DK2590803T3 - Wind turbine blade temperature measurement system and method for producing wind turbine blades - Google Patents
Wind turbine blade temperature measurement system and method for producing wind turbine blades Download PDFInfo
- Publication number
- DK2590803T3 DK2590803T3 DK11730894.0T DK11730894T DK2590803T3 DK 2590803 T3 DK2590803 T3 DK 2590803T3 DK 11730894 T DK11730894 T DK 11730894T DK 2590803 T3 DK2590803 T3 DK 2590803T3
- Authority
- DK
- Denmark
- Prior art keywords
- temperature
- blade
- optical
- components
- wind turbine
- Prior art date
Links
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- 238000009529 body temperature measurement Methods 0.000 title 1
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- 230000032798 delamination Effects 0.000 claims description 20
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- 238000012545 processing Methods 0.000 claims description 16
- 238000012544 monitoring process Methods 0.000 claims description 7
- 238000001514 detection method Methods 0.000 claims description 5
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
- B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
- B29C65/483—Reactive adhesives, e.g. chemically curing adhesives
- B29C65/4835—Heat curing adhesives
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
- F03D—WIND MOTORS
- F03D1/00—Wind motors with rotation axis substantially parallel to the air flow entering the rotor
- F03D1/06—Rotors
- F03D1/065—Rotors characterised by their construction elements
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- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D99/00—Subject matter not provided for in other groups of this subclass
- B29D99/0025—Producing blades or the like, e.g. blades for turbines, propellers, or wings
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
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- B29C66/90—Measuring or controlling the joining process
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- B29C66/9121—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C66/91221—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature of the parts to be joined
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C66/91411—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature of the parts to be joined, e.g. the joining process taking the temperature of the parts to be joined into account
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- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
- F03D—WIND MOTORS
- F03D1/00—Wind motors with rotation axis substantially parallel to the air flow entering the rotor
- F03D1/06—Rotors
- F03D1/065—Rotors characterised by their construction elements
- F03D1/0675—Rotors characterised by their construction elements of the blades
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
- F03D—WIND MOTORS
- F03D3/00—Wind motors with rotation axis substantially perpendicular to the air flow entering the rotor
- F03D3/06—Rotors
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01K—MEASURING TEMPERATURE; MEASURING QUANTITY OF HEAT; THERMALLY-SENSITIVE ELEMENTS NOT OTHERWISE PROVIDED FOR
- G01K11/00—Measuring temperature based upon physical or chemical changes not covered by groups G01K3/00, G01K5/00, G01K7/00 or G01K9/00
- G01K11/32—Measuring temperature based upon physical or chemical changes not covered by groups G01K3/00, G01K5/00, G01K7/00 or G01K9/00 using changes in transmittance, scattering or luminescence in optical fibres
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01K—MEASURING TEMPERATURE; MEASURING QUANTITY OF HEAT; THERMALLY-SENSITIVE ELEMENTS NOT OTHERWISE PROVIDED FOR
- G01K11/00—Measuring temperature based upon physical or chemical changes not covered by groups G01K3/00, G01K5/00, G01K7/00 or G01K9/00
- G01K11/32—Measuring temperature based upon physical or chemical changes not covered by groups G01K3/00, G01K5/00, G01K7/00 or G01K9/00 using changes in transmittance, scattering or luminescence in optical fibres
- G01K11/3206—Measuring temperature based upon physical or chemical changes not covered by groups G01K3/00, G01K5/00, G01K7/00 or G01K9/00 using changes in transmittance, scattering or luminescence in optical fibres at discrete locations in the fibre, e.g. using Bragg scattering
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- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
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- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
- B29C66/721—Fibre-reinforced materials
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- B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
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- B29C66/91216—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux by measuring the temperature with special temperature measurement means or methods enabling contactless temperature measurements, e.g. using a pyrometer
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29L2031/085—Wind turbine blades
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- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
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- Y02E10/72—Wind turbines with rotation axis in wind direction
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
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- Y02E10/00—Energy generation through renewable energy sources
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- Y02E10/74—Wind turbines with rotation axis perpendicular to the wind direction
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Physics & Mathematics (AREA)
- Thermal Sciences (AREA)
- Chemical & Material Sciences (AREA)
- Combustion & Propulsion (AREA)
- Sustainable Energy (AREA)
- General Engineering & Computer Science (AREA)
- Sustainable Development (AREA)
- Life Sciences & Earth Sciences (AREA)
- General Physics & Mathematics (AREA)
- Chemical Kinetics & Catalysis (AREA)
- General Chemical & Material Sciences (AREA)
- Wind Motors (AREA)
Description
DESCRIPTION
Field of the Invention [0001] The invention relates to a system and method for the manufacture of a wind turbine blade. In particular, the invention relates to the bonding process used to join two turbine blade shells. The invention also relates to a system for detecting delamination of a wind turbine blade during use of the wind turbine blade.
