Method for producing blade root, root, root semi-finished product, blade and turbine

Abstract

The present application relates to a dry fibre fabric insert for embedding in a shell structure of a wind turbine blade and a method of manufacturing the dry fibre fabric insert wherein the manufacturing method comprises arranging two or more bushings and alternately arranging one or more dry fibre fabric inserts between the bushings, and the lining and the dry fiber fabric embedded part are fixedly connected together. The present application also relates to a wind turbine rotor blade comprising a plurality of dry fibre fabric inserts, and a method of manufacturing the blade.

Description

Technical Field

[0001] The present application relates to an insert for embedding in a housing structure of a wind turbine blade and a method of manufacturing the insert. The present application also relates to a wind turbine rotor blade including a plurality of such inserts and a method of manufacturing the blade. Background Art

[0002] Wind energy, as a renewable and clean energy source, is increasingly favored due to its low pollution. Wind turbine blades are carefully designed to maximize their efficiency, especially for offshore wind turbine blades with lengths exceeding 80 meters and even reaching over 100 meters. This increases the weight and cost of their components, particularly the size and weight of the wind turbine blades.

[0003] Traditional wind turbines consist of a tower, with a hub or nacelle located at the top of the tower. Inside the hub is the motor of the wind turbine, and the wind turbine blades are connected to the hub.

[0004] Wind turbine blades are typically made of fiber-reinforced polymer materials and are usually manufactured using two molds. Among them, the fiber-reinforced polymer material is placed in the mold and cured to form two wind turbine blade shells, and then these two wind turbine blade shells are assembled into a wind turbine blade.

[0005] The root region of the wind turbine blade, that is, the part where the blade is connected to the hub of the wind turbine, usually has a circular cross-section. The circular end face of the rotor blade root is usually connected or fixed to a matching circular metal flange on the hub of the wind turbine by bolts or threaded rods. Importantly, this connection between the wind turbine blade and the hub of the wind turbine can transmit and withstand large dynamic forces over a relatively long period of time. The typical root region of the wind turbine blade includes fiber material layers forming an outer layer and an inner layer, and a bushing for fastening the bolts or threaded rods of the hub between the fiber material layers is provided in the inner layer.

[0006] As the size of the wind turbine blade increases, the weight of the wind turbine blade and the outer diameter of the root of the wind turbine blade also increase accordingly. This increases the requirements for the strength or load-bearing capacity of the connection between the wind turbine blade and the nacelle or hub of the wind turbine, thus requiring an increase in the amount of reinforcing material used and the number of main bolts distributed circumferentially along the root end.

[0007] Traditionally, individually manufactured rigid pultruded profiles are placed between each pair of adjacent bushings, so that the bushings are separated from each other by the rigid pultruded profiles and are arranged between two layers of fiber materials and then consolidated.

[0008] EP3697603 discloses various cross-sectional profiles of a dog-bone-shaped profile arranged between root bushings, where an interval is formed between the side surface of the profile and the outer surface of the adjacent bushing. In these embodiments, the dog-bone-shaped profile can be formed from a single piece or multiple sub-pieces.

[0009] However, this method has drawbacks because the connection between the prefabricated rigid pultruded profile and the surrounding fiber material is limited, so the provided interface is relatively weak compared to the strength of the surrounding fiber material. This weak interface between the bushing and the separately manufactured rigid profile creates a weak point in the material of the root section of the wind turbine blade, posing a risk of disconnection, which may in turn lead to cracks in the root section of the wind turbine blade.

[0010] WO2023 / 139017 discloses a method for manufacturing a fiber material element for embedding between bushings in the shell structure of a wind turbine rotor blade. The element is made by arranging fiber material and an adhesive on a mold plate between two movable bushings, where one or both of the bushings can be pushed against the fiber material to compact and form the fiber material, and then the fiber material is at least partially hardened into a preform that is strong or rigid enough to maintain its shape, so as to be transferred from a first mold to the blade shell mold and placed in the mold between the bushings during the production of the wind turbine blade shell.

[0011] However, none of these prior arts solve the derived weakness of the connection between the bushing and the surrounding material, while enabling the application of a simple and flexible manufacturing method in which the design of the root section of the wind turbine blade can be adjusted without significant changes to the production equipment and process.

[0012] A separate step of manufacturing any type of preform to be inserted between the bushings in the root section of the wind turbine blade is an additional step in the manufacturing process, increasing complexity and cost. The prefabricated rigid preform needs to be shaped and pre-treated to be strong enough to be transferred from the manufacturing mold to the blade shell mold and placed between the bushings. In addition, the prefabricated preform needs to be handled with great care because any unwanted impurities or any dents or other changes on the surface of the prefabricated preform may affect the connection and the connection strength.

