METHOD FOR PRODUCING A SPLIT ROTOR BLADE, AND ROTOR BLADE

Abstract

A method for producing a split rotor blade, a method for connecting a split rotor blade, a rotor blade, a rotor blade segment, a rotor, a wind power plant, and a production device for producing rotor blades. A method for producing a split rotor blade, comprising: providing a rotor blade having a spar cap and an extension in the longitudinal direction from a blade root region to a blade tip; making at least one groove in the spar cap, the groove being arranged in a first connection region of the rotor blade, and a portion of the main extension direction of the groove being oriented parallel to the longitudinal direction; splitting the rotor blade, in the first connection region, into a rotor blade section facing the blade root and a rotor blade section facing away from the blade root, a first groove section being arranged in the rotor blade section facing the blade root and a second groove section being arranged in the rotor blade section facing away from the blade root.

Claims

1. A method for producing a split rotor blade, comprising providing a rotor blade having: a spar cap, and an extent in the longitudinal direction from a blade root region a blade tip, forming at least one groove in the spar cap, wherein the at least one groove is arranged in a first connection region of the rotor blade, and splitting the rotor blade, in the first connection region, into a rotor blade section facing the blade root and a rotor blade section (facing away from the blade root, wherein a first groove section is arranged in the rotor blade section facing the blade root and a second groove section is arranged in the rotor blade section facing away from the blade root.

2. The method as claimed in claim 1, wherein the rotor blade has an outer shell, wherein the at least one groove is in the outer shell and in the spar cap starting from the outer shell.

3. The method as claimed in claim 1, wherein splitting the spar cap takes place along at least one splitting plane, wherein the at least one splitting plane: extends substantially orthogonally to the longitudinal direction of the rotor blade, and is aligned at a slope to the longitudinal direction of the rotor blade.

4. The method as claimed in claim 1, wherein the at least one groove has a groove width orthogonally to the main direction of extent and orthogonally to a groove depth, wherein a groove opening has a greater extent in a direction of the groove width than a groove bottom.

5. The method as claimed in claim 1, wherein the at least one groove has a cross section in a plane orthogonal to a main direction of extent which is one of: T shaped, rectangular, triangular, or trapezoidal.

6. The method as claimed in claim 1, wherein at least one of: a leading edge section or a trailing edge section is partitioned off in the first connection region, wherein the leading edge section includes a section of the first connection region extending from the spar cap to the leading edge of the rotor blade, and wherein the trailing edge section includes a section of the first connection region extending from the spar cap to the trailing edge of the rotor blade.

7. The method as claimed in claim 3, wherein: a first front splitting point of the leading edge section lies outside the at least one splitting plane and/or at an end of the first connection region facing the blade root, a second front splitting point of the leading edge section lies outside the at least one splitting plane and/or at an end of the first connection region facing away from the blade root, a first rear splitting point of the trailing edge section lies outside the at least one splitting plane and/or at an end of the first connection region facing the blade root, and a second rear splitting point of the trailing edge section lies outside the at least one splitting plane and/or at an end of the first connection region facing away from the blade root.

8. The method as claimed in claim 1, comprising: forming a second groove in the spar cap, wherein: the second groove is arranged in a second connection region of the rotor blade, and the second connection region is spaced apart from the first connection region in the direction of the blade tip in the longitudinal direction of the rotor blade, and splitting of the rotor blade in the second connection region into a central rotor blade section and a rotor blade section facing the blade tip, wherein a third groove section of the second groove is arranged in the central rotor blade section, and a fourth groove section of the second groove is arranged in the rotor blade section facing the blade tip.

9. A method for connecting a split rotor blade, comprising providing a split rotor blade produced by the method as claimed in at claim 1, and adhesively bonding a connection piece to the first groove section and to the second groove section.

10. The method as claimed in claim 9, wherein a shape of the connection piece corresponds to a shape of the groove.

11. The method as claimed in claim 9, wherein a cross section of the connection piece corresponds to a cross section of the groove.

12. The method as claimed in claim 9, comprising: producing a connection at a splitting point of a web, and/or producing a connection at a first splitting point and/or at a second splitting point of a leading edge section, and/or producing a connection at a third splitting point and/or at a fourth splitting point of a trailing edge section.

13. A rotor blade, comprising a first rotor blade section facing the blade root, a second rotor blade section facing away from the blade root, wherein the first and second rotor blade sections are arranged abutting each other in a first connection region, a spar cap having a groove in the first connection region, wherein a first groove section is arranged in the first rotor blade section, and a second groove section is arranged in the second rotor blade section, and a connection piece bonded to the first groove section and to the second groove section.

