Sspar cap, device for manufacturing half-shell of wind turbine rotor blade, assembly comprising mould and spar cap, and method for manufacturing half-shell of wind turbine rotor blade

Abstract

The invention relates to a spar cap, a device for manufacturing a half shell of a wind turbine rotor blade, an assembly comprising a mould and a spar cap, and a method of manufacturing a half shell of a wind turbine rotor blade. The spar cap comprises a stack (141) of layers of fibrous material stacked in a stacking direction (147) from a bottom surface (143) to a top surface (144), and a clamping layer (145) arranged on the top surface (144) of the stack (141) wherein the clamping layer (145) protrudes beyond the stack (141) of layers of fibrous material in a lateral direction (148) perpendicular to the stacking direction (147).

Description

TECHNICAL FIELD

[0001] The present invention relates to a spar cap for a wind turbine rotor blade, a device for manufacturing a half shell of a wind turbine rotor blade, an assembly comprising a spar cap and a mold, and a method of manufacturing a half shell of a wind turbine rotor blade. BACKGROUND

[0002] Wind turbines with wind turbine rotor blades are well known in the prior art and are used for converting wind energy into electrical energy. Wind turbine rotor blades are usually manufactured in an aerodynamic shell design and comprise several components made of fiber reinforced laminates, such as the aerodynamic shell. Typically, a wind turbine rotor blade has an elongated design with a root for attaching the blade to a rotor hub. The wind turbine rotor blade extends from the root to a tip. Usually, two half shells are manufactured which are placed on top of each other and joined together after their respective manufacture to manufacture the wind turbine rotor blade. The half shells can themselves be segmented for manufacturing so-called split blades or segmented blades.

[0003] Typically, the cross-sectional shape of an elongated wind turbine rotor blade varies widely over its length. The cross-section of the cylindrical root becomes a flattened airfoil cross-section and the cross-section becomes increasingly smaller towards the tip. The wind turbine rotor blade has a leading edge and a trailing edge at opposite sides. The shape of the trailing edge in particular varies significantly over the body length.

[0004] Considering the loads acting on the rotor blade, it is necessary to provide reinforcing structures at or within the wind turbine rotor blade for providing the respective required stiffness. High stiffness is required in the edge regions and also in the region of the trailing edge, the shape and thickness of which varies significantly as mentioned above. To strengthen the trailing edge region, one or more spar caps comprising a number of individual fiber layers are arranged and respectively joined in the half shells of the wind turbine rotor blade. The design of these spar caps is challenging in view of the mechanical properties or stiffness required for these spar caps, since the spar cap thickness is limited by the limited space near the trailing edge. The joining of the spar caps is therefore difficult.

[0005] The precise placement of the spar caps near the trailing edge is crucial for the structural integrity, performance and efficiency of the wind turbine rotor blade. SUMMARY

[0006] It is an object of the present invention to provide an improved spar cap.

[0007] This object is achieved by the main aspects of the present invention. Advantageous embodiments are given in the dependent aspects of the invention.

[0008] According to a first aspect, a spar cap for a wind turbine rotor blade is presented, comprising a stack of layers of fibrous material and a clamping layer. The layers of fibrous material are stacked in the stack from a bottom face to a top face in a stacking direction. The clamping layer is arranged on the top face of the stack. The clamping layer protrudes beyond the stack of layers of fibrous material in a lateral direction perpendicular to the stacking direction.

[0009] The clamping layer, in particular the protruding portion of the clamping layer, is configured for fixing the spar cap in a mold, thereby allowing a high precision placement of the spar cap in the mold. Any unintentional movement of the spar cap relative to the layup surface of the mold after placement of the spar cap in the mold can be prevented by fixing the protruding portion of the clamping layer. Thus, the spar cap of the present invention is configured to be placed in the mold with high precision, thereby allowing the construction of a half shell of a wind turbine rotor blade in which the spar cap is placed with high precision.

[0010] The spar cap can be one of the main load carrying components in the rotor blade, which is designed to withstand bending moments and shear forces. Precise placement of the spar cap ensures that the loads are distributed correctly along the rotor blade. On the other hand, incorrect placement of the spar cap can lead to uneven load distribution, resulting in stress concentrations and potential structural failures, such as cracks or delaminations.

[0011] The spar cap helps to maintain the aerodynamic shape of the rotor blade. Precise placement of the spar cap ensures that the rotor blade maintains its designed airfoil profile, which is crucial for optimal aerodynamic performance. Precise placement of the spar cap in the rotor blade can maximize the rotor blade's ability to capture wind energy effectively, thereby enhancing the overall performance of the wind turbine.