[0013] Finally, since the rigid preform is prefabricated, there is limited possibility of modification, whether modifying the preform individually or in smaller groups of preforms. This results in a lack of flexibility because all bushings will be separated by the exactly same embedded prefabricated rigid preforms, such that the entire circumference of the root section of the wind turbine blade will have the same characteristics, which will also inhibit variations in blade design because the entire root section will have to be replaced.

[0014] Generally speaking, a solution is needed that can provide a stronger root section of a wind turbine blade, especially in terms of the strength of the section of the wind turbine blade that includes the root bushing, while also providing a simpler and more reliable production method and enhancing the flexibility of the design of the root section of the wind turbine blade. The strength of the section of the wind turbine blade that includes the root bushing directly affects the required diameter size of the root bolt of the wind turbine blade. A stronger root bushing section will enable the root bolts used for large rotor blades to have a smaller circular diameter.

[0015] Object of the Invention

[0016] An object of the present application is to provide a method for manufacturing a root section or a part of a root section, a semi-finished root section or a part of a root section, a wind turbine blade housing or a wind turbine blade, which overcomes the above problems of the prior art or at least provides an alternative solution.

[0017] Another object of the present application is to provide a method for manufacturing a root section or a part of a root section, a semi-finished root section or a part of a root section, a wind turbine blade housing or a wind turbine blade, which achieves a stronger connection between the bushing and the surrounding fibrous fabric material.

[0018] Yet another object of the present application is to provide a method for manufacturing a root section or a part of a root section, a semi-finished root section or a part of a root section, a wind turbine blade housing or a wind turbine blade, which enables easier laying and manufacturing of the blade root reinforcement. Summary of the Invention

[0019] An object of the present application is achieved by a method for manufacturing a root section or a part of a root section of a wind turbine blade housing, the method comprising:

[0020] a. arranging two or more bushings for directly or indirectly connecting the root section of the wind turbine blade to the hub of the wind turbine in a preset manner;

[0021] b. alternately arranging one or more dry fiber fabric inserts between each pair of adjacent bushings; and

[0022] c. Consolidate the bushing and the dry fiber fabric insert together using an infusion process.

[0023] The method provided by the present application provides a simple and effective way to produce a root section or a part of the root section of a wind turbine blade shell, resulting in a more uniform structure. Among them, the interface between the fiber fabric material between the bushings and the bushings is stronger than the interface between the fiber fabric material between the bushings and the bushings in the prior art.

[0024] The inventors of the present application have found that the uniform structure of the root section of a wind turbine blade achieved by co-infusion of all the components of the root section in one step results in a more complex fracture surface. The connection between the dry fiber fabric insert of the present application and the bushing surface does not create the same straight joint line as the joint between the prefabricated pultrusion and the bushing, because the joint line between the components will be irregular, resulting in a more complex fracture structure and thus achieving a stronger bond. On the other hand, the straight surface of the prefabricated profile will provide a straight fracture surface, resulting in the formation of long straight cracks along the joint line. The complex fracture surface provided by the present application restricts the propagation of cracks because the irregular surface inhibits the formation of long and straight cracks and achieves a stronger bond.

[0025] In an embodiment of the present application, a method for manufacturing a root section or a part of the root section of a wind turbine blade shell is provided, wherein the dry fiber fabric insert has been folded and formed before being arranged between the bushings and consolidated with the bushings through an infusion process.

[0026] By cutting off the separate prefabrication step of the preform between the bushings to be inserted into the root section of the wind turbine blade, the present application provides a simpler and cheaper manufacturing process. The prefabricated rigid preform needs to be formed and pre-treated to make it strong enough to be transferred from the manufacturing mold to the blade shell mold and placed between the bushings. The present application provides a method for manufacturing a root section or a part of the root section of a wind turbine blade shell, wherein the folded fiber fabric sheet of the dry fiber fabric is arranged between adjacent bushings.

[0027] An object of the present application is achieved by a semi-finished component of a root section of a wind turbine blade shell, the semi-finished component including two or more bushings, wherein the two or more bushings are arranged in a preset manner and dry fiber fabric inserts are alternately arranged between each pair of adjacent bushings, and wherein the two or more bushings and the fiber fabric inserts are consolidated together through an infusion process.

[0028] The semi-finished component of the root section of the wind turbine blade shell provided by the present application includes a more uniform structure, wherein the interface between the fiber fabric material between the bushings and the bushings is stronger than the interface in the prior art.

[0029] In one embodiment of the present application, a method of manufacturing a root section or a part of a root section of a wind turbine blade housing is provided. A surface such as a mold (such as a wind turbine blade housing mold) is provided, a bushing is directly disposed on the surface, and then dry fiber fabrics are alternately disposed between each pair of adjacent bushings, and the bushings and the dry fiber fabric inserts are consolidated together.

