CN116547128A - 在抗剪腹板与壳体之间具有改进的粘接接头的风力涡轮机叶片 - Google Patents
在抗剪腹板与壳体之间具有改进的粘接接头的风力涡轮机叶片 Download PDFInfo
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- CN116547128A CN116547128A CN202180076223.4A CN202180076223A CN116547128A CN 116547128 A CN116547128 A CN 116547128A CN 202180076223 A CN202180076223 A CN 202180076223A CN 116547128 A CN116547128 A CN 116547128A
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Abstract
在本发明的第一方面中,提供了一种风力涡轮机叶片,其包括壳体和连接在壳体的迎风内表面和壳体的背风内表面之间的抗剪腹板。抗剪腹板包括长形腹板面板和承载凸缘,该承载凸缘从腹板面板的第一侧横向延伸,以将抗剪腹板连接到壳体的迎风内表面或背风内表面。叶片还包括从腹板的第二侧横向延伸的至少一个非结构凸缘。非结构凸缘具有与壳体的迎风内表面或背风内表面以相对关系布置的基本上平面的粘合剂接收部分。承载凸缘和非结构凸缘由不同的材料形成。
Description
技术领域
本发明总体上涉及风力涡轮机,并且更具体地涉及风力涡轮机叶片。
背景技术
现代风力涡轮机叶片通常包括限定叶片的空气动力学轮廓的壳体以及用作叶片的主要承载结构的一个或多个纵向延伸的翼梁。翼梁典型地包括抗剪腹板,该抗剪腹板被构造成吸收风力涡轮机叶片在使用中经受的剪切载荷。抗剪腹板可以包括上凸缘和下凸缘,腹板经由上凸缘和下凸缘粘合地结合到壳体的内表面。凸缘可以从腹板面板延伸,使得抗剪腹板在横截面中基本上呈C形。
在制造之后,可以使用非破坏性测试(NDT)方法例行地从壳体的外部检查风力涡轮机叶片。这样的测试可以例如涉及发射超声波或其它高频信号通过叶片壳体,并且测量反射信号以建立壳体中和叶片内的材料布置的图像。超声信号在材料与较不致密材料(诸如空气)之间的边界处被反射。NDT方法可用于确定抗剪腹板在壳体内的位置,和/或评估抗剪腹板和壳体之间的接头。
然而,在一些情况下,使用NDT方法测量这些标准可能是具有挑战性的。例如,上凸缘和壳体之间的多余粘合剂可能落在下凸缘上或附近的壳体的下部内表面上,并且这种粘合剂可能干扰下壳体的NDT测试。此外,如果粘合剂从上凸缘和壳体之间被挤出,则这可能导致剩余的粘合剂不足以将腹板完全结合到壳体。这是C形抗剪腹板的特有问题,其中在腹板的跟部附近缺少粘合剂可能限制壳体和腹板面板之间的有效载荷传递。另外,如果在腹板的跟部附近缺少粘合剂,则NDT信号可能不像预期那样被反射以便于由NDT机器进行结论性读数。
针对该背景,已经开发了本发明。
发明内容
在本发明的第一方面中,提供了一种风力涡轮机叶片,其包括壳体和连接在壳体的迎风内表面和壳体的背风内表面之间的抗剪腹板。抗剪腹板包括长形腹板面板和承载凸缘,该承载凸缘从腹板面板的第一侧横向延伸,以将抗剪腹板连接到壳体的迎风内表面或背风内表面。叶片还包括从腹板面板的第二侧横向延伸的至少一个非结构凸缘。非结构凸缘具有与壳体的迎风内表面或背风内表面以相对关系布置的基本上平面的粘合剂接收部分。承载凸缘和非结构凸缘由不同的材料形成。
承载凸缘可包括增强纤维。优选地,承载凸缘由纤维增强聚合物材料形成。承载凸缘可以由玻璃纤维增强塑料(GFRP)形成。
非结构凸缘可以不包括增强纤维。非结构凸缘可以由非增强聚合物材料形成。优选地,所述非结构凸缘采用塑料挤压工艺形成。
非结构凸缘的粘合剂接收部分可以具有至少12.5mm的宽度。优选地,粘合剂接收部分具有至少25mm的宽度。更优选地,粘合剂接收部分可具有至少30mm的宽度。
非结构凸缘的近端可以连接到腹板面板。非结构凸缘可包括厚度渐缩的远侧凸缘末端。非结构凸缘可包括相对于粘合剂接收部分倾斜的远侧凸缘末端。优选地,远侧凸缘末端朝向壳体的相对的迎风内表面或背风内表面倾斜。
承载凸缘可以与腹板面板成一体。非结构凸缘可以不与腹板面板成一体。