Background of the invention [0002] Figure 1 ¡llustrates wind turbine 1, comprising a wind turbine tower 2 on which a wind turbine nacelle 3 is mounted. A wind turbine rotor 4 comprising at least one wind turbine blade 5 is mounted on a hub 6. The hub 6 is connected to the nacelle 3 through a low speed shaft (not shown) extending from the nacelle front. The wind turbine illustrated in Figure 1 may be a small model intended for domestic or light utility usage, or may be a large model, such as those that are suitable for use in large scale electricity generation on a wind farm, for example. In the latter case, the diameter of the rotor could be as large as 100 metres or more.
[0003] Wind turbine blades are typically made by forming two blade halves or shells, which are then bonded together to form the complete blade. Failure of the bond between the two shells, often called blade delamination, is a serious problem, as it most often occurs after the blade has been installed on a turbine.
[0004] The bonding process used to bond the two shells is critical in minimising the likelihood of delamination occurring and in increasing the useful lifetime of the turbine blade. Typically, the bonding of the two shells is performed by applying a bonding resin to one or both of the shells, pressing the shells together, and then curing the bonding resin in an oven. The temperature of the bonding resin during the curing process is critical in achieving good bond strength.
[0005] Typically, the blade is placed in an oven, and the oven temperature and curing time is controlled based on empirical data obtained from the manufacture of previous blades. Flowever, no two blades are ever identical, ñor is the performance of the oven used necessarily identical each time that it is used. We have appreciated that there is a need to provide a system and method for more accurate control of the bonding process for blade shells during wind turbine blade manufacture.
[0006] WO2010/023140 discloses a method of preparing an assembly, comprising providing a first structure; providing a second structure; providing at least one flexible adhesive limiting member extending between said structures; and providing an adhesive between said structures to bind said structures to each other; wherein the adhesive is limited by the flexible adhesive limiting member such that a concave front line surface of the adhesive is defined. The invention also relates to such an assembly as well as to a wind turbine rotor blade, and to a wind turbine, comprising such an assembly. In US7379169B1, an integrated measurement system for measuring a plurality of parameters is disclosed. The integrated system ineludes a fiber Bragg grating (FBG) sensor configurad for modulating a wavelength of an FBG input signal to provide an FBG output signal corresponding to an FBG parameter, a fiber Faraday rotator (FFR) sensor module configurad for rotating a polarization and modulating an intensity of an FFR input signal to provide an FFR output signal corresponding to an FFR parameter, wherein the FBG sensor and FFR sensor module are coupled to provide an integrated system output signal, and a detection system configurad for receiving the integrated system output signal and for using the integrated system output signal to obtain valúes associated with at least one FBG or FFR parameter. In one embodiment, light from a light source is used to interrógate the FBG sensor. In one example, the light source is a broadband light source and the wavelength modulated signal from the FBG sensor is obtained in the transmissive mode. The wavelength modulation is indicative of a sensed FBG parameter such as temperature or strain, which modifies the Bragg wavelength of the FBG. EP1677091 discloses a method of monitoring structural damage in a composite structure manufacturad by co-curing, co-bonding or secondary bonding of several sub-components, using fibra optic Bragg grating sensors attached or embedded to or between (in the bonding line) said sub-components, comprising a first step of measuring the wavelength spectra of said Bragg grating sensors at the end of the manufacturing of the part, and in a known load condition, considerad as reference and a second step of identifying the occurrence of a failure of the structure and the progress of said failure detecting the ralease of the residual stresses/strains stored during the curing process by measuring changes with respect to said reference wavelength spectra. DE102004060449A1 relates to the provisión of a rotor blade for a wind turbine generator with an optical deposition sensor at a leading edge thereof having a light transmitter/receiver either side of a transmission gap. The sensor is coupled to a signal processor via an optical link. Surface depositions can be detected in area of the sensor based on signáis transmitted across the transmission gap. DE10021445A1 discloses use of, heat-activated adhesive applied to plástic parís. IR radlatlon ¡s applled for suffident time to reach adheslve actlvatlon temperature. IR heat ¡nput ¡s controlled, by means of a closed control loop with temperature sensor ¡n the bond. Acontroller (28) ensures adequate heatlng for bonding.
