Method of manufacturing a wind turbine blade root

Abstract

A wind turbine blade root having fully bonded insert bushings with internal threads for mounting bolts for releasable attachment to a hub of a wind turbine is manufactured by arrangement of a plurality of the insert bushings on a first layer of fibre mat arranged on a holder having a plurality of spaced recesses for accommodation of the insert bushings such that the bushings extend largely in a longitudinal direction of the blade accommodated in the spaced recesses. Subsequently, a number of additional layers of fibre mat are arranged on top of the bushings, and the fibre mat layers are consolidated.

1. A method of manufacturing a blade root of wind turbine blade, having a plurality of fully bonded insert bushings having a longitudinal hole with internal thread for mounting bolts for releasable attachment to a hub of a wind turbine, the method comprising the steps of:
 providing an a segmented annular holder having a plurality of spaced recesses provided in an inner circumferential surface of the holder; 
 lining the inner circumferential surface of each segment of the holder with a first fibre mat layer such that said first fibre mat layer is at least partially received in the recesses; 
 respectively placing the plurality of insert bushings in said recesses such that said bushings contact the first fibre mat layer and extend substantially in the longitudinal direction of the blade; 
 providing an additional fibre mat layer over the insert bushings such that the insert bushing are substantially encased between the first fibre mat layer on an outer radial side of the insert bushings and the additional fibre mat layer on an inner radial side of the insert bushings; and 
 consolidating the fibre mat layers. 
 
     
     
       2. The method according to  claim 1 , further comprising the additional steps of using mat layers of a pre-preg type, and heating the blade root to consolidate the pre-preg mat layers. 
     
     
       3. The method according to  claim 2 , wherein said first portion of the insert bushing is substantially cylindrical. 
     
     
       4. The method according to  claim 2 , wherein the insert bushings are metallic. 
     
     
       5. The method according to  claim 2 , wherein a proximal portion of said first portion of each insert bushing is thread-free. 
     
     
       6. The method according to  claim 2 , wherein external surfaces of insert bushings are smooth. 
     
     
       7. The method according to  claim 2 , wherein external surfaces of insert bushings are slightly roughened. 
     
     
       8. The method according to  claim 1 , further comprising the step of using each insert bushing comprising a first portion and an extension portion having gradually increased flexibility in the direction away from the first portion. 
     
     
       9. The method according to  claim 8 , wherein the extension portion of each insert bushing is chamfered to provide a gradually reduced cross-section. 
     
     
       10. The method according to  claim 1 , further comprising the additional step of compacting the fibre mat layers using vacuum mats. 
     
     
       11. The method according to claim 1, wherein each segment of the holder has a semicircular cross-section. 
     
     
       12. The method according to claim 11, further comprising the additional steps of using mat layers of a pre-preg type, and heating the blade root to consolidate the pre-preg mat layers. 
     
     
       13. The method according to claim 1, wherein said insert bushings respectively include substantially cylindrical first portions. 
     
     
       14. The method according to claim 1, wherein the insert bushings are metallic. 
     
     
       15. The method according to claim 13, wherein a proximal portion of said first portion of each insert bushing is thread-free. 
     
     
       16. The method according to claim 1, wherein external surfaces of said insert bushings are smooth. 
     
     
       17. The method according to claim 1, wherein external surfaces of said insert bushings are slightly roughened. 
     
     
       18. The method according to claim 1, wherein each insert bushing includes a first portion and an extension portion, the extension portion having gradually increased flexibility in a direction extending away from the first portion. 
     
     
       19. The method according to claim 18, wherein the extension portion of each insert bushing is chamfered to provide a gradually reduced cross-section. 
     
     
       20. The method according to claim 1, further comprising the additional step of compacting the fibre mat layers using vacuum mats. 
     
     
       21. The method according to claim 1, further comprising the step of arranging respective fibre glass strips between adjacent bushings. 
     
     
       22. The method according to claim 21, wherein the arranging step comprises arranging multiple fibre glass strips between adjacent bushings.