WO2021104599A1 - Pale d'éolienne modulaire - Google Patents

Pale d'éolienne modulaire Download PDF

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Publication number
WO2021104599A1
WO2021104599A1 PCT/DK2020/050337 DK2020050337W WO2021104599A1 WO 2021104599 A1 WO2021104599 A1 WO 2021104599A1 DK 2020050337 W DK2020050337 W DK 2020050337W WO 2021104599 A1 WO2021104599 A1 WO 2021104599A1
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WO
WIPO (PCT)
Prior art keywords
blade
tension element
insert
bearing surface
modules
Prior art date
Application number
PCT/DK2020/050337
Other languages
English (en)
Inventor
Jonathan Smith
Leon Barton
Original Assignee
Vestas Wind Systems A/S
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 Vestas Wind Systems A/S filed Critical Vestas Wind Systems A/S
Priority to EP20819622.0A priority Critical patent/EP4065834A1/fr
Publication of WO2021104599A1 publication Critical patent/WO2021104599A1/fr

Links

Classifications

    • 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
    • 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
    • F05B2230/60—Assembly methods
    • 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
    • F05B2240/00—Components
    • F05B2240/20—Rotors
    • F05B2240/30—Characteristics of rotor blades, i.e. of any element transforming dynamic fluid energy to or from rotational energy and being attached to a rotor
    • F05B2240/302—Segmented or sectional 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
    • F05B2250/00—Geometry
    • F05B2250/20—Geometry three-dimensional
    • F05B2250/29—Geometry three-dimensional machined; miscellaneous
    • F05B2250/292—Geometry three-dimensional machined; miscellaneous tapered
    • 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
    • F05B2260/00—Function
    • F05B2260/30—Retaining components in desired mutual position
    • 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
    • F05B2280/00—Materials; Properties thereof
    • F05B2280/60—Properties or characteristics given to material by treatment or manufacturing
    • F05B2280/6003—Composites; e.g. fibre-reinforced
    • 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 invention relates generally to wind turbine blades, and more specifically to a modular wind turbine blade having an improved joint between blade modules.
  • a rotor blade may be designed as a modular assembly.
  • Such a modular blade may be divided into two or more modules that are easier to transport and which are then assembled on-site. Ease of on-site assembly is therefore a significant factor for consideration when designing a modular blade.
  • a particular challenge in the design of modular wind turbine blades is ensuring that the joint between blade modules is sufficiently robust.
  • Various types of joint have already been proposed, including bonded joints and bolted connections.
  • a modular wind turbine blade comprising a first blade module and a second blade module for connection end to end, each blade module having an outer shell extending longitudinally in a spanwise direction, and extending transversely in a chordwise direction between a leading edge and a trailing edge.
  • the first blade module comprises a first bearing surface and the second blade module comprises a second bearing surface, each bearing surface extends transversely and at least one of the bearing surfaces is angled such that the first and second bearing surfaces are mutually divergent when the first and second blade modules are arranged end to end.
  • the modular wind turbine blade further comprises a tension element configured to span an interface between the first and second blade modules, the tension element comprising first and second mutually-opposed contact surfaces.
  • the first contact surface is configured to engage the first bearing surface and the second contact surface is configured to engage the second bearing surface, wherein moving the tension element in a generally chordwise direction along the mutually divergent bearing surfaces causes the first and second blade modules to be pulled together in a generally spanwise direction, such that a pre-tensioned connection is established between the first and second blade modules.
  • the contact surfaces of the tension element may be angled such that they are mutually divergent.
  • the first contact surface of the tension element may be angled such that it is generally parallel to the first bearing surface.
  • the second contact surface may be angled such that it is generally parallel to the second bearing surface.
  • the tension element is preferably made from metal, for example steel.
  • the tension element preferably comprises a cross-bar extending between the first and second contact surfaces.
  • the contact surfaces may be defined by end portions of the tension element.
  • the tension element may be shaped such that it resembles a dog bone.
  • the contact surfaces may be defined by legs or other features that project from the cross-bar.
  • the modular wind turbine blade may further comprise a plurality of tension elements each configured to span the interface between the first and second blade modules.
  • the tension elements may be configured to be arranged side-by-side in the chordwise direction. Each tension element preferably engages a portion of the first and second bearing surfaces.
  • the tension elements may have the same overall dimensions. However, the separation between the first and second mutually-opposed contact surfaces of the tension elements may vary from one tension element to another. This separation is preferably selected to correspond to the spanwise separation between the first and second bearing surfaces at the intended chordwise position of the tension element.
  • the first and second blade modules may each comprise a spar cap.
  • the pre-tensioned connection may be between the spar cap of the first blade module and the spar cap of the second blade module.
  • the first blade module may comprise a first insert defining the first bearing surface.
  • the second blade module may comprise a second insert defining the second bearing surface.
