CN112912235A - 用于风力叶片翼梁盖中的突起的定位构型 - Google Patents

用于风力叶片翼梁盖中的突起的定位构型 Download PDF

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Publication number
CN112912235A
CN112912235A CN201880098799.9A CN201880098799A CN112912235A CN 112912235 A CN112912235 A CN 112912235A CN 201880098799 A CN201880098799 A CN 201880098799A CN 112912235 A CN112912235 A CN 112912235A
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spar cap
feature
locating
shear web
features
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CN201880098799.9A
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CN112912235B (zh
Inventor
韦恩·G·莫尼
尼古拉斯·沃乔尔
迈克尔·维拉
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Tepai Composite Materials Co ltd
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Tepai Composite Materials Co ltd
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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
    • 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
    • F03D13/00—Assembly, mounting or commissioning of wind motors; Arrangements specially adapted for transporting wind motor components
    • F03D13/10—Assembly of wind motors; Arrangements for erecting wind motors
    • 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
    • B29C65/7814—Positioning the parts to be joined, e.g. aligning, indexing or centring the parts to be joined comprising positioning features in the form of inter-cooperating positioning features, e.g. tenons and mortises
    • 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
    • B29C65/7829—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 integral with at least one of the parts to be joined
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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
    • B29C66/32—Measures for keeping the burr form under control; Avoiding burr formation; Shaping the burr
    • B29C66/322—Providing cavities in the joined article to collect the burr