[0030] In one embodiment of the present application, a method of manufacturing a root section or a part of a root section of a wind turbine blade housing is provided. A surface such as a mold (such as a wind turbine blade housing mold) is provided, and a fiber fabric layer is disposed on the surface, thereby constructing a fiber fabric cushion or pad for disposing the bushing and the dry fiber fabric inserts thereon.

[0031] Here, the term "fiber fabric layer" is defined as an amount of fiber fabric covering the surface, thereby constructing a separation portion between the surface and the bushing and the dry fiber fabric inserts. Here, the term "fiber fabric layer" is defined as any suitable amount of fiber fabric, such as a single piece of fiber fabric, such as multiple pieces of fiber fabric stacked on top of each other to produce a multi-layer fiber fabric layer, or any other undefined mass of fiber fabric disposed on the surface.

[0032] Here, the term "fiber fabric cushion" used in this specification is defined as any amount of fiber fabric. The bushing and the dry fiber fabric inserts can be disposed on a single piece of fiber fabric, such as multiple pieces of fiber fabric stacked on top of each other to produce a multi-layer fiber fabric layer, or any other undefined mass of fiber fabric.

[0033] In one embodiment of the present application, a method of manufacturing a semi-finished component of a root section of a wind turbine blade housing is provided. The semi-finished component includes two or more bushings, wherein the two or more bushings are disposed on a cushion of a fiber fabric layer in a preset manner, and fiber fabric inserts are alternately disposed between each pair of adjacent bushings.

[0034] In one embodiment of the present application, a semi-finished component of a root section of a wind turbine blade housing is provided. The semi-finished component includes two or more bushings, wherein the two or more bushings are disposed on a cushion of a fiber fabric layer in a preset manner, fiber fabric inserts are alternately disposed between each pair of adjacent bushings, and the two or more bushings, the fiber fabric inserts, and the fiber fabric cushion are consolidated together by an infusion process.

[0035] In one embodiment of the present application, a method of manufacturing a root section or a portion of a root section of a wind turbine blade shell is provided. A surface is provided, such as a mold, a wind turbine blade shell mold, a root section mold of a wind turbine blade shell. Wherein, a fiber fabric layer is arranged on the surface, thereby constructing a fiber fabric cushion layer. A bushing is arranged on the fiber fabric cushion layer, and then dry fiber fabrics are alternately arranged between each pair of adjacent bushings, and the fiber fabric cushion layer, the bushing and the dry fiber fabric inserts are consolidated together.

[0036] In one embodiment of the present application, a method of manufacturing a root section or a portion of a root section of a wind turbine blade shell is provided, wherein the fiber fabric layer is arranged on alternately arranged bushings and fiber fabric inserts.

[0037] Here, the term "fiber fabric layer" is defined as an amount of fiber fabric arranged above or on alternately arranged bushings and fiber fabric inserts. Here, the term "fiber fabric layer" is defined as any suitable amount of fiber fabric, such as a single piece of fiber fabric, such as multiple pieces of fiber fabric stacked on top of each other to produce a multi-layer fiber fabric layer, or any other undefined mass of fiber fabric arranged on alternately arranged bushings and fiber fabric inserts.

[0038] In one embodiment of the present application, a method of manufacturing a root section or a portion of a root section of a wind turbine blade shell is provided, wherein the fiber fabric layer is arranged on alternately arranged bushings and fiber fabric inserts, thereby producing a fiber fabric covering layer above or on the alternately arranged bushings and dry fiber fabric inserts.

[0039] Here, the term "fiber fabric covering layer" as used in this specification is defined as any amount of fiber fabric arranged on top of alternately arranged bushings and dry fiber fabric inserts, such as a single piece of fiber fabric, such as multiple pieces of fiber fabric stacked on top of each other to produce a multi-layer fiber fabric layer, or any other undefined mass of fiber fabric. Therefore, the term "fiber fabric covering layer" as used in this specification can be a thin fiber fabric layer or a thick fiber fabric layer.

[0040] In an embodiment of the present application, a method for manufacturing a root section or a part of the root section of a wind turbine blade housing is provided. A surface is provided, such as a mold, a mold of a wind turbine blade housing, or a mold of the root section of a wind turbine blade housing. A fiber fabric layer is arranged on the surface, thereby constructing a fiber fabric cushion layer. A bushing is arranged on the fiber fabric cushion layer, and then dry fiber fabrics are alternately arranged between each pair of adjacent bushings. Then, a fiber fabric layer is arranged on the alternately arranged bushings and fiber fabric inserts placed on the fiber fabric cushion layer, thereby generating a fiber fabric covering layer that at least partially covers the alternately arranged bushings and fiber fabric inserts. Then, the fiber fabric cushion layer, the bushings, the dry fiber fabric inserts, and the fiber fabric covering layer are consolidated together.