  • the first and second inserts may each extend in the spanwise direction between respective proximal and distal ends.
  • the proximal end of the first insert may abut the proximal end of the second insert when the first and second blade modules are connected.
  • the proximal end of each insert may be defined as the end of each respective insert nearest the interface between the first and second blade modules.
  • the first insert may be located at an interface end of the first blade module, preferably at the end of the spar cap.
  • the second insert may be located at an interface end of the second blade module, preferably at the end of the spar cap.
  • the inserts are preferably at least partially embedded in the spar caps.
  • the inserts may be embedded in a separate slab of material, such as glass or carbon fibre reinforced plastic, and this separate slab may then be integrated with the spar caps.
  • the spar caps may be formed primarily from composite material such as fibre reinforced plastic (FRP).
  • FRP fibre reinforced plastic
  • the spar caps are formed from stacked strips of carbon-fibre reinforced plastic (CFRP), which are preferably formed by pultrusions. The strips may at least partially overlap the inserts.
  • CFRP carbon-fibre reinforced plastic
  • the spar caps may be embedded in the outer shells of the blade modules, for example laminated into the shells, forming a so-called ‘structural shell’.
  • the spar caps may be separate from, but joined to, the outer shells.
  • the spar caps may be bonded to an inner surface of the outer shells.
  • the first and/or the second insert preferably tapers in thickness moving in a spanwise direction towards its distal end.
  • the thickness may reduce to near zero at the distal end such that the distal end is relatively sharp. Accordingly, the inserts may resemble spears when viewed in cross section.
  • the first and/or second inserts are preferably made from metal, for example steel.
  • the first insert may comprise a first channel extending in a generally chordwise direction at least partially through the first insert.
  • the first channel is preferably open at the proximal end of the first insert.
  • the first bearing surface may be located inside the first channel.
  • the second insert may comprise a second channel extending in a generally chordwise direction at least partially through the second insert.
  • the second channel is preferably open at the proximal end of the second insert.
  • the second bearing surface may be located inside the second channel.
  • the first and second channels may together define a slot extending generally chordwise when the proximal ends of the first and second inserts are in abutment.
  • the tension element(s) may be received inside the slot.
  • the tension element(s) may be inserted into the slot in a chordwise direction.
  • the tension element(s) may be moved freely in the chordwise direction until some resistance is experienced.
  • a chordwise force may then be applied to the tension element(s) to force a slight further chordwise movement of the tension element(s) resulting in the inserts being pulled together in the spanwise direction to pre-tension the connection between the blade modules.
  • the slot may have a cross section complementary in shape to a cross section of the tension element.
  • the cross-sectional shape of the slot may resemble a dog-bone.
  • the first and second inserts may together define a plurality of chordwise-extending slots.
  • the slots may be arranged one above another. At least one tension element may be received in each slot.
  • the first insert and/or the second insert may comprise a plurality of insert segments that are mutually adjacent in the chordwise direction. Each insert segment may define part of the first or second bearing surface.
  • the or each slot preferably extends through each of the insert segments.
  • the insert segments preferably have contoured side surfaces such that the inserts may nestle into neighbouring inserts.
  • the side surfaces are preferably curved such that the insert segments may accommodate a chordwise curvature of the blade shell.
  • a method of connecting first and second blade modules of a modular wind turbine blade comprises arranging a first blade module end to end with a second blade module.
  • Each blade module has an outer shell extending longitudinally in a spanwise direction, and extending transversely in a chordwise direction between a leading edge and a trailing edge.
  • the first blade module comprises a first bearing surface and the second blade module comprises a second bearing surface.
  • Each bearing surface extends transversely and at least one of the first and second bearing surfaces is angled such that the first and second bearing surfaces are mutually divergent.
  • the method comprises providing at least one tension element having first and second mutually-opposed contact surfaces; arranging the tension element spanning an interface between the first and second blade modules such that the first contact surface engages the first bearing surface and the second contact surface engages the second bearing surface; and moving the tension element in a generally chordwise direction along the mutually-divergent bearing surfaces, such that the first and second blade modules are pulled together in a generally spanwise direction, and a pre-tensioned connection is established between the first and second blade modules.
  • the method may further comprise arranging a plurality of tension elements side by side in the chordwise direction. Each tension element preferably spans the interface between the first and second blade modules. A first contact surface of each tension element preferably engages the first bearing surface. A second contact surface of each tension element preferably engages the second bearing surface. The method may further comprise applying a chordwise force to the plurality of tension elements to establish the pre-tensioned connection.
  • a method of making a modular wind turbine blade comprises providing a blade mould extending longitudinally in a spanwise direction, and extending transversely in a chordwise direction between a leading edge and a trailing edge.
  • the blade mould comprises a first spanwise portion shaped to define at least part of an outer shell of a first blade module and a second spanwise portion shaped to define at least part of an outer shell of a second blade module.