非结构凸缘可以是至少部分透明或半透明的。
非结构凸缘的粘合剂接收部分与壳体的迎风内表面或背风内表面间隔开的距离可以大于承载凸缘与壳体的同一迎风内表面或背风内表面之间的距离。
非结构凸缘的粘合剂接收部分可以与承载凸缘基本上共面。
非结构凸缘可以由基本上柔性的材料形成。优选地,非结构凸缘由弹性模量小于10GPa,更优选小于5GPa,并且最优选小于2.5GPa的材料形成。优选地,在叶片的制造期间,非结构凸缘的粘合剂接收部分可相对于腹板面板枢转。
非结构凸缘的横截面轮廓可以沿着抗剪腹板的长度变化。非结构凸缘的横截面轮廓可以沿着抗剪腹板的长度以逐步的方式变化。
非结构凸缘可以由沿着抗剪腹板的长度以端对端方式布置的多个纵向凸缘区段形成。每个非结构凸缘区段可包括沿其相应纵向轴线基本恒定的横截面轮廓。至少两个纵向相邻的凸缘区段可包括不同的横截面轮廓。
风力涡轮机叶片可包括第一非结构凸缘,该第一非结构凸缘具有与壳体的迎风内表面以相对关系布置的基本上平面的粘合剂接收部分,并且可进一步包括第二非结构凸缘,该第二非结构凸缘具有与壳体的背风内表面以相对关系布置的基本上平面的粘合剂接收部分。第一非结构凸缘和第二非结构凸缘的粘合剂接收部分可以从共用凸缘杆横向延伸。非结构凸缘可以经由共用凸缘杆连接到抗剪腹板。
附图说明
现在将参考附图仅通过非限制性示例来描述本发明的实施例,其中:
图1是包括壳体和布置在壳体内部的抗剪腹板的风力涡轮机叶片的示意性透视图;
图2a是风力涡轮机叶片的示意性剖视图,示出了连接到抗剪腹板的多个非结构凸缘;
图2b是抗剪腹板的上承载凸缘和非结构凸缘的放大图;
图3是示出具有倾斜远侧凸缘末端的非结构凸缘的示意性剖视图;
图4是示出非结构凸缘的示意性剖视图,该非结构凸缘的厚度朝向凸缘的远侧边缘逐渐减小;
图5a是在布置在叶片中之前连接到抗剪腹板的多个柔性非结构凸缘的示意性剖视图;
图5b是具有柔性非结构凸缘的叶片的示意性剖视图,该柔性非结构凸缘与壳体的内表面以相对关系布置;
图6a是抗剪腹板和由多个纵向凸缘区段形成的非结构凸缘的示意性透视图,所述多个纵向凸缘区段沿着腹板以端对端方式布置;
图6b是示出非结构凸缘并且以不同倾角指示多个粘合剂接收部分的示意性剖视图;以及
图7是抗剪腹板的示意性剖视图,第一和第二非结构凸缘经由共用凸缘杆连接到抗剪腹板。
具体实施方式
图1是风力涡轮机叶片10的示意性透视图。叶片10在根端12和末梢端14之间沿翼展方向(S)延伸,并且在前缘16和后缘18之间沿翼弦方向(C)延伸。叶片10包括壳体20,壳体20可由接合在一起的第一半壳22a和第二半壳22b形成。在图1所示的示例中,第一半壳22a限定叶片10的迎风侧24a,第二半壳22b限定叶片10的背风侧24b。
叶片10还包括抗剪腹板26,抗剪腹板26在壳体20内部沿翼展方向(S)纵向延伸并且形成加强翼梁结构的一部分。抗剪腹板26有助于吸收风力涡轮机叶片10在使用中所经受的结构载荷,特别是剪切载荷。叶片10可包括多个抗剪腹板26,例如主抗剪腹板26a和后缘抗剪腹板26b。抗剪腹板26在图2a的剖视图中更清楚地示出。
现在参考图2a,抗剪腹板26各自包括在承载凸缘30之间延伸的长形腹板面板28,用于将抗剪腹板26连接到壳体20的内表面32。例如,抗剪腹板26可以包括用于将腹板26连接到壳体20的迎风内表面32a的第一承载凸缘30a,以及用于将抗剪腹板26连接到壳体20的背风内表面32b的第二承载凸缘30b。承载凸缘30a、30b从腹板面板28的第一侧34a横向延伸。因此,抗剪腹板26可具有大致C形的横截面轮廓。应当理解,本文对抗剪腹板26的引用同样适用于主抗剪腹板26a和后缘抗剪腹板26b。
每个承载凸缘30是构造成在壳体20和抗剪腹板面板28之间传递剪切载荷的结构部件。因此,承载凸缘30可以包括增强纤维,诸如玻璃纤维或碳纤维,以促进有效载荷传递。优选地,承载凸缘30中的增强纤维主要相对于抗剪腹板26的纵向轴线以偏移角(诸如+/-45度)定向。因此,承载凸缘30可以有效地传递剪切载荷,而基本上不承受叶片10所经受的弯曲载荷。
承载凸缘30可以例如包括聚合物树脂基质中的双轴纤维增强材料。在一些示例中,承载凸缘30可以与腹板面板28成一体。例如,抗剪腹板26可以采用复合模制工艺中形成,其中腹板面板28和用于承载凸缘30的纤维增强材料与树脂集成以形成具有整体承载凸缘30的抗剪腹板26。
