CN106573419A - 涉及风轮机叶片制造的改进 - Google Patents

涉及风轮机叶片制造的改进 Download PDF

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Publication number
CN106573419A
CN106573419A CN201580042775.8A CN201580042775A CN106573419A CN 106573419 A CN106573419 A CN 106573419A CN 201580042775 A CN201580042775 A CN 201580042775A CN 106573419 A CN106573419 A CN 106573419A
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CN
China
Prior art keywords
shell
guide block
shear web
wind turbine
edge
Prior art date
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Granted
Application number
CN201580042775.8A
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English (en)
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CN106573419B (zh
Inventor
B·伯克莫斯
K·L·克里斯滕森
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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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • 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
    • B29C65/7802—Positioning the parts to be joined, e.g. aligning, indexing or centring
    • B29C65/7838—Positioning the parts to be joined, e.g. aligning, indexing or centring from the inside, e.g. of tubular or 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
    • 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
    • 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
    • B29C65/78—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
    • B29C65/7802—Positioning the parts to be joined, e.g. aligning, indexing or centring
    • B29C65/7805—Positioning the parts to be joined, e.g. aligning, indexing or centring the parts to be joined comprising positioning features
    • 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
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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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    • 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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    • 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
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    • B29C66/13—Single flanged joints; Fin-type joints; Single hem joints; Edge joints; Interpenetrating fingered joints; Other specific particular designs of joint cross-sections not provided for in groups B29C66/11 - B29C66/12
    • B29C66/131—Single flanged joints, i.e. one of the parts to be joined being rigid and flanged in the joint area
    • B29C66/1312—Single flange to flange joints, the parts to be joined being rigid
    • 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
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/301—Three-dimensional joints, i.e. the joined area being substantially non-flat
    • 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
    • B29C66/52—Joining tubular articles, bars or profiled elements
    • B29C66/524—Joining profiled elements
    • 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
    • B29C66/53—Joining single elements to tubular articles, hollow articles or bars
    • B29C66/532—Joining single elements to the wall of tubular articles, hollow articles or bars
    • B29C66/5326—Joining single elements to the wall of tubular articles, hollow articles or bars said single elements being substantially flat
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    • 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
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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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    • 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
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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
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
