CN111868374A - 与增材制造构件互连的抗剪腹板组件 - Google Patents

与增材制造构件互连的抗剪腹板组件 Download PDF

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Publication number
CN111868374A
CN111868374A CN201980022354.7A CN201980022354A CN111868374A CN 111868374 A CN111868374 A CN 111868374A CN 201980022354 A CN201980022354 A CN 201980022354A CN 111868374 A CN111868374 A CN 111868374A
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CN
China
Prior art keywords
spar
web
connection
joint
rotor blade
Prior art date
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Granted
Application number
CN201980022354.7A
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English (en)
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CN111868374B (zh
Inventor
D·罗伯茨
N·K·阿尔索夫
M·W·尼尔森
J·R·托宾
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LM Wind Power AS
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General Electric Co
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Publication of CN111868374A publication Critical patent/CN111868374A/zh
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Publication of CN111868374B publication Critical patent/CN111868374B/zh
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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
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • 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
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • 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
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • 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
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/1403—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the type of electromagnetic or particle radiation
    • B29C65/1425—Microwave radiation
    • 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
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • B29C65/22—Heated wire resistive ribbon, resistive band or resistive strip
    • 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
    • B29C65/56—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits
    • B29C65/565—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits involving interference fits, e.g. force-fits or press-fits
    • 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
