WO2019212551A1 - Bandes de cisaillement pour pales de rotor d'éolienne et leurs procédés de fabrication - Google Patents

Bandes de cisaillement pour pales de rotor d'éolienne et leurs procédés de fabrication Download PDF

Info

Publication number
WO2019212551A1
WO2019212551A1 PCT/US2018/030777 US2018030777W WO2019212551A1 WO 2019212551 A1 WO2019212551 A1 WO 2019212551A1 US 2018030777 W US2018030777 W US 2018030777W WO 2019212551 A1 WO2019212551 A1 WO 2019212551A1
Authority
WO
WIPO (PCT)
Prior art keywords
lattice structure
rotor blade
internal
internal lattice
securing
Prior art date
Application number
PCT/US2018/030777
Other languages
English (en)
Inventor
Bensely Albert
Amir Riahi
Original Assignee
General Electric Company
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 General Electric Company filed Critical General Electric Company
Priority to PCT/US2018/030777 priority Critical patent/WO2019212551A1/fr
Priority to CN201880095311.7A priority patent/CN112384357A/zh
Priority to EP18917235.6A priority patent/EP3787872A4/fr
Publication of WO2019212551A1 publication Critical patent/WO2019212551A1/fr

Links

Classifications

    • 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
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/38—Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
    • B29C70/382—Automated fiber placement [AFP]
    • 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
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
    • 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
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/20—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres
    • B29C70/205—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres the structure being shaped to form a three-dimensional configuration
    • 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
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y70/00—Materials specially adapted for additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y70/00—Materials specially adapted for additive manufacturing
    • B33Y70/10—Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y80/00—Products made by additive manufacturing
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/08—Blades for rotors, stators, fans, turbines or the like, e.g. screw propellers
    • B29L2031/082—Blades, e.g. for helicopters
    • B29L2031/085—Wind turbine blades
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05B—INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
    • F05B2230/00—Manufacture
    • F05B2230/30—Manufacture with deposition of material
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2230/00—Manufacture
    • F05D2230/30—Manufacture with deposition of material
    • 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
    • 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
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product