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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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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    • 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
    • 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
    • B29C66/51—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
    • B29C66/61—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
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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
    • 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
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    • 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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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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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    • B29C66/70—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
    • B29C66/737—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 state of the material of the parts to be joined
    • B29C66/7375—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 state of the material of the parts to be joined uncured, partially cured or fully cured
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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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    • F03D1/0608—Rotors characterised by their aerodynamic shape
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    • F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
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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
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Abstract

本文提供了一种翼梁盖，该翼梁盖具有用于引导和接收用于风力涡轮机叶片的抗剪腹板的构型。特别地，本公开提供了具有粘结间隙特征部的拉挤成型的翼梁盖，以维持均匀一致的空间来在翼梁盖与抗剪腹板之间分配粘结胶糊。而且，翼梁盖形成有定位特征部，该定位特征部引导和接收抗剪腹板的放置。

Description

用于风力叶片翼梁盖中的突起的定位构型
相关申请的交叉引用
本申请根据35USC 119要求享有2018年9月11日提交的美国临时申请No.62/729,501的优先权权益，其全部内容通过引用合并于本文。
技术领域
所公开的主题涉及一种制造大型复合结构(例如，风力涡轮机叶片)的系统和对应方法。这些大型复合材料结构通常由两件式模具形成，其在叶片半部成型后需要复杂的模具闭合过程来完成制造。
特别地，本公开提供了例如翼梁盖的结构元件，其构型具有既有助于放置又有助于组装例如抗剪腹板的其他部件的多种特征部。
背景技术
风力涡轮机叶片通常包括主要由诸如玻璃纤维增强塑料之类的复合材料制成的中空叶片壳体。叶片壳体通常由两个半壳体构成，即一个下部压力侧壳体和一个上部吸力侧壳体，它们分别在相应的凹形半模中模制而成，然后在叶片的前缘和后缘沿着凸缘粘结在一起。在图1A中示意性地示出了这种制造叶片的方法。
参照图1A，其示出了用于风力涡轮机叶片的模具10，该模具10被分成两个半模，即上部吸力侧模具10a和下部压力侧模具10b，这两个半模在模具的打开构造中并排布置。压力侧叶片壳体12a支撑在下部模具10a的模具表面14a上，而吸力侧叶片壳体12b支撑在上部模具10b的模具表面14b上。壳体12a、12b分别由多个玻璃纤维织物层构成，这些玻璃纤维织物层通过固化的树脂粘结在一起。
在相应的半模10a、10b中形成壳体12a、12b之后，将抗剪腹板16粘结到迎风叶片壳体12a的内表面17上。抗剪腹板16是纵向延伸的结构，该结构桥接叶片的两个半壳体12a、12b，并且在使用中用于将剪切载荷从叶片传递到风力涡轮机轮毂。在图1A中以截面示出的特定实施方式中，抗剪腹板16均包括腹板部18，腹板部18具有包括第一纵向延伸安装凸缘20的下边缘19和包括第二纵向延伸安装凸缘22的上边缘21。沿着这些安装凸缘22施加诸如环氧树脂之类的粘合剂，以便将抗剪腹板16粘结到相应的半壳体12a、12b上。然而，提供适量的粘合剂仍然是难以把握且有问题的。往往，施加的粘合剂量不足会导致包括叶片结构整体性在内的薄弱联合问题，或者施加的粘合剂过多会导致不利的重量分布和不良的清洁度/危险状况。
如图1B所示，一旦抗剪腹板16已粘结到上部叶片壳体12a上，就沿着抗剪腹板16的第二(上部)安装凸缘22以及沿叶片壳体12a、12b的前缘24和后缘26施加粘合剂。然后，将包括上部叶片壳体12b在内的上部模具10b提升、旋转并放置在下部叶片模具10a的顶部上，以便将两个叶片半壳体12a、12b沿着前缘24和后缘26粘结到一起并且将抗剪腹板16粘结到上部叶片壳体12b的内表面28。将一个半模具放在另一个半模具顶上的步骤称为闭合模具。
现在参照图1C，当闭合模具10时，可能会出现抗剪腹板16相对于上部壳体12b略微移动的问题。例如，抗剪腹板16在模具闭合期间可能在其自重的作用下略微移动，或者可能由于与上部壳体12b接触而移位。如图1C所示，上部壳体12b的凹曲率也具有将抗剪腹板16略微向一起迫压的趋势。在模具闭合期间，抗剪腹板16的这种移动可能导致抗剪腹板16在次优位置处粘结到上部壳体12b。
此外，有多种需要在模具闭合期间采用永久性固定装置来引导抗剪腹板的技术。在美国专利公开No.2017/0151711中提供了包括有腹板引导结构的示例，该专利文献的全部内容并入本文。但是，这种永久性固定装置的使用不利地影响了叶片的重量并增加了设计的复杂性和成本。
因此，仍然需要一种有效且经济的方法和系统，以在风力涡轮机装置的组装阶段期间提供对抗剪腹板的引导和粘结，从而确保在不影响产品结构的情况下正确放置抗剪腹板。
发明内容
所公开主题的目的和优点将在随后的描述中阐明并从中变得明显，并且将通过对所公开主题的实践而了解。通过在书面描述及其权利要求以及附图中特别指出的方法和系统，将实现并获得所公开的主题的其他优点。
为了实现这些和其他优点，并且根据所公开的主题的目的，如具体实施和广义描述的，所公开的主题包括翼梁盖，该翼梁盖包括：第一表面和第二表面，该第一表面与第二表面之间限定一厚度；至少一个定位特征部，该至少一个定位特征部设置在第一表面上；至少一个粘结间隙特征部，该至少一个粘结间隙特征部设置在第一表面上；其中，定位特征部和粘结间隙特征部中的至少一者构造为接合抗剪腹板。在一些实施方式中，定位特征部和粘结间隙特征部是突起，其中粘结间隙特征部可以从第一表面突出第一距离，而定位特征部从第一表面突出第二距离。在一些实施方式中，多个定位特征部关于翼梁盖的中心轴线对称地设置，例如，第一定位特征部和第二定位特征部之间具有粘结间隙特征部。粘结间隙特征部可以构造为接合抗剪腹板的底表面，并且定位特征部可以构造为接合抗剪腹板的侧表面；粘结间隙特征部和定位特征部均沿着翼梁盖跨度和/或叶片叶展的长度延伸。
另外，本公开包括一种形成风力涡轮机叶片部件的方法，该方法包括：形成翼梁盖，该翼梁盖具有第一表面和第二表面，在该第一表面与第二表面之间限定一厚度；在第一表面上形成至少一个定位特征部；在第一表面上形成至少一个粘结间隙特征部；其中，定位特征部和粘结间隙特征部中的至少一者构造为接合抗剪腹板。在一些实施方式中，成形包括拉挤成型。