  • the mould further comprises a chordwise split line between the first and second spanwise portions.
  • the method comprises arranging reinforcing material in the blade mould to form the outer shell of the first and second blade modules and arranging spar cap material in the blade mould to form a spar cap of the wind turbine blade.
  • the method further comprises providing first and second inserts in the mould in line with the spar cap material such that the first insert is arranged in the first spanwise portion of the mould on one side of the split line and the second insert is arranged in the second spanwise portion of the mould on the other side of the split line.
  • the inserts are connected together by a tension element arranged to span the split line.
  • Further reinforcing material and/or spar cap material is optionally arranged in the mould.
  • the method further comprises integrating the reinforcing material, spar cap material and the inserts to form at least part of the outer shells of the first and second blade modules. The tension element may then be removed and the outer shells of the first and second blade modules may be separated.
  • the inserts may be integrated directly with the spar caps.
  • the inserts may be provided in a separate slab of material, such as glass or carbon fibre reinforced plastic, and this separate slab may then be integrated with the spar caps.
  • the mould may comprise two separate spanwise mould sections arranged end to end.
  • a single mould may be used to form both blade modules, in which case the split line may be a notional split line.
  • the tension element may comprise first and second contact surfaces configured to engage respectively with first and second mutually divergent bearing surfaces of the first and second inserts.
  • the method may comprise moving the tension element in a generally chordwise direction along the mutually divergent bearing surfaces to cause the first and second inserts to be pulled together in a generally spanwise direction.
  • Figure 1 is a schematic perspective view of a modern utility-scale wind turbine
  • Figure 2 is a schematic plan view of first and second blade modules of a modular blade
  • Figure 3 is a schematic perspective view of first and second inserts of the first and second blade modules
  • Figure 4 is a schematic cutaway view of the first and second inserts and a tension element for arrangement with said inserts;
  • Figure 5 is a schematic cross-sectional plan view through the inserts of the first and second blade modules
  • Figure 6 is a further schematic cross-sectional plan view through the inserts of the first and second blade modules wherein the inserts are connected by a plurality of tension elements;
  • Figure 7 is a schematic perspective view of reinforcing material laid up in a mould to form part of an outer shell of the first and second blade modules;
  • Figure 8 shows a schematic side view of an alternative insert configuration having multiple rows of tension elements to connect the inserts together
  • Figure 9 is a schematic cross-sectional view of a variant insert formed of a plurality of side by side insert segments.
  • Figure 10 shows a schematic cross-sectional view of a further example of a tension element.
  • FIG. 1 is a schematic perspective view of a modern utility-scale wind turbine 10.
  • the wind turbine 10 comprises a tower 12 supporting a nacelle 14 to which a rotor 16 is mounted.
  • the rotor 16 comprises a plurality of radially extending modular wind turbine blades 18 which are attached at their respective root ends 20 to a central hub 22.
  • the rotor 16 comprises three blades 18, but in other examples the rotor 16 may have any number of blades 18.
  • the modular blades 18 may be assembled at the wind farm site to facilitate easier transportation of large components.
  • the blades 18 each comprise first and second blade modules 24a, 24b, though more than two modules 24 per blade 18 may be used in other examples.
  • the first blade module 24a is an inboard module, situated towards the root end 20 of the blade 18, and the second blade module 24b is an outboard module, situated towards a tip end 26 of the blade 18.
  • the first blade module 24a comprises the root end 20 of the blade 18, and the second blade module 24b comprises the tip end 26 of the blade 18.
  • the first and second blade modules 24a, 24b may not necessarily comprise the root end 20 or tip end 26 of the blade 18.
  • the first and second blade modules 24a, 24b are connected end to end at an interface 28.
  • An interface end 30a, 30b of each blade module 24a, 24b is therefore defined as the respective end of that module which connects to the other module.
  • FIG 2 is a schematic plan view of the first and second blade modules 24a, 24b of the modular wind turbine blade 18.
  • Each of the first and second blade modules 24a, 24b comprise an outer shell 32a, 32b extending longitudinally in a spanwise direction (S) and transversely in a chordwise direction (C) between a leading edge 34 and a trailing edge 36.
  • the blade modules 24a, 24b each comprise a spar cap 38a, 38b.
  • the spar caps 38a, 38b are embedded in the respective outer shells 32a, 32b to form a structural shell.
  • the spar caps 38a, 38b form part of a reinforcing spar structure which extends in the spanwise direction (S) to provide the modular blade 18 with structural and torsional rigidity.
  • the spar caps 38a, 38b are formed of a composite material such as carbon-fibre reinforced plastic (CFRP).
  • CFRP carbon-fibre reinforced plastic
  • each blade module 24a, 24b comprises an insert 40a, 40b located at the interface end 30a, 30b of the respective module.