Summaryof the Inventlon [0007] The present invention is defined in the appended independent claims to which reference should be made. Preferred aspects are set out in the dependent claims.
[0008] Accordlng to a first aspect of the Inventlon, there ¡s provlded a wind turblne blade comprlslng a flrst Shell, havlng a first bonding región, and a second shell having a second bonding región, wherein the second bonding región of the second shell is bonded to the first bonding reglón of the flrst shell; and a temperature sensor posltioned between the flrst bonding reglón and the second bonding reglón.
[0009] The invention can be applied to any bonds between components in a wind turbine blade. For example, wind turbine blades typically inelude a reinforcing spar or webs between the shells to increase the structural strength of the blade. The invention can be applied to the bonds between the spar or webs and the blade shells.
[0010] Havlng a temperature sensor positioned within the turbine blade, in the región at which the two shells of the turbine blade are bonded together, allows an accurate determination of the temperature of the critical bonding regions during blade manufacture.
[0011] Preferably, the wind turbine blade further comprises an adhesive or bonding material bonding the first shell to the second shell, and the temperature sensor is embedded in the bonding material. Typically, the bonding material is a curable compound that is cured at a temperature above room temperature. Following blade manufacture, the temperature sensor typically remains embedded within the turbine blade. For this reason it is important that the temperature sensor does not inelude any metallic, electrically conductive elements that might increase the risk of a lightning strike on the blade.
[0012] Accordingly, the temperature sensor is an optical temperature sensor. The optical temperature sensor ¡s preferably a Fibre Bragg Grating wthin an optical fibre. There may be a plurality of Fibre Bragg Gratings along the length of the optical fibre so as to detect the temperature of the bonding regions at a plurality of sepárate locations. A plurality of optical fibres, each induding one or more Fibre Bragg Gratings, may be positioned between the first bonding región and the second bonding región. The optical temperature sensor may be a single distributed sensor extending around the bonding región, for example a dlstributed strain and temperature sensor (DSTS) available from Oz Optlcs. Sensors of this type allow the temperature to be determined at any point along its length uslng a time división multiplexing (TDM) technique. This allows hot and coid spots in the bonding región to be detected.
[0013] The temperature sensor may be used during the use of the wind turbine blade to detect delamination of the wind turbine blade. To this end, the temperature sensor is preferably located in the trailing edge of the turbine blade, as this is where delamination most frequently occurs. Delamination can be detected or inferred ¡f the sensor ¡s broken Le. glves no signal, or suddenly gives a significantly different output. If the temperature sensor is a Fibre Bragg Grating sensor, then ¡t may be used to dlrectly measure strain, and so dlrectly detect whether there is significant deformation of the sensor in the bonding región.
[0014] In another aspect of the invention, there ¡s provided a method of assembly of a wind turbine blade, comprising: forming a first shell and a second shell; applying a heat curable bonding material to the first shell or the second shell, or both the first and second shell; providing a temperature sensor; placing the first shell in contad with the second shell, such that the bonding material and the temperature sensor are sandwiched between the first and second shells; and curing the bonding material, wherein the step of curing comprises monitoring the temperature detected by the optical temperature sensor, and controlling the heat applied to the bonding material based on the detected temperature.
