CN103097115B - 风轮机叶片温度测量***及风轮机叶片的制造方法 - Google Patents

风轮机叶片温度测量***及风轮机叶片的制造方法 Download PDF

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Publication number
CN103097115B
CN103097115B CN201180043065.9A CN201180043065A CN103097115B CN 103097115 B CN103097115 B CN 103097115B CN 201180043065 A CN201180043065 A CN 201180043065A CN 103097115 B CN103097115 B CN 103097115B
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China
Prior art keywords
temperature sensor
shell
blade
wind turbine
bonding zone
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Expired - Fee Related
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CN201180043065.9A
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English (en)
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CN103097115A (zh
Inventor
艾伯·斯温德·奥利森
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Vestas Wind Systems AS
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Vestas Wind Systems AS
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Priority claimed from GB1011543.4A external-priority patent/GB2481842A/en
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    • 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
    • B29D99/0025—Producing blades or the like, e.g. blades for turbines, propellers, or wings
    • 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
    • B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
    • B29C65/483—Reactive adhesives, e.g. chemically curing adhesives
    • B29C65/4835—Heat curing adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/03—After-treatments in the joint area
    • B29C66/034—Thermal after-treatments
    • B29C66/0342—Cooling, e.g. transporting through welding and cooling zone
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/112—Single lapped joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
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    • 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
    • B29C66/543—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 joining more than two hollow-preforms to form said hollow 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
    • B29C66/61—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
    • 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
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    • B29C66/912—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by measuring the temperature, the heat or the thermal flux
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
    • F03D—WIND MOTORS
    • F03D1/00—Wind motors with rotation axis substantially parallel to the air flow entering the rotor 
    • F03D1/06—Rotors
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
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    • G—PHYSICS
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    • G01K11/32—Measuring temperature based upon physical or chemical changes not covered by groups G01K3/00, G01K5/00, G01K7/00 or G01K9/00 using changes in transmittance, scattering or luminescence in optical fibres
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    • F05B2270/80—Devices generating input signals, e.g. transducers, sensors, cameras or strain gauges
    • F05B2270/804—Optical devices
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Abstract

本发明提供一种风轮机叶片，包括：具有第一粘合区的第一壳（30）以及具有第二粘合区的第二壳（31），其中，所述第二壳的所述第二粘合区粘合至所述第一壳的所述第一粘合区；以及置于所述第一粘合区与所述第二粘合区之间的温度传感器（22）。将温度传感器（22）置于风轮机叶片内，位于风轮机叶片的两个壳粘合在一起的粘合区中，这在叶片的制造过程中允许准确地确定并且控制关键粘合区的温度。所述温度传感器可在所述风轮机叶片的使用寿命期间用于检测所述风轮机叶片的脱层。