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Abstract

描述了一种制造风轮机叶片的方法以及由该方法形成的风轮机叶片，确保了抗剪腹板(42a，42b)在模具(30)闭合时的正确对准。该方法涉及：提供待接合到一起以形成所述风轮机叶片第一半壳(32a)和第二半壳(32b)。将抗剪腹板(42)的第一边缘(46)附接至所述第一半壳(32a)的内表面(36a)。在所述第二半壳(32b)的内表面(36b)上限定抗剪腹板安装区域。将至少一个导块(60a，60b)附接至所述第二半壳(32b)的所述内表面(36b)邻近所述抗剪腹板(42)安装区域。所述导块(60a，60b)具有被取向为横向于所述第二半壳的所述内表面(36b)的引导表面(70)。在模具(30)闭合时，所述第一和第二半壳(32a，32b)聚拢到一起，同时朝向限定在所述第二半壳(32b)的所述内表面(36b)上的所述抗剪腹板安装区域在安装的所述导块(60a，60b)的所述引导表面(70)上引导所述抗剪腹板(42)的第二边缘(52)。

Description

涉及风轮机叶片制造的改进
技术领域
本发明总体涉及风轮机叶片的制造，更具体地涉及用于在叶片制造期间确保抗剪腹板的正确位置的方法和设备。
背景技术
风轮机叶片(诸如在现代大型电站级风轮机上采用的长叶片)一般包括主要由复合材料(诸如玻璃纤维增强塑料)制成的中空叶片壳体。叶片壳体通常由两个半壳构成：迎风壳体和背风壳体，迎风壳体和背风壳体在沿着叶片的前缘和后缘处的凸缘结合在一起之前单独地模制在相应的阴半模中。这种制造叶片的方法示意性地示出在图1a中。
参照图1a，图1a示出了用于风轮机叶片的模具10，模具10被分成迎风模具10a和背风模具10b这两个半模，迎风模具10a和背风模具10b在模具的打开构造中并排布置。迎风叶片壳体12a支撑在迎风模具10a的模具表面14a上，并且背风叶片壳体12b支撑在背风模具10b的模具表面14b上。壳体12a、12b各由经固化树脂结合在一起的多个玻璃纤维织物层构成。
在相应半模10a、10b中形成壳体12a、12b之后，抗剪腹板16被结合到迎风叶片壳体12a的内表面17。抗剪腹板16是桥接叶片的两个半壳12a、12b并在使用中用于将剪切载荷从叶片传递到风轮机轮毂的纵向延伸结构。在如图1a所示的横截面中，抗剪腹板16各包括腹板18，腹板18具有：下边缘19，下边缘19包括纵向延伸的第一安装凸缘20；以及上边缘21，上边缘21包括纵向延伸的第二安装凸缘22。沿着这些安装凸缘22施加诸如环氧树脂的粘合剂，以便将抗剪腹板16结合到相应的半壳12a、12b。
相对术语‘上’和‘下’在本文中是为了方便使用并且指的是如图中所示的叶片的取向。这些术语不旨在限制本发明的范围。
现在参照图1b，一旦抗剪腹板16已被结合到迎风叶片壳体12a，粘合剂就沿着抗剪腹板16的第二(上)安装凸缘22施加，并且沿着叶片壳体12a、12b的前缘24和后缘26施加。然后，包括背风叶片壳体12b的背风模具10b被提升、转动并放置在迎风叶片模具10a的顶部，以便沿着前缘24和后缘26将两个叶片半壳12a、12b结合在一起并且将抗剪腹板16结合到背风叶片壳体12b的内表面28。将一个半模放置在另一个半模的顶部的步骤被称为闭合模具。
重要的是，抗剪腹板16在正确位置中被结合到迎风叶片壳体12a和背风叶片壳体12b两者。确保抗剪腹板16在迎风叶片壳体12a上的正确位置是相对简单的，因为当抗剪腹板16被结合到迎风壳体12a时叶片模具10处于打开构造中，因此迎风壳体12a的内表面17是容易接近的。因为当抗剪腹板16被结合到背风壳体12b时模具10处于闭合构造中并因此在结合过程中背风壳体12b的内表面28是不可接近的，所以更难以确保抗剪腹板16相对于背风壳体12b的正确位置。因此，目前，抗剪腹板16相对于背风壳体12b的位置应在模具10打开的情况下测量，并且在模具闭合以及挤压粘合剂期间必须依赖抗剪腹板16自身保持在适当位置。
现在参照图1c，当模具10被闭合时，可能出现问题，由此抗剪腹板16可相对于背风壳体12b稍微移动。例如，抗剪腹板16可在其自身重量下在模具闭合期间稍微移动，或者可通过与背风壳体12b接触而挪动。背风壳体12b的凹曲率还具有将抗剪腹板16稍微压在一起的趋势，如图1c所示。出于说明的目的，抗剪腹板16可移动的程度在图1c中已经被夸大了；而在实践中，移动的程度可小到几度或仅几毫米。然而，抗剪腹板16在模具闭合期间的较小移动水平可导致抗剪腹板16在次优位置结合到背风壳体12b。
