Method for manufacturing a wind turbine blade and wind turbine blade

Abstract

A method for manufacturing a wind turbine blade, comprising the steps of: arranging (S2, S3) a joining portion (8) comprising a fibre lay-up inside adjacent blade sections, covering (S4) the joining portion (8) and the adjacent blade sections at least partially with a vacuum bag, and applying vacuum to a space (54) covered by the vacuum bag (19, 38), infusing at least the fibre lay-up (12, 13, 14, 15, 16, 17) with a resin (43) and curing (S5) the resin (43) to obtain a cured joining portion (44) joining the blade sections (20, 24) inside. A light-weight and at the same time strong blade section joint is provided. In particular, the strength of this laminate joint formed by vacuum infusion is comparable to the strength of the pristine laminate. Compared to a connection using an adhesive, the laminate joint formed by vacuum infusion provides a lighter and stronger blade section joint, in particular, a better weight-to-strength performance.

Claims

1. A method for manufacturing a wind turbine blade, comprising: arranging a joining portion comprising a fiber lay-up inside adjacent blade sections, covering the joining portion and the adjacent blade sections at least partially with a vacuum bag, and applying vacuum to a space covered by the vacuum bag, infusing at least the fiber lay-up with a resin, and curing the resin to obtain a cured joining portion joining the blade sections inside such that the cured joining portion joins the adjacent blade sections on their inside surfaces, wherein the joining portion is provided on a mandrel, and the joining portion is arranged inside the adjacent blade sections by arranging the mandrel with the joining portion inside the adjacent blade sections, and wherein the vacuum bag is prepacked with the joining portion on the mandrel.

2. The method according to claim 1, wherein each of the adjacent blade sections comprises an outwardly tapered portion such that the outwardly tapered portions form a common recess, and the joining portion is arranged inside the adjacent blade sections by arranging the joining portion in the common recess.

3. The method according to claim 1, wherein the fiber lay-up comprises a fiber lay-up forming, once cured, one or more beam joints joining one or more beams of a first one of the adjacent blade sections with one or more corresponding beams of a second one of the adjacent blade sections, and/or wherein the fiber lay-up comprises a fiber lay-up forming, once cured, a shell joint joining a shell of a first one of the adjacent blade sections with a shell of a second one of the adjacent blade sections, and/or wherein the fiber lay-up comprises a fiber lay-up forming, once cured, a web joint joining a web of a first one of the adjacent blade sections with a web of a second one of the adjacent blade sections.

4. The method according to claim 3, wherein the one or more beams comprise a pressure-side beam, a suction-side beam, a leading-edge beam or reinforcement and/or a trailing edge beam or reinforcement.

5. The method according to claim 1, wherein the joining portion is arranged inside the adjacent blade sections comprising a first one of the blade sections and a second one of the blade sections by: inserting the joining portion partially into the first one of the blade sections such that a portion of the joining portion protrudes from the first one of the blade sections, and arranging the second one of the blade sections adjacent to the first one of the blade sections such that the second one of the blade sections receives the portion of the joining portion protruding from the first one of the blade sections.

6. The method according to claim 1, wherein the joining portion is arranged inside the adjacent blade sections by a lifting tool.

7. The method according to claim 1, wherein the fiber lay-up includes at least one of glass fibers, carbon fibers, aramid fibers and natural fibers, and/or wherein the fiber lay-up comprises fibers in dry condition, and/or wherein the fiber lay-up includes a core material.

8. The method according to claim 1, wherein the resin includes at least one of thermosets, thermoplastics, epoxy, polyurethane, vinyl ester and polyester.

9. The method according to claim 1, comprising, after infusing and curing the resin, the step of applying a sealing band covering a separation line between the adjacent blade sections from the outside.

10. The method according to claim 7, wherein the core material includes wood, balsa, PET foam, and/or PVC foam.

11. The method according to claim 1, wherein the joining portion comprises a fiber lay-up for a pressure-side beam joint, a fiber lay-up for a suction-side beam joint, a fiber lay-up for a leading-edge beam joint, a fiber lay-up for a trailing edge beam joint, and a fiber lay-up for a web joint.

