GB2523370A - Blade manufacturing method - Google Patents

Blade manufacturing method Download PDF

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Publication number
GB2523370A
GB2523370A GB1403152.0A GB201403152A GB2523370A GB 2523370 A GB2523370 A GB 2523370A GB 201403152 A GB201403152 A GB 201403152A GB 2523370 A GB2523370 A GB 2523370A
Authority
GB
United Kingdom
Prior art keywords
spar
shell
blade
separators
volume
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
GB1403152.0A
Other versions
GB201403152D0 (en
GB2523370B (en
Inventor
Raul Cacho-Oses
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Marine Current Turbines Ltd
Original Assignee
Marine Current Turbines Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Marine Current Turbines Ltd filed Critical Marine Current Turbines Ltd
Priority to GB1407911.5A priority Critical patent/GB2523414B/en
Priority to GB1403152.0A priority patent/GB2523370B/en
Publication of GB201403152D0 publication Critical patent/GB201403152D0/en
Priority to PCT/EP2015/053696 priority patent/WO2015124761A1/en
Publication of GB2523370A publication Critical patent/GB2523370A/en
Application granted granted Critical
Publication of GB2523370B publication Critical patent/GB2523370B/en
Expired - Fee Related legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F03MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
    • F03BMACHINES OR ENGINES FOR LIQUIDS
    • F03B3/00Machines or engines of reaction type; Parts or details peculiar thereto
    • F03B3/12Blades; Blade-carrying rotors
    • F03B3/121Blades, their form or construction
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • B29C44/18Filling preformed cavities
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F03MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
    • F03BMACHINES OR ENGINES FOR LIQUIDS
    • F03B13/00Adaptations of machines or engines for special use; Combinations of machines or engines with driving or driven apparatus; Power stations or aggregates
    • F03B13/12Adaptations of machines or engines for special use; Combinations of machines or engines with driving or driven apparatus; Power stations or aggregates characterised by using wave or tide energy
    • F03B13/26Adaptations of machines or engines for special use; Combinations of machines or engines with driving or driven apparatus; Power stations or aggregates characterised by using wave or tide energy using tide energy
    • F03B13/264Adaptations of machines or engines for special use; Combinations of machines or engines with driving or driven apparatus; Power stations or aggregates characterised by using wave or tide energy using tide energy using the horizontal flow of water resulting from tide movement
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F03MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
    • F03DWIND MOTORS
    • F03D1/00Wind motors with rotation axis substantially parallel to the air flow entering the rotor 
    • F03D1/06Rotors
    • F03D1/065Rotors characterised by their construction elements
    • F03D1/0675Rotors characterised by their construction elements of the blades
    • YGENERAL 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
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02EREDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00Energy generation through renewable energy sources
    • Y02E10/20Hydro energy
    • YGENERAL 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
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02EREDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00Energy generation through renewable energy sources
    • Y02E10/30Energy from the sea, e.g. using wave energy or salinity gradient
    • YGENERAL 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
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02EREDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00Energy generation through renewable energy sources
    • Y02E10/70Wind energy
    • Y02E10/72Wind turbines with rotation axis in wind direction
    • YGENERAL 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
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50Manufacturing or production processes characterised by the final manufactured product

Abstract

A method of assembling a turbine blade e.g. for a tidal turbine comprises shaping first and second blade shells 2, 5 and curing the shells. A spar 4 is installed in the first shell 2 using an adhesive 6. Adhesive 7 is applied to an opposing surface of the spar 4 and to the edges of the blade shell 2, and a volume of a foam forming substance 8 is provided in the first shell 2, at least partially in contact with the spar 4. The second shell 5 is then fitted to the first shell 2 to enclose the spar 4 and the assembled blade is 10 cured. The substance 8 is foamed in situ and rises 9 to fill the blade. This avoids the need to cut foam blocks to the required tolerances.

