Highly Reliabile, Low Cost Wind Turbine Rotor Blade

Abstract

A wind turbine rotor blade and a wind turbine incorporating the rotor blade include a first and second composite skin. A first and a second spar pultrusion having a base and a plurality of integral ribs generally normal to base are attached to the inside surface of the first and second composite skins and extend the span of the rotor blade. At least one shear web connects a rib of the first spar pultrusion to a corresponding rib of the second spar pultrusion. The width of the spar pultrusions decreases in a step-wise fashion along the span of the rotor blade from the root to the tip. The leading or trailing edge of the rotor blade may be selectably opened for inspection and repair.

1 . A method of inspecting a rotor blade for a wind turbine, the method comprising:
 a. providing a first skin and a second skin, said first skin and said second skin each defining a trailing edge portion, said trailing edge portion of said first skin being releasably attached to said trailing edge portion of said second skin;   b. detaching said trailing edge portion of said first skin from said trailing edge portion of said second skin;   c. inspecting the rotor blade.   
     
     
         2 . The method of  claim 1  wherein the rotor blade has a trailing edge, said trailing edge being defined by said trailing edge portions of said first and said second skins when said trailing edge portions are releasably attached, said step of inspecting the rotor blade further comprising: opening said trailing edge. 
     
     
         3 . The method of  claim 2  wherein said step of providing said first skin and said second skin further comprising: providing a mechanical lock, said mechanical lock releasably attaching said trailing edge portions of said first and second skins one to the other, said mechanical lock being located proximal to said trailing edge. 
     
     
         4 . The method of  claim 3  wherein said step of providing said mechanical lock further comprising: providing a male portion and a female portion defining said mechanical lock, said male portion being attached to said trailing edge portion of a one of said first and second skins, said female portion being attached to said trailing edge portion of the other of said first and said second skins, said male and said female portions of said mechanical lock releasably attaching said trailing edge portions of said first and second skins one to the other. 
     
     
         5 . The method of  claim 4  wherein said step of detaching said trailing edge portion of said first skin from said trailing edge portion of said second skin comprising: detaching said male portion and said female portion of said mechanical lock. 
     
     
         6 . The method of  claim 1  wherein said step of providing said first and said second skins further comprising: providing a first spar and a second spar, said first spar having an attachment to said first skin, said second spar having an attachment to said second skin, said first spar having an attachment to said second spar. 
     
     
         7 . The method of  claim 6  wherein said step of inspecting the rotor blade further comprising: inspecting said attachment between said first skin and said first spar, inspecting said attachment between said second skin and said second spar, and inspecting said attachment between said first spar and said second spar. 
     
     
         8 . The method of  claim 1  wherein the rotor blade has a leading edge and each of said first and second skins defines a leading edge portion, the method further comprising: providing a leading edge skin, said leading edge skin being in a hinged connection to said leading edge portion of a one of said first skin and said second skin, said leading edge skin defining said leading edge of the rotor blade. 
     
     
         9 . The method of  claim 8  wherein said step of providing said leading edge skin further comprising: providing a leading edge skin hinge, said leading edge skin hinge releasably attaching said leading edge skin to said leading edge portion of said first or said second skins, said leading edge skin hinge defining said hinged connection. 
     
     
         10 . The method of  claim 9  wherein said step of providing said leading edge skin hinge further comprising: providing a skin leading edge pultrusion and a retaining pin, said leading edge pultrusion being attached to said leading edge portion of said first or said second skins, said leading edge skin hinge being attached to said leading edge skin, said retaining pin releasably attaching said leading edge pultrusion and said leading edge skin hinge, and wherein said step of inspecting the rotor blade further comprising: removing said leading edge skin. 
     
     
         11 . A method of inspecting a rotor blade of a wind turbine, the method comprising:
 a. providing a first skin and a second skin, said first skin and said second skin each defining a trailing edge portion, said trailing edge portions of said first and said second skins having a configuration for releasable attachment one to the other;   b. providing a first spar and a second spar, said first spar having an attachment with said first skin, said second spar having an attachment with said second skin, said first spar having an attachment to said second spar;   c. inspecting said attachment between said first spar and second spar; and   d. releasably attaching said trailing edge portions of said first and said second skins.   
     
     
         12 . The method of  claim 11  wherein the rotor blade has a trailing edge, said trailing edge being defined by said trailing edge portions of said first and said second skins when said trailing edge portions are releasably attached. 
     
     
         13 . The method of  claim 12 , the method further comprising: inspecting said attachment between said first skin and said first spar and inspecting said attachment between said second skin and said second spar prior to said step of releasably attaching said trailing edge portions of said first and second skins. 
     
     
         14 . The method of  claim 11  wherein the rotor blade has a trailing edge, said step of providing said first skin and said second skin further comprising: providing a mechanical lock proximal to said trailing edge of the rotor blade, said mechanical lock being configured to releasably attach said trailing edge portions of said first and second skins one to the other, said mechanical lock defining said configuration for releasable attachment of said trailing edge portions of said first and second skins. 
     
     
         15 . The method of  claim 14 , said step of providing said mechanical lock further comprising: providing a male portion and a female portion defining said mechanical lock, said male portion being attached to said trailing edge portion of a one of said first and second skins, said female portion being attached to said trailing edge portion of the other of said first and said second skins, said male and said female portions of said mechanical lock being configured to releasably attach said trailing edge portions of said first and second skins one to the other. 
     
     
         16 . The method of  claim 15 , said step of releasably attaching said trailing edge portion of said first skin to said trailing edge portion of said second skin comprising: releasably attaching said male portion and said female portion of said mechanical lock. 
     
     
         17 . The method of  claim 11  wherein the rotor blade has a leading edge, the method further comprising: providing a leading edge skin, said leading edge skin being in a hinged connection to said leading edge portion of a one of said first skin and said second skin, said leading edge skin defining said leading edge of the rotor blade. 
     
     
         18 . The method of  claim 17  wherein said step of providing said leading edge skin further comprising: providing a leading edge skin hinge, said leading edge skin hinge releasably attaching said leading edge skin to said leading edge portion of said first or said second skins, said leading edge skin hinge defining said hinged connection. 
     
     
         19 . The method of  claim 11  wherein said first spar and said second spar each defines a plurality of elongated ribs and wherein said attachment between said first spar and said second spar is a shear web, said shear web having a first shear web edge and an opposing second shear web edge, said first shear web edge being attached to a one of said ribs of said first spar, said second shear web edge being attached to a one of said ribs of said second spar, said step of inspecting said attachment between said first and second spars comprising: inspecting said attachments of said first edge of said shear web and said rib of said first spar and said attachment of said second edge of said shear web and said rib of said second spar.