    • B29C65/782—Positioning the parts to be joined, e.g. aligning, indexing or centring by setting the gap between the parts to be joined
    • B29C65/7823—Positioning the parts to be joined, e.g. aligning, indexing or centring by setting the gap between the parts to be joined by using distance pieces, i.e. by using spacers positioned between the parts to be joined and forming a part of the joint
    • B29C65/7826—Positioning the parts to be joined, e.g. aligning, indexing or centring by setting the gap between the parts to be joined by using distance pieces, i.e. by using spacers positioned between the parts to be joined and forming a part of the joint said distance pieces being non-integral with the parts to be joined, e.g. particles
    • 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
    • B29C65/82—Testing the joint
    • 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
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • 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
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • 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
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/114—Single butt joints
    • 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
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/12—Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
    • B29C66/124—Tongue and groove joints
    • B29C66/1246—Tongue and groove joints characterised by the female part, i.e. the part comprising the groove
    • B29C66/12461—Tongue and groove joints characterised by the female part, i.e. the part comprising the groove being rounded, i.e. U-shaped or C-shaped
    • 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
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B29C66/434—Joining substantially flat articles for forming corner connections, fork connections or cross connections
    • B29C66/4344—Joining substantially flat articles for forming fork connections, e.g. for making Y-shaped pieces
    • B29C66/43441—Joining substantially flat articles for forming fork connections, e.g. for making Y-shaped pieces with two right angles, e.g. for making T-shaped pieces, H-shaped 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
    • 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
