Method and system for bonding wind turbine blades

Abstract

A method for bonding component parts of a wind turbine blade (16) along an adhesive line (32, 34, 35) with: Placing at least one barrier (60) within an internal cavity (25) of the sheet at a specified adhesive line width (38) along the length of the adhesive line; Establishing a plurality of spaced external access points (50) with a plurality of hoses (52) flowing into the inner cavity (25) along the adhesive line defined by the barrier; successively injecting an adhesive paste (36) into the plurality of tubes (52) to fill the adhesive line; and leaving at least part of the hoses (52) permanently in the connection ports (50), and sealing the external ends (56) of the hoses.

Description

Field of invention

[0001] The present invention relates generally to the field of wind turbines and in particular to methods for bonding component parts of wind turbine blades and a system for bonding components of a wind turbine blade along an adhesive line. Background of the invention

[0002] Turbine blades are the fundamental components of wind turbines for converting wind energy into electrical energy. The blades have the cross-sectional profile of an airfoil, so that during operation, air flows over the blade, creating a pressure difference between the sides. This creates a lift force on the blade, directed from the pressure side towards the suction side. The lift force generates a torque on the main rotor shaft, which is then transmitted to a generator to produce electricity.

[0003] The turbine blades typically consist of an upper (suction-side) shell element and a lower (pressure-side) shell element, bonded together along a bond line running along the leading and trailing edges of the blade. Internal spar caps and webs are also bonded to each of the shell elements. The bond lines are generally formed by applying a suitable adhesive paste or compound along the bond lines at a minimum designed bond width between the shell elements before the molds are brought together to join the shell elements. However, the adhesive paste tends to migrate a considerable distance beyond the designed bond width and into the inner blade cavity, particularly along the trailing edge of the blade. This excess adhesive paste can lead to a significant increase in the rotor blade's weight, negatively impacting the blade dynamics and the overall performance of the wind turbine.The excess adhesive paste can also break off and cause damage to the internal structure and components during operation of the wind turbine, as well as generate loud noises when the blades rotate.

[0004] Accordingly, an improved method and system for bonding component parts of a wind turbine blade would benefit the industry by reducing at least certain disadvantages of previously known methods.

[0005] US 2009 / 0 257 881 A1 describes a method for manufacturing a wind turbine rotor blade in which the blade is formed as a laminated structure by placing a composite material of fiber reinforcement material and / or core material into a mold. US 2009 / 0 146 433 A1 describes a method for assembling a wind turbine blade, which includes the formation of a preformed pressure side element and a preformed suction side element. US 2008 / 0 075 603 A1 describes a method for creating a connection between a first and a second shell of a blade. Brief description of the invention

[0006] Some aspects and advantages of the invention are set out in the following description, or are obvious from the description, or can be learned by carrying out the invention.

[0007] According to aspects of the invention, a method for bonding component parts of a wind turbine blade along a bonding line is provided. The method can be used, for example, for bonding upper and lower shell elements along the leading and trailing edges of the wind turbine blade, or for bonding the spar web to the shell elements within the internal cavity of the blade. The method comprises placing one or more barriers within the internal cavity of the blade at a defined bonding line width along the length of the bonding line. A plurality of spaced-apart external access points with a plurality of hoses, which are in flow communication with the internal cavity along the bonding line defined by the barrier, are positioned along the bonding line, providing external access to the internal cavity of the shell elements.A suitable adhesive paste is injected sequentially into the numerous connection ports to fill the bonding line. The process further includes permanently leaving at least a portion of the tubing in the connection ports and sealing the external ends of the tubing.

[0008] In a particular embodiment, the method comprises placing the barrier between the upper and lower shell elements along an adhesive line (e.g., the trailing or leading edge adhesive lines) at the specified adhesive width and defining the external connection access points by means of a plurality of spaced-apart tubes placed between a gap at the edges of the upper and lower shell elements, or, according to an alternative embodiment, by means of tubes or passages in the shell elements. The tubes have an outer end and an inner end that projects into the inner cavity within the dimensions of the adhesive defined by the barrier. The barrier and the tubes can be placed in their respective molds prior to the casting of the shell elements, which may necessitate covering the internal ends of the tubes before the casting process. The tubes are opened prior to the injection step.