本发明解决了该问题。
发明内容
根据本发明，提供了一种制造风轮机叶片的方法，所述方法包括：
a、提供待接合在一起以形成所述风轮机叶片的第一半壳和第二半壳，各半壳均在纵向方向上延伸；
b、将抗剪腹板的第一边缘附接至所述第一半壳的内表面；
c、在所述第二半壳的内表面上限定抗剪腹板安装区域；
d、将至少一个导块附接至所述第二半壳的所述内表面邻近所述抗剪腹板安装区域，所述导块具有被取向为横向于所述第二半壳的所述内表面的引导表面；
e、在朝向限定在所述第二半壳的所述内表面上的所述抗剪腹板安装区域在安装的所述导块的所述引导表面上引导所述抗剪腹板的第二边缘的同时将所述第一半壳和所述第二半壳聚拢到一起；以及
f、将所述抗剪腹板的所述第二边缘附接至所述第二半壳的所述抗剪腹板安装区域。
所述或每个导块有利地用于在各半壳聚拢到一起时将所述抗剪腹板引导并指引到所述第二半壳上的正确位置。
每个导块的所述引导表面被取向为横向于所述第二半壳的局部内表面，所述导块位于所述局部内表面处。
优选地，将多个导块附接至所述第二半壳的所述内表面邻近所述抗剪腹板安装区域。所述导块在所述纵向方向上以一定间隔隔开。
优选地，所述或每个导块由诸如泡沫、聚苯乙烯或轻木的轻质材料制成。在本发明的优选实施方式中，所述导块由聚氨酯泡沫制成。
优选地，借助粘合剂将所述导块结合到所述第二半壳的所述内表面。
优选地，将所述抗剪腹板的所述第二边缘结合到所述第二半壳的所述抗剪腹板安装区域。因而，所述方法优选地涉及：将粘合剂施加到所述抗剪腹板的所述第二边缘和/或施加到限定在所述第二半壳的所述内表面上的所述抗剪腹板安装区域。
抗剪腹板安装区域可限定在所述第一半壳的所述内表面上。所述抗剪腹板的所述第一边缘可附接至所述第一抗剪腹板安装区域，例如可使用粘合剂结合到合适的位置。
所述方法可涉及：将预定的图案投影到所述第二半壳的所述内表面上，和/或使用激光投影或其它投影技术将所述图案投影到所述第一半壳的所述内表面上。所述图案可表示所述抗剪腹板安装区域和/或所述或每个导块的预定安装位置。
在本发明的优选实施方式中，所述或每个导块为大致楔形。所述或每个导块的厚度可从厚端朝向薄端渐缩。所述导块的所述厚端限定安装表面，将所述安装表面附接至所述第二半壳的所述内表面。在使用中，当叶片半壳聚拢到一起时，在从所述导块的所述薄端朝向所述厚端的方向上在所述引导表面上引导所述抗剪腹板。
优选地，将所述引导表面取向为在所述第一半壳和第二半壳聚拢到一起以形成所述叶片时在从所述叶片的中心纵向轴线朝向所述叶片的前缘或后缘向外的方向上引导所述抗剪腹板。
优选地，所述引导表面的第一部分邻近所述抗剪腹板安装区域并取向为大致垂直于所述第二半壳的所述内表面。将所述引导表面的所述第一部分定向为大致垂直于所述第二半壳的局部表面。优选地，使所述引导表面的第二部分相对于所述第一部分倾斜。在各半壳聚拢到一起时，优选地首先在所述引导表面的所述第二部分上随后在所述引导表面的所述第一部分上将所述抗剪腹板引导到所述第二半壳的所述内表面上。
所述引导表面的垂直第一部分邻近所述安装区域用于在模具闭合时在大致垂直所述第二半壳的局部内表面的方向上将所述抗剪腹板直接引导到安装区域上。这有利地防止在模具闭合时将剪切力施加到所述导块以及所述抗剪腹板与所述第二半壳之间的粘合剂上。从而确保所述抗剪腹板与所述第二半壳之间强的结合，并且防止所述导块因剪切力而挪动。
优选地，所述方法包括：将粘合剂施加到所述第一半壳和第二半壳中的一者或两者的前缘凸缘和后缘凸缘。所述粘合剂用于将各半壳结合在一起。所述方法优选地涉及：使所述第二半壳相对于所述第一半壳移动，以便将各半壳聚拢到一起。然而，在其它实例中，所述第一半壳可以相对于所述第二半壳移动，或两半壳均可以移动。优选地，将所述第二半壳放置在所述第一半壳的顶部。
各半壳优选地均在风轮机叶片模具的相应半模中形成，并且所述方法优选地涉及：将各半模聚拢到一起以接合所述第一壳体和第二壳体。所述模具优选地具有打开构造和闭合构造。在所述打开构造中，各半模优选地并排布置；而在所述闭合构造中，各半模聚拢到一起，一个半模通常放置在另一个半模的顶部。优选地，在模具打开的情况下执行所述方法的步骤(c)和(d)。步骤(e)优选地涉及：闭合所述模具。例如，步骤(e)可包括：提升并转动所述第二半模；以及将所述第二半模降低到所述第一半模上。在闭合模具时，优选地在大致竖直方向上例如经由上述引导表面的所述第一部分将所述抗剪腹板引导成与所述第二半壳接合。
