CN116529058A - 一种用于生产风力涡轮机的转子叶片的方法 - Google Patents

一种用于生产风力涡轮机的转子叶片的方法 Download PDF

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Publication number
CN116529058A
CN116529058A CN202180076592.3A CN202180076592A CN116529058A CN 116529058 A CN116529058 A CN 116529058A CN 202180076592 A CN202180076592 A CN 202180076592A CN 116529058 A CN116529058 A CN 116529058A
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China
Prior art keywords
rotor blade
resistive element
resin
components
thermoplastic
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CN202180076592.3A
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English (en)
Inventor
K·阿斯兰纳
M·博斯布姆
J·J·加兹泰卢门迪勒库奥纳
F·J·耶罗-奥拉巴里亚萨尔加多
H·明尼玛
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Siemens Gamesa Renewable Energy Innovation and Technology SL
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Siemens Gamesa Renewable Energy Innovation and Technology SL
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Publication of CN116529058A publication Critical patent/CN116529058A/zh
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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
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/34—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement"
    • B29C65/3404—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" characterised by the type of heated elements which remain in the joint
    • B29C65/342—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" characterised by the type of heated elements which remain in the joint comprising at least a single wire, e.g. in the form of a winding
    • B29C65/3432—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" characterised by the type of heated elements which remain in the joint comprising at least a single wire, e.g. in the form of a winding comprising several wires, e.g. in the form of several independent windings
    • 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
    • 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
    • B29C65/34—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement"
    • B29C65/3404—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" characterised by the type of heated elements which remain in the joint
    • B29C65/344—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" characterised by the type of heated elements which remain in the joint being a woven or non-woven fabric or being a mesh
    • 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
    • B29C65/34—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement"
    • B29C65/3472—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" characterised by the composition of the heated elements which remain in the joint
