RUDDER BLADE WITH A MODULAR STRUCTURE, SEGMENT FOR A RUDDER BLADE OR FOR AN APPARATUS FOR IMPROVING PROPULSION AND METHOD FOR MANUFACTURING A RUDDER BLADE

Abstract

In order to provide a rudder blade, which has a low level of weight, is easier and more inexpensive to manufacture, that meets the various strength and stability requirements for various rudder-blade sections, which can be at least partly manufactured in an automated manner and for which the manufacturing of irregular surfaces, in particular, the leading edge, is made easier, a rudder blade is proposed, which has a modular structure, wherein the rudder blade comprises at least two prefabricated rudder-blade segments and is composed of the at least two prefabricated rudder-blade segments.

Claims

1. A rudder blade having a modular structure, wherein the rudder blade comprises at least two prefabricated rudder-blade segments and is composed of the at least two prefabricated rudder-blade segments.

2. The rudder blade according to claim 1, wherein the rudder blade comprises a main section and a front rudder-blade section with a leading edge, wherein the main section comprises or is a first rudder-blade segment and wherein the front rudder-blade section comprises or is a second rudder-blade segment, and/or wherein the rudder blade comprises a rear rudder-blade section with a trailing edge, wherein the rudder blade comprises at least three prefabricated rudder-blade segments and is composed of the at least three prefabricated rudder-blade segments, wherein the rear rudder-blade section comprises or is a third rudder-blade segment, and/or wherein the rudder blade comprises an intermediate section, wherein the rudder blade comprises at least four prefabricated rudder-blade segments and is composed of the at least four prefabricated rudder-blade segments, wherein the intermediate section comprises or is a fourth rudder-blade segment.

3. The rudder blade according to claim 1, wherein at least one rudder-blade segment of the at least two rudder-blade segments (10, 11, 12, 13) comprises another material and/or is made of another material and/or is manufactured by means of another manufacturing method than at least one other rudder-blade segment of the at least two rudder-blade segments, wherein, preferably, the main section, in particular, the first rudder-blade segment, comprises another material and/or is manufactured by means of another manufacturing method than the front rudder-blade section, in particular, the second rudder-blade segment.

4. The rudder blade according to claim 2 or 3, wherein the front rudder-blade section, in particular, the second rudder-blade segment, comprises a rudder-blade-bottom section, and/or that the front rudder-blade section comprises a propulsion bulb.

5. The rudder blade according to claim 1, wherein at least one rudder-blade segment, in particular, the first rudder-blade segment, is a welded construction with transverse ribs and longitudinal ribs, and/or that at least one rudder-blade segment, in particular the second rudder-blade segment, is manufactured by means of a generative manufacturing method and/or an additive manufacturing method, in particular, a 3D-printing method, and/or that at least one rudder-blade segment, in particular the third rudder-blade segment, is a lightweight element, wherein the lightweight construction element is preferably a T-honeycomb component, a panel component or an all-steel honeycomb component.

6. The rudder blade according to claim 2, wherein the front rudder-blade section, in particular the second rudder-blade segment, comprises a surface with bionic structures, wherein, preferably, the bionic structure is designed to reduce a flow resistance, wherein particularly preferably the bionic structure is a sharkskin structure and/or wherein the bionic structure is a fin structure, in particular a whale-fin structure.

7. The rudder blade according to claim 1, wherein at least one of the at least two rudder-blade segments, preferably the first rudder-blade segment and/or the second rudder-blade segment and/or the third rudder-blade segment and/or the fourth rudder-blade segment, comprises at least two sub-segments, wherein, preferably, the first rudder-blade segment comprises a first sub-segment and a second sub-segment, and is composed of the first sub-segment and the second sub-segment, wherein, particularly preferably, a connecting body is arranged between the first sub-segment and the second sub-segment, being a stabilization plate in particular.

8. (canceled)

9. A segment for a rudder blade or for an apparatus for improving propulsion, in particular, a rudder-blade segment or a nozzle segment, wherein the segment is manufactured by means of a generative manufacturing method and/or an additive manufacturing method, in particular, a 3D-printing method, wherein the segment preferably comprises a leading edge.

