JP3825346B2 - Composite blade for wind turbine generator - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a blade for a wind turbine generator, and more particularly to a composite blade composed of a skin and a main girder.
[0002]
[Prior art]
The blades for wind power generators are required to be lightweight, high-strength, and easy to manufacture. The composite structure meets these needs. An example of a conventional composite blade will be described with reference to the drawings. FIG. 15 shows the entire structure, FIG. 16 shows the blade cross-sectional structure, and FIG. 17 shows the blade root structure. As can be seen from the drawings, the conventional composite blade 1 is conceptually composed of two members, an outer skin 3 and a main girder 5, which are bonded and assembled to obtain a predetermined overall structure. The aforementioned outer skin 3 is formed as a two-part structure composed of an abdominal side and a back side. On the other hand, the main girder 5 has a cylindrical integrated structure up to the blade root, and after the outer skin 3 and the main girder 5 are bonded together. The urethane foam 7 is filled and assembled as an intermediate material. In addition, a metal bolt 9 for attaching the blade is embedded in the blade root portion of the main girder 5.
[0003]
[Problems to be solved by the invention]
The structure of the composite blade 1 as described above is easy to manufacture, can be manufactured at low cost, and is excellent in mass production in a relatively small blade having a blade length of less than 20 m.
[0004]
However, when the blade is configured as a large and large blade having a blade length exceeding 20 m, in the above-described structure, it is particularly difficult to integrally manufacture the member of the main girder 5, so that the mass productivity is poor and the manufacturing cost ( There is a problem that man-hours) increase significantly. Below, the problem in the case of manufacturing a large and long blade having a blade length exceeding 20 m with a conventional blade structure will be specifically described.
[0005]
The conventional manufacturing method of the main girder 5 is a so-called winding method in which a glass fiber fabric having a predetermined width is impregnated with a resin and wound around a rotating cylindrical mold. This method is very promising because it is inexpensive, relatively stable in quality, and excellent in mass productivity. However, in manufacturing a main girder for a large and long blade having a blade length exceeding 20 m, means for supporting the bending of a long cylindrical mold is necessary, and the manufacturing itself is very difficult. As a countermeasure, there can be considered a method in which the main girder is divided into a plurality of parts in the length direction and then joined, but there remains a problem in manufacturing cost and mass productivity. Further, the blade root portion in which the metal bolt for attaching the blade is embedded becomes an ultra-thick FRP member having a thickness exceeding 100 mm. For this reason, it is more difficult to manufacture, and this part is manufactured while rotating the entire main girder whose length is more than 20 m, ensuring quality (dimensional accuracy), manufacturing cost and mass productivity. Very difficult and near impossible.
[0006]
In the conventional blade structure 1, after the outer skin 3 and the main girder 5 are bonded, the urethane foam 7 is filled and assembled as an intermediate material. . Thus, large blades with a blade length of more than 20 m have a very large volume filled with foamed urethane, so that unfilled parts are generated and even if filled, the material is uneven (filling density). Variation), and it is difficult to ensure quality.
[0007]
Accordingly, an object of the present invention is to provide a composite blade for a wind power generator that is good in manufacturability and good quality even when configured as a large wing having a blade length exceeding 20 m.
[0008]
[Means for Solving the Problems]
In order to solve the above-described problems, according to the present invention, a composite blade for a wind turbine generator is made of a glass fiber reinforced plastic and has an outer skin defining a wing shape, and is disposed inside the outer skin. A main fiber girder made of glass fiber reinforced plastic, an adhesive layer for joining the outer skin and the main girder, and a blade root part made of glass fiber reinforced plastic for attaching the composite blade. The composite blade has a divided structure divided into two in the width direction, and each divided part has a long plate-shaped portion extending in the longitudinal direction of the wing, and both edges of the long plate-shaped portion The portion is bonded to the back inner surface and the vent inner surface of the outer skin through a reinforcing layer made of high-strength glass fiber reinforced plastic or carbon fiber reinforced plastic formed between the adhesive layer and the outer skin. Features.