12. The method according to claim 11, wherein the joining portion further comprises a fiber lay-up for a shell joint.

13. A method for manufacturing a wind turbine blade, comprising: arranging a joining portion comprising a fiber lay-up inside adjacent blade sections, covering the joining portion and the adjacent blade sections at least partially with a vacuum bag, and applying vacuum to a space covered by the vacuum bag, infusing at least the fiber lay-up with a resin, and curing the resin to obtain a cured joining portion joining the blade sections inside such that the cured joining portion joins the adjacent blade sections on their inside surfaces, wherein the joining portion comprises a fiber lay-up for a pressure-side beam joint, a fiber lay-up for a suction-side beam joint, a fiber lay-up for a leading-edge beam joint, a fiber lay-up for a trailing edge beam joint, and a fiber lay-up for a web joint.

14. The method according to claim 13, wherein each of the adjacent blade sections comprises an outwardly tapered portion such that the outwardly tapered portions form a common recess, and the joining portion is arranged inside the adjacent blade sections by arranging the joining portion in the common recess.

15. The method according to claim 13, wherein the joining portion is provided on a mandrel, and the joining portion is arranged inside the adjacent blade sections by arranging the mandrel with the joining portion inside the adjacent blade sections.

16. The method according to claim 13, wherein the fiber lay-up comprises a fiber lay-up forming, once cured, one or more beam joints joining one or more beams of a first one of the adjacent blade sections with one or more corresponding beams of a second one of the adjacent blade sections; and/or wherein the fiber lay-up comprises a fiber lay-up forming, once cured, a shell joint joining a shell of a first one of the adjacent blade sections with a shell of a second one of the adjacent blade sections; and/or wherein the fiber lay-up comprises a fiber lay-up forming, once cured, a web joint joining a web of a first one of the adjacent blade sections with a web of a second one of the adjacent blade sections.

17. The method according to claim 13, wherein the joining portion is arranged inside the adjacent blade sections comprising a first one of the blade sections and a second one of the blade sections by: inserting the joining portion partially into the first one of the blade sections such that a portion of the joining portion protrudes from the first one of the blade sections, and arranging the second one of the blade sections adjacent to the first one of the blade sections such that the second one of the blade sections receives the portion of the joining portion protruding from the first one of the blade sections.

18. The method according to claim 13, comprising, after infusing and curing the resin, the step of applying a sealing band covering a separation line between the adjacent blade sections from the outside.

19. The method according to claim 15, wherein the vacuum bag is prepacked with the joining portion on the mandrel.

20. The method according to claim 13, wherein the joining portion further comprises a fiber lay-up for a shell joint.

Description

BRIEF DESCRIPTION

(1) Some of the embodiments will be described in detail, with reference to the following figures, wherein like designations denote like members, wherein:

(2) FIG. 1 shows a wind turbine according to an embodiment;

(3) FIG. 2 shows a perspective view of a joining portion on a mandrel according to an embodiment, the joining portion being configured for joining two blade sections of a blade of the wind turbine of FIG. 1;

(4) FIG. 3 shows the joining portion of FIG. 2 without the mandrel;

(5) FIG. 4 shows a perspective view of the joining portion of FIG. 2 during inserting it into a first blade section;

(6) FIG. 5 shows a perspective view of a second blade section during arranging it adjacent to the first blade section of FIG. 4;

(7) FIG. 6 shows a cross-section view of the first and second blade sections of FIG. 5 arranged adjacent to each other, the cross-section being taken along line B of FIG. 5;

(8) FIG. 7 shows a fiber lay-up for a beam joint of the joining portion of FIG. 2 in cross-section taken along line B of FIG. 5;

(9) FIG. 8 shows a view similar as FIG. 7 but with the joining portion inserted into the first blade section;

(10) FIG. 9 shows a view similar as FIG. 8 but with the second blade section arranged adjacent the first blade section;

(11) FIG. 10 shows a view similar as FIG. 9 but with a vacuum bag attached and sealed;

(12) FIG. 11 shows a fiber lay-up for a shell joint of the joining portion of FIG. 2 in cross-section taken along line C of FIG. 5;