抗剪腹板26通过粘合剂36连接到壳体20,粘合剂36将承载腹板凸缘30a、30b粘结到壳体20的相应内表面32a、32b,即,粘结到迎风内表面和背风内表面。抗剪腹板26在叶片10的制造期间结合到壳体20的内表面32a、32b,如现在将参照图2a简要描述的。
制造风力涡轮机叶片10可涉及分别形成第一半壳22a和第二半壳22b。每个半壳22可以采用复合材料制造方法形成,例如真空辅助树脂传递模塑(VARTM)。一旦形成,半壳22a、22b可以在接合过程中接合在一起以形成完整的壳体20。接合过程通常涉及将半壳22a、22b彼此上下布置以形成具有基本上中空内部38的壳体20。例如,迎风半壳22a可以布置在背风半壳22b的顶部,并且两个壳可以利用沿着前缘16和后缘18施加的粘合剂结合在一起。
在接合过程期间,一个或多个抗剪腹板26可以布置在半壳22a、22b之间并且例如通过粘合剂36连接在相应的内表面32a、32b之间。在一些示例中,所述或每个抗剪腹板26布置在两个半壳22的下部中,并且粘合剂36布置在下部承载腹板凸缘30b和半壳22b的内表面32b之间。粘合剂36还被布置成使得,当半壳22a、22b接合在一起时,上承载腹板凸缘30a连接到上半壳22a的内表面32a。例如,在形成完整的壳体20并且将抗剪腹板26夹在半壳22之间之前,粘合剂36可以布置在上承载凸缘30a上和/或上半壳22a的内表面32a上。
优选地,布置在承载凸缘30和壳体20的内表面32之间的粘合剂36延伸跨越凸缘30的整个宽度。特别地,粘合剂36应当优选地将抗剪腹板26的跟部部分40结合到壳体20的内表面32,在该处,承载凸缘30与腹板面板28相遇。将跟部部分40结合到壳体20通过最小化壳体20和腹板面板28之间的载荷路径的长度而促进了最佳载荷传递。在一些示例中,这可以涉及将腹板面板28的边缘结合到壳体20的内表面32。在其它示例中,这可以涉及将承载凸缘30的近侧边缘(最靠近腹板面板28的边缘)结合到壳体20的内表面32。
然而,在叶片10包括C形纤维腹板的示例中,结合过程可能引入如以上背景技术部分所述的复杂性。简要地参考上承载凸缘30a,如果粘合剂36从上承载凸缘30a和半壳22a之间被挤出,则该多余的粘合剂可能掉落并落在下半壳22b的内表面32b上。当检查成品叶片10时,这可能导致对非破坏性测试信号的干扰,从而导致不完整或不可靠的检查数据。粘合剂36也可能在固化之前从承载凸缘30a和半壳22a之间向下滑动。这可能导致跟部部分40没有完全结合到壳体20的情况,因为粘合剂36不再存在于跟部部分40和半壳22a的内表面32a之间。此外,多余的挤出粘合剂36可能在使用期间在叶片10内部松动。这种松散的粘合剂可能通过在使用中在叶片10中四处移动而引起附加噪声,并且可能潜在地损坏叶片10内的叶片内部和/或子部件。
为了克服上述挑战中的至少一些,根据本发明的风力涡轮机叶片10包括从腹板面板28的第二侧34b横向延伸的非结构凸缘42,如现在将参照其余附图描述的。在一些示例中,风力涡轮机叶片10可包括非结构凸缘42,其相对于壳体20的迎风内表面32a和背风内表面32b两者以相对关系布置,如图2a所示。
现在参考图2a和图2b,每个非结构凸缘42被配置为在叶片10的制造期间接收从抗剪腹板26与壳体20的相应迎风内表面32a或背风内表面32b之间挤出的多余粘合剂36。这样,非结构凸缘42包括与壳体20的相应内表面32以相对关系布置的粘合剂接收部分44。粘合剂接收部分44提供可供任何多余的挤出粘合剂36附着的表面。例如,如果迎风内表面32a在接合过程期间是上部内表面,则非结构凸缘42捕获从迎风内表面32a和上承载凸缘30a之间挤出的任何粘合剂36。因此,非结构凸缘42确保过剩的粘合剂36不会落到背风内表面32b上。
优选地,用于将抗剪腹板26粘结到壳体20的粘合剂36足够粘,使得粘合剂接收部分44的设置阻止了粘合剂36从腹板跟部40和壳体20之间掉落。值得注意的是,设置非结构凸缘42使得可以施加比将承载凸缘30结合到壳体20所需的更多的粘合剂36,而没有前面描述的多余挤出粘合剂36的缺点。施加多余的粘合剂36意味着粘合剂胶层可以在接合过程期间被压缩,在大致翼弦方向(C)上散布粘合剂36并且确保包括腹板26的跟部部分40的基本上整个凸缘30被彻底地结合到壳体20的内表面32。
