WIND TURBINE BLADE WITH IMPROVED GLUE JOINT AND RELATED METHOD

Abstract

A blade shell part for a wind turbine blade and a wind turbine blade are disclosed. The blade shell part is made of a composite structure comprising a reinforcement material embedded in a polymer matrix, the blade shell part extending from a tip end to a root end, wherein the blade shell part comprises: a blade shell body with a leading edge and a trailing edge, and a first glue flange extending from the leading edge and having a first glue flange edge and a first glue surface with a first width, wherein the first glue flange is provided with one or more spacer elements. Further, a method of manufacturing a wind turbine blade is described.

Claims

1. A blade shell part (70, 70A) for a wind turbine blade, wherein the blade shell part is made of a composite structure comprising a reinforcement material embedded in a polymer matrix, the blade shell part extending from a tip end to a root end, wherein the blade shell part comprises: a blade shell body (74) with a leading edge (76) and a trailing edge, and a first glue flange (78) extending from the leading edge (76) and having a first glue flange edge (80) and a first glue surface (82) with a first width, wherein the first glue surface is provided with one or more spacer elements (84, 84A, 90, 90A).

2. Blade shell part according to claim 1, wherein the first glue flange (78) comprises a longitudinally extending gasket (86) for at least partly contacting an inner surface of another blade shell part.

3. Blade shell part according to claim 2, wherein the gasket (86) is a rubber gasket arranged on the first glue flange edge (80).

4. Blade shell part according to claim 1, wherein the one or more spacer elements comprises a first set of first spacer elements, each first spacer element having a height in the range from 1 mm to 10 mm.

5. Blade shell part according to claim 4, wherein a distance between two neighbouring first spacer elements is in the range from 20 cm to 150 cm, and/or wherein the first spacer elements are arranged at respective first distances from the first glue flange edge along the first glue surface, the first distances being less than 0.5*W1, where W1 is the first width of the first glue surface.

6. Blade shell part according to claim 1, wherein the one or more spacer elements comprises a second set of second spacer elements, each second spacer element having a height in the range from 1 mm to 10 mm and being arranged at respective second distances from the first glue flange edge along the first glue surface, the second distances being in the range from 0.5*W1 to W1, where W1 is the first width of the first glue surface, e.g. wherein a distance between two neighbouring second spacer elements is in the range from 20 cm to 150 cm.

7. Blade shell part according to claim 1, wherein the first glue flange is flexible.

8. Blade shell part according to claim 1, wherein the first glue flange has a maximum thickness in the range from 1 mm to 20 mm.

9. Blade shell part according to claim 1, wherein the thickness of the first glue flange varies along the first glue surface from the leading edge to the first glue flange edge.

10. Blade shell part according to claim 1, wherein the first glue flange has one or more openings (120).

11. Blade shell part according to claim 1, wherein the blade shell part comprises a leading edge seal (88) extending along the leading edge.

12. A wind turbine blade (91) comprising a first blade shell part (70) and a second blade shell part (90), wherein the first blade shell part is a blade shell part according to any of the preceding claims, the second blade shell part comprising a blade shell body with a leading edge and a trailing edge and having a second glue surface (98) on an inner surface thereof, wherein at least one of the spacer elements contact the second glue surface and glue (102) is arranged between the first glue surface (82) and the second glue surface (98).

13. Wind turbine blade according to claim 12, wherein the second blade shell part comprises one or more openings in the blade shell body.

14. A method of manufacturing a wind turbine blade, wherein the wind turbine blade is manufactured as a composite structure comprising a reinforcement material embedded in a polymer matrix, the method comprising: providing a first blade shell part comprising a blade shell body with a leading edge and a trailing edge, and a first glue flange at the leading edge, the first glue flange having a first glue flange edge and a first glue surface with a first width; providing one or more spacer elements on the first glue flange; providing a second blade shell part comprising a blade shell body with a leading edge and a trailing edge, and a second glue surface; arranging the second blade shell part on the first blade shell part such that at least one of the spacer elements contact the second glue surface of the second blade shell part; and injecting glue between the first glue surface and the second glue surface.

