Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B38/00—Ancillary operations in connection with laminating processes
  • B32B38/18—Handling of layers or the laminate
  • B32B38/1808—Handling of layers or the laminate characterised by the laying up of the layers
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • 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
  • B29D99/0028—Producing blades or the like, e.g. blades for turbines, propellers, or wings hollow blades
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B38/00—Ancillary operations in connection with laminating processes
  • B32B38/0004—Cutting, tearing or severing, e.g. bursting; Cutter details
• • 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
  • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
  • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
  • B29C70/28—Shaping operations therefor
  • B29C70/40—Shaping or impregnating by compression not applied
  • B29C70/50—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
  • B29C70/52—Pultrusion, i.e. forming and compressing by continuously pulling through a die
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2305/00—Condition, form or state of the layers or laminate
  • B32B2305/10—Fibres of continuous length
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2307/00—Properties of the layers or laminate
  • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
  • B32B2307/514—Oriented
• • 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
  • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
  • Y02E10/00—Energy generation through renewable energy sources
  • Y02E10/70—Wind energy
  • Y02E10/72—Wind turbines with rotation axis in wind direction

Definitions

• the invention relates to a system and a method for producing a rotor blade belt with pultruded rods made of a fiber-reinforced material.
• Rotor blade belts generally consist of strong strands of parallel oriented fibers, usually glass fibers or carbon fibers embedded in a resin matrix.
• the rotor blade belts usually pass the rotor blades over a majority of the rotor blade length from the rotor blade tip to the rotor blade root and serve to transmit the forces acting on the rotor blade to the rotor blade root.
• Rotor blade belts are usually manufactured in a layered construction in which either dry fiber webs are stacked in parallel and then manufactured in a Harzinfusionshabilit to Rotorblattgurt, or there are pre-made layers of resin already embedded in fiber serged materials, so-called prepregs, stacked together and then joined together. Since rotor blade belts are similar in length to modern rotor blades, ie can be over 40 m or 50 m long, the fiber materials used are correspondingly long and bulky.
• the curing of the resin is an exothermic process, so it creates heat.
• the distributed over large volumes of heat can lead to a wave formation in the fiber material, so that this is no longer ideally aligned parallel over the entire belt length. This then affects the tensile strength and thus the structural compactness and the operability of the rotor blade belt thus produced.
• the present invention seeks to provide a system and a method for producing a rotor blade with pultruded rods of a fiber-reinforced material with which the construction of a rotor blade with pultruded rods is fast, reliable and flexible possible.
• a system for producing a rotor blade belt with pultruded rods of a fiber-reinforced material which is further developed by at least one holding device for rotatably supporting at least one rod roll with a rolled layer of juxtaposed pultruded rods, a lamination for receiving layers pultruded rods, at least one guide device and at least one trimming device are formed, wherein the guide device is adapted to guide a rolled from a rod roll role of pultruded rods on the lamination, wherein the trimming device for trimming the layers of pultruded rods a sawing device and / or having a milling device.
• the belt is thus constructed in layers with the system according to the invention, wherein each layer in one step in or on a laminating on or is applied.
• the pultruded rods are already rolled up as a layer on the rod roll and are removed as a layer.
• every single one Roll bar in a separate step and bring up or in the form This method requires only a fraction of the time per shelf storage over the previously known method in which each individual bar was unrolled.
• the guide device which is designed to guide the entire shelf.
• the guide device ensures that the position of the pultruded rods remains together and does not dissolve into individual rods, so that this layer is applied or applied as a whole and uniformly in or on the laminating mold.
• the trimming device handles the lengthening, trimming and dimensioning of the position of pultruded rods during unwinding. In this way, the desired final contour for the respective position can already be generated during cutting and does not have to be reworked consuming in the final state.
• a post-processing can of course still be provided according to the invention.
• This guide device ensures that the material is placed in the correct position relative to the mold surface. This relates above all to the position with regard to the width of the laminating mold, for example to ensure a defined offset of the individual layers relative to one another or to be able to lay the layers exactly one on top of the other. since it is advantageous to keep the guide unit always flush with the surface of the uppermost layer, since for example in a main belt many layers must be superimposed and so the height of the guide unit must be adjusted.
• the position of pultruded rods can be rolled up as such directly on the rod roll in the context of the invention, alternatively also on one side or on both sides of a cover layer of a flexible material, such as a fiber mesh, a felt material or a nonwoven material to be covered.
• a cover layer supports the cohesion of the shelf. It can protect the bars of the bar tray when rolling and when passing through the guide device and also from mechanical damage.
• Such a cover layer should be permeable to liquid resin material in order to be part of the belt structure.
• the holding device has a drive device and / or a braking device for a rod roll held in the holding device and / or at least one force-loaded pressure roller which presses on the rolled-up shelf, wherein in particular the at least one pressure roller has a soft surface.
• This measure improves the rolling of the layer of pultruded rods from the rod roll because the pultruded rods are quite stiff and have a tendency to slacken on the rod roll.
• the rolled-up bars act like a rolled-up spring whose spring force pushes outward.
• the pressure roller or the pressure rollers act against it.
