MULTI SEGMENT WIND TURBINE BLADE JOINT BUSHING

Abstract

A joint bushing that accommodates the dithering and sliding in multi segment wind turbines. The joint bushing includes a self-lubricating liner that is a composite system incorporating woven Polytetrafluoroethylene fibers intermixed with structural reinforcement fibers in a composite matrix. The composite system provides sufficient life without requiring re-lubrication.

Claims

1. A bushing for a segmented wind turbine blade, the bushing comprising: a tubular segment having an inside surface extending from a first axial end to a second axial end thereof; a self-lubricating liner having a mounting surface and a bearing surface, the mounting surface is adhered to the inside surface of the tubular segment; and the self-lubricating liner being configured to withstand dithering and rotational sliding between the liner and a shaft extending therethrough.

2. The bushing of claim 1, wherein the self-lubricating liner withstands dithering of about 4 degrees.

3. The bushing of claim 1, further comprising a thrust component extending radially outward from and circumferentially around the first axial end.

4. The bushing of claim 3, wherein the thrust component comprises a first flange formed integrally with the tubular segment.

5. The bushing of claim 1, wherein the self-lubricating liner comprises a composite system incorporating plurality of woven polytetrafluoroethylene fibers intermixed with reinforcement fibers encapsulated within a composite matrix.

6. The bushing of claim 5, wherein the self-lubricating liner comprises a dither accommodating concentration of polytetrafluoroethylene fibers proximate the bearing surface.

7. The bushing of claim 5, wherein the self-lubricating liner comprises a strength accommodating concentration of structural reinforcement fibers proximate the mounting surface.

8. The bushing of claim 1, further comprising a second flange extending radially inward from the second axial end.

9. The bushing of claim 6, wherein the second flange defines a mounting aperture.

10. The bushing of claim 1, further comprising a circumferential groove penetrating the inside surface of the tubular segment.

11. The bushing of claim 1, wherein the inside surface of the tubular segment proximate the first axial end defines a first retention feature and the bushing further comprises a threaded plug having an outer circumferential surface defining a second retention feature complementary to the first retention feature, wherein the first retention feature engages the second retention feature to fix the threaded plug within the first axial end of the tubular segment.

12. A segmented wind turbine blade, comprising: a first segment having a channel interrupting a first end of the first segment and a support aperture penetrating the channel from an edge of the first segment; a second segment having a tongue extending from a second end of the second segment, the tongue is complementary in shape to the channel, the tongue is disposed in the channel, the tongue comprises a bore extending there through, a bushing disposed in the bore; and a mounting shaft disposed in the support aperture and having an end that is disposed in the bushing, the mounting shaft couples the second segment to the first segment, wherein the bushing comprises a self-lubricating liner secured to an inside surface of the bushing, the self-lubricating liner configured to withstand dithering and rotational sliding between the self-lubricating liner and the mounting shaft extending therethrough.

13. The segmented wind turbine blade of claim 12, wherein the self-lubricating liner has a mounting surface and a bearing surface and the mounting surface is adhered to the inside surface of the tubular segment.

14. A segmented wind turbine blade, comprising: a first segment having a channel interrupting a first end of the first segment and forming a first support leg and a second support leg, the first segment having a first support aperture penetrating the first support leg and a second support aperture penetrating the second support leg and the first support aperture being aligned with the second support aperture; a second segment having a tongue extending from a first tongue end to a second tongue end of the second segment, the tongue is complementary in shape to the channel, the tongue is disposed in the channel, the tongue comprises a bore extending from a first tongue side to a second tongue side, the first tongue side disposed proximate the first support leg and the second tongue side disposed proximate the second support leg, a first bushing disposed in the first support aperture, the first bushing comprising a tubular segment having an inside surface extending from a first axial end to a second axial end thereof and a first circumferential groove penetrating the inside surface of the tubular segment; a second bushing disposed in the bore proximate the first tongue side; a third bushing disposed in the bore proximate the second tongue side; a fourth bushing disposed in the second support aperture, the fourth bushing comprising a tubular segment having an inside surface extending from a first axial end to a second axial end thereof and a second flange extending radially inward from the second axial end; and a mounting shaft disposed in the first support aperture, the bore and the second support aperture, the mounting shaft having an exterior surface extending from a first end disposed in the first bushing to a second end disposed in the fourth bushing, a second circumferential groove penetrating the exterior surface of the mounting shaft proximate the first end and the mounting shaft couples the second segment to the first segment, wherein a collapsible ring engages the first circumferential groove and the second circumferential groove to axially secure the first end of the shaft to the first support and the second flange engages the second end of the shaft to axially secure the second end of the shaft to the second support.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0021] FIG. 1A is an isometric view of a wind turbine blade incorporating a joint bushing according to the present disclosure;

