CN113757036A - 一种改进后缘结构的风电叶片及其制作方法 - Google Patents

一种改进后缘结构的风电叶片及其制作方法 Download PDF

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CN113757036A
CN113757036A CN202111014885.7A CN202111014885A CN113757036A CN 113757036 A CN113757036 A CN 113757036A CN 202111014885 A CN202111014885 A CN 202111014885A CN 113757036 A CN113757036 A CN 113757036A
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trailing edge
blade
web
reinforcement
lower shell
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CN202111014885.7A
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CN113757036B (zh
Inventor
冯学斌
侯彬彬
邓航
胡杰桦
赵建刚
杨军
彭超义
凡盛
刘鹏辉
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Zhuzhou Times New Material Technology Co Ltd
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Zhuzhou Times New Material Technology Co Ltd
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Priority to CN202111014885.7A priority Critical patent/CN113757036B/zh
Priority to EP21955679.2A priority patent/EP4205958A4/en
Priority to PCT/CN2021/122969 priority patent/WO2023029150A1/zh
Priority to US18/264,227 priority patent/US20240035441A1/en
Publication of CN113757036A publication Critical patent/CN113757036A/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
    • F03D1/069—Rotors characterised by their construction elements of the blades of the trailing edge region
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    • 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
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    • B29D99/0028—Producing blades or the like, e.g. blades for turbines, propellers, or wings hollow 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
    • F03D1/00—Wind motors with rotation axis substantially parallel to the air flow entering the rotor 
    • F03D1/06—Rotors
    • F03D1/0608—Rotors characterised by their aerodynamic shape
    • F03D1/0633—Rotors characterised by their aerodynamic shape of the blades