在一些实施方式中，该方法包括通过将抗剪腹板定位在翼梁盖的第一定位特征部与第二定位特征部之间而使抗剪腹板与定位特征部接合，以及通过将抗剪腹板定位在翼梁盖的粘结间隙特征部的顶部上而使抗剪腹板与粘结间隙特征部接合。另外，可以在翼梁盖的粘结间隙特征部附近施加粘合剂，其中，将粘合剂朝向定位特征部引导。
应当理解，前面的总体描述和下面的详细描述都是示例性的，并且旨在提供所要求保护的所公开主题的进一步解释。
包含有包括在本说明书中并构成本说明书一部分的附图以说明并提供对所公开主题的方法和系统的进一步理解。与描述一起，附图用于解释所公开主题的原理。
附图说明
参照以下进行了简要说明的附图，提供对本文所描述主题的各个方面、特征和实施方式的详细描述。附图是说明性的，并且不必定按比例绘制，为了清楚起见，放大了一些部件和特征部。附图示出了本主题的各个方面和特征，并且可以全部或部分地示出本主题的一个或多个实施方式或示例。
图1A至图1C描绘了常规风力涡轮机叶片模具和制造方法的截面图。
图2和图11、图12是根据本公开的实施方式的翼梁盖构型的截面图。
图3至图5是定位在根据本公开的实施方式的翼梁盖构型内的多种抗剪腹板的几何形状的截面图。
图6是与根据本公开的实施方式的翼梁盖构型接合的粘合剂引导靴的横截面。
图7至图10是根据本公开的多种翼梁盖的几何形状的截面图。
具体实施方式
现在将详细参照所公开主题的示例性实施方式，其示例在附图中示出。将结合对所述系统的详细描述来描述所公开主题的方法和相应步骤。
本文提出的方法和系统可以用于大型结构的构建。所公开的主题特别适合于风力涡轮机叶片的构建。为了解释和说明而非限制的目的，在图2至图12中示出了根据所公开主题的系统的示例性实施方式，并且这些示例性实施方式总体上由附图标记1000指示。可以在本文呈现的各个视图和附图中提供相似的附图标记(由前导数字进行区别)来表示功能上对应但不一定相同的结构。
叶片可以包括一个或多个纵向延伸的结构部件，该结构部件构造为向叶片提供增加的刚度、抗屈曲性和/或强度。例如，叶片可以包括一对纵向延伸的翼梁盖100，该对翼梁盖100构造为分别接合抵靠叶片的压力侧和吸力侧上的两相对内表面。另外，一个或多个抗剪腹板120可以设置在翼梁盖之间而形成梁状构造。翼梁盖通常可以设计成在风力涡轮机操作期间控制弯曲应力和/或在大体叶展方向(与叶片的叶展平行的方向)上作用在叶片上的其他载荷。类似地，翼梁盖还可以设计成承受在风力涡轮机操作期间发生的叶展方向的压缩。
本公开的翼梁盖可以由多个拉挤成型构件构成，所述多个拉挤成型构件被组合在一起而形成翼梁盖的第一部分。在某些实施方案中，拉挤成型构件可以通过用树脂浸渍多根纤维(例如，玻璃纤维或碳纤维)并固化该浸渍的纤维而形成。可以使用本领域中已知的任何合适的方法以树脂浸渍纤维。此外，树脂可以包括任何合适的树脂材料，包括但不限于聚酯、聚氨酯、聚对苯二甲酸丁二酯(PBT)、聚对苯二甲酸乙二醇酯(PET)、乙烯基酯、环氧树脂或类似物。此外，如图所示，当翼梁盖接近叶片根部时，拉挤成型构件分离成一个或多个拉挤成型构件束，从而形成翼梁盖的第二部分。
更具体地，翼梁盖100由多个拉挤成型构件构成，这些拉挤成型构件组合在一起以形成一层或多层。由此，这些层可以彼此上下叠置并使用任何合适的方式连结在一起，例如，通过将这些构件真空灌注在一起或通过将这些构件借由粘合剂、半预浸材料、预浸材料或类似物粘结在一起。
本文所述的方法和系统有利于获得厚度均匀一致的翼梁盖构型部段，并限制/防止沿着构型部段的增强纤维的长度产生波动，从而增加了翼梁盖中的增强纤维的排列。本文所述的方法和系统进一步有助于增加翼梁盖中的单个增强纤维的承载特性，从而为了获得整个翼梁盖的给定承载特性，得以使用较少的增强纤维，进而减少了翼梁盖的质量。另外，本文所述的方法和系统有助于在制造翼梁盖时使用较便宜的增强纤维——诸如碳纤维，从而降低了与制造翼梁盖相关的材料成本和人工成本。这样，本文所述的方法和系统有助于降低与制造风力涡轮机有关的成本，同时增加了风力涡轮机的使用寿命。
如图2所示，将一系列定位元件/特征部形成在风力涡轮机叶片的翼梁盖的拉挤成型物构型中。所提的“拉挤成型物”或类似物通常包含以树脂浸渍并且被拉过固定模具而使得树脂固化或进行聚合的增强材料(例如，纤维或是编织或编制股线)。这样，拉挤成型构件的制造工艺通常特征在于由复合材料生产具有恒定横截面的复合零件的连续工艺。还应当理解，除了翼梁盖，本文所述的拉挤成型构件还可以用于构造各种其他转子叶片部件。例如，在某些实施方式中，拉挤成型构件可以用于构造抗剪腹板或受益于由本文所述的拉挤成型零件构建的任何其他转子叶片部件。
