CN105517785A - 风轮机叶片 - Google Patents

风轮机叶片 Download PDF

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Publication number
CN105517785A
CN105517785A CN201480048857.9A CN201480048857A CN105517785A CN 105517785 A CN105517785 A CN 105517785A CN 201480048857 A CN201480048857 A CN 201480048857A CN 105517785 A CN105517785 A CN 105517785A
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Prior art keywords
housing parts
wind turbine
turbine blade
unit
plug
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CN201480048857.9A
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CN105517785B (zh
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A·莱特
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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
    • 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
    • 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
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14311—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles using means for bonding the coating to the articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B11/00—Making preforms
    • B29B11/06—Making preforms by moulding the material
    • B29B11/10—Extrusion moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B11/00—Making preforms
    • B29B11/14—Making preforms characterised by structure or composition
    • B29B11/16—Making preforms characterised by structure or composition comprising fillers or reinforcement
    • 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
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14065—Positioning or centering articles in the mould
    • 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
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    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
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    • B29C2045/14114—Positioning or centering articles in the mould using an adhesive
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/1222—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section comprising at least a lapped joint-segment
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    • B29C66/1224—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section comprising at least a butt joint-segment
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    • B29C66/1226—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section comprising at least one bevelled joint-segment
    • 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
    • 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
    • B29C66/543—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 joining more than two hollow-preforms to form said hollow 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
    • B29C66/50—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
    • B29C66/63—Internally supporting the article during joining
    • 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
    • B29C66/71—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 characterised by the composition of the plastics material of the parts to be joined
    • 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
    • B29C66/72—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 characterised by the structure of the material of the parts to be joined
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    • B29C66/7212—Fibre-reinforced materials characterised by the composition of the fibres
    • 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
    • B29C66/73—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 characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
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    • B29C66/7394—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 characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoset
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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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    • B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
