WO2023226387A1 - 一种分段叶片及其制造方法 - Google Patents
一种分段叶片及其制造方法 Download PDFInfo
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- WO2023226387A1 WO2023226387A1 PCT/CN2022/139362 CN2022139362W WO2023226387A1 WO 2023226387 A1 WO2023226387 A1 WO 2023226387A1 CN 2022139362 W CN2022139362 W CN 2022139362W WO 2023226387 A1 WO2023226387 A1 WO 2023226387A1
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- Prior art keywords
- coupling part
- barrel
- shell
- blade
- bearing member
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 23
- 230000008878 coupling Effects 0.000 claims abstract description 159
- 238000010168 coupling process Methods 0.000 claims abstract description 159
- 238000005859 coupling reaction Methods 0.000 claims abstract description 159
- 230000003014 reinforcing effect Effects 0.000 claims abstract description 9
- 230000002787 reinforcement Effects 0.000 claims description 16
- 239000000853 adhesive Substances 0.000 claims description 14
- 230000001070 adhesive effect Effects 0.000 claims description 13
- 238000000034 method Methods 0.000 claims description 12
- 239000007767 bonding agent Substances 0.000 abstract 1
- 238000010586 diagram Methods 0.000 description 10
- 238000005516 engineering process Methods 0.000 description 10
- 238000010276 construction Methods 0.000 description 6
- 238000000465 moulding Methods 0.000 description 6
- 238000007711 solidification Methods 0.000 description 5
- 230000008023 solidification Effects 0.000 description 5
- 230000009286 beneficial effect Effects 0.000 description 4
- 230000005540 biological transmission Effects 0.000 description 4
- 238000009434 installation Methods 0.000 description 4
- 239000000463 material Substances 0.000 description 4
- 239000002131 composite material Substances 0.000 description 3
- 239000000243 solution Substances 0.000 description 3
- 239000003365 glass fiber Substances 0.000 description 2
- 238000002347 injection Methods 0.000 description 2
- 239000007924 injection Substances 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 239000011347 resin Substances 0.000 description 2
- 229920005989 resin Polymers 0.000 description 2
- 238000007493 shaping process Methods 0.000 description 2
- 230000007547 defect Effects 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 238000005553 drilling Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 239000004744 fabric Substances 0.000 description 1
- 239000011152 fibreglass Substances 0.000 description 1
- 238000012805 post-processing Methods 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- 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
-
- 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
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/70—Wind energy
- Y02E10/72—Wind turbines with rotation axis in wind direction
Definitions
- the present application relates to the field of blade technology, and specifically to a segmented blade and a manufacturing method thereof.
- segmented blades are the main development trend in the future.
- the main purpose of connecting segmented blades is to ensure continuous and effective load transmission of the main load-bearing structure.
- the connection of segmented blades is generally achieved through bonding, pin connection, bolt connection and other connection methods.
- the existing structural design, molding methods, coupling assembly positioning methods, etc. of segmented coupling positions all have implementation flaws in different aspects. Examples are as follows:
- CN112955647A discloses that adjacent blade segments are connected through a segmented connection structure, in which the segmented connection structure is a box girder plug-in type, and both the root and the tip are butt-jointed box girder structures.
- the box girder at the root and the tip are not
- the direct coupling connection is coupled with the root and tip box beams respectively through the third box girder component.
- the third box girder is cemented with the tip box girder, and the third box girder and the root box girder are connected through longitudinal pins.
- the technical problem to be solved by this application is at least to overcome the above-mentioned defects in the related art, thereby providing a segmented blade and a manufacturing method thereof.
- An embodiment of the first aspect of the present application provides a segmented blade, including: a first blade segment, a second blade segment, a connecting member and a reinforcing member.
- the first blade segment includes a first shell and a first barrel-shaped bearing member, Part of the first barrel-shaped bearing member is located in the first housing and connected to the first housing.
- the first coupling portion of the first barrel-shaped bearing member is exposed to the first housing.
- Each outer wall surface of the first coupling portion is provided with a first slope. , the first inclined surface is inclined toward the inner side of the first coupling part in a direction close to the end of the adjacent first blade segment.
- the second blade segment includes a second casing and a second barrel-shaped carrier.
- Part of the second barrel-shaped carrier is located in the second housing and connected to the second housing.
- the second coupling portion of the second barrel-shaped carrier is exposed on the second housing.
- each inner wall surface of the second coupling part is provided with a second inclined surface, and the second inclined surface is inclined toward the outside of the second coupling part in a direction close to the end of the adjacent second blade segment, and the first coupling part is inserted into
- adhesive is filled between the first inclined surface and the second inclined surface.
- the connecting piece fastens the first coupling part and the second coupling part.
- the reinforcing member includes an inner bushing and/or an outer bushing, wherein the inner bushing is arranged inside the first coupling part, and the outer bushing is arranged outside the second coupling part.
- the ratio of the maximum thickness of the first bevel to the length of the first bevel is greater than or equal to 1/200 and less than or equal to 1/20, and the ratio of the maximum thickness of the second bevel to the length of the second bevel is greater than or equal to 1/ 200 and less than or equal to 1/20.
- connection member includes a bolt and a rivet nut
- the rivet cap of the rivet nut is located between the first bevel and the second bevel
- the bolt is connected to the threaded rod of the rivet nut
- the outer bushing is an outer lining frame
- the outer lining frame is integrally formed or provided separately
- the outer lining frame and the second coupling part are integrally formed or provided separately.
- the lining sleeve includes a lining frame and a lining end cap.
- the lining end cap is provided at a port of the lining frame.
- the lining frame and the lining end cap are formed integrally or separately. .
- the reinforcing member includes an inner bushing and an outer bushing; the second barrel-shaped bearing member is provided with a limiting member, and the limiting member limits the inner bushing.
- the stopper is provided with a drainage hole.
- An embodiment of the second aspect of the present application provides a method for manufacturing segmented blades, including the following steps: shaping: forming a first blade segment: forming the first blade segment through a first barrel-shaped carrier and a first shell, wherein, A first slope is formed on each outer wall surface of the first coupling part of the first barrel-shaped bearing member; a second blade segment is formed by the second barrel-shaped bearing member and the second shell, wherein, on the second barrel-shaped bearing member Each inner wall surface of the second coupling part is formed with a second slope, and a reinforcement member is connected to the corresponding coupling part; assembly: insert the first coupling part into the second coupling part, and fasten the first coupling part through the connector. the coupling part and the second coupling part, and the adhesive is filled between the first bevel and the second bevel.
- assembling further includes connecting the third housing to the first coupling portion and the second coupling portion such that the first housing, the second housing and the third housing form an aerodynamic profile of the segmented blade.
- forming the first blade segment through the first barrel-shaped bearing member and the first shell includes: the first suction surface main beam of the first barrel-shaped bearing member, the first suction surface shell of the first shell are integrally formed, and Located on the first mold, the first pressure surface main beam of the first barrel-shaped bearing member and the first pressure surface shell of the first shell are integrally formed and located on the second mold.
- the first front edge web of the first barrel-shaped bearing member The inner sides of the plate and the first trailing edge web of the first barrel-shaped load-bearing member are connected through the inner lining sleeve of the reinforcement; the first leading edge web and the first trailing edge web are connected to the first suction surface shell and the first One of the two pressure surface shells is connected to the other one of the first suction surface shell and the first pressure surface shell through the first mold and the second mold to form the first blade segment.
- forming the first blade segment through the first barrel-shaped bearing member and the first shell includes: using a chordwise positioning member to adjust the first suction surface main beam, the first pressure surface main beam, and the first leading edge web.
- the first trailing edge web is positioned chordally, and the first suction surface main beam, the first pressure surface main beam, the first leading edge web, and the first trailing edge web are axially positioned through the axial positioning piece, Both the first mold and the second mold are provided with chordal positioning parts and axial positioning parts.
- forming the second blade segment through the second barrel-shaped carrier and the second shell includes: the second suction surface main beam of the second barrel-shaped carrier and the second suction surface shell of the second shell are integrally formed; Located on the first mold, the second pressure surface main beam of the second barrel-shaped bearing member and the second pressure surface shell of the second shell are integrally formed and located on the second mold.