[0015] By directly monitoring the temperatura of the curable bonding material, and controlllng the applled heat ¡n response to the detected temperatura, the physical properties of the bond between the first shell and the second shell can be assured. Preferably, the method ineludes providing a plurality of temperatura sensors between the first and second shells. This allows a good bond to be assured in a plurality of locations, which might reach different temperaturas during the curing process.
[0016] The temperatura sensor is an optical temperatura sensor. Preferably, the optical temperatura sensor is a Fibra Bragg Gratlng sensor within an optical fibra. Preferably, the optical fibra extends around a perlphery of the first and second shells ¡n a reglón ¡n which they are bonded. The optical fibra may contaln a plurality of Fibra Bragg Gratlng sensors.
[0017] In yet a further aspect of the ¡nventlon, there Is provlded a system for manufacturlng a wind turblne blade, comprlslng: an oven, the oven holding first and second blade shells; a temperatura sensor placed between the blade shells In a reglón where the first and second blade shells are to be bonded together;
Processing electronics connected to the temperatura sensor for determining a temperatura in the región in which the first and second blade shells are to be bonded together, based on signáis from the temperatura sensor; and an oven controller, the oven controller connected to the processing electronics, the oven controller controlling the heat supplied to the oven, based on the temperatura of the bonding región, as determined by the processing electronics.
[0018] The oven may allowfor local heating control so that more heat can be applied to thicker portions of the blade than to thinner portions of the blade. Preferably, the system includes a temperatura sensor, or a plurality of temperatura sensors capable of providing a measure of temperatura at a plurality of locations. The processing electronics may then be configurad to provide a plurality of temperatura measurements to the oven controller and the oven controller may then provide different amounts of heat to different parts of the oven based on the temperatura measurements. This can be an automated process, for example using suitable software in the oven controller, or can be a manually controlled process.
[0019] The temperatura sensor is an optical temperatura sensor. The optical temperatura sensor is preferably a Fibra Bragg Grating within an optical fibra. There may be a plurality of Fibra Bragg Gratings along the length of the optical fibra so as to detect the temperatura of the bonding regions at a plurality of sepárate locations. Alternatively, a plurality of optical fibras, each including one or more Fibra Bragg Gratings, may be positioned between the first bonding región and the second bonding región.
[0020] In a further aspect of the invention, there is provided a wind turbine blade comprising a plurality of componente, at least two of the componente bonded together ¡n a bonding región; and a temperatura sensor positioned in the bonding región between the two components. The two components may be a first blade shell and one of a second blade shell, a spar and a web.
[0021] In a still further aspect of the invention, there is provided a wind turbine blade comprising a first shell, having a first bonding región, and a spar having a second bonding región, wherein the second bonding región of the spar is bonded to the first bonding región of the first shell; and a temperatura sensor positioned between the first bonding región and the second bonding región.
[0022] In a still further aspect of the invention, there is provided a wind turbine blade comprising a first shell, having a first bonding región, and a web having a second bonding región, wherein the second bonding región of the web is bonded to the first bonding región of the first shell; and a temperatura sensor positioned between the first bonding región and the second bonding región.
[0023] In a still further aspect of the invention, there is provided a method of assembly of a wind turbine blade, comprising: forming first and second components of the wind turbine blade; applying a heat curable bonding material to one or both of the components; providing a temperatura sensor; placing the first component in contact with the second component, such that the bonding material and the temperatura sensor are sandwiched between the first and second components; and curing the bonding material, wherein the step of curing comprises monitoring the temperatura detected by the optical temperatura sensor, and controlling the heat applied to the bonding material based on the detected temperature. The first and second components may be a first blade shell and one of a second blade shell, a spar and a web.
[0024] In a still further aspect of the invention, there ¡s provided a method of assembly of a wind turbine blade, comprislng: forming a first shell and a spar; applying a heat curable bonding material to the first shell or the spar, or both the first shell and the spar; providing a temperature sensor; placing the first shell in contad with the spar, such that the bonding material and the temperature sensor are sandwiched between the first shell and the spar; and curing the bonding material, wherein the step of curing comprises monitoring the temperature detected by the optical temperature sensor, and controlling the heat applied to the bonding material based on the detected temperature.
