Method and adhesive machine for constructing segmented rotor blades

Abstract

An adhesive machine for constructing segmented rotor blades having at least three prefabricated rotor blade parts contains a first accommodating region for receiving a first prefabricated rotor blade part, a second accommodating region for receiving a second prefabricated rotor blade part and a third accommodating region for receiving a third prefabricated rotor blade part. The first accommodating region, the second accommodating region and the third accommodating region can be moved relative to each other so that, following successful receiving of the three prefabricated rotor blade parts in the proper accommodating regions in an open position of the adhesive machine, the rotor blade parts can be brought into direct or indirect contact with each other via predetermined adhesion regions and thus transferred into an adhesion position.

Claims

1. An adhesive machine for constructing segmented rotor blades each having at least three prefabricated rotor blade parts, the adhesive machine comprising: accommodating regions, including: a first accommodating region for receiving a first prefabricated rotor blade part; a second accommodating region for receiving a second prefabricated rotor blade part; and a third accommodating region for receiving a third prefabricated rotor blade part, said first accommodating region, said second accommodating region and said third accommodating region being movable relative to each other in such a way that, after the three prefabricated rotor blade parts have been received in respective ones of said accommodating regions in an open position of the adhesive machine, the prefabricated rotor blade parts are brought into direct or indirect contact with each other along predetermined adhesion regions, and thus transferred into an adhesion position, said first accommodating region and said third accommodating region being movable toward one another and toward the second accommodating region while the second accommodating region remains spatially fixed in place, said second accommodating region being disposed between said first accommodating region and said third accommodating region.

2. The adhesive machine according to claim 1, further comprising at least one additional, fourth accommodating region, configured to receive or mount a flange, which can be adhesively bonded with at least one of the three prefabricated rotor blade parts over a predetermined adhesion region.

3. The adhesive machine according to claim 2, wherein at least one of said first, second, third and fourth accommodating regions can be tilted relative to one other one of said accommodating regions while transferring the prefabricated rotor blade parts situated in said accommodating regions into the adhesion position.

4. The adhesive machine according to claim 1, wherein said first accommodating region, said second accommodating region and said third accommodating region execute a movement relative to each other that is perpendicular to a progression of a gravitational field while transferring the prefabricated rotor blade parts situated in said three accommodating regions into the adhesion position.

5. The adhesive machine according to claim 1, wherein at least one of said three accommodating regions is pivotable in design.

6. The adhesive machine according to claim 2, wherein at least one of said accommodating regions can be adjusted to a geometric shape of the prefabricated rotor blade part or the flange provided as intended for accommodation.

7. The adhesive machine according to claim 1, wherein at least one of said first, second or third accommodating regions of the adhesive machine exhibit a longitudinal extension, which is generally oriented parallel to a longitudinal extension of a rotor blade to be constructed.

8. The adhesive machine according to claim 1, further comprising an adhesive apparatus, which can at least sectionally move along the predetermined adhesion regions, in particular perpendicular to a directional progression of earth's magnetic field along the predetermined adhesion regions.

9. The adhesive machine according to claim 2, further comprising at least one tempering device configured to expose the predetermined adhesion regions of at least one of the prefabricated rotor blade parts or the flange to heat on a locally limited basis.

10. The adhesive machine according to claim 2, further comprising at least one pressing unit configured to be able to press at least one end of the prefabricated rotor blade parts against the flange for purposes of adhesive bonding.

11. The adhesive machine according to claim 1, further comprising at least one suction unit for retaining at least one of the prefabricated rotor blade parts in a respective one of said accommodating regions under a vacuum.

12. The adhesive machine according to claim 1, wherein at least one of said three accommodating regions is pivotable in design and can pivot by at least 90.

13. A method for adhesively bonding several prefabricated rotor blade parts for constructing a segmented rotor blade, which comprises the steps of: adhesively bonding the prefabricated rotor blade parts by means of an adhesive machine according to claim 1, such that at least one of the prefabricated rotor blade parts are accommodated by the adhesive machine, and brought into direct or indirect contact with another of the prefabricated rotor blade parts along predetermined adhesion regions so as to be adhesively bonded in an adhesion position.