[0022] FIG. 1B is an enlarged view of detail 1B of FIG. 1A with a mounting shaft and the joint bushings of FIGS. 2, 5, 6 and 8A depicted in phantom;

[0023] FIG. 1C is cross sectional view of a portion of the turbine blade incorporating the joint bushing of FIG. 3, taken across section 1C-1C;

[0024] FIG. 1D is a cross sectional view of the portion of the turbine blade of FIG. 1A incorporating and depicting in phantom the joint bushings of FIGS. 2, 5, 6 and 8A taken along the center of the mounting shaft retained therein;

[0025] FIG. 2 is a side sectional view of a joint bushing according to the present disclosure;

[0026] FIG. 3 is front cut away view of the turbine blade incorporating the joint bushing of FIG. 1B, shown with a portion of the first wing section cut away to show the tongue;

[0027] FIG. 4A is an isometric view of a composite system of a self-lubricating liner according to the present disclosure;

[0028] FIG. 4B is a cross sectional view of a self-lubricating liner mounted to a backing substrate;

[0029] FIG. 5 is a side sectional view of an alternate embodiment of a joint bushing according to the present disclosure;

[0030] FIG. 6 is a side sectional view of an alternate embodiment of a joint bushing according to the present disclosure;

[0031] FIG. 7 is a cross sectional view of a straight bushing and separate thrust washer;

[0032] FIG. 8A is a side sectional view of an alternate embodiment of a joint bushing according to the present disclosure;

[0033] FIG. 8B is a side view of an end plug compatible with the joint bushing of FIG. 8A;

[0034] FIG. 8C is a cross sectional view of a portion of the turbine blade incorporating the joint bushing of FIG. 8A and the end plug of FIG. 8B; and

[0035] FIG. 8D is a cross sectional view of the portion of the turbine blade of FIG. 8C taken along line D-D.

DETAILED DESCRIPTION

[0036] As shown in FIGS. 1A, 1B and 1D, a wind turbine blade 100 includes a first segment 102 and a second segment 104. A tongue 106 extends from the second segment 104 at a first tongue end 106A to a second tongue end 106B. The tongue 106 mates with (i.e., is disposed in) a complementary groove (e.g. a channel) 108 in the first segment 102. A mounting shaft 110 (as depicted in FIG. 1D) penetrates the first segment 102 via a first support aperture 102X (e.g., a bore) that extends inwardly from an edge 102E of the first segment 102. The tongue 106 has a bore 106X extending therethrough that is coaxial with the support aperture 102X. A joint bushing 10 is disposed in the bore 106X. The joint bushing 10 has a tubular segment 12 that is coaxial with the bore 106X and the first support aperture 102X. The mounting shaft 110 (e.g., a support rod) is disposed in the first support aperture 102X and into an interior area the tubular segment 12 of the joint bushing 10. The mounting shaft 110 couples the second segment 104 to the first segment 102 along a seam 103 therebetween by fixing the tongue 106 in the groove 108. In some embodiments, multiple shafts and joint bushings are incorporated into a single wind turbine blade.