  • the first blade module 24a therefore comprises a first insert 40a located at the interface end 30a of the first module 24a.
  • the second blade module 24b comprises a second insert 40b located at the interface end 30b of the second module 24b.
  • the inserts 40a, 40b are provided in-line with the spar caps 38a, 38b.
  • the inserts 40a, 40b are embedded in the spar caps 38a, 38b of the first and second blade modules 24a, 24b respectively.
  • the inserts 40a, 40b may be considered as forming part of the spar caps 38a, 38b.
  • the inserts 40a, 40b each extend in the spanwise direction (S) between a proximal end 42a, 42b and a distal end 44a, 44b. ‘Proximal’ and ‘distal’ are defined relative to the interface 28 between the blade modules 24a, 24b, such that the proximal end 42a, 42b of an insert 40a, 40b is the end nearest the interface 28.
  • Figure 3 shows a schematic perspective view of the first and second inserts 40a, 40b arranged end to end with their proximal ends 42a, 42b in abutment.
  • the outer shells 32a, 32b and spar caps 38a, 38b are omitted from Figure 3 for clarity.
  • the first insert 40a comprises a first channel 46a which extends in a generally chordwise direction at least partially through the first insert 40a.
  • the second insert 40b comprises a second channel 46b which extends in a generally chordwise direction at least partially through the second insert 40b.
  • the channels 46a, 46b extend through the entire respective insert 40a, 40b, from a trailing edge side 48 of the insert to a leading edge side 50 thereof.
  • the first channel 46a is open at the proximal end 42a of the first insert 40a.
  • the second channel 46b is open at the proximal end 42b of the second insert 40b.
  • the first and second channels 46a, 46b therefore together define a slot 52 when the proximal ends 42a, 42b of the first and second inserts 40a, 40b are in abutment.
  • the slot 52 is defined by the channels 46a and 46b, the slot 52 also extends through the inserts 40a, 40b in a generally chordwise direction.
  • the first and second insert 40a, 40b in this example define first and second bearing surfaces 54a, 54b which extend transversely across the respective first and second blade modules 24a, 24b.
  • the first bearing surface 54a is located in the first channel 46a and the second bearing surface 54b is located in the second channel 46b.
  • the bearing surfaces 54a, 54b extend substantially perpendicularly from a floor 56a, 56b and ceiling 58a, 58b of each channel 46a, 46b.
  • At least one of the bearing surfaces 54a or 54b is angled relative to the chordwise direction (C).
  • each of the bearing surfaces 54a, 54b is angled relative to the chordwise direction (C).
  • the bearing surfaces 54a, 54b are angled such that they are mutually divergent when the first and second blade modules 24a, 24b are arranged end to end and the proximal ends 42a, 42b of the inserts 40a, 40b are brought into abutment. That is to say, a spanwise separation X between the bearing surfaces 54a, 54b changes between different chordwise positions across the modular blade 18.
  • the separation X in the spanwise direction (S) between the bearing surfaces 54a and 54b increases going from the trailing edge side 48 to the leading edge side 50 of the inserts 40a, 40b.
  • Figure 4 shows a schematic cutaway view of the first and second inserts 40a, 40b of the first and second blade modules 24a, 24b arranged with their proximal ends 42a, 42b in abutment.
  • the outer shells 32a, 32b and spar caps 38a, 38b are omitted from Figure 4 for clarity.
  • a tension element 60 is shown, which is configured for insertion into the slot 52 in the direction of arrow Y to connect the inserts 40a, 40b (and hence the blade modules 24a, 24b) together.
  • the tension element 60 is a metal component.
  • the tension element 60 is made of steel.
  • the tension element 60 may be formed of a composite material such as carbon fibre reinforced plastic (CFRP).
  • the tension element 60 comprises a first contact surface 62a and a second contact surface 62b which is arranged in opposed relation to the first contact surface 62a.
  • the first contact surface 62a is configured to engage the first bearing surface 54a
  • the second contact surface 62b is configured to engage the second bearing surface 54b.
  • the first contact surface 62a is therefore angled substantially parallel to the first bearing surface 54a
  • the second contact surface 62b is angled substantially parallel to the second bearing surface 54b.
  • the first and second contact surfaces 62a, 62b of the tension element 60 are mutually divergent, in accordance with the mutually divergent bearing surfaces 54a, 54b.
  • a cross-bar 64 extends between the first and second contact surfaces 62a, 62b such that the contact surfaces are fixed relative to one another.
  • the tension element 60 has the shape of a dog bone.
  • FIG 5 is a schematic cross-sectional plan view through the inserts 40a, 40b of the first and second blade modules 24a, 24b.
  • the modular blade 18 comprises a plurality of tension elements 60.