Description

风轮机叶片温度测量***及风轮机叶片的制造方法
技术领域
本发明涉及一种用于制造风轮机叶片的***与方法。具体地说，本发明涉及用于接合两个风轮机叶片壳的粘合过程。本发明还涉及一种用于在使用风轮机叶片期间检测风轮机叶片的脱层的***。
背景技术
图1示出了风轮机1，其包括风轮机塔架2，在该风轮机塔架上安装有风轮机机舱3。至少包括一个风轮机叶片5的风轮机转子4安装在轮毂6上。轮毂6通过从机舱前部延伸的低速轴(未示出)连接至机舱3。图1中所示的风轮机可以是打算家用或轻型使用的小型风轮机，或者可以是例如诸如适合风电厂的大型发电使用的大型风轮机。在后一种情况下，转子的直径能达100米或更大。
通常，通过形成两个叶片半部或两个叶片壳，而后将其粘合在一起而制成风轮机叶片。两个壳之间的粘合失效(通常称作叶片脱层)是严重的问题，由于其最常在叶片安装在风轮机上以后发生。
用于粘合两个壳的粘合过程是减小脱层发生的可能性而延长风轮机叶片使用寿命的关键。通常，通过将粘合树脂施加至一个或两个壳，将这些壳按压在一起，然后在炉中固化粘合树脂，从而完成两个壳的粘合。固化过程中粘合树脂的温度是实现良好粘合强度的关键。
通常，将叶片置于炉中，基于从制造在先叶片获得的经验数据控制炉温与固化时间。然而，没有两个叶片总是相同，所使用的炉的性能在每次使用时也不是必然相同。申请人已意识到存在一种需求：提供一种在风轮机叶片制造过程中更准确地控制叶片壳粘合过程的***与方法。
发明内容
根据本发明的第一方面，提供一种风轮机叶片，该风轮机叶片包括：具有第一粘合区的第一壳以及具有第二粘合区的第二壳，其中，所述第二壳的所述第二粘合区粘合至所述第一壳的所述第一粘合区；以及置于所述第一粘合区与所述第二粘合区之间的温度传感器。
本发明可应用于风轮机叶片中的部件之间的任何粘合。例如，风轮机叶片通常在壳之间包括加强翼梁或腹板，以提高叶片的结构强度。本发明可应用于所述翼梁或所述腹板与所述叶片壳之间的粘合。
在风轮机叶片内在风轮机叶片的两个壳粘合在一起的粘合区中设置温度传感器，从而允许在制造叶片过程中能准确地测定关键粘合区的温度。
优选的是，所述风轮机叶片还包括将所述第一壳粘合至所述第二壳的粘合剂或粘合材料，并且所述温度传感器嵌入在所述粘合材料中。通常，所述粘合材料是一种在室温以上的温度下固化的固化复合物。
在之后的叶片制造中，所述温度传感器通常保持嵌在所述风轮机叶片内。为此，重要的是所述温度传感器不包括可能增加叶片上的雷击风险的任何金属性导电元件。因此，在优选的实施方式中，所述温度传感器是光学温度传感器。所述光学温度传感器优选为光纤内的光纤布拉格光栅传感器。沿着所述光纤的长度可具有多个光纤布拉格光栅，以便在多个分开的位置检测所述粘合区的温度。均包括一个或多个光纤布拉格光栅的多根光纤可置于所述第一粘合区与所述第二粘合区之间。所述光学温度传感器可以是绕粘合区延伸的单个分布式传感器，例如可从Oz Optics得到的分布式应变温度传感器(DSTS)。这种类型的传感器使得能利用时分多路复用(TDM)技术测定沿其长度的任意点的温度。这使得能检测到所述粘合区中的热点与冷点。
所述温度传感器可用于在所述风轮机叶片的使用过程中检测所述风轮机叶片的脱层。为此目的，优选将所述温度传感器定位在所述风轮机叶片的尾缘，因为这里最常发生脱层。如果所述传感器损坏，即不发出信号，或突然发出明显异常的输出，就可检测或推测出脱层。如果所述温度传感器是光纤布拉格光栅传感器，就可用于直接测量应变，从而直接检测在所述粘合区是否存在传感器的显著变形。
在本发明的另一方面中，提供一种装配风轮机叶片的方法，该方法包括：形成第一壳与第二壳；将热固化粘合材料施加至所述第一壳或所述第二壳，或施加至所述第一壳及所述第二壳二者；设置温度传感器；将所述第一壳放置成与所述第二壳接触，使得所述粘合材料与所述温度传感器被夹在所述第一壳与所述第二壳之间；以及固化所述粘合材料，其中固化步骤包括监控由光学温度传感器检测到的温度，并基于检测到的温度控制施加至所述粘合材料的热。
通过直接监控固化粘合材料的温度并响应于所检测到的温度控制施加的热，可保证所述第一壳与所述第二壳之间的粘合的物理特性。优选的是，本方法包括在所述第一壳与所述第二壳之间设置多个温度传感器。这使得能在固化过程中会达到不同温度的多个位置保证良好的粘合。