Definitions

  • the present disclosure relates in general to wind turbine rotor blades, and more particularly to shear webs for wind turbine rotor blades and methods of manufacturing same.
  • a modem wind turbine typically includes a tower, a generator, a gearbox, a nacelle, and one or more rotor blades.
  • the rotor blades capture kinetic energy of wind using known foil principles.
  • the rotor blades transmit the kinetic energy in the form of rotational energy so as to turn a shaft coupling the rotor blades to a gearbox, or if a gearbox is not used, directly to the generator.
  • the generator then converts the mechanical energy to electrical energy that may be deployed to a utility grid.
  • the rotor blades generally include a suction side shell and a pressure side shell typically formed using molding processes that are bonded together at bond lines along the leading and trailing edges of the blade.
  • the pressure and suction shells are relatively lightweight and have structural properties (e.g., stiffness, buckling resistance and strength) which are not configured to withstand the bending moments and other loads exerted on the rotor blade during operation.
  • the body shell is typically reinforced using one or more structural components (e.g. opposing spar caps with a shear web configured therebetween) that engage the inner pressure and suction side surfaces of the shell halves.
  • Such structural components are typically constructed of various materials, including but not limited to glass fiber laminate composites and/or carbon fiber laminate composites. More specifically, the shell of the rotor blade is generally built around the spar caps of the blade by stacking layers of fiber fabrics in a shell mold. The layers are then typically infused together with a resin material. Further, the shear web is typically constructed using a similar molding process and then mounted between the spar caps.
  • the present disclosure is directed to a method for manufacturing a rotor blade component of a rotor blade of a wind turbine.
  • the method includes forming an internal lattice structure of the rotor blade component. More specifically, the internal lattice structure includes a plurality of open cells.
  • the method includes covering at least a portion of the internal lattice structure with an outer skin layer to form the rotor blade component.
  • the method includes forming the internal lattice structure of the shear web via at least one of additive manufacturing, continuous liquid interface production, maypole braiding, or automated fiber placement.
  • the outer skin layer may be constructed of a composite laminate material.
  • the method may include securing the outer skin layer to the internal lattice structure via fusion bonding. More specifically, in certain embodiments, fusion bonding may include frictional heating, electromagnetic heating, bulk heating, or one or more thermal techniques.
  • the method may include securing at least one face plate to one or more ends of the internal lattice structure to the outer skin layer. More specifically, in such embodiments, the step of securing at least one face plate to the one or more ends of the internal lattice structure to the outer skin layer may include securing a first face plate at a first end of the internal lattice structure and securing a second face plate an opposing, second end of the internal lattice structure. Thus, the first and second face plates are configured to be secured to opposing spar caps of the rotor blade.
  • the method may include filling at least a portion of the lattice structure with a core material.
  • the core material may include foam, cork, composites, balsa wood, or any other suitable lightweight material.
  • the internal lattice structure may include a plurality of lattice structure segments.
  • the method may further include joining the plurality of lattice structure segments together, e.g. via one or more interlocking components.
  • the internal lattice structure may be constructed of a thermoplastic material or a thermoset material.
  • the method may include reinforcing the internal lattice structure with at least one fiber material, including but not limited to glass fibers, nanofibers, carbon fibers, metal fibers, wood fibers, bamboo fibers, polymer fibers, ceramic fibers, or similar.
  • the fiber material may include short fibers, long fibers, or continuous fibers.
  • the rotor blade component may include a shear web, a blade tip segment, a spar cap, or any other component of the rotor blade.
  • the present disclosure is directed to a method for manufacturing a shear web of a rotor blade of a wind turbine.
  • the method includes printing, via computer numeric control (CNC), an internal lattice structure of a shear web directly onto one of an inner surface of a blade shell of the rotor blade or one or more spar caps of the rotor blade.
  • the internal lattice structure includes a plurality of open cells.
  • the internal lattice structure of the shear web bonds to the inner surface of the blade shell or one of the spar caps during printing. It should also be understood that the method may further include any of the additional steps and/or features as described herein.
  • the present disclosure is directed to a method for a method for manufacturing a rotor blade of a wind turbine.
  • the method includes forming an internal lattice structure of a shear web. More specifically, the internal lattice structure includes a plurality of open cells.
  • the method further includes securing the internal lattice structure between a pressure side shell and suction side shell of the rotor blade.
  • the method further includes forming the internal lattice structure of the shear web directly onto the inner surface of the blade shell via at least one of additive manufacturing, continuous liquid interface production, maypole braiding, or automated fiber placement.
  • the method may include covering at least a portion of the internal lattice structure with an outer skin layer to form the shear web.