[0009]
In a preferred embodiment of the present invention, the reinforcing layer is preferably wider than an edge of the main girder long plate shape portion. Moreover, it is also possible to make the said reinforcement layer the shape which straddles the edge part of the said 2 divided main beam. Furthermore, the main girder and the blade root portion can be integrally formed or separated. It is also desirable that the outer skin or the main girder is composed of a glass fiber reinforced plastic single plate portion and a sandwich structure portion in which a solid foam is sandwiched between glass fiber reinforced plastics. Furthermore, reinforcing ribs made of glass fiber reinforced plastic or carbon fiber reinforced plastic can be disposed on the outer skin.
[0010]
Moreover, it is preferable to embed a metal bolt for attaching the composite blade in the blade root portion. Further, the blade root portion and the outer skin are joined by adhesive bonding only, a combination of adhesive bonding and a taper, or a combination of adhesive bonding and fitting of irregularities. The main girder having a divided structure is preferably integrated at the blade root portion by an adhesive or a laminated adhesion of glass fibers or carbon fibers.
[0011]
DETAILED DESCRIPTION OF THE INVENTION
Next, embodiments of the present invention will be described with reference to the accompanying drawings. In addition, the same code | symbol shall be attached | subjected to the same part over all the figures.
First, FIG. 1 to FIG. 3 show an embodiment of a composite blade composed of an outer skin and a main girder according to the present invention, FIG. 1 is a plan view thereof, FIG. 2 is a sectional view thereof, and FIG. FIG. 3 is a partial view thereof. The outer skin of the composite blade 10 according to the present invention consists of two halves, a ventral outer skin 11a and a back outer skin 11b, which, when combined, define a wing shape. On the other hand, the main girder 13 has a split structure in which the main girder is vertically divided in the wing width direction, that is, divided into two parts. In this embodiment, each half divided into two parts has a predetermined interval. The members 13a and 13b have a U-shaped cross section facing each other. The bent ends of the members 13 a and 13 b and the outer skins 11 a and 11 b are firmly joined to each other by the adhesive layer 15 and integrated as a blade 10.
[0012]
Further, as shown in FIG. 3, semi-annular flange portions 13c and 13d are formed on the blade root side of the members 13a and 13b, respectively, and when these are combined, an annular blade mounting flange is formed. It is supposed to be. That is, the main girder and the blade root portion including the blade mounting flange are integrally formed. Further, the blade root side of the ventral outer skin 11a and the back outer skin 11b has a semi-annular shape, and when these are combined, the annular blade mounting flange of the main girder 13 and the concentric annular portion are formed. It is configured. Then, the inner peripheral surface of the concentric outer ring-side annular portion and the outer peripheral surface of the flange on the main girder 13 side are firmly joined to each other by the adhesive layer 15. Thus, since the joint part of both members is formed concentrically long, compared with the prior art example shown in FIG. 17, the connection between the outer skin and the main girder at the blade root part becomes stronger. A blade fixing metal bolt 19 is embedded in the blade root portion of the main beam 13, that is, the flange portions 13c and 13d of the members 13a and 13b.
[0013]
The manufacturing procedure of the composite blade 10 having the above-described structure will be described in detail. In the blade 10, the members 13a and 13b and the outer skins 11a and 11b of the main girder 13 are separately manufactured and then bonded. It is a structure in which these are assembled with each other at a predetermined position. Thus, since the main girder is divided into two in the wing width direction, even when the main girder of a large and long composite blade exceeding 20 m is manufactured integrally, the manufacture of the blade becomes very easy.
[0014]
Further, not only the outer skin 11a, 11b of the composite blade 10 but also the long main girder 13 is divided into two parts, both of which are made of glass fiber reinforced plastic without being constrained by the conventional winding method, and are wet laminated (hand Lay-up method), vacuum resin impregnation method or pressure resin impregnation method, and the like, and an easy and inexpensive production method can be selected according to the shape and dimensions of the main beam. As a result, the quality, cost, and mass productivity of large and large blades with blade lengths exceeding 20 m can be dramatically improved at the same time.
