Efficient wind turbine blades, wind turbine blade structures, and associated systems and methods of manufacture, assembly and use

• US 9,518,558 B2
• Filed: 07/26/2013
• Issued: 12/13/2016
• Est. Priority Date: 12/05/2008
• Status: Active Grant

• Current Assignee: Vestas Wind Systems A/S
• Original Assignee: Vestas Wind Systems A/S
• Inventors: Arendt, Cory P., Madrid, Bernard G., Baker, Myles L., Vilhauer, Sheldon
• Primary Examiner(s): EDGAR, RICHARD A
• Application Number:
  US13/951,727
• Publication Number:
  US 20140154091A1
• Time in Patent Office: 1,236 Days
• Field of Search: 416/226, 416/230, 416/229.R
• US Class Current: 1/1
• CPC Class Codes: B29C 70/304 In-plane lamination by juxtaposing or interleaving of plies, e.g. scarf joining
• CPC Class Codes: B29D 99/0028 hollow blades
• CPC Class Codes: B29L 2031/085 Wind turbine blades
• CPC Class Codes: F03D 1/0675 of the blades
• CPC Class Codes: F03D 13/10 Assembly of wind motors; Arrangements for erecting wind motors
• CPC Class Codes: F05B 2240/30 Characteristics of rotor blades, i.e. of any element transforming dynamic fluid energy to or from rotational energy and being attached to a rotor
• CPC Class Codes: F05B 2240/302 Segmented or sectional blades
• CPC Class Codes: Y02E 10/72 Wind turbines with rotation axis in wind direction
• CPC Class Codes: Y02E 10/74 Wind turbines with rotation axis perpendicular to the wind direction
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product
• CPC Class Codes: Y10T 156/10 Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 29/49316 Impeller making
• CPC Class Codes: Y10T 29/49337 Composite blade
• CPC Class Codes: Y10T 29/49339 Hollow blade

Abstract

Wind turbine systems and methods are disclosed herein. A representative system includes a wind turbine blade having an inner region that has an internal load-bearing truss structure, and an outer region that has an internal, non-truss, load-bearing structure. In particular embodiments, the truss structure can include a triangular arrangement of spars, and/or can include truss attachment members that connect components of the truss without the use of holes in the spars. Spars can be produced from a plurality of pultruded composite members laminated together in longitudinally extending portions. The longitudinally extending portions can be connected at joints that interleave projections and recesses of each of the spar portions. The blades can include fan-shaped transitions at a hub attachment portion, formed by laminated layers and/or a combination of laminated layers and transition plates.

Claims

1. A wind turbine blade, comprising:

an external aerodynamic surface having a longitudinally-extending spanwise axis, a chordwise axis extending transverse to the spanwise axis, and a thickness axis extending transverse to both the chordwise and spanwise axes; and

a plurality of longitudinally-extending spars providing internal support for the aerodynamic surface, wherein at least one of the spars includes a laminate of precured composite material, the laminate of precured composite material including;

a plurality of precured, pultruded composite layers, wherein each of the pultruded composite layers overlaps with the others in the at least one spar at at least one longitudinal location; and

a plurality of adhesive layers interposed between adjacent precured, pultruded composite layers.

2. The wind turbine blade of claim 1 wherein each of the precured, pultruded composite layers includes a precured fiber-reinforced resin product.

3. The wind turbine blade of claim 1 wherein the aerodynamic surface defines an airfoil cross-section, wherein the plurality of longitudinally-extending spars include a pressure spar and a suction spar spaced apart from each other along the thickness axis, and an aft spar spaced apart from both the pressure and suction spars along the chordwise axis, and wherein each of the pressure, suction and aft spars are comprised of a laminate of precured composite pultrusions.

4. The wind turbine blade of claim 1, further comprising a plurality of longitudinally spaced-apart ribs, and wherein the at least one spar is attached to the ribs.

5. The wind turbine blade of claim 1, further comprising a strap clamped circumferentially around the plurality of precured, pultruded composite layers.

6. The wind turbine blade of claim 1, further comprising:

a plurality of longitudinally spaced-apart ribs; and

a plurality of truss attachment members, wherein each of the truss attachment members includes a first piece and a corresponding second piece, wherein each of the first pieces is attached to the corresponding second piece to clamp a portion of the precured composite layers together therebetween, and wherein at least one of the first piece and the second piece of each truss attachment member is attached to one of the longitudinally spaced apart ribs.

7. The wind turbine blade of claim 1 wherein the at least one spar tapers in at least an outboard direction, and wherein the taper results from precured, pultruded composite layers terminating at different longitudinal locations.

8. The wind turbine blade of claim 1 wherein individual precured, pultruded composite layers terminate at different longitudinal locations.

9. The wind turbine blade of claim 1 wherein individual precured, pultruded composite layers terminate at different longitudinal locations, and wherein the terminations are chamfered.

10. The wind turbine blade of claim 1 wherein individual precured, pultruded composite layers have a chordwise extent and a thickness extent less than the chordwise extent.

11. The wind turbine blade of claim 1 wherein individual precured, pultruded composite layers are flat along the chordwise axis.

12. The wind turbine blade of claim 1 wherein individual precured, pultruded composite layers are formed separately from the external aerodynamic surface.

13. The wind turbine blade of claim 1 wherein inner and outer surfaces of the at least one spar are generally parallel to a mean slope of the local external aerodynamic surface.

14. The wind turbine blade of claim 13 wherein the inner and outer surfaces of the at least one spar are generally flat and wherein the local external aerodynamic surface is curved.

15. A wind turbine blade, comprising:

an external aerodynamic surface having a longitudinally-extending spanwise axis, a chordwise axis extending transverse to the spanwise axis, and a thickness axis extending transverse to both the chordwise and spanwise axes; and

a plurality of longitudinally-extending spars providing internal support for the aerodynamic surface, wherein at least one of the spars has inner and outer surfaces that are generally flat and wherein the local external aerodynamic surface is curved, further wherein the at least one spar includes a laminate of precured composite material, the laminate of precured composite material including;

a plurality of precured, pultruded composite layers, wherein each of the pultruded composite layers overlaps with the others in the at least one spar at at least one longitudinal location, and wherein individual precured, pultruded composite layers have a chordwise extent and a thickness extent less than the chordwise extent; and

a plurality of adhesive layers interposed between adjacent precured, pultruded composite layers.

16. The wind turbine blade of claim 15 wherein individual precured, pultruded composite layers terminate at different longitudinal locations.

17. The wind turbine blade of claim 16 wherein the terminations are chamfered.

18. The wind turbine blade of claim 17 wherein the terminations are staggered to form a tapered shape along the longitudinal axis.