TIP AIR RECEPTOR

Abstract

Disclosed is a tip section for a wind turbine blade. The tip section comprises an intermediary blade section comprising a first shell part forming a first side of the intermediary blade section and a second shell part forming a second side of the intermediary blade section, the intermediary blade section having a leading edge and a trailing edge and extending from an intermediary blade section first end to an intermediary blade section second end; a tip part forming an end of the tip section and having been rigidly attached to the intermediary blade section first end, the tip part having an outer surface comprising a metal area; and a number of one or more superficial metal strips extending along an outer surface of the intermediary blade section. A wind turbine blade with such a tip section and the manufacturing of such a wind turbine blade is also disclosed.

Claims

1. A wind turbine blade tip section (301, 302, 303, 1301) for a wind turbine blade, comprising: an intermediary blade section (310) comprising a first shell part (310a) forming a first side of the intermediary blade section and a second shell part (310b) forming a second side of the intermediary blade section, the intermediary blade section having a leading edge (18) and a trailing edge (20) and extending from an intermediary blade section first end (321) to an intermediary blade section second end (322), a tip part (312) forming an end of the tip section and having been rigidly attached to the intermediary blade section first end (321), the tip part having an outer surface comprising a metal area, a number of one or more superficial metal strips (314a, 314b) extending along an outer surface of the intermediary blade section.

2. (canceled)

3. (canceled)

4. (canceled)

5. (canceled)

6. A wind turbine blade tip section in accordance with claim 1, wherein at least one superficial metal strip of the tip section is arranged at a distance from the leading edge and the trailing edge.

7. A wind turbine blade tip section in accordance with claim 1, wherein at least one superficial metal strip of the tip section is placed near a thickest portion of the intermediary blade section.

8. A wind turbine blade tip section in accordance with claim 1, wherein a chordwise position of a centerline of at least one superficial metal strip of the tip section lies in the range x=0.2 to x=0.7, where x is the chordwise airfoil coordinate and x=0 coincides with the leading edge and x=1 coincides with the trailing edge.

9. A wind turbine blade tip section in accordance with claim 1, wherein the one or more superficial metal strips are substantially parallel to a longitudinal axis of the intermediary blade section.

10. A wind turbine blade tip section in accordance with claim 1, wherein the one or more superficial metal strips are arranged in recesses in the shell parts (310a, 310b) to achieve a flush surface around the one or more superficial metal strips.

11. (canceled)

12. A wind turbine blade tip section in accordance with claim 1, further comprising: a downconductor coupler (316) arranged inside the intermediary blade section, the tip part being electrically connected to the downconductor coupler only via the one or more superficial metal strips.

13. A wind turbine blade tip section in accordance with claim 12, wherein the downconductor coupler comprises a metal piece, such as a solid metal piece, that extends to an outer surface of the first shell part and is electrically connected to the exactly one metal strip.

14. A wind turbine blade tip section in accordance with claims 1, wherein the number of superficial metal strips is exactly two, wherein a first metal strip of the two superficial metal strips is arranged on the first side of the intermediary blade section, and a second metal strip of the two superficial metal strips is arranged on the second side of the intermediary blade section.

15. A wind turbine blade tip section in accordance with claim 14, wherein the downconductor coupler comprises a metal piece that extends to an outer surface of the first shell part where it is electrically connected to the first metal strip, and the metal piece of the downconductor further extends to an outer surface of the second shell part where it is electrically connected to the second metal strip.

16. A wind turbine blade tip section in accordance with claim 1, wherein a length, Lint, of the intermediary blade section is in the range 15-100 cm.

17. (canceled)

18. A wind turbine blade tip section in accordance with claim 1, wherein the tip part is made of copper or a copper alloy.

19. A wind turbine blade tip section in accordance with claim 1, wherein a length, Lstrip, of all of the superficial metal strips is in the range 20-110 cm, a width, W, of all of the superficial metal strips is in the range 30-100 mm, a thickness of all of the superficial metal strips is in the range 2-30 mm, and a length, Ltip, of the tip part is in the range 30-200 mm.

20. (canceled)

21. A wind turbine blade tip section in accordance with claim 1, further comprising a non-conducting barrier, such as a solid barrier, such as a solid barrier made of polyurethane or epoxy, the barrier being adapted to electrically separate the tip part from the downconductor coupler.

22. A wind turbine blade having a root end and a tip end, wherein the wind turbine blade comprises a tip section in accordance with claim 1.

