WIND TURBINE BLADE TOOL AND METHOD FOR PRODUCING A WIND TURBINE BLADE

Abstract

Disclosed is a blade mould system for manufacturing of a wind turbine blade shell, the blade mould system comprising a blade mould having a moulding surface for defining an outer shape of a blade shell part, the blade shell part having an outer surface facing the moulding surface and an inner surface facing away from the moulding surface, and a first placement tool being positioned at a first placement tool position relative to the blade mould, the placement tool being adaptable between a first configuration and a second configuration. The first placement tool being configured to engage with a blade component being in a primary component position and position the blade component at a secondary component position relative to the moulding surface by the first placement tool attaining the second configuration, wherein the blade component is configured to be attached to the blade shell part in the secondary component position, wherein the first placement tool comprises a first movable part and a first stationary part.

Claims

1. A blade mould system for manufacturing of a wind turbine blade shell, the blade mould system comprising: a blade mould having a moulding surface for defining an outer shape of a blade shell part, the blade shell part having an outer surface facing the moulding surface and an inner surface facing away from the moulding surface; and a first placement tool being positioned at a first placement tool position relative to the blade mould, the placement tool being adaptable between a first configuration and a second configuration, the first placement tool being configured to: engage with a blade component being in a primary component position; and position the blade component at a secondary component position relative to the moulding surface by the first placement tool attaining the second configuration, wherein the blade component is configured to be attached to the blade shell part in the secondary component position, wherein the first placement tool comprises a first movable part and a first stationary part.

2. Blade mould system according to claim 1, wherein the blade component in the secondary component position is configured to contact an attachment area of the inner surface of the blade shell part, the attachment area comprising adhesive.

3. Blade mould system according to claim 1, wherein the first placement tool is fixed to an outer part of the blade mould.

4. Blade mould system according to claim 1, wherein the first placement tool comprises a first engaging surface configured to contact and releasably attach to a primary side surface part of the blade component.

5. Blade mould system according to claim 4, wherein the first engaging surface comprises a first alignment tab configured to align the primary side surface part in a predefined position on the first engaging surface.

6. Blade mould system according to claim 4, wherein the first placement tool comprises a first guiding part and the blade mould comprises a mould guiding part, wherein the first guiding part is configured to engage with the mould guiding part when the first placement tool is in the second configuration.

7. Blade mould system according claim 4, comprising a component holder configured to retain the blade component in the primary component position, wherein the first placement tool is configured to engage with the blade component in the primary component position by attaining the first configuration wherein the first placement tool is able to retrieve the blade component from a component holder.

8. Blade mould system according to claim 6, wherein the first movable part comprises the first engaging surface and the first guiding part.

9. Blade mould system according to claim 8, wherein the first movable part is in a first position relative to the first stationary part when the first placement tool is in the first configuration, and wherein the first movable part is in a second position relative to the first stationary part, different from the first position, when the first placement tool is in the second configuration.

10. Blade mould system according to claim 8, wherein the first placement tool comprises a first extending part configured to extend and retract the first movable part relative to the first stationary part along an extension axis.

11. Blade mould system according claim 8, wherein the first placement tool comprises a hinge joint between the first movable part and the first stationary part, and wherein the first movable part is rotatable around a rotation axis.

12. Blade mould system according to claim 8, comprising a plurality of placement tools including the first placement tool and a second placement tool, the plurality of placement tools being distributed along the longitudinal direction of the blade mould.

13. A method for assembling a wind turbine blade with a blade mould system comprising a blade mould and a first placement tool, the blade mould having a moulding surface for defining an outer shape of a blade shell part, the blade shell part having an outer surface facing the moulding surface and an inner surface facing away from the moulding surface, the first placement tool comprising a first movable part and a first stationary part, the first placement tool being positioned at a first placement tool position relative to the blade mould, the placement tool being adaptable between a first configuration and a second configuration, the method comprising: engaging the first placement tool with a blade component being in a primary component position; and positioning the blade component at a secondary component position relative to the moulding surface by the first placement tool attaining the second configuration, wherein the blade component is configured to be attached to the blade shell part in the secondary component position.

14. Method according to claim 13 comprising the first placement tool attaining the first configuration prior to engaging the first placement tool with the blade component.

