CN114714644A - 制造可适应碳纤维梁的方法 - Google Patents
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Abstract
本发明涉及制造可适应碳纤维梁的方法。本发明描述了制造可适应预铸树脂灌注碳纤维梁(1)的方法,所述方法包括步骤:并排布置多个细长碳纤维块体(1B);布置片材(11、12、13)以包封块体(1B)并在相邻块体(1B)的相对面上延伸;布置片材(11、12、13)以在相邻块体(1B)之间的接合处会聚为向外伸出的细长卷边(1H);和拉紧细长卷边(1H)以在树脂灌注步骤的过程中阻止块体(1B)之间的树脂流动。本发明进一步描述了使用该方法制成的预铸可适应碳纤维梁(1);制造风力涡轮机转子叶片(3)的方法;和风力涡轮机转子叶片(3)。
Description
技术领域
本发明描述了制造可适应碳纤维梁的方法;预铸可适应碳纤维梁;制造风力涡轮机转子叶片的方法;和风力涡轮机转子叶片。
背景技术
在风力涡轮机的运行过程中,转子叶片可能经受大的弯矩,特别是在内侧区域。弯矩的量级随转子叶片长度的增加而增加,长的转子叶片必须构造成具有足够刚度以避免在风力涡轮机的正常运行期间或在高的风荷载条件期间的过度变形。
由于这些原因,对风力涡轮机转子叶片设计而言已经变得常见的是,在内侧区域,尤其是在后缘和前缘区域包括大量玻璃纤维增强材料。已知的是,在较平的转子叶片内侧区域中并入具有厚玻璃纤维层和芯板的夹层结构。但是,制造转子叶片以包括这样的增强材料是耗时且昂贵的。这些增强材料的另一缺点是不利地增加转子叶片的重量。
一种替代方法是使用碳材料代替玻璃纤维以增强关键的转子叶片区域。但是,玻璃纤维增强材料可作为多种多样的柔性垫和粗纱获得,它们可容易地布置成依循转子叶片模具的形状,而具有同等刚度特性的拉挤或预铸碳纤维元件通常只能作为扁梁或板形元件获得。由于转子叶片内侧区域中,特别是在呈圆形的前缘和尖锐的后缘处的高度弯曲表面,这种限制是成问题的。以期望的精度将扁平预铸碳纤维元件布置在较少弯曲的转子叶片区域中也是困难的。
转子叶片质量矩朝内侧区域累积,并且实际可实现的转子叶片长度因此取决于在内侧区域可实现的刚度。但是,与使内侧转子叶片区域加强刚度相关联的困难意味着转子叶片长度通常小于可实现的长度。受限的转子叶片长度又对可生成的输出功率施加限制。
发明内容
因此,本发明的目的是提供提高转子叶片的内侧区域中的刚度以克服上述问题的方法。
通过权利要求1的制造可适应碳纤维梁的方法;通过权利要求6的预铸可适应碳纤维梁;通过权利要求12的制造风力涡轮机转子叶片的方法;和通过权利要求13的风力涡轮机转子叶片实现这一目的。
发明概述
根据本发明,制造可适应或“形状可调”的预铸树脂灌注碳纤维梁的方法包括步骤:并排布置多个细长碳纤维块体,以使相邻块体跨过间隙彼此面对,然后布置纤维片材以包封块体并在相邻块体的相对面上延伸。换言之,在此阶段,块体组装件的长表面被片材覆盖。在下一步骤中,将片材聚集以在相邻块体之间的接合处会聚为向外伸出的细长卷边(bead)或“管道(piping)”。通过在两个相邻块体的相对侧面之间将片材向下推并超过它们的下表面(也将底部片材向下推),有效地形成卷边,并且现在向外延伸的片材的层统称为“卷边”。例如,通过聚集一个底部片材层和一个顶部片材层形成的卷边将包括四个层。在后续步骤中,该组装件经受树脂灌注步骤。在这种树脂灌注步骤的过程中,形成卷边的片材层在卷边的整个长度上被压在一起。这有效地阻止树脂在树脂灌注步骤的过程中从一个块体流向另一个块体,即卷边充当相邻块体之间的树脂屏障,以阻止树脂流入卷边。因此,防止分处卷边两侧的块体的相对表面“粘在一起”;卷边在相邻碳块体之间形成“铰链”;并且卷边的材料保持“干燥”,即不含树脂,因此在风力涡轮机转子叶片的模制过程中有利地与复合材料良好结合。