  • the modular blade 18 is shown in a partially-assembled state, wherein two tension elements 60 are arranged in place, spanning the interface 28, and a further tension element 60 is shown prior to being inserted into the slot 52 (as shown in Figure 4).
  • the tension elements 60 are arranged side by side in the chordwise direction (C).
  • said tension elements 60 each comprise a chordwise width W1 which is substantially narrower than a chordwise width W2 of the inserts 40a, 40b.
  • the slot 52 extends the entire way through each insert 40a, 40b, and as such the tension elements 60 each comprise a chordwise width W1 which is substantially narrower than a chordwise width W3 of the slot 52.
  • each tension element 60 is therefore substantially narrower than that of a single-piece tension element in examples where said tension element extends substantially across the chordwise width W2 of the inserts 40a, 40b.
  • the tension elements 60 in Figure 5 are therefore substantially narrow in comparison to a single piece tension element 60.
  • each tension element 60 shown in dashed lines on Figure 5 are configured in a manner complementary to a portion of the bearing surface 54a, 54b with which they engage. Further, a spanwise separation Z between the first and second contact surfaces 62a, 62b of each tension element 60 approximately corresponds to the spanwise separation X between the first and second bearing surfaces 54a, 54b at the given chordwise position of the tension element 60.
  • the tension elements 60 configured to span the interface 28 at different chordwise locations, each comprise varying spanwise separations Z between their respective contact surfaces 62a, 62b.
  • the external dimensions of the tension elements 60 may be substantially uniform such that they may each be moved in the chordwise direction (C) within the slot 52.
  • Each tension element 60 therefore generally resembles the tension element 60 shown in Figure 4.
  • the modules are arranged end to end such that the proximal ends 42a, 42b of the first and second inserts 40a, 40b are in abutment. At least one tension element 60 is then arranged in the slot 52 to span the interface 28 between the blade modules 24a, 24b.
  • Each tension element 60 is arranged in the slot 52 by moving said tension element 60 along the mutually divergent bearing surfaces 54a, 54b in a generally chordwise direction.
  • moving the tension elements 60 along the bearing surfaces 54a, 54b in a chordwise direction (C) causes the first and second blade modules 24a, 24b to be pulled together in a generally spanwise direction (S).
  • Figure 6 shows a further schematic cross-sectional plan view through the inserts 40a, 40b of the first and second blade modules 24a, 24b wherein the inserts 40a, 40b are connected together by a plurality of tension elements 60.
  • Five tension elements 60 are arranged in the slot 52 to span the interface 28 and pull the blade modules 24a, 24b together in the spanwise direction (S).
  • a chordwise force is applied to the tension elements 60 by bolts 66 arranged with a fixture 68 which is fastened to each of the first and second inserts 40a, 40b. As the bolts 66 are rotated in the fixture 68, they extend further through said fixture 68 in the chordwise direction (C), applying a force to the tension elements 60 against which they interface.
  • the proximal ends 42a, 42b of the first and second inserts 40a, 40b are abutted such that no further spanwise movement of the inserts 40a, 40b or blade modules 24a, 24b is possible. Further, the spanwise separation Z between the contact surfaces 62a, 62b of each tension element 60 is fixed by the cross-bar 64. As the tension element 60 is pressed into the slot 52, the contact surfaces 62a, 62b of the tension element 60 run along the mutually divergent bearing surfaces 54a, 54b. Forcing a tension element 60 further in the chordwise direction (C) results in tensile loading of said tension element 60.
  • the tension element 60 therefore undergoes tensile loading because the spanwise separation X between the mutually divergent bearing surfaces 54a, 54b increases with chordwise position from the trailing edge side 48 in this example. A pre-tensioned connection is thereby established between the first and second blade modules 24a, 24b.
  • the inserts 40a, 40b are embedded in the spar caps 38a, 38b of the first and second blade module 24a, 24b respectively.
  • the pre-tensioned connection is formed between the spar cap 38a of the first blade module 24a and the spar cap 38b of the second blade module 24b.
  • Embedding the inserts 40a, 40b in the spar caps 38a, 38b of each module facilitates a strong joint between the main load bearing elements of the blade modules 24a, 24b.
  • Forming the pre-tensioned connection between the load bearing elements of each module 24a, 24b enables a large amount of loading to be transferred across the interface 28 between modules 24a, 24b in a relatively small area.
  • the inserts 40a, 40b and tension elements 60 are formed of a material such as steel, having a high elastic modulus, the size of such components can be reduced on account of the load-bearing properties of their materials. A relatively compact connection solution is thereby achieved without adding considerable mass to the modular blade 18.
  • a modular blade 18 may flex, due for example to varied wind conditions or the effect of gravity at different positions during rotation of the rotor 16.
  • the tension elements 60 are pre-tensioned, even when flexing of the blade 18 causes the tension elements 60 to compress slightly from their loaded state, the elements 60 are still loaded in tension.