[0012] Precise placement of the spar cap in the rotor blade can contribute to the overall balance of the rotor blade, thereby reducing vibrations during operation of the rotor blade. This prolongs the lifespan of the rotor blade and minimizes the noise generated by the rotor blade during its operation.

[0013] By arranging the clamping layer on the top face of the stack, the clamping layer can be prevented from causing a deformation of the stack, in particular a so-called buckling. If the clamping layer were added at the middle of the stack or on the bottom face of the stack, the layers of fibrous material would be placed above the clamping layer, which laterally protrudes beyond the clamping layer. This would cause a deformation of the otherwise flat layers of fibrous material, resulting in a buckling of the stack. It is of utmost importance that the spar cap is free of buckling, as only a spar cap free of buckling can reliably transmit forces.

[0014] The clamping layer can comprise one or more layers of bidirectional fibrous material. For the clamping layer, all kinds of fibrous materials can be used, for example, the clamping layer can comprise triaxial fibrous material.

[0015] The clamping layer can also be a preform comprising glass fiber reinforced plastic (GFRP). The clamping layer can be formed as a tab. A tab is generally a flat or slightly curved component for connecting, reinforcing or fastening other components. The clamping layer can be incorporated into the resin infusion or can be fixed to the top face of the stack in another way, for example by gluing or by lamination to the top face of the stack.

[0016] In one embodiment, the stack of fiber material layers and the clamping layer are resin infused. Prior to resin infusion, the stack of fiber material layers and the clamping layer can be enclosed in a vacuum foil and the resin infusion can be carried out under vacuum atmosphere. The stack of fiber material layers and the clamping layer are permanently fixed together by the resin infusion. Since the spar cap is typically formed by resin infusion of the stack of fiber material layers, no additional manufacturing step is required to fix the clamping layer to the stack of fiber material layers.

[0017] As an alternative, the clamping layer formed as a preform comprising glass fiber reinforced plastic can be fixed to the top face of the stack after the stack is resin infused by gluing or lamination.

[0018] In one embodiment, the clamping layer forms a fixing element configured to fix the spar cap in the mold. The protruding portion of the clamping layer can be configured to be clamped between a clamping device and a clamping surface of the mold.

[0019] In one embodiment, the chord-wise cross-sectional shape of the clamping layer is complementary to the chord-wise cross-sectional shape of the protrusion forming the edge of the mold. This can allow the clamping layer to smoothly abut the protrusion on the mold, thereby further improving the precision of the positioning of the spar cap in the mold.

[0020] In one embodiment, the spar cap is a trailing edge spar cap. The trailing edge spar cap is arranged directly at or in close proximity to the trailing edge of the half shell of the rotor blade. Preferably, the spar cap forms the trailing edge at least in a section (region) between the root end of the half shell and the tip end of the half shell.

[0021] The second aspect relates to a device for manufacturing a half shell of a rotor blade of a wind turbine. The half shell manufactured with the device can comprise a spar cap as described above with respect to the first aspect. The embodiments described above with respect to the first aspect are similarly applicable to the second aspect.

[0022] The device comprises a mold comprising a lay-up surface and a protrusion defining an edge of the mold. The device further comprises at least one block configured to be arranged on the protrusion to raise the height of a portion of the protrusion.

[0023] The semi-shell manufactured using this device can vary in its longitudinal dimensions. The block can be used to adapt the height of the protrusion to the shape of the semi-shell. For example, when the spar cap is laid into the mold, the trailing edge spar cap of the semi-shell can be higher than the protrusion. The block allows the height of the protrusion to be adjusted so that the end face of the trailing edge spar cap is flush with the top surface of the protrusion. Thus, the block helps to secure the trailing edge spar cap to the mold during the manufacturing process.

[0024] The laminated surfaces can be configured as elements for laying out the semi-shell, such as the main laminate, spar cap, fiber material layer, core material, shear web, etc.

[0025] In one embodiment, the protrusion extends longitudinally from the root end of the mold to the tip end of the mold, wherein the length of the block in the longitudinal direction is a portion of the length of the protrusion. For example, the length of the block in the longitudinal direction may be less than one-hundredth of the length of the protrusion in the longitudinal direction. This block can be used to provide a surface for the clamping layer to abut. Since the clamping layer has a relatively small extension in the lateral direction, the block can also have a small extension in the lateral direction. For example, the block can have a length in the range of 3 cm to 30 cm, preferably in the range of 5 cm to 20 cm.

[0026] In one embodiment, the device includes a plurality of blocks configured to be arranged on the protrusion to raise the height of various portions of the protrusion, wherein at least two of the blocks differ in height. The height of the half-shell varies. The spar cap may extend beyond the protrusion in at least one segment along the longitudinal direction. Towards the tip, the half-shell becomes narrower and smaller. Therefore, the height of the half-shell extending beyond the protrusion may decrease towards the tip. To match the height of the protrusion to the height of the half-shell, the spar cap requires blocks of different heights along the entire length of the half-shell.