10. The segment according to claim 9, wherein the segment comprises a surface with bionic structures, wherein the bionic structures are preferably designed to reduce a flow resistance, wherein the bionic structure is, particularly preferably, a sharkskin structure and/or wherein the bionic structure, is a fin structure, in particular a whale-fin structure, wherein, most preferably, the bionic structures are manufactured by means of a generative manufacturing process and/or an additive manufacturing method, in particular, by means of a 3D-printing method and/or by means of a material-removal method, in particular, a milling method and/or by means of a casting method.

11. The segment according to claim 9 or 10, wherein the segment comprises at least two sub-segments and/or that the segment is composed of at least two sub-segments, wherein, preferably, the sub-segments are connected to each other, in particular, using a click fastener system, by means of gluing, screwing together or welding.

12. The segment according to claim 9, wherein the segment is designed as a front rudder-blade section and comprises a rudder-blade-bottom section.

13. The segment according to claim 12, wherein the rudder-blade-bottom section is composed of sub-segments, wherein the sub-segments are preferably designed with a U-shape and comprise a recess or groove running in a longitudinal direction for connection to another segment, and/or wherein the sub-segments (44) comprise a first face side and a second face side, wherein connection means are arranged in the first face side and the second face side to connect two sub-segments to the face sides respectively.

14. A method for manufacturing a rudder blade with modular constructions, comprising the steps: manufacturing a first rudder-blade segment, manufacturing a second rudder-blade segment, joining at least the first rudder-blade segment and the second rudder-blade segment.

15. The method according to claim 14, wherein the first rudder-blade segment is a main section of a rudder blade and/or that the second rudder-blade segment is a front rudder-blade section, and/or that the first rudder-blade segment is manufactured by means of a welding method by panelling a bare framework structure composed of transverse ribs and longitudinal ribs and/or that the second rudder-blade segment is manufactured by means of a generative manufacturing method and/or an additive manufacturing method, in particular, a 3D-printing method.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0120] The present invention is described in detail below with reference to the drawings. The figures show

[0121] FIG. 1 a perspective view of a rudder blade with a modular structure,

[0122] FIG. 2 an exploded view of a rudder blade with a modular structure.

[0123] FIG. 3 a rudder-blade segment designed as a front rudder-blade section,

[0124] FIG. 4 a structured surface with bionic structures,

[0125] FIG. 5 a rudder-blade segment designed as a main section with a first sub-segment and a second sub-segment,

[0126] FIG. 6 a perspective view of a sub-segment for a rudder-blade-bottom section.

[0127] FIG. 7a a front view of a sub-segment for a rudder-blade-bottom section,

[0128] FIG. 7b a back view of a sub-segment for a rudder-blade-bottom section,

[0129] FIG. 8a a top view of a sub-segment for a rudder-blade-bottom section, and