可适应碳纤维梁可具有任何长度,例如量级为20米或更大的长度。可适应碳纤维梁的宽度取决于碳纤维块体的数量和这些块体的宽度等因素。
细长碳纤维块体可假定为在环氧基质中拉挤。环氧基质在灌注步骤的过程中在被加热时液化,并布满整个块体。液体树脂在各个块体的层之间穿行。
在固化后,可适应碳纤维梁的细长卷边充当某种“铰链”,因为分处该铰链两侧的块体在树脂灌注步骤的过程中没有互相粘合,因此可 - 至少在一定程度上 - 围绕卷边枢转。本发明的碳纤维梁的优点在于,这种铰接结构能使碳梁的形状适应于其随后将嵌入的结构的形状。块体的数量(控制梁宽度)、它们的截面形状和块体的长度(控制梁长度)可基于具体实施方案选择,例如以便将梁布置在风力涡轮机转子叶片的弯曲前缘处,或布置在渐窄的后缘处。
根据本发明,制造风力涡轮机转子叶片的方法包括步骤:提供转子叶片模具以接收复合铺层(layup);提供这样的预铸可适应碳纤维梁;将预铸碳纤维梁布置在复合铺层中并根据转子叶片模具的形状调节预铸碳纤维梁的形状,和随后进行树脂灌注和固化以将预铸碳纤维梁粘合在转子叶片的复合壳体中。
这样的转子叶片的制造有利地是经济的,因为在模制程序的过程中直截了当地将可适应碳纤维梁布置在复合铺层中。可适应碳纤维梁的形状可调节成依循转子叶片形状的曲率,并同时有利地容易定位在复合铺层中。此外,预铸可适应碳纤维梁本身可以比如上文解释的更复杂的增强结构更便宜。
如上文解释,块体的数量和细长卷边或铰链的数量可根据预期的实施方案来选择。例如,为了在弯曲前缘处实施,可适应碳纤维梁可制成在每对相邻块体之间具有这样的“铰链”,并且块体本身可相对较窄。为了在更平坦和渐窄的后缘处实施,可适应碳纤维梁的块体可以更宽,并且单个“铰链”可能就足够。
根据本发明,这样的转子叶片在转子叶片的过渡区中包括许多本发明的预铸可适应碳纤维梁。过渡区应被理解为是通常圆形的根部与翼型区之间延伸的区域。根据转子叶片的几何形状,90米转子叶片的过渡区可例如延伸转子叶片长度的5%至30%。
本发明的转子叶片的优点在于,可极大提高其在关键过渡区中的结构强度,而不显著增加制造成本。由于本发明的转子叶片能够更好地承受弯曲荷载,可增加转子叶片的长度,以使配备这样的转子叶片的风力涡轮机的功率输出更高。
通过从属权利要求给出如在以下描述中揭示的本发明的特别有利的实施方案和特征。不同权利要求类别的特征可酌情组合以给出本文中没有描述的进一步实施方案。
在下文中,可以假定,在闭合模具并进行树脂灌注程序之前,通过将玻璃纤维层(垫、粗纱等)和结构增强部件布置在模具中来制造转子叶片。
在下文中,为简单起见,“细长碳纤维块体”可简单地称为“块体”,并且该术语应被理解为是指在本发明的预铸可适应梁中形成细长碳纤维块体的层堆叠体。
本发明的可适应碳纤维梁可并入转子叶片的受益于结构增强的任何部分。在本发明的一个优选实施方案中,转子叶片在其前缘处,优选在过渡区的内侧包括一个或多个这样的预铸可适应碳纤维梁。替代性地或附加地,转子叶片优选地在其后缘处,优选在过渡区的内侧包括一个或多个这样的预铸可适应碳纤维梁。
