CN102248678B - 用于制造风力涡轮机用的叶片主梁的方法 - Google Patents

用于制造风力涡轮机用的叶片主梁的方法 Download PDF

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Publication number
CN102248678B
CN102248678B CN201110070500.9A CN201110070500A CN102248678B CN 102248678 B CN102248678 B CN 102248678B CN 201110070500 A CN201110070500 A CN 201110070500A CN 102248678 B CN102248678 B CN 102248678B
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girder
section
girder section
adhesion
fibrage
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CN201110070500.9A
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CN102248678A (zh
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J·里希特
T·科勒德
A·赫奇斯
A·哈尔
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Vestas Wind Systems AS
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Vestas Wind Systems AS
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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
    • 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
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
    • B29C65/483—Reactive adhesives, e.g. chemically curing adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/50—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like
    • B29C65/5007—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like characterised by the structure of said adhesive tape, threads or the like
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
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    • B29C65/7832—Positioning the parts to be joined, e.g. aligning, indexing or centring by setting the overlap between the parts to be joined, e.g. the overlap between sheets, plates or web-like materials
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
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    • B29C65/7855—Provisory fixing
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract

一种用于制造风力涡轮机用的叶片主梁的方法，包括如下步骤：放置(17)具有第一粘附部分(8)的第一主梁段(2)；在第一主梁段(2)处放置(18)具有第二粘附部分(9)的第二主梁段(3)，于是第一粘附部分(8)和第二粘附部分(9)至少部分交迭，其中在交迭的粘附部分(8，9)之间至少部分地放置粘结剂；至少在第一和第二主梁段(2，3)的接头区域(11)，在第一和第二主梁段(2，3)的外表面上，放置(22)浸满未固化树脂的至少一个纤维层(13)；和同时固化(23)所述粘结剂(10)和所述树脂，于是将第一和第二主梁段(2，3)相互固定。

Description

用于制造风力涡轮机用的叶片主梁的方法
技术领域
本发明涉及一种用于制造风力涡轮机用的叶片主梁的方法，具体地，涉及一种具有主梁段的主梁的制造以及一种具有由这种方法制成的主梁的风力涡轮机用的转子叶片。
背景技术
通常，风力涡轮机的转子叶片由主梁以及例如连接到主梁的两半叶片制成。现在，风力涡轮机的叶片很大，例如其长度大约50m或更长，这样的叶片是由复合材料制成的。
DE10 2008 037 367中公开了将如此非常大的叶片进行分段并且单独运输。所述叶片段比如在风力涡轮机现场进行连接。内叶片段的内主梁段可被部分地插到外叶片段的外主梁段，然后内外主梁段彼此粘结在一起。
在DE10 2008 055 513A1中公开了类似的方法。在叶片段的主梁段处设置网格结构，该结构被插入另一叶片段的另一主梁段内，目的是改善粘结剂的分布，由此提高主梁段彼此之间的粘结力。
此外，EP 0690 228B1公开了一种方法，其中将叶片主梁和两个叶片带粘结在一起，通过将浸满树脂的外层纤维层搭叠在一起，加强连接。可选地，预处理好的两个带放置在一半叶片内，通过对一半叶片以及预处理的带进行最终处理，使叶片主梁与预处理的带粘结在一起。
WO2009/156061A2公开了在两个以上叶片段基础上制造叶片的另一方法。在该成片的风力涡轮机叶片的制造过程中，至少两个叶片段在结合装置中互联。在所述结合装置中，至少一个腹板部件和至少一个带被连接到叶片段。
所述段、腹板部件和带均由纤维层和树脂制成。在第一步，段、腹板部件和带进行预处理，在预处理后，它们彼此粘结用于互联。接着，互联部分被固化。
本发明的目的是提供一种制造段式叶片主梁的改进方法。
发明内容
按照第一方面，本发明提供一种用于制造风力涡轮机叶片用的叶片主梁的方法，包括如下步骤：设置具有第一粘附部分的第一主梁段；在第一主梁段处设置具有第二粘附部分的第二主梁段，使得第一粘附部分和第二粘附部分至少部分地交迭，在交迭的粘附部分之间至少部分地设置粘结剂；至少在第一和第二主梁段的接头区域，在第一和第二主梁段的外表面上提供浸满未固化树脂的至少一个纤维层；和同时固化所述粘结剂和所述树脂，从而将第一和第二主梁段相互固定。
按照第二方面，本发明提供一种风力涡轮机用转子叶片，包括主梁，该主梁至少部分地按照第一方面所述方法制造。
按照第三方面，本发明提供一种用于制造风力涡轮机叶片用的叶片主梁的方法，包括如下步骤：设置具有第一连接部分的第一主梁段；在第一主梁段处设置具有第二连接部分的第二主梁段，使得第一连接部分和第二连接部分至少部分地交迭；提供至少部分地穿过交迭连接部分的厚度的多个固定元件；至少在第一和第二主梁段的接头区域，在第一和第二主梁段的外表面上提供浸满未固化树脂的至少一个纤维层；和固化所述树脂，从而将第一和第二主梁段相互固定。