    • B29C65/3476—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" characterised by the composition of the heated elements which remain in the joint being metallic
    • 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
    • B29C65/34—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement"
    • B29C65/3472—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" characterised by the composition of the heated elements which remain in the joint
    • B29C65/3476—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" characterised by the composition of the heated elements which remain in the joint being metallic
    • B29C65/348—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" characterised by the composition of the heated elements which remain in the joint being metallic with a polymer coating
    • 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
    • B29C65/34—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement"
    • B29C65/3472—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" characterised by the composition of the heated elements which remain in the joint
    • B29C65/3484—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" characterised by the composition of the heated elements which remain in the joint being non-metallic
    • B29C65/3492—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" characterised by the composition of the heated elements which remain in the joint being non-metallic being carbon
    • 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
    • B29C65/34—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement"
    • B29C65/3472—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" characterised by the composition of the heated elements which remain in the joint
    • B29C65/3484—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" characterised by the composition of the heated elements which remain in the joint being non-metallic
    • B29C65/3496—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" characterised by the composition of the heated elements which remain in the joint being non-metallic with a coating, e.g. a metallic or a carbon coating
    • 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
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/50—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like
    • B29C65/5007—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like characterised by the structure of said adhesive tape, threads or the like
    • B29C65/5035—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like characterised by the structure of said adhesive tape, threads or the like being in thread form, i.e. in the form of a single filament, e.g. in the form of a single coated filament