• a pinch roller is preferably located where the location of the pultruded rods tangentially away from the rod roll during unwinding. In order not to injure the bars of the situation, the pressure roller or the pressure rollers preferably have a soft surface.
• the rod material can also be fixed on the rod support rollers for transport with straps. These prevent individual pultruded rods from rolling up and releasing from the roll, which would cause significant extra manufacturing overhead, as the rods would have to be repositioned or the entire roll discarded would have to be. These bands are, when the role is suspended in the holding device, for example, replaced by the pressure roller.
• At least one sensor is arranged in the guide device and / or on a pressure roller and / or on a pressure roller with force acting device, wherein a signal transmission channel from at least one sensor to a control or regulating device of the drive and / or braking device is present and the control or regulating device is designed to control or regulate the movement of a rod roll depending on transmitted sensor signals.
• the sensor signals are used to control the automatic control of the Abwickeins and in particular also the trimming and the input or application in or on the lamination. This can be produced in a largely automatic manner a desired belt shape.
• the movement of the rod roll is controlled or controlled so that the rolling out of the material between the roller and the guide device is force-free.
• a control device for the guide device is provided, which is adapted to track the position of the guide device with respect to its vertical and / or horizontal position with respect to the lamination, in particular depending on the position of the surface of the uppermost layer of pultruded rods in the lamination , With this measure, the positioning of the rods of each layer in or on the lamination can be done largely automatically.
• the guide device has guide rollers, between which the position of pultruded rods passes through, wherein in particular at least one non-contact sensor and / or at least one impeller sensor for measuring a discharged length of a layer of pultruded rods is included.
• the guide rollers can be particularly accurately determine the length of the previously developed rods, which in turn is used as information for the construction of the rotor blade belt.
• At least one guide roller on a drive and / or a brake is also designed to handle the position of pultruded rods as gently and force-free, especially in interaction with the drive device in the fixture, and thus introduce without deformations in the laminating.
• the material can be applied quickly and smoothly in the laminating. This is particularly important for large rotor blades, which have a length of, for example, more than 50 m or in particular more than 65 m, since here an application of the material is extremely time-consuming and laborious and therefore expensive only by muscle power.
• the layer of pultruded rods in the guide device is preferably provided in the invention that the position is clamped at the end between two rods, of which at least one has handles at their respective ends.
• the rods hold the position of the rods together and allow threading in the guide device, possibly assisted by the drive of the holding device.
• This trimming unit is characterized in that it has a sawing or milling unit, with which the material is severed in such a way that a simultaneous creation in Di direction results.
• the trimming device is designed so that the material can be cut at any angle to the longitudinal axis of the material and also the angle of the Schaftung can be chosen freely.
• the sawing device and / or the milling device are or are preferably designed to generate a shank in the thickness direction and / or for transection at an angle to the longitudinal axis of the position of the pultruded rods, in particular with a shank angle between 2 ° and 10 ° to the surface of the sheet and / or at an angle of 90 ° to ⁇ 45 ° to the longitudinal axis of the sheet.
• the trimming device the material can be severed in such a way that simultaneously results in a shift in the thickness direction.
• the trimming device is designed so that the material can be severed at almost any angle to the longitudinal axis of the material and also the angle of the Schaftung can be chosen freely.
• An angle of 90 ° to the longitudinal axis of the layer means that the cutting edge runs exactly transversely to the longitudinal axis, while, however, another angle to the longitudinal axis can be set.
• the trimming device preferably has a dustproof encapsulation and in particular a connection for a dust extraction device.
• This embodiment of the trimming unit is particularly advantageous, since the dust can not penetrate into the area of the laminating mold and thus contaminates the already stored semi-finished product, which would lead to a deterioration of the strengths to be achieved in the finished laminated component.
• the holding device, the guide device and / or the trimming device is or are preferably stationary or on one mounted substantially parallel to the surface of the laminating movable support device.
• the stationary arrangement has the advantage of stable and reproducible storage.
• a storage on a movable support device has the advantage that the last unrolled position of pultruded rods does not have to be pushed over the previously deposited layers, but is placed on this and unrolled. It no longer comes to a friction of the surfaces together with the risk of disturbing the previously deposited structure of layers of pultruded rods of the rotor blade belt.
• a particularly stable stratification of the layers of pultruded rods is achieved if the bars of the individual layers are not arranged directly on top of one another but rather offset from one another. Then, as in the case of a stone wall, the joints form non-continuous lines that form potential structural weak points, but a meandering shape that allows a secure join.
• at least one lateral rod of reduced width is made in each layer, so that despite the dislocations, the width of the rotor blade belt is constant over the entire thickness.
• the holding devices both at one end of the lamination or at opposite ends of the lamination or on the movable Carrying device are arranged.
• two rod support rollers each having a marginal rod of lesser width than the remaining members of the layer, are arranged in the holding devices for producing the rotor blade belt such that the marginal rods smaller width are arranged on different sides with respect to the Lamiernierform.
• Due to the alternating sequence of the layers of the respective bar is arranged with a smaller width alternately at the left edge or the right edge, so as to give the desired offset.
• the holding devices for the two bar roll rolls can also be arranged at opposite ends of the rotor blade belt or the laminating mold. Since these are rolled in opposite directions, already results from this rotation or reorientation an arrangement of the narrower bars on the opposite sides.