如上文解释,可适应碳纤维梁的几何形状可为其预期的实施方案来定制。下面解释一般制造方法。在第一预备步骤中,将基础片材(包括至少一个单向碳纤维材料片材)铺展在组装表面上。然后通过堆叠各自具有基本矩形形状的拉挤碳纤维条的层,在这种基础片材布置上组装碳纤维块体。拉挤元件的长度可全部相同。各个块体优选包括至少两个,更优选三个或更多个拉挤碳条的堆叠体。当然,使用的拉挤碳条的数量取决于它们的厚度和所需的梁厚度。在本发明的一个特别优选的实施方案中,将双轴碳纤维片材布置在每个堆叠层上,即铺设双轴碳纤维片材以覆盖同一层的所有拉挤碳条。如果每个块体具有三个层,则使用两个双轴碳纤维片材。最后一层拉挤碳条随后被顶片材(至少一个单向碳纤维材料片材)覆盖。该组装件又可被玻璃纤维材料片材包封。
为了易于并入复合铺层,可适应碳纤维梁优选构造成包括沿各个外部块体的外侧面布置的楔形元件。渐窄或楔形元件也可作为拉挤碳纤维元件提供。
本发明的预铸可适应碳纤维梁的优点在于,(在固化或硬化后)可通过分处细长卷边两侧的块体的枢转而改变其形状。如果碳纤维块体具有矩形截面,分处卷边两侧的块体可倾斜远离彼此。但是,如果碳纤维块体具有梯形截面并且在底部较宽,分处卷边两侧的块体也可朝彼此转动,以使预铸可适应纤碳维梁的灵活性更大。因此,在本发明的一个特别优选的实施方案中,碳纤维块体由堆叠层组装,其中堆叠层的形状使得相邻块体的相对面包着5°至20°的角。例如,拉挤元件可具有一个垂直侧面和一个倾斜侧面,或两个倾斜侧面。一对相邻块体的一个或两个相对面可具有倾斜侧面。在这样的实现方式中,可适应碳纤维梁的底面的总面积超过其顶面的面积。可适应碳纤维梁的可实现的曲率半径随后取决于梯形块体的几何形状,也取决于细长卷边“铰链”的数量。
细长卷边可通过将所有片材向下推过相邻块体之间的间隙来形成,以使所有片材在组装件的下侧会聚成“捆(bundle)”。为此目的,可使用任何合适的工具。当这捆层被向下拉离组装件的下侧时,效果是将片材压向相对的块体面。
在本发明的一个优选实施方案中,将可充气软管布置在出现于组装件下侧的层“捆”的中心。软管本身可用于将所有片材向下推过相邻块体之间的间隙。在树脂灌注步骤的过程中,软管被充气,并且其效果是向下拉动片材层,以实现将片材层压向相对的块体面的表面的期望结果。
在本发明的另一个优选的实施方案中,在合适的模制台上制备该组装件,该模制台已制成包括若干细长段并且沿相对的面具有凹口或凹槽以接收片材捆和可充气软管。在将块体组装在基础片材上并用顶片材覆盖块体后,将软管布置在相邻块体之间的间隙上方,并向下推入模制台的细长段之间的间隙中。模制台可构造成包括多个区段以接收这样的可充气软管。在准备树脂灌注步骤时,将软管充气以将片材层牢固地向下拉动,从而将片材层压向块体侧面。软管保持充气直到树脂固化。只要片材层被压向块体侧面,绷紧的片材就充当树脂屏障,以防止液体树脂移入卷边或扩散到相邻块体。在将软管放气后,可将这些软管移除,并将预铸可适应碳纤维梁提离模制台。技术人员熟悉将离型涂层施加到模制台和任何其它相关元件的通常措施。