[0037] The joint bushing 10, 10, 10, 10, 210, disclosed herein is configured to carry a significant loads exceeding 5000 pounds per square inch with tight compliance, high rigidity, and limited running clearances. In some embodiments, the running clearance is between 0.001 and 0.010 inches. The bushing 10, 10, 10, 10, 210 has a self-lubricating liner 20, 20, 20, 20, 120 as shown in FIG. 1C, secured thereto which is configured to accommodate dithering caused by relative movement between the first segment 102 and the second segment 104. The bushing 10 is configured to withstand dithering, or frequent low magnitude rotations of approximately 2 (as shown by the arrow D in FIG. 3). Dithering occurs when high frequency, low magnitude motion contributes to microscopic wear that eventually causes macroscopic failure due to lack of lubrication. Dithering particularly affects the bond between the bushing and the liner, causing the liner to fatigue and eventually disband from the mating surface with the bushing. The self-lubricating liner 20, 20, 20, 20, 120 permits less than 0.015 of wear after over 7 million cycles of the mounting shaft 110 within the joint bushing 10, 10, 10, 10, 210. Referring to FIG. 1D, the shaft 110 is retained within the first segment 102 and the second segment 104 of the wind turbine blade 100 by four bushings 10, 10, 10 and 10. The channel 108 of the first segment 102 forms a first support leg 102A and a second support leg 102B on either side of the channel 108. A first support aperture 102X penetrates the first support leg 102A and a second support aperture 102X penetrates the second support leg 102B. The first support aperture 102X is aligned with the second support aperture 102X. The tongue 106 of the second segment 104 extends from a first tongue end 106A to a second tongue end 106B. The tongue 106 is complementary in shape to the channel 108 and the tongue 106 is disposed in the channel 108. The tongue 106 has a bore 106X extending from a first tongue side 106C to a second tongue side 106D. The shaft 110 extends from a first end 110A proximate to the edge 102E of the first segment 102 in the first support aperture 102X of the first support leg 102A through the bore 106X in the tongue and to an opposite second end 110B in the second support aperture 102X in the second support leg 102B. The first end 110A of the shaft 110 is radially retained by a bushing 10 disposed within the first support aperture 102X in the first segment. A lock washer 13W engages an inner groove 13 in the bushing 10 and an outer groove 21 in the shaft 110 to axially retain the shaft 110, as discussed in detail below. The second end 110B of the shaft 110 is radially retained by a bushing 10 disposed within a second support aperture 102X in the first segment 102. A second flange 17 of the bushing 10 axially retains the shaft 110, as discussed in detail below. A bushing 10 is disposed in the bore 106X at both the first tongue side 106C and the second tongue side 106D of the bore 106X. The bushings 10, 10 radially retain the shaft 110. In the embodiment depicted in FIGS. 8A-8D, the first end 110A is axially retained by a bushing 10 in cooperation with a threaded plug 13P, as discussed in detail below.

[0038] Referring to FIGS. 2 and 3, the joint bushing 10 has the tubular segment 12 extending from a first axial end 14 to a second axial end 16 thereof. FIG. 3 is depicted with a portion of the first wing section 102 removed (i.e., the portion that is located between the first end 106A and the second end 106B of the tongue 106). A flange 18 (e.g., a thrust component) extends radially outwardly from the tubular segment 12 at the first axial end 14, away from a central axis A. In one embodiment, the flange 18 is integral with the tubular segment 12. The flange 18 resists thrust loads on the joint bushing 10 and allows for small rotations and/or translations while limiting extraneous components in the system. An exterior circumferential surface of the self-lubricating liner 20 defines a mounting surface 20Y that is mounted (e.g., adhered) to an inside surface 12A of the tubular segment 12, as shown in FIGS. 1C and 2. An interior circumferential surface of the self-lubricating liner 20 defines a bearing surface 20X. The bearing surface 20X surrounds the mounting shaft 110 and accommodates rotation of the mounting shaft 110 therein. As shown in FIGS. 1C and 2, a portion 20F of the self-lubricating liner 20 extends over the flange 18 extending radially outward from the first end 14 of the tubular member 12. As shown in FIG. 1C, the portion 20F self-lubricating liner 20 slidingly engages a side wall of the groove 108 to accommodate and withstand the dithering. In the embodiment shown in FIG. 4B, the self-lubricating liner 20 attaches to a bearing substrate 20M of the joint bushing 10. In the embodiment depicted in FIGS. 2-3, the self-lubricating liner 20 withstands dithering of about 4 degrees.