  • the method may include securing at least one face plate to one or more ends of the internal lattice structure to the outer skin layer.
  • the method may include placing a step feature on the inner surface of the blade shell and securing the at least one face plate to the step feature.
  • the method may include forming a plurality of internal lattice structures so as to form a plurality of shear webs and securing each of the plurality of internal lattice structures to the inner surfaces of the blade shell of the rotor blade. It should also be understood that the method may further include any of the additional steps and/or features as described herein.
  • FIG. 1 illustrates a perspective view of one embodiment of a wind turbine according to the present disclosure
  • FIG. 2 illustrates a perspective view of one of the rotor blades of FIG. 1;
  • FIG. 3 illustrates a cross-sectional view of the rotor blade of FIG. 2 along line 3-3;
  • FIG. 4 illustrates a perspective view of one embodiment of an internal lattice structure of a shear web according to the present disclosure, particularly illustrating a plurality of lattice structure segments joined together to form the internal lattice structure;
  • FIG. 5 illustrates a cross-sectional view of one embodiment of joined interlocking components of adjacent lattice structure segments according to the present disclosure
  • FIG. 6 illustrates a perspective view of one embodiment of an internal lattice structure of a shear web covered by an outer skin layer according to the present disclosure, particularly illustrating the internal lattice structure having a plurality of open cells;
  • FIG. 7 illustrates a perspective view of one embodiment of an internal lattice structure of a shear web covered by an outer skin layer according to the present disclosure, particularly illustrating the internal lattice structure filled with a core material;
  • FIG. 8 illustrates a perspective view of one embodiment of an internal lattice structure of a shear web covered by an outer skin layer according to the present disclosure, particularly illustrating face plates at opposing ends of the internal lattice structure;
  • FIG. 9 illustrates a partial, perspective view of one embodiment of a shear web comprising an internal lattice structure according to the present disclosure secured to an inner surface of a body shell of a rotor blade;
  • FIG. 10 illustrates a partial, perspective view of one embodiment of a shear web comprising an internal lattice structure according to the present disclosure secured to an inner surface of a body shell of a rotor blade as well as a step feature secured to the inner surface of the body shell;
  • FIG. 11 illustrates a partial, perspective view of one embodiment of a plurality of shear webs comprising an internal lattice structure according to the present disclosure secured to an inner surface of a body shell of a rotor blade; and [0034] FIG. 12 illustrates a perspective view of one embodiment of a plurality of shear webs comprising an internal lattice structure according to the present disclosure secured to an inner surface of a body shell of a rotor blade.
  • the present disclosure is directed to methods for manufacturing lightweight rotor blade components, such as shear webs, having a lattice structure using automated deposition of materials via technologies such as 3-D printing, additive manufacturing, automated fiber deposition, as well as other techniques that utilize CNC control and multiple degrees of freedom to deposit materials.
  • the methods described herein provide many advantages not present in the prior art.
  • the methods of the present disclosure provide lightweight rotor blade components that can be easily printed faster than conventional manufacturing methods.
  • the methods of the present disclosure provide a high level of automation, faster throughput, and reduced costs.
  • FIG. 1 illustrates a perspective view of a horizontal axis wind turbine 10.
  • the wind turbine 10 may also be a vertical-axis wind turbine.
  • the wind turbine 10 includes a tower 12, a nacelle 14 mounted on the tower 12, and a rotor hub 18 that is coupled to the nacelle 14.
  • the tower 12 may be fabricated from tubular steel or other suitable material.
  • the rotor hub 18 includes one or more rotor blades 16 coupled to and extending radially outward from the hub 18.
  • the rotor hub 18 includes three rotor blades 16.
  • the rotor hub 18 may include more or less than three rotor blades 16.
  • the rotor blades 16 rotate the rotor hub 18 to enable kinetic energy to be transferred from the wind into usable mechanical energy, and subsequently, electrical energy.
  • the hub 18 may be rotatably coupled to an electric generator (not illustrated) positioned within the nacelle 14 for production of electrical energy.
  • FIGS. 2 and 3 one of the rotor blades 16 of FIG. 1 is illustrated according to the present disclosure.
  • FIG. 2 illustrates a perspective view of the rotor blade 16
  • FIG. 3 illustrates a cross-sectional view of the rotor blade 16 along the sectional line 3-3 shown in FIG. 2.
  • the rotor blade 16 generally includes a blade root 30 configured to be mounted or otherwise secured to the hub 18 (FIG. 1) of the wind turbine 10 and a blade tip 32 disposed opposite the blade root 30.
  • a body shell 21 of the rotor blade generally extends between the blade root 30 and the blade tip 32 along a longitudinal axis 27.
  • the body shell 21 may generally serve as the outer casing/covering of the rotor blade 16 and may define a substantially aerodynamic profile, such as by defining a symmetrical or cambered airfoil-shaped cross-section.
  • the body shell 21 may also define a pressure side 34 and a suction side 36 extending between leading and trailing ends 26, 28 of the rotor blade 16.
  • the rotor blade 16 may also have a span 23 defining the total length between the blade root 30 and the blade tip 32 and a chord 25 defining the total length between the leading edge 26 and the trialing edge 28.
