CN100999137A - 制造风力涡轮机转子叶片的方法 - Google Patents

制造风力涡轮机转子叶片的方法 Download PDF

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CN100999137A
CN100999137A CNA2006101689267A CN200610168926A CN100999137A CN 100999137 A CN100999137 A CN 100999137A CN A2006101689267 A CNA2006101689267 A CN A2006101689267A CN 200610168926 A CN200610168926 A CN 200610168926A CN 100999137 A CN100999137 A CN 100999137A
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reinforcing fibre
fibre
wind turbine
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resin
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CN100999137B (zh
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J·T·利文斯顿
A·H·E·伯克
J·W·巴克惠斯
S·范布吕格尔
A·比伦
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Abstract

一种制造风力涡轮机叶片(114)的叶根部(116)的方法，包括，在一个示例性的实施例中，提供一个加强纤维的外层(132)，该外层包含至少两层加强纤维的编织垫，提供一个加强纤维的内层(130)，该内层包含至少两层加强纤维的编织垫，在所述外层和内层间布置至少两个加强纤维段(134，136)，其中每段加强纤维包含至少两层加强纤维的编织垫。所述方法更进一步包括：将一个任意分布的加强纤维的垫(140)设置在每对相邻的加强纤维段之间，将聚合树脂引入风力涡轮机叶片的叶根部，将树脂注入透外层、内层、每个加强纤维段和每个任意分布的加强纤维段，使树脂凝固以形成风力涡轮机叶片的叶根部。

