Joints for segmented wind turbine blades, segmented wind turbine blades and methods for manufacturing the same

Abstract

A joint for a segmented wind turbine blade, a segmented wind turbine blade, and a method of manufacturing the same are disclosed. The joint includes a laminate socket integrally formed on a first blade segment of the segmented wind turbine blade, and a protruding laminate integrally formed on a second blade segment of the segmented wind turbine blade. The laminate socket is configured to receive the protruding laminate, and when the segmented wind turbine blade is assembled on site, the laminate socket and the protruding laminate are connected together to assemble the first blade segment and the second blade segment.

Description

Technical Field

[0001] The present disclosure generally relates to wind turbines, and more particularly, to joints for segmented wind turbine blades, segmented wind turbine blades, and methods of manufacturing the same. Background Art

[0002] In order to achieve the goal of increasing power generation, the size of modern wind turbines has been continuously increasing, and the equipped wind turbine blades have become longer and longer. As the blades become longer, in some parts of the world, transporting such blades becomes extremely difficult or even impossible. Navigating in areas with complex terrain and underdeveloped infrastructure is challenging for road transportation of long blades, and in some cases, limits the blade length that can be transported to the wind turbine site. One way to overcome this challenge is to segment the blade, thus turning the blade into two or more sections for transportation and then assembling the blade on site. Segmented blades also have several additional advantages. It can reduce the manufacturing material investment for producing extremely long blades and also reduce transportation costs. In this way, clean and sustainable wind energy can be generated in areas where it was previously impossible, improving the operation and economic development of wind farms in areas with inconvenient transportation.

[0003] Segmented blades can be joined or assembled in various different ways, such as through bolted joint connectors, adhesive joints, laminated joints, etc. These joining methods are well-known and have been proven in many application scenarios such as automobiles and aircraft, and even appear in wind turbine blade designs. However, the practice of these joining strategies in the application scenario of segmented blades has not been fully demonstrated and is not widespread. This is largely affected by the fact that although the concept of segmented blades has been around for decades in theory, its practice and industrialization in the wind energy industry are limited. The segmented blade design increases the technical complexity of the blade and leads to increased derived costs, and has not been favored historically. However, with the increasing trend of the size of wind turbine rotors in areas with complex terrain, this situation is beginning to change. The demand for segmented blades is emerging rapidly, having a positive impact on the economic situation of certain wind power projects. Therefore, the development and application of mechanical joints for segmented blades have become emerging technologies, and this mechanical joint technology will be applied to new and innovative solutions. Summary of the Invention

[0004] Some embodiments of the present disclosure provide joints for segmented wind turbine blades, segmented wind turbine blades, and methods of manufacturing segmented wind turbine blades.

[0005] In one aspect, a joint for a segmented wind turbine blade is provided. The joint includes a laminate glove integrally formed on a first blade segment of the segmented wind turbine blade, and a protruding laminate integrally formed on a second blade segment of the segmented wind turbine blade. The laminate glove is configured to receive the protruding laminate, and when the segmented wind turbine blade is assembled on site, the laminate glove and the protruding laminate are connected together, thereby assembling the first blade segment and the second blade segment.

[0006] In another aspect, a segmented wind turbine blade is provided. The segmented wind turbine blade includes at least two blade segments and one or more joints. The at least two blade segments include a first blade segment and a second blade segment. The one or more joints are configured to connect the first blade segment and the second blade segment. Each of the one or more joints includes a laminate glove integrally formed on the first blade segment and a protruding laminate integrally formed on the second blade segment. The protruding laminate is received in and connected to the laminate glove to assemble the first blade segment and the second blade segment together.

[0007] In yet another aspect, a method of manufacturing a segmented wind turbine blade is provided. The segmented wind turbine blade includes at least a first blade segment and a second blade segment. The method includes: laying one or more material layers in a blade mold, the one or more material layers including the laminate glove of the first blade segment and the protruding laminate of the second blade segment, the laminate glove receiving the protruding laminate; co-injecting the one or more material layers together in the blade mold to form a single-piece wind turbine blade; demolding the single-piece wind turbine blade from the blade mold; and separating the laminate glove from the protruding laminate to form a first blade segment with the laminate glove and a second blade segment with the protruding laminate, thereby forming a segmented wind turbine blade, and when the segmented wind turbine blade is assembled on site, the first blade segment and the second blade segment can be reassembled by connecting the laminate glove and the protruding laminate. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] To more clearly describe the technical solutions in the embodiments of the present disclosure, the drawings that describe the embodiments of the present disclosure will be briefly introduced below. Obviously, the drawings described below only relate to some embodiments of the present disclosure, and those skilled in the art can obtain other drawings without creative efforts based on these drawings.