[0009] The sequential injection step can comprise injecting the adhesive paste into the tubes in succession, with the injection step being followed by the next subsequent tube when the adhesive paste is detected on the corresponding next subsequent tube. The sequential operation can start on a first tube and continue to a last tube, or it can start on an intermediate tube and continue in one or both directions along the adhesive line. The presence of the adhesive paste on a tube can be detected in various ways, in particular by visual inspection. In a particular embodiment, the presence of adhesive paste is determined by detecting a change in the air pressure in the tube caused by the presence of the adhesive paste within the inner cavity extending towards the tube.This can be done by measuring the ambient pressure inside the tube, which increases as the adhesive paste flows into the tube, or by injecting air into the tube and detecting a restriction of the airflow through the tube due to the presence of the adhesive paste within the inner cavity running to the tube.

[0010] Other methods can also be used to detect the absence or presence of the adhesive paste on a particular tube. For example, a change in the light conditions passing through the tube can be detected as a result of the adhesive paste flowing onto the tube. A variety of other suitable detection methods can also be used, in particular capacitive sensors. The type and location of the sensors can depend on the viscosity of the adhesive paste. It should be understood that the invention is not limited to any particular type of sensor or detection technique.

[0011] After the injection step, the outer ends of the hoses can be shortened and sealed, with the remaining part of the hoses permanently remaining between the shell elements.

[0012] In one embodiment where the method is used for bonding a spar web adhesive line, the connection access points can be defined by a shell element along the spar web adhesive line. A plurality of hoses can be inserted through holes or access points defined in the shell elements, such that the internal ends of the hoses extend into the bonding area defined by the barriers along the spar web adhesive line. Access to the spar web adhesive line can also be provided through gaps in the shell elements along either the trailing edge, the leading edge, or both.

[0013] The injection step can be carried out in various ways, in particular by manual or automated injection. In a particular embodiment, an injection system is used that includes an adhesive paste dispensing system and a distribution system that is fluidly connected to the dispensing system and configured to be connected to a first hose within a first connection port for supplying the adhesive paste along the adhesive line. In a particular embodiment, the dispensing system includes a pump that is supplied with adhesive paste from a reservoir, and the dispensing system includes any suitable configuration of hoses, valves, manifolds, or other types of guide elements to convey the adhesive paste from the pump to the connection ports.In a particular embodiment, the dispensing system is configured as a machine or vehicle that moves along a path across the sheet and, as it moves along the adhesive line, successively connects to and disconnects from the connection ports. The machine may include an adhesive paste reservoir and a pump for distributing the adhesive paste through the distribution system, which may comprise any configuration of hoses, valves, and the like that connect to the connection ports. The machine may be configured with any type of pressure sensor, air line, light sensor, and the like to detect the presence of the adhesive paste, as discussed above, in the downstream hose. The injection machine may be configured to simultaneously inject adhesive paste along two or more different adhesive lines or into multiple hoses within the same adhesive line.Branches of the supply lines may be equipped with valves to control where the flow of paste is directed.

[0014] According to further aspects, the invention also includes a system for bonding components of a wind turbine blade along an adhesive line, aspects of which have been discussed above. In certain embodiments, the system comprises an adhesive paste reservoir and a pump with an inlet port connected to the reservoir. One or more supply hoses or other types of conduit elements are connected to the pump and have an end configured to connect to a first port in the wind turbine blade in order to supply an internal adhesive line within the wind turbine blade with the adhesive paste. A sensor is configured to detect the presence of the adhesive paste running along the adhesive line from the first hose within the first port to an adjacent hose in a neighboring port.A control unit is in data communication with the pump and the sensor to control the flow of the adhesive paste into the first port as a function of the detection of adhesive paste at the adjacent port, e.g. to stop the flow into the first port when the paste is detected at the adjacent port.

[0015] In one embodiment, the sensor can be an air pressure sensor that detects a change in air pressure at the adjacent port as a result of the adhesive paste flowing to that port. In another embodiment, the sensor can be a pressure line that fits the adjacent port, with the detection of a restriction in airflow indicating that the adhesive paste has flowed to the adjacent port. In yet another embodiment, the sensor can be a light sensor that detects changes in light conditions due to the absence or presence of the adhesive paste.

[0016] The system can be configured to simultaneously fill different adhesive lines along the sheet with a variety of supply tubes and sensors.

[0017] In a particular embodiment, the system is configured as a movable vehicle that moves along the wind turbine blade for the bonding process.

