WIND TURBINE ROTOR BLADE AND METHOD

Abstract

The disclosure concerns a segmented wind turbine rotor blade, which is formed by at least two rotor blade segments, wherein at a division area of the wind turbine rotor blade the segments are firmly connected together at respective connection ends via a plurality of connecting elements, wherein a gap is formed between the connection ends, and a fairing is attached to the segments at the division area, the fairing covering the gap and the connecting elements; wherein the fairing is divided into at least two separate fairing sections, the fairing sections are coupled together at coupling regions at the pressure side and/or at the suction side of the rotor blade, and the coupling regions are spaced apart from the trailing edge or leading edge. The disclosure also concerns a method.

Claims

1. A wind turbine rotor blade comprising: a first rotor blade segment having a first connection end; a second rotor blade segment having a second connection end; said first rotor blade segment and said second rotor blade segment conjointly defining a division area of the wind turbine rotor blade; a plurality of connecting elements; said first rotor blade segment and said second rotor blade segment being configured to be firmly interconnected at said first connection end and said second connection end at said division area via said plurality of connecting elements, wherein said first connection end and said second connection end conjointly define a gap formed therebetween; a fairing attached to said first rotor blade segment and said second rotor blade segment at the division area, wherein said fairing covers said gap and said plurality of connecting elements; said fairing being divided into at least two separate fairing sections each having a coupling region; the wind turbine rotor blade having a suction side, a pressure side, a leading edge, and a trailing edge; said at least two fairing sections being coupled together at said coupling regions at least at one of the pressure side and the suction side of the wind turbine rotor blade; and, said at least two coupling regions being spaced apart from the trailing edge or leading edge.

2. The wind turbine rotor blade of claim 1, wherein said fairing sections each have an essential pressure region and said coupling regions are each arranged outside of corresponding ones of said essential pressure regions.

3. The wind turbine rotor blade of claim 2, wherein said essential pressure regions are disposed close to the leading edge on the suction side, close to the leading edge on the pressure side, and between the trailing edge and a maximum profile height on the pressure side.

4. The wind turbine rotor blade of claim 1, wherein said at least two fairing sections overlap in said coupling regions such that a step is formed transverse to a flow direction of air during an operation of the wind turbine rotor blade, wherein air flows downwardly over said step during operation of the wind turbine rotor blade.

5. The wind turbine rotor blade of claim 4, wherein at least one of: said step has a height of 3 millimeters or less; and, said step tapers with an angle of 15 degrees or less.

6. The wind turbine rotor blade of claim 1, wherein said at least two fairing sections include a first fairing section comprising the trailing edge.

7. The wind turbine rotor blade of claim 6, wherein the first fairing section comprises the trailing edge and is made from metal.

8. The wind turbine rotor blade of claim 6, wherein the first fairing section comprises the trailing edge and is made from a metal casting or metal cast element.

9. The wind turbine rotor blade of claim 6, wherein the trailing edge tapers with an angle of 15 degrees or less.

10. The wind turbine rotor blade of claim 6, wherein said first fairing section defines a drainage opening.

11. The wind turbine rotor blade of claim 6, wherein said fairing consists essentially of said first fairing section and a second fairing section; said first fairing section includes the trailing edge and said second fairing section includes the leading edge.

12. The wind turbine rotor blade of claim 11, wherein said fairing defines a fairing length; and, said second fairing section has a second section length which accounts for at least 80% of said fairing length.

13. The wind turbine rotor blade of claim 1, wherein at least one of said two fairing sections is formed of an electrically non-conductive material.

14. The wind turbine rotor blade of claim 1 further comprising a sealing between at least one of said two fairing sections and a first fairing section of said two fairing sections; and, wherein said first rotor blade segment and said second rotor blade segment have a surface formed by a deformable material.

15. The wind turbine rotor blade of claim 1, wherein said fairing is connected to a lightning protection system via at least one of screws and threaded bolts; and, wherein said at least one of screws and threaded bolts serve as lightning receptors.

