MOULDING STATION FOR SHEAR WEB PRODUCTION AND A MANUFACTURING METHOD THEREOF

Abstract

This invention relates to a moulding station and a method using such moulding station, wherein the moulding station comprises a first web mould and a second web mould arranged on different levels. The first web mould is configured for manufacturing a first shear web and the second web mould is configured for manufacturing a second shear web. The first and second shear webs are moved to a post-moulding sub-station for assembly or finishing steps or to a transfer area. The present invention enables the sets of shear webs to be manufactured at multiple levels, thereby increasing the production capacity.

Claims

1. A moulding station comprising a first web mould (23) and at least a second web mould (24), the first web mould (23) comprising a moulding surface (34) for moulding a first shear web, the second web mould (24) comprising a moulding surface (34) for moulding a second shear web, wherein each of said first and second web moulds (23, 24) comprises a first end (30), a second end (31), a first side (32) and a second side (33), characterised in that the first web mould (23) is arranged at a ground level (20) and the second web mould (24) is arranged at an upper level (21) located above the ground level (20).

2. The moulding station according to claim 1, characterised in that said upper level (21) is formed by a working platform (22) extending in a longitudinal direction and in a transverse direction, wherein said first web mould (23) is arranged below said working platform (22).

3. The moulding station according to claim 1, characterised in that at least a third web mould (25) is further arranged at the ground level (20) relative to the first web mould (23) and/or at the upper level (21) relative to the second web mould (24), the third web mould (25) comprising a moulding surface (34) for moulding at least a third shear web.

4. The moulding station according to claim 3, characterised in that said first or second web mould (23, 24) and said third web mould (25) are aligned in the longitudinal direction.

5. The moulding station according to claim 3, characterised in that said first or second web mould (23, 24) and said third web mould (25) are aligned in the transverse direction.

6. The moulding station according to claim 1, characterised in that the moulding station (19) further comprises a lifting system (35, 37) configured to lift a selected shear web between a first position and a second position, wherein said lifting system (35, 37) are configured to move relative to at least the first or second web mould (23, 24).

7. The moulding station according to claim 1, characterised in that the moulding station further comprises at least one post-moulding substation (27) arranged at the ground level (20) or the upper level (21).

8. A method of manufacturing a shear web component for a wind turbine blade, the method comprises the steps of: providing a moulding station (19) comprising a first web mould (23) and at least a second web mould (24), manufacturing a first shear web in said first web mould (23) using a moulding process, further manufacturing a second shear web in said second web mould (24) using a moulding process, characterised in that said manufacturing of the first shear web is performed at a ground level (20) while said further manufacturing of the second shear web is performed at an upper level (21), the upper level (21) being located above the ground level (20).

9. The method according to claim 8, characterised in that the method further comprises the step of: moving said first or second shear web to a post-moulding sub-station (27) using a lifting system (35, 37) of the moulding station (19).

10. The method according to claim 8, characterised in that a first set of shear webs of one wind turbine blade (5) are manufactured at one level (20) while a second set of shear webs of another wind turbine blade (5) are manufactured at another level (21).

11. The method according to claim 8, characterised in that a first set of shear webs of one wind turbine blade (5) are manufactured in selected web moulds at the ground and upper levels (20, 21) and while a second set of shear webs of another wind turbine blade (5) are manufactured in further selected web moulds at the ground and upper levels (20, 21).

Description

DESCRIPTION OF DRAWINGS

[0060] The invention is explained in detail below with reference to embodiments shown in the drawings, in which

[0061] FIG. 1 shows a wind turbine,

[0062] FIG. 2 shows an exemplary embodiment of the wind turbine blade having a base aerodynamic profile,

[0063] FIG. 3 shows a first exemplary embodiment of a moulding station according to the invention,

[0064] FIG. 4 shows a second exemplary arrangement of the set of web moulds,

[0065] FIG. 5 shows a third exemplary arrangement of the set of web moulds,

[0066] FIG. 6 shows a second exemplary embodiment of the moulding station,

[0067] FIG. 7 shows a third exemplary embodiment of the moulding station, and

[0068] FIG. 8 shows a fourth exemplary embodiment of the moulding station.