    • 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
    • B29C66/54—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
    • 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
    • B29C66/61—Joining from or joining on the inside
    • 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
    • B29C66/636—Internally supporting the article during joining using a support which remains in the joined object
    • 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
    • B29C66/721—Fibre-reinforced materials
    • 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
    • B29C66/739—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
    • B29C66/7392—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 thermoplastic
    • 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
    • B29C66/739—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
    • B29C66/7392—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 thermoplastic
    • B29C66/73921—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 thermoplastic characterised by the materials of both parts being thermoplastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D15/00—Electrolytic or electrophoretic production of coatings containing embedded materials, e.g. particles, whiskers, wires
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D5/00—Electroplating characterised by the process; Pretreatment or after-treatment of workpieces
    • C25D5/10—Electroplating with more than one layer of the same or of different metals
    • C25D5/12—Electroplating with more than one layer of the same or of different metals at least one layer being of nickel or chromium
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D7/00—Electroplating characterised by the article coated
    • C25D7/008—Thermal barrier coatings
    • 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
    • F01D5/12—Blades
    • F01D5/14—Form or construction
    • F01D5/20—Specially-shaped blade tips to seal space between tips and stator
    • 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
    • F01D5/12—Blades
    • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • F01D5/288—Protective coatings for blades
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract

本发明涉及一种用于组装风力涡轮机的抗剪腹板组件的方法，包括提供至少一个翼梁帽。该方法还包括经由增材制造形成热塑性材料的翼梁连接部件。此外，该方法包括将翼梁连接部件固定至翼梁帽。此外，该方法包括：提供抗剪腹板；经由增材制造形成热塑性材料的腹板连接部件；以及将腹板连接部件固定在抗剪腹板的第一端处。另外，该方法包括在接头处将腹板连接部件和翼梁连接部件互连。因此，该方法还包括加热接头以将腹板连接部件和翼梁连接部件固定在一起。

Description

与增材制造构件互连的抗剪腹板组件
技术领域
本发明总体上涉及风力涡轮机，并且更具体地涉及与增材制造构件互连的用于风力涡轮机的抗剪腹板(shear web)。
背景技术
风力被认为是目前可用的最清洁的最环境友好的能源之一，且就此而言，风力涡轮机已得到更多关注。现代风力涡轮机通常包括塔架、发电机、变速箱、机舱和一个或多个转子叶片。转子叶片是将风能转换成电能的主要元件。叶片具有翼型件的横截面轮廓，使得在操作期间，空气流过叶片而在侧面之间产生压力差。因此，从压力侧朝向吸入侧的升力作用在叶片上。升力在主转子轴上产生转矩，主转子轴齿轮连接至用于制造电力的发电机齿轮。
转子叶片通常由吸入侧壳和压力侧壳构成，它们沿叶片的前缘和后缘在粘结线处粘结在一起。内部抗剪腹板在压力侧壳部件和吸入侧壳部件之间延伸，并粘结至固定在壳部件内面的翼梁帽(spar cap)。为了使抗剪腹板横跨在翼梁帽之间并在翼梁帽和抗剪腹板之间实现具有足够的宽度和厚度尺寸的粘结，需要相对精确的长度尺寸。实现这些尺寸以及适当的粘结可能是困难的，并且在翼梁帽和抗剪腹板之间的接合是耗时且冗长的过程，这通常需要大量的返工。
对于典型的叶片构造，抗剪腹板是横跨在翼梁帽之间的连续部件，并且刚性凸缘用于实现施加在翼梁帽与抗剪腹板的横向端之间的粘结糊剂(bond paste)的期望的粘结宽度。然而，这种构造在抗剪腹板和翼梁帽之间的接合处施加了很大的应力，并且经常导致使用过量的粘结糊剂以在该临界接合处实现期望的粘结宽度。然而，过量的糊剂会给叶片带来不必要的重量。另外，过量挤出的糊剂会破裂成固化糊剂的碎片，其可在风力涡轮机的操作期间在转子叶片的内部到处嘎嘎作响(来自风力涡轮机所有者/操作者的并非不常见的抱怨)。同样，在典型构造中，气隙和粘结糊剂的不可预料的挤出会导致粘结强度降低的区域，这在不可能从转子叶片内部进行修复的叶片区段中尤其成问题。
因此，该行业将受益于解决了上述问题的抗剪腹板和翼梁帽之间的改进的接头。
发明内容
本发明的方面和优点将在以下描述中阐明，或可从描述中清楚，或可通过实施本发明理解到。
一方面，本公开涉及一种用于组装风力涡轮机的转子叶片的方法。该方法包括形成第一翼梁连接部件。该方法还包括提供抗剪腹板。此外，该方法包括在抗剪腹板的第一端处提供第一腹板连接部件。第一翼梁连接部件和第一腹板连接部件由热塑性材料形成。因而，该方法包括在第一接头处将第一腹板连接部件和第一翼梁连接部件互连。另外，该方法包括加热第一接头以将第一腹板连接部件和第一翼梁连接部件固定在一起。
在一个实施例中，该方法还可包括形成由热塑性材料制成的第二翼梁连接部件、提供在抗剪腹板的相对的第二端处并也由热塑性材料制成的第二腹板连接部件、在第二接头处将第二腹板连接部件和第二翼梁连接部件互连，以及加热第二接头以将第二腹板连接部件和第二翼梁连接部件固定在一起。
在另一个实施例中，该方法可包括形成转子叶片的下壳部件；在下壳部件上形成第二翼梁帽，第二翼梁帽包含第二翼梁连接部件；在第二接头处将第二腹板连接部件和第二翼梁连接部件互连；形成转子叶片的上壳部件；在上壳部件上形成第一翼梁帽，第二翼梁帽包含第二翼梁连接部件；在第一接头处将第一腹板连接部件和第一翼梁连接部件互连；以及加热第一接头和第二接头。
在其它实施例中，该方法可包括经由增材制造、热成型、真空成型、拉挤成型、连续模制、挤出模制(例如，以几个部分)或其组合中的至少一种来形成第一腹板连接部件和第二腹板连接部件。类似地，该方法可包括经由增材制造、热成型、真空成型、拉挤成型、连续模制、挤出模制或其组合中的至少一种来形成第一翼梁连接部件和第二翼梁连接部件。
在另外的实施例中，该方法可包括经由超声信号传输材料形成第一接头和/或第二接头；以及经由无损检测(NDT)检查来检查第一接头或第二接头中的至少一个。
在若干实施例中，该方法可进一步包括通过经由灌注、插入/过盈配合、粘合剂、紧固件或其组合中的至少一种将第一腹板连接部件和第二腹板连接部件分别固定到抗剪腹板的第一端和第二端。
在特定实施例中，形成具有第一翼梁连接部件和第二翼梁连接部件的第一翼梁帽和第二翼梁帽的步骤可分别包括将第一翼梁连接部件与第一翼梁帽共同灌注，并且将第二翼梁连接部件与第二翼梁帽共同灌注。
在某些实施例中，第一翼梁连接部件和第二翼梁连接部件可各自包括母连接器，而第一腹板连接部件和第二腹板连接部件可各自包括对应的公连接器。
在更进一步的实施例中，该方法还可包括在第一翼梁连接部件和第二翼梁连接部件或第一腹板连接部件和第二腹板连接部件中的至少一个的顶部提供覆盖材料，以在互连之前保护连接部件不受碎屑的影响。在这样的实施例中，该方法可包括在将第一腹板连接部件与第一翼梁连接部件和第二腹板连接部件与第二翼梁连接部件互连之前，从第一翼梁连接部件和第二翼梁连接部件或第一腹板连接部件和第二腹板连接部件中的至少一个移除覆盖材料。
在另外的实施例中，该方法可包括将定位间隔件(positioning spacer)放置在第一翼梁连接部件和第二翼梁连接部件中的至少一个的顶部，以使第一腹板连接部件和第二腹板连接部件中的至少一个对准。在又另一实施例中，该方法可包括用至少一种纤维材料来增强热塑性材料。