本发明包括一种根据上述方法制造的风轮机叶片，以及一种包括这样的风轮机叶片的风轮机。
本发明还提供一种风轮机叶片，该风轮机叶片包括：叶片壳体，所述叶片壳体由接合到一起并在纵向方向上延伸的第一半壳和第二半壳形成；内部区域，所述内部区域限定在所述第一半壳和第二半壳的对置的内表面之间；至少一个抗剪腹板，所述抗剪腹板位于所述叶片的所述内部区域中，所述抗剪腹板具有附接至所述第一半壳的所述内表面的第一边缘并具有附接至所述第二半壳的所述内表面的第二边缘；以及至少一个导块，所述导块附接至所述第二半壳的所述内表面邻近所述抗剪腹板的所述第二边缘，所述导块具有被取向为横向于所述第二半壳的所述内表面的引导表面。
优选地，多个导块邻近所述抗剪腹板的所述第二边缘在所述纵向方向上以一定间隔隔开。所述或每个导块可相对于所述叶片的中心纵向轴线定位在所述抗剪腹板的内侧。优选地，所述或每个导块由诸如泡沫、聚苯乙烯或轻木的轻质材料制成。在优选实施方式中，所述导块由聚氨酯泡沫制成。可借助粘合剂将所述或每个导块结合到所述第二半壳。
在优选实施方式中，所述或每个导块为大致楔形。具体地，所述或每个导块的厚度从厚端朝向薄端渐缩。所述导块的所述厚端附接至所述第二半壳的所述内表面，并且所述导块的所述薄端面对所述第一半壳。
所述或每个导块的所述引导表面可包括第一部分，所述第一部分被布置成邻近所述抗剪腹板的所述第二边缘并且大致垂直于所述第二半壳的所述内表面。所述或每个导块的所述引导表面可包括相对于所述第一部分倾斜的第二部分。
优选地，借助粘合剂将所述抗剪腹板的所述第一边缘和/或所述第二边缘结合到相应的半壳。
当就设备而言表述时，相对于所述方法描述的本发明的可选特征同样适用于本发明，反之亦然。
附图说明
图1a至图1c示出了制造风轮机叶片的现有技术方法并且已经在上文通过本发明的背景技术的方式进行了描述。
为了使本发明可更容易理解，现在将参考以下附图更详细地描述本发明的非限制性实例，其中：
图2a示出了风轮机叶片模具，该风轮机叶片模具包括打开构造中的迎风半模和背风半模，并且具有结合到支撑在迎风半模中的迎风半壳的一对抗剪腹板并具有结合到支撑在背风半模中的背风半壳的导块；
图2b示出了闭合期间的风轮机叶片模具，背风半模上翻并支撑在迎风半模上方；
图2c示出了闭合构造中的风轮机叶片模具，第一半壳和第二半壳被结合在一起以形成完整的风轮机叶片；
图3示出了从根端并沿着叶片的中心纵向轴线观察时的完整的风轮机叶片；以及
图4示出了隔离的导块。
具体实施方式
参照图2a，图2a示出了风轮机叶片模具30，风轮机叶片模具30包括打开构造中的迎风半模30a和背风半模30b。固化的迎风半壳32a被支撑在迎风半模30a的表面34a上，并且固化的背风半壳32b被支撑在背风半模30b的表面34b上。半壳32a、32b各具有在壳体32a、32b的前缘38与后缘40之间延伸的凹内表面36a、36b。
第一抗剪腹板42a和第二抗剪腹板42b被结合到迎风半壳32a的内表面36a。抗剪腹板42a、42b沿着迎风壳体32a纵向延伸。每个抗剪腹板42a、42b均包括腹板44，腹板44具有包括纵向延伸的第一安装凸缘48的下边缘46并具有包括纵向延伸的第二安装凸缘52的上边缘50。每个抗剪腹板42a、42b的第一安装凸缘48被结合到限定在迎风半壳32a的内表面36a上的抗剪腹板安装区域54。
根据本发明，借助粘合剂将多个聚氨酯导块60a、60b结合到背风半壳32b的内表面36b。导块60a、60b是大致楔形的并将参考图4更详细地描述。第一导块60a和第二导块60b在图2a的示意性横截面视图中是可见的。参照图2a的放大部分，第一导块60a被安装成邻近限定在背风半壳32b的内表面36b上的纵向延伸的第一抗剪腹板安装区域62a(由虚线区域62a示出)。第二导块60b被安装成邻近限定在背风半壳32b的内表面36b上的纵向延伸的第二抗剪腹板安装区域62b。
在实践中，并且如图3的立体图中更清楚示出的，多个第一导块60a邻近第一抗剪腹板安装区域62a以一定的纵向间隔隔开，并且多个第二导块60b邻近第二抗剪腹板安装区域62b以一定的纵向间隔隔开。抗剪腹板安装区域62a、62b各具有内边缘64和外边缘66(还示出在图2a的放大部分中)。第一导块60a和第二导块60b各沿着相应抗剪腹板安装区域62a、62b的内边缘64进行安装。
相对术语‘内’和‘外’相对于叶片的中心纵向轴线C(在图2c中示意性地表示并且大致垂直于页面延伸)进行限定。