[0009] Figure 1 A schematic diagram of a segmented wind turbine blade according to an embodiment of the present disclosure is shown.

[0010] Figure 2 Shows Figure 1Cross-sectional view of the segmented wind turbine blade along line A-A.

[0011] Figure 3 Shows Figure 1 Cross-sectional view of the segmented wind turbine blade along line B-B.

[0012] Figure 4 Schematic diagram showing a part of a first blade segment according to an embodiment of the present disclosure.

[0013] Figure 5 Schematic diagram showing a second blade segment according to an embodiment of the present disclosure.

[0014] Figure 6 Flowchart showing a method for manufacturing a segmented wind turbine blade according to an embodiment of the present disclosure. Detailed Description

[0015] The technical solutions of the embodiments of the present disclosure will be clearly and fully described below in conjunction with the accompanying drawings in the embodiments of the present disclosure. Obviously, the described embodiments are only some but not all embodiments of the present disclosure. Other embodiments achieved by those skilled in the art based on the embodiments in the present disclosure without creative efforts should fall within the protection scope of the present disclosure.

[0016] Figure 1 Schematic diagram showing a segmented wind turbine blade 100 according to an embodiment of the present disclosure. Now refer to Figure 1 , a segmented wind turbine blade 100 according to an embodiment of the present disclosure may include at least two blade segments, and one or more joints 30 for connecting the at least two blade segments. The at least two blade segments may include, for example, but are not limited to, a first blade segment 10 and a second blade segment 20. The one or more joints 30 are for the segmented wind turbine blade 100 and are configured to connect the first blade segment 10 and the second blade segment 20. Therefore, through the one or more joints 30, the first blade segment 10 and the second blade segment 20 of the segmented wind turbine blade 100 can be assembled together, so that the wind turbine blade 100 can be transported in segments and the segments can be assembled on site.

[0017] The first blade segment 10 of the segmented wind turbine blade 100 includes one of a blade root segment and a blade tip segment, and the second blade segment 20 of the segmented wind turbine blade 100 includes the other of the blade root segment and the blade tip segment. For example, in one embodiment, the first blade segment 10 may include a blade root segment, while the second blade segment 20 may include a blade tip segment. In another embodiment, the first blade segment 10 may include a blade tip segment, while the second blade segment 20 may include a blade root segment.

[0018] However, it should be noted that the segmented wind turbine blade 100 of the present disclosure should not be limited to including only two blade segments. In other embodiments, the segmented wind turbine blade 100 of the present disclosure may further include three, four or even more blade segments. The number of the segmented wind turbine blades 100 of the present disclosure may range from 2 to any desired number. In addition, the segmented wind turbine blade 100 of the present disclosure should not be limited to including a blade root segment and a blade tip segment. In other embodiments, the segmented wind turbine blade 100 of the present disclosure may further include one or more intermediate blade segments located between the blade root segment and the blade tip segment. The above minor or equivalent changes or modifications will be covered within the spirit and scope of the present disclosure.

[0019] Figure 2 shows Figure 1 a cross-sectional view of the segmented wind turbine blade 100 along line A-A in Figure 3 shows Figure 1 a cross-sectional view of the segmented wind turbine blade 100 along line B-B in. As Figure 2 and Figure 3 shown, each joint 30 may include a laminate sleeve 31 and a protruding laminate 32. The laminate sleeve 31 is configured to receive the protruding laminate 32. The size and shape of the laminate sleeve 31 are suitable for the protruding laminate 32. In one embodiment, during the manufacturing process of the segmented wind turbine blade 100, the laminate sleeve 31 and the protruding laminate 32 of the joint 30 are co-infused.