另一方面，本公开涉及一种用于组装风力涡轮机的转子叶片的抗剪腹板组件的方法。该方法包括经由增材制造形成热塑性材料的翼梁连接部件。此外，该方法包括将翼梁连接部件固定至转子叶片(例如，至叶片壳和/或诸如翼梁帽的结构构件)。此外，该方法包括：提供抗剪腹板；经由增材制造形成热塑性材料的腹板连接部件；以及将腹板连接部件固定在抗剪腹板的第一端处。另外，该方法包括在接头处将腹板连接部件和翼梁连接部件互连。因此，该方法还包括经由热焊接、化学焊接、电阻焊接、溶剂焊接、一种或多种粘合剂或微波加热中的至少一种将接头固定在一起。
又另一方面，本公开涉及一种用于风力涡轮机的转子叶片组件。转子叶片组件包括转子叶片，该转子叶片具有：具有在其内面上构造的第一翼梁帽的上壳部件；具有在其内面上构造的第二翼梁帽的下壳部件，第一翼梁帽和第二翼梁帽分别包括第一翼梁连接部件和第二翼梁连接部件；以及沿转子叶片的纵向长度在第一翼梁帽和第二翼梁帽之间延伸的抗剪腹板。抗剪腹板包括从其相对端延伸的第一腹板连接部件和第二腹板连接部件。第一腹板连接部件和第二腹板连接部件分别容纳在第一翼梁连接部件和第二翼梁连接部件内以形成第一接头和第二接头。此外，第一翼梁连接部件和第二翼梁连接部件以及第一腹板连接部件和第二腹板连接部件各自由热塑性材料形成。因此，第一腹板连接部件和第二腹板连接部件经由热塑性焊接保持在第一翼梁连接部件和第二翼梁连接部件内。
在一个实施例中，第一接头和第二接头没有粘合剂。还应理解，转子叶片组件可包括本文所述的任何其它步骤和/或特征。
本发明的这些及其它特征、方面和优点将参照以下描述和所附权利要求变得更好理解。并入且构成本说明书的一部分的附图示出了本发明的实施例，且连同描述用于阐释本发明的原理。
附图说明
针对本领域普通技术人员的包括其最佳模式的本发明的充分且可实现的公开内容在参照附图的说明书中阐明，在附图中：
图1示出了根据本公开的风力涡轮机的透视图；
图2示出了根据本公开的风力涡轮机的转子叶片的透视图；
图3示出了根据本公开的风力涡轮机的转子叶片组件的一个实施例的横截面视图，尤其示出了根据本公开的方面构造的抗剪腹板；
图4示出了图3的转子叶片的局部放大横截面视图；
图5示出了根据本公开的用于组装风力涡轮机的转子叶片组件的方法的一个实施例的流程图；
图6示出了根据本公开的转子叶片组件的一个实施例的局部横截面视图，尤其示出了根据本公开的方面的覆盖材料和定位在翼梁帽连接部件顶部的间隔件；
图7示出了根据本公开的转子叶片组件的一个实施例的局部透视图尤其示出了根据本公开的方面的定位在翼梁帽连接部件顶部的间隔件；以及
图8示出了根据本公开的用于组装风力涡轮机的抗剪腹板组件的方法的一个实施例的流程图。
具体实施方式
现在将详细参照本发明的实施例，其一个或多个实例在附图中示出。每个实例通过阐释本发明的方式提供，而不限制本发明。实际上，对于本领域的技术人员将清楚的是，可在本发明中作出各种改型和变型，而不会脱离本发明的范围或精神。例如，示为或描述为一个实施例的一部分的特征可结合另一个实施例使用以产生更进一步的实施例。因此，旨在本发明包括归入所附权利要求以及等效形式的范围内的此类改型和变型。
大体上，本主题涉及使用热塑性玻璃纤维增材制造工艺构造的抗剪腹板组件。因此，在构件制造期间，可将增材构件共同灌注到一个或多个翼梁帽和/或一个或多个抗剪腹板中。然后可将翼梁帽模具中的加热元件加热到足够的温度，从而允许抗剪腹板增材构件熔化/融合在一起。因此，使用加热元件将连接部件连结(即熔化/融合)在一起可帮助减少当前的生产周期时间。备选地，如果在界面处获得足够的热量以热焊接热塑性界面的方面存在挑战，则其它实施例包括化学焊接界面(例如，溶剂焊接)、在界面处使用金属网带的电阻焊接、粘合剂和/或微波加热。在某些情况下，热塑性玻璃化转变温度可低于叶片壳树脂的热塑性玻璃化转变温度，以避免炭化/燃烧。
这样的构件有助于将抗一个或多个剪腹板准确地定位在翼梁帽上。另外，由于这些构件允许将一个或多个抗剪腹板和一个或多个翼梁帽焊接在一起，因此可减少或消除粘合剂的使用，从而减少粘合剂固化的周期时间。增材构件也可用于帮助在一个或多个抗剪腹板和一个或多个翼梁帽之间分配负载。
现在参看附图，图1示出了根据本公开的风力涡轮机10。风力涡轮机10包括塔架12，塔架上安装有机舱14。多个转子叶片16安装到转子毂18，转子毂继而又连接到主凸缘上，主凸缘转动主转子轴(未示出)。风力涡轮机发电和控制构件安置在机舱14内。图1的视图仅出于示范性目的提供，以将本发明置于示例性使用领域。应当认识到，本发明不限于任何特定类型的风力涡轮机构造。
现在参看图2，示出了根据本公开的转子叶片组件15的更详细的视图。如图所示，转子叶片组件15包括具有上壳部件20和下壳部件22的转子叶片16之一。此外，上壳部件20构造为叶片16的吸入侧表面，而下壳部件22构造为叶片16的压力侧表面。转子叶片16还包括前缘24和后缘26，以及根部28和尖端部30。如本领域中众所周知的，上壳部件20和下壳部件22可在前缘24和后缘26处连结在一起。转子叶片16还包括内腔25(图3)，在该内腔中可构造各种结构部件，如根据本公开的一个或多个抗剪腹板40和翼梁帽32。