粘合剂接收部分44基本上是平面的,并且提供了基本上平坦的表面,利用该表面反射非破坏性测试信号,在该示例中,非破坏性测试信号是超声测试信号。平坦表面确保从壳体20的外部朝向叶片内部38发射的非破坏性测试信号在与它们发射方向基本上相同的方向上反射回来。通过减小发射信号与其对应的反射信号(回波)之间的方向偏差,NDT装置能够捕获更多的返回信号,并且所收集的数据因此更清晰且更可靠。
优选地,粘合剂接收部分44的宽度根据非破坏性检测设备的分辨率来选择。在一些示例中,非结构凸缘42的平面粘合剂接收部分44具有至少12.5mm的宽度。这对应于由典型NDT设备(诸如FORCE技术AMS-71叶片阵列扫描仪)产生的图像中的一个像素表示的测量区域。根据测试设备的分辨率配置粘合剂接收部分44的宽度确保在收集的测试数据中反映反射信号,从而产生准确且可靠的图像。12.5mm的宽度还确保有足够的面积来接纳任何多余的粘合剂36。最优选地,粘合剂接收部分44的宽度为30mm,对应于NDT设备输出的结果数据中的两个以上像素。
在一些示例中,非结构凸缘42的粘合剂接收部分44可以基本上平行于其布置的壳体20的内表面32。这确保从壳体20外部引导到叶片10中的NDT信号从基本上平坦的表面反射并以极小偏差返回到测试设备。由于壳体20的复杂空气动力学轮廓,壳体20的内表面32的取向可相对于抗剪腹板面板28沿其长度变化。因此,非结构凸缘42的粘合剂接收部分44的倾斜度也可以相对于抗剪腹板面板28变化,以便在粘合剂接收部分44和壳体20的内表面32之间保持基本恒定的间隔。
抗剪腹板26被设计为,在半壳22a、22b接合在一起以形成壳体20之后,承载凸缘30a、30b之间的距离略小于壳体20的对应内表面32a、32b之间的距离。因此,抗剪腹板26被配置为在承载凸缘30与壳体20的内表面32之间留下用于给定厚度(例如5mm)的粘合胶层的空间。在一些示例中,粘合剂接收部分44与壳体20的内表面32间隔开的距离比承载凸缘30大。在接合过程中,非结构凸缘42和壳体20之间的增加的间隔减小了凸缘42和壳体20的内表面32之间的碰撞或接触的风险。增加的间隔还提供更大的容积,在该容积内接收多余的挤出粘合剂36。
非结构凸缘42的横截面可以是基本上L形的,例如在图2a和图2b中所示。因此,在一些示例中,非结构凸缘42包括从粘合剂接收部分44横向延伸的凸缘杆46。非结构凸缘42优选地与抗剪腹板面板28不成一体,即,非结构凸缘42优选地是连接到抗剪腹板26的单独形成的零件。非结构凸缘42可以经由凸缘杆46连接到抗剪腹板26。非结构凸缘42可以例如通过粘合剂连接到抗剪腹板26。这样,凸缘杆46可以结合到腹板面板28的第二侧34b。替代地或附加地,非结构凸缘42可以通过机械紧固装置(诸如螺栓连接)连接到抗剪腹板26。这样,凸缘杆46和腹板面板28可以包括孔(未示出)以接收螺栓。
非结构凸缘42被具体设计成不在壳体20和抗剪腹板26之间传递载荷。这样,非结构凸缘42由与制成承载凸缘30的材料不同的材料制成。优选地,非结构凸缘42不包括增强纤维,因此不承受承载凸缘30被具体地构造用以传递的任何载荷。非结构凸缘42可例如由聚合物材料形成,优选为非增强聚合物材料,诸如丙烯腈丁二烯苯乙烯(ABS)。因此,具有高可重复性的具有成本效益的制造工艺(诸如挤出或注塑模制)可用于形成非结构凸缘42。
在一些示例中,非结构凸缘42由足够柔性的材料形成,以允许粘合剂接收部分44在叶片10的制造期间相对于抗剪腹板面板28枢转。这样,如果非结构凸缘42在接合过程中由于某种原因接触壳体20,则粘合剂接收部分44可以简单地偏转。因此,非结构凸缘42和壳体20之间的任何接触不会导致抗剪腹板26移动离位,因为粘合剂接收部分44可以简单地在接触时偏转。此外,非结构凸缘42的柔性确保凸缘在与壳体20接触的情况下不会受损。优选地,在非结构凸缘42足够柔性的示例中,其由杨氏模量小于10GPa的材料形成。
在一些示例中,粘合剂接收部分44和凸缘杆46之间的拐角的几何形状可以被具体地配置为充当铰链,以便允许粘合剂接收部分44相对于凸缘杆46枢转。例如,粘合剂接收部分44和杆46之间的拐角的半径以及凸缘42的厚度可以被配置成使得拐角相对于杆46和/或粘合剂接收部分44具有增加的柔性。这样,在这样的示例中,非结构凸缘42和壳体20之间的任何接触将导致粘合剂接收部分44围绕拐角枢转。