16. The wind turbine rotor blade of claim 1 further comprising: a plurality of metal sheets having mounting tabs; said fairing being firmly connected to said mounting tabs of said metal sheets; said metal sheets being arranged between said first connection end of said first rotor blade segment and said second connection end of said second rotor blade segment; and, said mounting tabs being bent toward a middle between said first rotor blade segment and said second rotor blade segment or being bent away from the middle over edges of said first connection end and said second connection end.

17. The wind turbine rotor blade of claim 15 further comprising: a plurality of metal sheets having mounting tabs; said fairing being firmly connected to said mounting tabs of said metal sheets; said metal sheets being arranged between said first connection end of said first rotor blade segment and said second connection end of said second rotor blade segment; and, said mounting tabs being bent toward a middle between said first rotor blade segment and said second rotor blade segment or being bent away from the middle over edges of said first connection end and said second connection end.

18. The wind turbine rotor blade of claim 5, wherein said step has a height of 2.5 millimeters or less.

19. The wind turbine rotor blade of claim 5, wherein said step has a height of 2 millimeters or less.

20. A method of joining two rotor blade segments of a wind turbine rotor blade including a first rotor blade segment having a first connection end and a second rotor blade segment having a second connection end, the first rotor blade segment and the second rotor blade segment conjointly defining a division area of the wind turbine rotor blade, the wind turbine rotor blade further having a plurality of connecting elements and a fairing; the first rotor blade segment and the second rotor blade segment being configured to be firmly interconnected at the first connection end and the second connection end at the division area via the plurality of connecting elements, wherein the first connection end and the second connection end conjointly define a gap formed therebetween; the fairing is attached to the first rotor blade segment and the second rotor blade segment at the division area wherein the fairing covers the gap and the plurality of connecting elements, the fairing being divided into at least a first fairing section and a second fairing section each having a coupling region, wherein the wind turbine rotor blade has a suction side, a pressure side, a leading edge, and a trailing edge; the first fairing section and the second fairing section being coupled together at the coupling regions at least at one of the pressure side and the suction side of the wind turbine rotor blade; and, the at least two coupling regions being spaced apart from the trailing edge or leading edge; the method comprising: providing the second fairing section of the fairing on one of the first rotor blade segment and the second rotor blade segment; screwing together the first rotor blade segment and the second rotor blade segment at the division area of the wind turbine rotor blade via the connecting elements, wherein the gap is formed between the first connection end and the second connection end; sliding the second fairing section over the division area in order to cover the gap and the connecting elements; providing the first fairing section of the fairing; and, coupling the first fairing section and second fairing section to form the fairing.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0056] The invention will now be described with reference to the drawings wherein:

[0057] FIG. 1 shows a schematic view of a wind turbine;

[0058] FIG. 2 shows a schematic view of a split rotor blade with two rotor blade segments;

[0059] FIG. 3 shows a schematic sectional view of a bolt connection of the two rotor blade segments;

[0060] FIG. 4 shows a perspective view of bolt connections of a wind turbine rotor blade;

[0061] FIG. 5 shows a sectional view of a segmented wind turbine rotor blade at a division area;

[0062] FIGS. 6 to 18 show different views of a segmented wind turbine rotor blade and a fairing according to an embodiment of the disclosure;

[0063] FIGS. 19 and 20 show different mounting options for a fairing to be connected to a wind turbine rotor blade;

[0064] FIG. 21 shows a flow chart for a method of joining two rotor blade segments of a wind turbine rotor blade according to an embodiment of the disclosure; and,

[0065] FIGS. 22 to 24 show different mounting steps according to the method of joining.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0066] FIG. 1 shows a schematic view of a wind turbine 100, which includes a tower 102. The tower 102 is fixed to the ground via a foundation 104. At one end of the tower 102 opposite to the ground a nacelle 106 is rotatably mounted. The nacelle 106, for example, includes a generator which is coupled to a rotor 108 via a rotor shaft (not shown). The rotor 108 includes one or more (wind turbine) rotor blades 110, which are arranged on a rotor hub 112.