[0018] The invention also relates to a device for carrying out the disclosed methods and comprises device parts for carrying out each of the described method steps. The method steps can be carried out by means of hardware components, a computer programmed by appropriate software, a combination of both, or in any other way. Furthermore, the invention also relates to methods by which the described devices operate and / or according to which the described elements are assembled. It comprises method steps for carrying out each function of the device.

[0019] These and other features, aspects, and advantages of the present invention can be more fully understood with reference to the following description and the attached claims. The accompanying drawings, which form part of this description, illustrate embodiments of the invention and, together with the description, are intended to explain the principles of the invention. Brief description of the drawings

[0020] A complete and executable disclosure of the present invention, including its best embodiment, is set forth in the description which refers to the attached figures, wherein: Fig. Figure 1 is a perspective view of a conventional wind turbine; Fig. Figure 2 is a perspective view of a wind turbine blade configured with multiple connection access points for filling internal glue lines; Fig. Figure 3 is a cross-sectional view of the shell elements of an exemplary wind turbine blade within the corresponding shapes and configured with connection accesses for subsequent filling of internal adhesive lines according to the aspects of the invention; Fig. Figure 4 shows an enlarged cross-sectional view of the trailing edge of a wind turbine blade according to aspects of the invention; Fig. 5 is a view of the trailing edge from Fig. 4, which is filled with adhesive paste; Fig. Figure 6 is a side sectional view of an adhesive configuration on the leading edge of a wind turbine blade; Fig. Figure 7 is a side sectional view of a single ball joint connection for injecting adhesive paste through a shell element; and Fig. Figure 8 is a perspective view of the sheet. Fig. 2 with a system according to aspects of the invention, configured for filling and multiple internal adhesive lines. Detailed description of the invention

[0021] Detailed reference is made to embodiments of the invention, one or more examples of which are illustrated in the figures. Each example serves to explain the invention, not to limit it. Indeed, it is obvious to the person skilled in the art that various modifications and variations can be made to the present invention without departing from its scope or purpose. For example, features illustrated or described as part of one embodiment can be used in other embodiments to arrive at a further embodiment. The present invention is intended to encompass such modifications and variations as fall within the scope of the appended claims and their equivalents.

[0022] Fig. Figure 1 represents a conventional wind turbine 10. The wind turbine 10 comprises a tower 12 with a nacelle 14 attached to it. A multitude of rotor blades 16 are attached to the rotor hub 18, which in turn is attached to a main flange that rotates a main rotor shaft. The components for wind turbine energy generation and control are arranged inside the nacelle 14. The view of Fig. Figure 1 is provided solely for illustrative purposes to demonstrate the present invention in an exemplary field of use. It should be understood that the invention is not limited to any particular type of wind turbine configuration.

[0023] Fig. Figure 2 is a detailed view of aspects of the wind turbine blade 16. The blade 16 comprises an upper shell element 20 and a lower shell element 22. The upper shell element 20 can be configured as the suction side surface of the blade 16, while the lower shell element can be configured as the pressure side surface of the blade. The blade 16 comprises a leading edge 24 and a trailing edge 26, as well as a root portion 28 and a tip portion 30. As is well known in the prior art, the upper shell element 20 and the lower shell element 22 are joined to each other at a leading edge glue line 32 and a trailing edge glue line 34. An internal spar web glue line 35 is typically used to bond the spar web 29 to the internal spar ribs 31 ( Fig. 3) To form these adhesive lines 32, 34, 35, an adhesive paste 36 is used ( Fig. 5) injected in liquid viscous form between the matching laminate surfaces of the upper shell element 20 and lower shell element 22 along the length of the adhesive lines 32, 34, or through the shell elements for the adhesive line 35, as will be explained in greater detail below.

[0024] It should be understood that the term "adhesive paste" is used herein in a generic sense, encompassing any type of binding or adhesive material applied in an initially flowable state. The specific type of adhesive paste 36 is not of particular interest to the present invention, and any suitable type of epoxy, adhesive compound, or other material may be used in this context.

[0025] The adhesive paste 36 is applied in sufficient quantity and pattern to achieve a desired adhesive line width 38 and thickness 40 ( Fig. 4) To produce the different adhesive lines 34, 35, 36 to ensure a minimum adhesive surface between the components along the length of the respective adhesive lines. The design criteria for the adhesive width 38 and thickness 40 can vary between different types of sheets based on any combination of design factors, as is well understood by those skilled in the art.