在一些示例中,非结构凸缘42的横截面轮廓可以适于提供多个附加益处,如现在将参考其余附图描述的。
参考图3,非结构凸缘42的近侧边缘48和远侧边缘50关于它们相对于抗剪腹板面板28的接近度而被限定。例如,非结构凸缘42的近侧边缘48可以连接到抗剪腹板面板28,或者可以至少与腹板面板28接触。在一些示例中,非结构凸缘42的远侧边缘50可以是“自由端”或“无支撑端”,如图3所示。
非结构凸缘42的远侧边缘50可由远侧凸缘末端52限定。如图3所示,在一些示例中,远侧凸缘末端52可以相对于粘合剂接收部分44倾斜。倾斜的远侧凸缘末端52可以通过提供屏障来阻挡粘合剂以防粘合剂从非结构凸缘42滑落来帮助将多余的挤出粘合剂36容纳在粘合剂接收部分44上。倾斜的远侧凸缘末端52在粘合剂接收部分44例如沿着后缘抗剪腹板26b以小于90°(度)定向到抗剪腹板面板28的示例中可以是特别有利的。
在接合过程期间在非结构凸缘42和壳体20之间的任何潜在接触最可能发生在远侧边缘50处。因此,在一些示例中,远侧凸缘末端52可以附加地或替代地在厚度上朝向远侧边缘50渐缩。减小远侧凸缘末端52的厚度增加了其柔性,并且有利于末端52在与壳体20可能接触时偏转,而不损坏凸缘42或不使抗剪腹板26在壳体20内移动。
如上文参考图2a和图2b所述,并且如图3所示,当从横截面观察时,非结构凸缘42的粘合剂接收部分44可以基本上平行于壳体20的内表面32。粘合剂接收部分44相对于腹板面板28的倾斜度可以沿着腹板26的长度变化,以根据内表面32的倾斜度的变化来保持非结构凸缘42和壳体20之间的恒定间隔。然而,对于所有非结构凸缘42来说不一定如此。例如,粘合剂接收部分44相对于腹板面板28的倾斜度可以沿着腹板26的长度基本上恒定,即,非结构凸缘44可以沿其长度具有基本上恒定的横截面轮廓。这样,在内表面32相对于腹板面板28的倾斜度沿着腹板26的长度变化的情况下,在叶片10的一些翼展部分中,粘合剂接收部分44可以不平行于内表面3,如图4所示。
非结构凸缘42的粘合剂接收部分44可以沿着凸缘42的长度以基本上匹配内表面32相对于腹板面板28的平均倾斜度的角度倾斜。这样,粘合剂接收部分44可以相对于腹板面板28以“最佳配合”角度倾斜。这可以便于使用单个标准部件,这使得非结构凸缘42与腹板26的组装是相对直接的过程,并且还意味着凸缘42可以以成本有效的方式批量生产或批量制造。虽然图4中的粘合剂接收部分44被定向为基本上垂直于抗剪腹板面板28的第二侧34b,但是应当理解,粘合剂接收部分44可以以任何合适的倾斜度定向。
优选地,非结构凸缘42的远侧边缘50可以与对应的承载凸缘30的平面基本上对准。因此,在接合过程期间,当腹板26被夹在半壳22a、22b之间时,非结构凸缘42的远侧边缘50可以非常接近壳体20的内表面32或与壳体20的内表面32轻接触。这可有助于在非结构凸缘42上容纳挤出粘合剂36。远侧凸缘非结构凸缘42可另外包括倾斜的远侧凸缘末端52(参见图3)以进一步包含如前所述的粘合剂36。
在非结构凸缘42沿其长度具有基本上恒定的横截面轮廓的示例中,非结构凸缘42具有一定程度的柔性是特别有益的。这可以允许粘合剂接收部分44使其倾斜度适应壳体20的内表面32沿着腹板26的长度的变化的倾斜度。因此,当非结构凸缘42与壳体20的内表面32接触时,柔性凸缘42和抗剪腹板26不被损坏。如先前通过使凸缘42的厚度朝向远侧边缘50渐缩和/或通过形成柔性材料的非结构凸缘42和/或通过配置粘合剂接收部分44与凸缘杆46之间的拐角的几何形状以充当如上所述的铰链,可以实现增加的凸缘柔性。
图5a和图5b的剖视图中所示的非结构凸缘42被有意地构造成在接合过程期间接触壳体20的内表面32。图5a示出了在腹板26被布置在壳体20内部之前连接到抗剪腹板26并且处于中性状态的非结构凸缘42。图5b示出了在接合过程之后壳体20内部的腹板26和非结构凸缘42。
参考图5a和图5b两者,非结构凸缘42可以被配置成在接合过程期间基本上偏转。壳体20的内表面32和非结构凸缘42的粘合剂接收部分44之间的接触导致粘合剂接收部分44朝向叶片10的内部38偏转。粘合剂接收部分44相对于抗剪腹板面板28枢转以符合壳体20的内表面32的倾斜度。非结构凸缘42沿其长度可以具有基本上恒定的横截面轮廓,因为粘合剂接收部分44的偏转可以确保,与壳体20的接触不会损坏非结构凸缘42。
