DE102010055874B3 - Method for producing a rotor blade of a wind energy plant - Google Patents

Abstract

A method for producing a rotor blade (10) for a wind turbine, comprising the steps of: producing two rotor blade half-shells (20, 30) that form a rotor blade in a first tool form consisting of two tool half-shells in a manner known per se, producing at least one trailing edge belt (40) in at least one second tool shape, and connecting the rotor blade half-shells (20, 30) to one another and to the at least one prefabricated trailing edge element (40).

Description

The invention relates to a method for producing a rotor blade of a wind turbine and a rotor blade produced by the method.

The production of rotor blades for wind turbines is a very labor-intensive process with high demands on the individual working steps mostly manually executing staff.

Such methods are for example from DE 198 33 869 C1 . DE 10 2008 045 601 A1 . DE 10 2008 045 578 A1 . DE 30 14 347 A1 and the EP 2 295 235 A1 known.

Usually, the rotor blades are composed of two half-shells, which are made of impregnated with epoxy resin glass and carbon fiber mats, so that at a relatively low weight high strength of the rotor blades can be achieved.

For this purpose, consisting of two heatable half-shells tool mold is coated with a release agent and then with glass fiber mats and in areas that require additional reinforcement, with other fiberglass or carbon fiber fabric or -gelege or other suitable material in sandwich construction, so a structure with two Core material surrounded layers, designed.

In particular in the area of the sheet trailing edge to be formed, belts made of continuous fibers, so-called trailing edge belts, must additionally be inserted, which are arranged graduated depending on the position in the sheet. The trailing edge belts are necessary in order to be able to comply with the expansion level of the rotor blade, which is intended to withstand the alternating self-weight moments of the rotor blade occurring during use and torque loads resulting from the torque. The straps are typically 10 to 20 cm wide and must be placed in overlapping layers, with the areas of overlap varying over the length of the sheet.

This manual labor requires a great deal of experience and represents a considerable source of error in the manufacture of the rotor blade. This approach is particularly beneficial in closing and gluing the blade profile due to partially non-uniform distribution of the adhesive, the formation of air bubbles and the resulting different stiffness and waviness of the trailing edge belts narrow radii problematic. On the one hand, there is a risk that the trailing edge straps are formed in both halves of the sheet too thick, so that the blade profile can not be closed. On the other hand, there is the possibility that the trailing edge straps are made too thin, so that in the further course can lead to Fehlverklebungen the blade halves.

After inserting a mixture of resin / hardener system leading hoses in the half-shells, the half-shell airtight occlusive film is placed so that created in a further step, a vacuum and the resin mixture into the glass fiber and optionally carbon fiber fabric or -gelege sucked and the Mats can be so impregnated. Subsequently, the rotor blade halves are cured at about 70 ° C and the two halves of the sheet glued together, sanded to remove the release agent, leveled to compensate for bumps, coated with means for protection against moisture and light and painted.

Since it may come due to a faulty design of the trailing edge straps to a faulty bonding of the blade halves (see above), it is an object of the invention to provide a method by which the Blätthalbschalen can be optimally interconnected without vulnerabilities, in particular, simplifies the production of trailing edge straps and the error-proneness should be eliminated.

This object is achieved by the method having the features of claim 1. The subclaims reflect advantageous embodiments of the invention.

The basic idea of the invention is to prefabricate an independent profile for the area of the blade trailing edge in a separate second tool mold and then to glue it to the two sheet profile half shells. For this purpose, the second tool mold preferably consists of a V-shaped upwardly open mold, in the resin impregnated fiber reinforcement material, for. As fiberglass or carbon fiber fabric or -gelege or particularly advantageous rovings are inserted, so that the second tool mold filled and the Hinterkantengurtprofil then under the usual conditions, such as temperature, humidity, time etc. can be cured. The method for producing the trailing edge belt profile is thus very similar to the method for producing the rotor blade half shells in relation to the use of the materials, so that substantially no further measures are required apart from an additional tool shape.

The invention will be described with reference to a particularly preferred embodiment and explained in more detail with reference to the accompanying drawings. Show it:

1 a cross section through a rotor blade according to the prior art;

2 a schematic plan view of the rotor blade 1 ;

3 a sectional detail view of the trailing edge in a first portion of a rotor blade according to the prior art;

4 a detailed sectional view of the trailing edge of the rotor blade 3 in a second section;

5 a sectional detail view of the trailing edge in a first portion of a rotor blade according to the invention; and

6 a detailed sectional view of the trailing edge in a second portion of a rotor blade according to the invention.

1 shows a cross section through a rotor blade according to the prior art. The rotor blade 10 is made of two half shells 20 . 30 when using the rotor blade 10 particularly heavily stressed areas are particularly designed. This is how the rotor blade points 10 between the half-shells 20 . 30 vertical walkways 60 for absorbing transverse forces, which are like half-shells 20 . 30 usually also consist of a sandwich construction. The half-shells 20 . 30 and the footbridges 60 For example, they can be constructed from a sandwich with epoxy resin-glass fiber laminate and PVC foam.

Next are the half-shells 20 . 30 in the area of the bridges 60 with in the longitudinal direction of the sheet 10 running straps 50 reinforced, thus the sheet 10 To form bending moments can be formed rigid.