  • the chord 25 may generally vary in length with respect to the span 23 as the rotor blade 16 extends from the blade root 30 to the blade tip 32.
  • the body shell 21 of the rotor blade 16 may be formed as a single, unitary component.
  • the body shell 21 may be formed from a plurality of shell components and/or segments.
  • the body shell 21 may be manufactured from a first shell half generally defining the pressure side 34 of the rotor blade 16 and a second shell half generally defining the suction side 36 of the rotor blade 16, with such shell halves being secured to one another at the leading and trailing ends 26, 28 of the blade 16.
  • the body shell 21 may be formed from a plurality of blade segments aligned in a span- wise end-to-end configuration.
  • the body shell 21 includes a blade root segment 40 and blade tip segment 42. In such embodiments, the blade tip segment 42 may be changed according to a desired aerodynamic characteristics of the rotor blade 16.
  • the body shell 21 may generally be formed from any suitable material.
  • the body shell 21 may be formed entirely from a laminate composite material, such as a carbon fiber reinforced laminate composite or a glass fiber reinforced laminate composite.
  • one or more portions of the body shell 21 may be configured as a layered construction and may include a core material, formed from a lightweight material such as wood (e.g., balsa), foam (e.g., extruded polystyrene foam) or a combination of such materials, disposed between layers of laminate composite material.
  • the rotor blade 16 may also include one or more longitudinally extending structural components configured to provide increased stiffness, buckling resistance and/or strength to the rotor blade 16.
  • the rotor blade 16 may include a pair of longitudinally extending spar caps 20, 22 configured to be engaged against the opposing inner surfaces 35, 37 of the pressure and suction sides 34, 36 of the rotor blade 16, respectively.
  • one or more shear webs 24 may be disposed between the spar caps 20, 22 so as to form a beam-like configuration.
  • the spar caps 20, 22 may generally be designed to control the bending stresses and/or other loads acting on the rotor blade 16 in a generally span-wise direction (a direction parallel to the span 23 of the rotor blade 16) during operation of a wind turbine 10. Similarly, the spar caps 20, 22 may also be designed to withstand the span-wise compression occurring during operation of the wind turbine 10.
  • the present disclosure is directed to methods for manufacturing a rotor blade component of a rotor blade of a wind turbine.
  • the rotor blade component(s) as described herein may include a shear web, a blade tip segment, or a spar cap, though it should be understood that the methods of the present disclosure may be further applied to any other suitable rotor blade components. More specifically, as shown in the illustrated embodiment, the present disclosure is directed to methods for manufacturing the shear web 24 of the rotor blade 16 of the wind turbine 10. It should be understood, however, that the illustrations are for illustrative purposes only and are not meant to limit the methods of the present disclosure to a shear web and manufacturing methods thereof.
  • one embodiment of the method includes forming an internal lattice structure 44 of the shear web 24.
  • the method includes forming the internal lattice structure 44 of the shear web 24 via at least one of additive manufacturing, continuous liquid interface production, maypole braiding, or automated fiber placement. Additive
  • manufacturing is generally understood to encompass processes used to synthesize three-dimensional objects in which successive layers of material are formed under computer control (e.g. via computer numeric control (CNC)) to create the objects.
  • CNC computer numeric control
  • objects of almost any size and/or shape can be produced from digital model data.
  • the methods of the present disclosure are not limited to 3-D printing, but rather, may also encompass more than three degrees of freedom such that the printing techniques are not limited to printing stacked two-dimensional layers, but are also capable of printing curved shapes.
  • the internal lattice structure 44 may include a plurality of open cells 46, thereby providing a lightweight shear web 24 for the rotor blade 16. Further, as shown in FIGS. 4 and 5, the internal lattice structure 44 may include a plurality of lattice structure segments 50 joined together to form the overall structure 44. In such embodiments, the method may include forming or printing the plurality of lattice structure segments 50 and joining the plurality of lattice structure segments 50 together via one or more interlocking components 52. In addition, as shown in FIG.
  • the interlocking components 52 may have a dovetail configuration. In alternative embodiments, the interlocking components 52 may include a snap fit. Further, as shown in FIG. 4, multiple rows 53 of lattice structure segments 50 may be joined together and then the multiple rows 53 may be subsequently joined together to form the overall structure 44. Alternatively, the internal lattice structure 44 may be printed as a single structure.
  • the internal lattice structure 44 may be constructed of a thermoplastic material or a thermoset material.
  • the thermoplastic materials as described herein generally encompass a plastic material or polymer that is reversible in nature.
  • thermoplastic materials typically become pliable or moldable when heated to a certain temperature and returns to a more rigid state upon cooling.
  • thermoplastic materials may include amorphous thermoplastic materials and/or semi-crystalline thermoplastic materials.
  • some amorphous thermoplastic materials may generally include, but are not limited to, styrenes, vinyls, cellulosics, polyesters, acrylics, polysulphones, and/or imides.