在这种示例中,非结构凸缘42优选地由足够柔性的材料形成,以允许粘合剂接收部分44在与壳体20接触时偏转。在一些示例中,由于来自粘合剂接收部分44与壳体20的内表面32之间的过量挤出粘合剂36的反压力,粘合剂接收部分44可以朝向叶片内部38偏转。因此,在一些示例中,非结构凸缘42可以在壳体20和粘合剂接收部分44之间没有直接接触的情况下偏转。
现在参考图6a,非结构凸缘42可以由多个纵向凸缘区段54形成。在这样的示例中,凸缘区段54优选地沿着抗剪腹板26的长度以端对端方式布置。纵向相邻的凸缘区段54优选地彼此对接,以确保多余的挤出粘合剂36被包含在凸缘42的粘合剂接收部分44上,并且不会掉落穿过凸缘区段54之间的间隙。如图6a所示,在一些示例中,凸缘区段54可以具有基本上相同的横截面轮廓。
替代地,凸缘区段54可以根据它们沿着抗剪腹板26的长度的相应位置而具有不同的横截面轮廓。例如,图6b中的虚线轮廓示出了凸缘区段54的粘合剂接收部分44相对于抗剪腹板面板28的不同倾斜度。此外,每个单独的凸缘区段54可以具有从相应的凸缘区段54的第一端56到第二端58的基本上恒定的横截面轮廓。每个纵向凸缘区段54的横截面轮廓可以根据壳体20的内表面32的对应部分相对于腹板面板28的倾斜度来配置。因此,在一些示例中,纵向相邻的凸缘区段54可包括不同的横截面轮廓。因此,非结构凸缘42的横截面轮廓可以沿着抗剪腹板26的长度以逐步的方式变化。
在一些示例中,风力涡轮机叶片10可包括共用公共凸缘杆60的第一非结构凸缘42a和第二非结构凸缘42b,如图7所示。在这样的示例中,第一非结构凸缘42a和第二非结构凸缘42b基本上组合成具有公共凸缘杆60的单个部件。这样,第一和第二非结构凸缘42a、42b的粘合剂接收部分44a、44b从同一共用凸缘杆60横向延伸。粘合剂接收部分44a、44b被配置为与壳体20的迎风内表面32a和背风内表面32b中的每一个以相对关系布置。
共用凸缘杆60提供用于将粘合剂接收部分44a、44b两者连接到抗剪腹板26的单个连接点。共用杆60可以通过粘合剂(例如液体粘合剂或胶带)连接到抗剪腹板26。在其它示例中,共用杆60可以通过螺栓连接(未示出)连接到抗剪腹板26。优选地,设置在腹板面板28中的任何孔与腹板26的跟部部分40尽可能远地间隔开,以最小化在使用中形成在高负载区域中的应力集中的风险。因此,在非结构凸缘42布置在叶片10的末梢端14附近的示例中(其中腹板面板28的高度减小),在单个部件上提供两个粘合剂接收部分44是特别有益的,因为可以通过抗剪腹板面板28的中部进行螺栓连接,充分远离抗剪腹板26的跟部部分40。
若干额外特征可适用于上文所描述的实例中的任一者。例如,非结构凸缘42的粘合剂接收部分44可以包括粗糙或不平坦的表面纹理,即,粘合剂接收部分44的表面可以不平滑。这可有助于促进粘合剂接收部分44与接收在其上的任何粘合剂36之间的粘附。此外,一旦粘合剂36已经固化,粗糙表面纹理可以有助于确保位于粘合剂接收部分44上的多余挤出粘合剂36保持粘附并且在叶片10使用时不会松动。
在一些示例中,非结构返回凸缘42可以由至少部分透明或半透明的材料形成。这有利于从叶片内部38内对容纳在非结构凸缘42上的多余挤出粘合剂36进行视觉检查。因此,可以确定在接合过程期间腹板26是否已经完全结合到壳体20,使得多余的粘合剂36被挤出到非结构凸缘42上。这使得可以通过视觉检查确认在壳体20和腹板26的跟部部分40之间存在粘合剂36。与诸如超声扫描的非破坏性测试相比,视觉检查明显更容易且耗时更少。因此,如果可以通过替代地促进视觉检查来减少对非破坏性测试的依赖,则叶片制造设施可以管理叶片10的更高生产量。
虽然参考图2a的示例描述了非结构凸缘42与壳体20的内表面32间隔开的距离大于对应的承载凸缘30和内表面32之间的距离,但是在其它示例中,非结构凸缘42的粘合剂接收部分44可以替代地与承载凸缘30基本上共面。特别地,在接合过程期间在粘合剂接收部分44相对于抗剪腹板面板28枢转以符合壳体内表面32的倾斜度的示例中,粘合剂接收部分44可以与承载凸缘30基本上共面。例如,图5b中所示的非结构凸缘42的粘合剂接收部分44在抗剪腹板26被夹在半壳22a、22b之间之后与承载凸缘30基本共面。