[0015]
Next, a composite blade according to another embodiment of the present invention will be described. Referring to FIG. 4, the web height of the main girder 23 is slightly smaller than that of the main girder 13, and reinforcing layers 27a and 27b are formed between the adhesive layer 15 and the outer skins 11a and 11b. Yes. The reinforcing layers 27a and 27b are formed from high-strength glass fiber reinforced plastic, but may be formed from carbon fiber reinforced plastic. By disposing the high-strength reinforcing layers 27a and 27b in this portion, it is possible to efficiently increase the resistance of the blade 20 to the bending force caused by wind pressure. The inside of the outer skins 11a and 11b excluding the main girder 23 and the reinforcing layers 27a and 27b is hollow, and the blade 20 is lighter than that filled with plastic. In addition, since a tensile or compressive load in the blade longitudinal direction acts mainly on this portion, it is most effective to use a unidirectional material in which fibers are concentrated and aligned in the blade longitudinal direction.
[0016]
When a composite blade for a large-scale wind power generator with an output exceeding 500 kW is used, not only the bending force due to wind pressure but also the generated stress due to its own weight or the centrifugal force of rotation rapidly increases. Therefore, with the conventional structure and material, the weight of the blade becomes very large, and an excessive force acts on the rotor shaft and the bearing that support the blade. According to the present invention, the weight of the blade 20 is increased. Is minimized by the hollow structure, and greatly contributes to the weight reduction and cost reduction of the entire apparatus.
[0017]
Further, a composite blade according to another embodiment of the present invention will be described with reference to a sectional view of FIG. In the figure, the outer skins 31 and 32 of the composite blade 30 are composed of single plate portions 31a and 32a made of glass fiber reinforced plastic and sandwich structure portions 31b and 32b in which a solid foam is sandwiched between glass fiber reinforced plastics. As described above, when the sandwich structure is formed by sandwiching the solid foam in the outer skin, the digging strength of the outer skin is improved even though the plate thickness is thin, and the blade can be significantly reduced in weight.
[0018]
The main girders 33 and 34 include glass plate reinforced plastic single plate portions 33a and 34a and sandwich structure portions 33b and 34b in which a solid foam is sandwiched between glass fiber reinforced plastics. As described above, when the sandwich structure is formed by sandwiching the solid foam in the main girder, the rigidity of the main girder is improved despite the thin plate thickness, and the blade can be significantly reduced in weight. In this embodiment, the sandwich structure portion is provided on both the outer skin and the main girder. However, depending on the required strength, only one of them can be used as appropriate.
[0019]
A composite blade according to still another embodiment of the present invention will be described with reference to a cross-sectional view of FIG. In the figure, the outer skins 11a, 11b of the composite blade 40 are joined to the members 13a, 13b of the main beam 13 via the adhesive layer 15, but the reinforcing ribs 41 made of glass fiber reinforced plastic, 43, 45, and 47 are joined by an adhesive layer. The material of the reinforcing ribs 41 to 47 may be carbon fiber reinforced plastic. As shown in FIG. 6, the shape of the reinforcing rib is as shown in FIG. 7, as shown in FIG. 7. Appropriate ones such as I type (e), widening channel type (f), and matching channel type (g) can be employed. The reinforcing ribs are not limited to the shapes shown in FIGS. 6 and 7 because the reinforcing ribs improve the drilling strength of the outer skins 11a and 11b having a small plate thickness. Also, as can be seen from FIG. 6, several types of reinforcing ribs may be used simultaneously on one blade. Furthermore, as shown in FIGS. 7E, 7F, and 7G, the outer skins 11a and 11b may be mechanically continuous.
[0020]
As described above, the modified embodiment of the outer skin and the main girder in the composite blade has been described with reference to FIGS. 4 to 7. However, a modified example of the blade root structure of the composite blade will be described with reference to FIG. In the composite blades 20, 30, 40, the outer skins 11 a, 11 b (31, 32) and the main beam 13 (23, 33, 34) are firmly joined to each other by the adhesive layer 15 at the blade root part. A tapered portion 11c is formed on the blade root portion of (23, 33, 34) so as to narrow toward the outer surface side, that is, toward the blade mounting flange. If it does in this way, outer skin 11a, 11b (31, 32) and the main girder 13 (23, 33, 34) will be integrated more closely, and the reliability of a joint part can be improved. The taper angles θ ₁ and θ ₂ of the taper portion 11c are preferably as large as possible, but are different depending on the length of the adhesive portion, the size of the blade, the size of the load to be applied, and the like, and thus a specific value of the blade is given.