优选的是，所述温度传感器是光学温度传感器。优选的是，所述光学温度传感器是光纤内的光纤布拉格光栅传感器。优选的是，所述光纤在所述第一壳与所述第二壳粘合的粘合区中绕所述第一壳与所述第二壳的外周延伸。所述光纤可包含多个光纤布拉格光栅传感器。
在本发明的再一方面中，提供一种用于制造风轮机叶片的***，该***包括：炉，所述炉保持第一叶片壳与第二叶片壳；温度传感器，所述温度传感器在所述第一叶片壳与第二叶片壳要被粘合在一起的粘合区中置于这些叶片壳之间；处理电子设备，该处理电子设备连接至所述温度传感器，以基于来自所述温度传感器的信号确定所述第一叶片壳与所述第二叶片壳要被粘合在一起的所述粘合区中的温度；以及炉控制器，所述炉控制器连接至所述处理电子设备，所述炉控制器基于由所述处理电子设备确定的所述粘合区的温度来控制供给至所述炉的热。
所述炉可允许局部热控制，从而向所述叶片的厚部施加比所述叶片的薄部更多的热。优选的是，所述***包括能够在多个位置提供温度测量的一个温度传感器或者多个温度传感器。于是，所述处理电子设备可构造成为所述炉控制器提供多个温度测量值，那么所述炉控制器可基于这些温度测量值为所述炉的不同部分提供不同的热量。这可以是自动化过程，例如在所述炉控制器中使用适当的软件，或者可以是手动控制过程。
在优选的实施方式中，所述温度传感器是光学温度传感器。所述光学温度传感器优选为光纤内的光纤布拉格光栅。沿所述光纤的长度可具有多个光纤布拉格光栅，以便在多个分开的位置检测所述粘合区的温度。可选的是，均包括一个或多个光纤布拉格光栅的多根光纤可置于所述第一粘合区和所述第二粘合区之间。
在本发明的另一方面中，提供一种风轮机叶片，该风轮机叶片包括：多个部件，这些部件中的至少两个部件在粘合区中粘合在一起；以及在这两个部件之间置于所述粘合区中的温度传感器。所述两个部件可以是第二叶片壳、翼梁以及腹板之一与第一叶片壳。
在本发明的再一方面中，提供一种风轮机叶片，所述风轮机叶片包括：具有第一粘合区的第一壳以及具有第二粘合区的翼梁，其中，所述翼梁的所述第二粘合区粘合至所述第一壳的所述第一粘合区；以及置于所述第一粘合区与所述第二粘合区之间的温度传感器。
在本发明的再一方面中，提供一种风轮机叶片，所述风轮机叶片包括：具有第一粘合区的第一壳以及具有第二粘合区的腹板，其中，所述腹板的所述第二粘合区粘合至所述第一壳的所述第一粘合区；以及置于所述第一粘合区与所述第二粘合区之间的温度传感器。
在本发明的再一方面中，提供一种装配风轮机叶片的方法，该方法包括：形成所述风轮机叶片的第一部件与第二部件；将热固化粘合材料施加至这些部件中的一者或两者；设置温度传感器；将所述第一部件放置成与所述第二部件接触，使得所述粘合材料与所述温度传感器夹在所述第一部件与所述第二部件之间；以及使所述粘合材料固化，其中固化步骤包括监控由所述光学温度传感器检测到的温度，并基于检测到的温度控制施加至所述粘合材料的热。所述第一部件和所述第二部件可以是第二叶片壳、翼梁以及腹板之一与第一叶片壳。
在本发明的再一方面中，提供一种装配风轮机叶片的方法，该方法包括：形成第一壳与翼梁；将热固化粘合材料施加至所述第一壳或所述翼梁，或者施加至所述第一壳与所述翼梁二者；设置温度传感器；将所述第一壳放置成与所述翼梁接触，使得所述粘合材料与所述温度传感器夹在所述第一壳与所述翼梁之间；以及使所述粘合材料固化，其中固化步骤包括监控由所述光学温度传感器检测到的温度，并基于检测到的温度控制施加至所述粘合材料的热。
在本发明的再一方面中，提供一种装配风轮机叶片的方法，该方法包括：形成第一壳与腹板；将热固化粘合材料施加至所述第一壳或所述腹板，或者施加至所述第一壳与所述腹板二者；设置温度传感器；将所述第一壳放置成与所述腹板接触，使得所述粘合材料与所述温度传感器夹在所述第一壳与所述腹板之间；以及使所述粘合材料固化，其中固化步骤包括监控由所述光学温度传感器检测到的温度，并基于检测到的温度控制施加至所述粘合材料的热。