在所示的示例性实施方式中，翼梁盖100被拉挤成型有如下构型，该构型包括在“顶”表面(即，如在下文中进一步详细讨论的，将与抗剪腹板构件接合的表面)上的定位特征部102和粘结间隙特征部103。定位特征部102a、102b在组装以及模具闭合期间将抗剪腹板结构的适当横向部位固定至翼梁盖。粘合间隙特征部103建立了用于在组装过程中将风力叶片的抗剪腹板结构连结到翼梁盖上的粘合剂的最小粘结间隙空间或最小粘结间隙厚度。
定位特征部
在一些实施方式中，定位特征部102a、102b构造为突起，该突起从翼梁盖的顶表面101向上延伸比粘结间隙特征部103更大的距离。定位特征部可以成形为具有平面状内表面的大体上矩形结构，该平面状内表面构造为在将抗剪腹板120插入翼梁盖100内时配合地接合该腹板。定位特征部102可以自抗剪腹板120向上延伸等于或大于该抗剪腹板120上的凸缘的厚度/高度的距离(如图3所示)，如果存在则一些抗剪腹板可以形成为不具有凸缘。定位特征部102延伸的距离越大，与抗剪腹板120的接合和支撑的程度就越大。在一些实施方式中，定位特征部102的内表面可以包括深度标记，以指示抗剪腹板插入到定位特征部内的距离，从而使操作员在施加粘合剂之前和/或之后可以在视觉上确认实现了所需的深度(以及由此的稳定性和牢固性)。而且，定位特征部102a、102b的外边缘可以被斜切或倒圆，以便提供平滑的弧形表面，从而减少在叶片的制造和组装期间伤害人员和/或损坏其他部件的风险。另外，定位特征部102可以关于翼梁盖100的中心轴线对称地布置。
定位特征部102可以与翼梁盖100一体地形成，并且沿着翼梁盖的长度延伸。由于通过拉挤成型形成此整体结构，在联接至翼梁盖的过程中不需要额外的部件来引导/定位抗剪腹板120，由于其避免了过多的复杂性、重量和成本，这是有利的。
粘结间隙特征部
根据本公开的另一个方面，提供了粘结间隙特征部103，用于在抗剪腹板120和翼梁盖101的上表面之间建立并维持一空间或间隙。在所示的示例性实施方式中，粘结间隙特征部103是设置在定位特征部102a、102b之间并与其等距的突起。如图所示，粘结间隙特征部103可以是具有峰部或尖顶的单个突起。另外地或可替代地，在一些实施方式中，粘结间隙特征部103可以是一系列突起或“凸块”，这一系列突起或“凸块”形成用于将粘合剂朝着定位特征部102a、102b和/或沿着翼梁盖的跨度引导的路径，如下面更详细描述的。通常，粘结间隙特征部103从翼梁盖101的表面延伸远离一定距离，该距离小于定位特征部102a、102b延伸的距离。粘结间隙特征部103和定位特征部102a、102b的尺寸可以设置成沿着翼梁盖和/或叶片叶展延伸相同的距离，例如，延伸整个长度。然而，如果需要的话，粘结间隙特征部103也可以沿着翼梁盖和/或叶片叶展延伸不同的距离。
粘结间隙特征部103可以形成为具有变化的尺寸和形状。在一些实施方式中，粘结间隙特征部103沿着翼梁盖的跨度具有均匀一致的尺寸和形状，并且与翼梁盖一体地形成。因此，类似于定位特征部102a、102b，粘结间隙特征部103不能相对于翼梁盖移位或移开。因此，因为这些特征部可以用作形成叶片的各种其他部件的整体几何形状的基准点/框架，抗剪腹板的组装得以简化并且得以更精确地执行。
组装
操作中，将粘合剂施加在限定于定位特征部102a、102b之间的区域内，以利于将抗剪腹板组装到翼梁盖。如上所述，由于在操作期间施加在叶片上的力是通过该抗剪腹板和翼梁盖的联合体传递的，该联合体的完整性对于疲劳寿命和叶片性能是至关重要的。因此，确保在抗剪腹板120的底部与翼梁盖101之间维持足够的空间对于提供“袋部”或间隙供粘合剂驻留进而永久地联接抗剪腹板120与翼梁盖100是必须的。
抗剪腹板120定位于叶片模具内，例如，降低到与粘结间隙特征部103接触并定位在定位特征部102a、102b之间。在一些实施方式中，在移动抗剪腹板120与翼梁盖的粘结间隙特征部103和定位特征部102a、102b接合之前(至少部分地)施加粘合剂。附加地或替代地，可以在抗剪腹板与翼梁盖接合之后再施加粘合剂。在这种随后进行的粘合剂施加中，可以从翼梁盖的一端分配粘合剂，其中粘结间隙特征部103具有用于沿着翼梁盖的跨度引导粘合剂的通道或一系列突起。而且，由粘结间隙特征部103形成的间隙使得能够易于视觉确认已经施加了足够的粘合剂来填充形成在抗剪腹板120与翼梁盖101之间的整个空隙或空腔。类似地，粘结间隙特征部103可以是形成为具有一定形状，例如，如图3所示的三角形，该形状还将粘合剂朝向定位特征部102a、102b引导或转向。因此，粘结间隙特征部103在抗剪腹板103的边缘和翼梁盖100的位置处提供了粘合剂线的无应力竖立形状。
抗剪腹板
尽管在示例性实施方式中仅示出了单个抗剪腹板120，但是在本公开的范围内可以采用附加的抗剪腹板。此外，尽管在图3中将抗剪腹板120绘制为工字梁构造，但是也可以采用替代的抗剪腹板构造，例如，如果需要的话，采用呈大体U形或V形构造的裂隙梁。