14. The method according to claim 13, wherein the three prefabricated rotor blade parts are accommodated by the adhesive machine.

15. The adhesive machine according to claim 1, wherein at least one of said first, second, third accommodating regions can be tilted relative to one other one of said accommodating regions while transferring the prefabricated rotor blade parts situated in said accommodating regions into the adhesion position.

16. The adhesive machine according to claim 1, wherein at least one of said accommodating regions can be adjusted to a geometric shape of the prefabricated rotor blade part or the flange provided as intended for accommodation.

17. The adhesive machine according to claim 1, further comprising at least one tempering device configured to expose the predetermined adhesion regions of at least one of the prefabricated rotor blade parts or the flange to heat on a locally limited basis.

18. The adhesive machine according to claim 1, further comprising at least one pressing unit configured to be able to press at least one end of the prefabricated rotor blade parts against the flange for purposes of adhesive bonding.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

(1) FIG. 1 is a perspective view of an embodiment of an adhesive machine or device according to the invention, which incorporates an embodiment of a rotor blade according to the invention;

(2) FIG. 2 is a side view of the embodiment of the adhesive device according to the invention as depicted on FIG. 1, which incorporates no rotor blade;

(3) FIG. 3 is a top plan view of the embodiment of the adhesive device according to the invention as depicted on the preceding figures, which incorporates no rotor blade;

(4) FIG. 4 is a perspective view of a second accommodating region for receiving a middle part segment of an embodiment of the rotor blade according to the invention corresponding to the embodiment of the adhesive device depicted on the preceding figures; and

(5) FIG. 5 is a perspective view of an adhesive apparatus of an embodiment not further depicted of the adhesive device shown on the preceding figures.

DETAILED DESCRIPTION OF THE INVENTION

(6) Referring now to the figures of the drawings in detail and first, particularly to FIG. 1 thereof, there is shown a perspective view of an embodiment of an adhesive machine or device 10 according to the invention, which incorporates an embodiment of a rotor blade 5 according to the invention. The rotor blade 5 consists of three different rotor blade parts 1, 2 and 3. The first rotor blade part 1 is here configured as a nose shell 1, the second rotor blade part 2 as a middle part segment 2, and the third rotor blade part 3 as a rear edge segment 3. Adhesion regions 21 between the nose shell 1 and the middle part segment 2 are essentially oriented in the direction of longitudinal extension, and formed on both the suction and pressure side of the rotor blade. In a like manner, adhesion regions 22 between the rear edge segment 3 and the middle part segment 2 are essentially oriented in the direction of longitudinal extension, and formed on both the suction and pressure side of the rotor blade. Both the nose shell 1 along with the rear edge segment 3 are each joined with a flange 4 by a belt 6, which is respectively anchored in the interior of the nose shell 1 or rear edge segment 3. In addition, the flange 4 is situated in a fourth accommodating region 14. The flange 4 is arranged in this way by tightening several of the bolts provided on the flange 4. The bolting process fixes the flange 4 in place, so that the flange 4 could only be moved inadvertently, and after exposed to high mechanical forces.

(7) In its depicted production stage, the rotor blade 5 further exhibits an opening 25, which can still ensure access to the interior of the rotor blade 5. The opening is necessary for even further processing the belts or webs inside the rotor blade 5. After processing is complete, the opening 25 is closed with a component not further depicted, wherein the outer skin of the rotor blade 5 is secured to the flange 4 on all sides. The opening 25 is closed by gluing the boundaries of the component configured as adhesion regions with the middle part segment 2 and nose shell 1 with an adhesive. In addition, a device not further depicted can be used for curing purposes by exposing the adhesive to heat.

(8) In order to manufacture the rotor blade 5 according to the invention, a first prefabricated rotor blade part 1 (nose shell) is first placed into a first receptacle 11 of the adhesive device 10 and attached therein. The attachment is established by suitably secured aspiration ports, which enable mounting under a vacuum. In a like manner, a third prefabricated rotor blade part 3 (rear edge segment) is placed into a third receptacle 13 of the adhesive device 10 and attached therein. The attachment is again established through vacuum-assisted mounting.