在本发明的再一方面中，提供一种用于制造风轮机叶片的***，该***包括：炉，所述炉保持第一叶片部件与第二叶片部件；温度传感器，所述温度传感器在所述第一叶片部件与所述第二叶片部件要粘合在一起的粘合区中置于这些叶片部件之间；处理电子设备，所述处理电子设备连接至所述温度传感器，以基于来自所述温度传感器的信号确定所述第一叶片部件与所述第二叶片部件要被粘合在一起的所述粘合区中的温度；以及炉控制器，所述炉控制器连接至所述处理电子设备，所述炉控制器基于由所述处理电子设备确定的所述粘合区的温度来控制供给至所述炉的热。所述第一叶片部件与所述第二叶片部件可以是第二叶片壳、翼梁以及腹板之一与第一叶片壳。
在本发明的再一方面中，提供一种用于制造风轮机叶片的***，该***包括：炉，所述炉保持第一叶片壳与翼梁；温度传感器，所述温度传感器在所述第一叶片壳与所述翼梁要粘合在一起的粘合区中置于所述第一叶片壳与所述翼梁之间；处理电子设备，所述处理电子设备连接至所述温度传感器，以基于来自所述温度传感器的信号确定所述第一叶片壳与所述翼梁要被粘合在一起的所述粘合区中的温度；以及炉控制器，所述炉控制器连接至所述处理电子设备，所述炉控制器基于由所述处理电子设备确定的所述粘合区的温度来控制供给至所述炉的热。
在本发明的再一方面中，提供一种用于制造风轮机叶片的***，该***包括：炉，所述炉保持第一叶片壳与腹板；温度传感器，所述温度传感器在所述第一叶片壳与所述腹板要粘合在一起的粘合区中置于所述第一叶片壳与所述翼梁之间；处理电子设备，所述处理电子设备连接至所述温度传感器，以基于来自所述温度传感器的信号确定所述第一叶片壳与所述腹板要被粘合在一起的所述粘合区中的温度；以及炉控制器，所述炉控制器连接至所述处理电子设备，所述炉控制器基于由所述处理电子设备确定的所述粘合区的温度来控制供给至所述炉的热。
在本发明的再一方面中，提供一种包括根据第一方面的风轮机叶片的风轮机。
在本发明的再一方面中，提供一种叶片脱层检测***，所述叶片脱层检测***包括根据第一方面所述的风轮机叶片、以及连接至所述光学温度传感器的光学检测器，其中，所述光学检测器构造成检测所述光学温度传感器的输出中的指示叶片脱层的阶跃变化。
应当明了的是，涉及与本发明的一方面相关的特征可同样适用于本发明的其他方面。具体地说，涉及与叶片壳相互粘合有关的特征可同样适用于叶片壳与加强翼梁或腹板的粘合。
附图说明
现在将参照附图以实施例方式描述本发明的优选实施方式，在附图中：
图1示出公知的风轮机；
图2是带有光纤温度传感器的风轮机叶片的示意图，所述光纤温度传感器定位在两个风轮机叶片壳之间的粘合区中；
图3是图2的两个风轮机叶片壳的示意剖面图，示出了所述光纤温度传感器的位置；
图4是示出根据本发明的形成风轮机叶片的方法的流程图；
图5是两个风轮机叶片壳的示意剖面图，示出了粘合至所述两个壳的翼梁的位置；
图6是图5的叶片的示意图，示出了翼梁的纵向范围；以及
图7是两个风轮机叶片壳的示意剖面图，示出了粘合至这两个壳的一对腹板的位置。
具体实施方式
图2是在将两个风轮机叶片壳粘合在一起的固化过程中，位于炉21中的风轮机叶片20的示意图。图3是图2的风轮机叶片的分解剖面图，该图更清晰地示出了两个壳30、31以及两个壳之间的光纤温度传感器22的位置。
图3中非常清晰地示出了根据本发明的风轮机叶片的结构。风轮机叶片包括上壳30与下壳31，两者粘合在一起而形成完整的叶片20。通常，每个壳30、31由树脂浸渍纤维复合物形成。本技术领域中公知风轮机叶片的这种叶片结构。
上壳30与下壳31在其外缘(在此称作“粘合区”)粘合在一起。粘合区绕每个壳的边缘延伸，并且实质上是两个壳置于一起时相接而形成完整的叶片之处。
壳也可在内部区域中粘合在一起，因此粘合区可不限于两个壳的边缘。例如，大型风轮机叶片常设置有翼梁或腹板，该翼梁或腹板在叶片的内部中在两个壳之间延伸。翼梁或腹板提供结构强度。在粘合区使用与将两个壳直接相互粘合所用的相同类型的树脂将翼梁或腹板粘合至每个壳。
在粘合区中将粘合树脂32置于一个或两个壳上，以便将两个壳粘合在一起。在图3所示的实施例中，将粘合树脂应用于上壳30与下壳31两者。粘合树脂可以是本技术领域中公知的热固化树脂、粘合剂或胶的任何适当类型。