使用激光投影确定抗剪腹板42a、42b和导块60a、60b在背风壳体32b的内表面36b上的正确位置。具体地，将激光投影的图案叠加在背风半壳32b的内表面36b上，以表示用于定位抗剪腹板42a、42b和导块60a、60b的正确位置。然后，使用笔或其它标记装置在背风壳体32b的内表面36b上标记抗剪腹板安装区域62a、62b以及用于安装导块60a、60b使之邻近这些区域的位置。然后，借助粘合剂将导块60a、60b安装在这些位置中。
现在参照图2b，为了将迎风半壳32a和背风半壳32b接合到一起，沿着相应半壳32a、32b的前缘38和后缘40以及沿着抗剪腹板42a、42b的纵向延伸的第二(上)凸缘52施加粘合剂。然后，将背风半模30b提升、转动180度并放置在迎风半壳30a的顶部。
如作为背景技术描述的，以及如图2b中示出的，抗剪腹板42a、42b可在模具闭合过程中稍微移动。根据本发明，在模具30闭合时，抗剪腹板42a、42b的第二(上)边缘50与导块60a、60b接触，并且由导块60a、60b引导到限定在背风半壳32b的内表面36b上的正确位置(即预限定的抗剪腹板安装区域62a、62b)。
更具体地，并且现在参照图2b的放大部分，每个导块60a、60b均包括引导表面70，引导表面70朝向限定在背风壳体32b的内表面36b上的适当的抗剪腹板安装区域62a、62b倾斜。在该实例中，第一导块60a被安装到背风半壳32b，使得第一导块60a的相应引导表面70将第一抗剪腹板42a朝向第一抗剪腹板安装区域62a引导，并且第二导块60b被安装到背风半壳32b，使得第二导块60b的相应引导表面70将第二抗剪腹板42b朝向第二抗剪腹板安装区域62b引导。
另外参照图2c，导块60a、60b的净效应在于，在模具闭合期间，第一抗剪腹板42a和第二抗剪腹板42b相对于叶片的中心纵向轴线C向外移动并且移向叶片的前缘38或后缘40中的一者。在该实例中，第一抗剪腹板42a朝向后缘40稍微向外移动，并且第二抗剪腹板42b朝向前缘38稍微向外移动。因此，抗剪腹板42a、42b相对于彼此向外移动。结果，并且如图2c中示出的，当模具30完全闭合时，抗剪腹板42a、42b两者大致竖直并且正确地定位在背风半壳32b上。
现在参照图4，图4更详细地示出了导块60中的一个。导块60为大致楔形并且具有厚端76和薄端78。导块60的厚端76包括安装表面80(在该实例中为大致矩形)。导块60进一步包括引导表面70，如前所述，引导表面70在导块60的厚端76与薄端78之间在导块60的一个侧面上延伸。引导表面70包括主引导表面82和次引导表面84。主引导表面82为大致矩形并且从导块60的薄端78延伸到导块60的边缘86(与导块60的安装表面80稍微间隔开)。次引导表面84为大致矩形并且位于导块60的主引导表面82与安装表面80之间。次引导表面84被定向为大致垂直于导块60的安装表面80。主引导表面82相对于次引导表面84倾斜并且相对于导块60的安装表面80倾斜。
在该实例中，厚端76处导块60的厚度t1约为6cm，并且薄端78处导块60的厚度t2约为1cm。导块60的高度(h)(即厚端76与薄端78之间的距离)约为10cm。导块60的主引导表面82的长度L1约为15cm，并且次引导表面84的长度L2约为2cm。导块60的主引导表面82、次引导表面84和安装表面80的宽度W各约为5cm。
导块60的安装表面80被结合到背风壳体32b，使得当模具30闭合时导块60的薄端78面对迎风半壳32a。当导块60被安装到背风半壳32b时，引导表面70被取向为横向于背风半壳32b的内表面36b。具体地，次引导表面84被取向为在导块60的位置大致垂直于背风半壳32b的弯曲内表面36b。主引导表面82相对于背风半壳32b的局部表面以约135度(在该实例中)的角度倾斜。
在使用中，在闭合模具30期间，抗剪腹板42a、42b最初在导块60的主引导表面82上朝向限定在背风壳体32b上的相应安装区域62a、62b被引导。抗剪腹板42a、42b最初在导块60的薄端78附近与导块60接触；并且在模具30闭合时，在朝向导块60的厚端76的方向上沿着主引导表面82引导抗剪腹板42a、42b。