本发明的其它方面如从属权利要求、下面的说明书和附图所述。
附图说明
参照下列附图描述本发明的各个实施例，其中：
图1示意地表示被分成根部主梁段和末端主梁段的叶片主梁；
图2示意地表示按照本发明的一个实施例末端主梁段部分地插入根部主梁段并且在二者之间带有粘结层的局部截面视图；
图3表示在图2的末端主梁段和根部主梁段的连接处覆盖有纤维层的局部截面视图；和
图4表示按照本发明图1-3所示的末端主梁段和根部主梁段的接头的制造方法流程图。
具体实施方式
图1-3表示风力涡轮机叶片用的叶片主梁1的实施例，它被分成根部主梁段2和末端主梁段3，这些段按照本发明进行连接。在对叶片主梁1的制造方法进行详细说明之前，先讨论一些一般信息。
如前所述，现在风力涡轮机的大叶片都在50米或50米以上，比如DE10 2008037367A1公开了将如此大的叶片和叶片主梁沿着纵向方向分成段，以便简化制造和运输。然后在风力涡轮机的竖立点将叶片段和主梁段连接在一起。
通常，风力涡轮机叶片由包括纤维诸如碳纤维和/或玻璃纤维以及树脂比如环氧树脂的复合材料制成。所述叶片在各个实施例中比如由两个半叶片制成，一个半叶片用于叶片的压力侧，一个半叶片用于叶片的吸力侧。在被分成段的叶片的情况下，为了制造所述半叶片，在相应的叶片模具或者叶片模具段中，比如包括浸有诸如聚酯或环氧树脂的树脂的碳纤维或玻璃纤维的纤维层被层叠在一起并固化。
叶片主梁设置在叶片的中间，作为接收运行过程中作用在风力涡轮机叶片上的剪应力和扭力的结构部件。叶片主梁通过这样的方法进行制造，例如提供半叶片中的各个结构部件，所述半叶片比如在前述WO2009/156061 A2和EP 0690 22 B1所述的模具中制造。
主梁或主梁段也可以预先制造，比如将相应的带和腹板部件粘结或安装在一起。也已知的是，比如在前面的EP0690 228 B1中所述的，将由纤维如碳纤维或玻璃纤维制成的卷绕材料缠绕在卷绕模具或卷绕芯上，制成卷绕主梁或主梁段。
由于风力涡轮机叶片在运行过程中有受到高剪切力和张力的倾向，叶片段的接头，特别是主梁段的接头必须能够承受这些高的力。
在前面提及的DE 10 2008 037 367 A1中，已知的是，通过将内主梁段部分地插入外主梁段并用粘结剂将它们粘结在一起，实现内主梁段和外主梁段的连接。在前面提及的DE 10 2008 055 513A1中也指出，这种将主梁段彼此粘结在一起的方法存在缺陷，因为粘结剂分布不均匀，由此为了改善粘结剂的分布，建议在被插入的主梁段上设置特定的网格。
本发明的发明人已经认识到，主梁段的彼此连接能够通过两种类型的连接得到改进。主梁段在其内部粘附在一起，以及另外在主梁段的接头外部至少设置一层纤维层。此外，发明人还认识到，当粘结剂和纤维层所浸满的树脂同时固化的时候，主梁段能够具有很强的连接，而且制造主梁所需的时间也缩短。
在各个实施例中，用于风力涡轮机的叶片主梁的制造方法包括这样的步骤，即提供和放置具有第一粘结部分的第一主梁段以及具有第二粘结部分的第二主梁段。所述第二主梁段设置在第一主梁段处，使得第一和第二粘结部分至少部分地交迭。为了在后续的固化步骤中将第一和第二主梁段相互粘结在一起，在所述交迭粘结部分之间设置粘结剂。
在一些实施例中，所述主梁还包括两个以上的主梁段，但是至少两个主梁段通过此处制造叶片主梁的所述方法彼此连接在一起。主梁可以在纵向方向和/或垂直于纵向方向被分成段。主梁段在一些实施例中可以预先制造，而且可以由前述的复合材料制成。
第一和第二粘结部分重叠，从而在第一和第二粘结部分之间形成用于粘结剂的间隙。在将第二主梁段放置在第一主梁段处之前，将粘结剂设置在第一和/或第二粘结部分上。比如，粘结层如预浸料坯层能够包绕第二主梁段的粘结部分。在第二主梁段设置在第一主梁段处之前设置粘结剂的情况下，当第二主梁段设置在第一主梁段时，所述间隙已经被粘结剂填满。