在一些示例中,非结构凸缘42可以由单个零件形成并且可以具有变化的横截面轮廓。例如,粘合剂接收部分44相对于腹板面板28的倾斜度可以在凸缘42的第一端和凸缘42的第二端之间变化。在这样的示例中,尽管凸缘的横截面轮廓变化,粘合剂接收部分44可以沿着凸缘42的长度限定基本上不间断的表面。在非结构凸缘42由多个纵向凸缘区段54形成的情况下,凸缘区段54可各自包括变化的横截面轮廓。因此,在凸缘区段54的第一端56与凸缘区段54的第二端58之间,给定凸缘区段54的粘合剂接收部分44的倾斜度可相对于腹板面板28变化。
抗剪腹板26可以是通过将腹板面板28和承载凸缘30与树脂和纤维材料集成而形成的复合零件。可替代地,抗剪腹板面板28和承载凸缘30可以在固定在一起以形成抗剪腹板26之前形成为单独的零件。优选地,当制造叶片10时,抗剪腹板26布置为单个零件,例如作为子组件或作为单个集成零件。
在一些示例(未在附图中示出)中,非结构凸缘42的远侧边缘50与壳体20的内表面32间隔开的距离比凸缘42的近侧边缘48与壳体20的内表面32间隔开的距离远。在接合过程期间,非结构凸缘42的近侧边缘48不太可能与壳体20接触,因为近侧边缘48紧邻承载凸缘30,承载凸缘30首先与壳体20接触。如前所述,非结构凸缘42的远侧边缘50最可能接触壳体20。因此,非结构凸缘42的远侧边缘50比近侧边缘48更远离壳体20的内表面32可有助于避免在接合过程期间壳体20与远侧边缘50之间的任何接触。
在一些示例中,抗剪腹板26可以通过仅一个承载凸缘30连接到壳体20的内表面32。虽然已经参考基本上C形的抗剪腹板26描述了本发明,但是应当理解,非结构凸缘42可以连接到具有任何形状的抗剪腹板26。优选地,非结构凸缘42的远侧边缘50在翼弦方向(C)上延伸超过抗剪腹板26的任何部分,以确保从腹板26和壳体20之间挤出的粘合剂36被接收在非结构凸缘42上。
在一些示例中,叶片10可以仅包括一个非结构凸缘42,其相对于壳体20的迎风内表面32a或背风内表面32b中的一者以相对关系布置。在这样的示例中,叶片10优选地包括非结构凸缘42,该非结构凸缘42被构造成在接合过程期间与壳体20的为上部内表面32的任何内表面32布置,以便阻挡落在壳体20的相对的下部内表面32上的任何多余的挤出粘合剂36。
在不脱离如在所附权利要求中限定的本发明的范围的情况下,可以对上述示例进行许多修改。应当理解,在不脱离由所附权利要求限定的本发明的范围的情况下,关于上述每个示例描述的特征可以容易地与参考任何其它示例描述的特征组合。
Claims (15)
1.一种风力涡轮机叶片(10),所述风力涡轮机叶片包括壳体(20)和抗剪腹板(26),所述抗剪腹板连接在所述壳体的迎风内表面(32a)和所述壳体的背风内表面(32b)之间,所述抗剪腹板包括长形腹板面板(28)和承载凸缘(30),所述承载凸缘(30)从所述腹板面板的第一侧横向延伸以将所述抗剪腹板连接到所述壳体的迎风内表面或背风内表面,
所述叶片还包括从所述腹板面板(28)的第二侧横向延伸的至少一个非结构凸缘(42),所述非结构凸缘具有与所述壳体的所述迎风内表面或背风内表面以相对关系布置的基本上平面的粘合剂接收部分(44),
其中所述承载凸缘(30)和所述非结构凸缘(42)由不同的材料形成。
2.根据权利要求1所述的风力涡轮机叶片,其中,所述承载凸缘(30)包括增强纤维。
3.根据权利要求1或2所述的风力涡轮机叶片,其中,所述非结构凸缘(42)不包括增强纤维。
4.根据前述权利要求中任一项所述的风力涡轮机叶片,其中,所述非结构凸缘的所述粘合剂接收部分(44)具有至少12.5mm的宽度,并且优选地具有至少25mm的宽度,并且更优选地具有至少30mm的宽度。
5.根据前述权利要求中任一项所述的风力涡轮机叶片,其中,所述非结构凸缘(42)的近侧边缘(48)连接到所述腹板面板(28)。
6.根据前述权利要求中任一项所述的风力涡轮机叶片,其中,所述非结构凸缘(42)包括厚度渐缩的远侧凸缘末端(52)。
7.根据前述权利要求中任一项所述的风力涡轮机叶片,其中,所述非结构凸缘(42)包括相对于所述粘合剂接收部分(44)倾斜的远侧凸缘末端(52)。
8.根据前述权利要求中任一项所述的风力涡轮机叶片,其中,所述承载凸缘(30)与所述腹板面板(28)成一体。
