Field of the Invention

The present invention relates to a support module for supporting for example a wind turbine blade during storage, transport and the like.

The surface of the module is pressed in tight contact with the surface of the blade and the result produces a friction force for holding the blade in a fixed position.

In order to ensure that the friction is present and maintained it is important to instigate detection, action and control of the conditions of the module in order to secure and control a specific and defined friction force between the surface of the blade and the surface of the module under changing conditions of the environment and different chal- lenges/conditions, for example during transport.

Background of the Invention

A blade for a wind turbine is a large construction and the transportation from factory facilities to the storage place or the place for the wind turbine to be erected can have many challenges due to for example dimensions, weight and logistics. The blade is often placed in racks/consoles, where the blade has a two-point support - a base support near the end/root where the blade is to be mounted and a dynamic support near the tip of the blade or at a determined position along the blade (away from the root). The racks/consoles can be placed on a truck or ship for transportation or on the ground for storage.

The base support is often fixed in the rack/console.

The dynamic support can be placed at a point along the centre line of the blade, where it can give the most optimal support to the blade, and then it is fixed in this position. It is important that the dynamic support is fixed, partly for preventing the blade from sliding when it is fastened and partly to ensure that the blade is fixed in the rack/console to secure safe handling, transport or storage. The blade has two surfaces. The dynamic support often has two shields or plates which are fastened with one shield/plate on each surface of the blade. In order to give the best contact between the shield/plate and the surface of the blade it is very common to mould the shield/plate in the shape of the blade, such that the shield/plate follows the contour of the blade’s surface. This is very expensive as the contour of the blade may change, i.e. blades may be produced in relatively small/limited series, whereby the shield/plate can only be used a few times. The design and shape of the blade is a parameter for optimization and every time the design of the blade is changed, new forms for the shield/plates are made.

The moulded plates are, in order to give strength, not very resilient. When there are issues with the transport due to vibration, lifting the rack/console or when the truck is driving on bumpy roads the blade may for example be twisted. If the shield/plate has less resilience it can cause damage on the blade and less friction force between the surface of the blade and the shield/plate when the area of friction is not complete.

In order to ensure a good contact for the friction area of the blade and/or a gentle support for the blade the shield/plate has often a cushion layer between the surface of the shield/plate and the surface of the blade. As an example, textiles, rubber or composite material can be used. Due to the large area of friction, less resilience in the shield/plate, the large forces, the weight of the blade and the issues as a result of weather conditions and transportation the layer in between will often crumple, slip, loosen or slide with damages to the surface of the blade as a result.

It is desirable to have a modular and scalable solution usable for many different contours, forms and designs of the blade that can be adapted with flexibility and resilience and with hollow sections has low weight, high stability for temperatures and good drainage due to wet conditions and give no staining to the surface. Object of the Invention

The object of this invention is a solution and a method to make it possible to provide conditions required to ensure that the friction force needed for support and fixation of blades for wind turbines under storage or transportation is provided.

Description of the Invention

The invention addresses this object by providing a module for supporting a blade for a wind turbine during transport said module having a main body made from a resilient material integral with a base plate, where the module has a width and a length and a thickness orthogonal to a plane defined by the width and length where an upper surface of the main body is suitable for contact with the wind turbine blade and where the base plate is suitable to be mounted on or be in contact with a support wagon, and where the material of the main body has a plurality of hollow sections, such that the thickness of the resilient material varies.

The module comprises a main body of soft/resilient material. When the modules are mounted on the shield/plate, in use they are urged towards and fastened in contact with the surface of the blade. The resilient material of the module can adapt to the form of the blade and give the surface of the modules mounted on the shield/plate a close and tight contact to the surface of the blade. This will ensure that a large and sufficient friction force can be produced for the purpose of fixating the blade in position.

The modules are arranged in arrays in order to have a substantially continuous surface on at least two flexible shields/plates and then mounted in a rack/console where the two shields/plates are turned opposite each other so that the resilient material of the modules are turned against and in contact with the surface of the blade. The array of modules on the shield/plate makes it possible to have an optimal friction area for surface contact.

The design of the arrays, the resilient body and the tight contact to surfaces of the blade in combination create a friction between the surfaces and make it possible to have an adaptable, gentle and secure support for a blade for a wind turbine when transport and/or storage is needed. In use there is at least one module on a shield/plate, but mostly there are more than one module bolted on a shield/plate arranged in an array so that the modules can provide as large an area of friction as possible to the blade surface. The shield/plate is often formed closely to the shape/contour of the blade to give a uniform distribution of force across the shield/plate, and hence distribute friction force between the surface of the module and the surface of the blade.

