CN103661937A - 翼型构件和优化芯部加固的翼型构件的结构特性的方法 - Google Patents

翼型构件和优化芯部加固的翼型构件的结构特性的方法 Download PDF

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CN103661937A
CN103661937A CN201310422068.4A CN201310422068A CN103661937A CN 103661937 A CN103661937 A CN 103661937A CN 201310422068 A CN201310422068 A CN 201310422068A CN 103661937 A CN103661937 A CN 103661937A
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next door
unit
airfoil
airfoil component
core
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CN103661937B (zh
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保罗·K·奥尔德罗伊德
李维岳
小詹姆斯·D·赫思科克
约翰·R·麦卡洛
帕特里克·R·蒂斯代尔
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Bell Helicopter Textron Inc
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  • Chemical & Material Sciences (AREA)
  • Aviation & Aerospace Engineering (AREA)
  • Composite Materials (AREA)
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Abstract

本发明涉及一种翼型构件，该翼型构件可具有根端部、梢端部、前缘和后缘。该翼型构件可包括上部蒙皮、下部蒙皮和复合芯部构件，该复合芯部构件具有多个单元，单元的上表面网状结构粘结到上部蒙皮，单元的下表面网状结构粘结到下部蒙皮。复合芯部可具有隔壁层，隔壁层嵌入到形成复合芯部的单元中，隔壁层构造为提供翼型构件的定制特性。

Description

翼型构件和优化芯部加固的翼型构件的结构特性的方法
技术领域
本发明涉及一种复合旋翼桨叶以及一种制造所述复合旋翼桨叶的方法。
背景技术
传统旋翼桨叶包括翼梁构件，该翼梁构件构造为用于为旋翼桨叶提供主要的结构整体性。例如，翼梁构件通常需要用于抵抗动力操作负荷，如空气动力学负荷、惯性负荷和离心负荷。然而，通常必须在与其他旋翼桨叶构件组装前单独地对翼梁构件进行固化，这样可能会提高制造成本。此外，翼梁构件仅仅是旋翼桨叶本体的一部分，因此，为了将翼梁构件和旋翼桨叶本体的其余部分和蒙皮之间的结构负荷路径一体化，必须做出相当大的努力。
因此，存在改善旋翼桨叶中的结构效率以及降低与旋翼桨叶的制造相关的费用的需求。
附图说明
在所附权利要求中阐述了本申请的实施方式的被认为具有新颖性的特征。然而，通过参考下列详细说明当结合附图进行阅读时将最佳地理解实施方式本身和应用的优选模式及其另外的目的和优点，其中：
图1是根据说明性的实施方式的具有旋翼桨叶的旋翼飞行器的侧视图；
图2是根据说明性的实施方式的旋翼桨叶的俯视图；
图3是根据说明性的实施方式的沿图2中的剖切线3-3截取的旋翼桨叶的横截面图；
图4是根据说明性的实施方式的旋翼桨叶的分解图；
图5是根据说明性的实施方式的旋翼桨叶的部分移除的细节图；
图6是根据说明性的实施方式的沿图5中的剖切线6-6截取的旋翼桨叶的横截面图；
图7是根据说明性的实施方式的制造定制芯部的方法的部分分解示意图；