• the object underlying the invention is also achieved by a method for producing a rotor blade belt with pultruded rods made of a fiber-reinforced material, which is characterized in that a sequence of layers with juxtaposed pultruded rods of a fiber-reinforced material in a laminating form is superimposed, solved in particular by means of a previously described system according to the invention, wherein the layers are rolled alternately by two roll of stock rolls, each having at one edge a bar of lesser width than the remaining bars of the sheet, the marginal bars having smaller widths on different sides with respect to the laminating mold are arranged.
• the bar stock rolls together moving a movable support device on the laminating, wherein when moving in one direction, a layer of a rod roll and a movement in the opposite direction, a layer is unrolled from the other roll rod role.
• the layers are unrolled from stationary mounted fixtures stationarily disposed at one end or at opposite ends of the laminating mold.
• the rolling out of the material between the rod support roller and a guide device is preferably force-free.
• the non-frictional coasting ensures that the bars do not change in structure as they roll out, thus maintaining the desired orientation for the rotor blade belt.
• the adjustment of the positioning is carried out in a particularly advantageous embodiment automatically by the position of the surface of the uppermost layer is determined with respect to a reference point and the guide device is tracked by a control and / or regulating device accordingly.
• a further advantageous embodiment of the method according to the invention is that the length of the material applied in the guide device, in particular via the rotation of the rollers or contactless by optical sensors or by an additional impeller, is measured and adjusted with a laminate plan stored in a control device, which determines the length of each position of the material to be applied. Due to this feature, the length of each layer does not have to be laboriously measured, but the material can be applied quickly to the intended length and then cut to length.
• FIG. 1 is a schematic side view of a system according to the invention
• FIG. 2 is a schematic representation of the layer arrangement of a rotor blade belt
• a system for producing a rotor blade belt 1 from layers 6 of pultruded rods is shown schematically.
• the layers 6 of pultruded rods are made available on roll bars 2, on which the bar layers 4 are rolled up, which are then later unrolled into bar shelves 6.
• the bar roll 2 rotatably rests on a holding device 10 which has a frame 12 for holding the bar roll 2.
• a drive and braking device 13 is arranged, by means of which the rod support roller 2 can be rotated, for example in the unwinding 3.
• the holding device 10 has at least one pressure roller 14 with a soft surface, which is arranged on a hinged Andruckarm 15, which is subjected to a force by means of a spring 16.
• the pressure roller 14 thus presses in the direction 17 of the spring force against the rolled-up tray 4 and thus prevents them from unrolling under their own spiral spring force.
• the pressure roller 14 is arranged where the rolled-up tray 4 is unrolled.
• pinch rollers 14 which may also be spring-loaded, may be arranged around the circumference of the rod tray 4.
• the bar tray 4 is unrolled and guided by a guide device 20 with two guide rollers 22. This takes up the bar tray 4 and forwards them to a trimming device 30, which may have milling and / or sawing devices to define the end edge of a bar layer 6.
• the bar layer 6 is further unrolled and placed in the desired position on a laminating 40 or inserted into this.
• a control device 1 1 which can receive signals via dashed signal channels, which may be wired or wireless, from sensors 19, 19 ', 29 which are the control devices. 1 1 about the progress of unwinding.
• sensors 19, 19 ', 29 may be, for example, sensors 19, which are arranged on a force application device, for example a spring, with which a pressure roller 14 is acted upon.
• a sensor 19 ' can also be arranged directly on a pressure roller 14.
• An alternative or additional sensor 29 may also observe the progress of unwinding on a guide roller 22.
• Such a sensor 29 may be a non-contact sensor or, for example, a rotary wheel or impeller.
• the control device 1 1 also has a control channel, wireless or wired, to the drive and brake device 13 of the holding device 10. Also, a driven guide wheel 22 can be controlled in the same way, so that automatically a pre-programmed contour of the rotor blade belt to be built can be adjusted. Also, the height of the guide rollers 22 and the guide device 20 can be adjusted to successively adjust the height reached during the construction of the rotor blade belt of successive layers 6 of pultruded rods.
• the trimming device 30 is shown with a dust-tight encapsulation 32, which additionally has a connection 34 for the suction of dust arising. In this way, the trimming is made largely dust-free.
• FIG. 2 the layer structure of a rotor blade belt according to the invention is shown schematically.
• the cross-section shows at the bottom the laminating mold 40, on which three layers 6, 6 'of pultruded rods 7, 8 are arranged.
• Each ply 6, 6 ' has a multiplicity of normally wide pultruded rods 7 and in each case one lateral pultruded rod 8 of smaller width, in particular half pultruded rod 8. over width, up.
• the latter are arranged in the layers 6 in Fig.
• FIGS. 3a), 3b) and 3c three alternatives for producing the structure of a rotor blade belt 1 shown in FIG. 2 are shown.
• Fig. 3a) are from the blade root-side end and the blade tip side end of two bar stock rolls 2, 2 'in opposite directions according to the arrow direction layers 6, 6' alternately.
• the layers 6 have the rods 8 reduced width on one side, the sprocket 2 'on the opposite side, so that the structure of FIG. 2 results.
• Fig. 3c an alternative solution is shown, in which the rod tray rollers 2, 2 'not, as shown in Fig. 3a) and 3b) are mounted stationary, but on a movable support device or a carriage 18.
• the two arrows To the left and right of the carriage 18 or slide show that the carriage 18 is successively each one method in one direction and in the opposite direction from one end of the strap to the other and back again, ie from the blade tip to Root and back.
• a layer 6 of pultruded rods 7, 8 is unrolled from the right roll 2, while in the opposite direction, ie in the movement to the left, a layer 6 'of the bar roll 2' is unrolled. Since this also takes place alternately, the staggered structure of the pultruded rods 7, 8 shown in FIG. 2 again results.
• roller 2 can be rotated so that it alternately assumes the different orientations needed, depending on the direction in which the carriage 18 is moved.