In another embodiment the shield/plate is flexible and resilient so that the shield/plate can adapt to the design/contour of the surface of the blade when the shields/plates are fastened.

In a further advantageous embodiment the upper surface is shaped with a plurality of contact sections separated by troughs (or grooves), and where the hollow sections are arranged between the upper surface of the contact sections and the baseplate.

The hollow sections will be more deformable than massive sections. Furthermore, the troughs/grooves allow for displacement of material when exposed to a load, in particular lateral loads. The troughs allow for slight movements of the contact sections.

In a further embodiment the base plate is provided with apertures connecting to the hollow sections.

The apertures connecting the hollow sections to the ambient environment allows for equalisation of air pressure, such that the support sections can be deformed - and not function as a kind of air spring.

Further aspects of the invention include that the material thickness of the resilient material of the contact sections above the hollow sections is 15 to 25% of the entire thickness of the module, and that the apertures in the base plate constitute 50-75% of the area of the base plate.

An important aspect of the invention is to select a suitable material able to provide the characteristics of the module. A suitable material may be that the resilient material is polyurethane, and further that the base plate is made from stainless steel, aluminium or a fibre reinforced resin plate.

In a further advantageous embodiment a temperature sensor and/or a heating element is cast into the resilient material, and a control box is provided in order to control the heating element with input from the sensor, to maintain a predefined temperature regime in the resilient material.

The at least one sensor is attached or embedded in the module. The sensor can detect e.g. temperature or mechanical stress or load or friction or viscosity or mechanical stretch or resilience or force or load or movements between contacting surfaces.

The module may have more sensors with equal and/or a combination of sensors.

The means for heating is a heating element integrated in the main body. The element is often a thread provided with electrical energy and when the energy is supplied the thread is getting warm and the heat is transmitted to the material of the main body. By controlling the temperature - e.g. by a thermostat - of the main body, the friction between the material of the module and the blade can be controlled.

In another embodiment the heating module is a tube containing fluid for heating.

In another embodiment the heating module is a heating plate integrated in the main body which is plugged to electrical energy, and by controlling the temperature - e.g. by a thermostat - of the main body, the friction between the material of the module and the blade can be controlled.

In another embodiment there is an external heating of the material of the main body, e.g. a heating fan.

The means for cooling may be a cooling element attached to or integrated in the main body. It is mostly a plate where the cooling emerges when the plate is provided with electrical energy and by controlling the temperature - e.g. by a thermostat - of the main body, the friction between the material of the module and the blade can be controlled. In another embodiment there is an external cooling of the material of the main body, e.g. a cooling fan.

In another embodiment the cooling element is a thread integrated in the main body and provided with electrical energy.

In another embodiment the cooling element is a tube integrated in the main body and with a fluid used for cooling.

The invention is also directed to a method where the blade for a turbine is placed between two shields/plates according to the invention where modules are mounted and arranged in an array on each shield/plate to give a tight and gentle support under transport and storage and where the control of the material properties of the module is required to ensure the friction force needed for fixation and/or a gentle support of the blade under storage or transportation due to the surrounding weather conditions (e.g. temperature, humidity, moist) wherein according to the invention at least one module has at least one hollow section.

One objective of the invention is achieved by a method of supporting a blade for a wind turbine during transport using multiple modules for supporting a blade for a wind turbine during transport. The modules comprise a main body made from a resilient material integral with a base plate. The module has a width, a length and a thickness orthogonal to a plane defined by the width and length where an upper surface of the main body is suitable for contact with the wind turbine blade and where the base plate is suitable to be mounted to a shield. The method comprises acts of:

- arranging the wind turbine blade between two shields, where on each shield multiple modules are mounted and arranged in an array, and

- arranging the wind turbine blade in contact with the modules for obtaining a resilient support during handling, transport and storage.

At least one of the multiple modules are a module according to one or more of the embodiments disclosed herein. The base plate is mostly produced in metal partly to give strength to the module and partly to give a strong base for the module to be mounted on by e.g. bolts, glue or adhesive to the shield/plate. Mostly there are at least one aperture for mounting to the shield/plate.

In another embodiments the base plate is produced e.g. in rubber, plastic or composite material to ensure a stable, stretchable and resilient mounting to the shield/plate.

The main body is mostly produced in Polyurethan (PUR).

In another embodiment the main body is produced in e.g. composite material, textile or rubber.

In another embodiment the main body comprises an array of hollow sections to give more flexibility (e.g. stretch, resilience) and attenuation and for reducing the amount of material thereby reducing costs.

Description of the invention

FIG 1A - IB: Illustrate the situation before and after mounting the dynamic support to the blade respectively.

FIG 2A - 2B: Illustrate examples of embodiments of arrays for the modules when the modules are mounted on the shield/plate.