图8是根据说明性的实施方式的制造定制芯部的方法的示意图；
图9是根据说明性的实施方式的在定制芯部中的纤维定向的局部视图；
图10是根据说明性的实施方式的在定制芯部中的纤维定向的局部视图；
图11是根据说明性的实施方式的制造定制芯部的方法的部分分解示意图；
图12是根据说明性的实施方式的制造定制芯部的方法的部分分解示意图；
图13是根据说明性的实施方式的制造定制芯部的方法的部分分解示意图；
图14是根据说明性的实施方式的制造定制芯部的方法的部分分解示意图；
图15是根据说明性的实施方式的制造定制芯部的方法的部分分解示意图；
图16是根据说明性的实施方式的制造定制芯部的方法的部分分解示意图；以及
图17是根据本申请的说明性的实施方式的计算机系统的示意性方框图。
具体实施方式
下面描述设备和方法的说明性的实施方式。为了清晰性的目的，在本说明中可能不对实际实施的所有特征做出描述。当然，应当理解的是，在任何这种实际实施方式的研发中，很多根据实施而特定的决定必须针对实现研发者的特定目标而做出，如顺从系统相关的和商务相关的约束条件，所述约束条件会在不同实施之间有所不同。此外，应理解的是，这样的研发努力可能会是复杂的并且耗时的，但无论如何对于已受益于本公开的本领域技术人员而言是例行工作。
在本说明中，可参考各个部件之间的空间关系，并且可参考部件的不同方位的空间定向，如在附图中所示装置。然而，如本领域那些技术人员在完整阅读本申请之后会意识到的，在此描述的装置、构件、设备等能够以任意期望的定向来定位。因此，诸如“上方”、“下方”、“上部”、“下部”的术语或类似的用于描述在各个部件之间的空间关系或用于描述这样的部件的方位的空间定向的术语的使用应当被理解为分别用于描述在部件之间的相对关系或这些部件的方位的空间定向，因为在此所描述的装置能够以任意期望的方向来定向。
本申请的一个说明性的实施方式包括旋翼桨叶，所述旋翼桨叶具有主要复合芯部的本体部。另一说明性的实施方式包括一种制造旋翼桨叶的方法。再一说明性的实施方式包括一种定制使用在旋翼桨叶中的复合芯部的方法。
参考图1，示出了旋翼飞行器101。旋翼飞行器101包括机身103、起落装置105、尾部构件107、旋翼系统109和多个旋翼桨叶201。应理解的是，旋翼飞行器101仅是可实施在此公开的设备和方法的多种飞行器的说明性例子。其他飞行器实施例可包括混合式飞行器、倾转旋翼飞行器、无人飞行器、旋翼机和多种直升机构造，仅举出了几个例子。此外，在此公开的方法可实施为设计和制造用于多种飞行器结构实施例的复合芯部，举例而言，如飞行器推进器和机翼。更进一步地，在此公开的方法可实施为设计和制造在非飞行器实施例中的芯部加固结构，举例而言，如空间结构、船只结构、水下结构、通用运输交通工具结构、运动结构和风力涡轮机结构。
现在还参考图2，示出了示例性旋翼桨叶201。旋翼桨叶201具有根端部203和梢端部205，根端部203和梢端部205在其之间限定了纵向轴线。旋翼桨叶201还具有前缘207和后缘209，前缘207和后缘209在其之间限定了弦向轴线。应理解的是，旋翼桨叶201仅为说明性的，并且旋翼桨叶201的可替代实施方式能够构造成各形状和尺寸。例如，旋翼桨叶201的一个实施方式可包括一定量的内置扭曲部。
在运行期间，旋翼桨叶201受到多种负荷，旋翼桨叶的设计必须适于这些负荷。例如，旋翼飞行器101可产生离心力（由方向箭头211示意性示出）、如超前/滞后（lead/lag）负荷的面内负荷（由方向箭头213示意性示出）、如扑翼负荷的面外负荷（在图1中由方向箭头215示意性示出）、和旋翼桨叶201的扭转负荷，如绕俯仰改变轴线217的扭曲。应理解的是，即使轴线217示出为俯仰改变轴线，轴线217也可以扩展地是翼展方向的轴线。通常，前述动力负荷引起应力和应变，在常规旋翼叶片中主要通过常规翼梁（如D形翼梁）来抵抗所述应力和应变。然而，旋翼桨叶201被独特地构造为能够去除翼梁，因为如此处进一步所讨论的，芯部部分定制为结合蒙皮构件抵抗动力负荷。此外，常规芯部是均质的；然而，旋翼桨叶201包括沿弦向、纵向方向和面外方向中的至少一个方向定制的芯部。如在此进一步讨论的，芯部的定制可通过改变芯部的作为弦向位置、纵向位置和面外位置的函数的一个或多个物理或材料特性来实现。