LIST OF REFERENCES

[0069] 1. Wind turbine [0070] 2. Wind turbine tower [0071] 3. Nacelle [0072] 4. Hub [0073] 5. Wind turbine blades [0074] 6. Pitch bearing [0075] 7. Blade root [0076] 8. Tip end [0077] 9. Leading edge [0078] 10. Trailing edge [0079] 11. Blade shell [0080] 12. Pressure side [0081] 13. Suction side [0082] 14. Blade root portion [0083] 15. Aerodynamic blade portion [0084] 16. Transition portion [0085] 17. Blade length of wind turbine blade [0086] 18. Chord length of wind turbine blade [0087] 19. Moulding station [0088] 20. Ground level [0089] 21. Upper level [0090] 22. Working platform [0091] 23. First web mould [0092] 24. Second web mould [0093] 25. Third web mould [0094] 26. Shear web component [0095] 27. Second position [0096] 28. Blade mould [0097] 29. Blade cradle [0098] 30. First end of web mould [0099] 31. Second end of web mould [0100] 32. First side of web mould [0101] 33. Second side of web mould [0102] 34. Moulding surface [0103] 35. First lifting system [0104] 36. Post-moulding sub-station [0105] 37. Second lifting system

[0106] The listed reference numbers are shown in abovementioned drawings where no all reference numbers are shown on the same figure for illustrative purposes. The same part or position seen in the drawings will be numbered with the same reference number in the figures.

DETAILED DESCRIPTION OF THE DRAWINGS

[0107] FIG. 1 shows a modern wind turbine 1 comprising a wind turbine tower 2, a nacelle 3 arranged on top of the wind turbine tower 2, and a rotor defining a rotor plane. The nacelle 3 is connected to the wind turbine tower 2, e.g. via a yaw bearing unit. The rotor comprises a hub 4 and a number of wind turbine blades 5. Here three wind turbine blades are shown, but the rotor may comprise more or fewer wind turbine blades 5. The hub 4 is connected to a drive train, e.g. a generator, located in the wind turbine 1 via a rotation shaft.

[0108] The hub 4 comprises a mounting interface for each wind turbine blade 5. A pitch bearing unit 6 is optionally connected to this mounting interface and further to a blade root of the wind turbine blade 5.

[0109] FIG. 2 shows a schematic view of the wind turbine blade 5 which extends in a longitudinal direction from a blade root 7 to a tip end 8. The wind turbine blade 5 further extends in a chordwise direction from a leading edge 9 to a trailing edge 10. The wind turbine blade 5 comprises a blade shell 11 having two opposite facing side surfaces defining a pressure side 12 and a suction side 13 respectively. The blade shell 11 further defines a blade root portion 14, an aerodynamic blade portion 15, and a transition portion 16 between the blade root portion 14 and the aerodynamic blade portion 15.

[0110] The blade root portion 14 has a substantially circular or elliptical cross-section (indicated by dashed lines). The blade root portion 14 together with a load carrying structure, e.g. a main laminate combined with a shear web or a box beam, are configured to add structural strength to the wind turbine blade 5 and transfer the dynamic loads to the hub 4. The load carrying structure extends between the pressure side 12 and the suction side 13 and further in the longitudinal direction.

[0111] The blade aerodynamic blade portion 15 has an aerodynamically shaped cross-section (indicated by dashed lines) designed to generate lift. The cross-sectional profile of the blade shell 11 gradually transforms from the circular or elliptical profile into the aerodynamic profile in the transition portion 16.

[0112] The wind turbine blade 5 has a blade length 17 of at least 35 metres, preferably at least 50 metres, measured in the longitudinal direction. The wind turbine blade 5 further has a chord length 18 as function of the blade length 17 measured in the chordwise direction, wherein the maximum chord length is found between the blade aerodynamic blade portion 15 and the transition portion 16.

[0113] FIG. 3 shows an exemplary embodiment of a moulding station 19 according to the invention, where the moulding station 19 comprises a ground level 20 and an upper level 21.

[0114] The ground level 20 is here formed by a floor of a manufacturing facility. The upper level 21 is formed by a working platform 22 extending in a longitudinal direction and further in a transverse direction. The working platform 22 is here formed as a semi-permanent structure positioned defining a defined area between the working platform 22 and the floor.

[0115] Here, a first web mould 23 is arranged at the ground level 20 below the working platform 22 while a second web mould 24 is arranged at the upper level 21. At least a third web mould 25 is further arranged at both the ground and upper levels 20, 21 relative to the first and second web moulds 23, 24, respectively. A set of web moulds is thus provided at the ground level 20 and a set of web moulds is further provided at the upper level 21.

[0116] The first and third web moulds 23, 25 extend continuously along the longitudinal direction, as illustrated in FIG. 3 to form one continuous production line. Further, the second and third web moulds 24, 25 extend continuously along the longitudinal direction to form another continuous production line.