[0020] Figure 4 shows a schematic view of a part of the first blade segment 10 according to an embodiment of the present disclosure. As Figure 4 shown, the laminate sleeve 31 of the joint 30 is integrally formed on the first blade segment 10 of the segmented wind turbine blade 100. The laminate sleeve 31 is a component part of the first blade segment 10. Figure 5 shows a schematic view of the second blade segment 20 according to an embodiment of the present disclosure. As Figure 5 shown, the protruding laminate 32 of the joint 30 is integrally formed on the second blade segment 20 of the segmented wind turbine blade 100. The protruding laminate 32 is a component part of the second blade segment 20.

[0021] When on-site assembly of the segmented wind turbine blade 100 is required, the laminate sleeve 31 can receive the protruding laminate 32, and the laminate sleeve 31 and the protruding laminate 32 can be connected together by various connection methods to assemble the first blade segment 10 and the second blade segment 20. The joint 30 of the present disclosure can enable the disassembly of the wind turbine blade 100 for transportation and enable re-assembly on-site for installation.

[0022] Now refer to Figure 2 - 5, in some embodiments, the laminate socket 31 of the joint 30 may have an outer socket laminate 311 and an inner socket laminate 312. The protruding laminate 32 of the joint 30 may be located between the outer socket laminate 311 and the inner socket laminate 312 of the laminate socket 31. Thus, the protruding laminate 32 can be received in the laminate socket 31. In one embodiment, when reassembled, the laminate socket 31 and the protruding laminate 32 may be connected together by an adhesive or resin. The adhesive or resin can serve as a load transfer mechanism between the laminate socket 31 and the protruding laminate 32. In another embodiment, the laminate socket 31 and the protruding laminate 32 may define one or more holes (not shown) for mechanical fasteners, and the laminate socket 31 and the protruding laminate 32 may be connected together by mechanical fasteners.

[0023] In some embodiments, the protruding laminate 32 is tapered in the spanwise direction D1 of the segmented wind turbine blade 100. Correspondingly, the outer socket laminate 311 and the inner socket laminate 312 of the laminate socket 31 form a tapered socket opening 313 for receiving the tapered protruding laminate 32. This tapered mating structure of the laminate socket 31 and the protruding laminate 32 can facilitate the detachment of the laminate socket 31 and the protruding laminate 32.

[0024] In some embodiments, the segmented wind turbine blade 100 may include one or more joints 30 on the suction side (SS) and one or more joints 30 on the pressure side (PS). In the drawings of the present disclosure, one joint 30 on the suction side and one joint 30 on the pressure side are shown as examples. Each joint 30 on the suction side includes a laminate socket 31 formed on the suction side of the first blade segment 10 and a protruding laminate 32 formed on the suction side of the second blade segment 20. The laminate socket 31 on the suction side is configured to receive the protruding laminate 32 on the suction side so as to form a load transfer joint connecting the first blade segment 10 and the second blade segment 20 on the suction side. Each joint 30 on the pressure side includes a laminate socket 31 formed on the pressure side of the first blade segment 10 and a protruding laminate 32 formed on the pressure side of the second blade segment 20. The laminate socket 31 on the pressure side is configured to receive the protruding laminate 32 on the pressure side, thereby forming a load transfer joint connecting the first blade segment 10 and the second blade segment 20 on the pressure side.

[0025] The joining member 30, i.e., the spar cap sleeve 31 and the corresponding protruding spar 32, can be located at any given desired spanwise position of the segmented wind turbine blade 100. The joining member 30 can also be located at any given desired chordwise position of the segmented wind turbine blade 100. In the cross-section of the segmented wind turbine blade 100, the joining member 30 can also be positioned at any given desired azimuth. The segmented wind turbine blade 100 can include a plurality of joining members 30 along the cross-section. The plurality of joining members 30 can be positioned in any desired pattern or spacing sequence along a given cross-section. That is, the first blade segment 10 can include one or more spar cap sleeves 31, and the second blade segment 20 can include one or more corresponding protruding spars 32.

[0026] The segmented wind turbine blade 100 of the present disclosure employs the joining member 30 in which the protruding spar 32 cooperates with the spar cap sleeve 31, so it can be disassembled for easy transportation and reassembled on-site for installation.

