CN101737250B - 涡轮机叶片制造 - Google Patents

涡轮机叶片制造 Download PDF

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CN101737250B
CN101737250B CN200910224639.7A CN200910224639A CN101737250B CN 101737250 B CN101737250 B CN 101737250B CN 200910224639 A CN200910224639 A CN 200910224639A CN 101737250 B CN101737250 B CN 101737250B
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blade
partition
integrated partition
described integrated
dividing plate
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CN101737250A (zh
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B·柯克佩特里克
P·L·贝曼
郭书敬
G·N·普拉维恩
Y·周
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LM Wind Power AS
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General Electric Co
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • B23P15/04—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass turbine or like blades from several pieces
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
    • F03D—WIND MOTORS
    • F03D1/00—Wind motors with rotation axis substantially parallel to the air flow entering the rotor 
    • F03D1/06—Rotors
    • F03D1/065—Rotors characterised by their construction elements
    • F03D1/0675—Rotors characterised by their construction elements of the blades
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05B—INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
    • F05B2240/00—Components
    • F05B2240/20—Rotors
    • F05B2240/30—Characteristics of rotor blades, i.e. of any element transforming dynamic fluid energy to or from rotational energy and being attached to a rotor
    • F05B2240/302—Segmented or sectional blades
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05B—INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
    • F05B2260/00—Function
    • F05B2260/30—Retaining components in desired mutual position
    • F05B2260/301—Retaining bolts or nuts
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/70—Wind energy
    • Y02E10/72—Wind turbines with rotation axis in wind direction
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49316—Impeller making
    • Y10T29/4932—Turbomachine making
    • Y10T29/49321—Assembling individual fluid flow interacting members, e.g., blades, vanes, buckets, on rotary support member
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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    • Y10T29/49332—Propeller making
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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    • Y10T29/49336—Blade making
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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    • Y10T29/49336—Blade making
    • Y10T29/49337—Composite blade
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10T29/49316—Impeller making
    • Y10T29/49336—Blade making
    • Y10T29/49339—Hollow blade
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10T29/49787—Obtaining plural composite product pieces from preassembled workpieces
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10T29/49794—Dividing on common outline
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10T29/49789—Obtaining plural product pieces from unitary workpiece
    • Y10T29/49796—Coacting pieces
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10T29/49826—Assembling or joining
    • Y10T29/49947—Assembling or joining by applying separate fastener
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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    • Y10T29/49826—Assembling or joining
    • Y10T29/49947—Assembling or joining by applying separate fastener
    • Y10T29/49948—Multipart cooperating fastener [e.g., bolt and nut]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
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    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49826—Assembling or joining
    • Y10T29/49947—Assembling or joining by applying separate fastener
    • Y10T29/49963—Threaded fastener
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
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    • Y10T29/53—Means to assemble or disassemble
    • Y10T29/53613—Spring applier or remover
    • Y10T29/53622—Helical spring
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
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    • Y10T29/53—Means to assemble or disassemble
    • Y10T29/53648—Brake lining to brake shoe

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  • Life Sciences & Earth Sciences (AREA)
  • Sustainable Development (AREA)
  • Sustainable Energy (AREA)
  • Chemical & Material Sciences (AREA)
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  • General Engineering & Computer Science (AREA)
  • Wind Motors (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)

Abstract

本发明涉及涡轮机叶片制造，具体而言，一种方法包括连接整体式隔板(20)和叶片壳体(22，24)以形成叶片(12)，并且在包括整体式隔板的部位处将叶片分成两个叶片片段，使得各叶片片段包括整体式隔板的一部分和叶片壳体的一部分。