    • 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
    • B29C65/50—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like
    • B29C65/5057—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like positioned between the surfaces to be joined
    • 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
    • B29C65/70—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by moulding
    • 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
    • B29C66/1142—Single butt to 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
    • B29C66/13—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
    • 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
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/303—Particular design of joint configurations the joint involving an anchoring effect
    • B29C66/3034—Particular design of joint configurations the joint involving an anchoring effect making use of additional elements, e.g. meshes
    • B29C66/30341—Particular design of joint configurations the joint involving an anchoring effect making use of additional elements, e.g. meshes non-integral with the parts to be joined, e.g. making use of extra 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
    • B29C66/52—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
    • B29C66/63—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
    • 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
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    • 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
    • B29C65/34—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement"
    • B29C65/36—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction
    • B29C65/3604—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction characterised by the type of elements heated by induction which remain in the joint
    • B29C65/362—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction characterised by the type of elements heated by induction which remain in the joint comprising at least a single wire, e.g. in the form of a winding
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Abstract

一种用于生产风力涡轮机(1)的转子叶片(5)的方法，该方法包括以下步骤：a)提供(S1)转子叶片(5)的至少两个不同部件(9、10、11)，b)将电阻元件(22)放置(S2)在部件(9、10、11)之间，c)将热塑性或可焊接的热固性树脂放置(S3)在部件(9、10、11)之间，d)使电阻元件(22)通电(S4)使得电阻元件(22)向热塑性或可焊接的热固性树脂施加热(H)以使其熔化或软化，以及(e)借助于熔化或软化的热塑性或可焊接的热固性树脂将部件(9、10、11)联接(S5)在一起。与使用比如环氧树脂的热固性树脂的已知连接方法相比，该方法允许在更短的时间内连接转子叶片(5)的部件(9、10、11)。一旦树脂通过电阻焊接工艺被熔化，就以所必需的量和形式添加树脂以补偿部件(9、10、11)之间的间隙。整个转子叶片(5)能够使用具有旋转及闭合系统的模具(30)在单次操作中焊接。

Description

一种用于生产风力涡轮机的转子叶片的方法
技术领域
本发明涉及一种用于生产风力涡轮机的转子叶片的方法。
背景技术