[0021]
Further, in order to obtain the same effect as described above, as shown in FIG. 9, a plurality of recesses 14 are provided on the outer peripheral surface of the blade root portion of the main girder 13 (23, 33, 34), and the outer skins 11a, 11b are provided. The protrusions 12 arranged may be fitted together. The shape of the unevenness varies depending on the length of the bonded portion, the size of the blade, the size of the load applied, and the like, and has a shape and dimensions unique to the blade.
[0022]
In the above embodiment, the composite blade is composed of the outer skin and the main girder (the main girder and the blade root part are integrally formed). However, in FIGS. 10 to 12, the main girder and the blade root part are formed. One embodiment of a composite blade composed of an outer skin, a main girder and a blade root is shown. The details will be described below.
[0023]
Referring to FIG. 10, the composite blade 50 includes a skin 51, a main girder 53, and a blade root piece 55 that functions as a blade root portion. As can be seen from FIG. 11, the outer skin 51 is composed of two halves, a ventral outer skin 51a and a back outer skin 51b, which, when combined, define a wing shape. An annular portion 51c (see FIG. 12) for accommodating the blade root piece 55 is formed, and has the same overall shape as the embodiment shown in FIG.
[0024]
On the other hand, the shape of the main girder 53 is different from the embodiment shown in FIG. 1, and a separate blade root piece 55 is provided on the blade root side. The main girder 53 has a split structure in which the main girder is vertically divided in the width direction of the wing, that is, divided into two parts. In this embodiment, each of the divided half parts is separated by a predetermined interval. The members 53a and 53b have opposed U-shaped cross sections. As shown in FIG. 11, both bent ends of the members 53 a and 53 b and the outer skins 51 a and 51 b are firmly joined to each other by the adhesive layer 57 and integrated as a blade 50.
[0025]
Further, the blade root side of the members 53a and 53b constituting the main girder 53 is terminated with a U-shaped cross section. On the other hand, as described above, the cylindrical blade root piece 55 is firmly joined to the inner side of the annular portion 51c formed on the blade root side of the outer skin 51 by a known technique such as adhesion. The members 53a and 53b of the main girder 53 are located further inside the blade root piece 55, and are firmly joined to the inner peripheral surface of the blade root piece 55 through the adhesive layer 57, respectively. An annular blade mounting flange 55 a is formed on the open tip side of the blade root piece 55. A blade fixing piece 55 is embedded with a metal bolt 59 for fixing the blade. As described above, the blade root piece 55 functions as a blade root portion including a blade mounting flange.
[0026]
As described above, the composite blade 50 is divided into the outer skin 51, the main girder 53, and the blade root piece 55, and the outer blade 51 and the main girder 53 are each further divided into two halves. Therefore, all are made of glass fiber reinforced plastic without being bound by the conventional winding method, and can be manufactured by an appropriate manufacturing method such as wet lamination (hand lay-up method), vacuum resin impregnation method or pressure resin impregnation method. It is possible to obtain the same effect as that of the composite blade composed of the outer skin and the main beam.
[0027]
The composite blade 50 has a structure in which separate members are assembled together at predetermined positions by bonding. In this case, the thick blade root portion has a thickness exceeding 100 mm, but since the blade root piece 55 is manufactured separately, it can be mass-produced while determining manufacturing conditions and ensuring quality. Further, since the long main girder 53 has a relatively uniform and thin structure other than the blade root portion, it is very easy to manufacture and the quality is stable.