(13) FIG. 12 shows a view similar as FIG. 11 but with the joining portion inserted into the first blade section;

(14) FIG. 13 shows a view similar as FIG. 12 but with the second blade section arranged adjacent the first blade section;

(15) FIG. 14 shows a view similar as FIG. 13 but with a vacuum bag attached and sealed;

(16) FIG. 15 shows a fiber lay-up for a web joint of the joining portion of FIG. 2 and the first blade section in cross-section taken along line D in FIG. 2;

(17) FIG. 16 shows a view similar as FIG. 15 but with the joining portion inserted into the first blade section;

(18) FIG. 17 shows an outside view of the first and second blade sections joined with each other by the joining portion; and

(19) FIG. 18 shows a flowchart illustrating a method for manufacturing the wind turbine blade of the wind turbine of FIG. 1.

DETAILED DESCRIPTION

(20) FIG. 1 shows a wind turbine 1 according to an embodiment. The wind turbine 1 comprises a rotor 2 having one or more blades 3 connected to a hub 4. The hub 4 is connected to a generator (not shown) arranged inside a nacelle 5. During operation of the wind turbine 1, the blades 3 are driven by wind to rotate and the wind's kinetic energy is converted into electrical energy by the generator in the nacelle 5. The nacelle 5 is arranged at the upper end of a tower 6 of the wind turbine 1. The tower 6 is erected on a foundation 7 such as a monopile or tripile. The foundation 7 is connected to and/or driven into the ground or seabed.

(21) In the following an improved method for manufacturing a wind turbine blade 3 comprising two or more blade sections 20, 24 is described with respect to FIGS. 2 to 18.

(22) In step S1 of the method, a joining portion 8 is provided on a mandrel 9, as shown in FIG. 2. The mandrel 9 comprises a first mandrel portion 10 and a second mandrel portion 11. The joining portion 8 comprises a fiber lay-up 12 for a pressure-side beam joint and a fiber lay-up 13 for a suction-side beam joint. Further, the joining portion 8 comprises a fiber lay-up 14 for a leading-edge beam joint and a fiber lay-up 15 for a trailing edge beam joint. Furthermore, the joining portion 8 comprises a fiber lay-up 16 for a web joint. The fiber lay-up 16 for the web joint is arranged between the first and second mandrel portions 10 and 11. The joining portion 8 comprises in addition a fiber lay-up 17 for a shell joint.

(23) In the described example, the fiber lay-ups 12, 13, 14, 15 and 17 for the beams and the shell comprise fibers in dry condition, i.e., without resin. Further, in the described example, the fiber lay-up 16 for the web joint comprises both fibers in dry condition as well as pre-casted fibers.

(24) FIG. 3 shows the joining portion 8 of FIG. 2 without the mandrel 9 for illustration purposes.

(25) For pre-packing the joining portion 8 as shown in FIG. 2, firstly a mould 18 is provided. On the mould 18, the fiber lay-up 13 for the suction-side beam joint and a part of the fiber lay-up 17 for the shell joint are provided. Then, vacuum bags 19 are provided on the fiber lay-ups 13, 17. In the next step, the mandrel 9, i.e., the mandrel portions 10 and 11, is arranged. The vacuum bags 19 are wrapped around the mandrel portions 10 and 11 at the leading edge and trailing edge side. Also, the fiber lay-up 16 for the web joint is arranged. Next, the fiber lay-up 12 for the pressure-side beam joint, the fiber lay-up 14 for the leading-edge beam joint, the fiber lay-up 15 for the trailing edge beam joint, and the remaining of the fiber lay-up 17 for the shell joint are provided. Finally, the vacuum bags 19 are arranged such that all fiber lay-ups 12, 13, 14, 15, 16 and 17 are covered on one side thereof by a vacuum bag 19. When using a mandrel 9 comprising more than one mandrel portion 10, 11, more than one vacuum bag 19 may be required.

(26) In step S2 of the method, the joining portion 8 comprising the fiber lay-ups 12, 13, 14, 15, 16 and 17 for the beam, shell and web joints is inserted together with the mandrel 9 partially into a first blade section 20.

