CN102794974B - 风力涡轮机多板叶片的粘合方法 - Google Patents

风力涡轮机多板叶片的粘合方法 Download PDF

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CN102794974B
CN102794974B CN201210164792.7A CN201210164792A CN102794974B CN 102794974 B CN102794974 B CN 102794974B CN 201210164792 A CN201210164792 A CN 201210164792A CN 102794974 B CN102794974 B CN 102794974B
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blade
band
wind turbine
height
adhesive
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CN102794974A (zh
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塞尔吉奥·贝莱斯·奥里亚
阿玛伊娅·祖嘎斯提·帕拉莫
弗朗西斯科·哈维尔·马林·马丁内斯
埃米利奥·罗德里格斯·塞兹
伊翁·阿若塞纳·德拉鲁阿
埃内科·桑斯·柏斯库
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Gamesa Eolica SA
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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
    • 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
    • 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
    • B29C65/4835—Heat curing adhesives
    • 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
    • B29C65/50—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
    • 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
    • B29C65/50—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
    • B29C65/5035—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 being in thread form, i.e. in the form of a single filament, e.g. in the form of a single coated filament
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    • 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
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    • B29C66/23—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being multiple and parallel or being in the form of tessellations
    • B29C66/232—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being multiple and parallel or being in the form of tessellations said joint lines being multiple and parallel, i.e. the joint being formed by several parallel joint lines
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    • B29C66/345—Progressively making the joint, e.g. starting from the middle
    • B29C66/3452—Making complete joints by combining partial joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
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    • B29C66/636—Internally supporting the article during joining using a support which remains in the joined object
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Abstract

一种粘合风力涡轮机叶片的第一和第二预制件的方法，包括以下步骤：在易控制未固化状态下跟随在上述部件的一个中的粘合区域上示意的轨迹（43、53、63）布置粘合剂材料带（45，55，65），粘合剂材料在固化阶段可以沿可控路线流动，所述带（45，55，65）的宽度（W）和高度（H）以及所述轨迹（43、53、63）之间的间隔（S1）已经设定，从而在粘合后，带（45，55，65）之间的预定间隔（S2）保持在0-300mm之间；在预定的压力和温度条件下粘合两个部件。本发明还涉及使用上述方法粘合的具有预制件的风力涡轮机叶片。