[0025] In a still further aspect of the invention, there is provided a method of assembly of a wind turbine blade, comprising: forming a first shell and a web; applying a heat curable bonding material to the first shell or the web, or both the first shell and the web; providing a temperature sensor; placing the first shell in contad wth the web, such that the bonding material and the temperature sensor are sandwiched between the first shell and the web; and curing the bonding material, wherein the step of curing comprises monitoring the temperature detected by the optical temperature sensor, and controlling the heat applied to the bonding material based on the detected temperature.
[0026] In a still further aspect of the invention, there is provided a system for manufacturing a wind turbine blade, comprising: an oven, the oven holding first and second blade components; a temperature sensor placed between the blade components in a región where the first and second blade components are to be bonded together;
Processing electronics connected to the temperature sensor for determining a temperature in the región in which the first and second blade components are to be bonded together, based on signáis from the temperature sensor; and an oven controller, the oven controller connected to the Processing electronics, the oven controller controlling the heat supplied to the oven, based on the temperature of the bonding región, as determined by the Processing electronics. The first and second components may be a first blade shell and one of a second blade shell, a spar and a web.
[0027] In a still further aspect of the invention, there is provided a system for manufacturing a wind turbine blade, comprising: an oven, the oven holding a first blade shell and a spar; a temperature sensor placed between the first blade shell and the spar in a región where the first blade shell and the spar are to be bonded together; Processing electronics connected to the temperature sensor for determining a temperature in the región in which the first blade shell and the spar are to be bonded together, based on signáis from the temperature sensor; and an oven controller, the oven controller connected to the Processing electronics, the oven controller controlling the heat supplied to the oven, based on the temperature of the bonding región, as determined by the processing electronics.
[0028] In a still further aspect of the invention, there ¡s provided a system for manufacturing a wind turbine blade, comprising: an oven, the oven holding a first blade shell and a web; a temperature sensor placed between the first blade shell and the web ¡n a reglón where the first blade shell and the web are to be bonded together; Processing electronics connected to the temperature sensor for determining a temperature in the región in which the first blade shell and the web are to be bonded together, based on signáis from the temperature sensor; and an oven controller, the oven controller connected to the Processing electronics, the oven controller controlling the heat supplied to the oven, based on the temperature of the bonding región, as determined by the processing electronics.
[0029] In a still further aspect of the invention, there is provided a wind turbine comprising a wind turbine blade in accordance with the first aspect.
[0030] In yet a further aspect of the invention there is provided a blade delamination detection system comprising a wind turbine blade in accordance with the first aspect, and an optical detector connected to the optical temperature sensor, wherein the optical detector is configured to detect a step change in the output from the optical temperature sensor indicative of blade delamination.
[0031] It should be clear that features referred to in connection with one aspect of the invention ay equally applied to other aspects of the invention. In particular features referred to in relation to the bonding of blade shells to one another may equally be applied to the bonding of a blade shell to a reinforcing spar or web.
Brief Description of the Drawings [0032] Preferred embodiments of the invention will now be described, by way of example, and with reference to the drawings, in which:
Figure 1 ¡llustrates a known wind turbine;
Figure 2 is a schematic illustration of a wind turbine blade with an optical fibre temperature sensor located in a bonding región between two shells of the wind turbine blade;
Figure 3 is a schematic cross-section of the two shells of the wind turbine blade of Figure 2, showing the position of the optical fibre temperature sensor;
Figure 4 is a flowdiagram illustrating a method of forming a wind turbine blade in accordance with the invention;
Figure 5 is a schematic cross-section of the two shells of a wind turbine blade, showing the position of a spar bonded to the two shells;
Figure 6 is a schematic illustration of the blade of Figure 5, showing the longitudinal extent of the spar; and
Figure 7 is schematic cross-section of the two shells of a wind turbine blade, showing the position of a pair of webs bonded to the two shells.
