WINDING CORE AND METHOD FOR PRODUCING BLADE ENDS, MOLD AND METHOD FOR PRODUCING TRAILING EDGE SEGMENTS, WIND TURBINE, ROTOR BLADE SERIES, ROTOR BLADE AND METHOD FOR PRODUCING SAME

Abstract

A winding core for producing blade ends for rotor blades of wind power installations and to a mold for producing trailing edge segments is provided. Methods for producing a blade end, for producing a trailing edge segment and for producing a rotor blade and also to a rotor blade and a rotor blade series are provided. The winding core comprises a first section with a first end for forming a hub connection geometry for connecting the blade end to a rotor hub, and a second section with a second end for forming an outer blade connection geometry for connecting the blade end to an outer blade, wherein it is possible by exchanging or completely or partially removing the first section to vary a longitudinal extent of the winding core and/or a diameter of the first section and/or a shape of the first section such that blade ends produced therewith are suitable for wind power installations with different rotor diameters.

Claims

1. A winding core for producing blade ends for rotor blades of wind power installations, the winding core comprising: a first section having a first end for forming a hub connection geometry for connecting the blade end to a rotor hub; and a second section having a second end for forming an outer blade connection geometry for connecting the blade end to an outer blade, wherein a portion or all of the first section is removable to vary at least one of: a longitudinal length of the winding core, a diameter of the first section, or a shape of the first section, such that the winding core is configured to produce different shaped blade ends for wind power installations having different rotor diameters.

2. The winding core as claimed in claim 1, wherein when all of the first section is removed, a first end of the second section is configured for forming the hub connection geometry for connecting the blade end to the rotor hub.

3. The winding core as claimed in claim 1, wherein the first section includes a plurality of winding core segments, wherein the plurality of winding core segments form the portion that is removable to vary at least one of: the longitudinal length of the winding core, the diameter of the first section, or the shape of the first section.

4. The winding core as claimed in claim 3, wherein the plurality of winding core segments includes at least a first winding core segment and a second winding core segment, wherein in the event the first winding core segment is removed, a first end of the second winding core segment is used for forming the hub connection geometry.

5. The winding core as claimed in claim 1, wherein the second section has a first end that corresponds to the first end of the first section.

6. The winding core as claimed in claim 1, wherein the first section and the second section have rotational symmetry.

7. The winding core as claimed in claim 1, wherein the first section has an essentially cylindrical shape.

8. The winding core as claimed in claim 1, wherein the second section has an essentially cylindrical or essentially frustoconical shape.

9. A mold for producing trailing edge segments for rotor blades of wind power installations, the mold comprising: a plurality of mold segments, wherein at least some of the plurality of mold segments are removable to vary at least one of: a longitudinal length of the mold, a shape of the mold, or a maximum dimension of the mold orthogonal to the longitudinal length in such a way that trailing edge segments produced by the mold are suitable for rotor blades for wind power installations with different rotor diameters.

10. A method for producing blade ends for rotor blades of wind power installations, the method comprising: providing a winding core as claimed in claim 1; winding fiber composite material and a matrix material onto the winding core; and curing the matrix material.

11. A method for producing trailing edge segments for rotor blades of wind power installations, the method comprising: providing a mold as claimed in claim 9; introducing fiber composite material and matrix material into the mold; and curing the matrix material.

12. A method for producing a rotor blade for a wind power installation, the method comprising: providing a blade end that is produced using a winding core as claimed in claim 1; and connecting the blade end to one or more attachment parts.

13. A rotor blade for a wind power installation, comprising a blade end that is produced using the winding core as claimed in claim 1 and further comprising a trailing edge segment coupled to the blade end.

14. A wind power installation, comprising at least one rotor blade as claimed in claim 13.

15. A rotor blade series for wind power installations, comprising: a first blade end and a second blade end that are produced using the winding core as claimed in claim 1; a first outer blade and a second outer blade; the first blade end being connected to the first outer blade to form a first rotor blade, the second blade end being connected to the second outer blade to form a second rotor blade; and the first rotor blade being suitable for a wind power installation with a first rotor diameter and the second rotor blade being suitable for a wind power installation with a second rotor diameter, the first rotor diameter being different from the second rotor diameter.

16. The winding core as claimed in claim 3, wherein the plurality of winding core segments each have a first end that correspond to the first end of the first section.