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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
    • F03D1/0608—Rotors characterised by their aerodynamic shape
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    • F03D1/0641—Rotors characterised by their aerodynamic shape of the blades of the section profile of the blades, i.e. aerofoil profile
    • 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 
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    • F03D1/0675—Rotors characterised by their construction elements of the blades
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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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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Sustainable Development (AREA)
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  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • General Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
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Abstract

本发明提供了一种改进后缘结构的风电叶片及其制作方法，风电叶片包括上壳体、下壳体与后缘，上壳体、下壳体与后缘围成的后缘粘接区域内填充有复合材料，所述复合材料在翼型弦向方向断开；制作方法包括以下步骤：S1.制作截面形状与后缘填充区域的截面形状一致的多段复合材料增强体；S2.将增强体、纤维布与上壳体一体成型，设置下壳体，将上壳体与下壳体合膜并加热，最终固化成型。本发明断开的填充结构设计减少了粘接胶和复合材料增强体的用量，小腹板可以增强后缘区域强度，减少后缘粘接宽度，综合实现风电叶片的轻量化。

Description

一种改进后缘结构的风电叶片及其制作方法
技术领域
本发明属于风力发电技术领域，尤其涉及一种改进后缘结构的风电叶片风电叶片后缘结构及其制作方法。
背景技术
风电叶片随着风能捕获需求越来越长，叶片弦向宽越来越宽，叶片重量增加、重心向叶尖偏移导致重力疲劳载荷和离心载荷显著增大，叶片与机组可靠性降低、成本增加，风电叶片的轻量化逐渐成为叶片族系延长设计技术的热点。为了减轻风电叶片的重量，现有的风电叶片将叶片腹板由两个减少为一个，使得后缘区域的空腔更大，在这些空腔区域叶片极易出现失稳失效的问题。
目前存在的风电叶片后缘维稳结构包括：(1)设计填充泡沫，对叶片后缘区域起到支撑作用，但大量填充硬质泡沫同样为风电叶片增加了重量；(2)增加后缘腹板，但叶片后缘粘接区域位置狭窄，布置后缘腹板具有困难。
因此，风电叶片领域仍缺乏一种既能减轻叶片整体重量，又能达到稳定效果的后缘结构设计。
发明内容
本发明所要解决的技术问题是风电叶片后缘失稳并同时实现轻量化，克服以上背景技术中提到的不足和缺陷，提供一种改进后缘结构的风电叶片风电叶片后缘结构及其制作方法。
为解决上述技术问题，本发明提出的技术方案为：
一种改进后缘结构的风电叶片，包括上壳体、下壳体与后缘，其特征在于，在所述后缘附近设计的需要粘结上壳体和下壳体的区域填充有多条复合材料，所述复合材料沿叶片长度方向呈条状分布，多条复合材料在翼型弦向方向间隔排列。翼型弦向方向如图1中箭头a所示。