15. Method according to claim 14, wherein injecting glue between the first glue surface and the second glue surface comprises injecting glue through one or more openings in the first glue flange or through one or more openings in the blade shell body of the second blade shell.

Description

DETAILED DESCRIPTION

[0050] The invention is explained in detail below with reference to the drawings, in which

[0051] FIG. 1 shows a wind turbine,

[0052] FIG. 2 shows a schematic view of a wind turbine blade,

[0053] FIG. 3 shows a schematic view of an airfoil profile,

[0054] FIG. 4 shows a schematic view of a wind turbine blade, seen from above and from the side,

[0055] FIG. 5 shows a part of a cross sectional view of a blade shell part according to the invention,

[0056] FIG. 6 shows a view of a blade shell part according to the invention,

[0057] FIG. 7 shows a part of a cross sectional view of a wind turbine blade according to the invention,

[0058] FIG. 8 shows a view of a blade shell part according to the invention,

[0059] FIG. 9 shows a cross-section of and exemplary first glue flange with gasket and spacer elements,

[0060] FIG. 10 shows an exemplary gasket, and

[0061] FIG. 11 shows a part of an exemplary wind turbine blade.

[0062] The present invention relates to manufacture of blade shell parts of wind turbine blades for horizontal axis wind turbines (HAWTs).

[0063] FIG. 1 illustrates a conventional modern upwind wind turbine according to the so-called Danish concept with a tower 4, a nacelle 6 and a rotor with a substantially horizontal rotor shaft. The rotor includes a hub 8 and three blades 10 extending radially from the hub 8, each having a blade root 16 nearest the hub and a blade tip 14 furthest from the hub 8. The rotor has a radius denoted R.

[0064] FIG. 2 shows a schematic view of an exemplary wind turbine blade 10. The wind turbine blade 10 has the shape of a conventional wind turbine blade with a root end and a tip end and comprises a root region 30 closest to the hub, a profiled or an airfoil region 34 furthest away from the hub and a transition region 32 between the root region 30 and the airfoil region 34. The blade 10 comprises a leading edge 18 facing the direction of rotation of the blade 10, when the blade is mounted on the hub, and a trailing edge 20 facing the opposite direction of the leading edge 18.

[0065] The airfoil region 34 (also called the profiled region) has an ideal or almost ideal blade shape with respect to generating lift, whereas the root region 30 due to structural considerations has a substantially circular or elliptical cross-section, which for instance makes it easier and safer to mount the blade 10 to the hub. The diameter (or the chord) of the root region 30 may be constant along the entire root area 30. The transition region 32 has a transitional profile gradually changing from the circular or elliptical shape of the root region 30 to the airfoil profile of the airfoil region 34. The chord length of the transition region 32 typically increases with increasing distance r from the hub. The airfoil region 34 has an airfoil profile with a chord extending between the leading edge 18 and the trailing edge 20 of the blade 10. The width of the chord decreases with increasing distance r from the hub.

[0066] A shoulder 40 of the blade 10 is defined as the position, where the blade 10 has its largest chord length. The shoulder 40 is typically provided at the boundary between the transition region 32 and the airfoil region 34.

[0067] It should be noted that the chords of different sections of the blade normally do not lie in a common plane, since the blade may be twisted and/or curved (i.e. pre-bent), thus providing the chord plane with a correspondingly twisted and/or curved course, this being most often the case in order to compensate for the local velocity of the blade being dependent on the radius from the hub.

[0068] The wind turbine blade 10 comprises a shell comprising two blade shell parts made of fibre-reinforced polymer and is typically made as a pressure side or upwind blade shell part 24 and a suction side or downwind blade shell part 26 that are glued together along bond lines 28 extending along the trailing edge 20 and the leading edge 18 of the blade 10. Typically, the root ends of the blade shell parts 24, 26 has a semi-circular or semi-oval outer cross-sectional shape.

[0069] FIGS. 3 and 4 depict parameters, which may be used to explain the geometry of blade shell parts to be manufactured according to the invention.