[0067] During operation, the rotor 108 is set in rotation by an air flow, for example wind. This rotational movement is transmitted to the generator via the rotor shaft and, if necessary, a gearbox. The generator converts the mechanical energy of the rotor 108 into electrical energy.

[0068] FIG. 2 shows a wind turbine rotor blade 110. The rotor blade 110 has the shape of a conventional rotor blade and has a rotor blade root area 114 facing the rotor hub 112. The rotor blade root area 114 typically has an essentially circular cross-section. The rotor blade root area 114 is followed by a transition area 116 and a profile area 118 of rotor blade 110. The rotor blade 110 has a pressure side 122 and an opposite suction side 124 with respect to a longitudinal extension direction 120 (also main extension direction). The rotor blade 110 is essentially hollow inside.

[0069] In the rotor blade root area 114 a rotor blade connection end 126 with a flange connection 128 is provided, via which the rotor blade 110 is mechanically connected to a pitch bearing or an extender.

[0070] The rotor blade 110 includes a division area 130 where a blade root-side rotor blade segment 132 (first rotor blade segment) and a blade tip-side rotor blade segment 134 (second rotor blade segment) are connected to each other. For this purpose, both segments 132, 134 each include a segment connection area 136, 138 (also named connection ends). The rotor blade 110 is thus a split or segmented rotor blade as described above. Each connection end 136, 138 has a multitude of sleeves or bushings 140, 142, which are arranged according to the profile (in circumferential direction) and include internal threads for the reception of screw bolts, also called bearing bolts or connecting bolts. For example, the first bushings 140 include left-hand threads (first internal threads) and the second bushings 142 right-hand threads (second internal threads) or vice versa. A connection end 136, 138 is realized for example as a flange insert, which is inserted into a production mold for the manufacture of the rotor blade 110. However, it is also conceivable that no flange insert is provided and the bushings are embedded and laminated directly into the rotor blade half shells. The bushings are steel sleeves, for example.

[0071] The connection of both rotor blade segments 132, 134 will be described in more detail using a single bolt connection as an example with the help of FIG. 3, which shows a schematic sectional view in the division area 130 of the two connected rotor blade segments 132, 134. The first connection end 136 of the first rotor blade segment 132 includes a multitude of first bushings 140 as described above. The second connection end 138 of the second rotor blade segment 134 includes a number of second bushings 142. A connecting bolt 146 is screwed into each pair of aligned first and second bushings 140, 142. This bolt 146 connects the two connection ends 136, 138 and thus the two rotor blade segments 132, 134 mechanically. In addition, a pressure piece 144 is clamped between the two connection ends 136, 138 per bolt connection 148.

[0072] FIG. 4 shows three bolt connections 148 of a segmented wind turbine rotor blade 110. Different to the schematically described embodiment of FIG. 3, between each connection end 136, 138 of the blade 110 and the pressure pieces 144 metal sheets 150 are clamped (also named clamping sheets), after screwing the segments 132, 134 together via the bolts 146. The metal sheets 150 are arranged along the circumference 151 of the blade 110 on the suction and pressure sides 124, 122. Each metal sheet 150 is electrically conductive and couples two pressure pieces 144 in an electrically conductive manner. In the shown embodiment, each metal sheets 150 includes two openings 152 (recesses). Through the openings 152 the connection bolts 146 can be passed. The pressure pieces 144 correspondingly are electrically conductive, too, and formed by a respective metal for example. The metal sheets 150 are configured and mounted between the segments 132, 134 and pressure pieces 144 such that no contact is established to the bolts 146.

[0073] One or more metal sheets 150, which are associated to the first connection end 136 or the first rotor blade segment 132 (root segment), are coupled to a first lightning conductor, for example, a cable, in an electrically conductive manner (not shown). Similarly, one or more metal sheets 150, which are associated to the second connection end 138 or the second rotor blade segment 134 (tip segment), are coupled to a second lightning conductor, for example, a cable, in an electrically conductive manner (not shown). The lightning conductor cables for example are part of a lightning protection system (not shown). For the connection to the lightning conductor system, the metal sheets 150 have one or more interfaces, for example, eyelets.