- the second front edge web of the second barrel-shaped bearing member The plate and the second trailing edge web of the second barrel-shaped carrier are connected through the stopper of the second barrel-shaped carrier, and an outer bushing of the reinforcement is connected to the outside of the second coupling part; connect the second front edge web
- the plate and the second trailing edge web are connected to one of the second suction surface shell and the second pressure surface shell, and are connected to the second suction surface shell and the second pressure surface through the first mold and the second mold clamping. Shell the other of the two to form the second leaf segment.
- forming the second blade segment through the second barrel-shaped bearing member and the second shell further includes: using a chordwise positioning member to adjust the second suction surface main beam, the second pressure surface main beam, and the second leading edge web.
- the plate and the second trailing edge web are positioned chordwise, and the second suction surface main beam, the second pressure surface main beam, the second leading edge web, and the second trailing edge web are axially positioned through the axial positioning piece.
- the first mold and the second mold are both equipped with chordal positioning parts and axial positioning parts.
- fastening the first coupling part and the second coupling part through the connector includes: inserting the first coupling part into the second coupling part, drilling holes through the outer bushing, the first coupling part, the second coupling part Coupling part and inner bushing to form mounting holes.
- fastening the first coupling part and the second coupling part through the connector further includes: separating the first blade segment and the second blade segment, and aligning the mounting holes on the first coupling part and the inner bushing. Expand the hole, install the rivet nut of the connector on the first coupling part and the inner bushing, and connect the second coupling part and the rivet nut through the bolt of the connector.
- a segmented blade provided by the embodiment of the present application, including: a first blade segment, the first blade segment includes a first casing and a first barrel-shaped carrier, part of the first barrel-shaped carrier is located in the first casing, and Connected to the first shell, the first coupling part of the first barrel-shaped bearing member is exposed to the first shell, each outer wall surface of the first coupling part is provided with a first slope, and the first slope is along the edge of the adjacent first blade segment.
- the direction of the end is inclined toward the inner side of the first coupling part;
- the second blade segment includes a second shell and a second barrel-shaped carrier, and part of the second barrel-shaped carrier is located in the second shell and connected to The second casing, the second coupling part of the second barrel-shaped bearing member is exposed from the second casing, each inner wall surface of the second coupling part is provided with a second slope, and the second slope is along the end close to the adjacent second blade segment
- the direction is inclined toward the outside of the second coupling part, the first coupling part is inserted into the second coupling part, and the adhesive is filled between the first bevel and the second bevel; the connector is fastened to the first coupling part and the second coupling part;
- the reinforcement includes an inner bushing and/or an outer bushing, wherein the inner bushing is arranged inside the first coupling part, and the outer bushing is arranged outside the second coupling part.
- a segmented blade of this structure is provided with a first barrel-shaped bearing member having a first inclined surface and a second barrel-shaped bearing member having a second inclined surface, so that the first inclined surface and the second inclined surface are overlapped and connected to facilitate positioning and Installing the first coupling part and the second coupling part helps to effectively transmit the axial load of the segmented blades; through the cooperation of fastening connection and bonding, there is no need to rely on external tooling to position the blade segments during bonding. It uses fastening connections to accurately position the blade segments to ensure cementation and solidification, ensuring the connection accuracy and connection strength of the segmented blades, which is beneficial to wind farm construction; by setting up reinforcements, the local stress of the connectors on the blade segments is shared , providing ample strength.
- the connection member includes a bolt and a rivet nut.
- the rivet cap of the rivet nut is located between the first bevel and the second bevel.
- the bolt is connected to the threaded rod of the rivet nut.
- This structure is a segmented blade. Since the riveted cap has a thickness, this thickness can provide space for the adhesive to bond.
- the reinforcement includes an inner bushing and an outer bushing; the second barrel-shaped bearing member is equipped with a limiting member, and the limiting member limits the inner bushing.
- a segmented blade of this structure facilitates preliminary positioning of the first blade segment and the second blade segment by providing a limiting member and an inner bushing to cooperate.
- the limiting member is provided with a drainage hole.
- a segmented blade of this structure is provided with drainage holes, which facilitates drainage inside the first blade segment.
- the manufacturing method of segmented blades includes the following steps: shaping: forming the first blade segment: forming the first blade segment through the first barrel-shaped carrier and the first shell, wherein in the Each outer wall surface of the first coupling part of a barrel-shaped bearing member is formed with a first slope; a second blade segment is formed by the second barrel-shaped bearing member and the second shell, wherein the second barrel-shaped bearing member Each inner wall surface of the coupling part is formed with a second slope, and a reinforcing member is connected to the corresponding coupling part; assembly: insert the first coupling part into the second coupling part, and fasten the first coupling part through the connector.
- a method for manufacturing segmented blades is used.
- the first slope of the first barrel-shaped carrier is overlapped and connected to the second barrel-shaped carrier with a second slope, which facilitates positioning and installation of the first coupling part and the second coupling. part, and contributes to the effective transmission of the axial load of the segmented blades; through the cooperation of fastening connections and bonding, there is no need to rely on external tooling to position the blade segments during bonding, but instead use fastening connections to position the blade segments.
- a method of manufacturing a segmented blade provided by the embodiment of the present application.
- Forming the first blade segment through the first barrel-shaped bearing member and the first shell includes: using the chordwise positioning member to adjust the first suction surface main beam, the first The pressure surface main beam, the first leading edge web, and the first trailing edge web are positioned in the chord direction, and the first suction surface main beam, the first pressure surface main beam, the first leading edge web, and The first trailing edge web is axially positioned, and both the first mold and the second mold are provided with chordwise positioning parts and axial positioning parts.
- Forming the second blade segment through the second barrel-shaped bearing member and the second shell also includes: using the chordwise positioning member to adjust the second suction surface main beam, the second pressure surface main beam, the second leading edge web, and the second trailing edge.
- the web is positioned in the chord direction, and the second suction surface main beam, the second pressure surface main beam, the second leading edge web, and the second trailing edge web are axially positioned through the axial positioning piece.
- Both molds are equipped with chordal positioning parts and axial positioning parts.
- a method for manufacturing segmented blades can realize the differential molding of two blade segments through the first mold and the second mold, which can improve the interchangeability of the blade segments; and when the segmented blades need to be extended , the blade tip can be replaced and then plugged into other blade segments; and by being provided with chordal positioning parts and axial positioning parts, the molding accuracy can be ensured.
- a method of manufacturing a segmented blade provided by the embodiment of the present application. Fastening the first coupling part and the second coupling part through a connector further includes: separating the first blade segment and the second blade segment, and aligning the first blade segment and the second blade segment. The mounting holes on the first coupling part and the inner bushing are expanded, the rivet nut of the connector is installed on the first coupling part and the inner bushing, and the second coupling part and the rivet nut are connected through the bolt of the connector.
- This step is a method of manufacturing segmented blades by enlarging the holes so that the mounting holes are adapted to the bolts of the connecting parts.
- Figure 1 is a cross-sectional view of the first barrel-shaped bearing member and the second barrel-shaped bearing member provided in Embodiment 1 of the present application when they are connected;
- Figure 2 is a schematic structural diagram of the first barrel-shaped bearing member and the second barrel-shaped bearing member shown in Figure 1 without showing the bolts;
- FIG 3 is a schematic structural diagram of the first blade segment shown in Figure 1;
- Figure 4 is a schematic structural diagram showing the inner bushing of the first blade segment shown in Figure 3;
- FIG. 5 is a schematic structural diagram of the second blade segment shown in Figure 1;
- Figure 6 is a schematic structural diagram showing the outer bushing of the second blade segment shown in Figure 5;
- Figure 7 is a schematic structural diagram of the second blade segment, the first mold and the second mold shown in Figure 5;
- Figure 8 is a cross-sectional view of the first mold and the second mold shown in Figure 7 being closed;
- Figure 9 is a schematic structural diagram of the first blade segment and the second mold shown in Figure 7;
- Figure 10 is a schematic structural diagram of the first blade section and the second blade section shown in Figure 1 when they are plugged together;
- Figure 11 is a schematic structural diagram of the first blade section and the second blade section shown in Figure 10 when they are plugged together without showing part of the casing;
- Figure 12 is a schematic structural diagram showing the mounting holes of the first blade segment and the second blade segment shown in Figure 10;
- Figure 13 is a schematic structural view of the first blade segment and the second blade segment shown in Figure 12 showing the stopper and the inner bushing;
- connection should be understood in a broad sense.