[0027] The third aspect relates to an assembly including a spar cap and a mold. The spar cap may be the spar cap described in the first aspect above. The mold may be part of the device described in the second aspect above. The embodiments described above with respect to the first and second aspects are similarly applicable to the third aspect.

[0028] In the assembly, the mold includes a stacked surface and a protrusion defining an edge of the mold. At least one block is disposed on the protrusion in a portion of the protrusion in which a clamping layer is positioned. A spar cap is configured to be disposed in the mold such that the end faces of the stacked parts are flush with the protrusion and / or the block, and the clamping layer protrudes beyond the protrusion and / or the block.

[0029] The protrusion can be flush with the end face of the stack without a block, or a block can be used to lift the protrusion so that it is flush with the top face of the stack.

[0030] The end faces of the stacked components can be perpendicular to the top and bottom surfaces of the stacked components. The end faces of the stacked components can also face the trailing edge of the half-shell.

[0031] This component allows for the construction of a semi-shell in which the trailing edge spars cap is precisely positioned within the semi-shell, and in which deformation, particularly undulation, of the trailing edge spars cap can be avoided.

[0032] In one embodiment, the component further includes a clamping device configured to secure the portion of the clamping element protruding beyond the protrusion and / or block to the mold. This contributes to the aforementioned functionality and advantages.

[0033] In one embodiment, the component is configured such that the position of the spar cap in the mold is maintained by a clamping device that fixes the portion of the clamping element protruding beyond the protrusion and / or block to the mold. This contributes to the aforementioned functionality and advantages.

[0034] In one embodiment, the spar cap includes a plurality of clamping layers, each arranged at a different location along the longitudinal direction of the spar cap, and each clamping layer protruding beyond a protrusion and / or block, wherein the clamping device is configured to secure the portion of each clamping element protruding beyond the protrusion to the mold. For each clamping layer, exactly one block may be provided on the protrusion. This contributes to the aforementioned functionality and advantages.

[0035] According to one embodiment, the height of the spar cap is greater than the height of the protrusion in at least a portion of the mold, wherein the assembly includes a plurality of blocks, each block configured to be arranged on the protrusion in a position where one of the clamping layers is disposed, thereby raising the protrusion. The height of the blocks is selected such that the top surface of the blocks is flush with the end face of the spar cap. This contributes to the aforementioned functions and advantages.

[0036] According to a fourth aspect, a method for manufacturing a semi-shell of a wind turbine rotor blade is proposed. The semi-shell may include the sparsus cap described above with respect to the first aspect, and the method may utilize the apparatus of the second aspect and the components of the third aspect. The embodiments described above with respect to the first to third aspects are similarly applicable to the fourth aspect.

[0037] The method includes the following steps:

[0038] i. Manufacturing a wing spar cap, the wing spar cap comprising a stack of fiber material layers stacked from bottom to top in a stacking direction, the stack of fiber material layers being arranged on the top surface of the stack such that the clamping layer protrudes beyond the stack of fiber material layers in a lateral direction perpendicular to the stacking direction.

[0039] ii. Provide a mold, wherein the mold includes a stacked surface and a protrusion defining the edge of the mold.

[0040] iii. Place the block on the protrusion at the location where the clamping layer will be positioned, wherein the block raises the protrusion.

[0041] iv. Arrange the wing spar cap in the mold, wherein the wing spar cap is arranged such that the end face of the stacked parts is flush with the protrusions and / or blocks and such that the clamping layer protrudes beyond the protrusions and / or blocks.

[0042] v. To secure the portion of the clamping element that protrudes beyond the protrusion to the mold.

[0043] In step i, multiple clamping layers may be provided on the spar cap. In step iii, multiple blocks may be placed on the protrusion, each block positioned where the clamping layers will be located. The blocks may vary in height, with the height of the blocks decreasing towards the tip of the spar cap.

[0044] Other advantages, features, and functions are set forth in the following exemplary embodiments of the invention, in conjunction with the accompanying drawings. Elements with the same, similar, or analogous functions are provided with the same reference numerals in the drawings. Attached Figure Description

[0045] In the attached diagram:

[0046] Figure 1 A schematic diagram of a wind turbine is shown.

[0047] Figure 2 A schematic diagram of the rotor blades is shown.

[0048] Figure 3 A schematic diagram of the cross-section of a wind turbine rotor blade is shown.

[0049] Figure 4 A schematic top view of a wind turbine rotor blade is shown.

[0050] Figure 5 A schematic diagram of the wing spars cap is shown.

[0051] Figure 6 It shows Figure 5 The cross-sectional view of the wing spars cap shown in the figure.