[0117] A second position 27 defined by a transfer area is arranged in extension of the first web mould 23, as illustrated in FIG. 3. The second position 27 is adapted to receive a shear web component 26, e.g. a first, second or third shear web, manufactured in a selected web mould, e.g. the first, second or third web mould.

[0118] A first lifting system (shown in FIG. 6) is used to move the shear web components 26 of at least the ground level 20 between a first position defined by the first or third web mould 23, 25 and the second position 27.

[0119] A second lifting system (shown in FIG. 6) is used to transfer the shear web components 26 between the second position 27 and a blade mould 28 or a blade cradle 29 for installation. Alternatively or additionally, the second lifting system is also used to directly move the shear web components 26 from the second or third web mould 24, 25 and into the blade mould 28 or blade cradle 29 or into the second position 27.

[0120] FIG. 4 shows a second arrangement of the set of web moulds where the first and third web moulds 23, 25 at ground level 20 extend in the transverse direction, thereby forming a row of parallel production lines. Alternatively or additionally, the second and third web moulds 24, 25 at upper level 21 extend in the transverse direction, thereby forming another row of parallel production lines.

[0121] Each of the web moulds 23, 24, 25 has a local length extending from a first end 30 to a second end 31 and a local width extending from a first side 32 to a second side 33. Each web mould 23, 24, 25 has a moulding surface 34 for laying up the materials of the shear web component 26 during the moulding process.

[0122] FIG. 5 shows a third arrangement of the set of web moulds. Unlike the second arrangement in FIG. 4, the first and third web moulds 23, 25 at the ground level 20 are here positioned in an angle relative to the longitudinal direction. Alternatively or additionally, the second and third web moulds 24, 25 at the upper level 21 are here positioned in an angle relative to the transverse direction.

[0123] FIG. 6 shows a second exemplary embodiment of the moulding station 19, wherein the first lifting system 35 is arranged relative to the working platform 22. The first lifting system 35 extends over the first or third web mould 23, 25 and further over a post-moulding sub-station 36 at the second position 27. The first lifting system 35 is configured to move the shear web component 26 between a selected web mould on the ground level 20 and the post-moulding sub-station 36.

[0124] Further, the second lifting system 37 is arranged relative to the working platform 22. The second lifting system 37 extends over the second or third web mould 24, 25 and over the post-moulding sub-station 36. The second lifting system 37 is configured to move the shear web component 26 between a selected web mould on the upper level 21, the post-moulding sub-station 36 and the blade mould 28 or blade cradle 29.

[0125] As illustrated in FIG. 6, only one web mould may be arranged at ground level 20 below the working platform 22. Alternatively or additionally, only one web mould be arranged on the working platform 22 and thus at the upper level 21.

[0126] Optionally, one or more finishing steps are performed on the shear web component 26 in the post-moulding sub-station 36 before installation.

[0127] FIG. 7 shows a third exemplary embodiment of the moulding station 19, wherein the web moulds at the ground and upper levels 20, 21 have different configurations. Here, the first web mould 23 and/or the third web mould 25 at the ground level 20 is/are configured for the manufacture of shear webs or segments thereof having a length of 30 meters, preferably 50 meters, or more.

[0128] The second web mould 24 and/or the third web mould 25 at the upper level 21 is/are configured for the manufacture of shear webs or segments thereof having a length of 30 meters, preferably 50 meters, or less.

[0129] As illustrated in FIG. 7, the web moulds at the ground level 20 extend in a first direction, e.g. the longitudinal direction, while the web moulds at the upper level 21 extend in a second direction, e.g. the transverse direction.

[0130] The post-moulding sub-station 36 is here configured to receive a set of shear webs for a particular wind turbine blade 5, wherein the individual shear webs are assembled prior to being transferred to the blade mould 28 or blade cradle 29 for installation. The assembly is performed by joining any shear web segments and/or to interconnect the individual shear webs via temporary spacer means. Optionally, the shear webs are rotated into an installation position before, during or after the assembly process.

[0131] FIG. 8 shows a fourth exemplary embodiment of the moulding station 19, wherein the web moulds at the ground and upper levels 20, 21 have different configurations.

[0132] Here, the first web mould 23 and/or the third web mould 25 at the ground level 20 is/are configured for the manufacture of shear webs or segments dedicated for a first wind turbine blade 5. The second web mould 24 and/or the third web mould 25 at the upper level 21 is/are configured for the manufacture of shear webs or segments dedicated for a second wind turbine blade 5.

[0133] The first and second wind turbine blades 5 have different blade lengths, different aerodynamic profiles, and/or different structural properties.

[0134] The abovementioned embodiments may be combined in any combinations without deviating from the present invention.