Detailed Description [0033] Figure 2 ¡s a schematic illustration of a turbine blade 20 located in an oven 21, during a curing process to bond two shells of the wind turbine blade together.
Figure 3 ¡s an exploded cross sectional view of the wind turbine blade of Figure 2, more clearly showing the two shells 30, 31 and the position oían optical fibre temperature sensor 22 between the two shells.
[0034] The construction of a wind turbine blade in accordance with the present invention is most clearly shown in Figure 3. The turbine blade comprises an upper shell 30 and a lower shell 31 that are bonded together to form a completed blade 20. Each shell 30, 31 ¡s typlcally formed of a resln ¡mpregnated flbre composlte. Thls type of blade constructlon for wind turblne blades ¡s well-knowin the art.
[0035] The upper and lower shells 30, 31 are bonded together at their peripherles, herein referred to "bonding regions". The bonding regions extend around the edge of each shell and are essentially where the two shells meet when placed together to form a complete blade.
[0036] The shells may also be bonded together in an interior región and so the bonding regions may not be limited to the edges of the two shells. For example, large wind turblne blades are typlcally provlded with a spar or webs extending between the two shells within the interior of the blade. The spar or webs provide structural strength. The spar or webs are bonded to each shell at bonding regions uslng the same type of resin that ¡s used to both the shells dlrectly to one another, [0037] A bonding resin 32 is placed on one or both of the shells in their bonding regions, in order to bond the two shells together. In the example illustrated in Figure 3, bonding resin is applied to both the upper shell 30 and the lower shell 31. The bonding resin may be any suitable type of heat curable resin, adhesive or glue, known in the art.
[0038] In order to form a strong bond, the bonding resin must be heated to a particular curing temperature and then cooled. The rate of heating and coollng of the resln, as well as the absolute temperature reached by the resln, largely determine the physlcal propertles of the resultlng bond.
[0039] Figure 2 shows a turbine blade within an oven 21 used to raise the bonding resin to its curing temperature. The heat supplied by the oven 21 is controlled by an oven control system 23. The oven control system 23 is typically an electronic control system, and the oven is typically an electrically powered oven. The oven control system 23 may allow for local control so that different amounts of heat can be supplied to different portions of the oven.
[0040] Rather than simply detect the temperature at one position within the oven, or estímate the temperature based on the power or heat applied to the oven, the present invention directly detects the temperature of the resin that is to be cured. The detected temperature can then be continuously supplied to the oven control system 23 during the curing process in a feedback loop. In this way, the temperature of the resin in the curing process can be accurately controlled and made to follow the desired temperature profile, resulting in a strong bond.
[0041] In order to accurately and directly detect the temperature of the resin 32, an optical temperature sensor 22 is used. In the example illustrated in Figures 2 and 3, the optical temperature sensor is an optical Ubre 22, including one or more Fibre Bragg Gratings. The optical fibre 22 is placed between the upper and lower shells 30, 31 in the resin 32. The fibre extends from an opto-electronic processor 24 around the bonding región of the upper and lower shells 30, 31 and back to the opto-electronic processor 24. The processor 24 is typically located outside the oven 21. One or more Fibre Bragg Gratings within the optical fibre are used to detect the temperature within the bonding región. The use of Fibre Bragg Gratings to detect temperature is well-known. See, for example, US 7,379,169. Changes in the frequency response of a Fibre Bragg Grating can be used to determine changes in temperature at the position of the Fibre Bragg Grating. A single optical fibre forming a distributed sensor extending around the periphery of the blade may alternatively be used.
[0042] The opto-electronic processor 24 generates a signal indicative of the resin temperature at one or more locations within the bonding regions based on output from the señor or sensors, and passes that signal to the oven control system 23. The oven control system 23 then adjusts the heat or power supplied to the oven 21, or portions of the oven, to maintain the resin at the desired temperature.
[0043] Figure 4 is a flow diagram illustrating the steps carried out in a method for manufacturing a wind turbine blade in accordance with the present invention.