碳纤维是导电材料。因此,任何碳纤维增强元件必须与转子叶片内部的任何其它导电元件可靠地隔离,或直接连接到转子叶片的防雷系统。因此,在本发明的一个特别优选的实施方案中,可适应碳纤维梁组装成包括将其连接到转子叶片的LPS的装置。在本发明的一个优选实施方案中,可适应碳纤维梁组装成使得基础片材和顶片材是单个单向碳纤维片材的一部分,并且该单向碳纤维片材的一部分从预铸可适应碳纤维梁向外延伸,以使其可连接到LPS。单个单向碳纤维片材在预铸可适应碳纤维梁的整个结构周围延伸,确保任何电位均匀分布在可适应碳纤维梁周围,以使闪络风险最小化。
如上文解释,该组装件的块体和碳纤维片材可被玻璃纤维材料片材包封。这可以是在预期应用中粘合到复合铺层的织造或毡制玻璃纤维片材。玻璃纤维片材优选是“干的”,即未被树脂浸渍。
本发明的可适应碳纤维梁的制造使用与现有技术的非可适应碳纤维梁的制造相同的材料和树脂灌注工具。仅有的调整在于,如果要将可适应碳纤维梁向内弯曲以获得凹形,则块体可组装成具有倾斜侧面;并在树脂灌注后,片材聚集在细长卷边中以形成铰链。因此需要额外的片材,但卷边中的材料在该预铸步骤的过程中没有被树脂灌注,其是“干”的并因此保持柔性,以使细长卷边可有利地在转子叶片的树脂灌注过程中与转子叶片铺层的复合材料结合。
本发明的其它目的和特征将从结合附图考虑的以下详述中显而易见。但是,要理解的是,附图仅为了图解说明设计而非规定本发明的界限。
附图说明
图1显示穿过风力涡轮机转子叶片的一系列截面;
图2图解现有技术风力涡轮机转子叶片中的增强过渡区;
图3图解本发明的风力涡轮机转子叶片的一个实施方案中的增强过渡区;
图4 - 6图解在本发明的可适应碳纤维梁的制造中的阶段;
图7 - 9图解本发明的可适应碳纤维梁的一个实施方案的形状适应;
图10图解在风力涡轮机转子叶片的制造中的步骤;
图11图解制造本发明的可适应碳纤维梁的一种替代模式。
在图中,类似数字在各处是指类似对象。图中的对象不一定按比例绘制。
具体实施方式
图1显示穿过风力涡轮机转子叶片8的一系列截面,其从穿过圆形根部区80R的截面81开始且进展到穿过翼型区的截面85。如截面81-84所示,转子叶片的形状以复杂方式从初始圆形开始过渡。转子叶片的这一内侧部分被称为“过渡区”或“肩部区”,并且必须将尺寸设计为经得住在风力涡轮机的正常运行过程中以及在强风条件过程中的高弯矩。常用方法是使转子叶片壳体在过渡区中非常厚,但是添加的复合材料增加了转子叶片的重量。替代地,已知嵌入轻质但刚性的材料,如木材的增强结构,但这些结构的制造是耗时且昂贵的。在另一种方法中,如图2中的线框表示图所示,可将轻质碳纤维梁8C嵌入转子叶片8的过渡区80。但是,由经济的拉挤件制成的预铸碳纤维梁8C在形状上为矩形,因此不贴合弯曲的前缘LE或渐窄的后缘TE。此外,这种碳纤维梁8C的扁平形状使得在模制工艺中的转子叶片壳体的构建过程中难以将它们放置在复合层中。
图3是图解本发明的风力涡轮机转子叶片3的一个实施方案中的增强过渡区30的线框表示图。在此,将轻质的形状可适应的预铸碳纤维梁1嵌入转子叶片3的过渡区30中。各预铸可适应碳纤维梁1包括通过细长“铰链”1H连接的若干细长块体1B,以使梁1的形状可调节以在壳体模制程序的过程中顺应转子叶片壳体的形状。
图4 - 6图解在这样的预铸可适应碳纤维梁1的制造中的阶段。在图4中,将单向碳纤维片材11铺设在表面上。组装拉挤碳纤维元件10的块体1B,其中将双轴碳纤维材料的片材12布置在堆叠层之间。各拉挤碳纤维元件10可具有尺寸为大约50 mm x 50 mm的截面和大约20米的长度。如此处所示,选择元件10以形成具有直侧面或倾斜侧面的块体。完成的可适应碳纤维梁1的最小曲率半径取决于块体1B之间所包的角α。