[0041] In an embodiment of the present application, a semi-finished component of the root section of a wind turbine blade housing is provided. The semi-finished component includes two or more bushings arranged in a preset manner, wherein fiber fabric inserts are alternately arranged between each pair of adjacent bushings and are sandwiched between a fiber fabric cushion layer and a fiber fabric covering layer, and wherein the two or more bushings, the fiber fabric inserts, the fiber fabric cushion layer, and the fiber fabric covering layer are consolidated together by an infusion process.

[0042] In an embodiment of the present application, a method for manufacturing a root section or a part of the root section of a wind turbine blade housing is provided, wherein the fiber fabric material between the bushings and the bushings themselves are consolidated together in a single process. In another embodiment of the present application, a method for manufacturing a root section or a part of the root section of a wind turbine blade housing is provided, wherein the fiber fabric material between the bushings, the fiber material below the bushings, and the bushings themselves are consolidated together in a single process. In an embodiment of the present application, a method for manufacturing a root section or a part of the root section of a wind turbine blade housing is provided, wherein the fiber fabric material between the bushings, the fiber fabric material below the bushings, the fiber fabric material below the bushings, and the bushings themselves are consolidated together in a single process.

[0043] In an embodiment of the present application, a method for manufacturing a root section or a part of the root section of a wind turbine blade housing is provided, wherein the fiber fabric material between and / or below and / or above the bushings and the bushings themselves are consolidated together in a single process.

[0044] Accordingly, the present application provides a method for manufacturing a root section or a part of a root section of a wind turbine blade housing, wherein the fibrous fabric material between and / or below and / or above the bushings and the bushings themselves are consolidated together in a single process to construct a more uniform and unified consolidated structure with increased strength. In addition, the present application provides a flexible method for manufacturing a root section or a part of a root section of a wind turbine blade housing, wherein the properties of the manufactured root section or a part of a root section of the wind turbine blade housing can be changed by varying the amount and / or properties of the fibrous fabric material used in the fibrous fabric insert and / or fibrous fabric cushion layer and / or fibrous fabric cover layer. In one embodiment of the present application, there is provided a flexible method for manufacturing a root section or a part of a root section of a wind turbine blade housing, wherein the properties of the manufactured root section or a part of a root section of the wind turbine blade housing, such as load-bearing strength, interface strength between the bushings and the surrounding fibrous fabric material, distance between the bushings, weight, and volume, can be changed by varying the amount and / or properties of the fibrous fabric material used in the fibrous fabric insert and / or fibrous fabric cushion layer and / or fibrous fabric cover layer.

[0045] In one embodiment of the present application, there is provided a method for manufacturing a root section or a part of a root section of a wind turbine blade housing. The method includes the step of providing one or more fibrous fabric inserts. In one embodiment of the present application, there is provided a method for manufacturing a root section or a part of a root section of a wind turbine blade housing. The method includes the step of providing one or more fibrous fabric inserts, wherein each fibrous fabric insert is constructed by one or more (such as two or more) fibrous fabric sheets, the fibrous fabric sheets being configured as a laminate having a preset shape, and then folding the laminate into a fibrous fabric insert having a preset three-dimensional geometry.

[0046] In another embodiment of the present application, there is provided a method for manufacturing a root section or a part of a root section of a wind turbine blade housing. The method includes the step of providing one or more fibrous fabric inserts, wherein each fibrous fabric insert is constructed by one or more (such as two or more) fibrous fabric sheets, the fibrous fabric sheets being configured as a laminate having a preset shape, and then folding the laminate into a fibrous fabric insert having a preset three-dimensional geometry in a specific preset folding manner.

[0047] By different folding methods, the three-dimensional geometry of the obtained fiber fabric insert can be changed, such as the length of the obtained fiber fabric insert and / or the height of the obtained fiber fabric insert and / or the width of the obtained fiber fabric insert and / or the shape of the obtained fiber fabric insert. In addition, by different folding methods, physical properties can be changed, such as the density of the obtained fiber fabric insert.

[0048] In one embodiment of the present application, a method for manufacturing a root section or a part of the root section of a wind turbine blade housing is provided. The method includes: the step of providing one or more fiber fabric inserts, wherein each fiber fabric insert is constructed by one or more (such as two or more) fiber fabric sheets, and the fiber fabric sheets are configured to form a laminate with a preset shape, and the shape of the laminate can be set by cutting one or more (such as two or more) fiber fabrics and / or tapering one or more (such as two or more) fiber fabrics.

[0049] In one embodiment of the present application, a method for manufacturing a root section or a part of the root section of a wind turbine blade housing is provided. The method includes: the step of providing one or more fiber fabric inserts, wherein each fiber fabric insert is constructed by one or more (such as two or more) fiber fabric sheets, and the fiber fabric sheets are configured to form a laminate with a preset shape, and the shapes of one or more (such as two or more) fiber fabric sheets are independently set, and each individual fiber fabric sheet is individually cut and / or tapered.