[0052] Figure 7 The manufacturing process of the semi-shell is shown.

[0053] Figure 8 An apparatus including blocks arranged on protrusions of a mold is shown.

[0054] Figure 9 It shows Figure 8The device and the wing cap arranged in the mold,

[0055] Figure 10 Another block is shown arranged on the protrusion of the mold.

[0056] Figure 11 A flowchart illustrating a method for manufacturing a semi-shell of a wind turbine rotor blade is shown. Detailed Implementation

[0057] Figure 1 A schematic diagram of a wind turbine 100 is shown, which includes a tower 102. The tower 102 is fixed to the ground by means of a base 104. A nacelle 106 is rotatably mounted at one end of the tower 102 opposite to the ground. The nacelle 106 includes, for example, a generator coupled to a rotor 108 via a rotor shaft (not shown). The rotor 108 includes one or more rotor blades 110 arranged on a rotor hub 112.

[0058] During operation, rotor 108 is configured to rotate via an airflow, such as wind. This rotational motion is transmitted to a generator via the rotor shaft and, if necessary, via a gearbox. The generator converts the mechanical energy of rotor 108 into electrical energy.

[0059] Figure 2 An exemplary rotor blade 110 is shown. The rotor blade 110 has the shape of a conventional rotor blade and has a rotor blade root region 114 facing the rotor hub 112. The rotor blade root region 114 generally has a substantially circular cross-section. Following the rotor blade root region 114 are a transition region 116 and a profile region 118 of the rotor blade 110. The rotor blade 110 has a pressure side 122 extending along a longitudinal direction 120 (also the main extension direction) and an opposite suction side 124. The interior of the rotor blade 110 is substantially hollow.

[0060] In the rotor blade root region 114, a rotor blade root end portion 126 with a flange connection portion 128 is provided, through which the rotor blade 110 can be mechanically connected to the pitch bearing or extension. The rotor blade 110 can be a segmented rotor blade.

[0061] Figure 3 A schematic cross-sectional profile 138 of a wind turbine rotor blade 110 extending transversely to the longitudinal direction 120 is shown (see [reference]). Figure 2The rotor blade 110 has an aerodynamic housing 130, which includes two half-housings, namely a pressure-side half-housing 133 and an intake-side half-housing 132. The two half-housings 132 and 133 are firmly connected to each other along the longitudinal axis at opposing connecting surfaces located at the leading edge 134 and the trailing edge 135.

[0062] Each half-shell 132, 133 includes a shell structure comprising a shell laminate 139 and two spar caps 140, namely a main spar cap and a trailing edge spar cap. The shell laminate 139 includes core material sandwiched between one or more layers of the laminate.

[0063] The spar cap 140 is embedded in the housing structure. The spar cap 140, also commonly referred to as the "primary laminate," bears the primary load during operation of the rotor blade 110. Each spar cap 140 comprises a stack 141 of fiber layers arranged vertically relative to each other according to a specific lamination pattern during manufacturing. After lamination, the fiber layers are infused with resin and subsequently cured to form the rigid structural spar cap 14140. For the fiber layers, the raw materials used may be, for example, layers of fiber material or semi-finished products, such as pultruded sheets made of fiber-reinforced plastic materials. Each spar cap 140 may be manufactured as a prefabricated component or as an integral part of the rotor blade housing 130 during housing manufacturing.

[0064] The rotor blade 110 includes a shear web 142. The shear web 142 connects the main spar cap 140 of the pressure-side half-shell 132 to the main spar cap 140 of the suction-side half-shell 133. The two main spar caps 140 and the shear web 142 form the main load-bearing structural member.

[0065] In an alternative embodiment, the rotor blade 110 also includes a second shear web that connects the trailing edge spar caps 140 to each other.

[0066] Figure 4 A schematic top view of a wind turbine rotor blade 110 is shown, which has two spars caps 140 in each of the rotor blade half-shells 132, 133. Figure 4 In the middle, the pressure-side half-shell 133, including the main wing spars cap 140 and the trailing edge wing spars cap 140, is visible.

[0067] All the spar caps in the spar cap 140 extend along the longitudinal direction 120 of the wind turbine rotor blade 110, wherein the trailing edge spar cap 140 of the pressure side half-shell 133 and the trailing edge spar cap 140 of the intake side half-shell 132 extend closely along the trailing edge 135 in at least a section (or portion) between the root end 126 and the tip end 127.

[0068] In a portion of the rotor blade 110, the trailing edge 135 is formed by a bonded joint between two trailing edge spars 140 and the trailing edge spars 140. In this portion, the trailing edge spars 140 are directly disposed at the trailing edge 135. By directly disposing the trailing edge spars 140 at the trailing edge 135, an auxiliary load path is formed along the trailing edge 135 of the wind turbine rotor blade 110, which stabilizes the trailing edge 135, particularly under edge-load conditions. Furthermore, the trailing edge spars 140 contributes a significant portion of the edge stiffness of the wind turbine rotor blade 110.