23. A wind turbine blade in accordance with claim 22 , wherein the wind turbine blade comprises a first blade part (330) having an airfoil region (34), a root end connectable to a wind turbine hub, and a first end (323, 1305) opposite the root end (31), the first end of the first blade part being rigidly joined to the tip section at the second end of the intermediary blade section.

24. A wind turbine blade in accordance with claim 23, wherein a thickness of a wall of the first blade part at the first end (323) comprises a step (1331, 1332) that overlaps with a wall of the intermediary blade section to form a flush blade surface.

25. A wind turbine blade in accordance with claims 22, wherein the one or more superficial metal strips are substantially parallel to a longitudinal axis of the first blade part.

26. A method of manufacturing a wind turbine blade having a root end and a tip end, comprising: providing a first blade part (330) having an airfoil region, a root end connectable to a wind turbine hub, and a first end (323, 1305) opposite the root end, providing a tip section in accordance with claim 1, and rigidly joining the first end of the first blade part to the second end of the intermediary blade section of the tip section.

27. A method in accordance with claim 26, further comprising surrounding the downconductor coupler with a non-conductive material, such as polyurethane or epoxy.

28. (canceled)

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0062] The invention is explained in detail below with reference to the embodiments shown in the drawings.

[0063] FIG. 1 illustrates a wind turbine.

[0064] FIG. 2 shows a schematic view of a wind turbine blade.

[0065] FIG. 3 shows a schematic view of a wind turbine blade in accordance with an embodiment of the invention.

[0066] FIG. 4 schematically illustrates a tip section in accordance with an embodiment of the invention.

[0067] FIG. 5 schematically illustrates a cross-sectional view of a tip section in accordance with an embodiment of the invention.

[0068] FIG. 6 schematically illustrates a cross-sectional view of a tip section in accordance with an embodiment of the invention.

[0069] FIG. 7 schematically illustrates a tip section in accordance with an embodiment of the invention.

[0070] FIG. 8 schematically illustrates a tip section in accordance with an embodiment of the invention.

[0071] FIG. 9 schematically illustrates a cross-sectional view of a tip section in accordance with an embodiment of the invention.

[0072] FIGS. 10-11 schematically illustrate metal strips for a tip section.

[0073] FIG. 12 illustrates exemplary length definitions of parts of a tip section.

[0074] FIGS. 13-16 illustrate a tip section being joined to a first blade part.

DETAILED DESCRIPTION OF SELECTED EMBODIMENTS

[0075] Embodiments of the invention will be described in more detail in the following with reference to the accompanying drawings. Like reference numerals may refer to like elements throughout. The drawings show selected ways of implementing the present invention and are not to be construed as being limiting.

[0076] 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 farthest from the hub 8.

[0077] FIG. 2 shows a schematic view of a wind turbine blade 10. The wind turbine blade 10 has the shape of a conventional wind turbine blade and comprises a root region 30 closest to the hub, a profiled or an airfoil region 34 farthest 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. The outermost point of the blade 10 is the tip end 15, opposite the root end 31 that attaches to the wind turbine hub 8.

[0078] The airfoil region 34 (also called the profiled region) of the wind turbine 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 region 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 rfrom 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 from the hub.

[0079] 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. FIG. 2 also illustrates the longitudinal extent L.sub.B, length or longitudinal axis of the blade.

[0080] 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.

[0081] The blade is typically made from a pressure side shell part 36 and a suction side shell part 38 that are glued to each other along bond lines at the leading edge 18 and the trailing edge 20 of the blade 10.

[0082] FIG. 3 shows a wind turbine blade 30 in accordance with an embodiment of the invention. Generally, it is similar to the known wind turbine blade 10 shown in FIG. 2. However, the tip region is different from known wind turbine blade tips. The blade 300 has a first blade part 330 that extends from the root end 31, which is eventually attached to a wind turbine hub, to a first end 323. The first end 323 is attached to a tip section that has an intermediary blade section 310 and a tip part 312, attached to a first end 321 of the intermediary blade section 310. The tip part 312 is made of metal, such as copper. A metal strip 314 on the outer surface of the intermediary blade section 310 connects the metal tip to a lightning receptor arranged in the intermediary blade section (not visible in this drawing, as it is covered by the metal strip 314). The lightning receptor is connected to a downconductor coupler inside the intermediary blade section, and the downconductor coupler is further coupled to a downconductor inside the blade 300 that can conduct lightning current to ground.