[0050] In another embodiment of the present application, a method for manufacturing a root section or a part of the root section of a wind turbine blade housing is provided. The method includes: the step of providing one or more fiber fabric inserts, wherein each fiber fabric insert is constructed by one or more (such as two or more) fiber fabric sheets, and the fiber fabric sheets are configured to form a laminate with a preset shape, wherein one or more (such as two or more) fiber fabric sheets are co-molded, and one or more (such as two or more) fiber fabric sheets are co-cut and / or tapered.

[0051] In another embodiment of the present application, a method for manufacturing a root section or a part of the root section of a wind turbine blade housing is provided. The method includes the step of providing one or more fiber fabric inserts, wherein each fiber fabric insert is constructed by one or more (such as two or more) fiber fabric sheets, and the fiber fabric sheets are configured to form a laminate having a preset shape. The formation process is mixed to implement, for example, two or more fiber fabric sheets, such as setting the shape of individual fiber fabric sheets by cutting and / or tapering individual fiber fabric sheets, and / or setting the shape of one or more (such as two or more) fiber fabric sheets by jointly cutting and / or tapering one or more (such as two or more) fiber fabric sheets.

[0052] In one embodiment of the present application, a method for manufacturing a root section or a part of the root section of a wind turbine blade housing is provided. The method includes the step of providing one or more fiber fabric inserts, wherein each fiber fabric insert is constructed by a group of one or more (such as two or more) fiber fabric sheets, and the group of one or more (such as two or more) fiber fabric sheets includes at least one or more (such as two) fiber fabric sheets having different properties.

[0053] By using sheets with different properties, the physical properties of the fiber fabric inserts can be designed individually and / or in groups and / or jointly for each individual fiber fabric insert, thereby providing a highly flexible method for manufacturing the root section or a part of the root section of a wind turbine blade, wherein the physical properties of the manufactured root section or a part of the root section can be easily designed and changed.

[0054] One embodiment of the present application provides a flexible method for manufacturing the root section or a part of the root section of a wind turbine blade, wherein the properties of the manufactured root section or a part of the root section can be easily designed and changed.

[0055] In one embodiment, the present application provides a flexible method for manufacturing a root section or a portion of a root section of a wind turbine blade. By varying the number of fibrous fabric sheets used to construct the fibrous fabric insert and thereby varying the number of layers of the constructed fibrous fabric insert, the properties of the manufactured root section or portion of the root section can be easily designed and changed. Among them, for each individual fibrous fabric insert used to manufacture the root section or a portion of the root section of a wind turbine blade, the number of fibrous fabric sheets utilized can be independently varied, and / or for all fibrous fabric inserts used to manufacture the root section or a portion of the root section of a wind turbine blade, the number of fibrous fabric sheets utilized can be varied jointly, and / or for the fibrous fabric inserts used to manufacture the root section or a portion of the root section of a wind turbine blade, the number of fibrous fabric sheets utilized can be partially varied. And among them, any combination of variations in the number of fibrous fabric sheets used to construct the fibrous fabric insert and thereby construct the layers within the fibrous fabric insert can be achieved, including: manufacturing a root section or a portion of a root section of a wind turbine blade, wherein all the fibrous fabric inserts used include different numbers of fibrous fabric sheets and thereby different numbers of layers, and / or manufacturing a root section or a portion of a root section of a wind turbine blade, wherein all the fibrous fabric inserts used include the same number of fibrous fabric sheets and thereby the same number of layers, and / or manufacturing a root section or a portion of a root section of a wind turbine blade, wherein two or more groups including one or more fibrous fabric inserts include the same number of fibrous fabric sheets and thereby utilize the same number of layers.

[0056] In another embodiment, the present application provides a flexible method for manufacturing a root section or a part of a root section of a wind turbine blade. By changing the type and / or properties of the fiber fabric sheets used to construct the fiber fabric inserts, such as by changing the individual fiber fabric inserts used to manufacture the root section or a part of the root section of the wind turbine blade, the properties of the manufactured root section or a part of the root section can be easily designed and changed, and / or by changing the type and / or properties of more than one sheet and / or by changing the type and / or properties of all the fiber fabric sheets used to construct the one individual fiber fabric insert, such as by changing the type and / or properties of one sheet and / or by changing the type and / or properties of more than one sheet and / or by changing the type and / or properties of all the fiber fabric sheets of the fiber fabric used to manufacture a group of more than one individual fiber fabric inserts for manufacturing the root section or a part of the root section of the wind turbine blade, such as by changing the type and / or properties of one sheet and / or by changing the type and / or properties of more than one sheet and / or by changing the type and / or properties of all the fiber fabric sheets of the fiber fabric used to manufacture all the fiber fabric inserts used for manufacturing the root section or a part of the root section of the wind turbine blade.