Description

风力涡轮机多板叶片的粘合方法
技术领域
本发明总体涉及风力涡轮机多板叶片，且特别是风力涡轮机多板叶片的粘合方法以及用所述方法粘合的风力涡轮机多板叶片。
背景技术
风力涡轮机包括一转子，其支撑多个由此径向延伸的叶片，叶片用于捕捉风的动能并引起连接到发电机的传动系的旋转运动，来产生电能。
风力涡轮机产生的能力的数量取决于接受风的作用的转子叶片扫过的表面，因此，增加叶片的长度通常会增加风力涡轮机的能量输出。
但是，用于陆地为基地的风厂的叶片的尺寸目前某种程度上由于运输和基础建设而受到限制。尤其是，桥和隧道的尺寸限制叶片最大弦的尺寸。
为解决超长叶片带来的运输问题，现有技术将叶片分成两个或多个具有连接装置的纵向切片，使每个切片可以分开加工，而所有切片可以在风力涡轮机现场装配。下面是这种现有技术的例子。
DE3109566公开了一种风力涡轮机叶片，被分成至少两个通过膨胀螺栓连接在一起纵向切片。
US4,389,182公开了一种风力涡轮机叶片，被分成几个通过受拉杆件，如延伸通过叶片切片的钢绳相互连接的纵向切片。
EP1244873A1公开了一种风力涡轮机叶片，被分成通过对接接头连接的纵向切片，对接接头包括多个沿接头布置的夹子（具有固定在需要连接的切片上的各自的端部）和固定所述夹子的螺栓。
WO2005/100781,WO2006/103307,WO2007/051879以申请人的名义公开了几种风力涡轮机叶片，被分成具有改进连接装置的纵向切片。
还有现有技术将叶片在分成纵向切片之外或独立于纵向切片，将叶片分成几个横向切片。这种现有技术的例子如下。
EP1184566A1公开由装配的一个、两个或多个纵向切片形成的风力涡轮机叶片，每个切片包括由纵向碳纤维管形成的芯部，其上安装有一系列碳纤维或玻璃纤维的横肋，由连接到上述肋上的玻璃纤维或碳纤维形成覆盖层。
WO01/46582A2公开具有多个段元件的风力涡轮机叶片，段元件连接到负载传输箱型梁并通过塑料接头分开，塑料接头能使段相对于另一个移动，从而最小化段所在的叶片区域的张应力。
EP1965074以申请人的名义公开了一种风力涡轮机叶片，由并排在盒子中的两个帽状预制板件和两个网状预制板件组成，且至少两个壳长度切片分别形成对应的靠近中心梁段放置的叶片段的前沿和机翼后缘，叶片的空气动力学的外形由所述帽状板件和所述壳板件限定。
一种用于粘合上述提到这些叶片段的叶片部件的已知的方法是粘合剂粘合。应用于所述部件的一个表面的粘合剂的典型技术是从一个容器分配粘合剂，粘合剂的成分的用量在混合器中制成并由混合器控制，粘合剂是从混合器泵入容器中。
这个过程有几个缺点：需要非常苛刻的使用时间，执行操作的工人需要保护装备以及正确使用在粘合表面很困难。另一方面，该过程涉及粘合剂的过量使用，从而增加重量和成本。
目前风力工业中大转子叶片的趋势是需要新的转子叶片设计，适合遵循运输和质量制造的需要，叶片长度达到100m，弦8m左右，这里有提高分段的叶片的粘合组合的特殊要求。
本发明致力于满足所述要求。
发明内容
本发明的一个目的是提供一个用于粘合风力涡轮机叶片预制件的方法，允许控制粘合剂材料的体积，从而减少重量。
本发明的另一个目的是提供一个用于粘合风力涡轮机叶片预制件的方法，方便粘合剂材料在粘合区域的使用。
一方面，通过粘合风力涡轮机的第一和第二预制件的方法来实现这些或其他目的，包括以下步骤：
-将在易控制的未固化状态下的粘合剂材料的带沿所述部件中的一个的粘合区域上做信号用的轨迹布置，所述粘合剂材料在固化阶段可以沿可控路线流动，所述带的宽度和高度以及轨迹之间的间隔已决定，从而使粘合后所述带之间的预定间隔保持在0-300mm之间；
-在预先设定的压力和温度条件下粘合两个部件。
在优选实施例中，设置所述带的粘合剂材料以下列其中一种形式提供：带状、条状、卷装。因此，以一种形式使用粘合剂材料便于其应用在粘合表面同时完全控制其重量。
在优选实施例中，设置所述带的粘合剂材料以块的形式提供，因此，其使用粘合剂材料以一种完全适用于带上的形式。
在优选实施例中，粘合剂材料在未固化状态具有稠度，允许不经受压力时，保持其原始几何形状，当受到0.05到2MPa的压力时，粘合剂材料带的高度成比例地减少到原始高度的25%-95%(优选50%-95%)之间。因此，使用具有需要稠度的粘合剂材料，一方面允许其在半固态下应用，另一方面，在风力涡轮机的预制件粘合的典型条件下的固化阶段控制其流动。
在优选的实施例中，所述粘合剂材料在已固化状态具有超过15MPa的剪切附着力。因此，使用具有所需的剪切附着力的粘合剂材料用于风力涡轮机预制件的粘合。
在优选实施例中，所述压力和温度的预设条件是：压力0.05到2MPa之间和温度40°到100℃之间。这些是粘合风力涡轮机叶片预制件的典型的条件，因此，根据本发明的方法不需要任何特殊设备。
在优选实施例中，所述粘合剂材料是从下面其中之一选择的单组分粘合剂材料：聚氨酯、环氧树脂、乙烯酯或甲基丙烯酸酯。据此，获得使用公知的粘合剂组分的粘合方法。
在优选的实施例中，未固化状态的所述带的尺寸是：宽度30-150mm，高度2-40mm，轨迹之间的间隔20-300mm。因此，这种方法适用于各种不同尺寸的风力涡轮机叶片的预制件的粘合。