15. Method according to claim 13 wherein engaging the first placement tool with the blade component comprises contacting and releasably attaching a first engaging surface of the first placement tool to a primary side surface part of the blade component.

16. Method according to claim 15, wherein engaging the first placement tool with the blade component comprises applying a negative pressure between the first engaging surface and the primary side surface part.

17. Method according to claim 13, wherein engaging the first placement tool with the blade component comprises aligning the primary side surface part in a predefined position on the first engaging surface.

18. Method according to claim 13, wherein the first placement tool attaining the second configuration comprises engaging a first guiding part of the first placement tool with a mould guiding part of the blade mould.

19. Method according to claim 13, wherein positioning the blade component in the secondary component position comprises placing the blade component over an attachment area of an inner surface of the blade shell part.

20. Method according to claim 13, wherein positioning the first placement tool in the first and/or second configuration comprises rotating the first movable part relative to the first stationary part around a rotation axis.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0045] Embodiments of the invention will be described in more detail in the following with regard to the accompanying figures. Like reference numerals refer to like elements throughout. Like elements may, thus, not be described in detail with respect to the description of each figure. The figures show one way of implementing the present invention and are not to be construed as being limiting to other possible embodiments falling within the scope of the attached claim set. In addition, an illustrated embodiment needs not have all the aspects or advantages shown. An aspect or an advantage described in conjunction with a particular embodiment is not necessarily limited to that embodiment and can be practiced in any other embodiments even if not so illustrated, or if not so explicitly described.

[0046] FIG. 1 is a schematic diagram illustrating an exemplary wind turbine,

[0047] FIG. 2 is a schematic diagram illustrating an exemplary wind turbine blade,

[0048] FIG. 3 is a schematic diagram illustrating an exemplary wind turbine blade,

[0049] FIG. 4 is a schematic diagram illustrating a cross section of an exemplary wind turbine blade,

[0050] FIG. 5 is a schematic diagram illustrating a blade mould system,

[0051] FIGS. 6-11 are schematic diagrams illustrating exemplary instances of an exemplary method of assembling a wind turbine blade,

[0052] FIG. 12 is a schematic diagram illustrating a blade mould system, and

[0053] FIG. 13 is a block diagram of an exemplary method.

DETAILED DESCRIPTION

[0054] In the following figure description, the same reference numbers refer to the same elements and may thus not be described in relation to all figures.

[0055] FIG. 1 illustrates a conventional modern upwind wind turbine 2 according to the so-called “Danish concept” with a tower 4, a nacelle 6 and a rotor with a substantially horizontal rotor shaft. The rotor includes a hub 8 and three blades 10 extending radially from the hub 8, each having a blade root 16 nearest the hub and a blade tip 14 furthest from the hub 8.

[0056] FIG. 2 shows a schematic view of an exemplary wind turbine blade 10. The wind turbine blade 10 has the shape of a conventional wind turbine blade with a root end 17 and a tip end 15 and comprises a root region 30 closest to the hub, a profiled or an airfoil region 34 furthest away from the hub and a transition region 32 between the root region 30 and the airfoil region 34. The blade 10 comprises a leading edge 18 facing the direction of rotation of the blade 10, when the blade is mounted on the hub, and a trailing edge 20 facing the opposite direction of the leading edge 18.

[0057] The airfoil region 34 (also called the profiled region) has an ideal or almost ideal blade shape with respect to generating lift, whereas the root region 30 due to structural considerations has a substantially circular or elliptical cross-section, which for instance makes it easier and safer to mount the blade 10 to the hub. The diameter (or the chord) of the root region 30 may be constant along the entire root area 30. The transition region 32 has a transitional profile gradually changing from the circular or elliptical shape of the root region 30 to the airfoil profile of the airfoil region 34. The chord length of the transition region 32 typically increases with increasing distance r from the hub. The airfoil region 34 has an airfoil profile with a chord extending between the leading edge 18 and the trailing edge 20 of the blade 10. The width of the chord decreases with increasing distance r from the hub.

[0058] A shoulder 40 of the blade 10 is defined as the position, where the blade 10 has its largest chord length. The shoulder 40 is typically provided at the boundary between the transition region 32 and the airfoil region 34.

[0059] It should be noted that the chords of different sections of the blade normally do not lie in a common plane, since the blade may be twisted and/or curved (i.e. pre-bent), thus providing the chord plane with a correspondingly twisted and/or curved course, this being most often the case in order to compensate for the local velocity of the blade being dependent on the radius from the hub.