17. The winding core as claimed in claim 12, wherein the one or more attachment parts is at least one of: a trailing edge segment, an outer blade, or a blade tip.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0046] Preferred embodiments of the invention are described by way of example on the basis of the accompanying figures, in which:

[0047] FIG. 1 shows a schematic representation of a wind power installation;

[0048] FIG. 2A shows a schematic side view of a first embodiment, given by way of example, of a winding core;

[0049] FIG. 2B shows a winding core that is shortened in comparison with the variant represented in FIG. 2A;

[0050] FIG. 2C shows a winding core that is shortened further in comparison with the variant represented in FIG. 2B;

[0051] FIG. 3A shows a first embodiment, given by way of example, of a blade end with a trailing edge segment;

[0052] FIG. 3B shows a further embodiment, given by way of example, of a blade end with a trailing edge segment;

[0053] FIG. 3C shows a further embodiment, given by way of example, of a blade end with a trailing edge segment;

[0054] FIG. 4A shows a first embodiment, given by way of example, of a rotor blade with a blade end, a trailing edge segment and an outer blade;

[0055] FIG. 4B shows a further embodiment, given by way of example, of a rotor blade with a blade end, a trailing edge segment and an outer blade; and

[0056] FIG. 4C shows a further embodiment, given by way of example, of a rotor blade with a blade end, a trailing edge segment and an outer blade.

DETAILED DESCRIPTION

[0057] FIG. 1 shows a wind power installation 1100 with a tower 1102 and a nacelle 1104. Arranged on the nacelle 1104 is a rotor 1106 with three rotor blades 1108 and a spinner 1110. During operation, the rotor 1106 is set in a rotary motion by the wind, and thereby drives a generator in the nacelle 1104.

[0058] At least one of the rotor blades 1108, preferably all three rotor blades 1108, have been produced with a winding core according to FIG. 2A, 2B or 2C, have a blade end with a trailing edge segment according to FIG. 3A, 3B or 3C and/or correspond to a rotor blade according to FIG. 4A, 4B or 4C.

[0059] Represented in FIGS. 2A, 2B, 2C is a winding core 100, 100, 100, which in these three figures is varied. In FIGS. 3A, 3B, 3C, the blade ends 200, 200, 200 are represented with trailing edge segments 300, 300, 300, the blade ends 200, 200, 200 being produced by means of the variants of the winding core 100, 100, 100 according to FIGS. 2A, 2B, 2C. Represented in turn in FIGS. 4A, 4B, 4C are three rotor blades 500, 500, 500 with in each case a blade end 290, 290, 290, a trailing edge segment 390, 390, 390 and an outer blade 400, 400, which form a rotor blade series.

[0060] In FIG. 2A, the winding core 100 has its maximum longitudinal extent LWmax. In FIG. 2B, the winding core 100 is shortened by the amount R1 in comparison with the variant represented in FIG. 2A. In FIG. 2C, the winding core 100 is shortened by the amount R2 in comparison with the variant represented in FIG. 2A. The variants of the winding core 100, 100, 100 represented in FIGS. 2A, 2B, 2C consequently differ in their longitudinal extent.

[0061] The winding core 100, 100, 100 has a first section 110, 110, 110 and a second section 120. The second section 120 has a first end 121 and a second end 122 opposite therefrom. The second section 120 has a longitudinal extent LA2.

[0062] The first end 121 of the second section 120 is connected to a second end 112 of the first section 110, 110, 110.

[0063] The second end 122 is used for forming an outer blade connection geometry of a blade end when winding around the winding core with a fiber composite material and a matrix material.

[0064] The winding core 100 represented in FIG. 2A is used for producing the blade end 200 represented in FIG. 3A. In FIG. 2, the winding core 100 has a completely present first section 110, which has its maximum longitudinal extent LA1max. A first end 111 of the first section 110 is used for producing a hub connection geometry 211 of the blade end 200. At the first end 111, the first section 110 has a diameter D, preferably an outer diameter.

[0065] The first section 110 also has four winding core segments 130, 140, 150, 160. The four winding core segments 130, 140, 150, 160 have in each case a first end 131, 141, 151, 161 and in each case a second end 132, 142, 152, 162. The second end 162 of the fourth winding core segment 160 forms at the same time the second end 112 of the first section 110. The first end 131 of the first winding core segment 130 forms at the same time the first end 111 of the first section 110. The winding core segments 130, 140, 150, 160 are detachably connected to the respectively neighboring winding core segment(s).

[0066] The winding core 100 represented in FIG. 2A can be used to create the blade end 200 represented in FIG. 3A, the longitudinal extent LBmax of which corresponds to the longitudinal extent LWmax of the winding core 100.

