CN103362753A - 分离式风力涡轮机叶片的部件的制造方法 - Google Patents

分离式风力涡轮机叶片的部件的制造方法 Download PDF

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CN103362753A
CN103362753A CN2013101131640A CN201310113164A CN103362753A CN 103362753 A CN103362753 A CN 103362753A CN 2013101131640 A CN2013101131640 A CN 2013101131640A CN 201310113164 A CN201310113164 A CN 201310113164A CN 103362753 A CN103362753 A CN 103362753A
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艾恩·爱若斯纳·德拉鲁阿
艾妮可·桑斯·柏斯库
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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
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/86—Incorporated in coherent impregnated reinforcing layers, e.g. by winding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K3/00—Making engine or like machine parts not covered by sub-groups of B21K1/00; Making propellers or the like
    • B21K3/04—Making engine or like machine parts not covered by sub-groups of B21K1/00; Making propellers or the like blades, e.g. for turbines; Upsetting of blade roots
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/02—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising combinations of reinforcements, e.g. non-specified reinforcements, fibrous reinforcing inserts and fillers, e.g. particulate fillers, incorporated in matrix material, forming one or more layers and with or without non-reinforced or non-filled layers
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    • 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
    • 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
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/38—Moulds or cores; Details thereof or accessories therefor characterised by the material or the manufacturing process
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C39/02—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles
    • B29C39/10—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. casting around inserts or for coating articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
    • B29C53/56—Winding and joining, e.g. winding spirally
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D99/00—Subject matter not provided for in other groups of this subclass
    • B29D99/0025—Producing blades or the like, e.g. blades for turbines, propellers, or wings
    • B29D99/0028—Producing blades or the like, e.g. blades for turbines, propellers, or wings hollow blades
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/02—Layered products essentially comprising sheet glass, or glass, slag, or like fibres in the form of fibres or filaments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/18—Handling of layers or the laminate
    • 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
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    • F03D—WIND MOTORS
    • F03D80/00—Details, components or accessories not provided for in groups F03D1/00 - F03D17/00
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/30—Fixing blades to rotors; Blade roots ; Blade spacers
    • 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
    • F05B2230/00—Manufacture
    • F05B2230/50—Building or constructing in particular ways
    • 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
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Abstract

本发明提供一种分离式风力涡轮机叶片的部件（如内侧壳或内侧杆）的制造方法，该部件带有与其互补部件（如外侧的壳或外侧的杆）连接的连接元件。方法包括以下步骤：a）制造具有嵌入其中的连接元件的复合材料连接层压件，所述连接层压件构造成部件的一部分；b）用连接层压件做预制件来制造所述部件。本发明还涉及包括由上述制造方法制造的部件的分离叶片。