[0069] Figure 5 A perspective view shows the wing cap 140 according to the invention. Figure 6 The cut along line AA is shown. Figure 5 The cross-sectional view of the wing cap 140 shown in the figure. Figure 5 and Figure 6 The wing spars cap 140 shown is the trailing edge wing spars cap. Figure 5 and Figure 6 The spar cap 140 is shown as a prefabricated component before it is incorporated into the shell structure of the half-shell.

[0070] The wing cap 140 includes a stack of fiber material layers stacked from the bottom surface 143 of the wing cap 140 along the stacking direction 147 to the top surface 144 of the wing cap 140.

[0071] On the top surface 144 of the spar cap 140, a plurality of clamping layers 145 are arranged. The clamping layers 145 may comprise one or more layers made of a biaxially oriented fiber material or another fiber material. Alternatively, the clamping layers may comprise glass fiber reinforced plastic.

[0072] Clamping layers 145 are arranged at regular intervals along the trailing edge 146 of the spar cap 140. Each clamping layer 145 protrudes beyond the trailing edge 146 of the spar cap 140 in a lateral direction 148. When the spar cap 140 is incorporated into the rotor blade 110, the lateral direction 148 corresponds to the chordal direction. The lateral direction 148 is perpendicular to the stacking direction 147 of the stack of fiber material layers 141, and is substantially perpendicular to the longitudinal direction 120, which is the direction in which the spar cap 140 has its longest extension. For example, the lateral direction 148 and the longitudinal direction 120 can enclose an angle in the range of 75° to 105°, preferably, the two directions are perpendicular to each other.

[0073] The stacked fiber material layers 141 and the clamping layer 145 are infused with resin and cured, thereby securing them together. The clamping layer 145 forms a structure for securing the spar cap in the mold 149 during the manufacture of the rotor blade 110 (see [link]). Figure 7( ) fixed components.

[0074] In the final rotor blade 110, the portion of the stack of fiber material layers 141 protruding beyond the spar cap 140 of the clamping layer 145 is removed. The clamping layer 145 has a length in the lateral direction 148 ranging from 200 mm to 300 mm.

[0075] Figure 5 A plurality of clamping layers 145 are shown arranged along the trailing edge 146 of the spar cap 140. The clamping layers 145 arranged near the root end of the spar cap 140 include more layers of biaxial fiber material than those arranged near the tip end. The stack of fiber material layers 141 includes more layers at the root end compared to the region near the tip end. Therefore, in the region near the root end, stronger clamping layers 145, i.e., clamping layers 145 with more layers, are required to secure the spar cap 140 in the mold 149.

[0076] The end face 164 of the stacked component is located at the trailing edge 145. The end face 164 tapers relative to the stacking direction of the stacked component. (As in...) Figure 7 and Figure 9 As shown, this allows the end face 164 to abut against the tapered, inward-facing surface 161 of the mold 149 or the abutment block 158.

[0077] Figure 7 A half-shell 132 of a wind turbine rotor blade 110 during its manufacture is shown. To manufacture the half-shell 132 of the wind turbine rotor blade 110, a mold 149 is used, which includes a laminated surface 150 and two protrusions 151 defining the edges of the mold 149. One of the protrusions 151 defines an edge corresponding to the trailing edge 135 of the half-shell 132, and the other protrusion 151 defines an edge corresponding to the leading edge 134 of the half-shell 132.

[0078] In the outward direction away from the stacked surface 150, the mold 149 includes a stepped portion 152 adjacent to the protrusion 151 and a clamping surface 153. In an alternative embodiment, the stepped portion 152 may be omitted, and the protrusion 151 may be used as the clamping surface.

[0079] Each element of the semi-shell 132 is then arranged on the lamination surface 150 of the mold 149. Specifically, the outer laminate 156, the core material 155, and the inner laminate 154 are then arranged on the lamination surface 150 of the mold 149, thereby forming the shell structure of the semi-shell 132. In addition, prefabricated components, namely the main spar cap 140 and the trailing edge spar cap 140, are arranged on the lamination surface of the mold, wherein the spar cap 140 is adjacent to the core material 155.

[0080] The trailing edge spar cap 140 is arranged in the mold 149 such that the trailing edge of the fiber material layer stack 141 matches the contour of the protrusion 151 of the fiber material layer stack 141. A clamping layer 145 protruding beyond the protrusion 151 is arranged on and extends beyond the protrusion 151. The clamping layer 145 is also arranged on the clamping surface 153 of the mold 149.