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• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Moulding By Coating Moulds (AREA)
• Casting Or Compression Moulding Of Plastics Or The Like (AREA)
• Extrusion Moulding Of Plastics Or The Like (AREA)
• Chemical & Material Sciences (AREA)
• Composite Materials (AREA)

Priority Applications (10)

Applications Claiming Priority (2)

Related Child Applications (1)

Publications (1)

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Family Applications (1)

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Citations (5)

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• 2012
  • 2012-10-22 DE DE102012219224.7A patent/DE102012219224B3/de active Active
• 2013
  • 2013-10-07 WO PCT/EP2013/003007 patent/WO2014063783A1/de not_active Ceased
  • 2013-10-07 AU AU2013337091A patent/AU2013337091B2/en not_active Ceased
  • 2013-10-07 IN IN3966DEN2015 patent/IN2015DN03966A/en unknown
  • 2013-10-07 EP EP13782961.0A patent/EP2909015B1/de active Active
  • 2013-10-07 ES ES13782961T patent/ES2902849T3/es active Active
  • 2013-10-07 PT PT137829610T patent/PT2909015T/pt unknown
  • 2013-10-07 CN CN201380061105.1A patent/CN104968486B/zh active Active
  • 2013-10-07 CA CA2886809A patent/CA2886809C/en not_active Expired - Fee Related
  • 2013-10-07 KR KR1020157013513A patent/KR101814409B1/ko not_active Expired - Fee Related
  • 2013-10-07 DK DK13782961.0T patent/DK2909015T3/da active
• 2015
  • 2015-04-21 US US14/692,684 patent/US9849658B2/en active Active
  • 2015-05-07 ZA ZA2015/03122A patent/ZA201503122B/en unknown

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