现在也参考图3和4，旋翼叶片201可包括上部蒙皮219、下部蒙皮221、芯构部件223和磨损带225。上部蒙皮219和下部蒙皮221可以是在一个或多个工具上被组合和固化的复合层组合件。上部蒙皮219和下部蒙皮221可以具有由具体的实施而定的不同的厚度和材料叠层。在所示实施方式中，上部蒙皮219和下部蒙皮221是“结构蒙皮”，因为上部蒙皮219和下部蒙皮221与芯构部件223和磨损带225共同起结构组合件的作用。上部蒙皮219、下部蒙皮221、芯构部件223和磨损带225优选在单个的粘结循环中粘结在一起。优选的是，为了重量效率，芯部构件223借助于网状粘合剂粘结到上部蒙皮219和下部蒙皮221。在图示实施方式中，芯部构件223包括大型的单元碳芯部；然而，芯部构件223的精确的尺寸、形状和材料是视具体实施而定的。此外，芯部构件223在此示出为六角形蜂窝状芯部；然而，在此公开的内容不限制于六角形芯部，其他芯部形状也是可以实施的。
芯部构件223被独特地定制为具有必须经得住由旋翼桨叶201在运行期间经受的负荷的局部的和整体的性能。相对地，常规旋翼桨叶可具有用于加固旋翼桨叶的一个或多个部分的芯部，但该芯部是均质的并且缺少定制。因此，通常需要常规的翼梁为常规旋翼桨叶提供结构整体性。芯部构件223可制造为多个堆叠的基于条带的波状元件，或者制造为基于单个单元的元件的阵列，或者制造为二者的组合。关于芯部构件223制造为基于单个单元的元件的阵列，参见美国专利申请13/260,690，该专利作为美国专利申请公开文件US2012/0021165而被公开，其内容在此通过参引并入本文。芯部构件223可通过利用复合的、单向的、偏斜的和三轴向的材料的特征，使用与它们在旋翼桨叶201中的布置相结合的它们的单独的和组合的物理和机械性能来定制。此外，芯部构件223可通过下述方式来定制：纤维选择、纤维束尺寸或缝隙宽度、纤维束或束间隔、纤维束或束角度、纤维的混合、材料铺层的厚度和/或通过条带方向或没有条带方向。此外，可以通过任意上述变量控制芯部单元的螺旋形部件进行定制，或者通过在螺旋形芯部单元部件之间添加类似定制的沿特定方向的波状铺层来进行定制，或者可替代地通过单独地或成组地包裹或包封螺旋形芯部单元部件来进行定制，以便进一步定制芯部构件223的机械和物理性能。这些变量的任意组合可被用于产生方向稳定性（强度和/或刚度）、提高抗剪能力、以及定制旋翼桨叶201的一般性能。更为明确的是，旋翼桨叶201的可借助于定制芯部构件223而控制的一般性能是抗扭刚度、梁刚度、弦刚度和频率排布。芯部构件223的定制也可用于提高影响物理性能的能力，所述物理性能为如质心、质量分布、关于中轴的梁刚度和弦刚度（其也可以影响频率排布）。
芯部构件223的定制能够实现为了在旋翼桨叶201中的弦/梁/扭转性能而定制芯部边缘。此外，芯部构件223的定制能够实现利用纤维偏斜类型对在上部蒙皮219与下部蒙皮221之间的剪切能量进行方向定制。此外，芯部构件223的定制允许通过选择芯部构件223的角/间隔/条带方向来选择性地控制旋翼桨叶201的扭转性能。芯部构件223的定制可以实现改善的质量平衡和调谐机会，因为与在使用均质芯部的常规旋翼桨叶中使用均匀性能相反，性能能够沿任何工程方向实现。此外，芯部构件223的定制提高了使用传统的“L形”和“W形”条带方向的能力，但也从定制组合在材料等级、阔绸（broadgoods）等级、芯部结构和桨叶结构等级方面获得了额外的优点。
具体到旋翼桨叶，芯部构件223的偏斜类型提供了改善的抗剪能力，并且能够实现冗余的扭转负荷路径。在这样的旋翼桨叶中，整个芯部构件223提供了改善的抗剪能力和冗余的扭转负荷能力，这样能够消除对于传统的内部翼梁构件的需求。