Description

BLADE MANUFACTURING METHOD
This invention relates to a method of manufacturing a blade, in particular for use in water current turbines.
A water current turbine blade, such as for a tidal turbine, is highly loaded as compared with wind turbine blades, due to the density of water in comparison with the density of air. Reinforcement of the blade hydrodynamic shells is required due to the loads supported in the blade skin and in order to maintain the dimensional stability of the foil. One type of blade which addresses this need to support the blade shell is described in GB2485548 in which the blade is flooded, so that the internal and external pressure equalizes. However, this solution exposes the internal parts of the blade to sea water. In 6B2471 013, a hollow spar within outer shells is provided with spaced apart foam ribs within the shell to prevent the spar from deforming under changes in external pressure.
Alternatively, the blade could be filled with foam cut from one or more solid blocks as in the case with the rudders of some boats. However, a blade filled with cut foam is expensive to manufacture and requires lot of rework in the workshop to accommodate machined foam blocks in the internal shape that meets all manufacturing tolerances, Integrating the machined foam blocks with the shells of the blade using resins or adhesives may then cause the blade to fall outside acceptable manufacturing tolerances.
In accordance with a first aspect of the present invention a method of assembling a turbine blade comprises shaping first and second blade shells and curing the shells; applying adhesive to an inner surface of the first shell; installing a spar in the first shell, at least part of one surface of the spar being in contact with the adhesive; applying adhesive to an opposing surface of the spar; providing a volume of a foam forming substance in the first shell, at least partially in contact with the spar; fitting the second shell to the first shell to enclose the spar; and curing the assembled blade.
Preferably, the method further comprises inserting one or more separators between the spar and the inner surface of the first shell before providing the foaming agent.
In a spar having a hollow box type constmction, separators are not required, as the spar has sufficient strength to withstand the hydrostatic pressure. However, when the spar is has a hollow frame construction, the method further comprises installing separators within the spar.
The separators in the blade, or in the spar, may be angled with respect to the longitudinal axis of the blade, or spar, or with respect to one another, but preferably, the method comprises fitting the separators perpendicular to the longitudinal axis of the spar.
Preferably, the method comprises determining a volume formed between separators and calculating a volume of foam forming substance required before that volume of foam forming substance, In accordance with a second aspect of the present invention, a turbine blade comprises first and second blade shells sealed on their leading and trailing edges and containing a longitudinally extending spar, a plurality of separators perpendicular to the spar, and foam filling formed in situ within the shells from a forming material in accordance with a method according to the first aspect.
An example of a method of assembling a turbine blade according to the present invention will now be described with reference to the accompanying drawings in which: Figures Ia to Id illustrate a method of assembling a turbine blade according to the present invention; Figure 2 illustrates a section of a turbine blade constmcted according to the method of Fig.I; and, Figure 3 is a plan view of an example of a turbine blade constructed according to the present invention.
An example of a method of manufacturing a sealed foam filled blade I is described with respect to Figs I a to I d. A turbine blade formed with a sealed shell which does not flood and so does not expose the internal parts of the blade to the corrosive effects of seawater is typically formed by combining two outer shell halves forming the skins of the blade, bonding these to a spar and sealing the edges of the shell halves together, although other basic constructions are possible, such as one part non-bonded construction. As shown in Fig. 1 a, one shell half 2 is formed and cured and laid with its inner surface 3 facing upwards to receive a spar 4. It is desirable that the position of the spar in the shell half is fixed, for example, by means of a layer of adhesive 6 applied to the inner surface of the shell half 2 where the spar is to be positioned, or to a surface of the spar before it is inserted. In some cases bond position blocks may be inserted in the inner surface of the shell half 2 during its construction and the spar 4 slotted into position between the positioning blocks (not shown).
As illustrated in Fig. ib, a second shell half 5 is also formed and cured, ready to assemble with the first shell half 2. Before joining the shell halves 2, 5 those surfaces of the first shell half 2 and the spar 4 which will contact the second shell half 5 are coated with adhesive 7 to assist in the process of bonding the spar to the skin.
Generally, the shell halves remain in their mould before assembly because the mould is used to apply heat for curing and maintain both shells aligned in the assembly process.
In that case, there is no need to use ridges, or positioning blocks, in the shell halves, as the alignment with other shell half is provided by the mould alignment system.
However, if position blocks are being used to locate the spar in the shell halves, then the second shell half 5 is formed with these blocks in place and the adhesive may be applied to the trailing edge and leading edge of the first shell half, as well as over the spar 4, and the edges are then sealed. If prefered, the adhesive may be applied to the inner surface of the second shell half instead. A foam forming substance 8 is then poured into at least part of the first shell half 2, either side of the spar 4. The second shell half S is then lowered into place and into contact with the first shell half 2 and the spar 4 and the constmction so formed is then cured.
The effect of the curing step is to harden the adhesive, thereby sealing the two shell halves together and also to cure the foam forming substance 8. The foam forming process is typically a chemical reaction initiated by adding a foaming agent to a base substance and mixing this before pouring it into the first shell half and bringing the two shell halves 2, 5 brought together. The mixing immediately starts an exothermic reaction and the mixture is poured into the shell half 4. The exothermic reaction is allowed to stabilize, The foaming process continues after the shells have been closed until the process has finished and the foam has expanded to fill the volume, Once completed, energy may be applied to cure the foam forming substance and the structural adhesive. Fig. 1 c shows how the foam rises up as indicated by the arrows 9, substantially filling the space between the two shell halves and the spar. Fig. Id shows a section through the assembled and cured turbine blade 1, with foam 10 now filling the space available between the two shells and around the spar entirely, An advantage of the present invention is that the blade is completely filled with foam, avoiding the need for any machining process for the foam filling, or other manual process to fill the internal volume of the blade. The formed foam provides structural support to resist the forces applied by the water in use, without exposing the inner part of the blade to seawater.
A further feature which may be incorporated during the assembly process is to insert separator panels within the shell, so that a series of smaller volumes are formed.
This allows more accurate control of materials, as the correct amount of foam forming substance is calculated for each of the volumes formed and that amount is poured into the section and forms foam to fill that smaller volume. The separator panels also have the effect of restricting the direction of expansion of the foam, leading to a more uniform coverage within each section. This feature is illustrated in Figs.2 and 3. The illustration of Fig.2 shows separator panels 11, 12 in contact with the inner surface of the shell half 2 and with edges of the spar 4 forming volumes 14, 15. The calculated amount of foam forming substance is then applied within those volumes before the second shell half is put into place. This is more cost effective as only the required amount of the foam forming substance is used and the chance of over or under filling the blade by supplying an incorrect volume of foam is reduced. Furthermore, as the chemical reaction which forms the foam is exothermic, reducing the volume of each section prevents the heat generated by the reaction from becoming too high, as the heat generated is proportional to the volume.
The sections may be created by using chord wise panels, as illustrated in Fig.2, which may also be structural, The panels enclose the volume between the spar and the lower and the upper shell, so that the desired expanded volume of the foam is achieved.
In addition, as shown in Fig.3, if the hollow spar is constructed as an open framework, then the spar itself may be provided with separator panels forming different volumes inside the spar. In this case, the calculation of the required quantity of foam forming substance for each volume includes the volume formed by the frame and panels of the spar. For simplicity, the spar panels may be lined up with the panels outside the spar, or they may be offset as illustrated in Fig.3 according to the structural requirements of the spar. For a hollow box girder type construction, with solid walls, separator panels are not used as no foam is present within the spar. The examples illustrate chord wise panels, for ease of calculation of the volume and for the beneficial structural effects that these have, but the invention is not limited to this embodiment. The separator panels maybe installed at an angle to the surface of the spar, or additional panels may be installed parallel to a longitudinal axis of the spar to further reduce the total volume of a section.
The separator panels may be manufactured from wood, cardboard or other material according to the reaction temperature that they need to be able to withstand.
Unlike using machined foam inserts, the present invention has flexibility to fill the total blade volume from foam formed by thermal reaction, which expands into the space available in the closed shell. Thus, even if the manufacturing of the blade shell halves or separator panels is not exact, the foam will adapt to the actual shape. Thus, the blade assembly process of the present invention is more efficient, flexible and results in a better filled blade.

