METHOD FOR PRODUCING A WIND TURBINE ROTOR BLADE

Abstract

There is provided a method of producing a wind turbine rotor blade. A mold for a spar cap is provided. The mold has at least one negative cap edge. Glass fiber layers are laid in the mold and in the negative cap edge to achieve transverse scarfing at the ends of the glass fiber layers in such a way that a spar cap having a negative scarfing is provided. The spar cap having the negative scarfing is installed in a core material of the rotor blade.

Claims

1. A method comprising: producing a wind turbine rotor blade, wherein the producing comprises: laying glass fiber layers in a mold having a negative cap edge to achieve transverse scarfing at ends of the glass fiber layers in such a way that a spar cap having a first end and a second end is formed, wherein at least one of: the first end or the second end has a negative scarfing, and positively lockingly installing at least one of: the first end or the second end of the spar cap in a core material of the rotor blade.

2. The method according to claim 1 wherein the mold has a portion which has the negative scarfing.

3. The method according to claim 1 wherein the mold includes at least one resin passage.

4. The method according to claim 1 wherein the cap edge has an angle of between 20 and 40.

5. A wind turbine rotor blade comprising: at least one spar cap having a first end and a second end, wherein at least one of: the first or second end has a negative scarfing, wherein at least one of: the first or second end of the spar cap is positively lockingly installed in a core material of the rotor blade.

6. The method according to claim 4, wherein the cap edge has an angle of between 22 and 35.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0021] Advantages and embodiments by way of example of the invention are described in greater detail hereinafter with reference to the drawings.

[0022] FIG. 1 shows a diagrammatic cross-section of a wind turbine rotor blade according to the state of the art,

[0023] FIG. 2 shows a diagrammatic view of a wind turbine,

[0024] FIG. 3A shows a diagrammatic sectional view of a part of a rotor blade,

[0025] FIG. 3B shows a diagrammatic sectional view A-A in FIG. 3A,

[0026] FIG. 3C shows a diagrammatic sectional view B-B of the section shown in

[0027] FIG. 3A,

[0028] FIG. 4A shows a diagrammatic sectional view of a spar cap in the production thereof,

[0029] FIG. 4B shows a further diagrammatic sectional view of a spar cap in the production thereof,

[0030] FIG. 4C shows a further diagrammatic sectional view of a spar cap in the production thereof, and

[0031] FIG. 5 shows a diagrammatic cross-section of a part of a rotor blade according to an embodiment of the invention.

DETAILED DESCRIPTION

[0032] FIG. 2 shows a diagrammatic view of a wind turbine. The wind turbine 100 has a tower 102 and a pod 104 on the tower 102. Provided at the pod 104 is an aerodynamic rotor 106 having three rotor blades 200 and a spinner 110. The aerodynamic rotor 106 is caused to rotate in operation of the wind turbine by the wind and thus also rotates a rotor or rotor member of a generator coupled directly or indirectly to the aerodynamic rotor 106. The electric generator is arranged in the pod 104 and generates electric energy. The pitch angle of the rotor blades 200 can be varied by pitch motors at the rotor blade roots of the respective rotor blades 200.

[0033] FIGS. 3A to 3D show various diagrammatic sectional views of a part of the rotor blade 200 in the production of a spar cap. FIG. 3B is a diagrammatic sectional view along section A-A and FIG. 3C is a diagrammatic sectional view along section B-B.

[0034] The method of producing a spar cap 400 for a rotor blade 200 of a wind turbine uses a mold 300 with especially designed mold edges 310, 320. FIGS. 3A to 3C show a front edge 201 of the spar cap. In addition a core material 210 of the rotor blade 200 is shown in FIG. 3A. FIGS. 3B and 3C show the mold 300 with the mold edges 310, 320 as well as the spar cap 400 with a first and a second end 401, 402.

[0035] According to an aspect of the present invention the angle of a first mold edge 310 can be 35 and the angle of a second mold edge 320 can be 22. According to an aspect of the present invention those angles can be of a uniform configuration.

[0036] In FIG. 3B there can be provided a narrow cap 410 and/or a wide cap 420.

[0037] In FIG. 3C there is provided an alternative configuration of the mold 300 with a second mold edge 320.

[0038] FIGS. 4A to 4C show various diagrammatic sectional views of a spar cap. FIGS. 4A to 4C respectively show the mold 300 (above) and the mold 300 with the spar cap 400. The configuration of the mold 300 and the spar cap 400 shown in FIG. 4A substantially corresponds to the configuration of the mold and the spar cap of FIG. 3B. The configuration of the mold and the spar cap of FIG. 4B substantially corresponds to that of the mold 300 and the spar cap 400 in FIG. 3C.

[0039] FIG. 5 shows a diagrammatic cross-section of a part of a rotor blade according to an embodiment of the invention. FIG. 5 shows the core material 210, a spar cap 400 having a first and a second end 401, 402 and optionally a foam inlay 500. The first and second ends 401, 402 of the spar cap respectively have a negative scarfing. The foam inlay 500 has an inclined end 510 and optionally a resin passage 520. The resin passage 520 can be provided at the opposite side in relation to the end 510.

[0040] As can be seen from FIG. 5 there is provided a spar cap 400 with its two end which each have a negative scarfing in a core material 210 of the rotor blade. The shallow angle of the spar cap in combination with that of the core material 210 permits a large-area, positively locking and gap-free transition between the spar cap and the core material of the rotor blade.