优选的，所述复合材料包括增强体和增强体四周包裹的纤维布，所述增强体的材料包括发泡的PVC、PET、HPE或PMI泡沫中的一种或多种。
优选的，所述复多条复合材料中的第一条复合材料紧贴着后缘，后续每段复合材料与前一段复合材料隔开距离。
优选的，所述增强体截面形状与后缘粘接区域的截面形状一致。
优选的，所述风电叶片内部有一腹板，腹板与后缘围成一后缘腔体，所述后缘腔体内布置有后缘腹板。
优选的，所述后缘腹板沿叶片长度方向的起点设置在距叶根12-15％的叶片总长区域，后缘腹板沿叶片长度方向的终点设置在距叶根57-60％的叶片总长区域。
优选的，所述多条复合材料在翼型弦向方向间隔设置的数量随叶片长度方向发生变化，在所述后缘和后缘腹板之间的区域内设置数量少于叶片叶尖处附近设置的数量。
更具体分布为：在所述后缘和后缘腹板之间的区域内，复合材料在翼型弦向方向分为1-2段，每段宽度为50-80mm，每段间距为80-100mm；在所述的后缘腹板沿叶片长度方向的终点以后的后缘粘接区域内，复合材料在翼型弦向方向分为2-3段，每段宽度为50-80mm，每段间距为80-100mm，后缘和后缘腹板之间的区域内复合材料的数量少于叶片叶尖处附近的数量。
后缘腹板终点以后的区域内支撑减少，后缘失稳的可能性增加，稳定性相对较差，故而填充的泡沫段数较后缘腹板与后缘围成的区域更多，在使用断开填充结构保证轻量化的同时，又增加了后缘的稳定性，减小失稳风险。
优选的，所述后缘腹板的上侧和下侧横向扩宽为上脚板和下脚板，并将后缘腹板的上脚板和下脚板分别限定在上壳体和下壳体上。
优选的，所述限定后缘腹板的上脚板和下脚板的上壳体和下壳体区域布置有后缘辅梁，所述后缘辅梁的材料包括单向纤维布、玻纤拉挤板或碳拉挤板中的一种或多种。
后缘辅梁能够提高叶片刚度，并与后缘腹板组成工字梁结构。
在同一个技术构思下，本发明还提供一种改进后缘结构的风电叶片的制作方法，包括以下步骤：
S1.在所述后缘附近设计需要粘结上壳体和下壳体的后缘粘接区域，制作截面形状与后缘填充区域的截面形状一致的多段复合材料增强体；
S2.将增强体、纤维布设置在下壳体上，将上壳体与下壳体合膜并加热，通过树脂灌注工艺一体固化成型。
优选的，S1中所述制作截面形状与后缘填充区域的截面形状一致的多段增强体具体包括以下步骤：
a.制作成型上壳体和下壳体；
b.在塑料薄膜中包裹结构胶，并放置在预组装后的上壳体和下壳体之间的后缘填充区域；
c.开启模具加热，使结构胶固化成型得到一后缘填充区域增强模板；
d.基于上述整体增强模板并根据设计参数，每隔一段距离选取截面获得增强模板截面形状(即后缘填充区域腔体形状)，绘制多个增强体轮廓坐标图；
e.根据轮廓坐标图加工多个增强体。
在塑料薄膜中包裹结构胶能够防止结构胶固化后与上壳体、下壳体粘接在一起，导致难以取出等问题。
优选的，所述制作方法还包括后缘腹板与后缘辅梁的装配方法，具体为：
a.在上壳体和下壳体上铺设与后缘腹板上下面相配合的后缘辅梁；
b.将增强体、纤维布设置在下壳体上；
c.将后缘腹板粘接在下壳体对应的后缘辅梁上；
d.将上壳体与下壳体合膜并加热，通过树脂灌注工艺一体固化成型。
优选的，所述将后缘腹板粘接至下壳体上，需在后缘腹板与后缘辅梁间保证粘接间隙。
优选的，所述保证粘接间隙具体为每间隔2-4m铺设垫块。
铺设垫块能够垫出粘接间隙，有助于后缘腹板的上下脚板固定在后缘辅梁上，同时能够预留出填充结构胶的空隙，有助于合装时固化成型。
与现有技术相比，本发明的有益效果为：
(1)后缘粘接区域内填充的复合材料在翼型弦向方向断开，在为后缘填充区域提供支撑，增强后缘结构稳定性的同时，断开的填充结构设计减少了粘接胶和复合材料增强体的用量，实现风电叶片的轻量化；同时复合材料填充灵活，可以在不存在后缘腹板的区域增加一段复合材料，以加强叶片后缘区域的稳定性。
(2)后缘区域设计有小腹板，可以增强后缘区域强度，从而减少后缘粘接宽度，进而实现叶片轻量化；
(3)下腹板采用上下脚板的设计，并与之对应在上下壳体上设置后缘辅梁，使其能够稳定布置在空间窄小的后缘区域，进一步增强了后缘结构的稳定性；
(4)公开了与后缘填充结构和小腹板结构配套的制作方法，方法操作简单，实现了增强后缘结构的稳定性和轻量化的目的，适宜大规模工业化。
附图说明
为了更清楚地说明本发明实施例或现有技术中的技术方案，下面将对实施例或现有技术描述中所需要使用的附图作简单地介绍，显而易见地，下面描述中的附图是本发明的一些实施例，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据这些附图获得其他的附图。