  • exemplary amorphous thermoplastic materials may include polystyrene, acrylonitrile butadiene styrene (ABS), polymethyl methacrylate (PMMA), glycolised polyethylene terephthalate (PET-G), polycarbonate, polyvinyl acetate, amorphous polyamide, polyvinyl chlorides (PVC), polyvinylidene chloride, polyurethane, or any other suitable amorphous thermoplastic material.
  • exemplary semi- crystalline thermoplastic materials may generally include, but are not limited to polyolefins, polyamides, fluropolymer, ethyl-methyl acrylate, polyesters,
  • exemplary semi-crystalline thermoplastic materials may include polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polypropylene, polyphenyl sulfide, polyethylene, polyamide (nylon), polyetherketone, or any other suitable semi-crystalline thermoplastic material.
  • thermoset materials as described herein generally encompass a plastic material or polymer that is non-rev ersible in nature.
  • thermoset materials once cured, cannot be easily remolded or returned to a liquid state.
  • thermoset materials after initial forming, are generally resistant to heat, corrosion, and/or creep.
  • Example thermoset materials may generally include, but are not limited to, some polyesters, some polyurethanes, esters, epoxies, or any other suitable thermoset material.
  • the method may include reinforcing the internal lattice structure 44 with at least one fiber material, including but not limited to glass fibers, nanofibers, carbon fibers, metal fibers, wood fibers, bamboo fibers, polymer fibers, ceramic fibers, or similar or combinations thereof.
  • the fiber material may include short fibers, long fibers, or continuous fibers.
  • the direction of the fibers may include multi-axial, unidirectional, biaxial, triaxial, or any other another suitable direction and/or combinations thereof.
  • the method may include filling at least a portion of the internal lattice structure 44 with a core material 54.
  • the core material 54 described herein may be constructed of any suitable materials, including but not limited to low-density foam, cork, composites, balsa wood, composites, or similar.
  • Suitable low-density foam materials may include, but are not limited to, polystyrene foams (e.g., expanded polystyrene foams), polyurethane foams (e.g.
  • the internal lattice structure 44 may not include a core material 54.
  • the method may also include covering at least a portion of the internal lattice structure 44 (with or without the core material 54) with an outer skin layer 48 to form the shear web 24.
  • the outer skin layer 48 may be constructed of a composite laminate material, including, for example, a thermoset material and/or a thermoplastic material as described herein.
  • the method may include securing the outer skin layer 48 to the internal lattice structure 44 via fusion bonding. More specifically, in certain embodiments, fusion bonding may include frictional heating, electromagnetic heating, bulk heating, or one or more thermal techniques. Frictional heating, for example, may include spin welding, vibration welding, and/or ultrasonic welding.
  • Electromagnetic heating may include induction welding, microwave welding, dielectric welding, and/or resistance welding.
  • Bulk heating for example, may include hot melt adhesives and/or dual-resin bonding.
  • Additional thermal techniques for example, may include hot plate welding, hot gas welding, radiant welding, infrared welding, and/or laser welding.
  • the method may include securing at least one face plate 56, 58 to one or more ends 45, 47 of the internal lattice structure 44 to the outer skin layer 48. More specifically, in such embodiments, the method may include securing a first face plate 56 at a first end 45 of the internal lattice structure 44 and securing a second face plate 58 an opposing, second end of the internal lattice structure 44.
  • the face plates 56, 58 may be secured to the ends 45, 47 of the lattice structure 44 via any suitable attachment methods, including but not limited to adhesives, mechanical fasteners, and/or welding (e.g. thermoplastic welding).
  • first and second face plates 56, 58 of the shear web 24 may be secured to the opposing spar caps 20, 22 or the body shell
  • the face plates 56, 58 may be secured to the opposing spar caps 20, 22 22 or the body shell 21 of the rotor blade 16 via any suitable attachment methods, including but not limited to adhesives, mechanical fasteners, and/or welding (e.g. thermoplastic welding).
  • the method may include printing the internal lattice structure 44 of the shear web 24 directly onto an inner surface 35, 37 of the blade shell 21 of the rotor blade 16 and/or directly onto one of the spar caps 20, 22. In such embodiments, the internal lattice structure 44 bonds to the inner surfaces 35, 37 and/or the spar caps 20,
  • the method may include placing a step feature 60 on the inner surface 35 of the blade shell 21 and securing one of the face plates 56, 58 of the shear web 24 to the step feature 60.
  • the step feature 60 may have a generally triangular cross- section with a flat upper surface 62 so as to accommodate the curvature of the rotor blade 16.
  • one of the end plates 56, 58 of the shear web 24 is configured to sit atop the flat upper surface 62 of the step feature 60 and can easily be secured thereto, e.g. via adhesives, mechanical fasteners, and/or welding (e.g.
  • the end plates 56, 58 may also be directly secured to the inner surfaces 35, 37 of the body shell 21 of the rotor blade 16 rather than using the step feature 60.
  • the step feature(s) 62 described herein may be constructed of any suitable materials, such as e.g. a thermoplastic or thermoset material, and may be formed using any suitable manufacturing methods such as those methods described herein.
  • the method may also include forming a plurality of internal lattice structures 44 so as to form a plurality of shear webs 24 and securing each of the plurality of internal lattice structures 44 to the inner surfaces 35, 37 of the blade shell 21 and/or the spar caps 20, 22 of the rotor blade 16.
  • any number of shear webs 24 may be manufactured and installed into the rotor blade 16 to achieve a desired strength and/or stiffness of the blade 16.