14. A rotor blade segment comprising: a connection subregion for connection to another rotor blade segment having a corresponding connection subregion, and a spar cap, wherein the connection subregion has a groove section in the spar cap for the arrangement of a connection piece.

15. A rotor for a wind power installation, comprising: a the rotor blade as claimed in claim 13.

16. A wind power installation, comprising: a nacelle; and a rotor coupled to the nacelle, wherein the rotor is the rotor as claimed in claim 15.

17. A production system for producing rotor blades from a rotor blade section or segment facing the blade root and a rotor blade section or segment facing away from the blade root, comprising a first container and a second container, wherein at least one of the first and second containers comprises a device for aligning the rotor blade sections or segments, wherein the first and second containers are arranged and designed in such a way that the rotor blade section or segment facing the blade root and the rotor blade section or segment facing away from the blade root is configured to be connected for connection as claimed in claim 9.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0052] Preferred embodiments of the invention are explained by way of example with reference to the accompanying figures, of which:

[0053] FIG. 1 shows a schematic view of an illustrative embodiment of a wind power installation;

[0054] FIG. 2 shows a schematic plan view of an illustrative embodiment of a rotor blade;

[0055] FIG. 3 shows a schematic detail view of the connection region of the rotor blade shown in FIG. 2;

[0056] FIG. 4 shows a schematic cross-sectional view of the rotor blade shown in FIG. 2;

[0057] FIG. 5 shows a schematic three-dimensional view of an illustrative embodiment of a connection piece;

[0058] FIG. 6 shows a schematic view of a split web of a rotor blade shown in FIG. 2;

[0059] FIG. 7 shows another schematic view of the split web of the rotor blade shown in FIG. 2;

[0060] FIG. 8 shows another schematic cross-sectional view of the rotor blade shown in FIG. 2;

[0061] FIG. 9 shows a schematic detail view of an alternative connection region of the rotor blade shown in FIG. 2;

[0062] FIG. 10 shows a schematic detail view of another alternative connection region of the rotor blade shown in FIG. 2.

DETAILED DESCRIPTION

[0063] In the figures, elements that are identical or substantially functionally identical or functionally similar are denoted by the same reference signs.

[0064] FIG. 1 shows a schematic three-dimensional view of an illustrative embodiment of a wind power installation. In particular, FIG. 1 shows a wind power installation 100 having a tower 102 and a nacelle 104. A rotor 106 having three rotor blades 108 and a spinner 110 is arranged on the nacelle 104. In operation, the rotor 106 is set in rotation by the wind, and thereby drives a generator on the nacelle 104. The rotor blades 108 are produced by the method for producing a split rotor blade and the method for connecting a split rotor blade, and therefore the rotor blades 108 have a rotor blade section facing the blade root and a rotor blade section facing away from the blade root.

[0065] FIG. 2 shows a schematic plan view of an illustrative embodiment of a rotor blade. The rotor blade 200 extends in the longitudinal direction L from a blade root region 202 to a blade tip 204. A spar cap 230 furthermore extends from the blade root region 202 substantially as far as the blade tip 204. The rotor blade has a sheet-like extent, which is formed by an extent in the longitudinal direction L and in the direction of the width B. The rotor blade 200 has a leading edge 206 and a trailing edge 208, which are aligned substantially parallel to the longitudinal direction L. In the present case, this is a rotor blade to be split, wherein grooves 400 have already been made in the spar cap, but the rotor blade has not yet been split along the splitting plane 302.

[0066] Between the blade root region 202 and the blade tip 204, the rotor blade 200 has a first connection region 300. The first connection region 300 is, in particular, the section of the rotor blade 200 in which the splitting plane 302, the grooves 400, as well as the leading edge section 310 and the trailing edge section 320 are arranged. Splitting the rotor blade 200 along the splitting plane 302 gives rise to a rotor blade section 210 facing the blade root and a rotor blade section 220 facing away from the blade root.

[0067] The first connection region 300 of the rotor blade 200, which is illustrated in more detail in FIG. 3, comprises the grooves 400. In the present case, the grooves 400 have a main direction of extent which is aligned parallel to the longitudinal direction L of the rotor blade. Once the rotor blade has been split at the splitting plane 302, the first connection region 300 is split into a connection region section 300a facing the blade root and a connection region section 300b facing away from the blade root. Owing to the split, the connection region section 300a facing the blade root is arranged on the rotor blade section 210 facing the blade root. Owing to the split, the connection region section 300b facing away from the blade root is arranged on the rotor blade section 220 facing away from the blade root.