刚好在模具30闭合之前(即仅在背风壳体与迎风壳体的接合时间点之前)，由相应导块60的次引导表面84在大致垂直于背风壳体32b的局部表面36b的方向上引导抗剪腹板42a、42b的上安装凸缘22，即将抗剪腹板42a、42b直接引导到抗剪腹板安装区域62a、62b上。因此，在模具30闭合时的抗剪腹板42a、42b的最终运动是竖直的，因此在模具闭合时基本上没有剪切力施加到抗剪腹板42a、42b以及抗剪腹板42a、42b的上安装凸缘22与背风壳体32b之间的粘合剂并且挤压粘合剂。在挤压粘合剂时不施加剪切力确保在抗剪腹板42a、42b与背风壳体32b之间产生强的结合。抗剪腹板42a、42b在模具闭合时的竖直运动还基本上防止抗剪腹板42a、42b在导块60上施加剪切力，这有利地防止导块60在模具闭合时挪动。当处于安装区域62a、62b中的适当位置时，抗剪腹板42a、42b抵接导块60的次引导表面84，以方便用于在结合过程中维持抗剪腹板42a、42b处于正确位置。
在该实例中，导块60在叶片壳体32a、32b被结合在一起之后不被移除，因此保持结合到完整叶片中的背风壳体32b。导块60与叶片的整体尺寸比较相对较小并且有利地由轻质材料(在这种情况下为PU泡沫)制成，因此不会明显增加叶片的重量。将导块60留在合适的位置是有利的，因为在制造叶片之后不需要移除导块60(这可能是耗时的并且当在叶片内侧的封闭空间内工作时是困难的)。
上述具体实例可做出许多修改而不脱离本发明的范围。例如，虽然上述实例中的导块为大致楔形，但是导块在其它实施方式中可具有不同的形状。特别是，在本发明的范围内设想出具有弯曲的主引导表面的导块。
虽然在上述实例中在叶片模具打开的情况下将抗剪腹板结合到迎风壳体，即抗剪腹板和迎风壳体之间的粘合剂在闭合模具之前固化，但是在其它实例中，当模具闭合时，抗剪腹板可同时结合到迎风壳体和背风壳体两者。例如，抗剪腹板可最初附接至迎风壳体，不久之后该模具可闭合，使得抗剪腹板和迎风壳体之间的粘合剂与抗剪腹板和背风壳体之间的粘合剂同时固化，从而有利地减少叶片的生产时间。

Claims (37)

1.一种制造风轮机叶片的方法，所述方法包括：
a、提供待接合在一起以形成所述风轮机叶片的第一半壳和第二半壳，各半壳均在纵向方向上延伸；
b、将抗剪腹板的第一边缘附接至所述第一半壳的内表面；
c、在所述第二半壳的内表面上限定抗剪腹板安装区域；
d、将至少一个导块附接至所述第二半壳的所述内表面邻近所述抗剪腹板安装区域，所述导块具有被取向为横向于所述第二半壳的所述内表面的引导表面；
e、在朝向限定在所述第二半壳的所述内表面上的所述抗剪腹板安装区域在安装的所述导块的所述引导表面上引导所述抗剪腹板的第二边缘的同时将所述第一半壳和所述第二半壳聚拢到一起；以及
f、将所述抗剪腹板的所述第二边缘附接至所述第二半壳的所述抗剪腹板安装区域。
2.根据权利要求1所述的方法，其中，步骤(d)包括：将多个导块附接至所述第二半壳的所述内表面邻近所述抗剪腹板安装区域，所述导块在所述纵向方向上以一定间隔隔开。
3.根据权利要求1或2所述的方法，其中，步骤(d)包括：借助粘合剂将所述或每个导块结合到所述第二半壳的所述内表面。
4.根据前述权利要求中的任一项所述的方法，所述方法进一步包括：在步骤(e)之前，将粘合剂施加到所述抗剪腹板的所述第二边缘和/或施加到限定在所述第二半壳的所述内表面上的所述抗剪腹板安装区域。
5.根据权利要求4所述的方法，其中，步骤(f)包括：将所述抗剪腹板的所述第二边缘结合到所述第二半壳的所述抗剪腹板安装区域。
6.根据前述权利要求中的任一项所述的方法，其中，步骤(d)进一步包括：将预定的图案投影到所述第二半壳的所述内表面上，所述图案表示所述或每个导块的预定安装位置；以及将所述或每个导块附接在相应的安装位置处。
7.根据权利要求6所述的方法，其中，使用激光投影将所述图案投影到所述第二半壳上。
8.根据前述权利要求中的任一项所述的方法，其中，步骤(b)包括：在所述第一半壳的所述内表面上限定抗剪腹板安装区域；以及将所述抗剪腹板的所述第一边缘附接至所述第一抗剪腹板安装区域。
9.根据前述权利要求中的任一项所述的方法，其中，所述或每个导块为楔形。
10.根据前述权利要求中的任一项所述的方法，其中，所述或每个导块的厚度从厚端朝向薄端渐缩，所述导块的所述厚端限定安装表面，并且所述方法包括：将所述安装表面附接至所述第二半壳的所述内表面。
11.根据权利要求10所述的方法，所述方法进一步包括：在从所述导块的所述薄端朝向所述厚端的方向上在所述引导表面上引导所述抗剪腹板。
12.根据前述权利要求中的任一项所述的方法，其中，将所述引导表面取向为在所述第一半壳和第二半壳聚拢到一起以形成所述风轮机叶片时在从所述风轮机叶片的中心纵向轴线朝向所述风轮机叶片的前缘或后缘向外的方向上引导所述抗剪腹板。