Description

分离式风力涡轮机叶片的部件的制造方法
技术领域
本发明总体涉及分离式风力涡轮机叶片，更具体的是涉及制造带有与另一个叶片部件连接的连接元件的分离式风力涡轮机叶片的方法。
背景技术
风力涡轮机包括支撑多个叶片的转子，叶片在转子上径向延伸，用来捕捉风的动能并引起传动系旋转运动，传动系结合到产生电能的发电机上。
风力涡轮机产生能量的数量取决于转子叶片扫过的表面，该表面接受风的活动，因此，通常增加叶片长度会增加风力涡轮机能量输出。
但是，目前叶片的尺寸一定程度受到交通运输和基础设施的限制。
为了解决特别是由过长的叶片产生的运输问题，现有技术将叶片分成两个或配有连接装置的多个纵向节段，这样，每个节段可以单独制造，所有节段在风力涡轮机现场组装。
本申请人的申请WO2005/100781、WO2006/10330、EP2138715和EP2138716公开了用于分离风力涡轮机叶片的连接元件。
在这些带有与其他部件连接的连接元件的分离风力涡轮机叶片的纵向模块的传统制造方法中，这些连接元件在制造过程中结合到该部件上。
这种方法的缺点是使带有与其他部件连接的连接元件的分离风力涡轮机叶片的部件的制造复杂化。
发明内容
本发明的一个目的是提供一种分离风力涡轮机叶片的部件（如内侧壳或内侧杆）的简化制造方法，该部件带有与其互补部件（如外侧的壳或外侧的杆）连接的连接元件。
本发明的另一个目的是提供一种分离风力涡轮机叶片的部件（如内侧壳或内侧杆）的制造方法，该部件带有与其互补部件（如外侧的壳或外侧的杆）连接的连接元件，该方法改善了所述连接元件的集成度。
实现这些或其他目的的制造方法包括以下步骤：
a）制造具有嵌入其中的连接元件的复合材料连接层压件，所述连接层压件构造成部件的一部分；
b）用连接层压件做预制件来制造所述部件。
优势在于，连接层压件在固化状态制造，便于其运输到制造分离叶片的工厂。
在一个实施例中，分离叶片的部件在一个两用模具中制造，如，模具适用于制造一体式叶片的部件和分离叶片的部件。
在另一个实施例中，分离叶片的部件在一个为其特定的模具中制造。
方法包括内侧和外侧壳体的制造，内外侧壳体带有构造成壳体的纵向中心部分的连接层压件，包含相邻端的翼弦的30-70%，且延伸进壳体长度的至少20%。
方法包括内侧和外侧杆的制造，内外侧杆带有构造成杆的端帽的连接层压件，其延伸到杆长度的至少20%。
参考发明的随后具体描述和所附权利要求以及附图，制造根据本发明的带有与分离叶片其他部件连接的连接件的分离风力涡轮机叶片的部件的方法的其他特定和优势变得很清楚。
附图说明
图1是根据本发明的分离叶片的部件的连接层压件的示意性透视图。
图2a和2b是根据本发明使用连接层压件制造的分离风力涡轮机叶片的内侧和外侧壳体示意图。
图3a和3b是根据本发明使用连接层压件制造的分离风力涡轮机叶片的壳体横截面视图。
图4a和4b是根据本发明使用连接层压件制造分离的风力涡轮机叶片的内侧和外侧杆的示意图。
图5a和5b是根据本发明用连接层压件制造分离式风力涡轮机叶片的杆的示意图。
图6是用于制造分离叶片的壳体的模具的示意性透视图，分离叶片带有安装在合适位置的两个部件的连接层压件。
图7a和7b是用于分别制造分离式风力涡轮机叶片的内侧和外侧壳体的两个模具的示意性透视图，分离叶片带有安装在合适位置的的连接层压件。
具体实施方式
根据本发明，在制造带有与另一部件连接的连接元件的分离叶片部件的方法中，在第一阶段连接元件结合到合适的层压件中，在第二阶段使用固化或半固化状态的连接层压件作为预制件来制作部件。
图1显示了包含连接元件13的复合材料的连接层压件11的例子。
在一个方面，连接层压件11依赖用于叶片中的特殊连接元件13的特征。在另一方面，假设总有可能设计一特定连接层压件，用于一套特殊的连接元件13。
关于带有结构壳体的叶片结构，图2a和2b显示内侧壳体21和外侧壳体31，其分别用特定连接层压件23,33作为预制件来制造，层压件23,33包含了两个壳体21、23的预知连接元件。
连接元件13嵌入如特别设计的碳纤维增强塑料（CFRP）或玻璃纤维增强塑料（CFRP）的复合材料的连接层压件23,33中，一方面用于获得连接元件13较好的集成，另一方面用于提供合适的性能，用于制造内侧壳体21和外侧壳体31。
连接层压件23,33的形状和结构必须与其分别在内侧壳体21和外侧壳体31中占用的空间相配。
如图2a和2b所示，这些连接层压件23,33占有内侧和外侧壳体21,31的纵向中心部分，包括在每个壳体靠近其他壳体的一端的翼弦的30%到70%之间，其各自的长度L1，L2分别至少是内侧和外侧壳体21,31长度的20%。他们甚至可以具有与壳体21,31一样的长度。
如图3a和3b所示，连接层加结构23的厚度可以等于或小于内侧壳体21的中心部分的厚度。相同的厚度应用于对应外侧壳体31的连接层压件33。
至于带有内部杆的叶片结构，图4a和4b显示了内侧杆25和外侧干35，其分别用特定连接层压件27,37作预制件来制造，层压件27,37包含了两个杆25,35的预知连接元件。
连接层压件27,37的形状和结构必须与其分别在内侧杆25和外侧杆35中占用的空间相配。
如图4a和4b所示，这些连接层压件27,37占有内侧和外侧杆25,35的端帽，其各自的长度L3，L4分别至少是内侧和外侧杆25,35长度的20%。他们甚至可以具有与杆25,35一样的长度。
如图5a和5b所示，连接层加件27的厚度可以等于或小于内侧杆25的端帽的厚度。相同的厚度应用于对应外侧杆35的连接层压件37。
使用一个如图6所示用于整个叶片部件的一个合适模具（模具还可以用于这种非分离叶片的部件）或如图7a和7b所示的叶片的两个部件的两个合适模具可以制造具有在前一阶段制造的连接层压件的分离风力涡轮机叶片的任何上述部件。
在如图6所示第一种情况下，提前制造的包含连接元件的连接层压件23,33放置在模具50的相应位置上，由分隔板51分隔。内侧和外侧壳体21,31的制造完全可以使用任何已知的风力涡轮机的制造方法。内侧壳体21和外侧壳体31可以同时制造。
在如图7a，7b所示的第二种情况下，提前制造的包含连接元件的连接层压件23,33放置在模具60,62上由板61,63限定的相应位置上。内侧和外侧壳体21,31的制造完全可以使用任何已知的风力涡轮机的制造方法。
本发明的主要优势是允许集中制造连接层压件，这是确保具有特殊结构价值的叶片部分高质量控制水平和分离叶片的部件的集中制造所需要的，也是减少成本所需要的。
尽管已经结合不同实施例描述了本发明，从说明书可以看出，可以做出元件的不同组合、改变和改进，并包括在本发明的范围内。