Description

涡轮机叶片制造
技术领域
本文所公开的实施例大体上涉及涡轮机叶片和加工涡轮机叶片的方法，并且更具体而言，涉及多件式复合涡轮机叶片和加工这些多件式复合涡轮机叶片的方法。
背景技术
用于诸如风力涡轮机的应用的涡轮机叶片通常具有大尺寸。将大型叶片从制造叶片的所在地运输至将要使用叶片的所在地可能不方便且成本高。
在本领域中需要以分段的形式运输涡轮机叶片，并且然后在远程装配地点将分段连接在一起，而不会有不合乎需要的程度的复杂性和花费。因此，改进的连接系统将是有用的。
发明内容
根据本文所公开的一实施例，一种方法包括连接整体式隔板和叶片壳体以形成叶片；并且在包括整体式隔板的部位处将叶片分离成两个叶片片段，使得各叶片片段包括整体式隔板的一部分和叶片壳体的一部分。
附图说明
当参看附图(在其中，相同标号在所有附图中代表相同部件)来阅读下文详细描述时，本发明的这些和其它的特征、方面及优点将得到更好的理解，其中：
图1是包括数个叶片的风力涡轮机的示意性的示图。
图2是根据本发明的一实施例的叶片的局部截面视图。
图3-5是根据本发明的一实施例的隔板部分的透视图。
图6是根据本发明的另一实施例的叶片的局部截面视图。
图7是根据本发明的另一实施例的叶片的局部截面视图。部件列表：10风力涡轮机系统12叶片14转子16内侧叶片片段18外侧叶片片段19塔架20隔板22上叶片壳体24下叶片壳体26中心法兰28内侧周围法兰30外侧周围法兰32轴线34螺纹孔36内侧隔板部分38外侧隔板部分40进入孔42配合面44纵向肋条46槽50整体式隔板52内侧隔板部分54外侧隔板部分56间隔件
具体实施方式
如下文中详细地所论述的，本发明的实施例包括用于连接涡轮机叶片的方法。如本文中所使用的，用语“涡轮机叶片”是指在各种应用(例如但不限制于，风力涡轮机和航空器系统)中所使用的叶片。如本文中所使用的，诸如“一”、“一个”以及“该”的单数形式包括复数个所指物，除非上下文清楚地指出其它情况。例如，虽然出于图示的目的在附图中显示一个隔板、两片段叶片，但是如果希望的话，可包括更多的隔板和片段。
在一实施例中，一种方法包括连接整体式隔板和叶片壳体以形成叶片，并且在包括整体式隔板的部位处将该叶片分成两个叶片片段，使得各叶片片段包括整体式隔板的一部分和叶片壳体的一部分。在某些实施例中，隔板在其形成到叶片中之前制造成单件式部件。在其它的实施例中，隔板是复合部件，其带有彼此相联接且通过锁定元件而结合成隔板的第一隔板部分和第二隔板部分。
图1-7显示了在风力涡轮机系统10中使用的本发明实施例。参看图1，风力涡轮机系统10包括转子14和数个叶片12。各叶片12包括多个叶片片段16和18。如下文中所使用的，用语“外侧”表示离转子14较远，且“内侧”表示离转子14较近。因此，叶片片段16是内侧叶片片段，并且叶片片段18是外侧叶片片段。叶片12安装在塔架19的顶部。在某些实施例中，叶片12由能忍受恶劣的环境状况(例如但不限制于装配期间现场的险恶天气)的高强度复合材料制成。
图2是叶片12的沿着纵向的局部截面视图。叶片12包括被围在上叶片壳体22和下叶片壳体24中的整体式隔板20。在某些实施例中，上叶片壳体22和下叶片壳体24包括单件式壳体。隔板20包括中心法兰26，以及自中心法兰26朝内侧方向和外侧方向延伸的内侧周围法兰28和外侧周围法兰30。隔板20具有轴线32，其在一实施例中为中心法兰26的中心线。在某些实施例中，中心法兰26限定了延伸穿过中心法兰26的内侧表面和外侧表面的多个螺纹孔34。在一实施例中，隔板20包括诸如玻璃复合材料、碳纤维复合材料、不锈钢、钛、钛合金、铝、以及铝合金等材料。
根据本发明的一示范性的实施例，隔板20预先生成并且在叶片制造厂处装配叶片12期间构建在叶片12中。在某些实施例中，一种将隔板20构建到叶片12中的方法可包括使用模制的叶片壳体22和24。在一实施例中，壳体22和24包括玻璃纤维，以及木材和泡沫材料的组合物。整体式隔板20可然后在对上叶片壳体22和下叶片壳体24进行树脂浸渍过程期间结合到风力叶片中。在一实施例中，隔板20预固化，并且下叶片壳体24涂有粘合剂，以保持隔板20就位。在一非限制性的示例中，粘合剂包括环氧树脂、浸渍树脂或者其组合物。粘合剂可涂覆至上叶片壳体22或下叶片壳体24，或者涂覆至两者。内侧周围法兰28和外侧周围法兰30的外侧表面邻靠叶片壳体22和24的内侧表面。