[0068] By virtue of the split along the splitting plane 302, the grooves 400 have furthermore been split into first groove sections 400a and into second groove sections 400b. The first groove sections 400a are arranged on the rotor blade section 210 facing the blade root, and the second groove sections 400b are arranged on the rotor blade section 220 facing away from the blade root. Owing to the splitting of the rotor blade 200, the spar cap 230 is also split into a spar cap section 230a facing the blade root and a spar cap section 230b facing away from the blade root. This splitting of the spar cap 230 causes weakening of the strength of the rotor blade 200 in the longitudinal direction L. For this purpose, the grooves 400 or the first groove sections 400a and the second groove sections 400b are provided. The rotor blade section 210 facing the blade root and the rotor blade section 220 facing away from the blade root can be connected firmly to one another by inserting connection pieces of the kind described below into the groove sections 400a, 400b. The connection pieces are preferably adhesively bonded into the groove sections 400a, 400b, with the result that force flows from the rotor blade section 220 facing away from the blade root via the connection pieces to the rotor blade section 210 facing the blade root.

[0069] The view shown in FIG. 4 has a direction of view aligned parallel to the longitudinal direction L of the rotor blade. The rotor blade 200 has a suction-side spar cap 230 and a pressure-side spar cap 231. The two spar caps 230, 231 are connected to one another by means of a front web 250, which faces the leading edge 206, and of a rear web 260, which faces away from the leading edge 206. The rotor blade 200 is substantially encased by an outer shell 201. The spar caps 230, 231 are arranged on the inner sides of the outer shell 201. Grooves 402 facing the suction side are arranged in the suction-side spar cap 230. Grooves 404 facing the pressure side are arranged in the pressure-side spar cap 231. In this illustrative embodiment, the grooves 402, 404 have a T-shaped cross section. This is shown by way of example by means of the first groove 410 since said groove has a groove opening 412 that has a greater extent than a groove bottom 414.

[0070] The leading edge section 310 is arranged between the leading edge 206 and the spar caps 230, 231 in the first connection region. It is possible, for example, for the leading edge section 310 to be removed before the complete splitting of the rotor blade 200 in the region of the splitting plane 302. The section of the first connection region 300 between the trailing edge 208 and the spar caps 230, 231 is formed by the trailing edge section 320, which can likewise be removed before the rotor blade 200 is split at the splitting plane 302. In this case, the leading edge section 310 and/or the trailing edge section 320 are/is not split along the splitting plane 302.

[0071] FIG. 5 shows a schematic three-dimensional view of an illustrative embodiment of a connection piece. The connection piece 500 extends from a first end 502 to a second end 504. The connection piece 500 has a T-shaped cross section. The T-shaped cross section is formed by the fact that the connection piece 500 has a sheet-like holding section 506 and a sheet-like insertion section 508 arranged orthogonally to the surface thereof. The insertion section 508 is arranged centrally on a sheet-like extent of the holding section 506, thus giving rise to the T-shaped cross section.

[0072] The connection piece 500 furthermore has a plurality of connection piece openings 510 in the holding section 506. In particular, the connection piece openings 510 are arranged and designed in such a way that they can be used with a fastening element for fixing and/or for ventilation. In particular, the connection piece openings 510 can be designed in such a way that self-tapping screws can be arranged therein, wherein fixing of the connection piece 500 in the groove is made possible by means of the screws. Moreover, the connection piece 500 has three spacer elements 516, by means of which a defined spacing can be ensured between the connection piece 500 and a groove, in particular a groove bottom. Four or more spacer elements 516 can furthermore be installed.

[0073] A first cut-off surface 512 and a second cut-off surface 514 are illustrated with hatching. The connection piece can be produced without the first cut-off surface 512 and/or without the second cut-off surface 514, for example. The connection piece 500 thus has a partially circular geometry in the section which faces the groove bottom. This makes it possible, for example, to insert the connection piece into a groove that has been produced by means of a circular saw blade.

[0074] FIGS. 6 and 7 show the connection of a split web 250, wherein a web connection piece 254 is used to connect the web section 251 facing the blade root to the web section 252 facing away from the blade root. This is also accomplished by means of adhesive bonding on a first connection surface 256 and a second connection surface 258, for example. FIG. 8 shows another schematic cross-sectional view, which shows the spar caps 230, 231 in greatly simplified form, without the grooves being visible. The web connection pieces 254, 264 are furthermore embodied in a C profile which has an extent in the direction of the thickness D between the spar caps 230, 231 and furthermore has extensions substantially in the direction of the width B. The web connection pieces 254, 264 are designed in such a way that an extension rests against the pressure-side spar cap 231 and another extension rests against the suction-side spar cap 231.

