CN101920538A - 复合式风力涡轮机塔架的竖直制造 - Google Patents

复合式风力涡轮机塔架的竖直制造 Download PDF

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CN101920538A
CN101920538A CN2010101677618A CN201010167761A CN101920538A CN 101920538 A CN101920538 A CN 101920538A CN 2010101677618 A CN2010101677618 A CN 2010101677618A CN 201010167761 A CN201010167761 A CN 201010167761A CN 101920538 A CN101920538 A CN 101920538A
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template
resin
curable resin
reinforcement material
wind turbine
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CN101920538B (zh
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郑大年
L·D·威利
林玫玲
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General Electric Co
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B29C35/0805—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
    • B29C53/56—Winding and joining, e.g. winding spirally
    • B29C53/58—Winding and joining, e.g. winding spirally helically
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/36—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and impregnating by casting, e.g. vacuum casting
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • F03D—WIND MOTORS
    • F03D13/00—Assembly, mounting or commissioning of wind motors; Arrangements specially adapted for transporting wind motor components
    • F03D13/10—Assembly of wind motors; Arrangements for erecting wind motors
    • 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
    • F03D13/00—Assembly, mounting or commissioning of wind motors; Arrangements specially adapted for transporting wind motor components
    • F03D13/20—Arrangements for mounting or supporting wind motors; Masts or towers for wind motors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B29C35/0805—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
    • B29C2035/0822—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation using IR radiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B29C35/0805—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
    • B29C2035/0827—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation using UV radiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2791/00—Shaping characteristics in general
    • B29C2791/001—Shaping in several steps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/24—Condition, form or state of moulded material or of the material to be shaped crosslinked or vulcanised
    • B29K2105/243—Partially cured
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/766—Poles, masts, posts
    • 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
    • F05B2280/00—Materials; Properties thereof
    • F05B2280/60—Properties or characteristics given to material by treatment or manufacturing
    • F05B2280/6003—Composites; e.g. fibre-reinforced
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05C—INDEXING SCHEME RELATING TO MATERIALS, MATERIAL PROPERTIES OR MATERIAL CHARACTERISTICS FOR MACHINES, ENGINES OR PUMPS OTHER THAN NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES
    • F05C2253/00—Other material characteristics; Treatment of material
    • F05C2253/04—Composite, e.g. fibre-reinforced
    • 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
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    • 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
    • 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
    • Y02E10/728—Onshore wind turbines
    • 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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Abstract

本发明涉及复合式风力涡轮机塔架的竖直制造。一种制造复合式塔架(4)的方法包括：用可固化的树脂至少部分地填充模板(22)；使模板(22)中的树脂至少部分地固化；使模板(22)部分地升高到至少部分地固化的树脂上方；以及利用抵靠固化的树脂应用的更多可固化的树脂来至少部分地填充升高的模板(22)。