  • the tension elements 60 only undergo tensile loading, and do not particularly experience torsional loading or bending moments, the elements 60 can be reasonably small in size relative to the size of the blade 18, again reducing the weight of the connection between blade modules 24a, 24b.
  • FIG. 7 is a schematic perspective view showing part of a blade mould 70 used to form the first and second blade modules 24a, 24b.
  • the blade mould 70 extends longitudinally in the spanwise direction (S) and transversely in the chordwise direction (C) between a leading edge 72 and a trailing edge 74.
  • the mould 70 comprises a first spanwise portion 76a and a second spanwise portion 76b.
  • the first and second spanwise portions 76a, 76b are shaped to define part of the outer shell 32a, 32b of the first and second blade modules 24a, 24b respectively.
  • a split line 78 is defined between the first and second spanwise portions 76a, 76b of the blade mould 70.
  • the first and second blade modules 24a, 24b are formed in a single mould (a full blade mould 70) and the split line 78 is therefore a notional split line.
  • the blade mould 70 may comprise two separate mould sections which are physically separated at the split line 78.
  • Reinforcing material 80 is arranged in the mould 70 to form the outer shell 32a, 32b of each of the blade modules 24a, 24b.
  • the blade modules 24a, 24b comprise a shell 32a, 32b formed of glass fibre reinforced plastic (GFRP), and so the reinforcing material 80 comprises layers of glass fibre fabric.
  • GFRP glass fibre reinforced plastic
  • a first insert 40a is arranged in the first spanwise portion 76a of the mould 70 on one side of the split line 78 and a second insert 40b is arranged in the second spanwise portion 76b of the mould 70 on the other side of the split line 78.
  • the first and second inserts 40a, 40b taper in transverse thickness T towards their respective distal ends 44a, 44b.
  • the inserts 40a, 40b are therefore substantially wedge shaped when viewed in a spanwise cross section.
  • the first and second insert 40a, 40b are connected together in the mould 70 by one or more tension elements 60 which span the split line 78.
  • the first and second contact surfaces 62a, 62b of each tension element 60 respectively engage the first and second bearing surfaces 54a, 54b of the inserts 40a, 40b as described above with reference to Figures 4 to 6.
  • the inserts 40a, 40b in the blade mould 70 are therefore configured in the same orientation and relation to one another as they are when connecting two finished blade modules 24a, 24b together to form a modular blade 18.
  • Spar cap material 82 is arranged in each portion of the blade mould 76a, 76b to form the spar caps 38a, 38b of each blade module 24a, 24b.
  • the spar cap material 82 is arranged to overlap at least a portion of the tapered distal end 44a, 44b of each insert 40a, 40b.
  • the spar caps 38a, 38b are formed of a plurality of carbon fibre reinforced plastic (CFRP) pultrusions.
  • CFRP pultrusions are stacked in the mould 70 to form the spar caps 38a, 38b.
  • Further reinforcing material 80 may be arranged in the mould 70, for example covering the spar cap material 82.
  • the reinforcing material 80, spar cap material 82 and inserts 40a, 40b are then integrated to form part of the outer shell 32a, 32b of a first and second blade module 24a, 24b.
  • Integrating the various components in the mould 70 may for example comprise the introduction and curing of resin in a vacuum assisted resin transfer moulding (VARTM) process or other suitable integration process known in the art.
  • VARTM vacuum assisted resin transfer moulding
  • the first and second insert 40a, 40b are embedded in the spar caps 38a, 38b of the first and second module 24a, 24b by integrating the various components as described above.
  • the tapering thickness T of each insert 40a, 40b facilitates a gradual transfer of loads between the spar cap material 82 and the inserts, and reduces stress concentrations along the spar cap 38a, 38b.
  • a separating layer (not shown) may be arranged at the split line 78 between the blade materials forming the first and second blade modules 24a, 24b to facilitate separation of said modules after curing the resin.
  • a separating layer may for example be formed of silicone or polytetrafluoroethylene (PTFE) to limit fluid communication of the resin between components arranged in the first spanwise portion 76a of the mould 70 and those in the second spanwise portion 76b of the mould 70.
  • FIG 8 shows a schematic side view of an alternative insert configuration, wherein each of the first and second inserts 40a, 40b comprise a plurality of generally chordwise channels 46a, 46b.
  • the plurality of channels 46a, 46b in the first and second inserts 40a, 40b together define a plurality of chordwise-extending slots 52.
  • the first and second inserts 40a, 40b of this example each comprise three channels 46a, 46b, thereby defining three slots 52, it will be appreciated that in other examples the inserts may comprise any number of channels.
  • Each channel 46a, 46b includes bearing surfaces 54a, 54b and is similar to the channels 46a, 46b described in relation to Figure 3.
  • the slots 52 are arranged one above another.