[0081] As in Figure 7 As indicated, the clamping device 157 secures the portion of the clamping layer 145 protruding beyond the protrusion 151 to the mold 149. For example, the clamping layer 145 is clamped between the clamping device 157 and the clamping surface 153 of the mold 149. This allows the trailing edge spar cap 140 to be secured in its position before, for example, by resin injection, it is fixed to the housing structure of the half-shell 132.

[0082] By providing a clamping layer 145 that is clamped and secured to the mold 149, accidental movement of the trailing edge spar cap 140 relative to the mold 149 can be prevented. Therefore, the clamping layer 145 can position the trailing edge spar cap 140 in the half-shell 132 with high precision.

[0083] The semi-shell 132 is manufactured by (vacuum) resin infusion, wherein the elements arranged on the mold 149 are fixed to each other. Then, the protrusions of the clamping layer 145 are removed in a finishing operation. In the finishing operation, a grinder, such as an electric grinder or a pneumatic grinder, is used to remove the protrusions of the clamping layer 145.

[0084] exist Figure 7 In the embodiment shown, the protrusion 151 of the mold 149 is flush with the end face 164 of the stack of fiber material layers 141. The bottom surface 143 of the stack 141 is placed against the stacked surface 150 of the mold 149.

[0085] In an alternative embodiment, at another length position of the half-shell (not shown), the protrusion 151 is not flush with the end face 164 of the stack 141, and instead, the end face of the stack 141 may be higher than the protrusion 151, and thus may protrude beyond the protrusion 151. To raise the height of the protrusion 151 such that it becomes flush with the end face 164 of the stack 141, a block 158 is arranged on the protrusion 151. Specifically, the block 158 is arranged on the portion of the protrusion 151 in which the clamping layer 145 is positioned.

[0086] Figure 8 A block 158 is shown arranged on a portion of the protrusion 151. Figure 8In the design, the spar cap 140, including the clamping layer 145, is not shown. The spar cap 140 is disposed on the stacked surface 150 of the mold 149, wherein the position of the block 158 is selected such that the clamping layer 145 is disposed on the block 158.

[0087] The shape of block 158 is adapted to the shape of mold 149. Block 158 includes a bottom surface 159 facing mold 149. The shape of the bottom surface 159 of block 158 matches the shape of the protrusion 151, the step portion 152 and the clamping surface 153 of mold 149.

[0088] Block 158 includes a top surface 160 opposite to the bottom surface 159. The top surface 160 of block 158 includes three surfaces: a tapered, inward-facing surface 161, a surface 162 parallel to the protrusion 151, and a tapered, outward-facing surface 162. The height of block 158 is measured from the upper surface of the protrusion 151 to the portion of the top surface 160 of block 158 parallel to the protrusion 151.

[0089] Figure 9 This is shown after the spar cap 140 is arranged in the mold 149. Figure 8 The mold 149 is shown in the figure. When the spar cap 140 is arranged in the mold 149, the end face 164 of the fiber layer stack 141 abuts against the tapered inward surface 161 of the block 158. The top surface 144 is flush with the surface 162 of the block 158. The bottom surface 143 of the spar cap 140 is laid on the stacked surface 150 of the mold 149 (not visible). The clamping layer 145, positioned on the top surface 144 of the stack 141, is arranged on the surface 162 of the block 158 extending parallel to the protrusion 151 and the tapered outward surface 163. The clamping layer 145 extends beyond the block and is additionally arranged on the clamping surface 153. The clamping layer 145 is cured and corresponds to the shape of the protrusion 151.

[0090] like Figure 7 As shown, the clamping layer 145 can be temporarily secured to the mold by pressing the clamping layer 145 onto the clamping surface 153 by a clamping device 157. Alternatively, the clamping device 157 can secure a portion of the clamping layer 145 resting on a surface 162 of the block 158 that extends parallel to the protrusion 151.

[0091] Figure 10 Another block 158 on the protrusion 151 of the mold 149 is shown. Figure 10 The block 158 shown is arranged in a way that is more than Figure 8 The block 158 shown is positioned further towards the tip of the mold 149. (Compared to...) Figure 8 Compared to block 158 shown in the image, Figure 10The block 158 shown has a lower height. The height of the spar cap 140 decreases from the root end of the half-shell 132 along the longitudinal direction 120 toward the tip end of the half-shell 132. To match the height of the protrusion 151 with the height of the spar cap 140, the blocks 158 arranged on the protrusion 151 differ in height. The block 158 near the root end has the highest height, and the height of the block 158 gradually decreases toward the tip end of the protrusion 151. It is also conceivable that no block 158 is arranged in the region near the tip end, because in the region near the tip end, the spar cap 140 is flush with the protrusion 151, and therefore no block 158 is needed.