[0026] As mentioned, the present method concerns the bonding of components of the wind turbine blade 16 along the bonding lines 32, 34 and 35. With particular reference to the Fig. 2-4 of the method involves placing a barrier 60 within the internal cavity 25 of the sheet at the location of the specified adhesive width 38 along the longitudinal length of the adhesive line. This barrier 60 can be any type of rigid, semi-rigid, or flexible material that acts as a barrier against the flow of the adhesive paste. The barrier 60 can, for example, be a semi-rigid element with a pre-formed shape, such as a concave or convex shape. The barrier 60 can be a prefabricated mesh screen or other air-permeable material that allows air to pass through while preventing the flow of the adhesive paste through the screen.The barrier 60 can be glued at the appropriate location between the shell elements 20, 22 or to the spar web 29 and the spar flanges 31 with any type of suitable adhesive resin or similar to ensure that the barrier 60 is not displaced by the adhesive paste during the gluing process.

[0027] Since the barrier 60 prevents uncontrolled flow of the adhesive paste 36 into the internal cavity 25 of the sheet, the present method can provide the additional advantage that the viscosity of the adhesive paste 36 can be increased or otherwise modified to ensure a more complete application and to prevent air pockets or voids between the shell elements 20, 22 along the corresponding adhesive lines 32, 34, 35.

[0028] Again, with reference to the Fig. 2 - 4 are a plurality of spaced-apart external connection points 50 with a plurality of hoses (52) which are in flow communication with the inner cavity (25) along the adhesive line defined by the barrier, which are to be filled. Fig. 2. A plurality of these access points are provided along the leading edge adhesive line 32, the stringer adhesive line 35, and the trailing edge adhesive line. These connection access points 50 can be configured in various ways within the scope and spirit of the invention. In the illustrated embodiment, the connection access points 50 are defined by hose elements 52, which have an externally accessible end and an opposite end arranged within the internal cavity of the adhesive line, particularly within the dimensions of the adhesive line defined by the barrier element 60. For example, the plurality of hoses 52, with respect to Fig. 3, along the leading edge adhesive line 32 between the upper and lower shell elements 20, 22, and extends into the leading edge adhesive line defined by the barrier element 60. Similarly, a plurality of tubes 52 are inserted through the holes or passages defined in the laminate layers of the upper shell element 20 along the upper spar web adhesive line 35 and extend into the adhesive area defined by the barrier elements 60. Likewise, a plurality of tubes 52 are placed between the upper and lower shell elements 20, 22 along the trailing edge adhesive line 34 within the adhesive area defined by the barrier 60. The trailing edge adhesive line configuration is described in greater detail in Fig. Figure 4 illustrates this. It should be understood that the tubes for the spar web gluing line 35 can be arranged through the gap between the shell elements 20, 22 along either the leading edge, the trailing edge, or both. Similarly, the tubes 52 for the leading-edge and trailing-edge gluing lines 32, 34 can be arranged through the holes or passages defined by the shell elements 20, 22.

[0029] The various hoses 52 can be rigid, semi-rigid or flexible, and are designed so that they do not break or kink during the bonding process.

[0030] The method further comprises, at least in part, the successive injection of a flowable adhesive paste 36 into the plurality of tubes 52 along the corresponding adhesive line in order to fill the adhesive line along its longitudinal length within the area defined by the barrier 60. This adhesive line area has a width dimension 38 and a height dimension 40, as shown in Fig. Figure 4 shows the area defined by the barrier 60 and the inner surfaces of the upper and lower shell elements 20, 22 along the front and rear edges 24, 26. Along the spar web bonding line 35, the extent of the bonding area is defined by the barrier 60 and the structure of the spar flanges 31 and the spar web 29.

[0031] The invention encompasses any type of injection of the adhesive paste through the tubes 52 in a sequential manner, in particular manual or machine injection. With reference to the Fig. 8 The adhesive paste is injected, for example, into a first of the connecting hoses 52, which can be located at one of the two ends of the corresponding adhesive line or between the ends. In the embodiment of Fig. 8 The bonding process was initiated at the root end 28 of the leaf 16. As the bonding paste is injected into the first access tube 52, it fills the bonding area defined by barrier 60 and flows longitudinally along the length of the bond line. When the bonding paste is detected at the next adjacent access tube 52, the workflow stops injection at the first tube 52 and continues injecting the bonding paste at the adjacent tube 52. The injection process restarts until flow of the bonding paste to the next adjacent downstream access tube is detected, at which point the process shifts and repeats.It should therefore be understood that this sequential injection of the adhesive paste 36 into adjacent tubes 52 in adjacent connection ports 50 as a function of the detection of the adhesive paste at the adjacent connection port ensures a complete and uniform filling of the adhesive paste 36 along the entire longitudinal lengths of the adhesive line with a minimal risk of voids or air pockets being established along the adhesive line.