在一些实施例中，在第二主梁段放置在第一主梁段之后再放置粘结剂。在这样的实施例中，例如，在第二主梁段已经放置在第一主梁段之后，粘结剂被注入到间隙内。在其它的实施例中，在第二主梁段放置在第一主梁段之前和之后都放置粘结剂。在一些实施例中，粘结剂不包括任何纤维。在一些实施例中，在第一和/或第二粘结部分处逐点放置粘结剂。
粘结部分可以具有适于彼此粘结在一起的任意形状。在一些实施例中，第一主梁段的粘结部分的至少一个表面部分匹配第二主梁段的粘结部分的至少一个表面部分，即，所述粘结部分和它们的粘结表面分别具有类似的或者相同的形状。在一些实施例中，所述粘结部分具有适于接收粘结剂的纹理表面，目的是在交迭粘结部分之间的间隙内使粘结剂实现均匀分布。
所述粘结部分可以与主梁段成为一体，和/或它作为一个单独的元件，比如它在第二主梁段放置在第一主梁段之前或之后被安装到主梁段。
在一些实施例中，主梁段为圆柱形或者圆锥形，带有圆形、椭圆形、矩形等横截面。主梁段的形状也可以不同，比如根据它们在叶片内的位置。比如，在一些实施例中，第一主梁段为根部主梁段，其从叶片根部向着叶片末端向外延伸，第二主梁段为末端主梁段，其从根部主梁段延伸至叶片末端。在一些实施例中，根部主梁段具有基本为圆形和/或椭圆形的圆滑形状，而末端主梁段比如基本上为矩形。当然，不同形状的混合也能够实现。例如，根部主梁段在叶片根部位置具有基本上圆形横截面的部分。从该圆形部分，在朝向叶片末端的方向，形状变化为椭圆形横截面，然后变化为基本矩形的横截面。
第一主梁段和/或第二主梁段在一些实施例中包括比如碳纤维、玻璃纤维或者这些纤维的混合物以及比如环氧树脂的树脂的复合材料。主梁段能够按照本领域技术人员已知的方法预制，比如通过将卷绕材料缠绕在一个芯或类似物上，和/或通过将比如腹板和带部件这样的相应主梁部件安装/粘结在一起。
在一些实施例中，第一主梁段至少部分是中空的，而且当第二主梁段置于第一主梁段处时，它部分地容纳第二主梁段的端部。在一些实施例中，主梁被沿着纵向方向分成段，第二主梁段能够伸缩地插入第一主梁段的空腔，或者相反，即第一主梁段也能够插入第二主梁段的空腔。在一些实施例中，第一和第二主梁段中能够伸缩插入进彼此的那一部分，比如粘结部分的横截面具有相同或者至少相似的横截面形状，使得第一和第二主梁段的交迭部分(粘结部分)之间的间隙基本均匀。另外，第一和第二主梁段可以分别为圆锥形。
在这样的实施例中，即第二主梁段以伸缩方式部分插入第一主梁段(或者相反)，通过靠近被接收的第二主梁段外表面的空腔的内表面提供第一主梁段的第一粘附部分，第二主梁段的所述外表面因此提供第二主梁段的第二粘附部分。因此，其中填充有粘结剂的间隙形成在所插入的第二主梁段的外表面与第一主梁段的交迭内表面之间，该第一主梁段部分地接收第二主梁段。
接着，至少在接头区域在第一和第二主梁段的外表面上提供至少一个纤维层，该纤维层包含卷绕材料和/或者由纤维制成的至少一个厚片，其浸满未固化树脂，所述纤维比如为碳纤维或玻璃纤维。所述树脂比如包括环氧树脂。所述纤维层还包括至少一个预浸料坯。纤维层在其放置在所述外表面之前或者之后用树脂浸透。比如，干纤维放置在第一和第二主梁段的外表面上，然后比如用树脂注射方法将干纤维浸满树脂。
所述接头区域通过所述粘附部分的交迭而形成，具体地，接头区域包括第一主梁段即第一粘附部分的至少一个边缘分别与第二主梁段或第二粘附部分交迭。所述边缘构成接头区域的一种台阶。
在一些实施例中，接头区域围绕第一和第二主梁段的外周延伸，纤维层是至少在接头区域通过卷绕材料和/或至少一个厚片缠绕在第一和第二主梁段上形成的。
所述交迭粘附部分之间的粘结剂和所述至少一个纤维层的树脂同时进行固化。因此，第一和第二主梁段至少在两个区域，即在第一和第二粘附部分的区域和在第一及第二主梁段的外表面上相互固定，在前一个区域通过固化后的粘结剂固定，在后一个区域，所述浸满树脂的至少一层交迭纤维层发生固化并粘附到所述外表面。
因此，第一和第二主梁段之间能够具有持久的强烈粘附力。另外，这种接合具有很高的安全性，因为粘结剂以及所述至少一个纤维层可接受叶片和主梁的工作负荷。因为粘结剂与树脂的固化是同时执行，所以节约了制造时间，并优化了主梁的生产。