现在还参照图5和6，示出了为了提供旋翼桨叶201中的特定的机械性能或特性而对芯部构件223进行定制的一个示例。上部蒙皮219和下部蒙皮221可具有铺层递减（ply drop-off），如沿旋翼桨叶201纵向延伸的铺层递减231和233。为了对抗来自铺层递减231和233的潜在应力升高，可以将隔壁235和237定位在芯部构件223内，以提高芯部构件223在铺层递减231和233的区域中的强度/刚度。如果芯部构件223是传统的均质芯部，那么整个芯部会不得不过大以抵抗铺层递减的应力升高，因而导致非定制芯部倾向于在靠近后缘部分处过刚硬，并且不利地将旋翼桨叶的重心向后缘移动。类似地，隔壁239、241和243可以如所示地大致地定位在期望提供附加的强度以用于承受朝向桨叶附连孔245a和245b的面内负荷张力。隔壁235、237、239、241和243可以是一个或多个负荷材料铺层。隔壁的纤维定向、厚度等全部可以为旋翼桨叶201进行特殊定制。隔壁241、243和247尤其适于与基于单元的芯部一起使用，然而隔壁235尤其适于与基于条带的芯部一起使用。隔壁237即可以用在基于单元的芯部也可以用在基于条带的芯部中。
在定制的芯部构件223的另一个实施例中，被附上的隔壁247可用于包封形成定制特性的局部区域的多个单元并且增加形成定制特性的局部区域的多个单元周围的强度。
参照图7-16，示意性示出了制造定制芯部构件223的方法。参照图7，可以通过与复合材料的波状层进行粘合剂粘结或共固化而将例如隔壁235和239的横向穿过的隔壁构建在芯部构件223中，芯部构件223也可以被称为基于条带的芯部。而且，隔壁237、241和243能够以这种方法被结合到芯部构件223中。参照图8，如隔壁237、241、243和247的隔壁也可以通过如下方式被结合到芯部构件223中：在用于制造基于单元的芯部的过程中，将隔壁挤压到由模具801内部的心轴803支撑的单元之间。每个心轴803可以具有以任意类型的构造/定向缠绕的纤维。隔壁（举例示出的隔壁237）可以任意期望构造在单元之间定向。
在定制芯部构件223的另一实施例中，纤维角度被用户化，从而使得芯部构件223的特定部分产生特定的期望特性，举例而言，如梁刚度、弦刚度和扭转刚度。在一个实施例中，复合材料放置为形成芯部构件223的单元壁，从而使得在一部分中纤维以+/-45°定向，而在另一部分中使纤维以+/-30°定向，而在再一部分中使纤维以+/-60°定向。第一组纤维以+45°定向，而第二组纤维以-45°定向。尤其参照图10，基于单元的芯部可以仅由呈螺旋状地围绕心轴缠绕的单一角度的纤维259构成。相邻的单元在组装到芯部快中时制成+/-层压件。
在图9中示出的可替代实施方式中，第一组纤维901和第二组纤维903编织在一起。例如，芯部构件223可使得纤维在前缘附近以+/-45°编织，同时使纤维在后缘附近以+/-30°编织。此外，芯部构件223可使得纤维在根端部203附近以+/-60°编织，同时使纤维在梢端部205附近以+/-30°编织。以这种方式，梁刚度、弦刚度、扭转刚度以及其它特性可以通过定制芯部构件223来用户化。
现在特别地参照图11，示意性示出了如芯部构件223的芯部构件的制造。芯部构件可包括基于单元的芯部部分249或基于条带的芯部部分251，或如所示出的二者的组合。每个单元构件261能够以制造顺序被粘结在一起，所述制造顺序也允许出于定制目的的一个或多个隔壁的策略性布置。关于基于单元的芯部部分249，一个实施方式包括通过跳过单元位置来产生空隙部253，这样允许穿过那里放置隔壁235。隔壁253可以如图所示粘结在相邻的单元构件之间。在另一实施方式中，可以临近基于单元的芯部部分249或与基于条带的芯部部分251结合为一体的方式使用完全波状的隔壁237。可替代完全波状的隔壁237是部分波状的隔壁255，隔壁255与完全波状的隔壁237不同，其不与内部的单元壁匹配。也示出了作为笔直的隔壁的隔壁235。
也参照图12，关于基于单元的芯部249示出了波状的隔壁237。也参照图13和14，结合基于单元的芯部249示出了波状隔壁，如隔壁241、243。
也参照图15，关于基于单元的芯部249示出了隔壁247。隔壁235可以用于在组装单元构件以在形成基于单元的芯部249期间包封一组单元构件。