图5显示后续阶段。在此,所有片材层11、12在相邻块体1B之间的间隙中向下推,以在组装件的下侧形成卷边或铰链1H。该图还显示两个侧向渐窄元件1W,它们稍后有助于将可适应碳纤维梁并入转子叶片的复合铺层中。单向碳纤维片材11向外延伸到一侧,以充当用于电连接到转子叶片LPS的连接表面110。
图6显示在相邻块体1B之间的接合处形成“铰链”1H的一种方法。在此,模制表面是平台2,其具有成形为形成通道200的区段,这些通道将接收片材捆以及可充气软管20。在该图中,碳梁组装件显示为还包括包封其它部件的玻璃纤维片材13。如技术人员所知,可将整个组装件布置在真空袋内,从而为VARTM程序做准备。模制表面2还在各细长块体1B下方配有树脂入口/出口对(仅示意性示出)。在VARTM的过程中,真空泵24用于经树脂入口22从储器25吸入树脂,并经树脂出口23抽出过量树脂。
在左侧,该图显示在平台区段20之间的通道200的放大视图,其显示在充气前在片材捆11、12、13的中心的可充气软管。当软管充气时,如右侧所示,片材层11、12、13被拉紧并压在一起。因此,在树脂灌注过程中,卷边1H充当树脂的屏障,其阻止树脂进入卷边1H。因此,卷边1H保持“干燥”,并在固化后,块体可围绕沿着固化梁下侧的由卷边1H的干片材形成的“铰链”自由地枢转。即使如此,各个块体堆叠体的层10通过固化树脂牢固地熔合在一起,并牢固地熔合到它们的包封片材层11、12上。预铸可适应碳纤维梁1因此本质上是刚性的,同时形状可调节。这显示在图7 – 9中,其图解本发明的预铸可适应碳纤维梁1的形状适应。在铰链1H的任一侧的块体结构可在一定程度上枢转,该程度取决于在相邻块体之间所包的角α。图8显示当所有块体向内枢转到最大程度时的最小曲率半径,以使预铸可适应碳纤维梁1可呈现如曲线C所示的弧形。图9显示本发明的预铸可适应碳纤维梁1的一个实施方案的透视图,其显示在可适应碳纤维梁1的“下侧”的铰链1H和(尚未)枢转到其最大程度的块体。这种弯曲的预铸可适配碳纤维梁1可在铺设程序的过程中布置在转子叶片模具的前缘过渡区中,以使固化的转子叶片表现出给定的更高结构刚度而不增加其质量。转子叶片质量的减小和质量矩的减小可促进有利地更长的转子叶片长度和能量生产的相应增加。
可适应碳纤维梁1借助单向碳纤维片材11的向外延伸的带110连接到转子叶片LPS。利用这种布置,可使雷击过程中的闪络风险最小化。
图10图解在风力涡轮机转子叶片的制造中的步骤。该图显示了下半模3M,在穿过过渡区的截面处。该图显示本发明的预铸碳纤维梁1的一个实施方案,其在左侧,靠近后缘区。预铸碳纤维梁1可适应该区域的微小曲率,并可容易地嵌入转子叶片下半部的复合铺层3L中。该图还显示了本发明的预铸碳纤维梁1的另一实施方案,其在右侧,靠近前缘区。预铸碳纤维梁1也可容易地使其形状适应于嵌入在该区域中具有模具圆形形状的复合铺层3L中。这种前缘预铸碳纤维梁1显示为具有沿下半模3M与上半模(由虚线标示)之间的接合处定位的铰链。当下部铺层完成时,预制碳纤维梁1的上部可向上枢转。
图11显示形成预铸碳梁1的一种替代方式。组装件如上文在图4和图5中所述制备,并包括拉挤碳元件和玻璃纤维片材11、12的堆叠体。在此,细杆4用于将盈余的片材带到模制表面2的水平面之下,并在树脂灌注步骤的过程中,如箭头所示保持张力,以使片材层被压在一起以阻止树脂从块体1B流入卷边1H。代替使用如此处所示的杆4,可通过将片材层沿它们整个长度牢固地夹在一起而形成卷边1H。在此阶段的唯一要求在于,片材层11、12被压向彼此以防止液体树脂从块体1B进入卷边1H。