在一些实施例中，在设置所述至少一个纤维层之前，用至少一个固定元件临时将第一和第二主梁段固定。例如，通过在接头区域支撑第一和第二主梁段的支撑结构将主梁段固定。
如上所述，叶片主梁具有50米以上的长度，在一些实施例中，比如两个主梁段均具有大约25米的长度。在一些实施例中由复合材料制成的主梁段通常是柔性的，因此倾向于自重变形。在一些实施例中，设置在接头区域的纤维层沿着两个主梁段的任一纵向方向延伸约几米，并且它绕着接头区域进行缠绕。因此，在这种情况下，在接头区域支撑主梁段的支撑结构可能阻碍所述至少一个纤维层在接头区域的施加。因此，在一些实施例中，主梁段在设置纤维层的区域没有被支撑。为了避免在将第二主梁段设置在第一主梁段之后主梁段由于自重变形导致的错位以及为了避免接头区域的复合材料打断裂，多个固定元件设置在交迭粘附部分。在一些实施例中，所述固定元件，比如铆钉、螺钉、钉子等穿透交迭粘附部分的厚度，将第一和第二主梁段相互固定。因此，对于大的倾向于自重变形的主梁段，在设置纤维层之前，通过第一和第二主梁段的临时相互固定，可以省略比如在交迭粘附部分之间粘结剂的固化。在一些实施例中，固定元件不用去除。所述临时固定是指直到通过固化的粘结剂和固化后的纤维层将第一和第二主梁段相互固定的时间。因为固定元件不被去除，在固化之后它们也使第一和第二主梁段相互固定。
在一些实施例中，在固化树脂和粘结剂之前，放置真空包，至少包围所述至少一个纤维层的区域。施加真空将所述至少一个纤维层压到主梁段的表面，于是，所述至少一个纤维层被固定到主梁段。在所述包内施加真空之后，执行固化过程。
在一些实施例中，固化步骤包括在100℃以上温度的加热。在一些实施例中，所述固化步骤包括约在120℃温度的加热。例如，在一些实施例汇中，通过吹风机和加热器产生的热风吹过中空的主梁段，从而执行加热。此外，也能从主梁段的外部对接头区域和纤维层施加热量，比如通过热空气、加热垫、辐射加热器、炉子等。在一些实施例中，加热持续约3个小时，用于使粘结剂和所述至少一个纤维层固化。温度特别是加热时间取决于所用的复合材料、树脂、交迭粘附部分之间的粘结剂的厚度以及所述至少一个纤维层的厚度。
在一些实施例中，第一主梁段的第一粘附部分和/或第二主梁段的第二粘附部分是逐渐变细的。通过使粘附部分逐渐变细，接头区域的最终厚度能够减小，由于第二主梁段的插入端部为逐渐变细的形状，在一些实施例中，第二主梁段插入第一主梁段的插入能够简单化。在一些实施例中，在制造主梁段的过程中实现粘附部分的逐渐变细。在其它的实施例中，在制造主梁段之后，实现逐渐变细，或者在制造主梁的过程中和制造过程后实现逐渐变细。
所述至少一个纤维层的厚度在交迭粘附部分的接头区域比在接头区域之外的厚度更厚，从而更厚的区域设置在接头区域内。通过在接头区域施加更厚的纤维层或者更多的纤维层，能够补偿在逐渐变维的粘附部分处缺失的材料。此外，如上所述，在接头区域内，由于粘附部分的交迭，在第一和第二主梁段的接头处有一个台阶。通过改变纤维层的厚度，能够补偿所述台阶，而且连接的主梁段在接头区域的外表面能够更平滑。
如上，在一些实施例中，在第一和第二粘附部分的交迭区域，第一和第二叶片主梁段由多个固定元件相互固定。在这样的实施例中，可以省略粘附部分的相互粘附以及交迭粘附部分之间的粘结剂，或者第一和第二粘附部分之间的粘结剂可以与纤维层的固化独立地固化。因此，在这样的实施例中，用于制造风力涡轮机用的叶片主梁的方法，包括如下步骤：设置具有第一连接部分的第一主梁段；在第一主梁段处设置具有第二连接部分的第二主梁段，使得第一连接部分和第二连接部分至少部分地交迭；提供至少部分地穿过交迭连接部分的厚度的多个固定元件，比如铆钉、销、螺钉等；至少在第一和第二主梁段的接头区域，在第一和第二主梁段的外表面上提供浸满未固化树脂的至少一个纤维层；和固化所述树脂，从而将第一和第二主梁段相互固定。在这样的实施例中，第一和第二主梁段的第一和第二粘附部分分别被称为第一和第二连接部分，因为在这样的实施例中，粘附部分即连接部分之间的粘结剂能够省略。粘附部分的描述也可以适用于这些实施例中的连接部分。此外，通过固定元件将第一和第二主梁段相互固定的描述和同样的方法步骤的描述也适用于这些实施例。