也参照图16，基于单元的芯部构件249可在具有较厚的单元壁的一组多层单元257的内部具有空隙部253。与其他单元构件相比，较厚的单元壁可以通过组装较大数量的复合材料铺层来制成。这样的实施方式可以是借助于隔壁235来包封一组单元构件的可替代方案。
现在参照图17，示意性示出了计算机系统1001。系统1001构造为用于执行关于在此公开的有关定制芯部构件223和旋翼桨叶201的特性的方法以及在此公开的其他方法或工艺的一个或多个功能。
系统1001可包括输入/输出（I/O）界面1003、分析引擎1005和数据库1007。可替代实施方式可根据要求对输入/输出（I/O）界面1003、分析引擎1005和数据库1007进行组合或分配。系统1001的实施方式可包括一个或多个计算机，所述计算机包括构造为用于执行在此所述的任务的一个或多个处理器和存储器。这可以包括例如具有中央处理单元（CPU）和非易失性存储器的计算机，在所述非易失性存储器中存储用于指示CPU执行在此所述的任务中的至少一些任务的软件指令。这也可包括例如通过计算机网络进行通信的两个或多个计算机，在此所述计算机中的一个或多个包括CPU和非易失性存储器，并且计算机的非易失性存储器中的一个或多个存储有用于指示（一个或多个）CPU中的任意个执行在此所述的任务中的任意个的软件指令。因此，尽管就离散的机器方面对示例性的实施方式进行了描述，然而应理解的是，这种描述是非限定性的，并且本说明同样适用于涉及执行任务的一个或多个机器的许多其他的布置，所述任务以任何方式在该一个或多个机器之间进行分配。还应理解的是，这样的机器不需要完全致力于执行在此描述的任务，而取而代之地是，可以是多用途的机器，例如也适于执行其他任务的计算机工作站。
I/O界面1003可以提供在外界用户、系统和数据源以及系统1001的部件之间的通信连接。I/O界面1003可以构造为允许一个或多个用户经由任意已知的输入装置输入信息到系统1001。示例可包括键盘、鼠标、触摸屏和/或任意其他期望的输入装置。I/O界面1003可以个构造为允许一个或多个用户接收从系统1001经由任意已知输出装置输出的信息。示例可包括显示器、打印机和/或任意其他期望的输出装置。I/O界面1003可构造为允许其他系统与系统1001进行通信。例如，I/O界面1003可允许一个或多个远程计算机获取信息，输入信息和/或远程指示系统1001来执行在此描述的一个或多个任务。I/O界面1003能够构造为允许与一个或多个远程数据源进行通信。例如，I/O界面1003能够允许一个或多个远程数据源获取信息，输入信息和/或远程指示系统1001来执行在此描述的一个或多个任务。
数据库1007为系统1001提供持久稳定的数据存储。尽管主要使用术语“数据库”，而存储器或其他适合的数据存储装置可提供数据库1007的功能。在可替代的实施方式中，数据库1007可以集成到系统1001中或独立于系统1001，并且可以在一个或多个计算机上运行。数据库1007优选为任何适合于支持系统801运行的信息提供非易失数据存储，包括在此进一步讨论的不同类型的数据。
分析引擎1005可以构造为用于在设计阶段分析旋翼桨叶201的应力和应变。此外，分析引擎1005可以构造为用于优化芯部构件223和诸如上部蒙皮219和下部蒙皮221的其他旋翼桨叶部件的定制。分析引擎1005可以构造为用于结合诸如梁刚度、弦刚度和扭转刚度的一个或多个标准分析和优化芯部构件的定制特性。分析引擎1005可包括一个或多个处理器、存储器和软件部件的不同的组合。
以上公开的具体实施方式仅是说明性的，因为对于受益于在此的教导的本领域技术人员而言，可以以不同的但等效的方式对设备进行修改和实施。可以在不偏离本发明的保护范围的情况下对在此描述的设备进行修改、添加或省略。设备的部件能够是集成的或独立的。此外，设备的运行可以通过更多、更少或其他部件来执行。
此外，除了在权利要求中所描述的以外，不旨在对于在此示出的构造或设计的细节进行限制。因此，显然可以对上述具体实施方式进行更改或修改，并且所有变型方案视为在本申请的精神和保护范围之内。因此，在权利要求中阐明了在此所要求的保护范围。