例如，图4绘制了根据所公开主题的盒式抗剪腹板构造或双抗剪腹板构造。在这样的实施方式中，翼梁盖100形成有用于与抗剪腹板的第一腹板/凸缘接合的第一组定位特征部102a、102b和用于与抗剪腹板的第二腹板/凸缘接合的第二组定位特征部104a、104b。附加地，提供第一粘结间隙特征部103以与抗剪腹板的第一腹板/凸缘接合，并且提供第二粘结间隙特征部105以与抗剪腹板的第二腹板/凸缘接合。
在图5中绘制了另一示例性实施方式，其示出了C形抗剪腹板，该C形抗剪腹板具有接合定位特征部102b的竖向表面的第一“腿部”和接合定位特征部102a的竖向表面的第二“腿部”，其中抗剪腹板的底部与粘结间隙特征部103接合。这种构造使抗剪腹板能够相对于翼梁盖牢固且准确地放置，而无需任何附加的测量基准点，也无需任何附加部件(例如，夹具、托架、螺钉等)来将抗剪腹板固定至翼梁盖。
胶糊靴施加引导件
根据本公开的另一方面，提供了一种用于施加并引导粘合剂(例如，胶糊)的引导件，以便于翼梁盖100与抗剪腹板120的组装。
在图6所示的示例性实施方式中，引导件构造为胶糊靴引导件200。胶糊靴引导件200可以包括用于与翼梁盖的定位特征部102接合的配准特征。例如，胶糊靴引导件200可以包括横向延伸的凸缘202，该凸缘202配合地接收翼梁盖的定位特征部102，以固定这两个部件并防止其间的相对运动。如本文进一步描述的，这种接合以及相对运动的限制提供了均匀一致的限定的空腔或“袋部”来接收预定量的粘合剂。附加地，在一些实施方式中，胶糊靴引导件200包括用于接触翼梁盖100的突出脚204。
在一些实施方式中，胶糊靴200可以包括用于在胶糊靴界限内分配粘合剂的导管和端口。在胶糊靴200的界限内已经施加了足够的粘合剂之后，可以去除胶糊靴，进而可以将抗剪腹板安装就位。在一些实施方式中，胶糊靴200沿着翼梁盖的整个跨度延伸；在另一些实施方式中，胶糊靴可以是沿着叶片的叶展分布在选择位置的数个靴。
胶糊靴引导件提供的优点之一是减少了粘合剂施加的变化。无需手动标记一条线来标识胶糊的施加位置，胶糊靴引导件可以确保施加适量的粘合剂，并将粘合剂成形或引导成处于适当的位置(例如，抗剪腹板跟部)，从而在两部件之间形成牢固联合。
蒙皮定位件特征部
根据本公开的另一方面，可以将蒙皮定位件特征部结合到翼梁盖形成过程中。在图7-8所示的示例性实施方式中，翼梁盖可以形成为——例如，拉挤成型为——具有能够与叶片蒙皮接合的特征部。例如，翼梁盖可形成有用于配合地接收叶片蒙皮中的互补特征部的特征部110。出于说明而非限制的目的，蒙皮定位件特征部110示出为凹口，其构造为接收形成在叶片蒙皮上的互补突起310，如果需要的话，这些特征的凸/凹布置可以调换。
蒙皮定位件特征部110可以形成在翼梁盖的单个位置(例如，如图7所示的中心)，或者形成在翼梁盖表面101上的多个位置。该蒙皮定位件特征部的有利之处在于，其使得在叶片蒙皮各区段的铺放期间翼梁盖能够相对于叶片蒙皮快速且准确的定位/配准。这免除了使用外部模具中的固定装置作为基准点(这可能是不准确的，并且会随不同的制造周期和叶片几何形状而变化)的需要。附加地，蒙皮定位件特征部使得能够快速识别直接出现在翼梁盖和蒙皮上的定位部件，同时减少了错误并提供了对正确接合的即时视觉确认。
在一些实施方式中，翼梁盖可以形成为联接至叶片蒙皮的分立元件。在其他实施方式中，翼梁盖形成为编织或混入叶片蒙皮中而形成一体式联接的部件。
垫板定位件
根据本公开的另一方面，可以采用包括定位件特征202的垫板(caul plate)200。在图9所示的示例性实施方式中，垫板定位件特征部202接合翼梁盖定位特征部102。在一些实施方式中，垫板定位件特征部202可以包括可释放的联接件，例如螺钉或销钉，用于在随后的组装过程中将垫板和翼梁盖保持于接合状态。例如，垫板定位件特征部202可以接合翼梁盖定位特征部102以便限制垫板移动/移位，从而允许垫板200在灌注过程中保持存在并牢固地接合。
抗剪腹板跟部填充物
根据本公开的另一方面，可以引导或导向粘合剂来完全填充抗剪腹板的跟部附近的空隙。在图10所示的示例性实施方式中，翼梁盖的定位特征部102形成竖直壁，该竖直壁在粘合剂施加到翼梁盖100与抗剪腹板120之间的粘合间隙内期间充当堤坝件。该堤坝件迫使粘合剂沿着翼梁盖的定位特征部102向上行进，以完全填充空隙或袋部，包括抗剪腹板的跟部的过渡半径附近的区域在内。可以施加粘合剂，直到粘合剂延伸到翼梁盖的定位特征部102上方，从而提供了对已经施加了适量的粘合剂的即时视觉确认。应当注意的是，本文中的“上方”、“下方”、“顶部”、“底部”等是相对的且非限制性的，本文所述的结构和技术同样适用于在叶片的吸力侧和压力侧上形成的翼梁盖。