现代风力涡轮机转子叶片是由纤维增强塑料构建成的。转子叶片通常包括具有圆化前缘以及尖锐后缘的翼型。转子叶片以其叶片根部连接到风力涡轮机的轮毂。此外，转子叶片借助于允许转子叶片的俯仰运动的变桨轴承(pitch bearing)连接到轮毂。长的转子叶片经历高风力。这种类型的转子叶片能够具有超过60米的长度。
转子叶片是中空组合结构，其旨在是尽可能轻质并且坚硬的，以最大化从风转移到风力涡轮机的发电机的机械能。为了制造中空结构，最普遍使用的材料为复合材料，其中增强纤维被嵌入聚合物基体内。迄今为止，所使用的聚合物通常为热固性塑料，由于分子本性，其一旦固化到最终形状，就不能后成形或再熔化，并且是不可回收的。
发明内容
本发明的一个目的是提供一种用于生产风力涡轮机的转子叶片的改进方法。
据此，提供了用于生产风力涡轮机的转子叶片的方法。该方法包括以下步骤：a)提供转子叶片的至少两个不同部件，b)将电阻元件放置在部件之间，c)将热塑性或可焊接的热固性树脂放置在部件之间，d)使电阻元件通电，使得电阻元件向热塑性或可焊接的热固性树脂施加热以将其熔化或软化，以及e)借助于熔化或软化的热塑性或可焊接的热固性树脂将部件联接在一起。
由于使用了电阻元件和热塑性或可焊接的热固性树脂，可能非常快速地并且在不需要固化环氧树脂的情况下将部件联接在一起。转子叶片能够被分成部件或子模块并且能够在施工现场上被组装。这改进了转子叶片的可运输性，因为部件能够比整个转子叶片更容易地运输。
该方法也可用于将转子叶片的预组装的子模块联接在一起。例如，转子叶片可以沿其纵向方向分为部件或子模块，其能够在施工现场上借助于该方法被联接。在本上下文中的“子模块”或“部件”意指转子叶片包括一起形成转子叶片的多个子模块或部件。术语“部件”和“子模块”能够相互代替。提供部件包括制造该部件。
在本上下文中的“电阻元件”意指导电性的元件，并且其能够借助于向该电阻元件施加的电流产生热。电阻元件可以是加热装置的一部分。加热装置包括电阻元件、电压源或能量源以及用于将电压源连接到电阻元件的导线。将电阻元件“放置”在部件之间意指电阻元件作为外部部分被布置在必须被联接在一起的部件之间。可替代地，电阻元件也可以是部件中的一个的一部分。
热塑性树脂或热软化树脂是塑料聚合物材料，其在某升高温度下变得柔韧或可模塑，并且在冷却时凝固。热固性聚合物、树脂或塑料，通常被称为热固性，是一种通过从柔软的固体或粘稠的液体预聚物或树脂固化而不可逆转地硬化的聚合物。与这不同，可焊接的热固性树脂是一种材料，其至少能够通过施加热而被软化，使得可焊接的热固性树脂能够被用于将部件焊接在一起。优选地，热塑性或可焊接的热固性树脂能够作为外部部分放置在部件之间。可替代地，热塑性或可焊接的热固性树脂可以是一个或更多部件的一部分。
根据实施例，电阻元件被嵌入部件中的至少一个中。
这意指电阻元件是部件中的至少一个的一部分。可替代地，所有的部件都能够具有这种类型的电阻元件。在本上下文中的“嵌入”能够意指电阻元件被放置在部件的表面上或下方。
根据另一实施例，电阻元件具有导线或网的形式。
电阻元件能够由金属制成。例如，电阻元件是由铜制成的。可替代地，电阻元件能够由碳纤维制成。
根据另一实施例，在步骤c)中，将热塑性或可焊接的热固性树脂放置在呈树脂条的形式的部件之间。
优选地，树脂条是热塑性或可焊接的热固性树脂的连续条。该树脂条能够由纯树脂制成。可替代地，该树脂条可以是纤维增强但富含树脂的。
根据另一实施例，该树脂条是楔形的。
这允许填充必须被联接的部件之间的间隙。具体地，树脂条被用来封闭在转子叶片的后缘处的间隙。
根据另一实施例，在步骤c)中，通过在部件中的至少一个上形成富含树脂的表面层，将热塑性或可焊接的热固性树脂放置在部件之间。
这意指热塑性树脂或可焊接的热固性树脂是部件中的至少一个的一部分。所有部件都能够具有那种类型的富含树脂的表面层。在本上下文中的“富含树脂”意指纤维百分比低于90％，优选地低于80％，更优选地低于70％，更优选地低于60％，更优选地低于50％，更优选地低于40％，更优选地低于30％，更优选地低于20％，更优选地低于10％。
根据另一实施例，在步骤e)后，电阻元件仍保持在转子叶片中。
这意指电阻元件是转子叶片的整体部分。由此，在联接部件后，不将电阻元件从转子叶片移除。
根据另一实施例，电阻元件包括放置在部件之间的树脂涂覆的导线。
导线包括导电的芯以及由热塑性或可焊接的热固性树脂制成的涂层。芯能够由金属或碳纤维制成。当芯通电时，涂层熔化或软化，以将部件彼此联接。
根据另一实施例，在步骤d)和e)期间，向部件施加外部压力。
外部压力将部件压在一起，使得熔化或软化的热塑性或可焊接的热固性树脂将部件连接在一起。
根据另一实施例，借助于模具施加外部压力。
具体地，借助于整合在模具内的夹持系统施加外部压力。
本发明的另外的可能的实施方案或替代解决方案也涵盖上文或下文关于实施例所描述的特征的组合(本文中没有明确提及)。本领域技术人员也可以对本发明的最基本形式增加单个或单独的方面和特征。
附图说明
本发明的另外的实施例、特征和优势将结合附图从后续描述和从属权利要求中变得显而易见到，附图中：
图1示出了根据一个实施例的风力涡轮机的透视图；
图2示出了根据一个实施例的转子叶片的透视图；
图3示出了根据图2的转子叶片的分解图；
图4示出了沿图2的截交线IV—IV的风力涡轮机转子叶片的横截面视图；
图5示出了根据图4的详细视图V；
图6再次示出了根据图4的详细视图V；
图7再次示出了根据图4的详细视图V；
图8示出了根据图2的转子叶片的分解透视细节图；
图9示出了根据图2的转子叶片的另一分解透视细节图；
图10示出了根据一个实施例的树脂涂覆的导线的横截面视图；
图11示出了根据图2的转子叶片的另一分解透视细节图；
图12示出了根据图2的转子叶片的透视细节图；
图13示出了根据图2的转子叶片的另一透视细节图；
图14示出了根据图2的转子叶片的另一透视细节图；以及
图15示出了用于生产根据图2的转子叶片的方法的一个实施例的框图。
在图中，除非另有指示，否则同样的附图标记指示同样或功能等同的元件。
具体实施方式
图1示出了根据一个实施例的风力涡轮机1。
“风力涡轮机”目前指代将风的动能转换为旋转能的装置，旋转能可再次通过该装置转换为电能。
风力涡轮机1包括连接到发电机(未示出)的转子2，该发电机布置在机舱3内部。机舱3被布置在风力涡轮机1的塔架4的上端部处。