Claims (6)

  1. CLAIMSL A method of assembling a turbine blade, the method comprising shaping first and second blade shells and curing the shells; applying adhesive to an inner surface of the first shell; installing a spar in the first shell, at least part of one surface of the spar being in contact with the adhesive; applying adhesive to an opposing surface of the spar; providing a volume of a foam forming substance in the first shell, at least partially in contact with the spar; fitting the second shell to the first shell to enclose the spar; and curing the assembled blade.
  2. 2. A method according to claim, ftirther comprising inserting one or more separators between the spar and the inner surface of the first shell before providing the foaming agent.
  3. 3. A method according to claim or claim 2, wherein the spar is has a hollow frame constmction and wherein the method thrther comprises installing separators within the spar.
  4. 4. A method according to claim 2 or claim 3, wherein the method comprises fitting the separators perpendicular to the longitudinal axis of the spar.
  5. 5. A method according to claim 3 or claim 4, wherein the method comprises determining a volume formed between separators and calculating a volume of foam forming substance required before that volume of foam forming substance.
  6. 6. A turbine blade comprising first and second blade shells sealed on their leading and trailing edges and containing a longitudinally extending spar, a plurality of separators perpendicular to the spar, and foam filling formed in situ within the shells from a forming material in accordance with a method according to any preceding claim.Amendments to the claims have been filed as followsCLAIMSL A method of assembling a turbine blade, the method comprising shaping first and second blade shells and curing the shells; applying adhesive to an inner surface of the first shell; installing a spar in the first shell, at least part of one surface of the spar being in contact with the adhesive; applying adhesive to an opposing surface of the spar; providing a volume of a foam forming substance in the first shell, at least partially in contact with the spar; fitting the second shell to the first shell to enclose the spar; and curing the assembled blade.2. A method according to claim, ftirther comprising inserting one or more separators between the spar and the inner surface of the first shell before providing the foaming agent.3. A method according to claim or claim 2, wherein the spar is has a hollow frame constmction and wherein the method thrther comprises installing separators within the spar. r4. A method according to claim 2 or claim 3, wherein the method comprises fitting the separators perpendicular to the longitudinal axis of the spar.5. A method according to claim 3 or claim 4, wherein the method comprises determining a volume formed between separators and calculating a volume of foam forming substance required before providing that volume of foam forming substance.6. A turbine blade comprising first and second blade shells sealed on their leading and trailing edges and containing a longitudinally extending spar, a plurality of separators perpendicular to the spar, and foam filling formed in situ within the shells from a forming material in accordance with a method according to any preceding claim.
GB1403152.0A 2014-02-24 2014-02-24 Blade manufacturing method Expired - Fee Related GB2523370B (en)