Landscapes

  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Composite Materials (AREA)
  • Robotics (AREA)
  • Civil Engineering (AREA)
  • Ceramic Engineering (AREA)
  • Structural Engineering (AREA)
  • Textile Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Sustainable Development (AREA)
  • Sustainable Energy (AREA)
  • Combustion & Propulsion (AREA)
  • General Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Wind Motors (AREA)

Abstract

La présente invention concerne un procédé de fabrication d'un composant de pale de rotor, tel qu'une bande de cisaillement, d'une pale de rotor d'une éolienne. Le procédé comprend la formation, par impression 3D, d'une structure de treillis interne du composant de pale de rotor. Plus spécifiquement, la structure de réseau interne comprend une pluralité de cellules ouvertes. De plus, le procédé consiste à recouvrir au moins une partie de la structure de treillis interne avec une couche de peau externe pour former le composant de pale de rotor.
PCT/US2018/030777 2018-05-03 2018-05-03 Bandes de cisaillement pour pales de rotor d'éolienne et leurs procédés de fabrication WO2019212551A1 (fr)

Priority Applications (3)

Application Number Priority Date Filing Date Title
PCT/US2018/030777 WO2019212551A1 (fr) 2018-05-03 2018-05-03 Bandes de cisaillement pour pales de rotor d'éolienne et leurs procédés de fabrication
CN201880095311.7A CN112384357A (zh) 2018-05-03 2018-05-03 用于风力涡轮机转子叶片的抗剪腹板及其制造方法
EP18917235.6A EP3787872A4 (fr) 2018-05-03 2018-05-03 Bandes de cisaillement pour pales de rotor d'éolienne et leurs procédés de fabrication

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/US2018/030777 WO2019212551A1 (fr) 2018-05-03 2018-05-03 Bandes de cisaillement pour pales de rotor d'éolienne et leurs procédés de fabrication

Publications (1)

Publication Number Publication Date
WO2019212551A1 true WO2019212551A1 (fr) 2019-11-07

Family

ID=68386312

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2018/030777 WO2019212551A1 (fr) 2018-05-03 2018-05-03 Bandes de cisaillement pour pales de rotor d'éolienne et leurs procédés de fabrication

Country Status (3)

Country Link
EP (1) EP3787872A4 (fr)
CN (1) CN112384357A (fr)
WO (1) WO2019212551A1 (fr)

Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20100092300A1 (en) * 2007-01-25 2010-04-15 Find Molholt Jensen Reinforced blade for wind turbine
US20110176928A1 (en) 2008-06-23 2011-07-21 Jensen Find Moelholt Wind turbine blade with angled girders
US20120051937A1 (en) * 2010-08-24 2012-03-01 Karim Grase Structural element for an aircraft and spacecraft and method for producing a structural element of this type
US20150316026A1 (en) * 2014-04-30 2015-11-05 General Electric Company Rotor blade joint assembly with multi-component shear web
KR101642066B1 (ko) * 2011-12-16 2016-07-29 베스타스 윈드 시스템스 에이/에스 풍력 발전기 블레이드
WO2016209945A1 (fr) 2015-06-26 2016-12-29 Lieberman Steven D Structure cellulaire pour noyau composite sandwich et procédé de fabrication de panneaux sandwich
US20170058868A1 (en) 2015-09-01 2017-03-02 General Electric Company Shear web for a wind turbine rotor blade
WO2017092766A1 (fr) 2015-11-30 2017-06-08 Vestas Wind Systems A/S Éoliennes, pales d'éoliennes et procédés de fabrication de pales d'éoliennes
US20180264749A1 (en) * 2017-03-16 2018-09-20 General Electric Company Shear Webs for Wind Turbine Rotor Blades and Methods for Manufacturing Same