Description

制造风力涡轮机转子叶片的方法
技术领域
本发明总体上涉及风力涡轮机，更具体而言涉及制造风力涡轮机转子叶片的方法。
背景技术
近来，风力涡轮机作为一种环保且造价相对便宜的可选能源已经受到越来越多的关注。随着这种关注的提高，人们已经作出了很多努力以制造出可靠和有效率的风力涡轮机。
一般来说，风力涡轮机包括一个具有多个叶片的转子。转子安装在一个箱体或吊舱上，箱体或吊舱位于一个钢梁或一管状塔的顶部。公用电网(utilitygrade)风力涡轮机(即，设计用来提供电力给公用电网的风力涡轮机)可以具有大型的转子(例如，直径30米或更大)。这些转子上的叶片将风能转化为驱动一个或多个发电机的旋转扭矩或力，该发电机通过一变速箱旋转地连接在转子上或直接连接在转子上。所述变速箱，当有此设备时，为前述发电机逐级提高风力涡轮机转子的固有的低转速从而有效地将机械能转化为电能，该电能被输入公用电网。
已知风力涡轮机叶片是通过将树脂注入纤维卷绕的核心而制成。但是，由于叶片的叶根部为适应高负载而较厚，所以已知的将树脂注入厚部的方法并不总能在一个不长于树脂注满的周期内形成一个无缺陷的部件。一个可能发生的问题是在未注入树脂的地方形成干斑。一些为解决这些问题的方法是利用增加的预处理和/或后处理，以将树脂注入干斑处。这些解决办法通常会通过这些附加工序中的机器或设备而引起直接增加的人工成本、部分增加的周期时间和增加的便利。
发明内容
一方面，本发明提供一种制造风力涡轮机叶片的叶根部的方法。所述风力涡轮机叶片包括叶根部、主干部和叶尖部。所述方法包括如下步骤：提供加强纤维的外层，该外层包含至少两层加强纤维的编织垫，提供加强纤维的内层，该内层具有内表面和外表面并包含至少两层加强纤维的编织垫，在所述外层和内层间设置至少两个加强纤维段，其中每段加强纤维包含至少两层加强纤维的编织垫。所述方法还包括：将一个任意分布的加强纤维的垫设置在每对相邻的加强纤维段之间，将聚合树脂引入风力涡轮机叶片的叶根部，将树脂注入透过外层、内层、每个加强纤维段和每个任意分布的加强纤维的垫，使树脂凝固以形成风力涡轮机叶片的叶根部。
另一方面，本发明提供一种制造风力涡轮机叶片的叶根部的方法。所述风力涡轮机叶片包括叶根部、主干部和叶尖部。所述方法包括步骤：提供加强纤维的内层，其包含至少两层加强纤维的编织垫，所述内层具有内表面和外表面，将第一加强纤维段设置在与所述内层的外表面相邻位置，所述第一段具有内表面和外表面并包含至少两层加强纤维的编织垫，将任意分布的加强纤维的第一编织垫任意设置在与第一加强纤维段的外表面相邻位置，此第一编织垫具有内表面和外表面。此方法还包括：将第二加强纤维段设置在与所述第一编织垫的外表面相邻位置，此第二段具有内表面和外表面并包含至少两层加强纤维的编织垫，将一个包含至少两层加强纤维的编织垫的加强纤维外层设置在与所述第二段相邻位置，此外层具有内表面和外表面，将聚合树脂引入风力涡轮机的叶根部，将树脂注入透过外层、内层、每个加强纤维段和每个任意分布加强纤维垫，将树脂凝固以形成风力涡轮机叶片的叶根部。
另一方面，本发明还提供一种包括叶根部、主干部和叶尖部的风力涡轮机叶片，其中主干部位于叶根部和叶尖部之间。叶根部包括包含至少两层加强纤维的编织垫的加强纤维外层，具有内表面和外表面并包含至少两层加强纤维的编织垫的加强纤维内层，至少两段布置在外层和内层之间的加强纤维段，其中每段加强纤维包含至少两层加强纤维的编织垫。叶根部进一步还包括布置在每对相邻的加强纤维段之间的任意分布的加强纤维的垫，以及注入透过外层、内层、每个加强纤维段和每个任意分布加强纤维垫的聚合树脂。
附图说明
图1是一个风力涡轮机的示例性的配置的侧面视图。
图2是图1中所示的风力涡轮机转子叶片中之一的叶根部的一部分的分解剖视图。
部件列表：100风力涡轮机；102塔；104支撑表面；106吊舱；108底座；110转子；112轮毂；114转子叶片；116叶根部；118主体部；120叶尖部；122空腔；130内层；132外层；134加强纤维的第一段；136加强纤维的第二段；138加强纤维的第三段；140任意分布的加强纤维的垫；142第一段134的外表面；144第二段136的内表面；146第二段136的外表面；148第三段138的内表面；150内层130的内表面；152内层130的外表面；154第三段136的上表面。
具体实施方式
以下将详细描述一种制造风力涡轮机转子叶片根部的方法。本方法采用了在结构加强纤维段之间添加由任意分布的加强纤维形成的垫，其中结构加强纤维由至少两层加强纤维的编织垫形成。所述任意分布的纤维垫利于合成树脂注入透过叶片根部的整个厚度和消除结构中的“干斑”。此方法通过消除了对增加风力涡轮机叶片较厚部分(即叶根部)的第二工序的需要，从而减少了循环次数和成本。
参照附图，图1是一个例如一个水平轴风力涡轮机的风力涡轮机100的侧面视图。风力涡轮机100包括从支承表面104延伸出的塔102、连接在塔102的底座108上的吊舱106，以及安装在吊舱106上的转子110。转子110包括轮毂112和多个连接在轮毂112上的转子叶片114。在示例性的实施方式中，转子110包括三个转子叶片114。在一个可选实施方式中，转子110包括多于或少于三个的转子叶片114。每个转子叶片114包括将转子叶片114连接于轮毂112上的叶根部116、主体部118和叶尖部120。在示例性的实施方式中，塔102由管状钢材制成并包括一个在支撑表面104和吊舱106之间延伸的空腔122。在一个可选的实施方式中，塔102是格状结构塔。
在示例性的实施方式中，风力涡轮机100的不同部件都容纳在风力涡轮机100的顶部塔102的吊舱106中。塔102的高度基于本领域中已知的因素和工况来进行选择。在一些配置中，一个控制系统中的一或多个微控制器用于整个系统的监控并控制包括对节距和速度的调节、高速轴和偏航制动器的应用、偏航和泵用电动机的应用和故障监控。可选择的分布式或集中式控制结构用于风力涡轮机100的可选实施方式中。在示例性的实施方式中，叶片114的节距是单独进行控制的。轮毂112和叶片114一起组成了风力涡轮机转子110。转子110的转动带动发电机(图中未示出)发出电力。
在使用中，叶片114绕轮毂112设置，以利于旋转转子110将风的动能转化为可用的机械能。当风冲击叶片114且叶片114被转动并受到离心力时，叶片114受到不同的弯曲运动。由于这些原因，叶片114从一个中间或无偏离的位置偏离和/或旋转到一个偏离位置。而且，叶片114的螺旋角可以由一个角调节机构(未示出)来改变从而利于使叶片114增速或减速，进而利于减小塔102受到的冲击。
参照附图2，叶根部116由以聚合树脂注入的多层加强纤维层形成。特别地，叶根部116包括内层130和外层132。内层130和外层132的每个均由相互堆叠的至少两层加强纤维的编织垫形成。至少两段加强纤维段设置在内层130和外层132之间。在图2所示的实施例中，加强纤维的第一段134、加强纤维的第二段136和加强纤维的第三段138设置在内层130和外层132之间。第一段134、第二段136和第三段138每个均由相互堆叠的至少两层加强纤维的编织垫形成。适用于内层130和外层132、第一段134、第二段136和第三段138的加强纤维举例包括但不仅限于玻璃纤维、石墨纤维、碳纤维、聚合纤维、陶瓷纤维、芳香尼龙纤维、洋麻纤维、黄麻纤维、亚麻纤维、大麻纤维、纤维质纤维、剑麻纤维、椰皮纤维和它们的混合物。
另外，为了利于合成树脂注入叶根部116的整个厚度，一个任意分布的加强纤维垫140设置于每对相邻的加强纤维段之间。在图2示出的示例性实施方式中，一个任意分布的纤维垫140设置于加强纤维第一段134的外表面142和加强纤维第二段136的内表面144之间。另外一个任意分布的纤维垫140设置于加强纤维第二段136的外表面146和加强纤维第三段138的内表面148之间。此外，还可以在内层130的内表面150附近设置另一个任意纤维垫。聚合树脂注入包括有内层130、加强纤维第一段134、第二段136和第三段138、任意纤维垫140和外层132的叶根部116从而为叶根部116和叶片114提供完整性和强度。适用的树脂举例包括但不仅限于乙烯基酯树脂、环氧树脂、聚酯树脂及其混合物。
为了形成风力涡轮机叶片114的叶根部116，加强纤维第一段134设置在与内层130的外表面152相邻处并且一任意分布的纤维垫140设置为与加强纤维第一段134的外表面142相邻。然后将加强纤维第二段136设置为与任意分布的纤维垫140相邻。再将另一任意分布的纤维垫140设置为与加强纤维第二段136的外表面相邻并将加强纤维第三段138设置为与此任意分布的纤维垫140相邻。然后将外层132布置为与第三段136的上表面154相邻。可选地还可以在内层130的内表面150相邻处再布置一个任意分布的纤维垫。聚合树脂在真空作用下注入到这些加强纤维层各层中然后凝固。
尽管本发明依据各种特定的实施方式进行上述描述，但是本领域技术人员应当认识到，本发明可在权利要求的精神和范畴内修改实施。