    • B29C70/443—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding and impregnating by vacuum or injection
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract

本发明涉及一种制造风轮机叶片的壳体部件(101)的方法，风轮机叶片还包括沿着连接面与壳体部件(101)连接的附加组件(301，302)。所述方法包括以下步骤：提供插件(102)，该插件具有形状与连接面具有大致相同形状的侧表面；将插件定位在敞口模具中；以及将一个或多个材料层(105)放置在模具(103)中以形成壳体部件(101)，其中，材料层(105)被放置成与插件(102)的侧表面(104)毗邻，从而形成壳体部件(101)的与连接面具有大致相同形状的侧表面(108)。在树脂固化之后，取出插件(102)。本发明还涉及一种制造包括这种壳体部件(101)的风轮机叶片壳体构件(100)的方法，并且将材料层(105)与壳体部件(101)的侧表面(108)毗邻地放置在模具(103)中，以形成附加组件(301，302)。

Description

风轮机叶片
技术领域
本发明涉及一种制造风轮机叶片壳体构件的部件的方法，其中，所述风轮机叶片壳体构件包括壳体部件和沿着连接面连接的附加组件。本发明还涉及一种包括根据这种方法制造的壳体部件的风轮机叶片。
背景技术
现代的风轮机包括多个风轮机转子叶片，典型地包括三个叶片，各叶片均具有重达35吨的重量和长达80米以上的长度。
随着风轮机并因而风轮机叶片的大小不断扩大，必须增大制造设施和运输装置来操纵所需大小的叶片。这样还增加了对物流的要求并且提高了相关成本。
另外，风轮机叶片的不同部件对诸如材料和结构性质的因素和制造工艺有不同要求。这样可导致叶片制造过程变得复杂、劳动密集并且延长了制造时间。举例来说，后缘的形状和硬度显著影响了叶片的整体气动弹性参数以及从叶片发出的噪声的级别。另外，常常相当尖锐的后缘使得这个叶片部件特别敏感并且在制造和运输期间往往会受损。后缘因此经常涉及使用与其余叶片壳体不同的其它材料或额外制造步骤。
已知分部分或分段制造后续进行结合的风轮机叶片。然而，得到所连接叶片部件之间的接头的必要精度和强度和跨接头安全传递负载和力矩会存在一些问题。另外，在连接常常非常大的片段而不危及关于叶片的最终形状、硬度和重量考虑方面可能存在困难。
发明内容
因此，本发明的实施方式的一个目的在于克服或至少减少分部分制造的已知风轮机叶片的上述缺点中的一些或全部并且提供一种制造这种叶片的改进方法。
本发明的实施方式的另一目的是提供一种可分段或分部分有效制造但被以充分的接头精度、强度和硬度组装的风轮机叶片。
本发明的实施方式的另一目的是提供一种制造被准备用于接合并随后连接到另一组件的叶片壳体的这些部分的有效方法。
另一目的是提供一种对结合或接合表面的几何形状的控制有所改进的风轮机部件的制造方法。
本发明的另一目的是提供一种降低制造风轮机叶片的工具和模具成本的方法。
按照本发明，这是通过一种制造风轮机叶片壳体构件的部件的方法得到的，其中，所述风轮机叶片壳体构件包括壳体部件和沿着连接面连接的附加组件。所述方法包括：提供插件，该插件具有与所述连接面具有大致相同形状的侧表面；将所述插件定位在敞口模具中；以及将一个或多个材料层放置在所述模具中以形成所述壳体部件，其中，所述材料层被放置成与所述插件的所述侧表面毗邻，从而形成所述壳体部件的与所述连接面具有大致相同形状的侧表面。所述方法还包括：向所述材料层提供树脂，并且允许所述树脂至少部分固化并且取出所述插件。
所述风轮机叶片壳体构件可形成整个风轮机壳体、或背风侧壳体或迎风侧壳体、或其一部分。所述风轮机叶片壳体构件可包括一个或多个梁帽，所述梁帽充当在壳体中纵长地(即，在叶片的纵向方向上)延伸的加强梁。
所述附加组件可例如形成风轮机叶片的后缘部分或前缘部分、襟翼部分、或者叶片的末端部分或根部部分。所述附加组件还可或另选地形成风轮机壳体构件的主要部分，并且壳体部件形成例如叶片的前缘或后缘部分或末端或根部部分。所述附加组件可以被预先制造，并且当被放置在所述模具中时或者随后在脱模之后被结合到叶片壳体部件上。
所述连接面在进行连接时形成所述壳体部件和所述附加组件之间的接合面。
向所述材料层提供树脂的方法步骤可包括：将树脂注入和/或灌注到放置在所述模具中的所述材料层。另外地或另选地，可通过使用预浸渍材料来提供所述树脂。所述预浸渍材料可形成所述材料层中的一个或多个或者可以是除了所述材料层之外放置在所述模具中的材料。
通过在根据以上的制造方法中使用插件得到的是，可在第一步骤中进行构建期间省去风轮机壳体的组件，但是使得可随后将组件有效地结合到壳体部件。所述模具中的所述插件使精细侧表面细节能够被结合到所述叶片的所述壳体部件中。另外，所述插件确保所述壳体部件的侧表面的更精确位置和形状，借此确保随后与附加组件的接合线的更精确的位置和形状。由此，壳体部件被准备用于有效连接到附加组件，其中，精细侧表面细节和几何形状使得能够实现几何形状受良好控制的连接和接头，因此能够具有高强度。