Priority Applications (3)

Application Number Priority Date Filing Date Title
GB1407911.5A GB2523414B (en) 2014-02-24 2014-02-24 Turbine blade and method of manufacture
GB1403152.0A GB2523370B (en) 2014-02-24 2014-02-24 Blade manufacturing method
PCT/EP2015/053696 WO2015124761A1 (en) 2014-02-24 2015-02-23 Foam-filled turbine blade and method of manufacture

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB1403152.0A GB2523370B (en) 2014-02-24 2014-02-24 Blade manufacturing method

Publications (3)

Publication Number Publication Date
GB201403152D0 GB201403152D0 (en) 2014-04-09
GB2523370A true GB2523370A (en) 2015-08-26
GB2523370B GB2523370B (en) 2016-08-10

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Application Number Title Priority Date Filing Date
GB1407911.5A Expired - Fee Related GB2523414B (en) 2014-02-24 2014-02-24 Turbine blade and method of manufacture
GB1403152.0A Expired - Fee Related GB2523370B (en) 2014-02-24 2014-02-24 Blade manufacturing method

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Application Number Title Priority Date Filing Date
GB1407911.5A Expired - Fee Related GB2523414B (en) 2014-02-24 2014-02-24 Turbine blade and method of manufacture

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GB (2) GB2523414B (en)
WO (1) WO2015124761A1 (en)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN111561419A (en) * 2020-06-11 2020-08-21 国电联合动力技术(保定)有限公司 Design method for filling core material at rear edge of wind power blade

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
NL9100816A (en) * 1991-05-10 1992-12-01 Aerpac Holding B V Hollow plastic structure-reinforcement method - by joining sections by inflating and hardening adhesive auxiliary plastic structure
WO1994017303A1 (en) * 1992-11-05 1994-08-04 Bonus Energy A/S Windmill blade
US20110031759A1 (en) * 2009-08-05 2011-02-10 Nitto Denko Corporation Foam filling material for wind power generator blades, foam filling member for wind power generator blades, wind power generator blade, wind power generator, and method for producing the wind power generator blade
US20130183161A1 (en) * 2012-01-18 2013-07-18 Pika Energy LLC Low-Cost Molded Wind Turbine Blade

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE1059770B (en) * 1957-01-23 1959-06-18 Rhein West Flug Fischer & Comp Process for the production of aircraft wings and tail surfaces
FR2617119B1 (en) * 1987-06-26 1989-12-01 Aerospatiale BLADE OF COMPOSITE MATERIALS, WITH STRUCTURAL CORE AND PROFILED COVERING COVERING, AND MANUFACTURING METHOD THEREOF
US7732044B2 (en) * 2002-09-04 2010-06-08 Foam Matrix, Inc. Foam core-surface reinforced article and method

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
NL9100816A (en) * 1991-05-10 1992-12-01 Aerpac Holding B V Hollow plastic structure-reinforcement method - by joining sections by inflating and hardening adhesive auxiliary plastic structure
WO1994017303A1 (en) * 1992-11-05 1994-08-04 Bonus Energy A/S Windmill blade
US20110031759A1 (en) * 2009-08-05 2011-02-10 Nitto Denko Corporation Foam filling material for wind power generator blades, foam filling member for wind power generator blades, wind power generator blade, wind power generator, and method for producing the wind power generator blade
US20130183161A1 (en) * 2012-01-18 2013-07-18 Pika Energy LLC Low-Cost Molded Wind Turbine Blade

Also Published As

Publication number Publication date
GB2523414B (en) 2016-02-17
GB201403152D0 (en) 2014-04-09
GB2523370B (en) 2016-08-10
GB201407911D0 (en) 2014-06-18
GB2523414A (en) 2015-08-26
WO2015124761A1 (en) 2015-08-27

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PCNP Patent ceased through non-payment of renewal fee

Effective date: 20180224