图1为实施例1风电叶片含后缘腹板区域的后缘结构整体截面图；
图2为实施例1风电叶片后缘腹板沿叶片长度方向的终点以后的后缘粘接区域填充结构截面图；
图3为实施例1复合材料截面图；
图4为实施例1后缘腹板截面图；
图5为实施例1风电叶片腹板与填充复合材料的俯视位置示意图；
图6为一种后缘失稳形式示意图；
图7为增加后缘腹板后解决后缘失稳后效果示意图；
图8为一种后缘粘接区域失稳形式示意图；
图9为增加后缘填充结构后解决后缘失稳后效果示意图。
图中，1、上壳体；2、下壳体；3、复合材料；4、后缘腹板；5、腹板；7、后缘；9、后缘粘接区域；31、纤维布；32、增强体；41、起点；42、终点；43、上脚板；44、下脚板；45、后缘辅梁。
具体实施方式
为了便于理解本发明，下文将结合说明书附图和较佳的实施例对本发明做更全面、细致地描述，但本发明的保护范围并不限于以下具体实施例。
除非另有定义，下文中所使用的所有专业术语与本领域技术人员通常理解含义相同。本文中所使用的专业术语只是为了描述具体实施例的目的，并不是旨在限制本发明的保护范围。
除非另有特别说明，本发明中用到的各种原材料、试剂、仪器和设备等均可通过市场购买得到或者可通过现有方法制备得到。
实施例1：
一种改进后缘结构的风电叶片，如图2、图3所示，包括上壳体1、下壳体2和后缘7，在后缘7附近设计的需要粘结上壳体1和下壳体2的区域填充有多条复合材料3，该区域为后缘粘接区域9，所述复合材料3沿叶片长度方向呈条状分布，多条复合材料3在翼型弦向方向间隔排列。图1中箭头标注a表示翼型弦向方向。
复合材料3包括增强体32和增强体32四周包裹的纤维布31，所述增强体32的材料包括发泡的PVC、PET、HPE或PMI泡沫中的一种或多种。
如图1、图5所示，风电叶片中布置有一腹板5，腹板5与后缘7围成一后缘腔体，后缘腔体内布置有后缘腹板4；后缘腹板4沿叶片长度方向的起点41设置在距叶根12-15％的叶片总长区域，后缘腹板4沿叶片长度方向的终点42设置在距叶根57-60％的叶片总长区域。
如图1、图5所示，在后缘粘接区域9铺设有两段复合材料3，第一段复合材料3的增强体32紧贴后缘7，第二段复合材料3与第一段复合材料3之间在翼型弦向方向间隔约80mm，两段复合材料3宽度约80mm；如图2、图5所示，在后缘腹板4沿叶片长度方向的终点42以后的后缘粘接区域9内，后缘粘接区域9内没有后缘腹板4支撑，故相较于后缘腹板4和后缘7围成的区域增加一段复合材料3，宽度为80mm，与复合材料3在翼型弦向方向间隔约80mm。
最终，后缘腹板4和后缘7围成的区域内，复合材料3在翼型弦向方向存在2段，每段宽度为80mm，两段之间间距约80mm；后缘腹板4和后缘7围成的区域即后缘腹板4沿叶片长度方向的起点41到沿叶片长度方向的终点42与该段在叶片长度方向对应的后缘7之间的区域；在后缘腹板4沿叶片长度方向的终点42以后的后缘粘接区域9内，复合材料3在翼型弦向方向分为3段，每段宽度为80mm，两段之间的间距约80mm。
如图4所示，后缘腹板4的上侧和下侧横向扩宽为上脚板43和下脚板44，并将后缘腹板4的上脚板43和下脚板44分别限定在上壳体1和下壳体2上。
限定后缘腹板4的上脚板43和下脚板44的上壳体1和下壳体2区域布置有后缘辅梁45，所述后缘辅梁45材料为单向纤维布。
本实施例风电叶片后缘结构采用的制作方法如下：
S1.制作截面形状与后缘填充区域9的截面形状一致的多段复合材料增强体32，具体为：
1)制备上壳体1和下壳体2；
2)预组装上壳体1和下壳体2，确认上壳体1和下壳体2之间不存在干涉；
3)在塑料薄膜中包裹结构胶，并放置在预组装后的上壳体1和下壳体2之间后缘粘接区域，预组装上壳体1和下壳体2；
4)开启模具加热，使塑料薄膜中包裹结构胶固化成型得到一后缘填充区域增强模板；
5)基于上述整体增强模板并根据设计参数，每隔0.5m一个截面获得增强模板截面形状，即为后缘粘接区域腔体形状，并绘制后缘填充泡沫轮廓坐标图；
6)根据后缘填充泡沫轮廓图加工多个增强体32；
S2.制作后缘腹板4，具体为：
1)在三维外形中获得备用后缘腹板4；
2)将备用后缘腹板4粘接至上壳体1上，在备用后缘腹板4上脚板43与后缘辅梁间间隔2m垫垫块，并用专用下压工装保证粘接间隙；
3)在下壳体2后缘辅梁区域铺设塑料薄膜，在备用后缘腹板4下脚板44上刮涂结构胶；
4)进行预合模并开启模具加热程序，使结构胶固化；
5)打开模具，吊出带有固化后结构胶的备用后缘腹板4，并将其进行切边处理；
6)以备用后缘腹板4为阳模，翻制出后缘腹板4阴模；