FIG 3A: Illustrates a module where the main body of the module is upward.

FIG 3B: Illustrates a module where the base plate of the module is upward.

FIG 3C: Illustrates a cross-section (A-A) of the module.

FIG 4: Illustrates as an example various kinds of sensors mounted on the surface of the module, integrated in the module and inserted into the module respectively.

FIG 5 : Illustrates an example of an embodiment where heating/cooling plates are integrated in the module.

FIG 6: Illustrates an embodiment of the module with an example of hollow sections. Detailed Description of the Invention

FIG 1A - IB illustrate the situation before and after mounting the dynamic support to the blade (150) respectively. The blade (150) is placed in two consoles/racks (100) and mounted in abase support (210) and a dynamic support (220) respectively. The dynamic support (220) comprises a rack (100) and two shields/plates (300). The shields/plates have several modules (400) mounted in arrays modified to the design and contour of the surface of the blade (150). The tip of the blade (150) is placed between the two shields/plates (300), and the rack (100) with the dynamic support (220) is placed in a position where the dynamic support (220) can give fixation and the best support to the blade (150). The modules (400) are now in tight contact with the surface of the blade (150). With the dynamic support (220) in position the shields/plates (300) are fastened. The blade (150) is tightly, gently and sufficiently secured for transportation or storage.

FIG 2A - 2B illustrate examples of embodiments of arrays for the modules (400) when the modules (400) are mounted on the shield/plate (300) (see fig. 1A). The modules (400), in the sectional view in fig 2A - part of seven modules are illustrated, are placed in an array that gives the best support and contact to the blade (150) (see fig IB) and with an area in contact with the blade (150) that gives sufficient friction force for a secure fixation under transport and in storage.

FIG 3 A - 3B illustrate a module (400) in two positions. In FIG. 3 A the main body (430) is upwards and the apertures (435) of the main body (430) (see also fig 2A) are illustrated. In FIG. 3B the module (400) is turned upside down and the base plate (450) with apertures (455) is shown (see also fig. 2A).

FIG 3C illustrates a sectional cross-section (A-A) of the module (400). The main body (430) is in tight and strong contact with the base plate (450). The main body (430) and the base plate (450) can for example be glued or vulcanized to give a strong and non- stretchable fixation.

FIG 4 illustrates as an example where various kinds of sensors (510, 520, 530, 540) are mounted on the surface of the module (400), integrated in the module (400) and inserted in the module (400) respectively. These sensors (510, 520) could in another embodiment have a position on the surface of the base plate (FIG. 3B pos. 450). The integrated sensor (540) could have different positions in the main body (430) and is typically integrated when the moulding of the main body (430) takes place. It could be placed between the surfaces of the main body (430) and the surfaces of the base plate (450) when these for example are glued or vulcanized together. Inserting a sensor is a possibility for example when the blade (150) is in place (see fig. IB) and fixed in position between the shield/plate and there is a need for detecting if the module (400) exhibits the desired characteristics. Then a sensor (530) can be inserted into a desired position in the main body (430) for detection. The sensors (510,520) may for example be strain gauges or other suitable sensors for detecting stress or tension in the module (400). The sensors (540,530) may be temperature probes, sensing the temperature in the body of the main body.

The illustrated sensor (510) may also illustrate how a heating filament may be arranged inside the module (400).

FIG 5 illustrates an example of an embodiment where heating/cooling plates (610) are integrated in the module (400). The heating/cooling plates (610) are typically integrated when the moulding of the main body (430) takes place. The heating plates (610) could be placed between the surfaces of the main body (430) and the surfaces of the base plate (FIG. 3B pos. 450) when the main body and the base plate is assembled by means of for example glue or vulcanized. The heating/cooling plates (610) can adjust/regulate the temperature up or down of the main body (430). With the control (e.g. thermostatic) of the temperature an optimal condition for providing the friction force between the surface of the main body (430) and the surface of the blade (150) can be ensured. Also other configurations of heating elements is contemplated, such as for example embedded heating filaments (indicated above with reference to fig. 4 (see ref 510).

FIG 6 illustrates an embodiment of the module (400) with an example of hollow sec- tions/voids (710). The hollow sections (710) are primarily for optimizing the use of material in the main body (430). The hollow sections (710) can also contain different types of sensors in order to detect different characteristics. These sensors can be integrated and can be changed if needed when the module (400) is to be used under different conditions and with the possibility detecting different characteristics. The hollow sections (710) can give an integrated pillow of air when the main body (430) is for example glued or vulcanized to the base plate (FIG. 3B pos. 450). This pillow of air can give an attenuation to the dynamic support (220) of the blade (150).