在优选实施例中，对于属于叶片的梁的第一部件和属于叶片壳体的第二部件，所述带的尺寸在未固化状态是上一段中提到的尺寸。
在优选实施例中，对于粘合叶片的梁的板和粘合叶片的壳体，所述带的宽度为30-150mm，高度为2-25mm，轨迹之间的间隔为20-50mm。
本发明还涉及用于粘合风力涡轮机叶片预制件的上述方法的应用，风力涡轮机包括至少两个用上述方法粘合的预制件，无论他们属于叶片的一个模块还是属于整个叶片。
结合附图和随后的详细说明，可以更好理解本发明的其他特征和优点。
附图说明
图1a显示了分成两个模块的风力涡轮机叶片的内侧模块的主要部件的分解示意图。
图1b显示所述内侧模块的梁的主要部件的分解示意图。
图2是所示内侧模块的截面图。
图3a、3b、5a、5b、7a、7b分别是根据本发明的三个实施例的粘合所述内侧模块的两个部分之间的粘合剂的初始状态沿面A-A的示意图和截面图。
图4a、4b、6a、6b、8a、8b分别是根据本发明的三个实施例的粘合所述内侧模块的两个部分之间的粘合剂的最终状态沿面A-A的示意图和截面图。
具体实施方式
在多板风力涡轮机叶片中，整个叶片分成如一个外侧模块和一个内侧模块，在几个预制件中的他们中的每一个在现场或工厂装配。
如图1a、1b和2所示的叶片的内侧模块13由上和下壳体17、19和梁15组成，梁15也可以由上帽21、下帽23、前沿网25和后缘网27构成。
所有这些梁的单个部件都是预制的，然后装配粘合所述部件的法兰31、33。
在下一步中，装配粘合内侧模块，将预制的上、下壳体17、19粘合到梁15并粘合上下壳体17、19的边界。
在这个内侧模块中，有三个不同的粘合区域：梁部件的法兰31、33内的粘合区域41、上下壳体17、19各自与梁的帽21、23之间的粘合区域51以及上下壳体17、19的边界之间的粘合区域61。
其他多板风力涡轮机叶片的结构不需要具有相同的三个粘合区域。因此，下面将分别说明所述粘合区域41、51、61，技术人员很容易理解他们能适合任何特殊的风力涡轮机叶片结构。
本发明的基本概念是使用一种粘合剂材料，其
-具有稠度，允许带状、条状、卷状或块状形式供应；
-具有稠度，允许完全控制带状的粘合区域内粘合剂的分布在操作过程（在环境温度下实现）遵循需要的轨迹不变形，如，粘合剂材料在不经受压力（和高于风力涡轮机叶片厂的环境温度的温度）时，保持其原始几何形状。
-具有稠度，允许其在固化阶段沿可控线路流动，从而实现带之间的最终预定间隔S2在0-300mm之间；特别是，当粘合剂材料受到0.05到2MPa的压力时，粘合剂材料带的高度成比例地减少到原始高度H的25%-95%(优选50%-95%)之间。
-具有剪切附着力，特别是在压力0.05到2MPa之间和温度40°到100℃之间执行粘合过程后，剪切附着力大于15MPa。
一般来说，考虑到风力涡轮机的不同粘合区域，所述带具有宽度W在30-150mm之间，高度H在2-40mm之间，轨迹之间的间隔S1在20-300之间。
在本发明的实施例中，粘合如上帽21和后缘网27之间的粘合区域41的粘合剂是在易控制未固化状态下布置粘合剂材料带45，跟随在后缘网27的粘合区域41上做标记的轨迹43，如图3a和3b所示，轨迹的间隔为S1，将上帽21和后缘网27在压力和温度条件接结合而在一起，使粘合剂固化且所述部件被粘合。粘合剂材料在固化阶段可以沿可控路线流动，所述带45的宽度W和高度H以及所述轨迹43之间的间隔S1已经设定，从而在粘合过程结束时，带45具有预定宽度W1、高度H1和它们之间的间隔S2，如图4a和4b所示。
在本发明的特定实施例中，对于梁部件之间的粘合区域41，带45具有宽度W为30-150mm，高度H为2-25mm，已经布置在粘合区域41上，其轨迹43之间的间隔S1为20-50mm。粘合过程后，带宽度增加大约50%，高度减少大约50%。结果显示，合适流畅的粘合剂，粘合剂带的最终形状能控制并避免已知粘合剂联合的典型损失。
在本发明的实施例中，粘合如上壳17和上帽21之间的粘合区域51的粘合剂，在易控制未固化状态下跟随在上帽21的粘合区域51上的轨迹53布置粘合剂材料带55，如图5a和5b所示，轨迹的间隔为S1，将上壳17和上帽21在压力和温度条件接结合而在一起，使粘合剂固化且所述部件被粘合。粘合剂材料在固化阶段可以沿可控路线流动，所述带55的宽度W和高度H以及所述轨迹53之间的间隔S1已经设定，从而在粘合过程结束时，带55具有预定宽度W1、高度H1和它们之间的间隔S2，如图5a和5b所示。
在图6a和6b所述的情况下，没有最终的带55之间的间隔S2。如果需要连续的粘合剂层来避免没有粘合剂的那些壳部分发生下垂，这种是希望的。但是如果由于如一种特殊设计的壳体放在粘合剂带之间的凹槽上的壳体部分内没有下垂危险，也可能设计壳和带有带55的梁帽之间的联合，用于最小化粘合剂的体积，带55具有选择的宽度W和轨迹53之间的间隔S1。
在本发明的实施例中，粘合如上壳17的前沿和下壳19的后缘之间的粘合区域61的粘合剂，以类似梁部件之间的粘合区域41的方式完成。
尽管结合优选实施例全面描述了本发明，很明显，改进可以引入这个范围内，而不限于这些实施例，由下面权利要求的内容限定。