[0130] FIG. 8b a side view of a sub-segment for a rudder-blade-bottom section,

DETAILED DESCRIPTION OF THE FIGURES

[0131] FIG. 1 shows a perspective view of a rudder blade 100 with a modular structure. The rudder blade 100 comprises prefabricated rudder-blade segments 10, 11, 12, 13 and is composed of the prefabricated rudder-blade segments 10, 11, 12, 13. A first rudder-blade segment 10 is designed as a main section 14. A second rudder-blade segment 11 is designed as a front rudder-blade section 15. A third rudder-blade segment is designed as a rear rudder-blade section 16. A fourth rudder-blade segment 13 is designed as an intermediate section 17. The front rudder-blade section 15 comprises a leading edge 18 as well as propulsion bulb 19. The second rudder-blade segment 11 or the front rudder-blade section 15 is approximately L-shaped, wherein a rudder-blade-bottom section 21 adjoins in the lower region 20. The rudder-blade-bottom section 21 is orientated at approximately a right angle to the section of the second rudder-blade segment 11, at which the leading edge 18 is arranged and passes over into this section via a radius 22. The rudder-blade-bottom section 21 can be designed as a single piece with the second rudder-blade segment 11, which represents the front rudder-blade section 15. However, it is also possible that the rudder-blade-bottom section 21 is an independent rudder-blade segment. The third rudder-blade segment 12 comprises a trailing edge 23. The outer walls 24 of the rear rudder-blade section 16 and of the third rudder-blade section 12 are designed to be flat. The fourth rudder-blade segment designed as an intermediate section 17, which can also be called a semi-flat piece, primarily comprises slightly curved outer walls 25. In the arrangement shown, the first rudder-blade segment 10, the second rudder-blade segment 11 and third rudder-blade segment 12 enclose the intermediate section 17 and the fourth rudder-blade segment 13. The rudder 100 shown is a twisted rudder. That means that the upper section 26a of the leading edge 18 is offset with relation to a lower section 26b of the leading edge 18 so that the upper section 26a is offset in the port direction while the lower section 26b is offset in the starboard direction.

[0132] FIG. 2 shows an exploded view of the rudder 100 with a modular structure. The second rudder-blade segment 11, which is designed as a front rudder-blade section 15, comprises the leading edge 18, the propulsion bulb 19 as well as the rudder-blade-bottom section 21. The first rudder-blade segment 10, which is designed as a main section 14, is composed of a first sub-segment 27 and a second sub-segment 28. The first sub-segment 27 and the second sub-segment 28 are connected to each other via a connecting body 30 designed as a stabilization plate 29. A longitudinal rib 32 can be seen on the bottom 31 of the second sub-segment 28 of the main section 14. The main section 14 or the first rudder-blade segment 10 composed of the first sub-segment 27 and the second sub-segment 28 is manufactured by means of a conventional manufacturing method by means of panelling of a bare framework structure 33 with an outer wall 34 made of longitudinal ribs 32 and transverse ribs.

[0133] In contrast, the second rudder-blade segment 11, which forms the front rudder-blade section 15, is manufactured by means of a an additive or a generative manufacturing method, in particular, by means of a 3D-printing method.

[0134] The third rudder-blade segment 12 designed as a rear rudder-blade section 16 comprises an all-steel honeycomb component 36 in an interior space 35 so that the third rudder-blade segment 12 is designed as a lightweight element 37. The fourth rudder-blade segment 13 designed as an intermediate section 17 can be manufactured by means of a conventional manufacturing method by panelling a bare framework structure, by means of a 3D-printing method or by means of other methods.

[0135] Due to the different manufacturing methods, the materials of the rudder-blade segments 10, 11, 12, 13 are different. In this way, the second rudder-blade segment 11 manufactured by means of a 3D-printing method can be made of a plastic or a metal. In contrast, the main section 14 manufactured by means of a known manufacturing method is manufactured out of steel. The rear rudder-blade section 16 can also be manufactured by means of a conventional or known manufacturing method. However, it is also possible that the rear rudder-blade section 16 is manufactured out of a plastic or comprises a plastic.

[0136] FIG. 3 shows a perspective view of the second rudder-blade segment 11 designed as a front rudder-blade section 15. In the embodiment shown in FIG. 3, the second rudder-blade segment 11 comprises a structured surface 39. In particular, the leading edge 18 is provided with the structured surface 39. The structured surface 39 thereby comprises bionic structures 40. The bionic structures 40 can, for example, be designed as a sharkskin structure 41.

[0137] A section of the structured surface 39 of the leading edge 18 is shown in FIG. 4 in a detailed view. The bionic structure 40 comprising a sharkskin structure 41 comprises a plurality of elevations 42.

[0138] The structured surface 39 and the bionic structure 40 of the leading edge 18 of the second rudder-blade segment 11 is favourably manufactured at the same time during the same manufacturing step as the second rudder-blade segment 11 by means of a generative, additive or 3D-printing method. The bionic structures 40 must not be subsequently machined out of the second rudder-blade segment 11, for example by means of a milling method.