[0032] With reference to Fig. 3. The leaf shell components 20, 22 can be formed within their respective molds 62 using the conventional molding process. The barriers 60 and tubes 52 are placed between the components before the casting of the shell elements 20, 22. Fiber mat reinforcements can be placed around the tubes 52, which extend through the shell elements for the spar web bonding lines 35.

[0033] With reference to Fig. 4. Covers 58 can be used to seal the inner ends of the tubes 25 during the casting process. In this way, the atmospheric pressure inside the tube prevents the tube from collapsing during the casting process. The cover 58 is then removed or "broken" before the adhesive paste is injected through the tube 52.

[0034] The Fig. 4 and Fig. Figure 5 represents a special arrangement for inserting the tubes 52 along the trailing edge connection ports 50. The tubes are inserted between the skins of the upper and lower shell elements 20, 22 and are held in place by a flexible bladder 55. The bladder is also intended to prevent the adhesive paste from running out of the trailing edge adhesive line 34 during the bonding process. The bladder can be, for example, an inflatable element, a compressible element, or any other suitable sealing element. Fig. 5 represents the configuration of Fig. 4 after the injection of the adhesive paste 36. The shell elements 20, 22 are finally cut at the cutting line 57 after the paste 36 has hardened, in order to provide the desired adhesive width dimension 38, 40.

[0035] The hoses 52 are generally positioned in non-stressed areas of the shell elements 20, 22, so that they do not negatively affect the structural integrity of the sheet 16.

[0036] Fig. Figure 7 represents a helpful casting point configuration along the spar web gluing line. A ball valve or other type of hinged device 80 is positioned within the mold element 62. A conical passage is defined by the ball valve 82. This tapered cone shape facilitates the removal of cured adhesive within the ball valve 82. The conical shape and hinge of the ball valve 82 (relative to the axis 81) within the mold 62 also facilitates the removal of the shell element 20 from the mold 62. A tube 82 is configured within the shell element 20, defining a flow passage through the shell element for the adhesive paste. This tube 82 can remain within the shell element and should therefore be compatible with the shell element 20 and the cured adhesive paste. A flexible filler tube 84 is connected to the tube 82 and directs the adhesive paste to the spar web gluing side.This hose 84 can be attached using the shell casting method and can remain in the sheet.

[0037] The detection of the adhesive paste on the downstream adjacent tube 52 can be carried out in various ways. For example, the presence of the adhesive paste 36 within the adjacent tube 52 can be visually inspected. In this embodiment, the adhesive paste 36 would essentially fill the second tube and be visually detected within the tube. However, the presence of the adhesive paste 36 within the second tube 52 is not necessarily advantageous, and other detection methods can be used that do not necessarily depend on the downstream tube 52 being filled with adhesive paste. For example, a measuring line can be connected to the adjacent downstream tube 52 to detect a change in air pressure (positive or negative) within the tube caused by a flow of the adhesive paste 52 in the tube.For example, the measuring line may be connected to or include an ambient pressure detector that detects an increase in pressure inside the hose 52 caused by the adhesive paste 36 starting to run into the hose.

[0038] In an alternative embodiment, the detection of the adhesive paste 36 can be supplemented by a source of positive or negative pressure (e.g., a compressed air line) connected to the adjacent downstream hose 52. If the adhesive paste 36 initially flows into the inner end of the adjacent hose 52, an obstruction of the airflow is detected, for example, by a pressure increase within the compressed air line. This pressure signal can be used as a control variable to stop the injection of the adhesive paste into the upstream supply line.

[0039] The presence of the adhesive paste 36 on the downstream tube 52 can also be determined empirically without actually detecting the adhesive paste. For example, the amount of adhesive paste 36 required to fill the adhesive area between adjacent tubes 52 can be known from the dimensions of the adhesive area, and the method can be controlled as a function of the volumetric flow rate of the adhesive paste into the tubes such that the method switches to the next group of tubes when a measured amount of adhesive paste has been injected. Similarly, the method can be controlled as a function of the time required to fill the adhesive area between adjacent tubes 52 at a known volumetric flow rate.