Claims (13)

1.一种粘合风力涡轮机叶片的第一和第二预制件的方法，其特征在于，包括以下步骤：
在易控制未固化状态下跟随在上述部件中的一个上的粘合区域上示意的轨迹(43、53、63)布置粘合剂材料带(45，55，65)，粘合剂材料在固化阶段能沿可控路线流动，所述带(45，55，65)的宽度(W)和高度(H)以及所述轨迹(43、53、63)之间的间隔(S1)已经设定，从而在粘合后，带(45，55，65)之间预定的间隔(S2)保持在0-300mm之间；
在预定的压力和温度条件下粘合两个部件。
2.根据权利要求1所述的方法，其特征在于，用于布置所述带(45，55，65)的粘合剂材料以下列形式之一提供：带状、条状、卷状。
3.根据权利要求1所述的方法，其特征在于，用于布置所述带(45，55，65)的粘合剂材料以块状形式提供。
4.根据权利要求1-3之一所述的方法，其特征在于，所述粘合剂材料在未固化状态具有稠度，其允许
所述带(45，55，65)在未受到压力时，保持其原始几何形状；
受到0.05到2MPa的压力时，所述带的高度成比例地减少到原始高度(H)的25％-95％之间。
5.根据权利要求4所述的方法，其特征在于，受到0.05到2MPa的压力时，所述带的高度成比例地减少到原始高度(H)的50％-95％之间。
6.根据权利要求1所述的方法，其特征在于，所述粘合剂材料的剪切附着力在固化状态大于15MPa。
7.根据权利要求1所述的方法，其特征在于，所述预定的压力和温度条件如下：
压力是0.05到2MPa；
温度是40℃到100℃。
8.根据权利要求1所述的方法，其特征在于，所述粘合剂材料是从下面其中之一选择的单组分粘合剂材料：聚氨酯、环氧树脂、乙烯酯或甲基丙烯酸酯。
9.根据权利要求1所述的方法，其特征在于，未固化状态时：
所述带(45，55，65)的宽度(W)为30-150mm，高度(H)为2-40mm；
所述轨迹(43、53、63)之间的间隔为20-300mm。
10.根据权利要求1所述的方法，其特征在于，
所述第一和第二预制件是叶片的梁(15)的板件(27，21；27，23；25，21；25，23)；
所述带(45)的高度为2-25mm；
所述轨迹(43)之间的间隔(S1)为20-50mm。
11.根据权利要求1所述的方法，其特征在于，所述第一预制件属于叶片的梁(15)，所述第二预制件是叶片的一个壳体(17，19)。
12.根据权利要求1所述的方法，其特征在于，
所述第一和第二预制件是叶片的壳体(17，19)；
所述带(65)的高度为2-25mm；
所述轨迹(63)之间的间隔(S1)为20-50mm。
13.根据权利要求1-12之一所述的粘合风力涡轮机叶片预制件的方法的使用。
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