[0074] FIG. 5 shows exemplarily a cross section of a rotor blade segment 132 at the division area 130 with the metal sheets 150. Some or all of the metal sheets 150 can be part of the lightning protection system of the rotor blade 110.

[0075] FIG. 6 shows a perspective view of a rotor blade 110 according to an embodiment. As can be seen, at the division area 130 there is formed a gap 154 between the connection ends 136, 138 of the rotor blade segments 132, 134. In order to cover the gap 154 and the elements in between, that is, the bolt connections 148, pressure pieces 144 and the like, the gap 154 is covered by a fairing, as will be described below. In order to attach such fairing, some of the metal sheets 150 include tabs 156, which serve as mounting points. Thus, the fairing is connected to the lightning protection system.

[0076] FIG. 7 schematically illustrates a profile 159 of the wind turbine rotor blade 110 in the division area 130 and shows three main or essential pressure regions of during operation of the rotor blade 110. The rotor blade 110 has a trailing edge 158 and a leading edge 160. On the suction side 124 there is negative pressure region 162 close to the leading edge 160. On the pressure side 122, there are two main overpressure regions 164, one of them close to the leading edge 160 and one of them between the trailing edge 158 and the maximum profile height 166.

[0077] Following these essential pressure regions 162 and 164, the inventors identified three length sections a, b, c along the profile 159 (profile contour or circumference 151), in which a fairing with two separate fairing sections should be separated (see FIG. 8A) and/or coupled together. Length section “a” extends on the suction side 124 between the trailing edge 158 and a location of the maximum profile height 166. Length section “c” is located on the pressure side between the trailing edge 158 and 80% chord length 167 measured from the leading edge 160.

[0078] Length section “b” is located on the pressure side 122 in an area between 15% and 65% chord length 167.

[0079] FIGS. 8B and 8C show embodiments with possible locations for separating the fairing 168. In FIG. 8B the fairing consists of two sections, a first section 170 at the trailing edge and a second section 172 at the leading edge 160. In FIG. 8C the fairing consists of four sections. Additionally to the first section 170 and the second section 172 two intermediate sections 173 are provided, each one on the suction side 124 and the pressure side 122. In both embodiments the separation points are located in at least two of the length sections a, b or c.

[0080] FIG. 9 shows a fairing 168 which includes two separate fairing sections, namely a first fairing section 170 and a second fairing section 172. The first fairing section 170 and the second fairing section 172 are formed to be coupled together and to be mounted onto the rotor blade segments 132, 134. The fairing 168 is formed to essentially maintain the aerodynamic structure of the rotor blade 110, that is, the outer contour is essentially maintained. The first fairing section 170 could be named trailing edge fairing and the second fairing 172 could be named leading edge fairing. The fairing 168 forms a closed ring along the circumference 151 of the blade 110, that is, the profile 159. The fairing sections 170 and 172 are formed such that coupling regions 174 and 175, in which ends of the first and second fairing sections 170 and 172 overlap each other, are placed on the suction side 124 and the pressure side 122 in sections a and c as described above (s. FIGS. 8A to 8C).

[0081] The first fairing section 170 is way smaller than the second fairing section, for example, the first fairing section 170 amounts up to 20% of the contour length of the profile 159, whereas the second fairing section 172 amounts to 80% of the contour length of the profile 159. This first fairing section 170 is produced by injection molding and is made of a non-conductive material. The second fairing section 172 is made from a fiber-reinforced plastic material and has a wall thickness of approximately 2 mm. Further, both fairing sections 170 and 172 are made of electrically non-conductive material.