(27) FIG. 4 illustrates step S2 of arranging the joining portion 8 in the first blade section 20 of the wind turbine 1. The first blade section 20 has, in particular, been manufactured using fiber-reinforced resin. The first blade section 20 has, for example, been manufactured simultaneously to the step S1 of pre-packing the joining portion 8. In this example, the first blade section 20 is an inboard section of the blade 3. However, the joining portion 8 could also be inserted into an outboard section of the blade 3.

(28) In FIG. 4, the first blade section 20 is fixed in position by alignment jigs 21. The joining portion 8 is inserted into the first blade section 20 by a lifting tool 22. The lifting tool 22 in this example is a lifting truck. The joining portion 8 is, in particular, inserted partially into the first blade section 20 such that a portion 23 of the joining portion 8 is protruding from the first blade section 20, as shown in FIG. 5.

(29) Inserting the joining portion 8 into the first blade section 20 includes matching the fiber lay-ups 12, 13, 14, 15, 16, 17 of the joining portion 8 with corresponding layers of the first blade section 20.

(30) In order to more easily insert the joining portion 8 into the first blade section 20, the cross-section size of the joining portion 8 may be reduced temporarily. This could be done by temporarily bending one or more of the fiber lay-ups 12, 13, 14, 15 for the beams. Another or an additional option would be inward folding of the hollow mandrel 9 in areas were no fiber lay-ups 12, 13, 14, 15 for the beams are present. After inserting the joining portion 8 into the first blade section 20 the original size of the cross section of the joining portion 8 may be re-established.

(31) In step S3 of the method, a second blade section 24 of the blade 3 is arranged adjacent to the first blade section 20. In particular, the second blade section 24 is arranged adjacent to the first blade section 20 such that it accommodates the portion 23 of the joining portion 8 protruding from the first blade section 20, as shown in FIG. 5. In particular, the second blade section 24 is shoved onto the portion 23 of joining portion 8 until the second blade section 24 abuts the first blade section 20. The second blade section 24 is arranged adjacent to the first blade section 20 by an alignment jig 26. The alignment jig 26 is, for example, mounted such that the adjacent blade sections 20, 24 can be moved, e.g., on rails 27. Reference sign A denotes a longitudinal axis of the blade 3.

(32) Arranging the second blade section 24 adjacent to the first blade section 20 includes matching the fiber lay-ups 12, 13, 14, 15, 16, 17 of the joining portion 8 with corresponding layers of the second blade section 24.

(33) The second blade section 24 in this example is an outboard blade section. Further, in this example, the second blade section 24 comprises a blade tip 25. However, the second blade section 24 could also be an inboard blade section.

(34) FIG. 6 shows a cross-section view of a part of the blade 3 taken along line B in FIG. 5. Shown in FIG. 6 are the first and second blade sections 20 and 24 arranged adjacent to each other as well as the joining portion 8 arranged inside the first and second blade sections 20 and 24. The cross-section is taken through a pressure-side beam and a suction-side beam of the blade 3. In the upper part of FIG. 6 are shown the pressure-side beam 28 of the first blade section 20, the pressure-side beam joint 12 of the joining portion 8, and the pressure-side beam 29 of the second blade section 24 in cross-section. In the lower part of FIG. 6 are shown the suction-side beam 30 of the first blade section 20, the suction-side beam joint 13 of the joining portion 8, and the suction-side beam 31 of the second blade section 24.

(35) Each of the pressure-side beams 28 and 29 and of the suction-side beams 30 and 31 comprises an outwardly tapered portion 32, 33, 34, 35. The outwardly tapered portions 32 and 33 of the pressure-side beams 28 and 29 of the first and second blade sections 20, 24 form a common recess 36. The fiber lay-up 12 for the pressure-side beam joint of the joining portion 8 is arranged in the common recess 36. Likewise, the outwardly tapered portions 34 and 35 of the suction-side beams 30 and 31 of the first and second blade sections 20, 24 form a common recess 37. The fiber lay-up 13 for the suction-side beam joint of the joining portion 8 is arranged in the common recess 37.