[0092] Figure 11 A flowchart of a method for manufacturing a wind turbine rotor blade 110 is shown.

[0093] In the first step S1, a spar cap 140 is manufactured. The spar cap 140 includes a stack of fiber material layers 141 arranged from a bottom surface 143 to a top surface 144 along a stacking direction 147. The spar cap 140 also includes a clamping layer 145 arranged on the top surface 144 of the stack 141 such that the clamping layer 145 protrudes beyond the stack of fiber material layers 141 in a lateral direction 148 perpendicular to the stacking direction 147. For example, the spar cap 140 manufactured in step S1 may be... Figure 5 and Figure 6 The wing spar cap shown is the same as the wing spar cap.

[0094] In the subsequent second step S2, a mold 149 is provided. The mold 149 includes a stacked surface 150 and protrusions 151 defining the edges of the mold 149. The mold 149 provided in step S2 may correspond to... Figure 7 The mold shown in the image.

[0095] In the third step S3, block 158 is placed on the protrusion 151 of mold 149 at the location where the clamping layer 141 will be positioned. Block 158 raises the protrusion 151. In step S3, multiple blocks 158 can be arranged at different positions along the longitudinal direction 120 of the protrusion 151. For example, in Figure 8 and Figure 10 The image shows the block 158 arranged on the protrusion 151 in step S3.

[0096] In the subsequent fourth step S4, the spar cap 140 is arranged in the mold 149. The spar cap 140 is arranged such that the top surface 144 of the stack 141 is flush with the protrusion 151 raised by the block 158, and such that the clamping layer 145 protrudes beyond the protrusion 151 raised by the block 158. For example, in Figure 7 andFigure 9 The image shows a spar cap 140 arranged in mold 149.

[0097] Figure 7 The following embodiment is shown, wherein no block 158 is provided on the protrusion 151 of the mold 149, and wherein the stack 141 is flush with the protrusion 151. Figure 9 The following embodiment is shown, wherein block 158 is arranged on protrusion 151 at a position where clamping layer 145 will be arranged, and wherein end face 164 of stack 141 abuts against block 158.

[0098] In the subsequent fifth step S5, the portion of the clamping layer 145 that protrudes beyond the protrusion 151 of the mold 149 is fixed to the mold 149. For example, Figure 7 The clamping surface 153 of the mold 149 is shown, in which the clamping layer 145 is fixed to the mold 149 by the clamping device 157.

[0099] In the sixth step S6, the laminate and core material are further arranged on the laminated surface, thereby providing a shell structure.

[0100] In the seventh step S7, the spar cap is fixed to the shell structure, for example by resin infusion and curing, thereby forming a semi-shell.

[0101] Repeat steps S1 to S7 to manufacture the second half-shell.

[0102] In the eighth step S8, the two half-shells are fixed to each other, for example, by adhesive bonding at the rear edge and the front edge.

[0103] Figure Labels

[0104] 100 wind turbine

[0105] 102 towers

[0106] 104 bases

[0107] 106 Nacelle

[0108] 108 rotor

[0109] 110 rotor blades

[0110] 112 rotor hub

[0111] 114 Rotor blade root region

[0112] 116 Transition Zone

[0113] 118 outline area

[0114] 120 longitudinal direction

[0115] 122 pressure side

[0116] 124 Inhalation Side

[0117] 126 root end

[0118] 127 tip end

[0119] 128 flange connection

[0120] 130 housing

[0121] 132 intake side half shell

[0122] 133 Pressure Side Half-Shell

[0123] 134 Front Edge

[0124] Trailing edge of rotor blade 135

[0125] 138 cross-sectional profile

[0126] 139 Shell Laminate

[0127] 140 Wing Spall Cap

[0128] 141 fiber layer stack

[0129] 142 Shear Web

[0130] 143 bottom

[0131] 144 top surface

[0132] 145 sandwich layer

[0133] The trailing edge of the 146 wing spars cap

[0134] 147 stacking direction

[0135] 148 Lateral direction / chordal direction

[0136] 149 mold

[0137] 150 laminated surface

[0138] 151 Protrusion

[0139] 152 steps

[0140] 153 Clamping Surface

[0141] 154 internal laminate

[0142] 155 core material

[0143] 156 outer laminate

[0144] 157 clamping device

[0145] 158 pieces

[0146] 159 bottom surface

[0147] 160 top surface

[0148] 161 Inward-facing surface

[0149] 162 parallel surfaces

[0150] 163 outward-facing surfaces

[0151] 164 end face

Claims

1. A spar cap (140) for a wind turbine rotor blade (110), the spar cap (140) comprising: a stack (141) of fibre material layers stacked in a stacking direction (147) from a bottom face (143) to a top face (144), and a clamping layer (145) arranged on the top face (144) of the stack (141), wherein the clamping layer (145) protrudes beyond the stack (141) of fibre material layers in a lateral direction (148) perpendicular to the stacking direction (147).