[0057] In another embodiment, the present application provides a flexible method for manufacturing a root section or a part of a root section of a wind turbine blade. By changing the shape of the fiber fabric insert, the properties of the root section or a part of the root section being manufactured can be easily designed and changed, wherein the shape of the fiber fabric insert can be changed in different ways, such as independently, wherein the shape of an individual fiber fabric insert used to manufacture the root section or a part of the root section of the wind turbine blade is changed by changing the cutting applied to the fiber fabric laminate and / or by changing the tapering applied to the fiber fabric laminate and / or by changing the stitching applied to the fiber fabric laminate, such as partially, wherein the shape of a group of more than one individual fiber fabric inserts used to manufacture the root section or a part of the root section of the wind turbine blade is changed by changing the cutting applied to the fiber fabric laminates in the group and / or by changing the tapering applied to the fiber fabric laminates in the group and / or by changing the stitching applied to the fiber fabric laminates in the group; wherein the shape of all the fiber fabric inserts used to manufacture the root section or a part of the root section of the wind turbine blade is changed by changing the cutting applied to the fiber fabric laminate and / or by changing the tapering applied to the fiber fabric laminate and / or by changing the stitching applied to the fiber fabric laminate.

[0058] One embodiment of the present application provides a flexible method for manufacturing a root section or a part of a root section of a wind turbine blade, wherein by changing the shape of the fiber fabric insert, the characteristics of the root section or the part of the root section being manufactured can be easily designed and changed, and wherein changing the shape of the fiber fabric insert is achieved by changing the folding of the fiber fabric laminate for the fiber fabric insert (such as by changing the folding method for folding the fiber fabric laminate).

[0059] The folding method will directly affect physical properties such as the density and load-bearing properties of the constructed fiber fabric insert, as well as three-dimensional geometries such as the shape and size of the constructed fiber fabric insert.

[0060] In one embodiment of the present application, a flexible method for manufacturing a root section or a part of a root section of a wind turbine blade is provided, wherein by alternating the folding methods for folding the fiber fabric laminate, the characteristics of the root section or the part of the root section being manufactured can be easily designed and changed.

[0061] In one embodiment of the present application, a flexible method for manufacturing a root section or a part of a root section of a wind turbine blade is provided, wherein by changing the folding method for folding the fiber fabric laminate, the characteristics of the manufactured root section or the part of the root section can be easily designed and changed.

[0062] In one embodiment of the present application, a flexible method for manufacturing a root section or a part of a root section of a wind turbine blade is provided, wherein by changing the folding method for folding the fiber fabric laminate, the characteristics of the manufactured root section or the part of the root section can be easily designed and changed. Among them, different variations or changes are achieved, such as independent variations, wherein a single fiber fabric insert is changed by folding a single fiber fabric laminate in different folding methods (such as partial folding), wherein a group of more than one fiber fabric insert is changed by folding a group of more than one fiber fabric laminate according to different methods (such as jointly), and wherein all fiber fabric inserts are changed by folding all fiber fabric inserts according to different methods.

[0063] It should be understood that any variations and combinations of flexible changes can be achieved, wherein the fiber fabric inserts for manufacturing the root section or a part of the root section of the wind turbine blade can all be different or all the same, or any combination in between.

[0064] In one embodiment of the present application, a method for manufacturing a semi-finished component of a root section of a wind turbine blade housing is provided, wherein the semi-finished component includes two or more bushings arranged in a preset manner, and fiber fabric inserts are alternately arranged between each pair of adjacent bushings.

[0065] In one embodiment of the present application, a semi-finished component of a root section of a wind turbine blade housing is provided. The semi-finished component includes two or more bushings arranged on a fiber fabric cushion layer in a preset manner, and a fiber fabric covering layer arranged on the fiber fabric inserts and the bushings; wherein the fiber fabric inserts are alternately arranged between each pair of adjacent bushings; and wherein the fiber fabric cushion layer, the fiber fabric inserts, and the fiber fabric covering layer are consolidated together by an infusion process. Description of the Drawings

[0066] The embodiments are described below with reference to the drawings. The same reference numerals denote the same elements. Therefore, for the description of each drawing, the same elements will not be described in detail again. It should also be noted that the drawings are only intended to facilitate the description of the embodiments. They are not an exhaustive description of the claimed invention or a limitation on the scope of the claimed invention. In addition, the illustrated embodiments do not necessarily have all aspects or advantages shown. Aspects or advantages described in connection with a particular embodiment are not necessarily limited to that embodiment and may be implemented in any other embodiment, even if not so shown or explicitly described as such.