[0027] The segmented wind turbine blade 100 of the present disclosure is fully scalable in terms of the number of connections of each joining member 30. The segmented wind turbine blade 100 of the present disclosure is fully scalable in terms of size, positioning, and orientation.

[0028] The present disclosure also provides a manufacturing method for the above-mentioned segmented wind turbine blade 100. Figure 6 A flowchart showing a manufacturing method of the segmented wind turbine blade 100 according to an embodiment of the present disclosure is shown. As described above, the segmented wind turbine blade 100 includes at least a first blade segment 10 and a second blade segment 20. As Figure 6 shown, the method for manufacturing the segmented wind turbine blade 100 according to an embodiment of the present disclosure can include steps S11 to S14.

[0029] In step S11, one or more material layers are laid up in a blade mold. The one or more material layers include the spar cap sleeve 31 of the first blade segment 10 and the protruding spar 32 of the second blade segment 20. The spar cap sleeve 31 of the first blade segment 10 accommodates the protruding spar 32 of the second blade segment 20.

[0030] The one or more material layers can include one or more fiber layers. The one or more fiber layers can include at least one of a glass fiber layer and a carbon fiber layer. Optionally, the one or more material layers can further include one or more core material layers made of polymer foam or balsa wood.

[0031] In step S12, the one or more material layers are co-infused in a blade mold to form a single-piece wind turbine blade 100. For example, the one or more material layers are co-infused with a liquid resin in the blade mold to cure the one or more material layers.

[0032] In step S13, the single-piece wind turbine blade 100 is demolded from the blade mold.

[0033] In step S14, the spar socket 31 is separated from the protruding spar 32 to form a first blade segment 10 with the spar socket 31 and a second blade segment 20 with the protruding spar 32, thereby forming a segmented wind turbine blade 100. When the segmented wind turbine blade 100 is assembled on site, the first blade segment 10 and the second blade segment 20 can be reassembled together by connecting the spar socket 31 and the protruding spar 32.

[0034] The method of the present disclosure manufactures a segmented wind turbine blade 100 in an unsegmented blade mold, the blade having co-infused mating protruding spar 32 and spar socket 31. The segmented wind turbine blade 100 can then be disassembled for ease of transportation and reassembled on site for ease of installation.

[0035] By manufacturing the segmented wind turbine blade 100 in an unsegmented blade mold, the method of the present disclosure can uniquely eliminate the tolerance chain that can make it difficult to align the sections during on-site assembly.

[0036] The method of the present disclosure does not incur additional manufacturing expenses due to the use of an unsegmented blade mold.

[0037] In certain embodiments, as Figure 3 and Figure 4 shown, the spar socket 31 has an outer socket spar 311 and an inner socket spar 312, and the protruding spar 32 is located between the outer socket spar 311 and the inner socket spar 312. Accordingly, the step S11 of laying the one or more material layers may include: wrapping the inner socket spar 312 around the protruding spar 32 before co-infusion.

[0038] The laminate adapter 31 and the protruding laminate 32 are co-potted in the blade mold. The laminate adapter 31 and the protruding laminate 32 are processed in this specific manner so that the two components can be detached after demolding and reassembled after being transported to the wind farm site. Therefore, the method of the present disclosure may further include: during the process of laying one or more material layers in step S11, adding a processing material between the laminate adapter 31 and the protruding laminate 32 to facilitate the detachment of the laminate adapter 31 and the protruding laminate 32. In an alternative embodiment, adding the processing material between the laminate adapter 31 and the protruding laminate 32 may include: covering the protruding laminate 32 with the processing material.

[0039] The processing material of the present disclosure may have surface tension characteristics and bonding characteristics, which enable the protruding laminate 32 and the laminate adapter 31 to be detached. Therefore, a segmented wind turbine blade 100 that can be reassembled can be obtained. The processing material may include, for example, Teflon.

[0040] In some embodiments, the method of the present disclosure may further include: removing the processing material from the protruding laminate 32 before reassembly.