In particular, there are the nasal bonding of the half-shells 20 . 30 opposite in the region of the trailing or end edge of the rotor blade to the respective position in the rotor blade 10 adjusted rear edge straps 40 extending from the longitudinal direction of the sheet 10 oriented UD material (UD: unidirectional).

The position and arrangement of the trailing edge belts 40 in the sheet 10 is in a plan view in 2 and in detail in 3 and 4 in cross-section at different locations along the rotor blade 10 shown. In particular, will be off 2 clearly that the course of the trailing edge straps 40 along the outer sheet contour high demands on the executing staff in the adjustment of the trailing edge belts 40 to the respective position in the rotor blade 10 provides.

Not only that the outer shape of the trailing edge straps in sandwich construction of the upper half shell 20 and lower half shell 30 varies, but it also varies the relative position of the trailing edge belts 40 the upper half shell 20 in relation to the trailing edge straps 40 the lower half shell 30 , as well as their height and width across the blade axis. Finally, the amount of between the trailing edge straps also varies 40 the upper half shell 20 and the back edge straps 40 the lower half shell 30 introduced adhesive 70 ,

The present invention now obviates the above-mentioned disadvantages of the structure described above in that only one trailing edge belt element is prefabricated in a second tool mold and subsequently with the half shells 20 . 30 of the rotor blade 10 the known from the prior art Hinterkantengurte is glued replacing.

In particular, it is provided that the second tool mold one of the inner contour of the assembled rotor blade half shells 20 . 30 in the area of the trailing edge of the rotor blade 10 corresponding, ie filling form has. For this purpose, the second tool mold is substantially V-shaped and open at the top. For the formation of a trailing edge belt 40 according to the invention (see 5 and 6 ) Rovings impregnated with resin can preferably be drawn from the one end of the second tool mold in the longitudinal direction to the other end of the tool mold and, if appropriate, stepped in the second tool mold. The rovings readily adapt to the inner contour of the second tool mold so that a plurality of resin-soaked rovings can be placed one above the other in the second tool mold and fill the second tool mold.

After curing of the rovings, the trailing edge belt 40 be solved according to the invention in one piece from the second mold and removed, wherein the outer contour of the Hinterkantengurts thus prepared 40 in any position in the longitudinal direction of the rotor blade 10 into the geometry of the half-shells 10 . 20 inserts without requiring any special experience in the production process or further adaptations of the rear edge element produced in this way.

The one-piece trained Hinterkantengurt 40 comes with the laminate of the half shells 20 . 30 glued with a uniformly thick adhesive layer of about 2-3 mm, so that the possibility of incorrect bonding is reduced. As the 5 and the 6 in contrast to 3 and 4 show a uniformly thick bond to both sides of the Hinterkantegurts 40 according to the invention, while according to the prior art, the two trailing edge belt elements 40 are connected to each other with a different thickness adhesive layer. In particular, differences in the curing due to different adhesive application, different curing time, etc. are avoided by a uniformly thick bonding.

A particularly simple positioning of the separately manufactured, integrally formed trailing edge belt 40 can preferably take place in that in the half-shells 20 . 30 formed as stops formed structures to which the Hinterkantengurt 40 can be created.

Finally, the present invention also relates to a rotor blade 10 produced by the method of the invention.

In particular, the rotor blade 10 one of two half-shells 20 . 30 formed rotor blade profile, wherein the two half shells 20 . 30 in the area of the trailing edge of the rotor blade 10 with a separately manufactured rear edge belt 40 are glued. In particular, the trailing edge belt is 40 prefabricated from rovings according to a preferred embodiment.

Claims (7)

Method for producing a rotor blade ( 10 ) for a wind energy plant, comprising the steps of: - producing two rotor blade half shells forming a rotor blade ( 20 . 30 ) in a first tool mold consisting of two tool shells in a manner known per se, - producing at least one trailing edge belt ( 40 ) in at least one second tool mold, and - connecting the rotor blade half shells ( 20 . 30 ) with each other and with the at least one prefabricated Hinterkantengurt ( 40 ). A method according to claim 1, characterized in that the second tool mold one of the inner contour of the assembled rotor blade half shells ( 20 . 30 ) in the region of the trailing edge of the rotor blade ( 10 ) has corresponding shape. Method according to one of the preceding claims, characterized in that the trailing edge belt ( 40 ) by placing rovings soaked in resin into the second mold and allowing the rovings to cure. Method according to one of the preceding claims, characterized in that the trailing edge belt ( 40 ) on one in at least one rotor blade half shell ( 20 . 30 ) arranged stop is arranged. Rotor blade ( 10 ) with one of two half-shells ( 20 . 30 ) formed rotor blade profile, wherein both half shells ( 20 . 30 ) in the region of the trailing edge of the rotor blade ( 10 ) with a separately manufactured trailing edge belt ( 40 ) are glued. Rotor blade ( 10 ) according to claim 5, characterized in that the trailing edge belt ( 40 ) is made of rovings. Rotor blade ( 10 ) according to one of claims 5 or 6, characterized in that at least one half-shell ( 20 . 30 ) one the trailing edge belt ( 40 ) adjacent stop has.

Images