[0082] FIG. 10 shows the first fairing section 170. In the coupling regions 174 and 175, the first fairing section 170 includes outer sealings 176, which are arranged flat on the outer side of the first fairing section 170. The first fairing section 170 also has an inner sealing 178 that runs along the inner edges of the first fairing section 170 (see also FIG. 11 showing a sectional view of the first fairing section 170). The first fairing section 170 is coupled with the second fairing section 172 such that the second fairing section 172 overlaps the first fairing section 170. In between, the outer sealing 176 is arranged, in particular pressed in a finally coupled state, to seal both fairing sections 170 and 172 to each other. The inner sealing 178 is formed such that the first fairing section 170 is sealed to the rotor blade segments 132, 134. In other words, the first fairing section 170 surrounds at least partially (at the edges) both rotor blade segments 132, 134, wherein the inner sealing is arranged in between, in particular pressed in between. The sealings 176, 178 are made of closed cell rubber.

[0083] FIG. 12 shows detail view “Z” of FIG. 10 and FIG. 13 shows a sectional view of the detail shown in FIG. 12. As can be seen, at the trailing edge 158 the first fairing section 170 includes a first drainage opening 180, which opens at the trailing edge 158. Alternatively or additionally, a drainage opening 182 can be provided at the suction side 124 of the first fairing section 170.

[0084] FIGS. 14 and 15 detail the connection of the two fairing sections 170 and 172 to each other as well as to a rotor blade segment 132, 134. FIG. 14 shows a cross section through the fairing 168, whereas FIG. 15 shows a cross section through a mounting point. In the coupling regions 174, 175 the two fairing sections 170, 172 are screwed together via screws 184 (generally: connections means). The two fairing sections 170, 172 are screwed onto tabs 156 of the metal sheet 150 (which can also be referred to as a part of an existing system structure of the blade 110, in particular the lightning protection system). As can be seen from FIG. 15, the tabs 156 include openings or eyelets 186 for the screws 184 to be mounted to the segments 132, 134 of the blade 110. The screws 184 serve as lightning receptors in the shown embodiment. Further, an electrically conductive inner ring element 187 (cylindrical element) is arranged and clamped between a screw head 185 of screw 184 and the metal sheet 150, that is, the tab 156. This ensures that an electrically conductive connection is established from the screw head 185 to the metal sheet 150 and lightning currents are thus not only conducted via the screw shaft or screw thread, but in particular over the inner end face of the screw head 185 and the inner metal ring element 187. A sealing 190, for example, a sealing ring, can be provided between the screw head 185 and the outermost side of the second fairing section 172.

[0085] It is noted that the tabs 156 are bent away from a middle of the division area 130 with respect to the longitudinal direction of the blade 110. In particular, they are bent over edges of the segments 132, 134 at the connection ends 136, 138. As an alternative, the tabs 156 may also be bent towards the middle of the division area 130.

[0086] FIGS. 14 and 15 also show that the second fairing section 172 overlaps the first section 170 such that a step 188 is formed downwardly towards the trailing edge 158. In other words, the step 188 is formed such that the air flows downwardly during operation of the wind turbine rotor blade 110. The step 188 essentially runs transverse to an airflow during operation of the blade 110. The step 188 optionally has a height of 2 mm or less (that is, a wall thickness of the second fairing section 172). Further optionally, the step 188 tapers with an angle at 15 degrees or less. Optionally, also the trailing edge 158 of the first fairing section may taper with an angle at 15 degrees or less.

[0087] Similarly, FIGS. 16 to 18 show a connection of the second fairing section 172 to a rotor blade segment 132, 134. The above mentioned details similarly apply.

[0088] FIGS. 19 and 20 detail two variants of a connection of the two fairing sections 170, 172. FIG. 19 shows an embodiment with a screw 184 as a lightning receptor with a high structure, which is exemplarily used in the embodiment shown in FIGS. 14 and 15. Here, the screw head 185 has a flat end face 192, which lies on the inner metal ring element 187 to clamp it against the metal sheet 150, that is, a counter face of the tab 156. FIG. 20 shows an embodiment with a screw 184 as a lightning receptor with a low structure, wherein the screw 184 has a flat outer side, wherein an inner end face 194 is angled and lies on a metal ring element 196. The metal ring element 196 lies flat on the inner metal ring element 187 and is clamped again against the metal sheet 150.