(9) When inserting both the first prefabricated rotor blade part 1 and the third prefabricated rotor blade part 3, care is taken during the fitting process to maintain a predetermined alignment and the required accuracy. To assist in the fitting process, the receptacles 11 and 13 exhibit inserts, which correspond to the geometric circumferential shape of the rotor blade parts 1 and 3, thereby helping to bring about a perfect fit during placement. The inserts are each secured to a first retaining structure 15 and a third retaining structure 17.

(10) The retaining structures 15 and 17 are each braced against the ground on a set of rails 31, and can be moved toward or away from each other thereon.

(11) Situated at roughly the midpoint between the two retaining structures 15 and 17 is another second retaining structure 16, upon which is also provided a second accommodating region 12, which is not further depicted or visible. The second accommodating region 12 is used to receive the second prefabricated rotor blade part 2, which is configured as a middle part segment 2 situated between the nose shell 1 and rear edge segment 3 in the rotor blade 5 depicted.

(12) In order to manufacture the rotor blade 5, the first retaining structure 15 with the first rotor blade part 1 (nose shell) received in the first accommodating region 11 provided therein and the third retaining structure 17 with the third rotor blade part 3 (rear edge segment) received in the third accommodating region 13 provided therein are now moved relatively toward each other, i.e., both are moved toward the second rotor blade part 2 received in the second accommodating region 12. Therefore, the second accommodating region 12 as well as the second rotor blade part 2 incorporated therein remain spatially fixed in place, just as the flange 4. The movement continues until such time as the adhesion regions 21 of the nose shell 1 and the adhesion regions 21 of the middle part segment 2 have established sufficient contact with each other. The adhesive applied to the adhesion regions 21 can here prevent direct and immediate contact. In any case, however, the two components approach each other closely enough to bring about an adhesive bond via the adhesive.

(13) In a like manner, the movement takes place in such a way that the adhesion regions 22 of the rear edge segment 3 and middle part segment 2 come into sufficient contact with each other. Direct and immediate contact can here again be avoided by the adhesive applied to the adhesion regions 22. In any case, however, the two components approach each other closely enough to bring about an adhesive bond.

(14) The movement of the first retaining structure 15 and the third retaining structure 17 can be simultaneous or staggered in terms of time.

(15) Once the adhesion position has been reached, thermal energy is supplied in a localized manner along the two adhesion regions 21 and 22 by tempering devices 40, which each are provided in the first accommodating region 11 and the third accommodating region 13. The tempering devices 40 are here arranged and geometrically configured in such a way that essentially only the adhesion regions 21 and 22 are supplied with thermal energy. This leads to a targeted curing of the as yet uncured adhesive in the adhesion regions 21 and 22, thereby rigidly joining together the first rotor blade part 1 (nose shell), second rotor blade part 2 (middle part segment), and third rotor blade part 3 (rear edge segment).

(16) Joining with the flange 4 likewise takes place with the first rotor blade part 1 (nose shell), second rotor blade part 2 (middle part segment) and third rotor blade part 3 (rear edge segment), wherein the adhesive is here cured in the adhesion regions not further provided with reference numbers by a tempering device not further shown.

(17) According to the embodiment, the belt ends 6 on the side of the first rotor blade part 1 and the third rotor blade part 3 are joined by respective laterally arranged pressing units 50, which can likewise be moved on rails in the direction toward the flange 4. After a sufficient convergence, preformed surfaces press against the belt ends 6, which are adhesively bonded with the flange, and thereby cause the belt ends 6 to press against predetermined regions on the flange 4. Curing can take place on these regions through exposure to heat. A tempering device can again be provided on or in the pressing regions for this purpose.

(18) The movement by both the pressing units 50 as well as the first retaining structure 15 and third retaining structure 17 can be course-controlled and individually actuated.