Description

复合式风力涡轮机塔架的竖直制造
相关申请的交叉引用
本文公开的主题大体涉及2008年4月25日提交的关于“复合式风力涡轮机塔架及其制造方法”(A Composite Wind Turbine and aMethod for Fabricating Same)的序号为No.12/109463(律师案号No.229348)的共同拥有共同未决的美国专利申请，以及2008年2月27日提交的关于“复合式风力涡轮机塔架”(Composite Wind Turbine Tower)的序号为No.12/038,471(律师案号No.227235)的美国专利申请，各个申请通过引用而结合在本文中。
技术领域
本文公开的主题大体涉及风力涡轮机塔架结构和形成复合式风力涡轮机塔架结构的方法。
背景技术
风力涡轮机是用于将风中的动能转换成机械能的机器。如果该机械能直接被机器用来(例如)泵水或研磨小麦，则风力涡轮机可称为风车。类似地，如果将机械能转换成电，则该机器也可称为风力发电机或风力发电装置。
通常根据叶片围绕其旋转的竖直轴或水平轴来对风力涡轮机进行分类。图1中示意性地示出了一种所谓的水平轴风力发电机，且可从通用电气公司获得该水平轴风力发电机。风力涡轮机2的这种特定构造包括支承包围传动系8的机舱6的塔架4。叶片10布置在轮毂9上，以在机舱6外部、传动系8的一端处形成“转子”。旋转叶片10驱动齿轮箱12，齿轮箱12在传动系8的另一端处连接到发电机14上，该发电机14与接收来自风速计18的输入的控制系统16一起布置在机舱6内部。
当叶片10的大小增大时，塔架4的大小也增大。目前的风力涡轮机塔架4通常由钢板制成，钢板在较远的地方制造，且然后在涡轮机2的地点处组装。但是，制造、运输和组装这些材料通常是困难和昂贵的。虽然使用复合材料可降低塔架4的构件的重量和运输成本，但是传统技术往往仍然需要运输多个零件，然后这些零件必须在户外施工现场连结在一起。
发明内容
本文中通过在各种实施例中提供制造复合式塔架的方法来解决与这样的传统措施相关联的这些和其它缺点，该方法包括用可固化的树脂至少部分地填充模板；使模板中的树脂至少部分地固化；使模板部分地升高到至少部分地固化的树脂上方；以及利用抵靠固化的树脂应用的更多可固化的树脂来至少部分地填充升高的模板。
附图说明
现在将参照以下附图(“图”)来描述本技术的各种方面，附图未必是按比例绘制的，而是在几个视图中的所有各个中使用相同参考标号来标明对应的部件。
图1是传统风力发电机的示意性侧视图。
图2是用于图1所示的风力涡轮机塔架的竖直制造的系统的示意性截面图。
图3是用于图2所示的系统的加强系统的示意图。
图4是用于图2所示的系统的加强布置的示意图。
图5是用于图2所示的系统的另一种加强布置的示意图。
图6是用于图2所示的系统的又一种加强布置的示意图。
部件列表
2.风力涡轮机
4.塔架
6.机舱
8.传动系
9.轮毂
10.叶片
12.齿轮箱
14.发电机
16.控制系统
18.风速计
20.竖直制造系统
22.模板
23.盖
24.缆绳
26.紧固件
28.滑轮
29.支承结构
30.绞盘
32.树脂供给
34.槽
36.辐射源
38.环件
40.轴向线卷
42.突起
44.纤维
46.带
具体实施方式
图2是用于图1所示的风力涡轮机塔架4或者任何其它塔架的竖直制造的系统20的一个实施例的示意性截面图。虽然所示塔架4具有沿竖直方向具有递减的直径的基本圆形的截面，但是也可使用其它两种截面，包括椭圆形和/或多边形。
竖直制造系统20包括在塔架4的下部部分形成时升高的模板或套环22。模板22可为完全或部分地围绕塔架4延伸的环形。在此处显示的实例中，模板22由可松开的紧固件26(例如钩或扣)连接到链条或缆绳24上。缆绳24经过支承结构29上的一个或多个滑轮28和/或其它滑车而延伸到绞盘30，缆绳绕在绞盘30上，以便使模板22升高。因此系统20可称为“自升式套环”。但是，也可使用各种其它技术来升高和/或降低模板22。各个新的树脂层可为约二分之一英尺至一英尺高。可提供可选的盖23来保护塔架4的内部在制造期间不受环境的影响，且允许在内部放置生产材料。
树脂供给32对形成于模板22的内壁和外壁之间的槽34提供树脂和任何可选的加强材料。例如，可通过软管从地面泵送树脂。合适的树脂基质材料可包括但不限于聚酯、聚乙烯、环氧树脂或适用于形成复合材料的任何其它基质。
在初始位置上，当用树脂装填模板22时，模板22的底部将搁靠在基础上。如有必要，可使用各种密封技术来防止树脂从模板22中漏出。例如，模板22的底部可提供有永久的或可用后即弃的橡胶裙，该橡胶裙靠着塔架4的下部部分紧密地固定。备选地或另外，模板22的壁可提供这样的表面：靠着该表面，使用湿式或干式积层过程来形成塔架4。
允许树脂在模板22升高到新位置之前固化或部分固化。例如，可提供诸如红外线辐射或紫外线辐射的能量源36来促进固化过程。一旦树脂固化，或者部分固化，且模板22升高到新位置，就重复该过程。这样，塔架4就以搁靠在之前的层上的一系列相对薄的层逐步建立起来。
可使用各种技术来对塔架4提供加强，以便提高树脂基质的弯曲强度和/或硬度。如图3所示，一个或多个肋环件38可布置在槽34中。例如，环件38可在树脂固化或部分固化的同时固定到模板22上。也可利用轴向支承件(例如轴向线卷)40连接或以别的方式连结两个或更多个环件38。虽然图3中仅显示了两个轴向线卷40，但也可提供任何数量的线卷，且它们可在环件38周围延伸。连结的环件38中的一个可浸入装有树脂的槽34中，其它环件布置在槽34上方，以便在模板22向上移动时接收用于下一个环件的轴向线卷40。
如图4所示，竖直突起42可从塔架4的壁延伸到槽34中，以提供轴向加强。如图5所示，突起42可起心轴44的作用，可围绕该心轴44缠绕加强纤维44。备选地或另外，槽34的内壁可提供合适的心轴，以便于缠绕纤维44。就此而言，也可为模板22提供各种旋转能力，以便有利于缠绕纤维44。备选地或另外，可在槽34中提供短心轴(未显示)，纤维44可抵靠该短心轴而缠绕。模板22也可提供有多个壁，该多个壁充当用于纤维缠绕过程和树脂固化模具的心轴两者。还可在槽34中使用纤维预成形件。
如2008年2月27日提交的关于“复合式风力涡轮机塔架”(Composite Wind Turbine Tower)的序号为No.12/038,471(律师案号No.227235)的共同拥有共同未决的美国专利申请中所论述，纤维44可包括纵向纤维和环向纤维。备选地或另外，可在塔架4周围缠绕带46，如图6所示。轴向线卷40、竖直突起42、纤维44和/或带46可为天然纤维或人造纤维，例如玻璃纤维、碳纤维、金属纤维或适用于形成复合材料的任何其它纤维。带46可为具有高的轴向定向的织物带。线卷40、突起42和纤维44的数量不受限制，且可包括适用于提供合适的结实的复合材料的任何数量和任何密度。
以上描述的技术提供了优于传统措施的各种优点。例如，竖直制造系统20允许塔架4形成为连续的主体，而非多个段。一件式构造通过消除对内段法兰和伴随的螺栓扭矩维护的需要，大大降低了塔架的成本。系统20提供了对复合材料的使用，同时避免了与从工厂地点运输塔架段以及提供重要的现场制造设施相关联的昂贵的后勤补给。
应当强调的是，上面描述的实施例，且尤其是任何“优选”实施例，仅是本文已经阐述以便提供对本技术的各方面的清楚理解的各种实现的实例。在不显著偏离仅由所附的权利要求书的适当解释限定的保护范围的情况下，普通技术人员将能够更改这些实施例中的许多实施例。