Claims (9)

1、一种制造风力涡轮机叶片(114)的叶根部(116)的方法，所述风力涡轮机叶片包括叶根部、主干部(118)和叶尖部(120)，所述方法包括：
提供加强纤维的外层(132)，该外层包含至少两层加强纤维的编织垫；
提供加强纤维的内层(130)，该内层具有内表面(150)和外表面(152)，并包含至少两层加强纤维的编织垫；
在所述外层和内层之间设置至少两段加强纤维(134，136)，其中每段加强纤维包含至少两层加强纤维的编织垫；
将任意分布的加强纤维的垫(140)设置在每对相邻的加强纤维段之间；
将聚合树脂引入到风力涡轮机叶片的叶根部中；
透过外层、内层、每个加强纤维段和每个任意分布的加强纤维的垫来注入树脂；以及
使树脂凝固以形成风力涡轮机叶片的叶根部。
2、如权利要求1所述的方法，其特征在于，所述方法还包括在加强纤维内层(130)的内表面(150)的附近处设置另外一个任意分布的加强纤维的垫(140)。
3、如权利要求1所述的方法，其特征在于，所述加强纤维包括玻璃纤维、石墨纤维、碳纤维、陶瓷纤维、芳族聚酰胺纤维、洋麻纤维、黄麻纤维、亚麻纤维、大麻纤维、纤维质纤维、剑麻纤维和椰皮纤维中的至少一种。
4、如权利要求1所述的方法，其特征在于，所述树脂包括乙烯基酯树脂、环氧树脂和聚酯树脂中的至少一种。
5、如权利要求1所述的方法，其特征在于，所述透过外层(132)、内层(130)、每个加强纤维段(134～138)和每个任意分布的加强纤维的垫(140)来注入树脂包括将真空施加于风力涡轮叶片(114)的叶根部(116)处。
6、一种风力涡轮机叶片(114)，包括叶根部(116)、主干部(118)和叶尖部(120)，其中所述主干部位于叶根部和叶尖部之间，所述叶根部包括：
包含至少两层加强纤维的编织垫的加强纤维外层(132)；
具有内表面(150)和外表面(152)并包含至少两层加强纤维的编织垫的加强纤维内层(130)；
至少两段布置在所述外层和内层之间的加强纤维(134，136)，其中每个加强纤维段包含至少两层加强纤维的编织垫；
布置在每对相邻加强纤维段之间的任意分布的加强纤维的垫(140)；以及
透过所述外层、内层、每个加强纤维段和每个任意分布的加强纤维的垫而注入的聚合树脂。
7、如权利要求6所述的风力涡轮机叶片(114)，其特征在于，所述叶片还包括设置在加强纤维内层(130)的内表面(150)的附近的另外一个任意分布的加强纤维的垫(140)。
8、如权利要求6所述的风力涡轮机叶片(114)，其特征在于，所述加强纤维包括玻璃纤维、石墨纤维、碳纤维、陶瓷纤维、芳族聚酰胺纤维、洋麻纤维、黄麻纤维、亚麻纤维、大麻纤维、纤维质纤维、剑麻纤维和椰皮纤维中的至少一种。
9、如权利要求6所述的风力涡轮机叶片(114)，其特征在于，所述树脂包括乙烯基酯树脂、环氧树脂和聚酯树脂中的至少一种。
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