[0067] Preferably, the first section 110 is formed cylindrically, so as to produce a blade end 200 that has in this region LZ at least one cylindrical inner cavity.

[0068] The trailing edge segment 300 only extends over part of the longitudinal extent LBmax of the blade end 200.

[0069] The winding core 100, which is represented in FIG. 2B, is used for producing the blade end 200, which is represented in FIG. 3B. As can be seen in both figures, both the winding core 100 and the blade end 200 are shortened in their respective longitudinal extent by the amount R1 in comparison with the winding core 100 and the blade end 200 according to FIGS. 2A, 3A. This has been achieved by the first winding core segment 130 of the winding core 100 being removed. The extent in the longitudinal direction of the first winding core segment 130 thus corresponds to the degree of shortening R1.

[0070] The first end 111 of the first section 110 is formed in the case of the winding core 100 by the first end 141 of the second winding core segment 140 and is used for forming the hub connection geometry 211 of the blade end 200.

[0071] The winding core 100 represented in FIG. 2C is used for producing the blade end 200 represented in FIG. 3C. The first end 111 of the first section 110 is formed in the case of the winding core 100 by the first end 151 of the third winding core segment 150 and is used for forming the hub connection geometry 211 of the blade end 200.

[0072] In the case of a preferred cylindrical formation of the first section 110, 110, 110, a constant hub connection geometry 211, 211 211 of the blade ends 200, 211, 211 is also obtained in an advantageous way. Since in the case of the embodiment represented here the second section 120 of the winding core 100, 100, 100 is not varied, the blade ends 200, 200, 200 also have a constant outer blade connection geometry 222.

[0073] The trailing edge segments 300, 300, 300 only extend over part of the longitudinal extent of the blade ends 200, 200, 200. The respective shape of the trailing edge segments 300, 300, 300, in particular a radial and/or tangential extent of the trailing edge segments 300, 300, 300 orthogonal to their longitudinal extent, is preferably adapted to the respective rotor blade design. In particular, it is preferred that the three trailing edge segments 300, 300, 300 are produced in a mold for producing trailing edge segments, as described herein. In particular, a preferred mold may be one in which a maximum size of a trailing edge segment 300, in particular a maximum longitudinal extent LHmax, can be produced, and which can be varied by exchanging and/or adding one or more mold segments in such a way that the trailing edge segments 300, 300 can also be produced with the same mold.

[0074] The rotor blade series represented in FIGS. 4A, 4B, 4C has three different rotor blades 500, 500, 500. The two rotor blades 500, 500 have an identically formed outer blade 400 with a blade end connection geometry 401 and a blade tip 402. The rotor blades 500, 500 differ by differently formed blade ends 290, 290, which are connected by their outer blade connection geometries 222, 222 to the blade end connection geometries 401 of the outer blades 400.

[0075] The rotor blades 500, 500 also differ by differently formed trailing edge segments 390, 390. In the embodiments shown in FIGS. 4A, 4B, 4C, the trailing edge segments 390, 390, 390 also have connection geometries 392, 392, 392, in order also to adapt the trailing edge segments 390, 390, 390 to the outer blades 400 visually and/or with respect to the shape and/or the connection geometry. The blade ends 290, 290 differ primarily in their longitudinal extent. Preferably, the hub connection geometries 211, 211 and the outer blade connection geometries 222, 222 are in each case identically formed.

[0076] The third rotor blade 500 differs from the first two rotor blades 500, 500 not only by a differently formed blade end 290 and a differently formed trailing edge segment 390, but also by a different outer blade 400. The outer blade 400 has a shorter longitudinal extent than the outer blades 400. The blade end connection geometry 401 may correspond to the blade end connection geometries 401 of the outer blades 400. The blade tip 402 may also correspond to the blade tips 402 of the outer blades 400. The blade end connection geometry 401 and/or the blade tip 402 may however also be formed differently from the blades 400.

[0077] Also the hub connection geometry 200 and/or the outer blade connection geometry 222 and/or the connection geometry 392 may be formed identically to or differently from the corresponding geometries of the rotor blades 500, 500.

[0078] Among the advantages of the various aspects of the invention, which lead inter alia to the rotor blade series, is that various rotor blades can be produced quickly, inexpensively and reliably. In this way, the expenditure on the design, the construction and/or the production of different rotor blades for wind power installations with different rotor diameters can be reduced.