- connection or integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be an internal connection between two components.
- connection or integral connection
- connection or integral connection
- connection can be a mechanical connection or an electrical connection
- it can be a direct connection or an indirect connection through an intermediate medium
- it can be an internal connection between two components.
- specific meanings of the above terms in this application can be understood on a case-by-case basis.
- This embodiment provides a segmented blade as shown in Figures 1 to 13, including a first blade section, a second blade section, a connecting piece and a reinforcing piece.
- the first blade segment includes a first shell 11 and a first barrel-shaped bearing member 12. Part of the first barrel-shaped bearing member 12 is located in the first shell 11 and connected to the first shell 11.
- the first barrel-shaped bearing member 12 is The first coupling part 13 is exposed from the first casing 11;
- the second blade segment includes a second casing 21 and a second barrel-shaped carrier 22, and part of the second barrel-shaped carrier 22 is located in the second casing 21 and connected to the second casing. 21.
- the second coupling part 23 of the second barrel-shaped bearing member 22 is exposed from the second housing 21; the connecting member tightly connects the first coupling part 13 and the second coupling part 23.
- each outer wall surface of the first coupling part 13 is provided with a first slope 131 , and the first slope 131 faces the end of the first coupling part 13 in a direction close to the end of the adjacent first blade segment.
- the inner side is inclined; each inner wall surface of the second coupling part 23 is provided with a second inclined surface 231.
- the second inclined surface 231 is inclined toward the outside of the second coupling part 23 in a direction close to the end of the adjacent second blade segment.
- a coupling part 13 is inserted into the second coupling part 23 , and adhesive is filled between the first inclined surface 131 and the second inclined surface 231 , wherein the second inclined surface 231 is adapted to the first inclined surface 131 .
- the ratio of the maximum thickness of the first inclined surface 131 to the length of the first inclined surface 131 is greater than or equal to 1/200 and less than or equal to 1/20, and the ratio of the maximum thickness of the second inclined surface 231 to the length of the second inclined surface 231 is greater than or equal to 1/ 200 and less than or equal to 1/20.
- the maximum thickness of the first inclined surface 131 refers to the thickness of the first inclined surface 131 at the rightmost position in FIG. 1 , and the thickness at this position is greater than the thickness of the first inclined surface 131 at other positions.
- the maximum thickness of the first inclined surface 131, and the length of the first inclined surface 131 refers to the length of the first inclined surface 131 from the rightmost position to the leftmost position in Figure 1; and the maximum thickness of the second inclined surface 231 is Refers to the thickness of the second slope 231 at the leftmost position in Figure 1. The thickness at this position is greater than the thickness of the second slope 231 at other positions. This is the maximum thickness of the second slope 231, and the thickness of the second slope 231 The length refers to the length of the second slope 231 from the leftmost position to the rightmost position in FIG. 1 .
- the reinforcement includes an inner bushing 41 and an outer bushing 42.
- the inner bushing 41 is provided on the inside of the first coupling part 13, and the outer bushing 42 is provided on the inner side of the first coupling part 13.
- the reinforcing member may be provided to include an inner bushing 41 or an outer bushing 42 .
- the outer bushing 42 is an outer lining frame, the outer lining frame is integrally formed or provided separately, the outer lining frame and the second coupling part 23 are integrally formed or provided separately; and the inner bushing 41 includes an inner The lining frame and the lining end cap are provided at the port of the lining frame, and the lining frame and the lining end cap are formed integrally or separately.
- the connection member includes a bolt 31 and a rivet nut 32.
- the rivet cap 321 of the rivet nut 32 is located between the first bevel 131 and the second bevel 231.
- the bolt 31 is connected to the threaded rod of the rivet nut 32. . Since the riveting cap 321 has a thickness, the thickness can provide space for the adhesive to bond.
- the second barrel-shaped bearing member 22 is provided with a limiting member 5, and the limiting member 5 limits the position of the inner bushing 41.
- the limiting member 5 is provided with a drainage hole. By providing drainage holes, drainage inside the first blade segment is facilitated.
- a segmented blade in this embodiment is provided with the first barrel-shaped bearing member 12 having the first inclined surface 131 and the second barrel-shaped bearing member 22 having the second inclined surface 231, so that the first inclined surface 131 and the second inclined surface 231 overlap connection facilitates the positioning and installation of the first coupling part 13 and the second coupling part 23, and contributes to the effective transmission of the axial load of the segmented blades; through the cooperation of fastening connection and bonding, it is also possible during bonding It is not necessary to use external tooling to position the blade segments but to use fastening connections to accurately position the blade segments to ensure cementing and solidification, ensuring the connection accuracy and connection strength of the segmented blades, which is beneficial to wind field construction; by setting up reinforcements , sharing the local stress of the connecting piece on the blade segment and providing sufficient strength.
- This embodiment provides a method for manufacturing segmented blades, which can be based on the segmented blades in Embodiment 1 and includes the following steps:
- Forming forming the first blade segment: forming the first blade segment through the first barrel-shaped carrier 12 and the first shell 11, wherein each outer wall surface of the first coupling portion 13 of the first barrel-shaped carrier 12 is formed with The first slope 131; the second blade segment is formed by the second barrel-shaped carrier 22 and the second shell 21, wherein a second slope is formed on each inner wall surface of the second coupling portion 23 of the second barrel-shaped carrier 22 231, and reinforcements are connected to the corresponding coupling parts;
- forming the first blade segment through the first barrel-shaped carrier 12 and the first shell 11 includes: as shown in Figures 3 and 4, the first suction surface main beam 121 of the first barrel-shaped carrier 12, the first The first suction surface shell 111 of the shell 11 is integrally injection molded and located in the first mold 61 .
- the first pressure surface main beam 122 of the first barrel-shaped carrier 12 and the first pressure surface shell 112 of the first shell 11 are integrally injection molded.
- the first leading edge web 123 of the first barrel-shaped carrier 12 and the first trailing edge web 124 of the first barrel-shaped carrier 12 pass through the inner lining of the first barrel-shaped carrier 12 41 Adhesive connection; the first leading edge web 123 and the first trailing edge web 124 are adhesively connected to one of the first suction surface shell 111 and the first pressure surface shell 112 and passed through the first mold 61 and the second mold 62 is mold-joined and bonded to the other of the first suction surface shell 111 and the first pressure surface shell 112 to form the first blade segment;
- the first suction surface main beam 121, the first pressure surface main beam 122, the first leading edge web 123, and the first trailing edge web 124 are positioned in the first mold 61 and the second mold 62 through the chordwise positioning member 71.
- the first mold 61 and the second mold 62 are both provided with chordal positioning parts 71 and axial positioning parts 72; through the first mold 61 and the second mold 62, two blades can be realized.
- the special molding of the segments can improve the interchangeability of the blade segments; and when the segmented blades need to be extended, the blade tips can be replaced and other blade segments can be plugged in to achieve this; and by providing a chordwise positioning member 71, an axis To the positioning piece 72, the molding accuracy can be ensured;
- the chordwise positioning member 71 includes oppositely arranged chordwise positioning blocks, and the axial positioning member 72 is an axial positioning plate, and the axial positioning plate is connected to the chordwise positioning block, wherein the first mold 61
- the chordwise positioning block of one of the two molds 62 and the second mold 62 is provided with positioning posts 74 and the other chordwise positioning block is provided with positioning holes 73.
- the positioning posts 74 is inserted into the positioning hole 73; and, the first suction surface main beam, the first pressure surface main beam, the first leading edge web, and the first trailing edge web form the first coupling portion, respectively. Bevel.