Claims (10)

1.一种制造复合式塔架(4)的方法，包括：
用可固化的树脂至少部分地填充模板(22)；
使所述模板(22)中的树脂至少部分地固化；
使所述模板(22)部分地升高到所述至少部分地固化的树脂上方；以及
利用抵靠所述固化的树脂应用的更多可固化的树脂来至少部分地填充所述升高的模板(22)。
2.根据权利要求1所述的方法，其特征在于，所述方法还包括将加强材料添加到所述可固化的树脂的步骤。
3.根据权利要求2所述的方法，其特征在于，所述加强材料包括至少一个环件(38)。
4.根据权利要求3所述的方法，其特征在于，所述加强材料包括连结在一起的多个环件。
5.根据权利要求2至4中任一项所述的方法，其特征在于，所述加强材料包括延伸到所述更多可固化的树脂中的多个竖直突起(42)。
6.根据权利要求2至5中任一项所述的方法，其特征在于，所述加强材料包括螺旋带(46)。
7.根据权利要求2所述的方法，其特征在于，将加强材料添加到所述可固化的树脂中的所述步骤包括围绕心轴缠绕纤维(44)。
8.根据权利要求7所述的方法，其特征在于，所述心轴包括所述模板(22)的壁。
9.根据权利要求1至8中任一项所述的方法，其特征在于，所述模板(22)包括环形模板。
10.一种用于复合式塔架(4)的竖直制造的装置，包括：
环形模板(22)；
用于为所述模板(22)提供可固化的树脂的树脂供给(32)；以及
用于在所述树脂至少部分地固化之后使所述模板(22)部分地升高到所述可固化的树脂上方的绞盘(30)。
CN2010101677618A 2009-04-17 2010-04-16 复合式风力涡轮机塔架的竖直制造 Expired - Fee Related CN101920538B (zh)

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