[0060] The wind turbine blade 10 comprises a blade shell comprising two blade shell parts or half shells, a first blade shell part 24 and a second blade shell part 26, typically made of fibre-reinforced polymer. The wind turbine blade 10 may comprise additional shell parts, such as a third shell part and/or a fourth shell part. The first blade shell part 24 is typically a pressure side or upwind blade shell part. The second blade shell part 26 is typically a suction side or downwind blade shell part. The first blade shell part 24 and the second blade shell part 26 are fastened together with adhesive, such as glue, along bond lines or glue joints 28 extending along the trailing edge 20 and the leading edge 18 of the blade 10. Typically, the root ends of the blade shell parts 24, 26 has a semi-circular or semi-oval outer cross-sectional shape.

[0061] FIG. 3 shows a wind turbine blade 10 with a flatback profile at the trailing edge 20. The trailing edge 20 has a flattened profile. The flattened profile may increase the aerodynamic efficiency and also may reduce the chord width, thereby making it easier to transport the wind turbine blade 10. Furthermore, it also may reduce required manufacturing space.

[0062] FIG. 4 is a schematic diagram illustrating a cross sectional view of an exemplary wind turbine blade 10, e.g. a cross sectional view of the airfoil region of the wind turbine blade 10 as described in relation to FIG. 3. The wind turbine blade 10 comprises a leading edge 18, a trailing edge 20, a pressure side 24, a suction side 26 a first spar cap 74, and a second spar cap 76. The trailing edge 20 has a flattened profile for forming a flatback profile. The wind turbine blade 10 comprises a chord line 38 between the leading edge 18 and the trailing edge 20. The wind turbine blade 10 comprises shear webs 42, such as a leading edge shear web and a trailing edge shear web. The shear webs 42 could alternatively be a spar box with spar sides, such as a trailing edge spar side and a leading edge spar side. The spar caps 74, 76 may comprise carbon fibres, e.g. in combination with glass fibres, while the rest of the shell parts 24, 26 may comprise glass fibres.

[0063] The wind turbine blade 10, such as the shell parts 24, 26 may comprise sandwich panels, e.g. comprising lightweight materials such as balsa or foam sandwiched between fibre-reinforced layers. The trailing edge 20 forming the flattened profile may be provided as a third shell part, or as an integral part of the first shell part 24 or the second shell part 26. Alternatively, the trailing edge 20 may be provided by parts of both the first shell part 24 and the second shell part 26.

[0064] A glue joint for assembling the first shell part 24 and the second shell part 26 may be provided near the trailing edge 20, such as between a first trailing edge part of the trailing edge 20 and a second trailing edge part of the trailing edge 20. Alternatively, the glue flange may be provided between the trailing edge 20 and the first shell part 24 or between the trailing edge 20 and the second shell part 26.

[0065] FIG. 5 is a schematic diagram illustrating a blade mould system 50 for manufacturing of a wind turbine blade shell, e.g. a blade shell of the wind turbine blade 10 of the previous figures. The blade mould system 50 comprises a blade mould 52 with a moulding surface 54 for defining and outer shape of a blade shell part 56. The blade shell part 56 may be the first blade shell part 24, e.g. pressure side, or the second blade shell part 26, e.g. suction side, as illustrated in the previous figures. The blade shell part 56 comprises an outer surface 58 facing the moulding surface 54 and an inner surface 60 facing away from the moulding surface 54. For illustrative purposes, only part of the blade mould 52 and blade shell part 56 are shown.

[0066] The blade mould system 50 comprises a first placement tool 80. The first placement tool 80 is positioned at a first placement tool position relative to the blade mould 52 and is fixed to an outer part of the blade mould 52. The first placement tool 80 comprises a first movable part 88 and a first stationary part 89. The first placement tool 80 comprises a first joint 81, such as a hinge joint, between the first movable part 88 and the first stationary part 89. The first joint 81 allows rotation of the first movable part 88 relative to the first stationary part 89 around a rotation axis of the first joint 81. The rotation axis may be parallel to a longitudinal direction of the blade mould 52. The first placement tool 80 is adaptable between a first configuration (see FIG. 7) and a second configuration (see FIG. 9). The first placement tool 80 in FIG. 5 is in a third configuration between the first configuration and the second configuration.

