Methods for Manufacturing Spar Caps for Wind Turbine Rotor Blades Using Thermoplastic-Based Composite Plates
a technology of thermoplastic composite plates and wind turbines, which is applied in the manufacture of final products, machines/engines, other domestic articles, etc., can solve the problems of difficult control and often present challenges with respect to composite plates
Inactive Publication Date: 2019-06-13
GENERAL ELECTRIC CO
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- Abstract
- Description
- Claims
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Benefits of technology
The present invention is directed to a method and system for manufacturing a spar cap for a wind turbine rotor blade. The method involves stacking a plurality of plates together to form a plate assembly, where each plate is formed from a continuous fiber-reinforced composite including a plurality of fibers surrounded by a thermoplastic resin material. The plate assembly is then positioned relative to a mold and pressure is applied to conform the plate assembly to the mold surface. The system includes a heated pressing device for pressing the plates together and welding them together to form a plate assembly. The technical effects of the invention include improved manufacturing efficiency and accuracy of the spar cap, reduced labor costs, and improved wind turbine performance.
Problems solved by technology
In general, the body shell is relatively lightweight and has 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.
Such materials, however, can be difficult to control during the manufacturing process and / or are often defect prone and / or highly labor intensive due to handling of the non-cured fabrics and the challenges of infusing large laminated structures.
However, the use of these thicker, pre-formed composites also presents unique challenges during the blade manufacturing process.
For example, such composites often present challenges with respect to coupling or bonding adjacent composite structures together to form the spar cap.
Method used
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[0032]Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.
[0033]In general, the present subject matter is directed to methods for manufacturing spar caps for wind turbine rotor blades using thermoplastic-based, pre-formed composite plates, such as pultruded plates. Specifically, in several embodiments, a spar cap ...
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In one aspect, a method for manufacturing a spar cap for a wind turbine rotor blade may generally include stacking a plurality of plates together to form a plate assembly, wherein each of the plates is formed from a fiber-reinforced composite including a plurality of fibers surrounded by a thermoplastic resin material. The method may also include positioning the plate assembly relative to a mold defining a mold surface, wherein the mold surface is shaped so as to correspond to at least one blade parameter of the wind turbine rotor blade. In addition, the method may include applying pressure to the plate assembly via the mold such that at least a portion of the plate assembly conforms to the shape of the mold surface.
Description
FIELD OF THE INVENTION[0001]The present subject matter relates generally to spar caps for wind turbine rotor blades and, more particularly, to a method for manufacturing a spar cap using thermoplastic-based composite plates.BACKGROUND OF THE INVENTION[0002]Wind power is considered one of the cleanest, most environmentally friendly energy sources presently available, and wind turbines have gained increased attention in this regard. A modern wind turbine typically includes a tower, generator, gearbox, nacelle, and one or more rotor blades. The rotor blades capture kinetic energy from wind using known foil principles and transmit the kinetic energy through rotational energy 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.[0003]Wind turbine rotor blades typically include an outer body skin or shell formed from a com...
Claims
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IPC IPC(8): B32B27/12B32B27/08B32B7/04B32B1/00F03D1/06B32B5/26B29C70/46
CPCB32B27/12B32B27/08B32B7/04B32B1/00F03D1/0675B32B5/26B29C70/46B29K2101/12B32B2398/20B32B2305/10F05B2280/6013F05B2280/6003Y02E10/721B32B2262/106B32B2262/101B32B2260/021Y02P70/523B29K2105/08B29K2105/256B29L2009/00B29L2031/085B32B2603/00B32B2260/046B32B2260/023Y02E10/72Y02P70/50
InventorTOBIN, JAMES ROBERTCARUSO, CHRISTOPHER DANIELYARBROUGH, AARON A.HYNUM, DANIEL ALAN
OwnerGENERAL ELECTRIC CO