9.根据前述权利要求中任一项所述的风力涡轮机叶片,其中,所述非结构凸缘(42)与所述腹板面板(28)不成一体。
10.根据前述权利要求中任一项所述的风力涡轮机叶片,其中,所述非结构凸缘(42)是至少部分透明的或半透明的。
11.根据前述权利要求中任一项所述的风力涡轮机叶片,其中,所述非结构凸缘(42)的所述粘合剂接收部分(44)与所述壳体的所述迎风内表面或背风内表面间隔开的距离大于所述承载凸缘(30)与所述壳体的同一迎风内表面或背风内表面之间的距离。
12.根据权利要求1至10中任一项所述的风力涡轮机叶片,其中,所述非结构凸缘(42)的所述粘合剂接收部分(44)与所述承载凸缘(30)基本上共面。
13.根据前述权利要求中任一项所述的风力涡轮机叶片,其中,所述非结构凸缘(42)由基本上柔性的材料形成。
14.根据前述权利要求中任一项所述的风力涡轮机叶片,其中,所述非结构凸缘(42)的横截面轮廓沿着所述抗剪腹板(26)的长度变化。
15.根据前述权利要求中任一项所述的风力涡轮机叶片,其中,所述非结构凸缘(42)由多个纵向凸缘区段形成,所述多个纵向凸缘区段沿着所述抗剪腹板(26)的长度以端对端方式布置。
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EP2334932B2 (en) * | 2008-08-25 | 2024-05-01 | Vestas Wind Systems A/S | Assembly and method of preparing an assembly |
US8393871B2 (en) * | 2011-07-19 | 2013-03-12 | General Electric Company | Wind turbine blade shear web connection assembly |
US9458823B2 (en) * | 2011-12-12 | 2016-10-04 | General Electric Company | Wind turbine blade shear web connection assembly |
US20140064980A1 (en) * | 2012-08-30 | 2014-03-06 | General Electric Company | Rotor blades with infused prefabricated shear webs and methods for making the same |
US10265936B2 (en) * | 2012-12-03 | 2019-04-23 | Lm Wp Patent Holding A/S | System and method of manufacturing a wind turbine blade |
JP6096535B2 (ja) * | 2013-02-28 | 2017-03-15 | クレイトン・ポリマーズ・ユー・エス・エル・エル・シー | 透明かつ強靭なゴム組成物およびその製造方法 |
US9506452B2 (en) * | 2013-08-28 | 2016-11-29 | General Electric Company | Method for installing a shear web insert within a segmented rotor blade assembly |
GB2528852A (en) * | 2014-07-31 | 2016-02-10 | Vestas Wind Sys As | Composite component having a safety edge |
ES2964402T3 (es) * | 2018-12-03 | 2024-04-05 | Vestas Wind Sys As | Mejoras con relación a la fabricación de palas de aerogenerador |
CN113423562B (zh) * | 2018-12-20 | 2023-05-12 | 维斯塔斯风力系统有限公司 | 与风力涡轮机叶片制造相关的改进 |
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