(19) FIG. 2 shows a side view of the embodiment of the adhesive device 10 according to the invention as depicted on FIG. 1, which incorporates no rotor blade. The fourth accommodating region 14 is clearly shown, and provided for retaining the flange 4. The flange 4 is here held in place by several bolts of the bolt collar, which are accommodated by bolt receptacles 18. According to the embodiment, the bolt receptacles 18 are configured as bushings 18, through which the bolts are guided and tightened on the opposite side.

(20) Also clearly evident is the second accommodating region 12, which itself is placed on the second retaining structure 16 (the second accommodating region 12 as well as the second retaining structure 16, which are both situated in the image plane behind the fourth accommodating region 14, are foreshortened).

(21) FIG. 3 shows a perspective top view of the embodiment of the adhesive device 10 according to the invention as depicted on the preceding figures, which incorporates no rotor blade 5. Distinctly visible in the depiction is the first retaining structure 15, which exhibits the first accommodating region 11 for receiving the first rotor blade 1 (nose shell) (not shown). Further discernible is the third retaining structure 17, which exhibits the third accommodating region 13 for receiving the third rotor blade part 3 (rear edge segment) (not shown). Both retaining structures 15 and 17 are each arranged on one side of the second accommodating region 12, which is secured to the second retaining structure 16.

(22) Furthermore, a pair of rails 31 arranged parallel to each other run both on the side of the first retaining structure 15 and on the side of the third retaining structure 17, and are provided for a respective adhesive apparatus 30 (see also FIG. 5). Such adhesive apparatuses can be shifted along these rails 31, so that all adhesion regions 21 and 22 of the rotor blade parts 1, 2 and 3 not further depicted can be supplied and provided with adhesive. The rails 31 here essentially run parallel to the longitudinal extension of the second accommodating region 12.

(23) Also shown on FIG. 3 on the side of the first retaining structure 15 is a set comprised of three pairs of parallel running rails 31. The latter allow the first retaining structure 15 to move in the direction toward the second accommodating region 12. In addition, a set comprised of four pairs of parallel running rails 31 is arranged on the side of the third retaining structure 17. These allow the third retaining structure 17 to also move in the direction toward the second accommodating region 12. These rail pairs are arranged so as to run essentially perpendicular to the rails 31, which are provided for the adhesive apparatus.

(24) FIG. 4 shows a perspective view of the second accommodating region 12 for receiving a middle part segment of an embodiment of the rotor blade 5 according to the invention (not shown) based on the embodiment of the adhesive device 10 depicted on the preceding figures. The second accommodating region 12 is here comprised of two parts, and is held by the second retaining structure 16. The fourth accommodating region 14 for mounting the flange 4 is provided at the end, elongating the direction of longitudinal extension of the second accommodating region 12.

(25) The second accommodating region 12 is interrupted in roughly the middle of its longitudinal extension, and exhibits a recess. This recess can be advantageous for adjustment purposes if it exhibits adjustment aids, which are not shown here.

(26) FIG. 5 presents a perspective view of an adhesive apparatus 30 of an embodiment (not further depicted) of the adhesive device 10 shown on the preceding figures. The adhesive device 10 is suitable for accommodating several people (three individuals here), who can work on respectively different planes. The adhesive apparatus 30 exhibits two personal platforms 35, which can be vertically moved (corresponding to the orientation shown). Individuals can be equipped with hoses (not depicted here), which are suitable for applying and metering adhesive (for example, commercially available epoxy adhesive). To this end, the hoses can also exhibit suitable discharge nozzles, from which the adhesive is dispensed.

(27) On the other side of the hose, the hoses empty into a dispensing unit 36, which is provided with a suitable control. The dispensing unit 36 interacts with a non-illustrated pump, which distributes the provided adhesive on the hoses. From the dispensing unit 36, the hoses each branch off toward the top (corresponding to the present orientation), and are mounted on a hose bracket 38 for purposes of stress relief. The adhesive is taken from a storage container 37.

(28) For locomotion purposes, the adhesive apparatus 30 is made to abut against rails 31 (not further shown) by rail rollers 39, and can be autonomously moved on the latter by a suitable non-illustrated driving device.

(29) Additional embodiments may be derived from the subclaims. Let it further be noted that all features shown on the figures are here being claimed, whether in isolation or in conjunction with each other.