[0044] In steps 400 and 410 the upper and lower shells of the wind turbine blade are made. The upper and lower shells can be manufactured ¡n accordance with any standard techniques known in the art. In step 420 resin or glue is applied to the upper shell or the lower shell or both the upper and lower shell in their bonding regions. The optical fibre, including the Fibre Bragg Grating, is then placed in the resin on the upper or lower shell in step 430. The upper shell is then place on the lower shell at step 440, sandwiching the curable resin and the optical fibre between them. The blade is placed in an oven in step 450. Alternatively, steps 420 to 440 may be carried out in the oven before it is heated. The blade is then heated in step 460 in order to begin the curing process and bond the two blade shells together.
[0045] In step 470 the temperature of the resin is detected using the optical temperature sensor and, as described with reference to Figure 1, the amount of heat applied to the blade ¡s controlled dependent on the detected temperature. This feedback control ¡s ¡llustrated by a dotted line between steps 470 and 460 ¡n Figure 4. Once the desired temperature ¡s reached, the oven may maintain the resin at that temperature for a while to allowthe resin to completely cure.
[0046] In step 480 the blade is cooled. If the rate of cooling of the resin is ¡mportant, the temperature of the resin can continué to be monitored during the cooling step 480, and the rate of cooling accordingly controlled. This feedback control is ¡llustrated by a dotted line between steps 480 and 470 in Figure 4.
[0047] Once the blade is cooled back to ambient temperature, the manufacturing process is complete. This is ¡llustrated by step 490.
[0048] Although the present invention has been described with the resin being cured by placing the wind turbine blade in an oven, it is possible to apply heat to the resin by other means, for example by directly applying heating elemente to the surface of the blade.
[0049] More than one optical fibre may be provided between the upper and lower shells in accordance with the present invention. Having more than one optical fibre provides redundancy. It may also be more cost effective to use múltiple single grating fibres than a múltiple grating fibre or a fibre with an elongated grating. It may also allow blade delamination to be detected at an earlier stage, as described below.
[0050] As already described, it is possible to provide an optical temperature sensor in any bond in a wind turbine blade. Figure 5 shows a schematic cross-section of a wind turbine blade including a spar 50 bonded to the upper and lower shells 30, 31. Figure 6 illustrates the spar extending from near the root of the blade 20 to near to the tip of the blade. The spar is bonded to both the upper and lower shells using a heat curable resin in bonding regions 51, 52, in the same manner as the two shells are bonded to each other. One or more optical fibres 53 may be provided in each bonding región between the spar and the respective blade shell and can be used to monitor the temperature of the bonding resin during the assembly process.
[0051] Figure 7 is a schematic cross-section showing the use of reinforcing webs 70, 71 instead of the box spar 50 shown in Figure 5. The webs 70, 71 and the blade shells 30, 31 are bonded together using a heat curable ersin at bonding regions 72, 73, 74 and 75. One or more optical fibres 76 may be provided in each bonding región between a web and a blade shell and can be used to monitor the temperature of the bonding resin during the assembly process.
[0052] There is a particular additional advantage in including an optical temperature sensor, and in particular a Fibre Bragg Grating or Long Periond Grating (LPG), at the trailing edge of a wind turbine blade between the upper and lower shells. One common problem with wind turbine blades is separation of the upper and lower shells during Service. This is called blade delamination, and most frequently occurs at the trailing edge of the blade. The optical temperature sensor used in the manufacturing process of the present invention may subsequently be used during use and servicing of the wind turbine blade as a means of detecting blade delamination. A step change in the optical response of the optical temperature sensor, or simply failure of the optical temperature sensor, during use of the wind turbine blade, is indicative of blade delamination. Fibre Bragg Gratings can be used to directly measure strain at their location. A sudden change in the strain experienced by a Fibre Bragg Grating located between the upper and lower shells is indicative of blade delamination, particularly if uncorrelated to strain measurement taken elsewhere on the blade.
[0053] Accordingly, a wind turbine blade in accordance with the present invention has advantages both in the manufacture of the wind turbine blade and in detection of blade delamination during use of the wind turbine blade.