(36) In step S4 of the method, the joining portion 8 and the adjacent first and second blade sections 20, 24 are at least partially covered with a vacuum bag 19, 38. In this example, one or more first vacuum bags 19 have already been provided in step 51 during prepacking the mandrel 9. In step S4, a second vacuum bag 38 is provided at the outside surfaces 39, 40 of the first and second blade sections 20, 24. In step S4, the vacuum bags 19, 38 are sealed around the inner surfaces 41, 42 and the outer surfaces 39, 40 of the first and second blade sections 20, 24. FIG. 6 shows the sealing of the vacuum bags 19, 38 covering the fiber lay-up 12 for the pressure-side beam joint and the fiber lay-up 13 for the suction-side beam joint. The sealing is schematically and exemplarily indicated by sealing points 42 in FIG. 6. The sealing of the vacuum bags 19, 38 might be done by applying a sealing tape or any other suitable method. Although not shown in FIG. 6, the vacuum bags 19 and 38 are also sealed around the fiber lay-ups 14, 15, 16, 17 for the leading and trailing edge beam joints, the web joint and the shell joint.

(37) In step S5 of the method, a vacuum is generated within a cavity 54 defined by the sealed vacuum bags 19, 38. Then, a resin 43 is infused into the cavity 54 defined by the sealed vacuum bags 19, 38. FIG. 6 shows the resin 43 starting to fill the cavity 54 defined by the sealed vacuum bags 19, 38 and to embed the fiber lay-up 12 for the pressure-side beam joint. The infused resin 43 is fully embedding the fiber lay-ups 12, 13, 14, 15, 16, 17 of the joining portion 8. The resin 43 is then cured to obtain a cured joining portion. In FIG. 6 the reference sign 44 indicates the cured joining portion which is formed when the fiber lay-ups 12, 13 for the pressure-side and suction-side beam joints are fully embedded in the infused and cured resin 43. Although not shown in FIG. 6, the cured joining portion 44 also comprises the fiber lay-ups 14, 15, 16, 17 when embedded in the infused and cured resin 43. The vacuum infusion process may be a Vacuum Assisted Resin Transfer Moulding (VARTM) process. For further details of the generation of the vacuum, the infusion and curing of the resin 43, it is referred to EP 1 310 351 A1.

(38) FIGS. 7 to 10 show a further and more detailed illustration of the steps S1 to S5 of the method. FIGS. 7 to 10 show the joining of the pressure-side beam of the blade 3 by the joining portion 8 including the fiber lay-up 12 for the pressure-side beam joint. However, the beam joint of FIGS. 7 to 10 could be any of the pressure-side beam joint 12, suction-side beam joint 13, leading edge beam joint 14 or trailing edge beam joint 15.

(39) FIG. 7 shows the step S1 of prepacking the vacuum bag 19 and the joining portion 8 on the mandrel 9 (the mandrel 9 is only shown in FIG. 2). Firstly, the vacuum bag 19 is arranged on the mandrel 9, then the fiber lay-up 17 for an inner shell joint, the fiber lay-up 12 for the pressure-side beam joint, and the fiber lay-up 17 for an outer shell joint are arranged on the vacuum bag 19.

(40) FIG. 8 shows step S2 of partially inserting the prepacked joining portion 8 into the first blade section 20. The first blade section 20 comprises layers for the pressure-side beam 28 as well as layers 45 for the inner and outer shell. The joining portion 8 is inserted into the first blade section 20 such that the fiber lay-ups 12, 17 of the joining portion 8 match the corresponding layers 45, 28 of the first blade section 20.

(41) FIG. 9 shows step S3 of shoving the second blade section 24 onto the joining portion 8 such that the second blade section 24 abuts the first blade section 20 and the common recess 36 is formed.

(42) FIG. 10 shows step S4 of applying the second vacuum bag 38 and sealing the vacuum bags 19, 38. In the next step S5, a vacuum is generated inside the cavity defined by the sealed vacuum bags 19, 38 in order to infuse and cure the resin 43.

(43) FIGS. 11 to 14 show a further illustration of steps S1 to S5 of the method displaying the joining of the shell in areas without a beam. FIGS. 11 to 14 each show a cross-section view taken along line C of FIG. 5.