现在参看图3，示出了图2的转子叶片组件15的横截面视图，其结合了本公开的各个方面。如图所示，转子叶片16包括至少一个内部结构抗剪腹板40，该内部结构抗剪腹板横跨在上壳部件20和下壳部件22之间并且沿转子叶片16的纵向长度延伸。在特定的实施例中，如图所示，抗剪腹板40横跨在固定于壳部件20,22的内面的结构性第一翼梁帽32和第二翼梁帽34之间。另外，如图3和图4所示，第一翼梁帽32和第二翼梁帽34还分别包括第一翼梁连接部件36和第二翼梁连接部件38。类似地，如图所示，抗剪腹板40包括从其相对端42,44延伸的第一腹板连接部件46和第二腹板连接部件48。因此，如图所示，第一腹板连接部件46和第二腹板连接部件48容纳在第一翼梁连接部件36和第二翼梁连接部件38内，以分别形成第一接头50和第二接头52。应当理解，尽管抗剪腹板40和翼梁帽32,34形成大体I形的腹板，但是其它横截面形状也在本发明的精神和范围内，包括例如H形腹板或C形腹板。
另外，第一翼梁连接部件36和第二翼梁连接部件38以及第一腹板连接部件46和第二腹板连接部件48各自由热塑性材料形成。因此，在一个实施例中，第一腹板连接部件46和第二腹板连接部件48可经由热塑性焊接保持在第一翼梁连接部件38和第二翼梁连接部件38内。因此，第一接头50和第二接头52可没有粘合剂。备选地，可使用一些粘合剂来放置轮廓。
参看图3和图4，第一翼梁连接部件36和第二翼梁连接部件38可包括母连接器54。例如，如图所示，第一翼梁连接部件36和第二翼梁连接部件38可包括凹部。另外，如图所示，第一腹板连接部件46和第二腹板连接部件48可各自包括对应的公连接器56。例如，如图所示，第一腹板连接部件46和第二腹板连接部件48可包括突起、肋或类似物。另外，如图所示，公连接器56可包括相对的凸缘58，该凸缘抵靠在相应的第一翼梁帽32和第二翼梁帽34上。因此，应当理解，公连接器56可具有任何合适的横截面形状。例如，如图所示，公连接器56具有大体T形的横截面。在另外的实施例中，连接部件65可具有I形横截面或具有如本文所述的功能的能力的任何其它形状。
此外，在备选实施例中，应理解，第一翼梁连接部件36和第二翼梁连接部件38可各自包括公连接器56，而第一腹板连接部件46和第二腹板连接部件48可包括母连接器54。
用于形成本文所述的第一翼梁连接部件36和第二翼梁连接部件38和/或第一腹板连接部件46和第二腹板连接部件48的热塑性材料大体包括本质上可逆的塑料材料或聚合物。例如，热塑性材料通常在加热到一定温度时变得柔韧或可模制，并且在冷却时返回到更刚性的状态。此外，热塑性材料可包括非晶热塑性材料和/或半晶状热塑性材料。例如，一些非晶热塑性材料大体上可包括但不限于苯乙烯、乙烯树脂、纤维素塑料、聚酯、丙烯酸树脂、聚砜和/或酰亚胺。更确切地说，示例性非晶热塑性材料可包括聚苯乙烯、丙烯腈丁二烯 苯乙烯(ABS)、聚甲基丙烯酸甲酯、乙交酯聚对苯二甲酸乙二醇酯(PET-G)、聚碳酸酯、聚醋酸乙烯酯、非晶聚酰胺、聚氯乙烯(PVC)、聚偏二氯乙烯、聚氨酯或任何其它适合的非晶热塑性材料。另外，示例性半晶热塑性材料大体上可包括但不限于聚烯烃、聚酰胺、含氟聚合物、丁烯酸乙酯、聚酯、聚碳酸酯和/或缩醛。更确切地说，示例性半晶热塑性材料可包括聚对苯二甲酸丁二醇酯(PBT)、聚对苯二甲酸乙二醇酯(PET)、聚丙烯、聚苯硫醚、聚乙烯、聚酰胺(尼龙)、聚醚通或任何其它适合的半晶热塑性材料。
另外，如上所述，本文所述的热塑性材料能够可选地用纤维材料增强，纤维材料包括但不限于玻璃纤维、碳纤维、聚合物纤维、木纤维、竹纤维、陶瓷纤维、纳米纤维、金属纤维或其类似物或其组合。另外，纤维的方向可包括多轴、单向、双轴、三轴或任何其它合适的方向和/或其组合。此外，纤维含量可取决于对应的叶片构件中所需的刚度、叶片构件在转子叶片16中的区域或位置和/或构件的期望的可焊接性而变化。此外，一种或多种纤维材料可包括例如在拉挤成型中的连续纤维和/或短切纤维。
现在参看图5，示出了用于组装风力涡轮机10的转子叶片16的方法100的流程图。如102处所示，方法100包括形成具有第一翼梁连接部件36和第二翼梁连接部件38的第一翼梁帽32和第二翼梁帽34。例如，在某些实施例中，在制造期间，第一翼梁帽32和第二翼梁帽34可分别与第一翼梁连接部件36和第二翼梁连接部件38共同灌注。备选地，在制造过程期间，第一翼梁连接部件36和第二翼梁连接部件38可分别形成为第一翼梁帽32和第二翼梁帽34。在又另一实施例中，在制造过程期间，第一翼梁连接部件36和第二翼梁连接部件38可形成为叶片壳，而不是形成为翼梁帽32,34。
如104处所示，方法100包括经由诸如3-D打印、增材制造、自动纤维沉积以及利用CNC控制和多自由度来沉积材料的其它技术形成第一腹板连接部件46和第二腹板连接部件48。另外，方法100包括经由热成型、真空成型、拉挤成型、连续模制、挤出模制或其组合来形成第一腹板连接部件46和第二腹板连接部件48。类似地，方法100可包括经由增材制造、热成型、真空成型、拉挤成型、连续模制、挤出模制或其组合来形成第一翼梁连接部件36和第二翼梁连接部件38。例如，在一个实施例中，方法100可包括在同一过程中经由热成型和增材制造来形成各种连接部件36,38,46,48，其以快速且有效的方式使用在多个方向上的连续纤维增强(如双轴或三轴)来提供层压表面。更确切地说，通过热成型与翼梁帽32,34和一个或多个抗剪腹板40对接的腹板连接部件46,48的形状，本公开的方法100可快速地创建用于热塑性焊接的理想的连结表面，其能够可选地根据需要利用印刷网格结构来增强。因此，备选地或附加地，方法100还可包括在使用粘合剂来连结构件的区域中印刷网格结构。
