[0168] Compared to a rigid protection shell that can be only mounted on a predefined part of the leading-edge surface, the material of which the protective covers according to the present invention are built has a certain flexibility which allows their mounting along a much greater surface area along the leading-edge. As a result, the total number of individually designed protective covers can be reduced to a strict minimum. The resulting economic advantages with respect to production costs and logistic are quite obvious and important. Since in many cases, the surface shape along the leading-edge of a wind turbine blade changes only smoothly, it's even possible to use just two different sets of protective covers, plus a protective tip cover and a protective root cover. It is even possible to do with just two one set of protective covers, plus a protective tip cover.

[0169] for claim 7:

[0170] As stated before, the surface shape, and more precisely the leading edge radius, along the leading-edge of a wind turbine blade changes only smoothly. Therefore, the same manufacturing process can be used to build the protective covers of the different sets. Same 3D-mould may be used for multiple blades types. This is be advantageously used to reduce furthermore the associated production costs.