[0040] As the injection process progresses along the length of the adhesive line, the external ends of the tubes 52 are sealed or covered while the process continues with the next adjacent tube 52. When the injection process is complete, the tubes can be cut and sealed at the surface of the shell elements 20, 22. Any suitable finishing treatment process can then be used to fill and cover the tube ends.

[0041] For example, with reference to Fig. 8 The process can also include the simultaneous application of adhesive to several adhesive lines along the sheet 16. For example, the adhesive paste 36 can be injected into the spar web adhesive lines 35 and the leading edge adhesive lines 32 in a simultaneous application process. The flow rates of the adhesive paste into the respective adhesive lines can be controlled independently of one another, as can the monitoring of the presence of the adhesive paste in downstream tubes 52.

[0042] Fig. 5 displays the trailing edge adhesive line 34 Fig. Figure 4 shows the injection of the adhesive paste 36 through the tube 52. The cover 58 has been removed from the internal end 54 of the tube 52 under pressure or otherwise. The external end 56 of the tube is knotted, covered, or otherwise sealed while the process moves to the next downstream tube 52. Upon completion of the injection process, all tubes 52 can be cut, sealed, and finished at their access point between the shell elements 20, 22. Alternatively, as discussed above, the trailing edges can be cut along the cut line 57 so that no portion of the tubes 52 remains in the trailing edge adhesive line 34.

[0043] Fig. Figure 6 represents the filling of the leading edge adhesive line 32 between the shell elements 20, 22 by the supply tube 52, whereby the flow of the adhesive paste 36 into the sheet through the barrier 60, as discussed above, is prevented.

[0044] The present invention also encompasses any type of system used to carry out the bonding process as discussed above. The system can include any type of suitable adhesive paste dispensing system configured with a distributor system that is in flow connection with a first hose 52 within a first access point along the wind turbine blade. In a particular, in Fig. In the embodiment shown in Figure 8, this system can, for example, be implemented by a vehicle or machine 64 configured to move along the length of the sheet 16 in an automated or semi-automated gluing process. The adhesive paste dispensing system in this embodiment comprises an adhesive paste reservoir 72 and a pump 74. The adhesive paste distribution system can include any configuration of line elements for dispensing the adhesive paste, such as injection hoses 66 to the various connection ports and associated valves, multi-port distributors, manifolds, and the like. The pump 74 can be a variable displacement pump for filling different adhesive lines with different flow rates. In an alternative embodiment, different pumps can be provided for injecting several adhesive lines simultaneously at different flow rates. In the embodiment shown in Figure 8, the adhesive paste reservoir 72 is operated by a vehicle or machine 64 configured to move along the length of the sheet 16 in an automated or semi-automated gluing process. Fig. In the embodiment shown in Figure 8, a single pump 74 is used to inject paste along the spar web adhesive line 35 simultaneously with the leading edge adhesive line 32 at substantially the same flow rate.

[0045] The system can include any type of sensor configured to detect the presence of the adhesive paste 36 flowing along the corresponding adhesive line from the first tube 52 within the first port to the adjacent tube 52 in the adjacent port. As discussed above, the sensor can include measuring lines or compressed air lines 68 configured with the respective adjacent tubes 52 to detect a change in the ambient pressure within the tube 52 caused by the flow of the adhesive paste 32 into the tube. In an alternative embodiment, the measuring system can include a pressurized air source 70 that injects air into the adjacent tubes 52 and, when a restriction of the airflow is detected, generates a corresponding control signal indicating the presence of the adhesive paste on the tube 52.The measuring system can use a sensor to detect changes in the light conditions inside the tubes 52 as a result of the adhesive paste flowing along the tubes.

[0046] The system can include any type of suitable controller 76 configured with a connection to the pump 74 and measuring components to control and coordinate the injection steps.

[0047] The present invention also includes any configuration of a wind turbine 10 ( Fig. 1), in which at least one of the sheets 16 is configured with the unique advantages of the invention described above.

[0048] While the present invention has been described in detail with reference to the specific exemplary embodiments and methods, it should be understood from reading and understanding the above that a person skilled in the art can quickly produce changes, modifications, and equivalents of such embodiments. Accordingly, the present disclosure is exemplary and non-limiting in scope, and does not preclude the inclusion of such modifications, changes, and / or additions to the present subject matter that will be readily apparent to a person skilled in the art.