一些实施例涉及风力涡轮机的转子叶片，其包括至少部分按照上述方法制造的主梁。一些实施例涉及带有至少一个这样的转子叶片的风力涡轮机。如本领域人员已知的那样，所述风力涡轮机通常包括机舱、带有一个、两个、三个或更多转子叶片的转子、塔架、和用于将风能转换为电能的元件。
再参照图1-3，图示的是风力涡轮机叶片用的主梁1的实施例，该主梁通过包括图4所示流程图的步骤的制造方法，将根部主梁段2和末端主梁段3连接而成。主梁1的制造方法从步骤16(图4)开始，接着在步骤17将带有第一粘附部分8的预制根部主梁段2和在步骤18将带有第二粘附部分9的预制末端主梁段3设置在例如相应支撑结构上(没有示出)。根部主梁段2和末端主梁段3腹板包括复合材料。
根部主梁段2具有根部端4，当主梁被安装到风力涡轮机叶片时该根部端将被放置在叶片根部。在与根部端4相反的另一端，根部主梁段2具有末端5。根部主梁段2是中空的而且在根部端4的区域内的横截面基本为圆形，而在末端5的区域内横截面基本上为矩形，于是，两半叶片能够连接到根部主梁段2。此外，根部主梁段2具有锥形形状，即它在根部端4处的直径大于它在末端5处的直径。
末端主梁段3具有根部端6和末端7。末端主梁段3将以根部端6被伸缩式地插入根部主梁段的中空末端5内。当叶片主梁1被安装到风力涡轮机叶片时，末端主梁段3的末端7会处于叶片末端。末端主梁段3也具有锥形形状，而且它在根部端6处的直径大于它在末端7处的直径。末端主梁段3具有矩形横截面，这类似于根部主梁段2在末端5处的横截面形状，但是末端主梁段3的横截面小于末端5处的横截面，使得在根部主梁段2的末端5处，末端主梁段3能够伸缩地插入根部主梁段2。
在如上所述的替代实施例中，末端主梁段3的根部端6被插入根部主梁段2的末端5。
根部主梁段2在根部4区域内由复合材料制成，复合材料基本包括玻璃纤维和树脂，而且它是由复合材料缠绕在一个芯上制成的。末端主梁段3由包括碳纤维、玻璃纤维与树脂的混合物的复合材料制成。由于风力涡轮机运行期间作用在风力涡轮机上的负荷类型的不同，根部主梁段2和末端主梁段3的混合物是不同的。根部主梁段2安装成使根部端4处于风力涡轮机转子处，由此不得不承受转子叶片的总重量，而末端主梁段3放置在转子叶片的外部，并承受例如弯曲载荷和剪切载荷。如本领域技术人员已知的，因为碳纤维比玻璃纤维具有更高的柔性，所以通过改变复合材料中碳纤维和玻璃纤维的量，复合材料的机械性能能够改变。
根部主梁段2在末端5处具有第一粘附部分8(图2和3)，末端主梁段3在根部端6处具有第二粘附部分9。在该实施例中，第一和第二粘附部分8和9分别与根部主梁段2和末端主梁段3是一体的，并且分别绕末端5和根部端6的外周延伸。
如上所述，在一些实施例中，其中也可以省略交迭的第一和第二粘附部分之间的粘结剂，第一和第二粘附部分分别被称作第一和第二连接部分。除了这个区别外，本实施例的说明也适用于这样的实施例，即其中第一和第二段由固定元件15彼此连接。
此外，第一和第二粘附部分8、9逐渐变细(见图2和3)。根部主梁段2的第一粘附部分8在外表面上倾斜，使得复合材料的厚度在朝向末端5的方向逐渐变小。类似地，第二粘附部分9在外表面倾斜，使得复合材料的厚度在朝着根部端6的方向逐渐变小。逐渐变细的形状便于末端主梁段3的根部端6插入根部主梁段2的末端5，而且相对于根部主梁段2的非逐渐变细的末端5而言台阶12的高度得到降低。
在步骤19，粘结剂层10(图2和3)被缠绕在末端主梁段3处于第二粘附部分9的外表面。粘结剂层10由复合材料比如预浸料坯制成，其包括碳纤维和玻璃纤维以及环氧树脂的混合物。粘结剂层10的厚度约1mm，而且基本上是实心的。由于这种实心特性，粘结剂层10能够绕第二粘附部分9缠绕，并且由于环氧树脂，它粘结到粘附部分9上。