[0139] FIG. 5 shows a perspective view of the main section 14. The main section 14 is composed of a first sub-segment 27 and a second sub-segment 28, which are connected to each other via a stabilization plate 29. In the interior space of the main section 14, a bare framework structure 33 made of longitudinal ribs 32 and transverse ribs 43 are arranged, which is provided with an outer wall 34.

[0140] Returning to the FIG. 3, it can be recognized that the rudder-blade-bottom section 21 of the second rudder-blade segment 11 is also composed of a plurality of sub-segments 44. A sub-segment 44 of the rudder-blade-bottom section 21 is shown in a perspective view in FIG. 6. The sub-segment 44 of the rudder-blade-bottom section 21 is approximately U-shaped and comprises a recess or a groove 45, which runs in a longitudinal direction 46 of the sub-segment 44. Thereby, the groove 45 is not centrally arranged, but runs slightly offset within the sub-segment 44. A first face side 47 of the sub-segment 44 comprises connection means 49 designed as receiving openings 48.

[0141] In FIGS. 7a and 7b, the sub-segment 44 is shown in a front view (FIG. 7a) and in a back view (FIG. 7b). In the front view a second face side 50 of the sub-segment 44 is shown. Connection means 52 designed as receiving openings 51 are also located in the second face side 50. In the back view shown in FIG. 7b, the connection means 49 are shown again in the first face side 47.

[0142] FIGS. 8a and 8b show a top view (FIG. 8a) and a side view (FIG. 8b) of the sub-segment 44. The groove 45 in the upper side 53 of the sub-segment 44, which is not centrally arranged, can be clearly recognized. A plurality of sub-segments 44 can be arranged in such a way that a first face side 47 of a first sub-segment 44 comes to rest in contact with a second face side 50 of the second sub-segment 44. Snap hooks or click-connection elements or, if applicable, screws (all not shown) can be led into the receiving openings 48, 51, thereby connecting a plurality of sub-segments 44 with each other to form a rudder-blade-bottom section 21.

[0143] The sub-segment 44 is also manufactured as part of the second rudder-blade segment 11 by means of a 3D-printing method. The material is preferably PET-G or ABS. In the top view in FIG. 8a, it can furthermore be recognized that the contour of a first side 54 is more strongly curved than the contour of a second side 55 lying opposite to the first side 54. The different contour corresponds to the different contour of the side of the rudder blade 100, which is designed as a twisted rudder, thereby comprising a pressure side 56 and a suction side 57.

LIST OF REFERENCE NUMBERS

[0144] 100 rudder blade [0145] 10 first rudder-blade segment [0146] 11 second rudder-blade segment [0147] 12 third rudder-blade segment [0148] 13 fourth rudder-blade segment [0149] 14 main section [0150] 15 front rudder-blade section [0151] 16 rear rudder-blade section [0152] 17 intermediate section [0153] 18 leading edge [0154] 19 propulsion bulb [0155] 20 lower area [0156] 21 rudder-blade-bottom section [0157] 22 radius [0158] 23 trailing edge [0159] 24 outer wall [0160] 25 outer wall [0161] 26a upper section [0162] 26b lower section [0163] 27 first sub-segment [0164] 28 second sub-segment [0165] 29 stabilization plate [0166] 30 connecting body [0167] 31 bottom [0168] 32 longitudinal rib [0169] 33 bare framework structure [0170] 34 outer wall [0171] 35 interior space [0172] 36 honeycomb element [0173] 37 lightweight element [0174] 38 panel [0175] 39 structured surface [0176] 40 bionic structure [0177] 41 sharkskin structure [0178] 42 projection [0179] 43 transverse rib [0180] 44 sub-segment [0181] 45 groove [0182] 46 longitudinal direction [0183] 47 first face side [0184] 48 receiving opening [0185] 49 connection means [0186] 50 second face side [0187] 51 receiving opening [0188] 52 connection means [0189] 53 upper side [0190] 54 first side [0191] 55 second side [0192] 56 pressure side [0193] 57 suction side