  • the slots 52 are configured in a stacked arrangement, spaced apart from one another in a direction transverse to both the spanwise (S) and chordwise (C) directions.
  • At least one tension element 60 is received in each of the slots 52, each tension element 60 being arranged in a respective slot 52 as described previously with reference to Figures 4 to 6.
  • Preferably a plurality of tension elements 60 is arranged in each slot, in substantially the same way as shown in Figures 5 and 6.
  • Figure 9 shows an insert 40 of a blade module in a further example.
  • the insert 40 comprises a plurality of discrete insert segments 40i which are mutually adjacent in the chordwise direction (C).
  • the insert segments 40i are arranged side by side in the mould 70 when manufacturing the blade modules 24a, 24b.
  • Forming the insert 40 of a plurality of segments 40i allows the insert to conform more closely to the curved contour of the outer shell 32 of a blade module. Further, forming the insert 40 of a plurality of segments 40i facilitates easier handling within a production facility as the insert segments 40i are each smaller, and may be lighter in weight, than single-piece inserts 40a, 40b such as those shown in Figures 3 to 7.
  • Each of the insert segments 40i comprises a channel portion 46i.
  • a continuous channel 46 extending through the insert 40 in a generally chordwise direction is defined by the channel portions 46i of each of the insert segments 40i.
  • each insert segment 40i defines part of a first or second bearing surface 54 such that a continuous bearing surface 54 is formed when the insert segments 40i are arranged together.
  • the channel portions 46i of insert segments 40i of each of the inserts 40 together define a slot 52 which extends through each of the insert segments 40i.
  • a tension element 60 or a plurality of tension elements 60 can be arranged in the slot 52 with the contact surfaces 62a, 62b of each tension element 60 engaging the bearing surfaces 54.
  • each insert segment 40i is contoured such that the inserts segments 40i, when arranged together, may nestle into one another. That is to say, neighbouring insert segments 40i each comprise at least one of a convex or concave surface on the trailing or leading edge sides 48i, 50i, and said convex or concave surface is complementary to the side surface of a chordwise adjacent insert segment 40i.
  • Such configuration of the insert segments 40i facilitates a slight rotation of an insert segment 40i relative to a neighbouring insert segment 40i without forming a gap between said segments.
  • the insert 40 may therefore conform even more closely to the chordwise contour of the blade module 24.
  • the slot 52 defined by channels 46 of inserts 40 formed of a plurality of insert segments 40i may be curved or non-planar as a result of the insert segments 40i conforming to the curved contour of the blade module 24.
  • a plurality of tension elements 60 such as those shown in Figures 5 and 6 are used to connect the first and second blade modules 24a, 24b.
  • a plurality of tension elements 60 such as those shown in Figures 5 and 6 can accommodate a curved slot 52 because the position of each tension element 60 is independent of the position of any other tension elements 60. The tension elements 60 can therefore conform to the chordwise curvature of the slot 52.
  • the insert 40 shown in Figure 9 may be used as a first or second insert 40a, 40b in any of the examples described above.
  • each of the first and second inserts 40a, 40b may comprise a plurality of insert segments 40i as shown in the exemplary insert 40 of Figure 9.
  • the tension element 60 may comprise any cross-sectional profile suitable for establishing a pre-tensioned connection between the first and second blade modules 24a, 24b.
  • the tension element 60 depicted throughout is provided as an example only.
  • a further example of a tension element is shown in a spanwise cross- sectional view in Figure 10.
  • the contact surfaces 62a, 62b of a tension element 60 may be inclined relative to the spanwise direction (S).
  • Inclined contact surfaces 62a, 62b of a tension element 60 may form a chamfer between the cross bar 64 and first and second ends 84a, 84b of the tension element 60.
  • the corresponding bearing surfaces 54a, 54b and channels 46a, 46b of the first and second inserts 40a, 40b may be configured with a geometry complementary to that of a given tension element 60.
  • the bearing surfaces 54a, 54b may be inclined relative to the floor 56a, 56b and/or ceiling 58a, 58b of a given channel 46a, 46b.
  • each bearing surface 54a, 54b effectively forms a chamfer between the floor 56a, 56b and/or ceiling 58a, 58b of a respective channel 46a, 46b and a narrower neck portion 86a, 86b (indicated on Figure 3) of said channel 46a, 46b.
  • An inclined bearing surface 54a, 54b may comprise a greater surface area over which to distribute the contact force than a perpendicularly oriented bearing surface 54a, 54b such as those shown in Figure 3.
  • the channel 46 in one or more of the inserts 40 may not extend fully through the entire insert 40, and may instead be a blind channel.
  • Such a channel 46 may extend in the chordwise direction (C) from one of the trailing or leading edge sides 48, 50 of the insert 40 to a point between said sides 48, 50 of the insert 40.