[0039] While the flange 18 (e.g., a thrust component) is shown and described as extending radially outwardly from the tubular segment 12 at the first axial end 14, the present invention is not limited in this regard as the flange 18 may be replaced with a separate thrust washer 118 as shown and described with reference to FIG. 7. While the portion 20F of the self-lubricating liner 20 is shown and described as extending over the flange 18, the present invention is not limited in this regard as the flange 18 of the bushing 10 has no self-lubricating liner extending over the flange 18, as shown and described with reference to FIG. 5.

[0040] As shown in FIG. 2, an inner groove 13 penetrates the self-lubricating liner 20 and the inside surface 12A of the tubular segment 12. The inner groove 13 accommodates a split lock washer 13W or other form of a collapsible ring to provide an axial and/or radial retention surface for mating the bushing 12 with the shaft 110. In one embodiment, the split lock washer 13W mates with an outer groove 21 of the shaft 100 to axially retain the shaft 110 within the bushing 10.

[0041] While a bushing 10 having the split lock washer 13W, the inner groove 13 and a shaft 110 having the outer groove 21 is shown to axially retain the first end 110A of the shaft 110, the present disclosure is not limited in this regard, as other axial retaining configurations may be employed, including but not limited to the embodiment depicted in FIGS. 8A-8D, in which the shaft 110 (as depicted in FIG. 8C) is axially retained at the first end 110A by a threaded end plug 13P. The inside surface 12A of one end 14 of the tubular segment 12 of the bushing 10 defines a threaded end 15. The end plug 13P inserts into and engages a complementary retention feature in threaded end 15 to retain the shaft 110 (as depicted in FIG. 8C) in the assembly. Referring to FIG. 8B, an exterior circumferential surface of the threaded plug 13P defines threading 13T and the threaded plug 13P extends between a lubricated surface 13S at one axial end to reduce friction and wear in the assembly and a protrusion 13X extending from the other axial end. In the embodiment depicted in FIGS. 8A-8D, the lubricated surface 13S is formed by a lubricious liner 20S that is adhered to an axial face 13Q of the plug 13P. The liner 20S is made from the same material as the self-lubricating liner 20 to withstand dithering due to oscillatory rotation of the first end 110A of the shaft 110 within the bushing 10. The protrusion 13X (e.g., a hex head) eases assembly. In the embodiment depicted in FIGS. 8A-8C, the joint bushing 10 has a first mounting aperture 23A and a second mounting aperture 23B for receiving a locking feature. The plug 13P has a third mounting aperture 13C and a fourth mounting aperture 13D. A pin 88 extends through the first mounting aperture 23A, the third mounting aperture 13C and upper access aperture 102H1 and lower access aperture 102H2 in the first segment 102 (as depicted in FIG. 8D). While the pin 88 is shown, alternate retention means, including but not limited to wire, split pins or cotter pins to retain the threaded plug 13P within the bushing 10 do not depart from the present disclosure. The lubricated surface 13S of the threaded plug 13P provides an axial guide for a first end 110A of the shaft 110. Specifically, the lubricious liner 20S that is adhered to the axial face 13Q of the plug 13P withstands dithering due to the aforementioned oscillatory rotation of the first end 110A of the shaft 110 within the bushing 10.

[0042] Referring to FIG. 4A, the self-lubricating liner 20 includes a composite system incorporating plurality of woven Polytetrafluoroethylene (PTFE) fibers 24 intermixed with structural reinforcement fibers 26 and encapsulated within a polymer matrix 22. The composite system is made in such a way to have a high concentration of PTFE fibers 24 on the surface, specifically to accommodate the aforementioned dither. In some embodiments, the self-lubricating liner 20 is maintenance free throughout the service life of the bushing 10.

[0043] The reinforcement fibers 26 add to the strength and the rigidity of the self-lubricating liner 20 to accommodate stiff compliance and high loads. The reinforcement fibers 26 may be made from, but are not limited to: fiberglass, Dacron, polyester, cotton, Nomex, Kevlar, etc., and combinations of any two or more of the aforementioned materials. In some embodiments, the composite matrix 22 is made from, but is not limited to, a resin system consisting of: polyester, epoxy, phenolic, urethane, polyimide, polyamide, or other suitable resin system and potential additives to enhance composite performance.

