SYSTEMS AND METHODS OF ASSEMBLING A ROTOR BLADE EXTENSION FOR USE IN A WIND TURBINE

• US 20110076149A1
• Filed: 09/29/2009
• Published: 03/31/2011
• Est. Priority Date: 09/29/2009
• Status: Active Grant

• Current Assignee: General Electric Company
• Original Assignee: General Electric Company
• Inventors: Santiago, Pedro Luis Benito, Segovia, Eugenio Yegro
• Granted Patent: US 8,328,516 B2
• Time in Patent Office: Days
• US Class Current: 416/223.R
• CPC Class Codes: F03D 1/0675 of the blades
• CPC Class Codes: F05B 2230/80 Repairing, retrofitting or upgrading methods
• CPC Class Codes: F05B 2240/302 Segmented or sectional blades
• CPC Class Codes: F05B 2240/307 Blade tip, e.g. winglets
• CPC Class Codes: F05B 2260/96 Preventing, counteracting or reducing vibration or noise
• CPC Class Codes: Y02E 10/72 Wind turbines with rotation axis in wind direction
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product
• CPC Class Codes: Y10T 29/49318 Repairing or disassembling
• CPC Class Codes: Y10T 29/49336 Blade making
• CPC Class Codes: Y10T 29/49337 Composite blade

Abstract

A method of assembling a blade extension assembly for use with a wind turbine. The method includes removing a tip end of a tip portion of a rotor blade and coupling a tip wall to the tip portion. The tip wall extends between a first sidewall and a second sidewall and includes a plurality of slots defined therein. A blade extension assembly is coupled to the tip portion.

Claims

1. A method of assembling a blade extension assembly for use with a wind turbine, wherein the wind turbine includes a rotor blade and a hub, said method comprising:

removing a tip end from a tip portion of the rotor blade;

coupling a tip wall to the tip portion, the tip wall extending between a first sidewall and a second sidewall, the tip wall including a plurality of slots defined therein; and

,

coupling a blade extension assembly to the rotor blade tip portion.

2. A method in accordance with claim 1, wherein said coupling a blade extension assembly further comprises coupling a blade extension assembly uptower with the rotor blade coupled to the hub.

3. A method in accordance with claim 1, wherein the blade extension assembly comprises a base member and a plurality of support rods extending outward from the base member, said method further comprises:

inserting the support rods through the tip wall and into a cavity defined within the tip portion; and

,

coupling the support rods to the tip portion.

4. A method in accordance with claim 1, wherein the blade extension assembly comprises a base member and a plurality of support brackets extending outward from the base member, said method further comprises coupling at least one of the plurality of support brackets to a blade outer surface and to a base member outer surface.

5. A method in accordance with claim 1, further comprising coupling a winglet to the blade extension assembly, such that the winglet extends substantially perpendicularly outward from the blade extension assembly.

6. A blade extension assembly for use in a wind turbine, said blade extension assembly comprising:

a tip wall adapted to be coupled to a tip portion of a rotor blade, the tip portion comprising a blade outer surface;

a base member adapted to be coupled to the tip portion; and

,

a plurality of support rods coupled to and extending from said base member towards the tip portion, said plurality of support rods coupled to the tip portion.

7. A blade extension assembly in accordance with claim 6, wherein said tip wall comprises a plurality of slots sized to receive said support rods.

8. A blade extension assembly in accordance with claim 6, wherein said plurality of support rods comprises a plurality of openings extending through a tip end, said rotor blade comprising a plurality of openings extending though a first sidewall, said shear pins inserted at least partially through said first sidewall openings and said support rod openings.

9. A blade extension assembly in accordance with claim 6, further comprising:

a forward support rod inserted through a forward slot at least partially defined by said tip wall, said forward support rod positioned in a forward cavity of said rotor blade; and

,

an aft support rod inserted through an aft slot at least partially defined by said tip wall, said aft support rod positioned in an aft cavity of said rotor blade.

10. A blade extension assembly in accordance with claim 6, further comprising a plurality of openings extending through said base member, said support rods coupled to said base member with a plurality of shear pins inserted through said openings.

11. A blade extension assembly in accordance with claim 6, wherein said base member comprises an inner wall coupled to an interior surface, such that a cavity is defined therebetween, said cavity sized to receive said tip portion, such that said interior surface is in sealing contact with said rotor blade outer surface.

12. A blade extension assembly in accordance with claim 6, wherein said plurality of support rods comprises at least one support bracket extending from said base member towards said tip portion, said support brackets coupled to said blade outer surface and said base member outer surface with said plurality of shear pins.

13. A blade extension assembly in accordance with claim 6, further comprising a winglet coupled to said base member, said winglet extending substantially perpendicularly outward from a tip end of said base member.

14. A wind turbine, comprising:

a tower;

a nacelle coupled to said tower;

a hub rotatably coupled to said nacelle;

at least one rotor blade coupled to said hub, said rotor blade comprising a tip portion and a blade outer surface; and

,

a blade extension assembly coupled to said rotor blade, said blade extension assembly comprising;

a tip wall coupled to said tip portion;

a base member coupled to said tip portion; and

,

a plurality of support bars coupled to and extending from said base member towards said tip portion, said plurality of support bars coupled to said tip portion.

15. A wind turbine according to claim 14, wherein said tip wall comprises a plurality of slots sized to receive said support rods therein.

16. A wind turbine according to claim 14, wherein said plurality of support rods comprises a plurality of openings defined through a tip end, said rotor blade comprising a plurality of openings extending through a first sidewall, said shear pins inserted at least partially through said first sidewall openings and said support rod openings.

17. A wind turbine according to claim 14, wherein said blade extension assembly further comprises a plurality of openings defined within said base member, said support rods coupled to said base member with a plurality of shear pins inserted through said openings.

18. A wind turbine according to claim 14, wherein said base member comprises an inner wall coupled to an interior surface such that a cavity is defined therebetween, said cavity sized to receive said rotor blade tip portion, such that said interior surface is in sealing contact with said rotor blade outer surface.

19. A wind turbine according to claim 14, wherein said blade extension assembly further comprises a winglet coupled to said base member, said winglet extending substantially perpendicularly outward from a tip end of said base member.

20. A rotor blade for use with a wind turbine, said rotor comprising:

a tip portion; and

,

a blade extension assembly coupled to said tip portion, said blade extension assembly comprising;

a tip wall coupled to said tip portion;

a base member coupled to said tip portion; and

,

a plurality of support bars coupled to and extending from said base member towards said tip portion, said plurality of support bars coupled to said tip portion.