接着，在步骤20，末端主梁段2以根部端6部分地插入根部主梁段2的中空末端5，使得第一粘附部分8部分地与第二粘附部分9以及粘结层10交迭。在该实施例中，粘附部分8、9的交迭区域在纵向方向即在末端5和根部端6的纵向方向约长400mm。粘结剂层10的宽度与粘附部分8、9的交迭区域相适应，也约为400mm。粘结剂层10位于在第一粘附部分8的区域的根部主梁段2的内表面与在第一粘附部分9的区域的末端主梁段3的外表面之间，因此，它与复合材料的相应内表面和外表面相接触。第一和第二粘附部分8，9与粘结层10相接触的内表面和外表面是基本平坦的，使得在交迭粘附部分8，9之间具有均匀间隙，该间隙被粘结层10填充。
接着，在步骤21，设置多个铆钉15，这些铆钉穿透第一粘附部分8、粘结剂层10和第二粘附部分9的厚度。铆钉15绕着根部主梁段2的末端5的外周均匀分布。在插入和固定铆钉15之前，在第一和第二粘附部分8，9以及粘结层10上钻出通孔。铆钉15临时固定根部主梁段2和末端主梁段3，因为由于自重变形以及它们的长度，根部主梁段2和末端主梁段3否则有不对齐的倾向，根部主梁段2和末端主梁段3在根部和/或末端主梁段的复合材料中也有出现裂纹的倾向。比如在用铆钉15将它们相互固定之前，通过在这些区域由支撑结构(没有示出)支撑根部主梁段8和末端主梁段9，能够避免根部主梁段2和末端主梁段3出现弯曲，特别是在末端5和根部端6区域。在通过多个铆钉15将根部主梁段8和顶部主梁段9相互相互固定之后，可以去除所述支撑结构，使得支撑结构不再阻碍纤维层13的施加。
接着，在步骤22，纤维层13包绕在接头区域11。纤维层13由比如预浸料坯的复合材料制成，包括卷绕材料以及由碳纤维和玻璃纤维的混合物制成的厚片，碳纤维和玻璃纤维的混合物浸满未固化的环氧树脂。接头区域11是通过根部主梁段2的末端5的边缘与粘结剂层10所形成台阶12所在区域。在该实施例中，纤维层13在主梁1的纵向方向延伸大约6米，即从接头区域11在左右两侧各约3米，其平均厚度约为25mm。纤维层13不仅包括一层纤维，而且由多层纤维以及纤维制的厚片制成，使得它的平均厚度约为25mm。
此外，纤维层13形成为使得它在接头区域11的厚度大于其在接头区域外的厚度，因此在接头区域11内提供了更厚部分14，目的是补偿第一和第二粘附部分8，9的逐渐变细，并且由此补偿根部主梁段2和末端主梁段3的复合材料的粘附部分8，9以及粘结剂层10的复合材料的变小厚度(与这些部分之外的厚度相比)。此外，从末端主梁段3到具有中间台阶12的根部主梁段2的过渡通过纤维层13变得平缓。纤维层13的更厚部分14的厚度变化适应过渡区域的形状。
在一些实施例中，根部主梁段2包括在末端5区域内沿着根部主梁段2的纵向方向延伸的细长切口，目的是在第一粘附部分8内提供可被压向粘结剂层10的柔性部分。为了避免在细长切口的端部区域出现裂纹，比如在每个长切口的闭合端处在复合材料内钻出多个孔。
在执行固化之前，根部主梁段2和末端主梁段3在纤维层13所在区域被真空包(没有示出)包围，然后施加真空。空气压力挤压真空包，因此也挤压包围接头区域11的纤维层13。由于根部主梁段2的末端5区域内的细长切口，第一粘附部分8内的柔性部分压靠在粘结剂层10上，保证粘结剂层10与第一粘附部分8的内表面和第二粘附部分9的外表面之间的良好接触。
接着，在步骤23，纤维层13和粘结剂层10同时固化。通过热空气吹过中空的根部主梁段2和末端主梁段3，由此热空气也流过接头区域11，在约120℃的温度下执行固化。热空气加热根部主梁段2和末端主梁段，由此也加热固化的粘结剂层10。此外，从外面将热量施加给根部主梁段2和末端主梁段3，比如通过热吹风机(或炉子)对纤维层13施加热量并由此加热纤维层13。因此，粘结剂层10和纤维层13同时固化。
固化过程需要花费约3个小时，在固化步骤23之后，制造方法在步骤24结束。