为了形成强粘合，必须将粘合树脂加热至特定的固化温度，然后使其冷却。加热及冷却树脂的速度同树脂到达的绝对温度一样，在很大程度上决定所形成的粘合的物理特性。
图2示出用于将粘合树脂加温至其固化温度的炉21内的风轮机叶片。由炉21供给的热通过炉控制***23控制。通常，炉控制***23是电子控制***，并且炉通常是电动炉。炉控制***23可允许局部控制，以便向炉的不同部分供给不同热量。
本发明不是简单检测炉内一个位置的温度，或基于施加至炉的能量或热估测温度，而是直接检测待固化的树脂的温度。而后可在反馈环中在固化过程中向炉控制***23连续提供所检测到的温度。以此方式，可准确控制固化过程中树脂的温度，并使其遵循期望的温度分布，从而实现强粘合。
为了准确而直接地检测树脂32的温度，使用光学温度传感器22。在图2与图3所示的实施例中，光学温度传感器是光纤22，其包括一个或多个光纤布拉格光栅。光纤22在树脂32中置于上壳30与下壳31之间。光纤从光电处理器24开始绕上壳30与下壳31的粘合区延伸，并回到光电处理器24。通常，光电处理器24位于炉21外部。光纤内的一个或多个光纤布拉格光栅用于检测粘合区内的温度。使用光纤布拉格光栅检测温度是公知的。例如，参见US7,379,169。可使用光纤布拉格光栅的频率响应变化来确定光纤布拉格光栅位置处的温度变化。可另选地使用绕叶片外周延伸的形成分布式传感器的单个光纤。
光电处理器24基于一个传感器或多个传感器的输出而产生指示粘合区内一个或多个位置处的树脂温度的信号，并将该信号传送至炉控制***23。而后，炉控制***23调整供给至炉21的热或能量，或调整炉的多个部位，以使树脂维持在期望的温度。
图4是示出在根据本发明的风轮机叶片制造方法中执行的步骤的流程图。
在步骤400与410中制成风轮机叶片的上壳与下壳。可根据本技术领域中公知的任何标准技术制造上壳与下壳。在步骤420中，在粘合区中将树脂或胶施加至上壳或下壳、或者施加至上壳和下壳二者。而后，在步骤430中，将包括光纤布拉格光栅的光纤置于上壳或下壳上的树脂中。然后，在步骤440中，将上壳置于下壳上，光纤与可固化的树脂夹于其间。在步骤450中，将叶片置于炉中。可选的是，可在炉被加热之前，在炉中执行步骤420至440。接着，在步骤460中加热叶片以开始固化过程，使两个叶片壳粘合在一起。
在步骤470中，使用光学温度传感器检测树脂的温度，并且如参照图1所描述的，根据所检测到的温度控制施加至叶片的热量。图4中步骤470与步骤460之间的虚线示出反馈控制。一旦达到期望温度，炉可将树脂维持在该温度一段时间以使树脂能完全固化。
在步骤480中，冷却叶片。如果冷却树脂的速率很重要，那么可在步骤480的冷却过程中继续监控树脂的温度，并相应地控制冷却速率。该反馈控制由图4中步骤480与步骤470之间的虚线示出。
一旦叶片冷却至环境温度，制造过程完成。这由步骤490示出。
尽管已经通过将风轮机叶片置于炉中来固化树脂描述了本发明，但可通过其他方式向树脂施加热，例如，通过直接向叶片表面应用加热元件。
根据本发明可在上壳与下壳之间设置不止一根光纤。具有不止一根光纤会提供冗余。与使用多重光栅光纤或具有细长光栅的光纤相比，使用多根单光栅光纤也会是更具成本效益的。如下所述，也可允许在早期阶段检测叶片的脱层。
正如已经描述的，可在风轮机叶片中的任何粘合中设置光学温度传感器。图5示出风轮机叶片的示意剖面图，该风轮机叶片包括粘合至上壳30与下壳31的翼梁50。图6示出从叶片20根部附近延伸至叶梢附近的翼梁。以与使两个壳相互粘合相同的方式，在粘合区51、52中使用热固化树脂将翼梁粘合至上壳与下壳。可在翼梁与各个叶片壳之间的每个粘合区中设置一根或多根光纤53，并且所述光纤可用于在装配过程中监控粘合树脂的温度。
图7是示出替代图5中所示的箱形翼梁50而使用加强腹板70、71的示意剖面图。腹板70、71与叶片壳30、31在粘合区72、73、74、75处使用热固化树脂粘合在一起。可在腹板与叶片壳之间的每个粘合区中设置一根或多根光纤76，并且可将其用于在装配过程中监控粘合树脂的温度。