[0044] In one embodiment, additional lubricating and non-lubricating materials are added to the composite matrix 22 to fulfill certain mechanical or chemical requirements. These additives include but are not limited to: Molybdenum disulfide, Graphite, Carbon Fiber, lead, bronze, PEEK, PFA, FEP, silicon, tungsten disulfide, PVA, etc.

[0045] In one embodiment, the self-lubricating liner 20 is of a non-woven nature comprising of PTFE and a polymer matrix with or without reinforcement fibers as a randomly oriented composite structure. The self-lubricating liner 20 is able to be machined into complex shapes as required.

[0046] In one embodiment, as shown in FIG. 4B, the bearing substrate 20M is also of a composite nature, and is integrated with the lubricant continuously. In another embodiment, the bearing substrate 20M is a separate and distinct composite structure from the self-lubricating liner 20. In some embodiments, the bearing substrate 20M is composed of stainless steel, e.g., corrosion resistant steel (CRES).

[0047] In some embodiments, the bearing substrate 20M and/or the composite matrix 22 is made from lesser strength materials for the purposes of low load applications including but not limited to: acetyl (Delrin, POM, etc.), nylon, FEP, PVC, etc.

[0048] In one embodiment, the flange 18 has a highly polished stainless steel surface to facilitate mating against the aforementioned self-lubricated liner to allow small rotations and/or translations.

[0049] FIG. 5 depicts an alternate embodiment of the joint bushing 10. In the depicted embodiment, the inner groove 13 of FIG. 2 is omitted and the inner surface 12A of the tubular segment 12 provides a mounting surface for the uninterrupted self-lubricating liner 20 that extends from the first end 14 to the second end 16 of the tubular segment 12. As shown in FIG. 5, the flange 18 does not have any self-lubricating liner secured thereto. In some embodiments, a separate element, such as a lock ring or locking nut (not depicted) is used in conjunction with the joint bushing 10 to retain the shaft 110.

[0050] FIG. 6 depicts an alternate embodiment of the joint bushing 10 that has a second flange 17 extending radially inwardly at the second axial end 16 towards the central axis A. The inwardly directed second flange 17 defines a mounting aperture 19. In some embodiments, this mounting aperture 19 accommodates the shaft 110 (not depicted). In some embodiments, the mounting aperture 19 is used for additional pin retention and/or to facilitate the removal of the pin after installation. In some embodiments, the second flange 17 has the self-lubricating liner 20 mounted thereto, for accommodating dithering

[0051] In some embodiments, as shown in FIG. 7, the joint bushing 210 (i.e., a straight bushing 112) is separate from the thrust component 118 (e.g., a thrust washer) that replaces the flange 18 depicted in FIG. 2, such that the straight bushing 112 and thrust washer 118 are utilized in lieu of a flange.

[0052] In some embodiments, relief grooves or slots are incorporated into the bushing bore to allow for construction debris to fall into the grooves during operation.

[0053] In some embodiments, the self-lubricating liner 20, 20, 20, 120 is bonded or attached to a bearing substrate 20M of suitable strength, rigidity, toughness, and corrosion resistance for long life use within the wind turbine structure. In one embodiment, the bearing substrate 20M in composed of CRES or stainless steel.

[0054] In some embodiments, the self-lubricating liner 20, 20, 20, 120 is configured to withstand millions of cycles as demonstrated by laboratory testing.

[0055] In some embodiments, the use of composite liners utilizing reinforcement fibers 26 to accommodate the natural flexure of the turbine blade, while maintaining tight running clearances and high strength. This configuration allows for dither and changing load direction due to the rotation of the joint.

[0056] In some embodiments, the joint bushing 10, 10, 10, 10, 210 includes spherical bearings to allow for misalignment and resist axial and radial loading.

[0057] Although this invention has been shown and described with respect to the detailed embodiments thereof, it will be understood by those of skill in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiments disclosed in the above detailed description, but that the invention will include all embodiments falling within the scope of the appended claims.