- forming the second blade segment through the second barrel-shaped carrier 22 and the second shell 21 includes: as shown in Figures 5 to 9, the second suction surface main beam 221 of the second barrel-shaped carrier 22, the second shell
- the second suction surface shell 211 of 21 is integrally molded and located on the first mold 61.
- the second pressure surface main beam 222 of the second barrel-shaped carrier 22 and the second pressure surface shell 212 of the second shell 21 are integrally molded.
- the second leading edge web 223 of the second barrel-shaped carrier 22 and the second trailing edge web 224 of the second barrel-shaped carrier 22 pass through the limiting member of the second barrel-shaped carrier 22 5.
- Adhesive connection the second leading edge web 223 and the second trailing edge web 224 are adhesively connected to one of the second suction surface shell 211 and the second pressure surface shell 212 and passed through the first mold 61 and the second mold 62 is mold-joined and bonded to the other of the second suction surface shell 211 and the second pressure surface shell 212 to form a second blade segment;
- the second suction surface main beam 221, the second pressure surface main beam 222, the second leading edge web 223, and the second trailing edge web 224 are installed through the chordwise positioning member 71.
- the second suction surface main beam 221, the second pressure surface main beam 222, the second leading edge web 223, and the second trailing edge web 224 are axially positioned through the axial positioning member 72;
- second slopes 231 are respectively processed at the second coupling portion 23 of the second suction surface main beam 221, the second pressure surface main beam 222, the second leading edge web 223, and the second trailing edge web 224;
- An outer bushing 42 is adhesively connected to the outside of the second coupling part 23 .
- first coupling part 13 of the first barrel-shaped carrier 12 into the second coupling part 23 of the second barrel-shaped carrier 22.
- external tooling, a crane, etc. may be used to define the coupling posture.
- the first coupling part 13 and the second coupling part 23 are firmly connected through the connector.
- the external tooling, crane, etc. can be evacuated, and the adhesive can be filled between the first inclined surface 131 and the second inclined surface 231 without any need.
- the cloth laying process can be carried out, and then the third shell is connected to the first coupling part 13 and the second coupling part 23 to close the first coupling part 13 and the second coupling part 23, so that the first shell 11 and the second coupling part 23 are closed.
- the outer shell 21 and the third outer shell form the aerodynamic profile of the segmented blade.
- fastening the first coupling part 13 and the second coupling part 23 through the connector includes: as shown in Figures 10 and 11, inserting the first coupling part 13 of the first barrel-shaped carrier 12 into the second barrel
- the second coupling part 23 of the shaped carrier 22 is drilled through the outer bushing 42 , the first coupling part 13 , the second coupling part 23 and the inner bushing 41 to form the mounting hole 8 ; separate the second coupling part 23 In the first blade segment and the second blade segment, the mounting holes 8 located on the first coupling part 13 and the inner bushing 41 are expanded, and the rivet nuts 32 of the connector are installed on the first coupling part 13 and the inner bushing 41 through
- the bolt 31 of the connecting member connects the second coupling part 23 and the rivet nut 32 .
- the mounting hole 8 is adapted to the bolt 31 of the connecting piece.
- first suction surface main beam 121 , the first pressure surface main beam 122 , the second suction surface main beam 221 , and the second pressure surface main beam 222 can be made of pultruded plates or other materials.
- the second shell 21 can be made of skin or other materials.