转子2包括三个转子叶片5。转子叶片5连接到风力涡轮机1的轮毂6。这种类型的转子2可以具有范围从例如30至160米或甚至更大的直径。转子叶片5承受高风载荷。与此同时，转子叶片5需要是轻质的。出于这些原因，现代风力涡轮机1中的转子叶片5是由纤维增强复合材料制造的。通常情况下，使用呈单向纤维铺层的形式的玻璃纤维。
图2示出了根据一个实施例的转子叶片5。
转子叶片5包括空气动力学地设计的部分7，其形状适合于风能的最佳利用，以及用于将转子叶片5连接到轮毂6的叶片根部8。转子叶片5包括纵向方向L。纵向方向L沿空气动力学地设计的部分7的方向从叶片根部8开始。然而，纵向方向L也能够反之取向。
这些转子叶片5是中空组合结构，其旨在是尽可能轻质并且坚硬的，以最大化从风转移到发电机的机械能。为了制造中空结构，最普遍使用的材料为复合材料，其中增强纤维被嵌入聚合物基体内。迄今为止，所使用的聚合物通常为热固性塑料，由于分子本性，其一旦固化到最终形状，就不能后成形、联接或再熔化，并且是不可回收的。这些材料也不易钻孔并且对于常规紧固元件而言具有不良的载荷承载能力，由于超过60米长的当前转子叶片的庞大规模以及低重量的要求，该机械紧固方法也是不切实际的。由此，转子叶片的尺寸与低重量的要求相互冲突。
图3示出了转子叶片5的分解视图。
到目前为止，联接、粘接或焊接转子叶片5的中空结构的选项限制于或者在技术复杂并且要求专门工具装备的一次成型(one-shot molding)工艺中形成整个结构，或者借助于也使用热固性材料执行的粘合剂粘接工艺联接子部分—最常见地为叶片半壳体9、10。
转子叶片5的第一半壳体9以平行于第二半壳体10的方式被制造并且固化。然后，使用所述粘合剂将两个半壳体9、10以及附加结构元件11或若干结构元件11，诸如抗剪腹板或翼梁帽联接在一起。这种粘合剂以及所得的粘接线是一种材料，其也是不可回收的并且增加了重量，并且为转子叶片5的结构带来了潜在故障点。更一般地，半壳体9、10以及结构元件11可以被称为转子叶片5的“部件”。
联接工艺牵涉粘合剂膏的应用，其为要求混合与计量装备以及用于分配的加压泵的多成分系统，借助于牵涉转子叶片5的模具闭合操作实现粘接表面的物理联接，在升高的温度下固化粘合剂并且冷却以允许转子叶片5的脱模以及进一步加工。然后，转子叶片5在联接区上的拼合线必须用另外的玻璃纤维织物增强件以及树脂在内部和外部两者均被增强，以限制由粘合线引起的结构弱点。
由于转子叶片5的部件是通过湿法敷涂或在大型模具中的真空辅助灌注成型中的任一者制造的，所得的尺寸公差不允许所有部件的严密定位，从而导致在拼合线处的需要用粘合剂填充的间隙，从而进一步降低接头的机械性能并且增加重量。因此，改进这种工艺是期望的。
图4示出了根据图2中的截交线IV—IV的改进的转子叶片5的横截面视图。
转子叶片5具有包括第一半壳体9以及第二半壳体10的外叶片壳体12，第一半壳体9以及第二半壳体10在转子叶片5的前缘13处连接到彼此。半壳体9、10也在转子叶片5的后缘14处连接到彼此。外叶片壳体12可以包括复合纤维材料，特别是玻璃纤维铺层。该纤维材料用聚合材料浸渍，特别是用热塑性或可焊接的热固性树脂浸渍。第一半壳体9构成转子叶片5的吸力侧。第二半壳体10构成转子叶片5的压力侧。
第一半壳体9包括内表面15，并且第二半壳体10包括内表面16，内表面15、16彼此相对且面向彼此地布置。转子叶片5的内空间17借助于内表面15、16限定。结构元件11位于从第一半壳体9的内表面15延伸到第二半壳体10的内表面16的内空间17内部。
结构元件11沿纵向方向L伸展。结构元件11优选地包括纤维复合材料，具体地玻璃纤维铺层。该结构元件11可以是抗剪腹板、翼梁帽等。特别地，结构元件11为包括附接到内表面15、16的两个凸缘18、19以及将凸缘18、19连接到彼此的腹板20的抗剪腹板。
图5示出了根据图4中的细节图V的转子叶片5的分解细节图。
结构元件11的凸缘18具有面对转子叶片5的第一半壳体9的内表面15的表面21。转子叶片5包括电阻元件22。电阻元件22可以是结构元件11的一部分或第一半壳体9的一部分。电阻元件22可以嵌入表面21中或内表面15中。如在图5中能够看出的，电阻元件22被嵌入结构元件11的表面21中。然而，图5仅示出了转子叶片5的示例性实施例。
电阻元件22包括一种导电材料，比如例如金属或碳纤维。铜能够用作材料。例如，电阻元件22包括树脂涂覆的导线或树脂涂覆的网。电阻元件22具有连接部23、24。电压源25经由导线26、27连接到连接部23、24。电阻元件22、连接部23、24、电压源25以及导线26、27形成转子叶片5的加热装置28。导线26、27是可选的。电阻元件22也能够借助于感应被供能。
转子叶片5能够包括若干加热装置28。例如，结构元件11的每个凸缘18、19以及后缘14均具有那种类型的加热装置28。而且，前缘13能够具有加热装置28。
此外，提供了固体树脂条29。该树脂条29可以是富含树脂的纤维材料。树脂条29也可以是纯树脂。树脂是一种热塑性或可焊接的热固性树脂。电阻元件22能够被嵌入树脂条29中，或者可以是放置在半壳体9、10之间的单独的材料。转子叶片5的部件能够借助于通过电阻元件22的电压被加热，电阻元件22通过焦耳效应(Joule Effect)生成热。树脂条29优选地具有大约6±2mm的正常间隙厚度。
图6再次示出了根据图4的细节图V。
为了将结构元件11以及第一半壳体9连接到彼此，借助于模具30或真空袋向结构元件11以及第一半壳体9施加机械压力p。压力p优选地借助于模具30的合模系统施加，如在已知的粘合剂粘接中完成的那样。
然后，加热装置28通过向电阻元件22施加电流被供能。以这种方式，电阻元件22向树脂条29施加热H。然后，树脂条29的树脂被充分软化、化学激活或熔融到足以形成连续接头，且然后被冷却，从而再次凝固为均质的层压件。在加热树脂条29的期间，仍然施加压力p。
图7再次示出了根据图4的细节图V。
冷却后，转子叶片5被脱模。焊接工艺已经完成。结构元件11与第一半壳体9之间所得的接头是均质并且连续的层压件。导线26、27从连接部23、24移除并且转子叶片5可以被进一步加工。
图8示出了转子叶片5的分解透视细节图。
具体地，图8示出了转子叶片5的后缘14。如前面所提及的，树脂条29放置在第一半壳体9和第二半壳体10之间。电阻元件22(其如前面所提及的那样是加热装置28(未示出)的一部分)被嵌入第二半壳体10中，具体地在第二半壳体10的内表面16中。电阻元件22被灌注在内表面16中。可替代地，电阻元件22能够设置在第一半壳体9处或第一半壳体9中。半壳体9、10两者都能够具有电阻元件22。