[0070] FIG. 3 shows a schematic view of an airfoil profile 50 of a typical blade of a wind turbine depicted with the various parameters, which are typically used to define the geometrical shape of an airfoil. The airfoil profile 50 has a pressure side 52 and a suction side 54, which during usei.e. during rotation of the rotornormally face towards the windward (or upwind) side and the leeward (or downwind) side, respectively. The airfoil 50 has a chord 60 with a chord length c extending between a leading edge 56 and a trailing edge 58 of the blade. The airfoil 50 has a thickness t, which is defined as the distance between the pressure side 52 and the suction side 54. The thickness t of the airfoil varies along the chord 60. The deviation from a symmetrical profile is given by a camber line 62, which is a median line through the airfoil profile 50. The median line can be found by drawing inscribed circles from the leading edge 56 to the trailing edge 58. The median line follows the centres of these inscribed circles and the deviation or distance from the chord 60 is called the camber f. The asymmetry can also be defined by use of parameters called the upper camber (or suction side camber) and lower camber (or pressure side camber), which are defined as the distances from the chord 60 and the suction side 54 and pressure side 52, respectively.

[0071] Airfoil profiles are often characterised by the following parameters: the chord length c, the maximum camber f, the position d.sub.f of the maximum camber f, the maximum airfoil thickness t, which is the largest diameter of the inscribed circles along the median camber line 62, the position d.sub.t of the maximum thickness t, and a nose radius (not shown). These parameters are typically defined as ratios to the chord length c. Thus, a local relative blade thickness t/c is given as the ratio between the local maximum thickness t and the local chord length c. Further, the position d.sub.p of the maximum pressure side camber may be used as a design parameter, and of course also the position of the maximum suction side camber.

[0072] FIG. 4 shows other geometric parameters of the blade and blade shell parts. The blade and blade shell parts have a total blade length L. As shown in FIG. 3, the root end is located at position r=0, and the tip end located at r=L. The shoulder 40 of the blade shell parts is located at a position r=L.sub.w, and has a shoulder width W, which equals the chord length at the shoulder 40. The diameter of the root is defined as X. Further, the blade/blade shell parts is provided with a prebend, which is defined as y, which corresponds to the out of plane deflection from a pitch axis 22 of the blade.

[0073] FIG. 5 shows a part of a cross-sectional view of a blade shell part. The blade shell part 70 is arranged in a blade mould 72. The blade shell part 70 comprises a blade shell body 74 with a leading edge 76 and a trailing edge (not shown), and a first glue flange 78 extending from the leading edge 76 and having a first glue flange edge 80 and a first glue surface 82 with a first width. The first glue flange 78 is provided with one or more spacer elements on the first glue surface, including a first spacer element 84 of a first set of spacer elements on the first glue surface 82. The first spacer element 84 has a height of 3 mm and is arranged within a first distance from the first glue flange edge 80, where the first distance is less than half the first width. The first glue flange 78 comprises a longitudinally extending rubber gasket 86 arranged on the first glue flange edge 80 for at least partly contacting an inner surface of another blade shell part. The first glue flange 78 is flexible with a maximum thickness between 3 mm and 10 mm and configured to adapt to the inner surface of another (second) blade shell part that is lowered onto the blade shell part (first blade shell part) 70 and at the same time providing a sufficient sealing between the first glue flange edge 80 and the inner surface (not shown) of the second blade shell part. The blade shell part 70 comprises a leading edge seal 88 extending along the leading edge 76 in order to seal the glue cavity between first and second glue surfaces of first and second blade shell parts, respectively, at the leading edge 76.

[0074] FIG. 6 is a cross sectional perspective view of the blade shell part 70. A first set of first spacer elements comprises first spacer elements 84, 84A that are provided on the first glue flange 78 and extending from the first glue surface 82. The first glue surface 82 has a first width W1, optionally varying along the longitudinal axis X, and the first spacer elements 84, 84A are arranged on the first glue surface at respective first distances from the first glue flange edge 80. The first distances are in the range from 0.1*W1 to 0.5*W1. The first spacer element 84 and the neighbouring first spacer element 84A have a circular shape and are arranged with a longitudinal distance of 80 cm between each other. A second set of second spacer elements comprises second spacer elements 90, 90A that are provided on the first glue flange 78 and extending from the first glue surface 82. The second spacer elements 90, 90A have a circular shape and are arranged on the first glue surface at respective second distances from the first glue flange edge 80, wherein the second distances are in the range from 0.5*W1 to W1. The second spacer element 90 and the neighbouring second spacer element 90A have a longitudinal distance of 80 cm between each other. The second spacer element 90 is arranged between the first spacer elements 84, 84A along the longitudinal axis with a longitudinal distance to both first spacer elements 84, 84A of about 40 cm.