[0067] FIGS. 6-11 are schematic diagrams illustrating exemplary instances of an exemplary method of assembling a wind turbine blade with a blade mould system 50. For illustrative purposes, only part of the blade mould 52 and blade shell part 56 are shown.

[0068] The first placement tool 80 comprises a first engaging surface 82 configured to engage with a blade component 90, such as with a primary side surface part 92 of the blade component 90, e.g. when the blade component 90 is in a primary component position, such as in FIGS. 6 and 7. The first placement tool 80 comprises a first alignment tab 84 configured to align the primary side surface part 92 in a predefined position on the first engaging surface 82.

[0069] The blade component 90 is held in a component holder 94, as shown in FIGS. 6 and 7, configured to retain one or more blade components 90 in the primary component position. The component holder 94 is positioned at a component holder position relative to the blade mould 52.

[0070] FIG. 7 shows the first placement tool 80 engaging with the blade component 90 in the first configuration. In order for the first placement tool 80 to reach the blade component 90 the first movable part 88 may comprise a first extending part 87 configured to extend and retract the first movable part 88. The first engaging surface 82 of the first movable part 88 contacts and releasably attaches to the primary side surface part 92 of blade component 90, e.g. by creating a negative pressure between the two surfaces 92, 82 to create an attraction such as vacuum. Alternatively, the two surfaces may be attracted by magnetism or mechanical means. The first alignment tab 84 aligns the primary side surface part 92 of the blade component 90 in a predetermined position on the first engaging surface 82.

[0071] FIG. 8 shows the first extending part 87 of the first movable part 88 being retracted. The blade component 90 is attached to the first placement tool 80.

[0072] FIG. 9 shows the first placement tool 80 in the second configuration, where the first movable part 88 is in the second position relative to the first stationary part 89. The first movable part 88 has been rotated about the rotation axis of the first joint 81.

[0073] In the second configuration a first guiding part 86 of the first movable part 88 engages with a mould guiding part 66 on the blade mould 52. When the first guiding part 86 and the mould guiding part 66 are engaged, the guiding tool 80 is guided into a predefined second configuration and thereby the blade component 90 is guided into a predefined secondary component position. The two guiding parts 86, 66 secures the first placement tool 80 against movement relative to the blade mould 52, and provides an enhanced precision of the position of the blade component 90 when the first positioning tool 80 is in the second configuration. The first guiding part 86 may have a female configuration and the mould guiding part 66 may have a male configuration, or opposite.

[0074] The blade shell part 56 comprises an attachment area 62 on the inner surface 60, as illustrated in FIG. 10. The attachment area 62 may be provided with an adhesive, such as a fast curing adhesive. In the second configuration of the first placement tool 80, the blade component 90 contacts the attachment area 62 with the adhesive. The adhesive may cure and the blade component 90 is attached to the blade shell part 56 in the secondary component position.

[0075] The first placement tool 80 may release the blade component 90 once the adhesive is cured, as seen in FIG. 11. Releasing the blade component 90 may comprise deactivating attracting means, such as deactivating the negative pressure causing the vacuum. The first placement tool 80 may then be moved from the second configuration towards the first configuration, such as to a third configuration, and the process may be repeated with a second blade shell part and a second blade component.

[0076] The blade mould system 50 may comprise a plurality of placement tools. FIG. 12 is a schematic diagram illustrating a second placement tool 180, e.g. of the blade mould system 50. The second placement tool 180 may be located closer to the root and the first placement tool may be located closer to the tip. Alternatively, the second placement tool 180 may be located closer to the tip and the first placement tool may be located closer to the root.

[0077] The second placement tool 180 is positioned at a second placement tool position relative to the blade mould 52 and is fixed to an outer part of the blade mould 52. The second placement tool 180 comprises a second movable part 188 and a second stationary part 189. The second placement tool 180 is adaptable between a first configuration and a second configuration, as seen in FIG. 12.

[0078] The second placement tool 180 comprises a second engaging surface 82 configured to engage with the blade component 90, such as with a secondary side surface part 96 of the blade component 90, e.g. when the blade component 90 is in a primary component position. The second placement tool 180 comprises a second alignment tab 184 configured to align a secondary side surface part 96 in a predefined position on the second engaging surface 182. The secondary side surface part 96 may have a different shape than the primary side surface part 92. The second engaging surface 182 on the second placement tool 180 may have a different shape than the first engaging surface 82 of the first placement tool 80.