提出的所述插件的方法和使用意味着，可得到不同的连接面并且有可能得到比不使用插件的情况下可能的更复杂的形状。传统上，待连接到另一部件的壳体部件被铺放成具有平缓或减缩的侧表面。根据本发明，连接面进而接头几何形状是由插件的侧表面的形状和几何形状给出的，因此它可被控制并且用预定和固定的几何形状来明确地限定。由此，可以制成例如有更整齐表面的接合线，或者制成例如套式或阶梯状接头，或者使接合强度增大的指状物或齿状物。
由于壳体部件的侧表面的位置和几何形状受良好控制，导致壳体部件不需要或者唯有最小限度地需要在连接到附件组件之前被处理或加工。由此，在得到质量和强度增大的连接和接头的同时，显著减少制造时间和成本。
所提出的方法允许在缺少组件或片段的情况下构造和制备风轮机叶片壳体构件。如以上提到的，这些附加组件可例如是叶片前缘片段或后缘片段或末端部分的部件。于是这允许与壳体部件不同地制造附加组件，例如通过对于附加组件来说更优的不同制造方法；或者允许进行调整以适应诸如强化的腐蚀性质、低成本、低重量、避雷保护装置等特定要求。附加组件可同样有利地单独制造，由此能够使用例如另外与壳体部件制造过程不相容的不同材料(诸如，不同树脂)，或者将预浸渍材料用于附加组件或壳体部件中，但将树脂灌注在另一个中。在另一个示例中，壳体部件可由诸如碳纤维加强塑料的第一材料形成，并且附加组件由诸如玻璃加强塑料的第二组件形成。
所提出的方法的另一优点在于，允许模具为了不同目的而被再利用。由于现代风轮机叶片的尺寸非常大，导致模具的价格极高。另外，只有极少数几个模具由于其大小和其成本而针对各叶片类型制备。因此，有利地，能够为了不同目的而再利用同一模具，既为了传统制造一件式的一个叶片壳体构件，又为了制造被准备稍后也可在该模具中进行与附加组件的连接的壳体部件，和/或为了单独制造附加组件。模具成本由此大大降低。
所提出的方法还有利地允许在叶片壳体部件已被脱模之后或者在壳体部件仍然处于模具中时将附加组件连接到壳体部件。由此，可执行壳体部件和附加组件的连接，使得在生产线和可用制造设施方面最有效。
在本发明的一个实施方式中，所述壳体部件形成从根部区域延伸到末端区域的风轮机叶片壳体的至少中央部分。
在本发明的一个实施方式中，所述附加组件形成叶片后缘、叶片前缘和/或叶片末端的至少一部分。
如之前提到的，这允许制造可以用不同过程、在方便的不同时间、和/或在不同地点制造叶片壳体的不同模块和主要部分的模块化叶片。另外，这允许风轮机壳体的主要部分被改造成具有一系列不同后缘之中的例如对于特定风轮机场所而言最佳的一个后缘或者例如满足诸如发出噪声的特定要求等。
壳体部件和附件组件可稍后更靠近建立场所或者在建立场所处进行连接。这样可大大简化风轮机叶片的运输。
在本发明的一个实施方式中，所述插件的侧表面设置有成角度的表面部分，使得所述壳体部件适于以嵌接接头连接到所述附加组件。由此，得到的壳体部件的表面侧具有良好受控的几何形状，由此获得与附加组件的接头的良好受控的几何形状。成角度的表面部分使壳体部件和附加组件能够以嵌接接头连接，从而产生连接部件之间的增大的接触表面面积，由此产生高接合强度。
在本发明的一个实施方式中，所述插件的所述侧表面设置有阶梯状表面。这样在壳体部件和附加组件之间能够具有不同类型的阶梯状接头，并且有可能得到高精度和强度的接头或连接。
在本发明的另一实施方式中，所述插件的所述侧表面设置有成不同角度的表面部分，由此可在壳体部件和附加组件之间得到不同类型的接头(诸如，齿状物或指状物接头、钩状嵌接接头、或双面嵌接接头)。
根据以上实施方式的插件的侧表面的几何形状还允许壳体部件的侧表面具有不同几何形状，其中，在壳体部件与插件毗邻时，插件可形成最靠外部分，或者壳体部件可形成抵靠模具表面的最靠外部分。
在一个实施方式中，所述插件按照所述模具中或所述模具上的指示所述插件相对于所述模具的期望位置的标记而定位在所述模具中，和/或在所述模具中定位成顺随所述模具的外边缘。由此，得到插件的精确定位，由此得到壳体部件的侧表面和稍后壳体部件和附加组件之间的接头的精确几何形状。另外，这样允许当制造更多壳体部件时重复得到插件的相同位置，由此得到接合线的相同位置。
在另一实施方式中，所述方法还包括以下步骤：诸如用诸如可固化或不可固化热熔融树脂的粘合剂或者用带双面涂层的胶带或者诸如夹持件、线、或弹性构件的机械紧固装置，将插件至少暂时固定到模具。由此，可用简单装置将插件有效地保持就位，从而提高侧表面的几何形状和位置的精度进而提高接头的几何形状和位置的精度。
根据本发明的一个实施方式，所述方法还包括将外表面层材料和/或内表面层材料放置在模具中的步骤。这可以例如是溶胶涂层和/或树脂分布层。另外或另选地，这些内层和/或外层可包括灌注的内蒙皮和外蒙皮。