[0083] FIG. 4 illustrates a tip section 301 in accordance with an embodiment of the invention, such as for use as the tip section of the wind turbine blade shown in FIG. 3. It is seen from a suction side of the wind turbine blade in FIG. 3. The tip section has an intermediary blade section 310, comprising shell parts 310a and 310b, extending from a first end 321 to a second end 322. The suction side shell part 310a of the intermediary blade section is visible. Shell part 310b is shown in FIG. 5. The tip section 301 further comprises a metal tip 312 attached at the first end 321 of the intermediary blade section 310. In this example, the tip section 301 comprises a downconductor coupler 316 inside the intermediary blade section and a metal strip 314a on the suction side 310a. For illustration purposes, a first blade part 330 of the blade 300 is indicated, showing how the tip section is connected at the second end 322 to a first end 323 of the first blade part 330. The first blade part 330 extends from the root end 31 (see FIG. 3) to the first end 323 of the first blade part 330. Together, the first blade part 330 and the tip section 301 make up the wind turbine blade 300. The downconductor may instead be part of the first blade part 330.

[0084] The metal tip 312 attracts lightning, which is generally very likely to strike at the tip end 15 of a wind turbine blade. The metal strip 314a provides a conductive path from the metal tip 312 to the downconductor coupler 316, which will electrically couple the metal tip to a blade downconductor in the final wind turbine blade. The metal strips on the outer surface of the tip section provide the only conductive path from the metal tip 312 to the downconductor coupler 316. It has been found that by not providing a conductor inside the shell from the tip to the downconductor, the risk of internal damage is actually reduced. The shell is very thin near the tip, which means that there is a significant risk of lightning flashing over from the outside of the tip to a conductor located inside the tip. The metal strips also increase the metallic area to which lightning may be attracted.

[0085] In the present example, the tip section also comprises insulation 318 inside the tip section, surrounding the downconductor coupler 316. The insulation may for instance be made of polyurethane or epoxy.

[0086] FIG. 4 also illustrates an example of how downconductor cables (351/352) may be attached in the final blade. In this case, this is achieved by attaching downconductor cable shoes 342 to the downconductor coupler 316 using screws 341 that engage with the downconductor coupler 316. This is shown in more detail below. Insulation 318, cable shoes 342, screws 341, and downconductor cables 351/352 are shown with dashed lines, since they are located behind the shell part 310a.

[0087] It is noted that insulation 318, cable shoes 342, screws 341, and downconductor cables 351/352 are not essential parts of the tip section 301, but are illustrated to show the tip section 301 as used in a wind turbine blade, such as blade 300 illustrated in FIG. 3.

[0088] The leading edge 18 and trailing edge 20 are also indicated.

[0089] In the embodiment in FIG. 4, the metal strip 314a is 500 mm long, 50 mm wide, and 1 mm thick, and the metal tip 312 is 100 mm long. The lengths are measured along a longitudinal axis of the intermediary blade section, which coincides with line A-A. These dimensions provide a conductivity sufficient to conduct very intense lightning strikes with limited damage to the metal strip 314a.

[0090] A projection of the metal strip 314a on the plane defined by the longitudinal axis and the chord is parallel to the longitudinal axis in this example. However, said projection may alternatively form an angle with the longitudinal axis. Note that the projection of the metal strip onto a plane normal to the chord typically forms an angle with the longitudinal axis, since the metal strip follows the surface of shell part 310a, which diverges from the longitudinal axis in the direction towards the second end 322, since the thickness of the shell increases in that direction.

[0091] In the embodiment shown in FIG. 4, a centerline of the metal strip 314a is positioned approximately at x=0.32 at the second end 322 and x=0.45 at the first end 321. In the present embodiment, the airfoil profile is such that the metal strip 314a is furthermore close to a point of maximum thickness of the intermediary blade section. This results in low wear on the metal strip 314a from dust and the like.

[0092] FIG. 5 illustrates the cross-section of the tip section 301 shown in FIG. 4 along the line A-A. Both shell sides 310a (suction side) and 310b (pressure side) are visible, and each side has a metal strip 314a, 314b that connects the metal tip 312 to the downconductor coupler 316. The downconductor coupler 316 is surrounded by the insulating material 318. The downconductor coupler 316 extends to the outer surfaces of the shell sides 310a and 310b and therefore also acts as lightning receptor on either side of the intermediary blade section 310.

[0093] An example of how the tip part 312 may be attached to the intermediary blade section 310 is described later.