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2570254A1 (fr) * 2011-09-15 2013-03-20 Siemens Aktiengesellschaft Procédé de fabrication d'une pale de rotor d'éolienne avec âme de cisaillement
US10688737B2 (en) * 2017-09-14 2020-06-23 General Electric Company Method for forming fiber-reinforced polymer components

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20100092300A1 (en) * 2007-01-25 2010-04-15 Find Molholt Jensen Reinforced blade for wind turbine
US20110176928A1 (en) 2008-06-23 2011-07-21 Jensen Find Moelholt Wind turbine blade with angled girders
US20120051937A1 (en) * 2010-08-24 2012-03-01 Karim Grase Structural element for an aircraft and spacecraft and method for producing a structural element of this type
KR101642066B1 (ko) * 2011-12-16 2016-07-29 베스타스 윈드 시스템스 에이/에스 풍력 발전기 블레이드
US20150316026A1 (en) * 2014-04-30 2015-11-05 General Electric Company Rotor blade joint assembly with multi-component shear web
WO2016209945A1 (fr) 2015-06-26 2016-12-29 Lieberman Steven D Structure cellulaire pour noyau composite sandwich et procédé de fabrication de panneaux sandwich
US20170058868A1 (en) 2015-09-01 2017-03-02 General Electric Company Shear web for a wind turbine rotor blade
WO2017092766A1 (fr) 2015-11-30 2017-06-08 Vestas Wind Systems A/S Éoliennes, pales d'éoliennes et procédés de fabrication de pales d'éoliennes
US20180264749A1 (en) * 2017-03-16 2018-09-20 General Electric Company Shear Webs for Wind Turbine Rotor Blades and Methods for Manufacturing Same

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See also references of EP3787872A4

Also Published As

Publication number Publication date
EP3787872A4 (fr) 2021-11-24
EP3787872A1 (fr) 2021-03-10
CN112384357A (zh) 2021-02-19

Similar Documents

Publication Publication Date Title
US10828843B2 (en) Shear webs for wind turbine rotor blades and methods for manufacturing same
CN111601703B (zh) 用于制造具有打印网结构的风力涡轮转子叶片板的方法
US20220065217A1 (en) Methods for manufacturing wind turbine rotor blades and components thereof
US10830206B2 (en) Methods for manufacturing wind turbine rotor blades and components thereof
US10987879B2 (en) Methods of manufacturing rotor blade components for a wind turbine
EP3477097B1 (fr) Composants de pale de rotor de turbine éolienne formés par des tiges pultrudées
US10113532B2 (en) Pre-cured composites for rotor blade components
CN111587178B (zh) 制造具有打印的网格结构的风力涡轮转子叶片面板的方法
WO2020068537A9 (fr) Procédés de fabrication de composants de pale de rotor d'éolienne
EP3787871B1 (fr) Procédés de fabrication de pales de rotor d'éolienne et leurs composants
EP3713749B1 (fr) Composants de pale de rotor d'éolienne et leurs procédés de fabrication
CA3098688A1 (fr) Procedes de fabrication de pales de rotor d'eolienne et composants de celles-ci
EP3787882A1 (fr) Procédés de fabrication de composants de pale de rotor pour une éolienne
WO2019212551A1 (fr) Bandes de cisaillement pour pales de rotor d'éolienne et leurs procédés de fabrication
CN114786929A (zh) 用于制造具有硬化的网格结构的壳的方法

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 18917235

Country of ref document: EP

Kind code of ref document: A1

NENP Non-entry into the national phase

Ref country code: DE

WWE Wipo information: entry into national phase

Ref document number: 2018917235

Country of ref document: EP

ENP Entry into the national phase

Ref document number: 2018917235

Country of ref document: EP

Effective date: 20201203