[0089] The embodiments as described above enables the functions, effects and advantages as listed in the introductory part of this writing.

[0090] Some of the above described features can be omitted, for example, as indicated in the introductory part of the present disclosure.

[0091] In the following, a method of joining to rotor blade segments 132, 134 and mounting a fairing 168, as described above, is described with the aid of FIGS. 21 to 24. FIG. 21 shows a flow diagram and FIGS. 22 to 24 show the rotor blade 110 at different mounting steps.

[0092] The two rotor blade segments 132, 134 may already be prepared and provided to be mounted together, for example, arranged next to each other at a certain distance.

[0093] In a first step S1, the second fairing section 172 of the fairing 168 is provided and slid over one of the rotor blade segments along the longitudinal direction 120 (see FIG. 2), for example, the first segment 132. This is shown in FIG. 22.

[0094] In a next step S2, the rotor blade segments 132, 134 are screwed together at the division area connecting elements via the bolt connections 148, wherein the gap 154 is formed between the two connection ends 136, 138 (see FIG. 22).

[0095] Next, in step S3 the second fairing section 172 is provided, for example, slid, over the division area 130 in order to cover the gap 154 and the connection elements, that is, the bolt connections 148 (see FIG. 23). At this step, the second fairing section 172 can be firmly connected to the segments 132, 134, for example, by screwing as described above.

[0096] Next, in step S4, the first fairing section 170 of the fairing 168 is provided and pulled over the trailing edge 158 and is slipped over the gap 164.

[0097] Next, in step S5, the first fairing section 170 and the second fairing section 172 are coupled, wherein the first fairing section 170 is fastened by sliding it under the second fairing section 172 in the coupling regions 174, 175, so that an overlap of the second fairing section 172 over the first fairing section 170 is created and the corresponding sealing 176 is pressed there.

[0098] Finally, in step S6 the fairing sections 170, 172 may be screwed together.

[0099] It is understood that the foregoing description is that of the preferred embodiments of the invention and that various changes and modifications may be made thereto without departing from the spirit and scope of the invention as defined in the appended claims.

REFERENCE SIGNS

[0100] 100 wind turbine [0101] 102 tower [0102] 104 foundation [0103] 106 nacelle [0104] 108 rotor [0105] 110 rotor blade [0106] 112 rotor hub [0107] 114 rotor blade root area [0108] 116 transition area [0109] 118 profile area [0110] 120 longitudinal extension direction [0111] 122 pressure side [0112] 124 suction side [0113] 126 rotor blade connection end [0114] 128 flange connection [0115] 130 division area [0116] 132 first rotor blade segment [0117] 134 second rotor blade segment [0118] 136 first connection end (root side) [0119] 138 second connection end (tip side) [0120] 140 first bushing [0121] 142 second bushing [0122] 144 pressure piece [0123] 146 connection bolt [0124] 148 bolt connection [0125] 150 metal sheet [0126] 151 circumference [0127] 152 opening [0128] 154 gap [0129] 156 tab [0130] 158 trailing edge [0131] 159 profile [0132] 160 leading edge [0133] 162 negative pressure area [0134] 164 overpressure area [0135] 166 profile height [0136] 167 chord length [0137] 168 fairing [0138] 170 first fairing section [0139] 172 second fairing section [0140] 173 intermediate fairing section [0141] 174 coupling region [0142] 175 coupling region [0143] 176 outer sealing [0144] 178 inner sealing [0145] 180 first drainage opening [0146] 182 second drainage opening1 [0147] 184 screw [0148] 185 screw head [0149] 186 eyelet [0150] 187 inner metal ring element [0151] 188 step [0152] 190 sealing [0153] 192 flat inner end face [0154] 194 angled inner end face [0155] 196 metal ring element [0156] S1-S3 steps