[0094] FIG. 5 further indicates two cable shoes on downconductor cables 351, 353 being attached to the downconductor coupler 316. In this view, the downconductor cables 351, 353, cable shoes 342, and screws 341 are shown with dashed lines because they are located behind the downconductor coupler 316 and insulating material 318.

[0095] A first blade part 330 to which the tip section is eventually connected is also illustrated, similarly to FIG. 4.

[0096] The metal strips 314a, 314b connect at one end to the metal tip 312 and at the other end to the downconductor coupler 316, thereby providing electrical connection between the metal tip 312 and the downconductor coupler 316. As seen, there is no conductor connecting the metal tip 312 to the downconductor coupler 316 on the inside of the tip section, for the reasons described above.

[0097] In FIG. 5, the metal strips 314a, 314b are shown raised above the respective shell parts 310a, 310b to make it easier to discern the parts. However, to eliminate noise, the metal strips are preferably flush with the shell parts 310a, 310b, as illustrated in FIG. 6 and described below. This can be achieved for instance by forming the sides 310a, 310b with a recess having a shape that accommodates the respective metal strips 314a, 314b. The same applies at the tip part 312, which preferably has recesses similarly accommodating the metal strips 314a, 314b.

[0098] FIG. 6 illustrates the cross-section of the tip section 301 shown in FIG. 4 along the line B-B (see FIG. 4). Both shell sides 310a (suction side) and 310b (pressure side) are visible in this view. Each side has a metal strip 314a, 314b that connects the metal tip 312 to the downconductor coupler 316. In this view, the metal strips 314a, 314b are shown arranged in recesses in the corresponding shell parts 310a, 310b, which allows the surface of the tip section to have a more aerodynamic shape.

[0099] This prevents noise and turbulence from being created by the metal strips 314a, 314b.

[0100] At the cross-section B-B shown in FIG. 6, a centerline of the metal strip 314a is positioned approximately at x=0.33. As discussed in relation to FIG. 4, this is close to a point of maximum thickness of the intermediary blade section 310, as can be seen in FIG. 6. This results in low wear from dust and the like. The same considerations apply to the metal strip 314b, also shown in FIG. 6.

[0101] FIG. 6 further shows, as an example, four conductor cable shoes 342 connected to the downconductor coupler with respective screws 341, corresponding to four downconductor cables, including cables 351, 352, 353 of FIGS. 4 and 5. The cables are not indicated in FIG. 6.

[0102] As illustrated in FIGS. 4-5, the downconductor coupler 316, cables shoes 342, and screws 341 are surrounded by the insulation material 318.

[0103] The leading edge 18 and trailing edge 20 are also indicated in FIG. 6.

[0104] FIG. 7 illustrates a tip section 302 similar to the tip section 301 of FIGS. 4-6. FIG. 7 shows how in some embodiments the metal strip 314a may be fastened to the downconductor coupler 316 and the metal tip 312 with fastening means 361 such as a number of bolts or screws, in this example four bolts in either end.

[0105] The metal tip 312 may also be formed integrally with one or more of the metal strips 314a, 314b. Bolts or screws can be used to fasten the metal strips to the downconductor coupler 316.

[0106] FIG. 8 illustrates a tip section 303 in which the metal tip 312 is attached to the intermediary blade section 310 using for instance an epoxy to create a bonding epoxy piece 370 (further illustrated in FIG. 9 below). The epoxy piece 370 extends from inside the intermediary blade section 310 and into the metal tip 312, thereby bonding the two together. The epoxy piece 370 is located inside the intermediary blade section 310 and metal tip 312 and has therefore been indicated by schematic dashed lines 371, 372 indicating two ends 371, 372 of the epoxy piece 370. FIG. 9 illustrates the cross-section of the tip section 303 shown in FIG. 8 along the line C-C, showing the epoxy piece 370 extending between the intermediary blade section 310 and the metal tip 312 and bonding them together. Another advantage of the epoxy piece 370 is that it provides a dielectric barrier that reduces the risk of flashover from the metal tip 312 to electrically conductive components inside the blade, such as a carbon-fibre reinforced spar part. The ends 371, 372 are not necessarily regular as indicated by the planar ends of epoxy piece 370 in FIGS. 8 and 9.