在本实施例中，粘结剂层10的缠绕以及铆钉15的安装均需要花约10分钟的时间。纤维层13的缠绕花费约半个小时，如上所述，固化需要约3个小时。因为铆钉15是用于将根部主梁段2和末端主梁段3相互固定，所以在放置纤维层13以将根部主梁段8和末端主梁段9固定之前没有必要使粘结剂层10固化，从而节约了可能用于固化粘结剂层10所需的时间。如上所述，具体地，长叶片主梁段容易发生自重变形，因此在设置纤维层13之前，需要在接头区域11处进行固定，从而保证根部主梁段2和末端主梁段3彼此对齐，并且保证接头区域11内的复合材料不会因为自重变形发生断裂。
在其它实施例中，可以使用其它的固定元件，比如螺钉、销或者能够为相应的主梁段提供临时相互固定的任意其它适当固定元件。

Claims (12)

1.一种用于制造风力涡轮机叶片用的叶片主梁的方法，包括如下步骤：
用复合材料预制第一和第二主梁段(2，3)并使其固化，所述第二主梁段(3)具有根部端(6)，所述第一主梁段(2)具有末端(5)；
设置(17)具有第一粘附部分(8)的第一主梁段(2)；
在第一主梁段(2)处设置(18)具有第二粘附部分(9)的第二主梁段(3)，使得第一粘附部分(8)和第二粘附部分(9)至少部分地交迭，其中，所述第二主梁段(3)的根部端(6)被部分地插入第一主梁段(2)的末端(5)或者第一主梁段(2)的末端(5)被部分地插入所述第二主梁段(3)的根部端(6)，使得所述粘附部分(8，9)交迭，在交迭的粘附部分(8，9)之间至少部分地设置粘结剂；
至少在第一和第二主梁段(2，3)的接头区域(11)，在第一和第二主梁段(2，3)的外表面上提供(22)浸满未固化树脂的至少一个纤维层(13)，所述接头区域(11)围绕第一和第二主梁段(2，3)的外周延伸，所述纤维层是通过卷绕材料缠绕在第一和第二主梁段(2，3)上形成的；和
同时固化(23)所述粘结剂(10)和所述树脂，从而将第一和第二主梁段(2，3)相互固定；
所述方法还包括在设置所述至少一个纤维层(13)之前用至少一个固定元件(15)将第一主梁段和第二主梁段相互固定，所述至少一个固定元件(15)穿过所述交迭粘附部分(8，9)的厚度。
2.如权利要求1所述的方法，其特征在于，所述至少一个固定元件(15)包括铆钉。
3.如权利要求1或2所述的方法，其特征在于，固化所述粘结剂和所述树脂的步骤包括在100℃以上的温度加热的步骤。
4.如权利要求3所述的方法，其特征在于，固化所述粘结剂和所述树脂的步骤包括在大约120℃的温度加热的步骤。
5.如权利要求3所述的方法，其特征在于，固化所述粘结剂和所述树脂的步骤包括加热大约3个小时的步骤。
6.如权利要求1或2所述的方法，其特征在于，包括在执行固化所述粘结剂和所述树脂的步骤之前至少在所述至少一个纤维层(13)的区域施加真空的步骤。
7.如权利要求1或2所述的方法，其特征在于，所述粘结剂(10)包括预浸料坯层。
8.如权利要求7所述的方法，其特征在于，包括绕着第二粘附部分(9)缠绕所述预浸料坯层的步骤。
9.如权利要求1或2所述的方法，其特征在于，包括使第一主梁段(2)的粘附部分(8)和/或第二主梁段(3)的粘附部分(9)至少部分地逐渐变细的步骤。
10.如权利要求1或2所述的方法，其特征在于，设置所述至少一个纤维层(13)的步骤包括形成所述纤维层(13)使得在所述交迭粘附部分(8，9)的接头区域(11)比所述接头区域(11)外具有更厚部分(14)。
11.如权利要求1或2所述的方法，其特征在于，包括提供多个所述固定元件(15)。
12.一种用于风力涡轮机的转子叶片，包括按照前述任一权利要求的方法制造的主梁(1)。
CN201110070500.9A 2010-03-22 2011-03-21 用于制造风力涡轮机用的叶片主梁的方法 Expired - Fee Related CN102248678B (zh)

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