尽管已经以优选实施方案及其变型的形式公开了本发明,但是要理解的是,可对其作出许多附加的修改和变动而不背离本发明的范围。
为清楚起见,要理解的是,在本申请中通篇使用的“一”或“一”不排除复数,且“包括”不排除其它步骤或元件。
Claims (15)
1.制造可适应预铸树脂灌注碳纤维梁(1)的方法,所述方法包括步骤
- 并排布置多个细长碳纤维块体(1B);
- 布置片材(11、12、13)以包封块体(1B)并在相邻块体(1B)的相对面上延伸;
- 布置片材(11、12、13)以在相邻块体(1B)之间的接合处会聚为向外伸出的细长卷边(1H);和
- 拉紧细长卷边(1H)以在树脂灌注步骤的过程中阻止块体(1B)之间的树脂流动。
2.根据权利要求1的方法,其包括通过堆叠细长碳纤维条(10)的层而组装碳纤维块体(1B)的预备步骤。
3.根据前述权利要求任一项的方法,其包括在相继的堆叠层(10)之间布置双轴碳纤维片材(12)的步骤。
4.根据前述权利要求任一项的方法,其包括在卷边(1H)内部插入可充气软管(21)的步骤,并且其中通过将软管(21)充气实现拉紧细长卷边(1H)的步骤。
5.根据前述权利要求任一项的方法,其包括提供模具(2)的步骤,所述模具(2)具有用于卷边(1H)的模腔(200),所述模腔(200)成型为接收片材(11、12、13)和可充气软管(21)。
6.使用根据权利要求1至5任一项的方法制成的预铸可适应碳纤维梁(1),其包括多个树脂灌注块体(1B),其中至少一对相邻块体(1B)通过细长卷边(1H)接合并可围绕细长卷边(1H)枢转。
7.根据前一项权利要求的预铸可适应碳纤维梁,其包括布置为包封碳纤维块体(1B)的单向碳纤维片材(11)。
8.根据前述权利要求6和7任一项的预铸可适应碳纤维梁,其包括围绕单向碳纤维片材(11)布置的玻璃纤维覆盖片材(13)。
9.根据前述权利要求6至8任一项的预铸可适应碳纤维梁,其中各个块体(1B)包括至少两个拉挤碳条(10),更优选至少三个拉挤碳条(10)的堆叠体。
10.根据前述权利要求6至9任一项的预铸可适应碳纤维梁,其中相邻块体(1B)的相对面包着5°至20°的角(α)。
11.根据前述权利要求6至10任一项的可适应碳纤维梁,其包括沿块体(1B)的外侧面布置的楔形元件(1W)。
12.制造风力涡轮机转子叶片(3)的方法,所述方法包括步骤
- 提供转子叶片模具(3M)以接收复合铺层(3L);
- 提供根据权利要求6至11任一项的预铸可适应碳纤维梁(1);
- 将预铸碳纤维梁(1)并入复合铺层(3L)并根据转子叶片模具(3M)的形状调节预铸碳纤维梁(1)的形状。
13.使用权利要求12的方法制成的转子叶片(3),其在转子叶片(3)的过渡区(30)中包括许多预铸可适应碳纤维梁(1)。
14.根据权利要求13的转子叶片,其在过渡区(30)的前缘(LE)处包括预铸可适应碳纤维梁(1)。
15.根据权利要求13或权利要求14的转子叶片(3),其在过渡区(30)的后缘(TE)处包括预铸可适应碳纤维梁(1)。
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