[0067] Example embodiments of the present application are described in the drawings, wherein:

[0068] Figure 1 A wind turbine is shown;

[0069] Figure 2 A wind turbine blade housing mold is shown;

[0070] Figure 3 A wind turbine blade is shown;

[0071] Figure 4 A root section of a wind turbine blade is shown;

[0072] Figure 5 A picture of a fiber fabric laminate according to the present application;

[0073] Figures 6a to 6b Two pictures showing a fiber fabric laminate according to the present application and the folding of the fiber fabric laminate;

[0074] Figure 7 A picture of a consolidated portion of a root section of a wind turbine blade housing according to the present application;

[0075] Figures 8a to 8dShows different folding methods according to the present application. Detailed implementation mode

[0076] Exemplary embodiments of the present application will be described in detail below with reference to the accompanying drawings. The embodiments may have different forms and should not be construed as limited to the descriptions set forth herein. Therefore, these embodiments are described below only with reference to the accompanying drawings to explain various aspects of the present application.

[0077] Throughout the specification, when an element is referred to as "connected" to another element, the element may be "directly connected" to the other element, or "electrically connected", "fluidly connected" or "communicatively connected" to the other element, and there may be one or more intermediate elements therebetween.

[0078] The terms used herein are for the purpose of describing particular embodiments only and are not intended to limit the present application. As used herein, the terms "comprising" and / or "including" specify the presence of the stated features, integers, steps, operations, elements, components and / or groups, but do not preclude the presence or addition of one or more other features, such as integers, steps, operations, elements, components and / or combinations thereof.

[0079] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. It should also be understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

[0080] Figure 1 Shows a conventional wind turbine 1, which includes wind turbine blades 3, a hub 2 and a tower 4. A motor (not shown) is provided inside the hub 2.

[0081] Figure 2 Shows a conventional wind turbine blade housing mold 15 including a root section 16, Figure 3 Shows a conventional wind turbine blade 3 including a root section 8. As Figure 3 and Figure 4 shown, the profile of the wind turbine blade varies along the length of the blade, wherein the root sections 8, 16 have a circular cross-section.

[0082] Figure 4 Shows the root section 8 of the housing 5 of the wind turbine blade 3. The end of the root section 8 generally has a circular cross-section and includes a fiber material 6, wherein a plurality of bushings 7 are embedded in the fiber material 6.

[0083] As explained above, a conventional root section of a wind turbine blade typically consists of an inner layer and an outer layer, which generally include a fiber-reinforced fabric (usually made of glass fibers and / or carbon fibers) and a resin (such as epoxy resin, polyester or vinyl ester resin). Interposed between the two layers is an elongate bushing, which is usually disposed on the inner layer and is separated by a preformed profile or is disposed on the inner layer as a preformed element, the preformed element including a bushing embedded in a pultruded element.

[0084] Figure 5 is a picture of the laminate 12 of fiber fabrics according to the present application, as Figure 5 shown, the laminate is formed by cutting and / or tapering so as to be adapted to fold between the bushings 7.

[0085] Figure 6a is a picture of the folded laminate 12, whereby a dry fiber fabric insert 20 disposed between two bushings 7 is constructed, and as shown in the picture, the laminate has been formed by cutting and / or tapering.

[0086] Figure 6b is a picture of the folded laminate 12, whereby a dry fiber fabric insert 20 disposed between two bushings 7 is constructed, and as shown in the picture, the laminate 12 has been folded to produce a profile including a top section 17 and a bottom section 18 that are wider than a relatively small middle section 19, for aligning the folded laminate 12 with the profile of the bushing 7.

[0087] Figure 7 is a picture of a cross-section of the root section of a wind turbine blade housing according to the present application, showing a seamless structure of the consolidated fiber fabric material 6 surrounding the embedded bushing 7.

[0088] Figure 8a 、 Figure 8b 、 Figure 8c and Figure 8d show different embodiments of the folding method 13.

[0089] Experiment 1

[0090] An experiment is performed to evaluate the shear strength of a part of the root section of a wind turbine blade manufactured according to the provided method.

[0091] Two samples are produced, a baseline sample having a standard glass pultruded profile between metal bushing inserts, and a corresponding sample produced according to the present application having a dry fiber fabric insert between metal bushing inserts.

[0092] Except for the difference in the insert or preform between the metal bushings, the two samples follow the same production process and use the same resin and infusion method.

[0093] After producing two samples, 20 - mm incisions were made from each sample for testing. In the samples, each test incision sample with a 20 - mm thickness included three metal bushings / inserts.

[0094] To compare the static strength and fatigue strength of the provided bond, two incisions were subjected to simple shear tests in the form of static shear tests and fatigue compression - compression shear tests.

[0095] The two outer metal inserts had fixed boundary conditions, while the central metal insert was free to move, so that a load could be applied to the central insert. The load was applied using a universal testing machine. The applied load was measured using a load cell attached to the tensile machine.