- the first leading edge web 123 and the first trailing edge web 124 form the area of the first coupling part 13 and the second leading edge web 223 and the second trailing edge.
- the area where the web 224 forms the second coupling part 23 can be made of pultruded plate or other materials.
- the first leading edge web 123 and the first trailing edge web 124 do not form other areas of the first coupling part 13 and the second front edge web 224 .
- the edge web 223 and other areas of the second trailing edge web 224 that do not form the second coupling part 23 can be made of fiberglass sandwich composite or other materials.
- the inner bushing 41 can be made of glass fiber, resin, etc. or other composite materials.
- the outer bushing 42 can be made of glass fiber, resin, etc. or other composite materials.
- the first inclined surface 131 of the first barrel-shaped bearing member 12 is overlapped and connected to the second barrel-shaped bearing member 22 with a second inclined surface 231, which facilitates positioning and installation of the first barrel-shaped bearing member 12.
- the coupling part 13 and the second coupling part 23 are conducive to the effective transmission of the axial load of the segmented blades; through the cooperation of fastening connection and bonding, there is no need to use external tooling to position the blade segments during bonding.
- the blade segments are accurately positioned with the help of fastening connections to ensure cementation and solidification, ensuring the connection accuracy and connection strength of the segmented blades, which is beneficial to wind field construction; through the connection of reinforcements, the local stress of the connectors on the blade segments is shared, Provides plenty of strength.
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- Life Sciences & Earth Sciences (AREA)
- Sustainable Development (AREA)
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Abstract
本申请公开一种分段叶片及其制造方法。其中分段叶片包括：第一叶片段，第一叶片段包括第一桶状承载件，第一桶状承载件的第一耦合部设有第一斜面；第二叶片段，第二叶片段包括第二桶状承载件，第二桶状承载件的第二耦合部设有第二斜面，第一耦合部插接于第二耦合部内，第一斜面和第二斜面之间填充有粘接剂；连接件，紧固连接第一耦合部和第二耦合部；加强件，包括内衬套和/或外衬套。
Description
相关申请的交叉引用
本申请要求享有于2022年5月26日提交的名称为“一种分段叶片及其制造方法”的中国专利申请202210589554.4的优先权，该申请的全部内容通过引用并入本文中。
本申请涉及叶片技术领域，具体涉及一种分段叶片及其制造方法。
随着叶片越来越长，其运输的成本和困难显著增加。为了减小运输的困难，大幅节省运输成本，分段叶片是后续的主要发展趋势。分段叶片的连接主要目的是确保主承力结构传载连续有效，一般通过粘接、销接、螺栓连接等连接方式实现分段叶片的连接。现有的分段耦合位置的结构设计、成型方式、耦合组装定位方式等，均在不同方面有实施缺陷，举例如下：
相关技术CN110177933A，公开了通过工装的前后、上下、左右调节来控制分段叶片的耦合精度。但该相关技术叶片气动外形、粘接剂的厚度等因素的限制，需要移动工厂具有很高的控制精度，同时，风力发电场的地形环境复杂多变，严重限制了移动工厂的环境适应性，同时叶片胶结固化时须维持移动工厂各项状态，耗时较长，严重限制了移动工厂的使用效率。即，此相关技术的自定位能力弱，需要使用高精度工装来保证分段叶片的连接精度。
相关技术CN101463795B、CN111051693A，均公开了仅对主梁进行斜面搭接。但该相关技术由于仅对主梁进行斜面搭接，使得各向载荷传递能力相对偏弱。
相关技术CN112955647A，公开了相邻的叶片段通过分段连接结构连 接，其中分段连接结构为箱梁插接式，根部和尖部均为对接式箱梁结构，根部和尖部的箱梁不直接耦合连接而是通过第三箱梁部件分别与根部和尖部的箱梁耦合连接，第三箱梁与尖部箱梁胶结，第三箱梁与根部箱梁通过纵向销销接。但该相关技术需要借助外部工装来稳定叶片段的相对位置，保证胶结固化，使得施工周期长；以及为保证叶片段的连接精度，两个叶片段一般需要共模成型，成型后厂内拆分、后处理，厂外再连接，使得叶片段的互换性弱。
发明内容
因此，本申请要解决的技术问题至少在于克服相关技术中上述的缺陷，从而提供一种分段叶片及其制造方法。
本申请第一方面的实施例提供了一种分段叶片，包括：第一叶片段、第二叶片段、连接件以及加强件，第一叶片段包括第一外壳和第一桶状承载件，部分第一桶状承载件位于第一外壳内且连接于第一外壳，第一桶状承载件的第一耦合部外露于第一外壳，第一耦合部的各个外壁面均设有第一斜面，第一斜面沿靠近邻近的第一叶片段的端部的方向朝向第一耦合部的内侧倾斜设置。第二叶片段包括第二外壳和第二桶状承载件，部分第二桶状承载件位于第二外壳内且连接于第二外壳，第二桶状承载件的第二耦合部外露于第二外壳，第二耦合部的各个内壁面均设有第二斜面，第二斜面沿靠近邻近的第二叶片段的端部的方向朝向第二耦合部的外侧倾斜设置，第一耦合部插接于第二耦合部内，第一斜面和第二斜面之间填充有粘接剂。连接件，连接件紧固连接第一耦合部和第二耦合部。加强件包括内衬套和/或外衬套，其中内衬套设于第一耦合部的内侧，外衬套设于第二耦合部的外侧。
在一些实施例中，第一斜面的最大厚度和第一斜面的长度的比值大于等于1/200且小于等于1/20，第二斜面的最大厚度和第二斜面的长度的比值大于等于1/200且小于等于1/20。
在一些实施例中，连接件包括螺栓和铆螺母，铆螺母的铆接帽位于第一斜面和第二斜面之间，螺栓连接于铆螺母的螺接杆。
在一些实施例中，外衬套为外衬框体，外衬框体一体成型设置或者分体设置，外衬框体和第二耦合部一体成型设置或者分体设置。
在一些实施例中，内衬套包括内衬框体和内衬端盖，内衬端盖设于内衬框体的端口处，内衬框体和内衬端盖一体成型设置或者分体设置。
在一些实施例中，加强件包括内衬套和外衬套；第二桶状承载件内设有限位件，限位件对内衬套限位。
在一些实施例中，限位件设有排水孔。
本申请第二方面的实施例提供了一种分段叶片的制造方法，包括以下步骤：成型：形成第一叶片段：通过第一桶状承载件、第一外壳形成第一叶片段，其中，在第一桶状承载件的第一耦合部的各个外壁面均形成有第一斜面；通过第二桶状承载件、第二外壳形成第二叶片段，其中，在第二桶状承载件的第二耦合部的各个内壁面均形成有第二斜面，以及在对应的耦合部连接有加强件；组装：将第一耦合部插接于第二耦合部内，通过连接件来紧固连接第一耦合部和第二耦合部，以及将粘接剂填充于第一斜面和第二斜面之间。
在一些实施例中，组装还包括：将第三外壳连接于第一耦合部和第二耦合部，使得第一外壳、第二外壳和第三外壳形成分段叶片的气动型面。