[0079] The second placement tool 180 comprises a second joint 181, such as a hinge joint, between the second movable part 188 and the second stationary part 189. The second movable part 188 is configured to rotate about a rotation axis of the second joint 181.

[0080] Although not specifically illustrated, the second placement tool 180 may comprise a second guiding part, such as the first guiding part of the first placement tool, as illustrated in the previous figures.

[0081] FIG. 13 is a block diagram of an exemplary method 200 for assembling a wind turbine blade with a blade mould system, such as the blade mould system as described with respect to the previous figures.

[0082] The method 200 comprises a first placement tool attaining 202 a first configuration. The first placement tool attaining 202 the first configuration may comprise rotating 204 a first movable part into a first position. Rotation of the first movable part may be relative to a first stationary part of the first placement tool around a rotation axis. Alternatively, e.g. if the first placement tool already attains the first configuration, attaining 202 may be skipped.

[0083] The method 200 comprises engaging 206 the first placement tool with a blade component in a primary component position. Engaging 206 the placement tool with a blade component may comprise contacting and releasably attaching 208 a first engaging surface of the placement tool to a primary side surface part of the blade component. Engaging 206 the placement tool with the blade component may comprise aligning 210 the primary side surface part in a predefined position on the first engaging surface. Engaging 206 the placement tool with a blade component may comprise applying 212 a negative pressure between the first engaging surface and the primary side surface part, i.e. applying vacuum.

[0084] The method 200 comprises positioning 214 the blade component at a secondary component position relative to the moulding surface by the first placement tool attaining 215 a second configuration. Positioning 214 may comprise rotating 216 the first movable part of the first placement tool to a second position relative to the first stationary part, different from the first position. Positioning 214 may comprise engaging 218 a first guiding part of the first placement tool with the mould guiding part. Positioning 214 may comprise placing 220 the blade component over an attachment area of an inner surface of the blade shell part.

[0085] The method 200 may comprise waiting 222 until the blade component has been fixed to the attachment area, e.g. by an adhesive, before releasing 224 the blade component from the first placement tool.

[0086] The invention has been described with reference to preferred embodiments. However, the scope of the invention is not limited to the illustrated embodiments, and alterations and modifications can be carried out without deviating from the scope of the invention.

LIST OF REFERENCES

[0087] 2 wind turbine [0088] 4 tower [0089] 6 nacelle [0090] 8 hub [0091] 10 blade [0092] 14 blade tip [0093] 15 tip end [0094] 16 blade root [0095] 17 root end [0096] 18 leading edge [0097] 20 trailing edge [0098] 24 first blade shell part (pressure side) [0099] 26 second blade shell part (suction side) [0100] 28 bond lines/glue joints [0101] 30 root region [0102] 32 transition region [0103] 34 airfoil region [0104] 40 shoulder [0105] 42 shear web or spar side [0106] 50 blade mould system [0107] 52 blade mould [0108] 54 moulding surface [0109] 56 blade shell part [0110] 58 outer surface [0111] 60 inner surface [0112] 62 attachment area [0113] 66 mould guiding part [0114] 74 first spar cap [0115] 76 second spar cap [0116] 80 first placement tool [0117] 81 first joint [0118] 82 first engaging surface [0119] 84 first alignment tab [0120] 86 first guiding part [0121] 87 first extending part [0122] 17 [0123] 88 first movable part [0124] 89 first stationary part [0125] 90 blade component [0126] 92 primary side surface part [0127] 94 component holder [0128] 96 secondary side surface part [0129] 180 second placement tool [0130] 181 second joint [0131] 182 second engaging surface [0132] 184 second alignment tab [0133] 188 second movable part [0134] 189 second stationary part [0135] 200 method [0136] 202 attaining [0137] 204 rotating [0138] 206 engaging [0139] 208 contacting and attaching [0140] 210 aligning [0141] 212 applying negative pressure [0142] 214 positioning [0143] 215 attaining [0144] 216 rotating [0145] 218 engaging [0146] 220 placing [0147] 222 waiting [0148] 224 releasing