[0041] In one embodiment, the blade mold for manufacturing the segmented wind turbine blade 100 according to the present disclosure may include two half-molds. Therefore, in steps S11 and S12, one or more material layers may be laid and co-potted in the two half-molds respectively to form the suction-side blade shell and the pressure-side blade shell respectively. The laminate adapter 31 and the protruding laminate 32 are placed in each of the two half-molds. Therefore, the laminate adapter 31 and the corresponding protruding laminate 32 on the suction side, and the laminate adapter 31 and the corresponding protruding laminate 32 on the pressure side are formed.

[0042] In this case, the method of the present disclosure may further include: closing the two half-molds; and assembling the suction-side blade shell and the pressure-side blade shell together to form a single-piece wind turbine blade 100.

[0043] The method of the present disclosure can manufacture the segmented wind turbine blade 100 in a single-piece form in the blade mold and can demold the blade in a single-piece form. Therefore, the method of the present disclosure has a lower manufacturing cost.

[0044] In the description of this specification, terms such as "example", "some examples", "illustrative example", "embodiment", "specific example", or "certain examples" are intended to mean that a particular feature, structure, material, or property described in combination with an embodiment or example is included in at least one embodiment or example of the present disclosure. In this specification, the schematic expressions of the above terms do not necessarily refer to the same embodiment or example. In addition, the above-described particular features, structures, materials, or properties may be combined in a suitable manner in one or more embodiments or examples.

[0045] The above disclosure is only a schematic illustration of the examples of the present disclosure and does not impose any limitation on the present disclosure. Any modification, equivalent replacement, or adjustment made within the spirit and principle of the present disclosure shall fall within the scope of the present disclosure.

Claims

1. A method of manufacturing a segmented wind turbine blade, the segmented wind turbine blade comprising at least a first blade segment and a second blade segment, the method comprising: Laying one or more material layers in a blade mold, the one or more material layers including a spar cap of the first blade segment and a protruding spar of the second blade segment, the spar cap receiving the protruding spar; Co-injecting the one or more material layers together in the blade mold to form a single-piece wind turbine blade; Demolding the single-piece wind turbine blade from the blade mold; And Separating the spar cap from the protruding spar to form the first blade segment with the spar cap and the second blade segment with the protruding spar, thereby forming the segmented wind turbine blade, and when assembling the segmented wind turbine blade on site, the first blade segment and the second blade segment can be reassembled by connecting the spar cap and the protruding spar.

2. The method according to claim 1, wherein, The spar cap has an outer sleeve spar and an inner sleeve spar, and the protruding spar is located between the outer sleeve spar and the inner sleeve spar.

3. The method according to claim 2, wherein Laying the one or more material layers includes: Wrapping the inner sleeve spar around the protruding spar before co-injecting.

4. The method according to claim 1, further comprising: During the process of laying the one or more material layers, adding a treatment material between the spar cap and the protruding spar, the treatment material facilitating the detachment of the spar cap and the protruding spar.

5. The method according to claim 4, wherein Adding the treatment material between the spar cap and the protruding spar includes: Covering the protruding spar with the treatment material.

6. The method according to claim 5, further comprising: Removing the treatment material from the protruding spar before reassembly.

7. The method according to claim 4, wherein The treatment material includes Teflon.

8. The method according to claim 1, wherein, The blade mold includes two half-molds, and laying the one or more material layers in the mold and co-injecting the one or more material layers together in the mold includes: Laying and co-injecting the one or more material layers in the two half-molds respectively to form a suction side blade shell and a pressure side blade shell respectively, wherein the spar cap and the protruding spar are placed in each of the two half-molds.

9. The method according to claim 8, further comprising: Closing the two half-molds; And Assembling the suction side blade shell and the pressure side blade shell together to form the single-piece wind turbine blade.

10. The method according to claim 1, wherein, The one or more material layers include one or more fiber layers.

11. The method according to claim 10, wherein, The one or more fiber layers include at least one of a glass fiber layer and a carbon fiber layer.

12. The method according to claim 10, wherein The one or more material layers further include one or more core material layers made of polymer foam or balsa wood.

13. The method according to claim 1, wherein co-injecting the one or more material layers together in the blade mold includes: Co-injecting the one or more material layers with a liquid resin in the blade mold to cure the one or more material layers.

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