树脂条29具有所要求的形状以填充后缘14中的设计间隙。树脂条29可以是楔形的。这允许如所要求的那样更好地适应于后缘14的设计间隙。电阻元件22可以是网或碳层。
图9示出了转子叶片5的另一分解透视细节图。
在这种情况下，电阻元件22包括树脂涂覆的导线31、32。电阻元件22被放置在半壳体9、10之间。电阻元件22也提供用于联接半壳体9、10的树脂。
图10是导线31的横截面视图。
导线31包括导电的芯33。芯33可以是金属导线或碳丝。芯33能够由铜制成。芯33涂覆有热塑性或可焊接的热固性树脂34。芯33用作电阻元件。
图11示出了转子叶片5的另一分解透视细节图。
在这种情况下，电阻元件22呈碳或金属网的形式。电阻元件22放置在半壳体9、10之间。热塑性树脂灌注在半壳体9、10的层压件中，从而形成表面的富含树脂的层35、36。该层35、36可以通过使电阻元件22通电而被熔化或软化，以将半壳体9、10联接到彼此。
图12示出了转子叶片5的透视细节图。
在将电阻元件22(未示出)以及树脂条29放置在半壳体9、10之间后，借助于模具30(未示出)向后缘14施加压力p。半壳体9、10两者的边缘都与树脂条29接触。
图13示出了转子叶片5的另一透视细节图。
在施加压力p的同时，通过向电阻元件22施加电流使电阻元件22(未示出)通电。电阻元件22向树脂条29施加热H。树脂条29熔化或得到足够的分子移动性和/或反应性以与半壳体9、10的层压件聚合。
图14示出了转子叶片5的另一透视细节图。
转子叶片5的热影响区冷却并且树脂粘合到其自身。外部压力p被移除，并且转子叶片5被脱模。均质且单基体复合物作为结果保持。
一旦树脂由电阻焊接工艺熔化，就以必要的量和形式添加树脂，以补偿比如半壳体9、10以及结构元件11的部件之间的间隙。整个转子叶片5可以使用具有旋转及闭合系统的模具30在单次操作中被焊接。压力p将借助于模具30、整合在模具30和/或外部工具装备中的系统施加。
整个工艺的周期时间将比标准联接工艺低一个数量级，其在几秒钟内完全完成。不应存在在任何时候添加的附加材料，并且所得的转子叶片5将与所使用的基体材料一样可回收，其在热塑性树脂的情况下，可能意指树脂的100％回收。
因为不需要用外来膏材料来填充，而且所得的层压件将是均质结构，因此转子叶片5的部件之间的间隙可以变得更小，由此接头的机械性能也将得到改进。
在非常短的周期时间内形成微观结构连续的层压件的能力可能能够实现叶片设计的模块化，从而使得可能避免使用目前的全尺寸模具，其完全打乱(disrupt)了叶片的当前设计以及制造，其中周期时间约为30小时/叶片可能变成远低于5小时/叶片。这也意指，大尺寸叶片当前所面临的运输挑战将被前文提及的工艺的现场应用避开。
图15示出了用于生产转子叶片5的方法的一个实施例的框图。
在步骤S1中，提供至少两个不同的部件，即转子叶片5的半壳体9、10和/或结构元件11。在本上下文中的“提供”可以包括生产这些部件，例如借助于纤维材料的敷涂工艺。在下文中，半壳体9、10以及结构元件11将被称为“部件”。
该方法的步骤S2包括将电阻元件22放置在部件9、10、11之间。如前面所提及的，电阻元件22可以是部件9、10、11中的至少一个的一部分。在步骤S3中，热塑性或可焊接的热固性树脂被放置在部件9、10、11之间。这可以以树脂条29的形式完成，如更前面解释的那样。
在步骤S4中，使电阻元件22通电，使得电阻元件22对热塑性或可焊接的热固性树脂施加热H以使其熔化或软化。借助于加热装置28使电阻元件22通电。步骤S5包括借助于熔化或软化的热塑性或可焊接的热固性树脂将部件9、10、11联接在一起。以这种方式，形成转子叶片5。而且，能够以这种方式形成转子叶片5的子模块。在步骤S4以及S5期间，向部件9、10、11施加压力p。
尽管已经根据优选的实施例描述了本发明，但对本领域技术人员来说明显的是，在所有实施例中改型都是可能的。

Claims (10)

1.一种用于生产风力涡轮机(1)的转子叶片(5)的方法，所述方法包括以下步骤：
a)提供(S1)所述转子叶片(5)的至少两个不同的部件(9、10、11)；
b)将电阻元件(22)放置(S2)在所述部件(9、10、11)之间；
c)将热塑性或可焊接的热固性树脂放置(S3)在所述部件(9、10、11)之间；
d)使所述电阻元件(22)通电(S4)，使得所述电阻元件(22)向所述热塑性或可焊接的热固性树脂施加热(H)以使其熔化或软化，以及
e)借助于熔化或软化的所述热塑性或可焊接的热固性树脂将所述部件(9、10、11)联接(S5)在一起。
2.根据权利要求1所述的方法，其中，所述电阻元件(22)被嵌入所述部件(9、10、11)中的至少一个中。
3.根据权利要求1或2所述的方法，其中，所述电阻元件(22)具有导线或网的形式。
4.根据权利要求1至3中的任一项所述的方法，其中，在步骤c)中，所述热塑性或可焊接的热固性树脂以树脂条(29)的形式放置在所述部件(9、10、11)之间。
5.根据权利要求4所述的方法，其中，所述树脂条(29)是楔形的。
6.根据权利要求1至3中的任一项所述的方法，其中，在步骤c)中，所述热塑性或可焊接的热固性树脂通过在所述部件(9、10、11)中的至少一个上形成富含树脂的表面层(35、36)被放置在所述部件(9、10、11)之间。
7.根据权利要求1至6中的任一项所述的方法，其中，在步骤e)之后，所述电阻元件(22)保持在所述转子叶片(5)中。
8.根据权利要求1所述的方法，其中，所述电阻元件(22)包括放置在所述部件(9、10、11)之间的树脂涂覆的导线(31、32)。
9.根据权利要求1至8中的任一项所述的方法，其中，在步骤d)和e)期间，向所述部件(9、10、11)施加外部压力(p)。
10.根据权利要求9所述的方法，其中，借助于模具(30)施加所述外部压力(p)。
CN202180076592.3A 2020-11-13 2021-11-02 一种用于生产风力涡轮机的转子叶片的方法 Pending CN116529058A (zh)

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