在一备选的实施例中，将隔板20构建到叶片12中的方法可包括将隔板20嵌入在复合硬壳式(monocoque)壳体中。在某些实施例中，在复合硬壳式壳体的嵌入模制加工过程期间将隔板20构建在复合硬壳式壳体中。
在隔板20结合在叶片12内之后，叶片12沿着轴线32被分成内侧叶片片段16和外侧叶片片段18。在一实施例中，在叶片12完成之后，例如通过工具-诸如带锯或圆锯-沿着轴线32将叶片12切割成内侧片段16和外侧片段18。在工具的切口通过轴线32之后，隔板20就可被分成内侧隔板部分36和外侧隔板部分38。
在一实施例中，隔板20在结合到壳体22和24中之前最初制造成单件式元件。如果期望能够较容易地分离，单件式隔板20可在结合到壳体22和24中之前或在结合到壳体中的过程期间沿着轴线32以填垫的方式隔开。在另一实施例中，隔板20包括内侧隔板部分36和外侧隔板部分38，它们例如在与壳体22和24进行装配之前通过粘合剂或紧固件而结合在一起。下文关于图6论述了一个这样的示例。如果使用任何的硬件来紧固这些隔板部分，则这样的硬件将可能在分离期间被切断。在分离之后，可以可选地移除硬件，并且，可使保留的表面平滑。
在本发明的一备选实施例中，如图7中所示，上叶片壳体22和下叶片壳体24可包括两个上叶片壳体和两个下叶片壳体，其中两个顶部叶片壳体的端部位于分离部位的顶部处且两个下叶片壳体的端部位于分离部位的下部处，使得制造之前两个上壳体和两个下壳体沿着轴线32分段。如果希望的话，在轴线32的区域中可留下间隙23，使得仅隔板20需要沿着轴线32被分成外侧隔板部分36和内侧隔板部分38。
在分离之后，内侧叶片片段16和外侧叶片片段18被运输至现场以在风力涡轮机组件10的最终装配期间进行装配。在现场，将内侧叶片片段16和外侧叶片片段18对准并将其重新装配成叶片12。内侧叶片片段16和外侧叶片片段18通过(例如)利用固定在螺纹孔34中的固定元件(诸如螺栓或螺柱及螺母)而相互固定。在一实施例中，上叶片壳体22和下叶片壳体24分别限定了进入孔40，通过该进入孔，工具(未显示)可用于穿过该进入孔40将螺栓固定在螺纹孔34中。在这样的实施例中，可提供罩帽(未显示)以用于在叶片片段16，18被连结在一起之后覆盖进入孔40。可通过例如将另外的螺栓旋拧至壳体上将罩帽固定到壳体上。
图3-5根据一实施例从不同的观察点显示了一个隔板部分(例如内侧隔板部分36)的透视图。该隔板部分36包括配合面42(中心法兰26在此处分离)。该隔板部分36还可包括用于加固的多个纵向肋条44，以及限定在其之间的槽46(图4和图5)。螺纹孔34沿着中心法兰26的周向方向分布并与对应的槽46相连通。
图6是根据本发明的一实施例的叶片12的局部截面视图，其中，隔板包括内侧隔板部分52和外侧隔板部分54，以及处在内侧隔板部分52和外侧隔板部分54之间以用于使内侧隔板部分52和外侧隔板部分54隔开距离d的至少一个间隔件56。在一实施例中，内侧隔板部分52和外侧隔板部分54以及间隔件56限定了用于与固定元件58相配合以形成整体式隔板50的对应的螺纹孔。
在某些实施例中，固定元件58包括螺栓(诸如T型螺栓)，并且由高强度和耐疲劳的材料(诸如包括Ti-6Al-4V、Ti-6Al-6V-2Sn的钛合金以及钛合金的变体，或包括TS系列、300不锈钢、416-HT、Aermet 100的不锈钢，等等)制成。
在隔板50被结合之后，隔板50可以与如上文关于图2所论述的类似的方式构建到上叶片壳体22和下叶片壳体24中，以形成叶片12。然后，叶片12沿着轴线32分成内侧叶片片段16和外侧叶片片段18以便运输。间隔件56典型地在分离期间被破坏并从叶片12上移除。因此，在内侧叶片片段16和外侧叶片片段18被运输至现场并通过固定元件重新装配成叶片12之后，外侧隔板部分52和内侧隔板部分54可面对面地对准而不分开距离d。
将理解的是，根据任何具体的实施例不一定可实现上文所论述的所有此类的对象或优点。因此，例如，本领域的技术人员将认识到，本文所描述的系统和技术可以这样的方式来实施或执行：即实现或优化如本文中所教导的一个优点或一组优点，而不一定实现可能在本文中教导或建议的其它对象或优点。
此外，熟练技工将认识到来自不同的实施例的各种特征的可互换性。所描述的各种特征以及对于各特征的其它已知的等效物可由本领域的普通技术人员混合及匹配，以构成与本公开的原理一致的另外的系统和技术。
尽管本文中已图示和描述了本发明的仅某些特征，但本领域的技术人员将想到许多变型和变化。因此，将理解的是，所附权利要求意图涵盖落入本发明的真实精神内的所有这样的变型和变化。