因此，本公开提供了相对于常规叶片结构和制造技术的众多优点和改进，包括：
·消除了使用大型龙门架来定位抗剪腹板并将其在定位和粘结过程中保持就位的需求；
·避免了手动成形胶线以消除应力竖立形状以及抗剪腹板与翼梁盖之间的“碰撞状况”粘结线，进而使得更易于评估粘结线的粘合剂量且更小可能地出现缺陷；
·提供了对剪力腹板根部的完整填充，而无需添加/粘结辅助部件来重新引导粘合剂挤出；
·提供了相对于叶片部件而非外部模具框架的基准点，从而基准特征部可以保留在真空包装袋内；
·提供了翼梁盖的定位固定装置，该定位固定装置与翼梁盖成一体，消除了在铺放过程中滑动/移动的可能性。
尽管本文就某些优选实施方式对所公开的主题进行了描述，但是本领域技术人员将认识到，可以对所公开的主题进行各种修改和改进，而不脱离其范围。而且，尽管所公开的主题的一个实施方式的各单个特征可以在本文中讨论或在一个实施方式的附图中示出，而未在其他实施方式中示出，但应该清楚的是，一个实施方式的各单个特征可以与另一实施方式的一个或多个特征或来自多个实施方式的特征组合。
除了以下要求保护的特定实施方式之外，所公开的主题还针对具有以下要求保护以及以上披露的从属特征的任何其他可能组合的其他实施方式。这样，在所公开的主题的范围内，在从属权利要求中提出并在上文中公开的特定特征可以以其他方式彼此组合，从而使得应当认识到所公开的主题还具体针对具有任何其他可能组合的其他实施方式。因此，出于说明和描述的目的，已经给出了所公开的主题的特定实施方式的前述描述。并不旨在排他或将所公开的主题限制于所公开的那些实施方式。
对于本领域技术人员将显而易见的是，在不脱离所公开主题的精神或范围的情况下，可以对所公开主题的方法和系统进行各种修改和变化。因此，意图是所公开的主题包括在所附权利要求及其等同物的范围内的修改和变化。

Claims (20)

1.一种翼梁盖，包括：
第一表面和第二表面，所述第一表面和所述第二表面之间限定一厚度；
至少一个定位特征部，所述至少一个定位特征部设置在所述第一表面上；
至少一个粘结间隙特征部，所述至少一个粘结间隙特征部设置在所述第一表面上；
其中，所述定位特征部和所述粘结间隙特征部中的至少一者构造为接合抗剪腹板。
2.根据权利要求1所述的翼梁盖，其中，所述至少一个定位特征部是突起。
3.根据权利要求1所述的翼梁盖，其中，所述粘结间隙特征部是突起。
4.根据权利要求1所述的翼梁盖，其中，粘结间隙特征部从所述第一表面突出第一距离，而定位特征部从所述第一表面突出第二距离。
5.根据权利要求1所述的翼梁盖，进一步包括围绕所述翼梁盖的中心轴线对称地布置的多个定位特征部。
6.根据权利要求1所述的翼梁盖，进一步包括第一定位特征部和第二定位特征部，在所述第一定位特征部和所述第二定位特征部之间设置有粘结间隙特征部。
7.根据权利要求1所述的翼梁盖，其中，所述粘结间隙特征部构造为接合所述抗剪腹板的底表面。
8.根据权利要求1所述的翼梁盖，其中，所述定位特征部构造为接合所述抗剪腹板的侧表面。
9.根据权利要求1所述的翼梁盖，其中，所述粘结间隙特征部沿着叶片叶展的长度延伸。
10.根据权利要求1所述的翼梁盖，其中，所述定位特征部沿着叶片叶展的长度延伸。
11.一种形成风力涡轮机叶片部件的方法，包括：
形成翼梁盖，使所述翼梁盖具有第一表面和第二表面，所述第一表面和所述第二表面之间限定一厚度；
在所述第一表面上形成至少一个定位特征部；
在所述第一表面上形成至少一个粘结间隙特征部；
其中，所述定位特征部和所述粘结间隙特征部中的至少一者构造为接合抗剪腹板。
12.根据权利要求11所述的方法，其中，所述形成包括拉挤成型。
13.根据权利要求11所述的方法，其中，所述定位特征部与所述粘结间隙特征部中的至少一者是突起。
14.根据权利要求11所述的方法，还包括使抗剪腹板与所述翼梁盖的所述定位特征部接合。
15.根据权利要求14所述的方法，其中，使所述抗剪腹板与所述定位特征部接合包括将所述抗剪腹板定位在所述翼梁盖的所述第一定位特征部与所述第二定位特征部之间。
16.根据权利要求11所述的方法，还包括使抗剪腹板与所述翼梁盖的所述粘结间隙特征部接合。
17.根据权利要求16所述的方法，其中，使所述抗剪腹板与所述粘结间隙特征部接合包括将所述抗剪腹板定位在所述翼梁盖的所述粘结间隙特征部的顶部上。
18.根据权利要求11所述的方法，还包括在所述翼梁盖的所述粘结间隙特征部附近施加粘合剂。
19.根据权利要求18所述的方法，其中，将粘合剂朝向所述定位特征部引导。
20.根据权利要求11所述的方法，其中，所述定位特征部和所述粘结间隙特征部形成为沿着叶片叶展的长度延伸。
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