在一些实施例中，通过第一桶状承载件、第一外壳形成第一叶片段包括：第一桶状承载件的第一吸力面主梁、第一外壳的第一吸力面外壳一体成型且位于第一模具上，第一桶状承载件的第一压力面主梁、第一外壳的第一压力面外壳一体成型且位于第二模具上，第一桶状承载件的第一前缘腹板、第一桶状承载件的第一后缘腹板的内侧通过加强件的内衬套连接；将第一前缘腹板、第一后缘腹板连接于第一吸力面外壳和第一压力面外壳两者中的其中一个并通过第一模具和第二模具合模连接于第一吸力面外壳和第一压力面外壳两者中的另一个，以形成第一叶片段。
在一些实施例中，通过第一桶状承载件、第一外壳形成第一叶片段包括：通过弦向定位件对第一吸力面主梁、第一压力面主梁、第一前缘腹板、第一后缘腹板进行弦向定位，通过轴向定位件对第一吸力面主梁、第一压力面主梁、第一前缘腹板、第一后缘腹板进行轴向定位，第一模具、第二 模具均设有弦向定位件、轴向定位件。
在一些实施例中，通过第二桶状承载件、第二外壳形成第二叶片段包括：第二桶状承载件的第二吸力面主梁、第二外壳的第二吸力面外壳一体成型且位于第一模具上，第二桶状承载件的第二压力面主梁、第二外壳的第二压力面外壳一体成型且位于第二模具上，第二桶状承载件的第二前缘腹板、第二桶状承载件的第二后缘腹板通过第二桶状承载件的限位件连接，在第二耦合部的外侧连接有加强件的外衬套；将第二前缘腹板、第二后缘腹板连接于第二吸力面外壳和第二压力面外壳两者中的其中一个并通过第一模具和第二模具合模连接于第二吸力面外壳和第二压力面外壳两者中的另一个，以形成第二叶片段。
在一些实施例中，通过第二桶状承载件、第二外壳形成第二叶片段还包括：通过弦向定位件对第二吸力面主梁、第二压力面主梁、第二前缘腹板、第二后缘腹板进行弦向定位，通过轴向定位件对第二吸力面主梁、第二压力面主梁、第二前缘腹板、第二后缘腹板进行轴向定位，第一模具、第二模具均设有弦向定位件、轴向定位件。
在一些实施例中，通过连接件来紧固连接第一耦合部和第二耦合部包括：将第一耦合部插入第二耦合部，钻孔穿过外衬套、第一耦合部、第二耦合部、内衬套以形成安装孔。
在一些实施例中，通过连接件来紧固连接第一耦合部和第二耦合部还包括：分离第一叶片段、第二叶片段，对位于第一耦合部和内衬套上的安装孔进行扩孔，安装连接件的铆螺母于第一耦合部、内衬套，通过连接件的螺栓连接第二耦合部和铆螺母。
在一些实施例中，基于上述的分段叶片。
本申请技术方案，具有如下优点：
1.本申请实施例提供的一种分段叶片，包括：第一叶片段，第一叶片段包括第一外壳和第一桶状承载件，部分第一桶状承载件位于第一外壳内且连接于第一外壳，第一桶状承载件的第一耦合部外露于第一外壳，第一耦合部的各个外壁面均设有第一斜面，第一斜面沿靠近邻近的第一叶片段的端部的方向朝向第一耦合部的内侧倾斜设置；第二叶片段，第二叶片段 包括第二外壳和第二桶状承载件，部分第二桶状承载件位于第二外壳内且连接于第二外壳，第二桶状承载件的第二耦合部外露于第二外壳，第二耦合部的各个内壁面均设有第二斜面，第二斜面沿靠近邻近的第二叶片段的端部的方向朝向第二耦合部的外侧倾斜设置，第一耦合部插接于第二耦合部内，第一斜面和第二斜面之间填充有粘接剂；连接件，连接件紧固连接第一耦合部和第二耦合部；加强件，加强件包括内衬套和/或外衬套，其中内衬套设于第一耦合部的内侧，外衬套设于第二耦合部的外侧。此结构的一种分段叶片，通过设置有第一桶状承载件具有第一斜面和第二桶状承载件具有第二斜面，以使得第一斜面和第二斜面搭接连接，便于定位、安装第一耦合部和第二耦合部，并有助于分段叶片轴向载荷的有效传递；通过紧固连接和粘接的配合，使得粘接时也无需借助于外部工装对叶片段定位而是借助于紧固连接对叶片段进行精确定位，保证胶结固化，确保分段叶片的连接精度和连接强度，从而有利于风场施工；通过设置有加强件，分担连接件对叶片段的局部应力，提供充足的强度。
2.本申请实施例提供的一种分段叶片，连接件包括螺栓和铆螺母，铆螺母的铆接帽位于第一斜面和第二斜面之间，螺栓连接于铆螺母的螺接杆。此结构的一种分段叶片，由于铆接帽具有厚度，此厚度可提供空间给粘接剂进行粘接。
3.本申请实施例提供的一种分段叶片，加强件包括内衬套和外衬套；第二桶状承载件内设有限位件，限位件对内衬套限位。此结构的一种分段叶片，通过设置有限位件和内衬套的配合，便于初步定位第一叶片段和第二叶片段。
4.本申请实施例提供的一种分段叶片，限位件设有排水孔。此结构的一种分段叶片，通过设置有排水孔，有利于第一叶片段内部的排水。
5.本申请实施例提供的一种分段叶片的制造方法，包括以下步骤：成型：形成第一叶片段：通过第一桶状承载件、第一外壳形成第一叶片段，其中，在第一桶状承载件的第一耦合部的各个外壁面均形成有第一斜面；通过第二桶状承载件、第二外壳形成第二叶片段，其中，在第二桶状承载件的第二耦合部的各个内壁面均形成有第二斜面，以及在对应的耦合部连 接有加强件；组装：将第一耦合部插接于第二耦合部内，通过连接件来紧固连接第一耦合部和第二耦合部，以及将粘接剂填充于第一斜面和第二斜面之间。此步骤的一种分段叶片的制造方法，通过第一桶状承载件的第一斜面搭接连接于第二桶状承载件具有第二斜面，便于定位、安装第一耦合部和第二耦合部，并有助于分段叶片轴向载荷的有效传递；通过紧固连接和粘接的配合，使得粘接时也无需借助于外部工装对叶片段定位而是借助于紧固连接对叶片段进行精确定位，保证胶结固化，确保分段叶片的连接精度和连接强度，从而有利于风场施工；通过连接有加强件，分担连接件对叶片段的局部应力，提供充足的强度。
6.本申请实施例提供的一种分段叶片的制造方法，通过第一桶状承载件、第一外壳形成第一叶片段包括：通过弦向定位件对第一吸力面主梁、第一压力面主梁、第一前缘腹板、第一后缘腹板进行弦向定位，通过轴向定位件对第一吸力面主梁、第一压力面主梁、第一前缘腹板、第一后缘腹板进行轴向定位，第一模具、第二模具均设有弦向定位件、轴向定位件。通过第二桶状承载件、第二外壳形成第二叶片段还包括：通过弦向定位件对第二吸力面主梁、第二压力面主梁、第二前缘腹板、第二后缘腹板进行弦向定位，通过轴向定位件对第二吸力面主梁、第二压力面主梁、第二前缘腹板、第二后缘腹板进行轴向定位，第一模具、第二模具均设有弦向定位件、轴向定位件。此步骤的一种分段叶片的制造方法，通过第一模具、第二模具，可实现两个叶片段的异模成型，能够提升叶片段的互换性；并当分段叶片需要再延长时，可替换叶尖再插接其他的叶片段来实现；以及通过设置有弦向定位件、轴向定位件，可确保成型精度。
7.本申请实施例提供的一种分段叶片的制造方法，通过连接件来紧固连接第一耦合部和第二耦合部还包括：分离第一叶片段、第二叶片段，对位于第一耦合部和内衬套上的安装孔进行扩孔，安装连接件的铆螺母于第一耦合部、内衬套，通过连接件的螺栓连接第二耦合部和铆螺母。此步骤的一种分段叶片的制造方法，通过扩孔，使得安装孔适配于连接件的螺栓。
为了更清楚地说明本申请具体实施方式或相关技术中的技术方案，下面将对具体实施方式或相关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申请的一些实施方式，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为本申请的实施例1中提供的第一桶状承载件和第二桶状承载件连接时的剖视图；
图2为图1所示的第一桶状承载件和第二桶状承载件未显示螺栓的结构示意图；
图3为图1所示的第一叶片段的结构示意图；
图4为图3所示的第一叶片段显示内衬套的结构示意图；
图5为图1所示的第二叶片段的结构示意图；
图6为图5所示的第二叶片段显示外衬套的结构示意图；
图7为图5所示的第二叶片段、第一模具和第二模具的结构示意图；
图8为图7所示的第一模具和第二模具合模的剖视图；
图9为图7所示的第一叶片段和第二模具的结构示意图；
图10为图1所示的第一叶片段和第二叶片段插接时的结构示意图；
图11为图10所示的第一叶片段和第二叶片段插接时未显示部分外壳的结构示意图；
图12为图10所示的第一叶片段和第二叶片段显示安装孔的结构示意图；
图13为图12所示的第一叶片段和第二叶片段显示限位件和内衬套的结构示意图；
标记说明：
11-第一外壳，111-第一吸力面外壳，112-第一压力面外壳，12-第一桶状承载件，121-第一吸力面主梁，122-第一压力面主梁，123-第一前缘腹板，124-第一后缘腹板，13-第一耦合部，131-第一斜面，21-第二外壳，211-第二吸力面外壳，212-第二压力面外壳，22-第二桶状承载件，221-第 二吸力面主梁，222-第二压力面主梁，223-第二前缘腹板，224-第二后缘腹板，23-第二耦合部，231-第二斜面，31-螺栓，32-铆螺母，321-铆接帽，41-内衬套，42-外衬套，5-限位件，61-第一模具，62-第二模具，71-弦向定位件，72-轴向定位件，73-定位孔，74-定位柱，8-安装孔。
下面将结合附图对本申请的技术方案进行清楚、完整地描述，显然，所描述的实施例是本申请一部分实施例，而不是全部的实施例。基于本申请中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本申请保护的范围。