7)制备后缘腹板4；
S3.在上壳体1和下壳体2上铺设与后缘腹板4上下面相配合的后缘辅梁45；S4.将增强体32、纤维布31设置在下壳体2上；将后缘腹板4的上脚板43粘接至上壳体1对应的后缘辅梁45上，并用专用下压工装保证粘接胶厚度，在后缘腹板4下脚板44上刮涂结构胶设置在下壳体2对应的后缘辅梁45上；
S5.将上壳体1与下壳体2合膜开启模具加热程序，增强体32、纤维布31与上壳体1和下壳体2通过真空树脂灌注工艺一体固化成型，后缘腹板4与后缘辅梁45间的结构胶固化成型。
图6、7、8、9分别为两种典型的后缘失稳形式以及增加后缘腹板和后缘填充结构后的解决失稳效果示意图，图中清晰地展示出了本申请方案解决后缘失稳问题的作用方式。

Claims (11)

1.一种改进后缘结构的风电叶片，包括上壳体(1)、下壳体(2)与后缘(7)，其特征在于，在所述后缘(7)附近设计的需要粘结上壳体(1)和下壳体(2)的区域填充有多条复合材料(3)，所述复合材料(3)沿叶片长度方向呈条状分布，多条复合材料(3)在翼型弦向方向间隔排列。
2.如权利要求1所述的改进后缘结构的风电叶片，其特征在于，所述复合材料(3)包括增强体(32)和增强体(32)四周包裹的纤维布(31)，所述增强体(32)的材料包括发泡的PVC、PET、HPE或PMI泡沫中的一种或多种。
3.如权利要求2所述的改进后缘结构的风电叶片，其特征在于，所述多条复合材料(3)中的第一条复合材料(3))紧贴着后缘(7)，后续每段复合材料(3)与前一段复合材料(3)隔开距离。
4.如权利要求1所述的改进后缘结构的风电叶片，其特征在于，所述风电叶片内部有一腹板(5)，腹板(5)与后缘(7)围成一后缘腔体，所述后缘腔体内布置有后缘腹板(4)。
5.如权利要求4所述的改进后缘结构的风电叶片，其特征在于，所述后缘腹板(4)沿叶片长度方向的起点(41)设置在距叶根12-15％的叶片总长区域，后缘腹板(4)沿叶片长度方向的终点(42)设置在距叶根57-60％的叶片总长区域。
6.如权利要求4或5所述的改进后缘结构的风电叶片，其特征在于，所述多条复合材料(3)在翼型弦向方向间隔设置的数量随叶片长度方向发生变化，在所述后缘(7)和后缘腹板(4)之间的区域内设置数量少于叶片叶尖处附近设置的数量。
7.如权利要求4或5所述的改进后缘结构的风电叶片，其特征在于，所述后缘腹板(4)的上侧和下侧横向扩宽为上脚板(43)和下脚板(44)，并将后缘腹板(4)的上脚板(43)和下脚板(44)分别限定在上壳体(1)和下壳体(2)上。
8.如权利要求7所述的改进后缘结构的风电叶片，其特征在于，限定所述后缘腹板(4)的上脚板(43)和下脚板(44)的上壳体(1)和下壳体(2)区域布置有后缘辅梁(45)，所述后缘辅梁(45)的材料包括单向纤维布、玻纤拉挤板或碳拉挤板中的一种或多种。
9.一种改进后缘结构的风电叶片的制作方法，其特征在于，包括以下步骤：
S1.在后缘(7)附近设计需要粘结上壳体(1)和下壳体(2)的后缘粘接区域(9)，制作截面形状与后缘粘接区域(9)的截面形状一致的复合材料增强体(32)；
S2.将增强体(32)、纤维布(31)设置在下壳体(2)上，将上壳体(1)与下壳体(2)合膜并加热，通过树脂灌注工艺一体固化成型。
10.如权利要求9所述的一种改进后缘结构的风电叶片的制作方法，其特征在于，S1中所述制作截面形状与后缘粘接区域(9)的截面形状一致的增强体(32)具体包括以下步骤：
a.制作成型上壳体(1)和下壳体(2)；
b.在塑料薄膜中包裹结构胶，并放置在预组装后的上壳体(1)和下壳体(2)之间的后缘粘接区域(9)；
c.开启模具加热，使结构胶固化成型得到一后缘填充区域增强模板；
d.基于上述整体增强模板并根据设计参数，绘制多个增强体轮廓坐标图；
e.根据轮廓坐标图加工多个增强体(32)。
11.如权利要求9所述的一种改进后缘结构的风电叶片的制作方法，其特征在于，所述制作方法还包括后缘腹板(4)与后缘辅梁(45)的装配方法，具体为：
a.在上壳体(1)和下壳体(2)上铺设与后缘腹板(4)上下面相配合的后缘辅梁(45)；
b.将增强体(32)、纤维布(31)设置在下壳体(2)上；
c.将后缘腹板(4)粘接在上壳体(1)、下壳体(2)对应的后缘辅梁(45)上；
d.将上壳体(1)与下壳体(2)合膜并加热，增强体(32)、纤维布(31)、上壳体(1)和下壳体(2)通过树脂灌注工艺一体固化成型。
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