[0075] Alternative designs of the splitting plane 302 are illustrated in FIGS. 9 and 10. The splitting cut shown in FIG. 9 has a V-shaped geometry. In particular, the splitting cut has a first splitting plane 302a and a second splitting plane 302b, wherein the selected angle enclosed by the splitting planes 302a, 302b can be any angle between less than 360 degrees of arc, in particular less than 180 degrees of arc, and greater than 0 degrees of arc. The production of such splitting planes 302a, 302b can also be referred to as an arrow-shaped sawcut. The splitting plane 302 shown in FIG. 10 has a wavy or undulating splitting plane. Moreover, it is also possible for the splitting plane to have a crenellated or sawtooth profile. These splitting planes 302a, 302b, 302 of alternative design can improve the strength in the connection region 300, 300. In particular, a positive-locking connection of the rotor blade sections can be formed in respect of torsion.

[0076] Splitting into a spar cap section 230a facing the blade root and a spar cap section 230b facing away from the blade root, which is illustrated in FIGS. 9 and 10, is also possible in variants in which the splitting planes are arranged as a mirror image. This would correspond to schematic illustrations in which the spar cap sections facing the blade root and those facing away from the blade root are interchanged.

[0077] Through the production of a split rotor blade 200 having a first connection region 300, 300, 300, wherein grooves 400 are arranged in the region of a spar cap 230 and the rotor blade 200 is split along the splitting plane 302, 302, 302 in the first connection region 300, 300, 300, it is possible to provide a rotor blade 200 that can be transported in an advantageous manner. Through the connection of the rotor blade section 210 facing the blade root and of the rotor blade section 220 facing away from the blade root, e.g., at an erection side of a wind power installation 100, by means of connection pieces 500 inserted into the grooves 400, it is possible to provide a particularly weight-saving or neutral-weight connection of a split rotor blade 200. By means of the special arrangement of the grooves 400 in the first connection region 300, 300, 300 or in the spar cap 230 and the adhesive bonding of at least one connection piece 500, preferably a multiplicity of connection pieces, into the grooves 400, a connection that ensures strength can be achieved.

[0078] By virtue of the connection of two rotor blade sections, the weight of a rotor blade that is split in two can be kept so low that the weight thereof is comparable to the weight of a one-piece rotor blade. This type of splitting does not have a load-increasing effect on the rotor blade and the other components of the wind power installations due to a higher weight. Moreover, the connection is substantially maintenance-free.

REFERENCE SIGNS

[0079] 100 wind power installation

[0080] 102 tower

[0081] 104 nacelle

[0082] 106 rotor

[0083] 108, 200 rotor blade

[0084] 110 spinner

[0085] 201 outer sleeve

[0086] 202 blade root region

[0087] 204 blade tip

[0088] 206 leading edge

[0089] 208 trailing edge

[0090] 210 rotor blade section facing the blade root

[0091] 220 rotor blade section facing away from the blade root

[0092] 230 suction-side spar cap

[0093] 230a spar cap section facing the blade root

[0094] 230b spar cap section facing away from the blade root

[0095] 231 pressure-side spar cap

[0096] 250 front web

[0097] 251 web section facing the blade root

[0098] 252 web section facing away from the blade root

[0099] 254, 264 web connection piece

[0100] 256 first connection surface

[0101] 258 second connection surface

[0102] 260 rear web

[0103] 300, 300, 300 first connection region

[0104] 300a connection region section facing the blade root

[0105] 300b connection region section facing away from the blade root

[0106] 302, 302a, 302b, 302 splitting plane

[0107] 310 leading edge section

[0108] 320 trailing edge section

[0109] 400 grooves

[0110] 400a first groove sections

[0111] 400b second groove sections

[0112] 402 grooves facing the suction side

[0113] 404 grooves facing the pressure side

[0114] 410 first groove

[0115] 412 groove opening

[0116] 414 groove bottom

[0117] 500 connection piece

[0118] 502 first end

[0119] 504 second end

[0120] 506 holding section

[0121] 508 insertion section

[0122] 510 connection piece opening

[0123] 512 first cut-off surface

[0124] 514 second cut-off surface

[0125] 516 spacer element

[0126] B width

[0127] D thickness

[0128] L length