[0028]
In order to further strengthen the connection between the ventral skin 51a and back skin 51b of the composite blade 50 and the blade root piece 55, as shown in FIG. Shape. In this way, the three structural members of the outer skin 51, the blade root piece 55 and the main girder 53 are more closely integrated, and the bending force due to wind pressure, the load due to its own weight and the rotational centrifugal force are reliably transmitted to the blade root piece 55, And the reliability of a joint part can be improved. The taper angles θ ₁ and θ ₂ are preferably as large as possible. However, the taper angles θ ₁ and θ ₂ are different depending on the length of the bonded portion, the size of the blade, the size of the load to be applied, etc.
[0029]
Further, in order to obtain the same binding effect as described above, as shown in FIG. 14, a plurality of recesses 56 are provided on the outer peripheral surface of the blade root piece 55, and the protrusions 52 disposed on the outer skins 51a and 51b are fitted. May be combined. The shape of the unevenness varies depending on the length of the bonded portion, the size of the blade, the size of the load applied, and the like, and has a shape and dimensions unique to the blade.
[0030]
【The invention's effect】
Although the embodiment has been described in detail above, the main girder of the present invention has a divided structure in which the entire main girder is divided into two (vertically divided) in the width direction of the wing as described above. The divided main girder is adhesively bonded to the outer skin. In this way, by dividing the long main girder into two parts, the production method is not limited to the conventional winding method, but wet lamination (hand lay-up method), vacuum resin impregnation method or pressure resin impregnation method, etc. A plurality of manufacturing methods can be applied, and an easy and inexpensive manufacturing method can be selected according to the shape and dimensions of the main beam. This facilitates the manufacture of large and large blades with blade lengths exceeding 20 m, and can dramatically improve the quality, cost, and mass productivity at the same time.
[0031]
Further, the blade root portion of the conventional composite blade for wind power generator is formed integrally with the main beam. In this case, since the thin part at the tip of the main girder (thickness of 10 mm or less) to the thick part of the blade root (thickness of 100 mm or more) is simultaneously molded, the resin curing conditions become complicated and it is difficult to reduce the number of manufacturing steps. It was. In contrast, the composite blade of the present invention is manufactured independently by separating the thick blade root portion in which the metal bolt is embedded from the main girder, so that the manufacturing conditions are simplified, and the cost, mass productivity and quality are dramatically improved. Can be improved.
[0032]
As described above, the structure of the composite blade for wind power generator according to the present invention is easy to manufacture, excellent in mass productivity, inexpensive and excellent in quality, particularly in a large and long blade having a blade length exceeding 20 m. It is possible to provide a composite blade for a large wind power generator.
[0033]
It should be noted that the composite blade structure for wind power generators of the present invention is advantageous in that it is easy to manufacture and can be manufactured at a lower cost than conventional blade structures even in the case of a relatively small blade having a blade length of less than 20 m. Since the present invention can be expected, the present invention can be applied to the composite blades for wind power generators of all sizes to obtain a predetermined effect.
[Brief description of the drawings]
FIG. 1 is a plan view showing an overall structure of a composite blade composed of an outer skin and a main girder according to an embodiment of the present invention.
2 is a cross-sectional view taken along the line II-II in FIG.
3 is a partial cross-sectional view and a side view showing details of the composite blade of FIG. 1. FIG.
FIG. 4 is a cross-sectional view corresponding to FIG. 2, showing another embodiment of the present invention.
FIG. 5 is a cross-sectional view corresponding to FIG. 2, showing still another embodiment of the present invention.
FIG. 6 is a cross-sectional view corresponding to FIG. 2, showing still another embodiment of the present invention.
7 is an explanatory diagram showing a form of a reinforcing rib that can be employed in the composite blade according to the embodiment of FIG. 6;
8 is a partial cross-sectional view showing the structure of another portion that can be employed in the modified embodiment of FIGS. 4 to 6. FIG.
FIG. 9 is a partial cross-sectional view of another structure of another portion that can be employed in the modified embodiment of FIGS.
FIG. 10 is a plan view showing the overall structure of a composite blade composed of an outer skin, a main beam, and a blade root piece according to an embodiment of the present invention.
11 is a cross-sectional view taken along line XI-XI in FIG.
FIGS. 12A and 12B are a partial cross-sectional view and a side view showing the blade root structure of the auxiliary bar blade of FIG.