在利用拉挤成型的实施例中，拉挤成型部分设计成足够弯曲以与共形于转子叶片16的预弯曲形状。因此，在某些实施例中，拉挤成型件可为节段，这些节段可选地与它们之间的粘合剂一起布置，这些粘合剂将最终熔化在一起。在更进一步的实施例中，方法100可包括经由连续模制或挤出模制形成第一翼梁连接部件36和第二翼梁连接部件38和/或第一腹板连接部件46和第二腹板连接部件48。
仍然参看图5，如106处所示，方法100包括将第一腹板连接部件46和第二腹板连接部件48分别固定在抗剪腹板40的第一端42和第二端44处。例如，在若干实施例中，方法100可包括经由灌注、插入/过盈配合、粘合剂、紧固件或其组合将第一腹板连接部件46和第二腹板连接部件48分别固定到抗剪腹板40的第一端42和第二端44。本文所述的各种粘合剂可包括例如胶水、带、热固性树脂、甲基丙烯酸酯、环氧树脂、乙烯基酯或任何其它合适的粘合剂。
如所提及的，第一翼梁连接部件36和第二翼梁连接部件38和/或第一腹板连接部件46和第二腹板连接部件48由热塑性材料形成。如108处所示，方法100包括在第一接头50和第二接头52处分别将第一腹板连接部件46和第二腹板连接部件48与第一翼梁连接部件36和第二翼梁连接部件38互连。此外，如110处所示，方法100包括加热第一接头50和第二接头52以将第一腹板连接部件46和第一翼梁连接部件36以及第二腹板连接部件48和第二翼梁连接部件38固定在一起。
在另一个实施例中，方法100可包括形成转子叶片16的下壳部件22，将第二翼梁帽34放置到下壳部件22上，以及在第一接头50处将第一腹板连接部件46和第一翼梁连接部件36互连。在这样的实施例中，方法100还包括形成转子叶片16的上壳部件20，将第一翼梁帽32放置到上壳部件20上，并且在第二接头52处将第二腹板连接部件48和第二翼梁连接部件38互连。因此，如上所述，方法100还包括加热互连的第一接头50和第二接头52。
在另外的实施例中，该方法可包括经由超声信号传输材料形成第一接头50或第二接头52的一个或多个部分。因此，在这样的实施例中，方法100可包括经由无损检测(NDT)检查来检查第一接头50和第二接头52的一个或多个部分，以核查接头50,52中的缺陷。
现在参看图6，方法100还可包括在第一翼梁连接部件36和第二翼梁连接部件38和/或第一腹板连接部件46和第二腹板连接部件48的顶部提供覆盖材料60，以在互连之前保护各种连接部件不受碎屑(例如污垢或灰尘)影响。因此，覆盖材料60可起到保持连接部件的界面光滑以便于连结的功能。在这样的实施例中，方法100可包括在将公连接部件和母连接部件互连在一起之前，从相关联的连接部件移除覆盖材料60。另外，如果需要，覆盖材料60可用于表面粗糙度(例如，使用具有特定纹理的剥离层)。在这样的实施例中，方法100可包括将覆盖材料60保持在适当的位置，以帮助将公连接部件和母连接部件互连在一起。因此，覆盖材料60可用作模制镶嵌物，其被用于确保在灌注之前第一翼梁连接部件36和第二翼梁连接部件38的放置和间隔。
另外，如图7所示，方法100可包括将定位间隔件62放置在第一翼梁连接部件36和第二翼梁连接部件38的顶部，以使第一腹板连接部件46和第二腹板连接部件48中的至少一个对准。在这样的实施例中，如图所示，一个或多个隔离物62可位于覆盖材料60的顶部。
现在参看图8，示出了用于组装风力涡轮机10的抗剪腹板组件的方法200的另一实施例的流程图。如202处所示，方法200包括提供至少一个翼梁帽(例如，第一翼梁帽32)。如204处所示，方法200包括经由增材制造形成由热塑性材料制成的翼梁连接部件(例如，第一翼梁连接部件36)。如206处所示，方法200包括将翼梁连接部件36固定至翼梁帽32。如208处所示，方法200包括提供抗剪腹板，例如抗剪腹板40。如210处所示，方法200包括经由增材制造形成由热塑性材料制成的腹板连接部件(例如，第一腹板连接部件46)。如212处所示，方法200包括将腹板连接部件46固定在抗剪腹板40的第一端处。如214处所示，方法200包括在接头50处将腹板连接部件46和翼梁连接部件36互连。如216处所示，方法200包括经由热焊接、化学焊接、电阻焊接、粘合剂、溶剂焊接或微波加热中的至少一种将接头固定在一起。更确切地说，电阻焊接可在界面处使用金属网带。另外，对于电阻焊接，将网带连接到通常也位于抗剪腹板40上的引下线可能是重要的。
本书面描述使用了实例来公开本发明，包括最佳模式，且还使本领域的任何技术人员能够实施本发明，包括制作和使用任何装置或系统，以及执行任何并入的方法。本发明的专利范围由权利要求限定，且可包括本领域的技术人员想到的其它实例。如果此类其它实施例包括并非不同于权利要求的书面语言的结构元件，或如果它们包括与权利要求的书面语言无实质差别的等同结构元件，则这种其它实例旨在落在权利要求的范围内。

Claims (20)

1.一种用于组装风力涡轮机的转子叶片的方法，所述方法包括：
形成第一翼梁连接部件；
提供抗剪腹板；
在所述抗剪腹板的第一端处提供第一腹板连接部件，所述第一翼梁连接部件和所述第一腹板连接部件由热塑性材料形成；
在第一接头处将所述第一腹板连接部件和所述第一翼梁连接部件互连；以及
加热所述第一接头以将所述第一腹板连接部件和所述第一翼梁连接部件固定在一起。
2.根据权利要求1所述的方法，其特征在于，所述方法还包括：
形成第二翼梁连接部件；