(44) FIG. 11 shows step S1 of prepacking the vacuum bag 19 and the joining portion 8 on the mandrel 9 (the mandrel 9 is only shown in FIG. 2). Firstly, the vacuum bag 19 is arranged on the mandrel 9 and the fiber lay-up 17 for an inner shell joint is arranged on the vacuum bag 19. Then, a core material 46 such as balsa is arranged on the fiber lay-up 17 for the inner shell joint. Finally, the fiber lay-up 17 for an outer shell joint is arranged on the core material 46.

(45) FIG. 12 shows step S2 of partially inserting the prepacked joining portion 8 from FIG. 11 into the first blade section 20. The first blade section 20 comprises corresponding layers 47 for the shell and a corresponding core material 48. The joining portion 8 is inserted into the first blade section 20 such that the fiber lay-ups 17 and the core material 46 of the joining portion 8 match the corresponding layers 47 and corresponding core material 48 of the first blade section 20.

(46) FIG. 13 shows step S3 of shoving the second blade section 24 onto the joining portion 8 such that the second blade section 24 abuts the first blade section 20 and a common recess 49 is formed.

(47) FIG. 14 shows step S4 of applying the second vacuum bag 38 and sealing the vacuum bags 19, 38. In the next step S5, a vacuum is generated inside the cavity defined by the sealed vacuum bags 19, 38 in order to infuse and cure the resin 43.

(48) FIGS. 15 and 16 illustrate joining a web of the blade 3 by the fiber lay-up 16 for the web joint. FIGS. 15 to 16 each show a cross-section view taken along line D of FIG. 2. In the example of FIGS. 15 and 16, the fiber lay-up 16 for the web joint comprises a dry fiber lay-up portion 49 and a pre-casted fiber lay-up portion 50. The dry fiber lay-up portion 49 is comprised of dry fibers without resin. The pre-casted fiber lay-up portion 50 is, in particular, comprised of fibers embedded in cured resin.

(49) On the left part of FIG. 15, the prepacking of the joining portion 8 in step S1 is illustrated for the case of the web joint 16. Firstly, the vacuum bag 19 is arranged on the mandrel 9 (only shown in FIG. 2), in particular on the first and second portions 10, 11 of the mandrel 9. Then, the fiber lay-up 16 for the web joint is arranged between the vacuum bags 19. In step 2, the joining portion 8 is inserted in the first blade section 20 (FIG. 4). Thereby, the dry portion 49 of the fiber lay-up 16 for the web joint is accommodating a corresponding web element 51 of the first blade section 20.

(50) In step S3, the second blade section 24 (not shown in FIGS. 15 and 16) is arranged adjacent to the first blade section 20. Thereby, the fiber lay-up 16 for the web joint of the joining portion 8 is joined with a corresponding web element (not shown) of the second blade section 24 in similar way as the illustrated joining of the fiber lay-up 16 of the joining portion 8 with the web element 51 of the first blade section 20.

(51) In step S4 (FIG. 16), the vacuum bag 19 is sealed (sealing points 42 in FIG. 16). In step S5, vacuum is applied to a cavity defined by the sealed vacuum bag 19. Further, resin 43 is inserted into the cavity and cured.

(52) As shown in FIG. 17, in step S6 of the method, a sealing band 52, such as an adhesive tape, is applied to the outside surfaces 39, 40 of the first and second blade sections 20, 24. The sealing band 52 may cover any remaining gap at the boundary line between the first and second blade sections 20, 24.

(53) In step S7, the mandrel 9 and the vacuum bags 19, 38 are removed from the blade 3, e.g., through a root section of the blade 3.

(54) With the described method the whole joining process of joining two blade sections 20, 24 can be performed in one single process from inside the cavity of the blade 3. Furthermore, apart from eventually applying the sealing band 52, there is no finishing treatment of the outer surfaces 39, 40 of the blade 3 necessary.

(55) Although the present invention has been disclosed in the form of preferred embodiments and variations thereon, it will be understood that numerous additional modifications and variations could be made thereto without departing from the scope of the invention.

(56) For the sake of clarity, it is to be understood that the use of a or an throughout this application does not exclude a plurality, and comprising does not exclude other steps or elements.