在一个实施方式中，所述方法包括将不同材料的一个或多个元件放置在模具(例如，纤维加强材料的拉挤成型板和/或芯材料的块)中的步骤。
根据本发明的一个实施方式，提供树脂的步骤包括将预浸渍材料的一个或多个层放置在模具中和/或用树脂至少部分浸渍所述层。可用预浸渍材料中设置的所有树脂，或者用通过树脂注入或树脂灌注而提供的所有树脂，或者通过其组合，制造壳体部件。
在另一实施方式中，所述材料层包括诸如玻璃纤维和/或碳的纤维加强片材；并且所述树脂包括诸如基于环氧树脂或乙烯基酯树脂的热固性树脂。
根据另一实施方式，所述插件由塑料、木材、金属或其组合制成。由此，插件可用相对低的成本制成，但有可能使插件具有精细侧表面以得到壳体部件的精确和良好受控的侧表面。可用诸如硅树脂的材料覆盖插件，使得壳体部件不粘附于插件。
本发明还涉及一种包括根据如上所述方法的实施方式中的任一实施方式制造的风轮机叶片壳体部件的风轮机叶片。其优点是关于所述方法描述的。
本发明还涉及一种制造包括如之前描述地制造的壳体部件的风轮机叶片壳体构件的方法，其中，所述方法还包括：将材料层放置在模具中以形成附加组件，其中，所述材料层被放置成与所述壳体部件的侧表面毗邻；以及将树脂引入所述材料层中并且允许所述树脂至少部分固定，以将所述附加组件结合到所述壳体部件。由此，可在制造叶片壳体部件的同一模具中执行壳体部件和附加组件的连接。
另外，所提出的方法允许例如用诸如不同树脂类型的不同材料或诸如不同温度或压力的不同工艺参数，与附加组件不同地制造壳体部件，但却得到这两个连接构件之间的精确、良好受控的强力结合。另外，所述方法有利地允许在不需要中间制备或适配连接表面以得到所需装配的情况下结合壳体部件和附加组件。
此外，在不首先将壳体部件脱模的情况下，可创建附加组件在壳体部件上的连接和结合。其它优点是之前关于壳体部件制造方法提到的。
在另一方面，本发明提供了一种制造包括如之前描述地制造的壳体部件的风轮机叶片壳体构件的方法，其中，所述方法还包括提供附加组件并且将所述附加组件结合到所述壳体部件。由此，可在与壳体部件相同的模具或模具部分中或者在另一模具或模具部分中预先制造附加组件。
本发明的另一方面涉及一种制造包括上壳体和下壳体的风轮机叶片的方法，所述方法包括：根据以上描述的方法制造两个壳体部件以形成叶片的上壳体的部件和叶片的下壳体的部件；以及用在这两个壳体部件之间的在叶片的纵向方向上延伸的一个或多个互连抗剪腹板来连接所述壳体部件。另外，所述方法包括提供附加组件并且将所述附加组件连接到这两个壳体部件。由此，得到模块化制造风轮机叶片的方法，其中，在制备并且用腹板连接叶片的上壳体部件和下壳体部件之后，可将附加组件连接并结合到风轮机叶片壳体的主要部分。由此，叶片的不同部分和组件之间的接头位置可移动远离诸如在前缘或后缘处的更易出故障或复杂的位置和替代位置，例如，接触面的面积更大和/或风轮机叶片的气动弹性性质不容易受影响的位置。
附图说明
在下面，将参照附图描述本发明的不同实施方式，其中：
图1示出如在剖视图上看到的使用插件构建壳体部件的风轮机叶片的模具，
图2用剖视图示出根据本发明的一个实施方式的两个壳体部件的连接，以及
图3示出通过将后缘和前缘连接到图2中示出的叶片的连接来制造根据本发明的实施方式的组合式叶片的步骤。
具体实施方式
图1示出根据本发明的一个实施方式的(在剖视图中看到的)风轮机叶片壳体的部件101的制造和铺放。这里，风轮机的壳体构件100被铺放在模具103中，但省略前缘和后缘的部分，以备随后作为附加组件来添加。替代插件102被放置在模具103中。插件均包括形状与壳体部件101和附加组件之间的连接面的所需形状对应的侧表面104。
诸如内蒙皮和外蒙皮的材料层105随后被放置在模具中，以形成壳体部件。这些层可包括诸如织造或非织造片材或UD材料层的纤维增强材料层。可用树脂预浸渍这些层中的一些或全部，或者可通过灌注或注入将树脂引入模具中。另外，构成叶片壳体的其它元件可被放置在模具中，使诸如梁帽107和芯元件106在其间。梁帽可有利地包括碳纤维增强材料的拉挤成型板，并且芯材料可典型地是诸如泡沫材料或轻木的低重量的材料。
壳体部件的层105被放置成与插件102的侧表面104毗邻。由此，形成壳体部件的侧表面108，侧表面108具有与壳体部件和待连接的附加组件之间的所需连接面大致相同的形状。然后，允许树脂至少部分固化并且取出插件。由此制造的壳体部件可随后被脱模或者可留在模具中，以待结合到附加组件。
附加组件可被预先制造(例如，在同一模具103中)或者可被构建并且直接在模具中固化到叶片壳体上。
如图1中概述地，插件的侧表面104可具有例如阶梯状表面部分或成不同角度的表面部分。由此，壳体部件的侧表面108相应地成形，以产生当连接到附加组件时不同类型的接头。例如，在图1中绘出了阶梯状、指状物或嵌接接头或啮合特征的不同变形形式的略图。