在所述抗剪腹板的相对的第二端处提供第二腹板连接部件，所述第二翼梁连接部件和所述第二腹板连接部件由热塑性材料形成；
在第二接头处将所述第二腹板连接部件和所述第二翼梁连接部件互连；以及
加热所述第二接头以将所述第二腹板连接部件和所述第二翼梁连接部件固定在一起。
3.根据权利要求2所述的方法，其特征在于，所述方法还包括：
形成所述转子叶片的下壳部件；
在所述下壳部件上形成第二翼梁帽，所述第二翼梁帽包括所述第二翼梁连接部件；
在所述第二接头处将所述第二腹板连接部件和所述第二翼梁连接部件互连；
形成所述转子叶片的上壳部件；
在所述上壳部件上形成第一翼梁帽，所述第一翼梁帽包括所述第一翼梁连接部件；
在所述第一接头处将所述第一腹板连接部件和所述第一翼梁连接部件互连；以及
加热所述第一接头和所述第二接头。
4.根据权利要求2所述的方法，其特征在于，所述方法还包括经由增材制造、热成型、真空成型、拉挤成型、连续模制、挤出模制或其组合中的至少一种来形成所述第一腹板连接部件和所述第二腹板连接部件。
5.根据权利要求4所述的方法，其特征在于，所述方法还包括经由增材制造、热成型、真空成型、拉挤成型、连续模制、挤出模制或其组合中的至少一种来形成所述第一翼梁连接部件和所述第二翼梁连接部件。
6.根据权利要求2所述的方法，其特征在于，所述方法还包括：
经由超声信号传输材料形成所述第一接头或所述第二接头中的至少一个；以及
经由无损检测(NDT)检查来检查所述第一接头或所述第二接头中的至少一个。
7.根据权利要求2所述的方法，其特征在于，所述方法还包括通过经由灌注、插入、过盈配合、一种或多种粘合剂，或一个或多个紧固件中的至少一种将所述第一腹板连接部件和所述第二腹板连接部件分别固定到所述抗剪腹板的第一端和第二端。
8.根据权利要求3所述的方法，其特征在于，形成分别包括所述第一翼梁连接部件和第二翼梁连接部件的所述第一翼梁帽和所述第二翼梁帽还包括：
将所述第一翼梁连接部件与所述第一翼梁帽共同灌注；以及
将所述第二翼梁连接部件与所述第二翼梁帽共同灌注。
9.根据权利要求1所述的方法，其特征在于，所述第一翼梁连接部件和所述第二翼梁连接部件各自包括母连接器，所述第一腹板连接部件和所述第二腹板连接部件各自包括对应的公连接器。
10.根据权利要求2所述的方法，其特征在于，所述方法还包括在所述第一翼梁连接部件和所述第二翼梁连接部件或所述第一腹板连接部件和所述第二腹板连接部件中的至少一个的顶部提供覆盖材料。
11.根据权利要求10所述的方法，其特征在于，所述方法还包括在将所述第一腹板连接部件与所述第一翼梁连接部件和所述第二腹板连接部件与所述第二翼梁连接部件互连之前，从所述第一翼梁连接部件和所述第二翼梁连接部件或所述第一腹板连接部件和所述第二腹板连接部件中的至少一个移除所述覆盖材料。
12.根据权利要求10所述的方法，其特征在于，所述方法还包括将定位间隔件放置在所述第一翼梁连接部件和所述第二翼梁连接部件中的至少一个的顶部，以使所述第一腹板连接部件和所述第二腹板连接部件中的至少一个对准。
13.根据权利要求1所述的方法，其特征在于，所述方法还包括用至少一种纤维材料增强所述热塑性材料。
14.一种用于组装风力涡轮机的转子叶片的抗剪腹板组件的方法，所述方法包括：
经由增材制造形成热塑性材料的翼梁连接部件；
将所述翼梁连接部件固定到所述转子叶片；
提供抗剪腹板；
经由增材制造形成由热塑性材料制成的腹板连接部件；
将所述腹板连接部件固定在所述抗剪腹板的第一端处；
在接头处将所述腹板连接部件和所述翼梁连接部件互连；以及
经由热焊接、化学焊接、电阻焊接、溶剂焊接、一种或多种粘合剂或微波加热中的至少一种将所述接头固定在一起。
15.一种用于风力涡轮机的转子叶片组件，所述转子叶片组件包括：
转子叶片，其包括：
具有在其内面上构造的第一翼梁帽的上壳部件；
具有在其内面上构造的第二翼梁帽的下壳部件，所述第一翼梁帽和所述第二翼梁帽分别包括第一翼梁连接部件和第二翼梁连接部件；以及
沿所述转子叶片的纵向长度在所述第一翼梁帽和所述第二翼梁帽之间延伸的抗剪腹板，所述抗剪腹板包括从其相对端延伸的第一腹板连接部件和第二腹板连接部件，所述第一腹板连接部件和所述第二腹板连接部件分别容纳在所述第一翼梁连接部件和所述第二翼梁连接部件内以形成第一接头和第二接头，所述第一翼梁连接部件和所述第二翼梁连接部件以及所述第一腹板连接部件和所述第二腹板连接部件各自由热塑性材料形成，
其中所述第一腹板连接部件和所述第二腹板连接部件经由热塑性焊接保持在所述第一翼梁连接部件和所述第二翼梁连接部件内。
16.根据权利要求15所述的转子叶片组件，其特征在于，所述第一接头和所述第二接头没有粘合剂。
17.根据权利要求15所述的转子叶片组件，其特征在于，所述第一腹板连接部件和第二腹板连接部件以及所述第一翼梁连接部件和所述第二翼梁连接部件经由增材制造、拉挤成型、连续模制或挤出模制中的至少一种形成。
18.根据权利要求15所述的转子叶片组件，其特征在于，所述第一翼梁连接部件和所述第二翼梁连接部件各自包括母连接器，所述第一腹板连接部件和所述第二腹板连接部件各自包括对应的公连接器。
19.根据权利要求18所述的转子叶片组件，其特征在于，所述公连接器还包括相对的凸缘，所述相对的凸缘抵靠在相应的第一翼梁帽和第二翼梁帽上。
20.根据权利要求15所述的转子叶片组件，其特征在于，所述热塑性材料利用至少一种纤维材料增强。
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