在本申请的描述中，需要说明的是，术语“中心”、“上”、“下”、“左”、“右”、“竖直”、“水平”、“内”、“外”等指示的方位或位置关系为基于附图所示的方位或位置关系，仅是为了便于描述本申请和简化描述，而不是指示或暗示所指的装置或元件必须具有特定的方位、以特定的方位构造和操作，因此不能理解为对本申请的限制。此外，术语“第一”、“第二”、“第三”仅用于描述目的，而不能理解为指示或暗示相对重要性。
在本申请的描述中，需要说明的是，除非另有明确的规定和限定，术语“安装”、“相连”、“连接”应做广义理解，例如，可以是固定连接，也可以是可拆卸连接，或一体地连接；可以是机械连接，也可以是电连接；可以是直接相连，也可以通过中间媒介间接相连，可以是两个元件内部的连通。对于本领域的普通技术人员而言，可以具体情况理解上述术语在本申请中的具体含义。
此外，下面所描述的本申请不同实施方式中所涉及的技术特征只要彼此之间未构成冲突就可以相互结合。
实施例1
本实施例提供如图1至图13所示的一种分段叶片，包括第一叶片段、第二叶片段、连接件和加强件。其中，第一叶片段包括第一外壳11和第一桶状承载件12，部分第一桶状承载件12位于第一外壳11内且连接于第一 外壳11，第一桶状承载件12的第一耦合部13外露于第一外壳11；第二叶片段包括第二外壳21和第二桶状承载件22，部分第二桶状承载件22位于第二外壳21内且连接于第二外壳21，第二桶状承载件22的第二耦合部23外露于第二外壳21；连接件紧固连接第一耦合部13和第二耦合部23。
如图1和图2所示，第一耦合部13的各个外壁面均设有第一斜面131，第一斜面131沿靠近邻近的第一叶片段的端部的方向朝向第一耦合部13的内侧倾斜设置；第二耦合部23的各个内壁面均设有第二斜面231，第二斜面231沿靠近邻近的第二叶片段的端部的方向朝向第二耦合部23的外侧倾斜设置，第一耦合部13插接于第二耦合部23内，第一斜面131和第二斜面231之间填充有粘接剂，其中，第二斜面231适配于第一斜面131。
其中，第一斜面131的最大厚度和第一斜面131的长度的比值大于等于1/200且小于等于1/20，第二斜面231的最大厚度和第二斜面231的长度的比值大于等于1/200且小于等于1/20。需要说明的是，第一斜面131的最大厚度是指第一斜面131在图1中最右侧位置处的厚度，该位置处的厚度大于第一斜面131在其他位置处的厚度，为此为第一斜面131的最大厚度，而第一斜面131的长度则是指第一斜面131在图1中由最右侧位置处至最左侧位置处的长度；以及第二斜面231的最大厚度是指第二斜面231在图1中最左侧位置处的厚度，该位置处的厚度大于第二斜面231在其他位置处的厚度，此为第二斜面231的最大厚度，而第二斜面231的长度则是指第二斜面231在图1中由最左侧位置处至最右侧位置处的长度。
如图1、图2、图4和图6所示，加强件包括内衬套41和外衬套42，其中内衬套41设于第一耦合部13的内侧，外衬套42设于第二耦合部23的外侧。作为可替换的一种实施方式，可设置加强件包括内衬套41或外衬套42。
具体地，外衬套42为外衬框体，外衬框体一体成型设置或者分体设置，外衬框体和第二耦合部23一体成型设置或者分体设置；以及内衬套41包括内衬框体和内衬端盖，内衬端盖设于内衬框体的端口处，内衬框体和内衬端盖一体成型设置或者分体设置。
如图1和图2所示，连接件包括螺栓31和铆螺母32，铆螺母32的铆 接帽321位于第一斜面131和第二斜面231之间，螺栓31连接于铆螺母32的螺接杆。由于铆接帽321具有厚度，此厚度可提供空间给粘接剂进行粘接。
如图4、图7和图13所示，第二桶状承载件22内设有限位件5，限位件5对内衬套41限位。通过设置有限位件5和内衬套41的配合，便于初步定位第一叶片段和第二叶片段。其中，限位件5设有排水孔。通过设置有排水孔，有利于第一叶片段内部的排水。
本实施例中的一种分段叶片，通过设置有第一桶状承载件12具有第一斜面131和第二桶状承载件22具有第二斜面231，以使得第一斜面131和第二斜面231搭接连接，便于定位、安装第一耦合部13和第二耦合部23，并有助于分段叶片轴向载荷的有效传递；通过紧固连接和粘接的配合，使得粘接时也无需借助于外部工装对叶片段定位而是借助于紧固连接对叶片段进行精确定位，保证胶结固化，确保分段叶片的连接精度和连接强度，从而有利于风场施工；通过设置有加强件，分担连接件对叶片段的局部应力，提供充足的强度。
实施例2
本实施例提供一种分段叶片的制造方法，可基于实施例1中的分段叶片，包括以下步骤：
成型：形成第一叶片段：通过第一桶状承载件12、第一外壳11形成第一叶片段，其中，在第一桶状承载件12的第一耦合部13的各个外壁面均形成有第一斜面131；通过第二桶状承载件22、第二外壳21形成第二叶片段，其中，在第二桶状承载件22的第二耦合部23的各个内壁面均形成有第二斜面231，以及在对应的耦合部连接有加强件；
具体地，通过第一桶状承载件12、第一外壳11形成第一叶片段包括：如图3和图4所示，第一桶状承载件12的第一吸力面主梁121、第一外壳11的第一吸力面外壳111一体灌注成型且位于第一模具61，第一桶状承载件12的第一压力面主梁122、第一外壳11的第一压力面外壳112一体灌注成型且位于第二模具62上，第一桶状承载件12的第一前缘腹板123、第一桶状承载件12的第一后缘腹板124通过第一桶状承载件12的内衬套 41粘接连接；将第一前缘腹板123、第一后缘腹板124粘接连接于第一吸力面外壳111和第一压力面外壳112两者中的其中一个并通过第一模具61和第二模具62合模粘接连接于第一吸力面外壳111和第一压力面外壳112两者中的另一个，以形成第一叶片段；
其中，通过弦向定位件71对第一吸力面主梁121、第一压力面主梁122、第一前缘腹板123、第一后缘腹板124在第一模具61、第二模具62上进行弦向定位，通过轴向定位件72对第一吸力面主梁121、第一压力面主梁122、第一前缘腹板123、第一后缘腹板124在第一模具61、第二模具62上进行轴向定位，第一模具61、第二模具62均设有弦向定位件71、轴向定位件72；通过第一模具61、第二模具62，可实现两个叶片段的异模成型，能够提升叶片段的互换性；并当分段叶片需要再延长时，可替换叶尖再插接其他的叶片段来实现；以及通过设置有弦向定位件71、轴向定位件72，可确保成型精度；
具体参见图7和图8，弦向定位件71包括相对设置的弦向定位块，以及轴向定位件72为轴向定位板，轴向定位板连接于弦向定位块，其中第一模具61和第二模具62两者其中一个的弦向定位块设有定位柱74且两者另一个的弦向定位块设有定位孔73，第一模具61和第二模具62合模时，定位柱74插接于定位孔73内；并且，对第一吸力面主梁、第一压力面主梁、第一前缘腹板、第一后缘腹板形成第一耦合部处分别加工出第一斜面。
以及，通过第二桶状承载件22、第二外壳21形成第二叶片段包括：如图5至图9所示，第二桶状承载件22的第二吸力面主梁221、第二外壳21的第二吸力面外壳211一体灌注成型且位于第一模具61上，第二桶状承载件22的第二压力面主梁222、第二外壳21的第二压力面外壳212一体灌注成型且位于第二模具62上，第二桶状承载件22的第二前缘腹板223、第二桶状承载件22的第二后缘腹板224通过第二桶状承载件22的限位件5粘接连接；将第二前缘腹板223、第二后缘腹板224粘接连接于第二吸力面外壳211和第二压力面外壳212两者中的其中一个并通过第一模具61和第二模具62合模粘接连接于第二吸力面外壳211和第二压力面外壳212两者中的另一个，以形成第二叶片段；
其中，如图7和图9所示，通过弦向定位件71对第二吸力面主梁221、第二压力面主梁222、第二前缘腹板223、第二后缘腹板224进行弦向定位，通过轴向定位件72对第二吸力面主梁221、第二压力面主梁222、第二前缘腹板223、第二后缘腹板224进行轴向定位；
并且，对第二吸力面主梁221、第二压力面主梁222、第二前缘腹板223、第二后缘腹板224形成第二耦合部23处分别加工出第二斜面231；在第二耦合部23外粘接连接有外衬套42。
组装：在风场中，将第一桶状承载件12的第一耦合部13插入第二桶状承载件22的第二耦合部23内在此过程中可辅以外部工装、吊车等限定耦合姿态，通过连接件来紧固连接第一耦合部13和第二耦合部23，此时可撤离外部工装、吊车等，以及将粘接剂填充于第一斜面131和第二斜面231之间，无需等待固化完成即可进行下布工序，再将第三外壳连接于第一耦合部13和第二耦合部23以封闭第一耦合部13和第二耦合部23，使得第一外壳11、第二外壳21和第三外壳形成分段叶片的气动型面。
具体地，通过连接件来紧固连接第一耦合部13和第二耦合部23包括：如图10和图11所示，将第一桶状承载件12的第一耦合部13插入第二桶状承载件22的第二耦合部23，如图12所示，钻孔穿过外衬套42、第一耦合部13、第二耦合部23、内衬套41以形成安装孔8；分离第一叶片段、第二叶片段，对位于第一耦合部13和内衬套41上的安装孔8进行扩孔，安装连接件的铆螺母32于第一耦合部13、内衬套41，通过连接件的螺栓31连接第二耦合部23和铆螺母32。通过扩孔，使得安装孔8适配于连接件的螺栓31。
需要说明的是，第一吸力面主梁121、第一压力面主梁122、第二吸力面主梁221、第二压力面主梁222可通过拉挤板或者其他制成，第一外壳11、第二外壳21可通过蒙皮或者其他制成，第一前缘腹板123、第一后缘腹板124形成第一耦合部13的区域及第二前缘腹板223、第二后缘腹板224形成第二耦合部23的区域可通过拉挤板或者其他制成，第一前缘腹板123、第一后缘腹板124未形成第一耦合部13的其他区域及第二前缘腹板223、第二后缘腹板224未形成第二耦合部23的其他区域可通过玻璃钢夹 芯复合或者其他制成，内衬套41可通过玻纤、树脂等复或者其他合制成，外衬套42可通过玻纤、树脂等复合或者其他制成。