为了帮助专利局和任何基于此申请所发行的任何专利的任何读者理解所附权利要求，申请人希望被注意到的是，他们不打算使所附的任何权利要求援引35U.S.C§112的第6段，因为关于这一点其存在于申请日，除非表述“用于…的手段”或“用于…的步骤”明确地使用在特定的要求中。

Claims (20)

1.一种翼型构件，所述翼型构件具有根端部、梢端部、前缘和后缘，所述翼型构件包括：
上部蒙皮；
下部蒙皮；
复合芯部构件，所述复合芯部构件具有多个单元，所述单元的上表面网状结构粘结到所述上部蒙皮，所述单元的下表面网状结构粘结到所述下部蒙皮；
隔壁层，所述隔壁层嵌入到所述复合芯部中，所述隔壁层构造为提供所述翼型构件的定制特性。
2.根据权利要求1所述的翼型构件，其中，所述复合芯部构件的所述单元是六角形的。
3.根据权利要求1所述的翼型构件，其中，所述翼型构件是旋翼桨叶。
4.根据权利要求1所述的翼型构件，其中，所述翼型构件是用于飞行器的机翼。
5.根据权利要求1所述的翼型构件，其中，所述隔壁包括位于相邻的单元之间的呈波状几何形状的复合材料层，所述隔壁在从所述翼型构件的所述根端部朝所述梢端部的方向上延伸。
6.根据权利要求1所述的翼型构件，其中，所述隔壁包括下述复合材料层，所述复合材料层是直线式的，并且以交替的方式在相邻的单元之间横穿和穿过单元的内部。
7.根据权利要求6所述的翼型构件，其中，所述隔壁定位在相邻的单元之间且在从所述根端部朝向所述梢端部的方向上定向。
8.根据权利要求7所述的翼型构件，其中，所述翼型构件是旋翼桨叶，并且其中，所述隔壁构造为抵抗离心力负荷。
9.根据权利要求1所述的翼型构件，其中，所述隔壁包括包围一组单元的复合材料层。
10.根据权利要求1所述的翼型构件，其中，所述隔壁包括下述复合材料层，所述复合材料层是直线式的，并且以交替的方式在相邻的单元之间横穿和穿过单元的内部，所述隔壁相对于所述翼型构件的翼展方向轴线成角度地定向。
11.根据权利要求10所述的翼型构件，其中，所述翼型构件是旋翼桨叶，并且其中，所述隔壁构造为抵抗所述翼型构件的面内负荷。
12.根据权利要求11所述的翼型构件，其中，所述面内负荷是由超前/滞后操作运动引起的。
13.根据权利要求1所述的翼型构件，其中，所述隔壁包括下述复合材料层，所述复合材料层是直线式的，并且以交替的方式在相邻的单元之间横穿和穿过单元的内部，并且其中，所述隔壁位于所述上部蒙皮中的厚度减小部附近。
14.根据权利要求1所述的翼型构件，其中，所述隔壁包括下述复合材料层，所述复合材料层是直线式的，并且以交替的方式在相邻的单元之间横穿和穿过单元的内部，并且其中，所述隔壁位于所述下部蒙皮中的厚度减小部附近。
15.根据权利要求1所述的翼型构件，其中，所述隔壁包括下述复合材料层，所述复合材料层是直线式的，并且以交替的方式在相邻的单元之间横穿和穿过单元的内部，并且其中，所述隔壁位于所述上部蒙皮和所述下部蒙皮中的至少一个的厚度减小部附近，所述厚度减小部沿翼展方向延伸。
16.根据权利要求1所述的翼型构件，其中，所述复合芯部构件包括在所述根端部附近的具有以第一角度定向的纤维的单元和在所述梢端部附近的具有以第二角度定向的纤维的单元。
17.根据权利要求16所述的翼型构件，其中，在所述根端部附近的所述单元中以所述第一角度定向的纤维产生第一扭转刚度，而在所述梢端部附近的所述单元中以所述第二角度定向的纤维产生第二扭转刚度。
18.一种优化芯部加固的翼型构件的结构特性的方法，所述方法包括：
组装复合材料，以形成具有多个单元构件和至少一个隔壁的复合芯部，所述隔壁具有复合材料层；
将所述复合芯部在翼型组合件中定位成使得所述隔壁位于提供期望的结构特性的位置。
19.根据权利要求18所述的方法，其中，所述隔壁的位置通常对应于所述翼型构件的翼展方向。
20.根据权利要求18所述的方法，其中，所述隔壁环绕多个单元构件的一部分。
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