Claims (10)

1.一种加工涡轮机叶片的方法，包括：
连接整体式隔板(20)和叶片壳体(22，24)以形成叶片(12)；和
在包括所述整体式隔板的部位处将所述叶片分成至少两个叶片片段(16，18)，使得各个叶片片段包括所述整体式隔板的一部分和所述叶片壳体的一部分。
2.根据权利要求1所述的方法，其特征在于，连接包括将所述整体式隔板设在包括上叶片壳体和下叶片壳体的叶片壳体之间。
3.根据权利要求1所述的方法，其特征在于，连接包括将所述整体式隔板设在包括两个上叶片壳体和两个下叶片壳体的叶片壳体之间，其中，所述两个上叶片壳体的端部位于分离部位的上部处，并且，其中，所述两个下叶片壳体的端部位于所述分离部位的下部处。
4.根据权利要求1所述的方法，其特征在于，连接包括将隔板嵌入到复合硬壳式壳体中。
5.根据权利要求1所述的方法，其特征在于，所述方法还包括通过将所述整体式隔板模制为单件式部件来生产所述整体式隔板。
6.根据权利要求5所述的方法，其特征在于，所述方法还包括在连接所述整体式隔板和所述叶片壳体之前以填垫的方式隔开所述单件式部件。
7.根据权利要求1所述的方法，其特征在于，所述整体式隔板包括中心法兰，并且，其中，分离所述叶片包括沿着所述中心法兰的轴线分离。
8.根据权利要求1所述的方法，其特征在于，所述方法还包括通过利用固定元件将内侧隔板部分和外侧隔板部分结合在一起来生产所述整体式隔板。
9.根据权利要求1所述的方法，其特征在于，所述整体式隔板包括中心法兰，其中，分离所述叶片包括沿着包括固定元件的所述中心法兰的轴线分离。
10.根据权利要求9所述的方法，其特征在于，所述方法还包括在连接所述整体式隔板和所述叶片壳体之前在所述整体式隔板内提供间隔件。
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