Claims (14)

1.分成至少两个纵向模块的风力涡轮机模块部件（21,31；25,35）的制造方法，所述部件带有与另一个模块的互补部件（31,21；35,25）连接的连接元件，其特征在于，包括下列步骤：
a）制造具有嵌入其中的连接元件的复合材料连接层压件（23,33；27,37），所述连接层压件构造成部件的一部分；
b）用连接层压件（23,33；27,37）做预制件来制造所述部件（21,31；25,35）。
2.如权利要求1所述的制造方法，其特征在于，连接层压件（23,33；27,37）在固化状态制造。
3.如权利要求1所述的制造方法，其特征在于，连接层压件（23,33；27,37）在半固化状态制造。
4.如权利要求1-3任一所述的制造方法，其特征在于，步骤b）是在模具（50）里完成，模具（50）适于制造一体式叶片的部件和纵向分成至少两个模块的风力涡轮机叶片的部件。
5.如权利要求4所述的制造方法，其特征在于，部件（21,31；25,35）与另一模块的互补部件（31,21；35,25）同时制造，两者之间使用分隔板（51）。
6.如权利要求4所述的制造方法，其特征在于，部件（21,31；25,35）在模具（50）的相应段制造，不使用模具（50）的剩下部分。
7.如权利要求1-3任一所述的制造方法，其特征在于，步骤（b）在用于部件（21,31；25,35）的专用模具上完成。
8.如权利要求1-7任一所述的制造方法，其特征在于，所述部件是壳体（21,31）。
9.如权利要求8所述的制造方法，其特征在于，连接层压件（23,33）构造成壳体（21,31）的纵向中心部分，包括在靠近互补壳体（31,21）的一端的翼弦的30%到70%，从靠近互补壳体（31,21）的一端延伸进壳体长度的至少20%。
10.如权利要求9所述的制造方法，其特征在于，连接层压件（23,33）沿壳体（21,31）的整个长度延伸。
11.如权利要求1-7任一所述的制造方法，其特征在于，所述部件是杆（25,35）。
12.如权利要求11所述的制造方法，其特征在于，连接层压件（27,37）构造成杆（25,35）的端帽，从靠近互补杆（35,25）的一端延伸进杆长度的至少20%。
13.如权利要求12所述的制造方法，其特征在于，连接层压件（27,37）沿杆（25,35）的整个长度延伸。
14.分成至少两个纵向模块的分离式风力涡轮机叶片，包括具有与另一个模块的互补部件（31,21；35,25）连接的连接元件的部件（21,31；25,35），其特征在于，所述部件（21,31；25,35）是根据权利要求1-13任一所述的方法制造。
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