2. The spar cap (140) according to the preceding claim, wherein the stack (141) of fibre material layers and the clamping layer (145) are infused with resin.

3. The spar cap (140) according to any of the preceding claims, wherein the clamping layer (145) forms a fixing element configured to fix the spar cap (140) in a mould (149).

4. The spar cap (140) according to claim 3, wherein a chord-wise cross-sectional shape of the clamping layer (145) is complementary to a chord-wise cross-sectional shape of a protrusion (151) forming an edge of the mould (149).

5. The spar cap (140) according to any of the preceding claims, wherein, the spar cap (140) is a trailing edge spar cap (140).

6. An apparatus for manufacturing a half shell of a wind turbine rotor blade (110), the apparatus comprising: a mould (149) comprising a lay-up surface (150) and a protrusion (151) defining an edge of the mould (149), and at least one block (158) arranged on the protrusion (151) to raise a height of a portion of the protrusion (151).

7. The apparatus according to claim 6, wherein the protrusion (151) extends in a longitudinal direction from a root end of the mould (149) to a tip end of the mould (149), and wherein a length of the block (158) in the longitudinal direction is a fraction of a length of the protrusion (151).

8. The apparatus according to claim 6 or claim 7, comprising a plurality of blocks (158) arranged on the protrusion (151) to raise heights of portions of the protrusion (151), wherein at least two of the plurality of blocks (158) differ in their height.

9. An assembly comprising a mould (149) and a spar cap (140) according to any of claims 1 to 5, wherein, the mould (149) comprising a lay-up surface (150) and a protrusion (151) defining an edge of the mould (149), wherein at least one block (158) is arranged on the protrusion (151) in a portion of the protrusion (151) in which a clamping layer (145) is positioned, wherein the spar cap (140) is configured to be arranged in the mold (149) such that the top face (144) of the stack (141) is flush with the protrusion (151) and / or the block (158) and the clamping layer (145) protrudes beyond the protrusion (151) and / or the block (158).

10. The assembly according to claim 9, wherein, The assembly further comprises clamping means (157) configured to fix the portion of the clamping element protruding beyond the protrusion (151) and / or the block (158) to the mold (149).

11. The assembly according to claim 10, wherein The assembly is configured such that the position of the spar cap (140) in the mold (149) is maintained by the clamping means (157) fixing the portion of the clamping element protruding beyond the protrusion (151) and / or the block (158) to the mold (149).

12. The assembly according to any one of claims 9 to 11, wherein The spar cap (140) comprises a plurality of clamping layers (145), each clamping layer (145) being arranged at a different position along the longitudinal direction of the spar cap (140) and each clamping layer (145) protruding beyond the protrusion (151) and / or the block (158), and wherein the clamping means (157) are configured to fix the portion of each of the clamping elements protruding beyond the protrusion (151) and / or the block (158) to the mold (149).

13. The assembly according to claim 12, wherein, The height of the spar cap (140) is greater than the height of the protrusion (151) in at least a portion of the mold (149), wherein the assembly comprises a plurality of blocks (158), each block (158) being configured to be arranged on the protrusion (151) in a position in which one of the clamping layers (145) is arranged to raise the protrusion (151), wherein the height of the block (158) is chosen such that the top surface of the block (158) is flush with the end face (164) of the spar cap (140).

14. The assembly according to claim 13, wherein The end face (164) defines a trailing edge of the spar cap (140) at least in a section between a root end and a tip end of the half shell (132, 133).

15. A method of manufacturing a half shell of a wind turbine rotor blade (110), The method comprises the steps of: i. manufacturing a spar cap (140) comprising a stack (141) of layers of fibrous material stacked in a stacking direction (147) from a bottom face (143) to a top face (144) and a clamping layer (145) arranged on the top face (144) of the stack (141) such that the clamping layer (145) protrudes beyond the stack (141) of layers of fibrous material in a lateral direction (148) perpendicular to the stacking direction (147), ii. providing a mold (149), wherein the mold (149) comprises a lamination surface (150) and a protrusion (151) defining an edge of the mold (149), iii. placing a block (158) on the protrusion (151) at a position where the clamping layer (145) is to be positioned, wherein the block (158) elevates the protrusion (151), iv. arranging the spar cap (140) in the mold (149), wherein the spar cap (140) is arranged such that the top face (144) of the stack (141) is flush with the protrusion (151) and / or the block (158) and such that the clamping layer (145) protrudes beyond the protrusion (151) and / or the block (158), v. fixing the part of the clamping element protruding beyond the protrusion (151) at the mold (149).

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