图2用剖视图示出用抗剪腹板201连接的两个壳体部件101。虚线202示出风轮机叶片200的所需最终形状的轮廓。壳体部件101的侧表面108借助如关于图1描述的插件来成形，因此对应于将联接到壳体部件的附加组件的对应侧表面。
在图2和图3中示出的实施方式中，前缘301和后缘302形成两个预先制造的附加组件。这些附加组件接着被以单独操作结合到所连接的壳体部件101上。提供将壳体部件101和附加组件彼此定位和附接的夹具303。这样允许用单独过程制造前缘和后缘，这些过程被优化以最佳制造这些组件。
虽然已描述了本发明的优选实施方式，但应该理解，本发明没有如此受限并且可在不脱离本发明的情况下进行修改。本发明的范围由随附权利要求书限定，在文字上或者等同地在权利要求书的含义内的所有装置旨在被涵盖其中。

Claims (20)

1.一种制造风轮机叶片壳体构件的部件的方法，所述风轮机叶片壳体构件包括壳体部件和沿着连接面连接的附加组件，所述方法包括：
-提供插件，该插件具有与所述连接面具有大致相同形状的侧表面；
-将所述插件定位在敞口模具中；
-将一个或多个材料层放置在所述模具中以形成所述壳体部件，其中，所述材料层被放置成与所述插件的所述侧表面毗邻，从而形成所述壳体部件的与所述连接面具有大致相同形状的侧表面；
-向所述材料层提供树脂并且允许所述树脂至少部分固化；以及
-取出所述插件。
2.根据前述权利要求中的任一项所述的方法，其中，所述壳体部件形成从根部区域延伸到末端区域的所述风轮机叶片壳体的至少中央部分。
3.根据前述权利要求中的任一项所述的方法，其中，所述附加组件形成叶片后缘、叶片前缘和/或叶片末端的至少一部分。
4.根据前述权利要求中的任一项所述的方法，其中，所述插件的所述侧表面设置有成角度的表面部分，使得所述壳体部件适于以嵌接接头连接到所述附加组件。
5.根据前述权利要求中的任一项所述的方法，其中，所述插件的所述侧表面设置有阶梯状表面。
6.根据前述权利要求中的任一项所述的方法，其中，所述插件的所述侧表面设置有成不同角度的表面部分。
7.根据前述权利要求中的任一项所述的方法，其中，所述插件按照所述模具中或所述模具上的指示所述插件相对于所述模具的期望位置的标记而定位在所述模具中。
8.根据前述权利要求中的任一项所述的方法，其中，所述插件在所述模具中定位成顺随所述模具的外边缘。
9.根据前述权利要求中的任一项所述的方法，所述方法还包括将所述插件至少暂时固定到所述模具的步骤。
10.根据权利要求9所述的方法，其中，用诸如可固化或不可固化热熔融树脂的粘合剂或者用带双面涂层的胶带；或者诸如夹持件、线或弹性构件的机械紧固装置，将所述插件固定到所述模具。
11.根据前述权利要求中的任一项所述的方法，所述方法还包括将外表面层材料和/或内表面层材料放置在所述模具中的步骤。
12.根据前述权利要求中的任一项所述的方法，所述方法还包括将不同材料的一个或多个元件放置在所述模具中的步骤。
13.根据权利要求12所述的方法，其中，所述元件包括纤维增强材料的拉挤成型板和/或芯材料的块。
14.根据前述权利要求中的任一项所述的方法，其中，提供树脂的步骤包括将预浸渍材料的一个或多个层放置在所述模具中和/或用所述树脂至少部分浸渍所述层。
15.根据前述权利要求中的任一项所述的方法，其中，所述材料层包括诸如玻璃纤维和/或碳的纤维增强片材；并且所述树脂包括诸如环氧树脂或乙烯基酯树脂的热固性树脂。
16.根据前述权利要求中的任一项所述的方法，其中，所述插件由塑料、木材、金属或其组合制成。
17.一种风轮机叶片，所述风轮机叶片包括根据权利要求1至16中的任一项所述的方法制造的风轮机叶片壳体部件。
18.一种制造风轮机叶片壳体构件的方法，该风轮机叶片壳体构件包括根据权利要求1至16中的任一项制造的壳体部件，所述方法还包括：
-将材料层放置在所述模具中以形成所述附加组件，其中，所述材料层被放置成与所述壳体部件的所述侧表面毗邻；以及
-将树脂引入所述材料层中并且允许所述树脂至少部分固化，以将所述附加组件结合到所述壳体部件。
19.一种制造风轮机叶片壳体构件的方法，该风轮机叶片壳体构件包括根据权利要求1至16中的任一项制造的壳体部件，所述方法还包括提供所述附加组件并且将所述附加组件结合到所述壳体部件。
20.一种制造包括上壳体和下壳体的风轮机叶片的方法，所述方法包括：根据权利要求1至16中的任一项制造两个壳体部件以形成所述风轮机叶片的所述上壳体的部件和所述风轮机叶片的所述下壳体的部件；以及用在这两个壳体部件之间在所述风轮机叶片的纵向方向上延伸的一个或多个互连梁腹板来连接所述壳体部件；提供附加组件；以及将所述附加组件连接到这两个壳体部件。
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