  • bearing surfaces 54a, 54b may be angled, the other of the bearing surfaces 54a, 54b for example extending substantially parallel to the chordwise direction (C). Bearing surfaces 54a, 54b configured in this manner are nevertheless mutually divergent. Moving a tension element 60 as described above in a generally chordwise direction (C) therefore serves to pull the first and second blade modules 24a, 24b together in the spanwise direction (S) as described above.
  • first and second inserts 40a, 40b are defined by the first and second inserts 40a, 40b, it is anticipated that in other examples a connection between first and second blade modules 24a, 24b may be made without requiring inserts 40a, 40b embedded in the first and second blade modules 24a, 24b.
  • the channels 46a, 46b and bearing surfaces 54a, 54b could be machined into a monolithic spar structure.
  • proximal ends 42a, 42b of the inserts 40a, 40b are shown in the accompanying figures to be in direct contact with one another, in other examples, a plate or other member could be provided in between the proximal ends 42a, 42b, in which case said ends would be in indirect contact. Accordingly, the term ‘abut’ as used herein should be interpreted to include both direct and indirect contact between the proximal ends 42a, 42b of the inserts 40a, 40b.

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  • Engineering & Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Sustainable Development (AREA)
  • Sustainable Energy (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Wind Motors (AREA)

Abstract

Dans un premier aspect, l'invention concerne une pale d'éolienne modulaire comprenant un premier module de pale et un second module de pale pour raccordement bout à bout. Chaque module de pale comprend une coque externe s'étendant longitudinalement dans une direction d'envergure, et s'étendant transversalement dans une direction de corde entre un bord d'attaque et un bord de fuite. Le premier module de pale comprend une première surface d'appui et le second module de pale comprend une seconde surface d'appui. Chaque surface d'appui s'étend transversalement et au moins une des surfaces d'appui est inclinée de telle sorte que les première et seconde surfaces d'appui soient mutuellement divergentes lorsque les premier et second modules de pale sont disposés bout à bout. La pale d'éolienne modulaire comprend en outre un élément de tension conçu pour enjamber une interface entre les premier et second modules de pale, l'élément de tension comprenant des première et seconde surfaces de contact mutuellement opposées. La première surface de contact est configurée pour venir en prise avec la première surface d'appui et la seconde surface de contact est configurée pour venir en prise avec la seconde surface d'appui. Le déplacement de l'élément de tension dans une direction généralement dans le sens de la corde le long des surfaces de support mutuellement divergentes amène les premier et second modules de pale à être tirés ensemble dans une direction généralement dans le sens de l'envergure, de telle sorte qu'une liaison pré-tendue soit établie entre les premier et second modules de pale.
PCT/DK2020/050337 2019-11-29 2020-11-27 Pale d'éolienne modulaire WO2021104599A1 (fr)

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EP20819622.0A EP4065834A1 (fr) 2019-11-29 2020-11-27 Pale d'éolienne modulaire

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DKPA201970737 2019-11-29
DKPA201970737 2019-11-29

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Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2288807A2 (fr) * 2008-05-07 2011-03-02 Vestas Wind Systems A/S Aube sectionnelle
US20110158788A1 (en) * 2008-08-31 2011-06-30 Vestas Wind Systems A/S A sectional blade
WO2015011292A1 (fr) * 2013-07-26 2015-01-29 Societe Europeenne D'ingenierie Et De Developpement Des Energies Renouvelables Pale d'eolienne segmentee et eolienne munie d'une telle pale
US20170089324A1 (en) * 2014-05-29 2017-03-30 Nabrawind Technologies SL Bolted joint for a wind turbine blade
US20180223796A1 (en) * 2017-02-07 2018-08-09 General Electric Company Joint Configuration for a Segmented Wind Turbine Rotor Blade
WO2019219139A1 (fr) * 2018-05-16 2019-11-21 Vestas Wind Systems A/S Joint de raccordement pour pale d'éolienne en coupe et procédés associés

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2288807A2 (fr) * 2008-05-07 2011-03-02 Vestas Wind Systems A/S Aube sectionnelle
US20110158788A1 (en) * 2008-08-31 2011-06-30 Vestas Wind Systems A/S A sectional blade
WO2015011292A1 (fr) * 2013-07-26 2015-01-29 Societe Europeenne D'ingenierie Et De Developpement Des Energies Renouvelables Pale d'eolienne segmentee et eolienne munie d'une telle pale
US20170089324A1 (en) * 2014-05-29 2017-03-30 Nabrawind Technologies SL Bolted joint for a wind turbine blade
US20180223796A1 (en) * 2017-02-07 2018-08-09 General Electric Company Joint Configuration for a Segmented Wind Turbine Rotor Blade
WO2019219139A1 (fr) * 2018-05-16 2019-11-21 Vestas Wind Systems A/S Joint de raccordement pour pale d'éolienne en coupe et procédés associés

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