Claims

[1] A method for bonding component parts of a wind turbine blade (16) along a bonding line (32, 34, 35) with: Placing at least one barrier (60) within an internal cavity (25) of the sheet at a specified adhesive line width (38) along the length of the adhesive line; Establishing a plurality of spaced external access points (50) with a plurality of hoses (52) flowing into the inner cavity (25) along the adhesive line defined by the barrier; successively injecting an adhesive paste (36) into the plurality of tubes (52) to fill the adhesive line; and leaving at least part of the hoses (52) permanently in the connection ports (50), and sealing the external ends (56) of the hoses. [2] The bonding method according to claim 1, wherein the method is used to form a bonding line (32, 34) between upper (20) and lower (22) shell elements of the turbine blade (16), and further comprises placing the barrier (60) between the upper and lower shell elements along the bonding line. [3] The bonding method according to claim 2, comprising sequential injection of the adhesive paste (36) into a plurality of the tubes (52), wherein the injection step is shifted to the next subsequent tube upon detection of the adhesive paste on the corresponding next subsequent tube, wherein the presence of the adhesive paste (36) on the next subsequent tube (52) is detected by one of the following methods: - visual detection; - Measuring changes in the lighting conditions inside the tubes as a result of the adhesive paste running into the tubes; - Detecting a change in air pressure in the hose caused by the presence of the adhesive paste within the internal cavity leading to the hose; or - Detecting a change in the restriction of airflow through the hose caused by the presence of the adhesive paste within the internal cavity leading to the hose. [4] The bonding method according to claim 2, further comprising permanently leaving at least a part of the tubes (52) in a gap between the shell elements (20, 22) or in holes which are defined within the shell elements. [5] The bonding method according to one of the preceding claims, wherein the method is used to bond a spar web bonding line (35), wherein the connection accesses 50 are defined by the upper (20) shell element, the lower (22) shell element or both shell elements of the turbine blade (16), or by a gap between the lower shell element, the upper shell element, or both shell elements. [6] The bonding method according to any of the preceding claims, wherein the method is used to bond a front (32) or rear (34) edge bonding line, wherein the connection accesses (50) are defined by the lower (20) shell element, the upper (22) shell element, or by both shell elements of the turbine blade or by a gap between the upper and lower shell elements. [7] The bonding method according to one of the preceding claims, wherein the injection step is performed by an injection system (64) which successively connects and disconnects with the connection ports (50), wherein the injection system (64) comprises a machine which moves along the bonding lines (32, 34, 35), wherein the machine has a supply of the adhesive paste (36) and is connectable to the corresponding connection ports (50), and wherein the injection machine (64) simultaneously fills several bonding lines along the turbine blade (16). [8] The bonding method according to one of the preceding claims, comprising sealing the barrier (60) at a location within the internal cavity (25) between opposing internal structures of the turbine blade. [9] A system for bonding components of a wind turbine blade (16) along an adhesive line (32, 34, 35) for carrying out the method according to claim 1, wherein the system comprises: an adhesive paste dispensing system (64) with a supply (72) of adhesive paste (36); a distribution system which is in flow connection with the delivery system, wherein the distribution system is configured to be connected to a first hose (52) within a first connection access (50) in the wind turbine blade (16) to supply the adhesive paste to an internal adhesive line within the wind turbine blade; a sensor (68) configured to detect the presence of adhesive paste (36) running along the adhesive line from the first tube (52) within the first port access (50) to an adjacent tube (52) in an adjacent port access (50); and a controller (76) which is connected to the dispensing system and the sensor to control the flow of the adhesive paste into the first tube (52) in the first connection access (50) as a function of the detection of the adhesive paste at the adjacent tube (52) in the adjacent connection access (50). [10] The system according to claim 9, wherein the dispensing system (64) comprises a pump which is in flow connection with a storage reservoir (72) which is configured to store a supply of the adhesive paste (36), and wherein the distribution system comprises conduit elements (66) which convey the adhesive paste from the pump to the hoses (52) within the connection ports (50). [11] The system according to claim 9 or 10, wherein the distribution system (66) is configured for the simultaneous filling of several adhesive lines (32, 34, 35) along the wind turbine blade (16), wherein the dispensing system (64) is configured as a movable vehicle that travels along the wind turbine blade (16) for the adhesive application process, wherein the distribution system comprises conduit elements (66) that connect the movable vehicle (64) to the hoses (52) within the connection ports (50).

Images