[0075] FIG. 7 shows a part of a cross-sectional view of a wind turbine blade 91 comprising the blade shell part 70 as a first blade shell part and a second blade shell part 92. The second blade shell part 92 comprises a blade shell body 94 with a leading edge 96 and having a second glue surface 98 on an inner surface 100 thereof. The first spacer element 84 contacts the second glue surface 98 and glue 102 is arranged between the first glue surface and the second glue surface. The flexible first glue flange has adapted to the inner surface of the second blade shell part 92 and the gasket 86 provides a seal at the first glue flange edge. The first and second glue surfaces form, together with leading edge seal 88 and gasket 86, a glue cavity for the glue. Optionally, glue 102 has been injected through one or more openings in the shell body 94 of the second blade shell part 92 and/or through one or more openings in the first glue flange 78, the one or more openings providing access to the glue cavity from the outside of the wind turbine blade or from the inside of the wind turbine blade. The leading edge seal 88 is optionally removed in the post-processing of the wind turbine blade

[0076] FIG. 8 is a cross sectional perspective view of a blade shell part 70A. A first set of first spacer elements comprises first spacer elements 84, 84A that are provided on the first glue flange 78 and extending from the first glue surface 82. The first spacer elements 84, 84A are oblong and arranged on the first glue surface at respective first distances from the first glue flange edge 80 parallel to the longitudinal axis X. The first spacer elements may be angled with respect to the longitudinal axis, e.g. in the range from 0 degrees to 45 degrees or from 45 degrees to 90 degrees. The first distances are in the range from 0.1*W1 to 0.5*W1. The first spacer element 84 and the neighbouring first spacer element 84A are arranged with a longitudinal distance of 80 cm between each other. A second set of second spacer elements comprises second spacer elements 90, 90A that are provided on the first glue flange 78 and extending from the first glue surface 82. The second spacer elements 90, 90A are oblong and angled 45 degrees with respect to the longitudinal axis. The second spacer element 90 and the neighbouring second spacer element 90A have a longitudinal distance of 80 cm between each other. The second spacer element 90 is arranged between the first spacer elements 84, 84A along the longitudinal axis with a longitudinal distance to both first spacer elements 84, 84A of about 40 cm.

[0077] FIG. 9 shows a cross-sectional view of parts of a blade shell part. The blade shell part, e.g. the first blade shell part, comprises a first glue flange 78 extending from the leading edge 76 and having a first glue flange edge 80 and a first glue surface 82 with a first width. The first glue flange 78 comprises a longitudinally extending rubber gasket 86 with a longitudinally extending recess accommodating the first glue flange edge 80. The gasket in FIG. 8 is a self-sealing gasket for at least partly contacting an inner surface of another blade shell part to form a seal between the first glue flange edge and the inner surface of another blade shell part.

[0078] The first glue flange 78 is provided with one or more spacer elements including a first spacer element 84 of a first set of spacer elements. The first spacer element 84 has a height of 3 mm and is arranged within a first distance from the first glue flange edge 80, where the first distance is less than half the first width. The first glue flange 78 is flexible with a maximum thickness between 3 mm and 10 mm and configured to adapt to the inner surface of another (second) blade shell part that is lowered onto the blade shell part (first blade shell part) 70 and at the same time providing a sufficient sealing between the first glue flange edge 80 and the inner surface (not shown) of the second blade shell part. Further, a second spacer element 90 is arranged within a second distance from the first glue flange edge 80, where the second distance is larger than half the first width.