[0054] Given that the temperature sensor remains within the blade when it is mounted on a wind turbine, it is desirable that the optical temperature sensor does not inelude any metallic, or highly electrically conductive elements, which would significantly increase the risk of lightning strikes. For this reason, optical temperature sensors are most desirable, and Fibre Bragg Grating offer a particularly advantageous solution.
[0055] Although Fibre Bragg Gratings are a preferred form of temperature sensor, other types of temperature sensor may alternatively or additionally be employed. For example, Long Period Gratings (LPGs) may be used. LPGs may be used not only to detect temperature but also bending of the blade during its use. This allows for detection of general structural damage to the blade as well as delamination. Distributed optical fibre sensors based on Raman or Brillouin scattering may also be used.
[0056] The invention has been described with reference to example implementations, purely for the sake of ¡llustration. The invention ¡s not limited by these, as many modifications and variations would occur to the skilled person. The invention ¡s to be understood from the claims that follow.
REFERENCES CITED IN THE DESCRIPTION
This list of references cited by the applicant is for the reader's convenience only. It does not form part of the European patent document. Even though great care has been taken in compiling the references, errors or omissions cannot be excluded and the EPO disclaims all liability in this regard.
Patent documents cited in the description . WQ201002314GA ÍQOQSf • 113737916981 [0006] • EP1677Q91A fOOOS] • PE1020Q4Q60449A1 fOQOSl • DE10021445A1 [8006] . US7379169B [00411
Claims (16)
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
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US36238410P | 2010-07-08 | 2010-07-08 | |
GB1011543.4A GB2481842A (en) | 2010-07-08 | 2010-07-08 | Wind turbine blade comprising bonded shells and incorporating a temperature measurement system |
PCT/DK2011/050264 WO2012003836A1 (en) | 2010-07-08 | 2011-07-06 | Turbine blade temperature measurement system and method of manufacture of turbine blades |
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DK2590803T3 true DK2590803T3 (en) | 2017-04-24 |
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DK11730894.0T DK2590803T3 (en) | 2010-07-08 | 2011-07-06 | Wind turbine blade temperature measurement system and method for producing wind turbine blades |
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DK (1) | DK2590803T3 (en) |
GB (1) | GB2481842A (en) |
Cited By (1)
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CN113532304A (en) * | 2021-07-20 | 2021-10-22 | 哈尔滨工程大学 | Wing skin structure health state monitoring method based on quasi-distributed fiber bragg grating |
Families Citing this family (4)
Publication number | Priority date | Publication date | Assignee | Title |
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US8454311B2 (en) * | 2011-09-29 | 2013-06-04 | General Electric Company | Wind turbine blade edge monitoring system |
DK177744B1 (en) | 2012-10-16 | 2014-05-19 | Envision Energy Denmark Aps | Wind turbine having external gluing flanges near flat back panel |
DK3601783T3 (en) * | 2017-05-09 | 2022-05-02 | Siemens Gamesa Renewable Energy As | Wind turbine rotor blade with embedded sensors |
JP7481233B2 (en) * | 2020-11-19 | 2024-05-10 | 三菱重工業株式会社 | Lightning protection system for wind turbine blades, wind power generation equipment, and monitoring method for wind turbine blades |
Family Cites Families (4)
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US6251202B1 (en) * | 1999-05-05 | 2001-06-26 | Patent Holding Company | Method and system for bonding plastic parts together |
US6906537B2 (en) * | 2002-08-19 | 2005-06-14 | Hamilton Sundstrand | System for controlling the temperature of an aircraft airfoil component |
GB2440954B (en) * | 2006-08-18 | 2008-12-17 | Insensys Ltd | Structural monitoring |
US8172180B2 (en) * | 2007-11-30 | 2012-05-08 | Bae Systems Plc | Temperature monitoring |
-
2010
- 2010-07-08 GB GB1011543.4A patent/GB2481842A/en not_active Withdrawn
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2011
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Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
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CN113532304A (en) * | 2021-07-20 | 2021-10-22 | 哈尔滨工程大学 | Wing skin structure health state monitoring method based on quasi-distributed fiber bragg grating |
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GB2481842A (en) | 2012-01-11 |
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