13.根据前述权利要求中的任一项所述的方法，所述方法进一步包括：在所述第一半壳与第二半壳结合时在大致垂直于所述第二半壳的所述内表面的方向上在所述引导表面上引导所述抗剪腹板。
14.根据前述权利要求中的任一项所述的方法，所述方法进一步包括：在所述第一半壳与第二半壳结合时在大致竖直方向上在所述引导表面上将所述抗剪腹板引导成与所述第二半壳接合。
15.根据前述权利要求中的任一项所述的方法，所述方法包括：将所述或每个导块布置成使得所述引导表面的第一部分邻近所述抗剪腹板安装区域并取向为大致垂直于所述第二半壳的所述内表面，并且使所述引导表面的第二部分相对于所述第一部分倾斜。
16.根据权利要求15所述的方法，所述方法包括：在将各半壳聚拢到一起时，首先在所述导块的所述引导表面的所述第二部分上随后在所述导块的所述引导表面的所述第一部分上将所述抗剪腹板引导到所述第二半壳的所述内表面上。
17.根据前述权利要求中的任一项所述的方法，所述方法进一步包括：在步骤(e)之前，将粘合剂施加到所述第一半壳和第二半壳中的一者或两者的前缘凸缘和后缘凸缘。
18.根据前述权利要求中的任一项所述的方法，其中，步骤(e)包括：使所述第二半壳相对于所述第一半壳移动。
19.根据权利要求18所述的方法，其中，步骤(e)包括：将所述第二半壳放置在所述第一半壳的顶部。
20.根据前述权利要求中的任一项所述的方法，所述方法进一步包括：提供具有第一半模和第二半模的风轮机叶片模具；并且其中，所述方法的步骤(a)包括：在所述第一半模中形成所述第一半壳以及在所述第二半模中形成所述第二半壳。
21.根据权利要求20所述的方法，其中，在模具处于打开构造的情况下执行步骤(c)和(d)。
22.根据权利要求20或21所述的方法，其中，步骤(e)包括：闭合所述模具。
23.根据权利要求18至20中的任一项所述的方法，其中，步骤(e)包括：将所述第二半模放置在所述第一半模的顶部。
24.根据权利要求23所述的方法，其中，步骤(e)包括：提升并转动所述第二半模；以及将所述第二半模降低到所述第一半模上。
25.一种根据前述权利要求中的任一项所述的方法制造的风轮机叶片。
26.一种包括权利要求25所述的风轮机叶片的风轮机。
27.一种风轮机叶片，该风轮机叶片包括：
叶片壳体，所述叶片壳体由接合到一起并在纵向方向上延伸的第一半壳和第二半壳形成；
内部区域，所述内部区域限定在所述第一半壳和所述第二半壳的对置的内表面之间；
至少一个抗剪腹板，所述抗剪腹板位于所述风轮机叶片的所述内部区域中，所述抗剪腹板具有附接至所述第一半壳的所述内表面的第一边缘并具有附接至所述第二半壳的所述内表面的第二边缘；以及
至少一个导块，所述导块附接至所述第二半壳的所述内表面邻近所述抗剪腹板的所述第二边缘，所述导块具有被取向为横向于所述第二半壳的所述内表面的引导表面。
28.根据权利要求27所述的风轮机叶片，所述风轮机叶片包括多个导块，所述多个导块邻近所述抗剪腹板的所述第二边缘在所述纵向方向上以一定间隔隔开。
29.根据权利要求27或28所述的风轮机叶片，其中，所述或每个导块相对于所述风轮机叶片的中心纵向轴线定位在所述抗剪腹板的内侧。
30.根据权利要求27至29中的任一项所述的风轮机叶片，其中，所述或每个导块由诸如泡沫、聚氨酯或轻木的轻质材料制成。
31.根据权利要求27至30中的任一项所述的风轮机叶片，其中，借助粘合剂将所述或每个导块结合到所述第二半壳。
32.根据权利要求27至31中的任一项所述的风轮机叶片，其中，所述或每个导块为大致楔形。
33.根据权利要求32所述的风轮机叶片，其中，所述或每个导块的厚度从厚端朝向薄端渐缩，所述导块的所述厚端附接至所述第二半壳的所述内表面，并且所述导块的所述薄端面对所述第一半壳。
34.根据权利要求27至33中的任一项所述的风轮机叶片，其中，所述或每个导块的所述引导表面包括第一部分，所述第一部分被布置成邻近所述抗剪腹板的所述第二边缘并且大致垂直于所述第二半壳的所述内表面。
35.根据权利要求34所述的风轮机叶片，其中，所述或每个导块的所述引导表面包括相对于所述第一部分倾斜的第二部分。
36.根据权利要求27至35中的任一项所述的风轮机叶片，其中，借助粘合剂将所述抗剪腹板的所述第一边缘和/或所述第二边缘结合到相应的半壳。
37.一种包括权利要求27至36中的任一项所述的风轮机叶片的风轮机。
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