[0096] The test results are shown in Table 1. Incision 1 was the incision of a baseline sample produced using a standard glass pultrusion profile, while incision 2 was the incision of a sample produced according to the present application. The actual measured strength is not shown in Table 1 because the measured strength of the baseline sample was set as the baseline with a value of 1.

[0097] Table 1 Shear Strength Measurements

[0098] Test Cut 1 Cut 2 Static shear strength coefficient 1 1.89 Fatigue shear strength coefficient at 2 million cycles 1 1.26

[0099] As shown in Table 1, the shear strength was significantly improved using the method provided in the present application, and the results clearly show that the present application achieved excellent strength.

[0100] List of Reference Numerals:

[0101]

[0102]

Claims

1. A method for manufacturing a root section or a part of a root section of a wind turbine blade shell, characterized in that, The method includes: a. Arranging two or more bushings for directly or indirectly connecting the root section of a wind turbine blade to the hub of the wind turbine in a preset manner; b. Alternately arranging one or more dry fiber fabric inserts between each pair of adjacent bushings; and c. Consolidating the bushings and the dry fiber fabric inserts together using an infusion process.

2. The method according to claim 1, wherein The dry fiber fabric inserts used in step c are folded into a preset shape to align with the shape of the pair of adjacent bushings.

3. The method according to claim 1, characterized in that, Step a includes: a.i. Providing a surface adapted to support the fiber fabric and the bushings during the infusion process; a.ii. Arranging the fiber fabric on the surface, thereby creating a cushion layer of the fiber fabric on the surface; and a.iii. Arranging two or more bushings for directly or indirectly connecting the root section of a wind turbine blade to the hub of the wind turbine on the fiber fabric cushion layer in a preset manner; wherein step c includes consolidating the bushings, the dry fiber fabric inserts, and the fiber fabric cushion layer together.

4. The method according to claim 3, wherein The surface provided in step a.i is a mold adapted to manufacture the root section or a part of the root section of the wind turbine blade housing.

5. The method according to any one of claims 1 to 4, characterized in that Step b includes: b.i. Providing one or more pieces of fiber fabric; b.ii. Constructing one or more laminates with a preset shape using the one or more pieces of fiber fabric; b.iii. Folding the one or more laminates with a preset shape so as to construct one or more dry fiber fabric inserts with a preset three-dimensional geometry; and b.iv. Alternately arranging the one or more dry fiber fabric inserts between each pair of adjacent bushings.

6. The method according to claim 5, characterized in that, Step b includes: b.v. Arranging a covering layer of fiber fabric on the alternately arranged bushings and fiber fabric inserts; wherein step c includes consolidating the bushings, the dry fiber fabric inserts, and the fiber fabric covering layer together, or consolidating the bushings, the dry fiber fabric inserts, the fiber fabric covering layer, and the fiber fabric cushion layer together.

7. The method according to claim 5, characterized in that, Folding the one or more fiber fabric inserts with a preset three-dimensional geometry constructed in step b.iii according to a preset folding method.

8. The method according to claim 6, wherein Folding the one or more fiber fabric inserts with a preset three-dimensional geometry constructed in step b.iii according to a preset folding method.

9. The method according to claim 5, characterized in that Constructing the fiber fabric laminate with a preset shape in step b.ii includes: cutting the one or more pieces of fiber fabric and / or tapering the one or more pieces of fiber fabric.

10. The method according to claim 5, wherein Providing one or more pieces of fiber fabric in step b.i includes: selecting a group of at least two fiber fabrics including different characteristics.

11. The method according to claim 10, wherein Constructing the fiber fabric laminate with a preset shape in step b.ii includes: stitching the at least two fiber fabrics together.

12. The method according to claim 3, characterized in that, Dry fiber fabric and / or fiber fabric with an adhesive is used for the fiber fabric cushion layer.

13. The method according to claim 6, wherein Dry fiber fabric and / or fiber fabric with an adhesive is used for the fiber fabric covering layer.

14. A root section or part of a root section of a wind turbine blade, characterized in that, The root section or a part of the root section of the wind turbine blade is manufactured by the method according to any one of claims 1 to 13.

15. A semi-finished component of a root section of a wind turbine blade housing, comprising two or more bushings, characterized in that, The two or more bushings are arranged in a preset manner by the method according to any one of claims 1 to 13, and dry fiber fabric inserts are alternately arranged between each pair of adjacent bushings.

16. A root section or a part of a root section of a wind turbine blade housing, characterized in that, Comprising: Two or more semi-finished components of the root section according to claim 15.

17. A wind turbine blade, characterized in that, Comprising a semi-finished component of the root section according to claim 15, or comprising a root section or a part of the root section according to claim 16.

18. A wind turbine, characterized in that, Comprising: A wind turbine blade according to claim 17.

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