本实施例中的一种分段叶片的制造方法，通过第一桶状承载件12的第一斜面131搭接连接于第二桶状承载件22具有第二斜面231，便于定位、安装第一耦合部13和第二耦合部23，并有助于分段叶片轴向载荷的有效传递；通过紧固连接和粘接的配合，使得粘接时也无需借助于外部工装对叶片段定位而是借助于紧固连接对叶片段进行精确定位，保证胶结固化，确保分段叶片的连接精度和连接强度，从而有利于风场施工；通过连接有加强件，分担连接件对叶片段的局部应力，提供充足的强度。
显然，上述实施例仅仅是为清楚地说明所作的举例，而并非对实施方式的限定。对于所属领域的普通技术人员来说，在上述说明的基础上还可以做出其它不同形式的变化或变动。这里无需也无法对所有的实施方式予以穷举。而由此所引伸出的显而易见的变化或变动仍处于本发明创造的保护范围之中。
Claims (16)
- 一种分段叶片，包括：第一叶片段，所述第一叶片段包括第一外壳和第一桶状承载件，部分所述第一桶状承载件位于所述第一外壳内且连接于所述第一外壳，所述第一桶状承载件的第一耦合部外露于所述第一外壳，所述第一耦合部的各个外壁面均设有第一斜面，所述第一斜面沿靠近邻近的所述第一叶片段的端部的方向朝向所述第一耦合部的内侧倾斜设置；第二叶片段，所述第二叶片段包括第二外壳和第二桶状承载件，部分所述第二桶状承载件位于所述第二外壳内且连接于所述第二外壳，所述第二桶状承载件的第二耦合部外露于所述第二外壳，所述第二耦合部的各个内壁面均设有第二斜面，所述第二斜面沿靠近邻近的所述第二叶片段的端部的方向朝向所述第二耦合部的外侧倾斜设置，所述第一耦合部插接于所述第二耦合部内，所述第一斜面和所述第二斜面之间填充有粘接剂；连接件，所述连接件紧固连接所述第一耦合部和所述第二耦合部；加强件，所述加强件包括内衬套和/或外衬套，其中所述内衬套设于所述第一耦合部的内侧，所述外衬套设于所述第二耦合部的外侧。
- 根据权利要求1所述的一种分段叶片，其中，所述第一斜面的最大厚度和所述第一斜面的长度的比值大于等于1/200且小于等于1/20，所述第二斜面的最大厚度和所述第二斜面的长度的比值大于等于1/200且小于等于1/20。
- 根据权利要求1或2所述的一种分段叶片，其中，所述连接件包括螺栓和铆螺母，所述铆螺母的铆接帽位于所述第一斜面和所述第二斜面之间，所述螺栓连接于所述铆螺母的螺接杆。
- 根据权利要求1或2所述的一种分段叶片，其中，所述外衬套为外衬框体，所述外衬框体一体成型设置或者分体设置，所述外衬框体和所述第二耦合部一体成型设置或者分体设置。
- 根据权利要求1或2所述的一种分段叶片，其中，所述内衬套包括内衬框体和内衬端盖，所述内衬端盖设于所述内衬框体的端口处，所述内 衬框体和所述内衬端盖一体成型设置或者分体设置。
- 根据权利要求1或2所述的一种分段叶片，其中，所述加强件包括所述内衬套和所述外衬套；所述第二桶状承载件内设有限位件，所述限位件对所述内衬套限位。
- 根据权利要求6所述的一种分段叶片，其中，所述限位件设有排水孔。
- 一种分段叶片的制造方法，包括以下步骤：成型：形成第一叶片段：通过第一桶状承载件、第一外壳形成第一叶片段，其中，在所述第一桶状承载件的第一耦合部的各个外壁面均形成有第一斜面；通过第二桶状承载件、第二外壳形成第二叶片段，其中，在所述第二桶状承载件的第二耦合部的各个内壁面均形成有第二斜面，以及在对应的耦合部连接有加强件；组装：将所述第一耦合部插接于所述第二耦合部内，通过连接件来紧固连接所述第一耦合部和所述第二耦合部，以及将粘接剂填充于所述第一斜面和所述第二斜面之间。
- 根据权利要求8所述的一种分段叶片的制造方法，其中，所述组装还包括：将第三外壳连接于所述第一耦合部和所述第二耦合部，使得所述第一外壳、所述第二外壳和所述第三外壳形成所述分段叶片的气动型面。
- 根据权利要求8所述的一种分段叶片的制造方法，其中，所述通过所述第一桶状承载件、第一外壳形成第一叶片段包括：所述第一桶状承载件的第一吸力面主梁、所述第一外壳的第一吸力面外壳一体成型且位于第一模具上，所述第一桶状承载件的第一压力面主梁、所述第一外壳的第一压力面外壳一体成型且位于第二模具上，所述第一桶状承载件的第一前缘腹板、所述第一桶状承载件的第一后缘腹板的内侧通过所述加强件的内衬套连接；将所述第一前缘腹板、所述第一后缘腹板连接于所述第一吸力面外壳和所述第一压力面外壳两者中的其中一个并通过所述第一模具和所述第二模具合模连接于所述第一吸力面外壳和所述第一压力面外壳两者中的另一个，以形成所述第一叶片段。
- 根据权利要求10所述的一种分段叶片的制造方法，其中，所述通 过所述第一桶状承载件、第一外壳形成第一叶片段包括：通过弦向定位件对所述第一吸力面主梁、所述第一压力面主梁、所述第一前缘腹板、所述第一后缘腹板进行弦向定位，通过轴向定位件对所述第一吸力面主梁、所述第一压力面主梁、所述第一前缘腹板、所述第一后缘腹板进行轴向定位，所述第一模具、所述第二模具均设有所述弦向定位件、所述轴向定位件。
- 根据权利要求10所述的一种分段叶片的制造方法，其中，所述通过第二桶状承载件、第二外壳形成第二叶片段包括：所述第二桶状承载件的第二吸力面主梁、所述第二外壳的第二吸力面外壳一体成型且位于所述第一模具上，所述第二桶状承载件的第二压力面主梁、所述第二外壳的第二压力面外壳一体成型且位于所述第二模具上，所述第二桶状承载件的第二前缘腹板、所述第二桶状承载件的第二后缘腹板通过所述第二桶状承载件的限位件连接，在所述第二耦合部的外侧连接有所述加强件的外衬套；将所述第二前缘腹板、所述第二后缘腹板连接于所述第二吸力面外壳和所述第二压力面外壳两者中的其中一个并通过所述第一模具和所述第二模具合模连接于所述第二吸力面外壳和所述第二压力面外壳两者中的另一个，以形成所述第二叶片段。
- 根据权利要求12所述的一种分段叶片的制造方法，其中，所述通过第二桶状承载件、第二外壳形成第二叶片段还包括：通过弦向定位件对所述第二吸力面主梁、所述第二压力面主梁、所述第二前缘腹板、所述第二后缘腹板进行弦向定位，通过轴向定位件对所述第二吸力面主梁、所述第二压力面主梁、所述第二前缘腹板、所述第二后缘腹板进行轴向定位，所述第一模具、所述第二模具均设有所述弦向定位件、所述轴向定位件。
- 根据权利要求13所述的一种分段叶片的制造方法，其中，所述通过连接件来紧固连接所述第一耦合部和所述第二耦合部包括：将所述第一耦合部插入所述第二耦合部，钻孔穿过所述外衬套、所述第一耦合部、所述第二耦合部、所述内衬套以形成安装孔。
- 根据权利要求14所述的一种分段叶片的制造方法，其中，所述通过连接件来紧固连接所述第一耦合部和所述第二耦合部还包括：分离所述第一叶片段、所述第二叶片段，对位于所述第一耦合部和所述内衬套上的 所述安装孔进行扩孔，安装所述连接件的铆螺母于所述第一耦合部、所述内衬套，通过所述连接件的螺栓连接所述第二耦合部和所述铆螺母。
- 根据权利要求8所述的一种分段叶片的制造方法，其中，基于权利要求1至7中任意一项所述的分段叶片。
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| CN113056602A (zh) * | 2018-08-28 | 2021-06-29 | 通用电气公司 | 用于接合式风力涡轮转子叶片的翼梁构造 |
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| CN114526193A (zh) * | 2022-03-22 | 2022-05-24 | 中材科技风电叶片股份有限公司 | 风电叶片主承力结构连接接头和风力发电机组 |
| CN217270597U (zh) * | 2022-02-23 | 2022-08-23 | 中材科技风电叶片股份有限公司 | 分段叶片及风力发电机组 |
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- 2022-12-15 WO PCT/CN2022/139362 patent/WO2023226387A1/zh unknown
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| US20070253824A1 (en) * | 2006-04-30 | 2007-11-01 | Enno Eyb | Modular rotor blade for a wind turbine and method for assembling same |
| CN101990599A (zh) * | 2008-09-04 | 2011-03-23 | 三菱重工业株式会社 | 风车翼 |
| US20140286780A1 (en) * | 2011-08-05 | 2014-09-25 | Tecsis Tecnologia E Sistemas Avancados S.A. | Aerogenerator blade tip segment and method of assembly |
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