[0107] FIG. 10 illustrates the metal strip 314a from FIG. 4 in isolation. The metal strip in this example is rectangular, having a length L.sub.strip and a width W.sub.strip. As described in relation to FIG. 4, the metal strip 314a is 500 mm long, 50 mm wide, and 1 mm thick. However, other parameters may be chosen as needed. FIG. 11 illustrates a metal strip 1114 that is tapered, having one width W.sub.1 at one end and a different width W.sub.2 at the other end, and a length L.sub.strip. Shapes other than those shown in FIGS. 10-11 may be used as appropriate.

[0108] FIG. 12 illustrates exemplary definitions of a length L.sub.int of the intermediary blade section (shell part 310a), a length L.sub.tip of the tip part 312, and a length L.sub.strip of the metal strip 314a. The tip section in FIG. 12 is the tip section 301 shown in FIG. 4. In this example, the lengths are generally measured relative to a longitudinal axis of the blade.

[0109] FIGS. 13-16 illustrate an example of how a tip section 1301 can be attached to a first blade part 330.

[0110] Referring to FIG. 13, the first blade part 330 in this embodiment has been manufactured with a first section 1331 that steps down from a second section 1332 near the end 1305 of the first blade part. In accordance with the first aspect of the invention, the tip section 1301 to be attached to the first blade part 330 comprises a first intermediary blade section 310, a tip part 312, and a metal strip 314a on the surface of the intermediary blade section 310. Cross-section D-D indicated in FIG. 13 is shown in FIG. 14, which illustrates the step from section 1332 to section 1331 in the first blade part in more detail. The step may for instance be made in a mould having a corresponding step.

[0111] The first blade part 330 also comprises a metal piece 316 extending the first side 310a to the second side 310b. The metal piece doubles as lightning receptor on either side.

[0112] The step from second section 1332 to first section 1331 is configured to engage with an inner surface of the intermediary blade section 310. FIG. 15 shows the first blade part 330 has been joined with the intermediary blade section 310 of the tip section 1301. In this embodiment, a thickness of a wall of the intermediary blade section 310 is such as to form, together with the first section 1331 of the first blade part 330, a wall having a thickness equal to a thickness of the second section 1332 of the first blade part 330 near the first section 1331. With this design, little finishing processing is required to achieve a flush surface after the first blade part 330 and the tip section 1301 are joined.

[0113] The intermediary blade section 310 has a cutout 1340 that can accommodate the metal piece 316, whereby the tip section can easily slide onto the first blade part.

[0114] An adhesive may be used to adhere the inner surface of the intermediary blade section 310 to the surface of the first section 1331 of the first blade part 330, whereby the completed shell is obtained. For simplicity, and in accordance with the indication of cross-section D-D in FIG. 13, the cross-section D-D does not include the tip part 312, which is therefore not part of FIGS. 14 and 15.

[0115] FIG. 16 illustrates the combined first blade part 330 and tip section 1301 with metal strip 314a bolted to the metal piece 316. The end 1305 of the first blade part is located inside the intermediary blade section 310, as described above.

[0116] If the tip section 1301 becomes damaged to a critical degree, it can be replaced by a new tip section. To achieve this, the blade is cut through at the end of the first section 1331 of the first blade part 330, i.e. at end 1305. Then, the material from the damaged intermediary blade section of the damaged tip section overlapping section 1331 is ground away to restore the step from first section 1331 to second section 1332 of the first blade part 330. The new tip section can then be joined to the first blade part 330.

[0117] List of references

TABLE-US-00001 2 wind turbine 4 tower 6 nacelle 8 hub 10 blade 14 blade tip 15 tip end 16 blade root 18 leading edge 20 trailing edge 30 root region 31 root end 32 transition region 34 airfoil region 36 pressure side shell part 38 suction side shell part 40 shoulder 300 wind turbine blade 301-303 tip section 310 intermediary blade section 310a, 310b intermediary blade section sides 312 tip part 314 metal strip 314a, 314b metal strip 316 lightning receptor/solid metal piece. downconductor coupler 318 insulation for solid metal piece 321 intermediary blade section first end 322 intermediary blade section second end 323 first blade part first end 330 first blade part 341 screw 342 cable shoe 351-353 downconductor cable 361, 362 fastening means, bolts, screws 370-372 epoxy piece 1114 metal strip 1301 tip section 1305 first blade part edge 1331 first section of first blade part 1332 second section of first blade part 1340 cutout L.sub.B length/ longitudinal axis of blade L.sub.tip length of tip part Lint length of intermediary blade section L.sub.strip length of metal strip W.sub.strip width of metal strip W.sub.1, W.sub.2 width of metal strip