FIG. 13 is a partial sectional view showing another blade root structure of the present invention.
FIG. 14 is a partial sectional view showing still another blade root structure of the present invention.
FIG. 15 is a plan view showing an overall structure of a conventional composite blade for a wind turbine generator.
16 is a cross-sectional view taken along line XVI-XVI in FIG.
FIG. 17 is a partial cross-sectional view and a partial side view showing a blade root structure of a composite blade for a conventional wind power generator.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 10 ... Composite blade, 11a, 11b ... Outer skin, 11c ... Tapered part, 12 ... Protrusion, 13 ... Main girder, 13a, 13b ... Member, 13c, 13d ... Flange part, 14 ... Recess, 15 ... Adhesive layer, 20 ... Composite blade, 23 ... Main girder, 23a, 23b ... Member, 27a, 27b ... Reinforcement layer, 30 ... Composite blade, 31, 32 ... Skin, 31a, 32a ... Shell single plate part, 31b, 32b ... Shell sandwich structure Body part, 33, 34 ... main girder, 33a, 34a ... main girder single plate part, 33b, 34b ... main girder sandwich structure part, 40 ... composite blade, 41, 43, 45, 47 ... reinforcing rib, 50 ... Composite blade, 51 ... outer skin, 51a ... ventral skin, 51b ... back skin, 51c ... annular part, 52 ... projection, 53 ... main girder, 53a, 53b ... member, 55 ... blade root piece, 5a ... blade mounting flange, 56 ... recess, 57 ... adhesive layer, 59 ... metal bolt.

Claims (11)

A skin made of glass fiber reinforced plastic and defining a wing shape ;
A main girder made of glass fiber reinforced plastic disposed inside the outer skin;
An adhesive layer for joining the outer skin and the main beam;
In a composite blade for a wind power generator comprising a blade root made of glass fiber reinforced plastic for mounting the composite blade,
The main beam has a divided structure that is divided into two in the width direction of the composite blade,
Each divided part has a long plate-shaped portion extending in the longitudinal direction of the wing,
Both edges of the long plate-shaped portion are formed on the back inner surface and the belly of the outer skin through a reinforcing layer made of high-strength glass fiber reinforced plastic or carbon fiber reinforced plastic formed between the adhesive layer and the outer skin. A composite blade for a wind power generator, wherein the composite blade is joined to each side inner surface. The composite blade for a wind turbine generator according to claim 1, wherein the reinforcing layer is wider than an edge of the main girder long plate shape portion. The composite blade for wind power generator according to claim 1, wherein the reinforcing layer has a shape straddling an edge of the two divided main beams. It said main The order of magnitude as the blade root portion, claims 1 to 3 composite blades for wind power generation apparatus according to any one of the characterized in that it is integrally molded. The composite blade for wind power generator according to any one of claims 1 to 3, wherein the main girder and the blade root part are separate bodies. The composite for wind power generator according to any one of claims 1 to 5 , wherein the outer shell comprises a glass fiber reinforced plastic single plate portion and a sandwich structure portion in which a solid foam is sandwiched between glass fiber reinforced plastics. Wood blade. The wind turbine generator according to any one of claims 1 to 5 , wherein the main girder includes a glass fiber reinforced plastic single plate portion and a sandwich structure portion in which a solid foam is sandwiched between glass fiber reinforced plastics. Composite blade. The composite blade for wind power generator according to any one of claims 1 to 5 , wherein reinforcing ribs made of glass fiber reinforced plastic or carbon fiber reinforced plastic are arranged on the outer skin. The junction between the outer skin and the blade root part, claims 1 to 5 or 1 composite blade for wind power generator according to paragraph among, characterized in that it is constituted by adhesive bonding and tapered. The composite material for a wind turbine generator according to any one of claims 1 to 5 , wherein a joint portion between the outer skin and the blade root portion is formed by adhesive bonding and uneven fitting. blade. 5. The composite for wind power generator according to claim 4 , wherein the main girder having a divided structure is integrated at the blade root portion by an adhesive or a fiber-reinforced plastic laminated adhesive of glass fiber or carbon fiber. Wood blade.

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