[0079] FIG. 10 shows an exemplary gasket. The gasket 89 is a self-sealing gasket and comprises a concave first surface 104 facing the first glue surface 82. The gasket comprises a second surface 106 configured to at least partly facing and/or contacting an inner surface of a blade shell part. When glue is filled into to glue cavity, the glue presses on the first surface 104 and forces a part of the second surface 106 against the inner surface of the blade shell part, thus sealing the glue cavity between the first glue surface and the second glue surface.

[0080] A first edge 108 of the gasket 86 is configured for attachment to the first glue flange edge 80 by a press-fit arrangement. Accordingly, the first edge 108 of the gasket is provided with a longitudinally extending recess 110 for accommodating the first glue flange edge. The gasket 86 has a second edge 112. One or more barbs (not shown) extend into the recess 110 at the first edge 108 of the gasket. The gasket may be glued to the first glue flange edge. A first and second longitudinally extending protrusion 114, 116 is arranged on the second surface at the second edge 112 of the gasket (at a distance less than 3 cm from the second edge). The protrusions 114, 116 conform to the inner surface of the second blade shell part and act as a seal for the glue cavity.

[0081] FIG. 11 shows a perspective view of and exemplary wind turbine blade. The wind turbine blade comprises a first blade shell part 70 and second blade shell part 92. Upon arranging the second blade shell part on the first blade shell part, glue is injected through openings 120 in the second glue surface of the second blade shell part 92 into the glue cavity formed by respective first and second glue surfaces, gasket and leading edge seal. Openings 120 are spaced in the range from 50 cm to 3 m along the wind turbine blade. The openings 120 allow for a sequential filling of the glue cavity.

[0082] The invention has been described with reference to preferred embodiments. However, the scope of the invention is not limited to the illustrated embodiments, and alterations and modifications can be carried out without deviating from the scope of the invention that is defined by the following claims. The invention is not limited to the embodiments described herein, and may be modified or adapted without departing from the scope of the present invention.

LIST OF REFERENCE NUMERALS

[0083] 2 wind turbine

[0084] 4 tower

[0085] 6 nacelle

[0086] 8 hub

[0087] 10 blade

[0088] 14 blade tip

[0089] 15 tip end section

[0090] 16 blade root

[0091] 17 root end face

[0092] 18 leading edge

[0093] 20 trailing edge

[0094] 22 pitch axis

[0095] 24 pressure side blade shell part/upwind blade shell part

[0096] 26 suction side blade shell part/downwind blade shell part

[0097] 28 bond lines

[0098] 29 horizontal

[0099] 30 root region

[0100] 32 transition region

[0101] 34 airfoil region

[0102] 50 airfoil profile

[0103] 52 pressure side/upwind side

[0104] 54 suction side/downwind side

[0105] 56 leading edge

[0106] 58 trailing edge

[0107] 60 chord

[0108] 62 camber line/median line

[0109] 70, 70A blade shell part/first blade shell part

[0110] 72 blade mould

[0111] 74 blade shell body

[0112] 76 leading edge

[0113] 78 first glue flange

[0114] 80 first glue flange edge

[0115] 82 first glue surface

[0116] 84 first spacer element

[0117] 84A first spacer element

[0118] 86 gasket

[0119] 88 leading edge seal

[0120] 90 second spacer element

[0121] 90A second spacer element

[0122] 91 wind turbine blade

[0123] 92 second blade shell part

[0124] 94 shell body

[0125] 96 leading edge

[0126] 98 second glue surface

[0127] 100 inner surface

[0128] 102 glue

[0129] 104 first surface of gasket

[0130] 106 second surface of gasket

[0131] 108 first edge of gasket

[0132] 110 recess

[0133] 112 second edge of gasket

[0134] 114 first longitudinally extending protrusion

[0135] 116 second longitudinally extending protrusion

[0136] 120 opening/glue inlet/glue outlet

[0137] c chord length

[0138] d.sub.t position of maximum thickness

[0139] d.sub.f position of maximum camber

[0140] d.sub.p position of maximum pressure side camber

[0141] f camber

[0142] L blade length

[0143] r local radius, radial distance from blade root

[0144] t thickness

[0145] D blade root diameter

[0146] y prebend

[0147] X longitudinal axis