在风轮机叶片的尾缘处在上壳与下壳之间包括光学温度传感器，具体地说是包括光纤布拉格光栅或长周期光栅(LPG)，这具有额外的独特优势。伴随风轮机叶片的一个普遍问题是在服务期内上壳与下壳分离。这称为叶片脱层，并且最常在叶片的尾缘发生。用于在本发明制造过程中使用的光学温度传感器可随后作为检测叶片脱层的手段用在风轮机叶片的使用与维护中。在使用风轮机叶片的过程中，光学温度传感器的光学响应中的阶跃变化或仅仅是光学温度传感器的失效，表示叶片脱层。光纤布拉格光栅可用于直接测量其所在位置处的应变。位于上壳与下壳之间的光纤布拉格光栅所经历的突然应变变化，特别是如果该变化与在叶片其他位置得到的应变测量值不相关，则表示叶片脱层。
因此，根据本发明的风轮机叶片在风轮机叶片的制造以及风轮机叶片使用过程中的叶片脱层检测中都具有优势。
鉴于当温度传感器安装在风轮机上时，温度传感器保持在叶片内，期望光学温度传感器不包括可显著增加雷击风险的任何金属性或高导电性元件。为此，光学温度传感器是最理想的，并且光纤布拉格光栅提供了特别有利的解决方案。
尽管光纤布拉格光栅是温度传感器的优选形式，但是也可另选地或附加地采用其他类型的温度传感器。例如，可使用长周期光栅(LPG)。LPG不仅能用于检测温度，而且可用于检测叶片在使用中的弯曲。这允许在检测叶片脱层的同时也考虑到叶片的总体结构损害。也可使用基于拉曼或布里渊散射的分布式光纤传感器。
仅为了说明而参照示例性实施方式描述了本发明。本发明不受此限制，本领域技术人员可想到多种变型以及变更。本发明根据所附权利要求来理解。

Claims (31)

1.一种风轮机叶片，该风轮机叶片包括：具有第一粘合区的第一壳以及具有第二粘合区的第二壳，其中，所述第二壳的所述第二粘合区粘合至所述第一壳的所述第一粘合区；以及置于所述第一粘合区与所述第二粘合区之间的温度传感器，该风轮机叶片还包括粘合材料，该粘合材料使所述第一壳粘合至所述第二壳，其中，所述温度传感器嵌入在所述粘合材料中，所述温度传感器是光学温度传感器。
2.根据权利要求1所述的风轮机叶片，其中，所述光学温度传感器是光纤内的光纤布拉格光栅。
3.根据权利要求2所述的风轮机叶片，该风轮机叶片还包括沿所述光纤的长度的多个光纤布拉格光栅。
4.根据权利要求1所述的风轮机叶片，其中，所述光学温度传感器是光纤内的长周期光栅。
5.根据权利要求1至4中任一项所述的风轮机叶片，该风轮机叶片包括位于所述第一粘合区与所述第二粘合区之间的多个光学温度传感器，这些光学温度传感器包括多根光纤，每根光纤包括一个或多个光纤布拉格光栅。
6.根据权利要求1至4中任一项所述的风轮机叶片，其中，所述温度传感器被定位在所述风轮机叶片的尾缘中。
7.根据权利要求5所述的风轮机叶片，其中，所述温度传感器被定位在所述风轮机叶片的尾缘中。
8.一种装配风轮机叶片的方法，该方法包括：
形成第一壳与第二壳；
将热固化粘合材料施加至所述第一壳或所述第二壳，或施加至所述第一壳及所述第二壳二者；
设置温度传感器，所述温度传感器是光学温度传感器；
将所述第一壳放置成与所述第二壳接触，使得所述粘合材料与所述温度传感器被夹在所述第一壳与所述第二壳之间；以及
固化所述粘合材料，其中固化步骤包括监控由所述光学温度传感器检测到的温度，并基于检测到的温度控制施加至所述粘合材料的热。
9.根据权利要求8所述的方法，其中，所述方法包括在所述第一壳与所述第二壳之间设置多个温度传感器。
10.根据权利要求8所述的方法，其中，所述光学温度传感器是光纤内的一个或多个光纤布拉格光栅。
11.根据权利要求8所述的方法，其中，所述光学温度传感器是光纤内的长周期光栅。
12.根据权利要求10或11所述的方法，其中，所述光纤在所述第一壳与所述第二壳粘合的粘合区中绕所述第一壳与所述第二壳的外周延伸。
13.一种用于制造风轮机叶片的***，该***包括：
炉，所述炉保持第一叶片壳与第二叶片壳；
温度传感器，所述温度传感器在所述第一叶片壳与第二叶片壳要被粘合在一起的粘合区中置于这些叶片壳之间；
处理电子设备，该处理电子设备连接至所述温度传感器，以基于来自所述温度传感器的信号确定所述第一叶片壳与所述第二叶片壳要被粘合在一起的所述粘合区中的温度；以及
炉控制器，所述炉控制器连接至所述处理电子设备，所述炉控制器基于由所述处理电子设备确定的所述粘合区的温度来控制供给至所述炉的热，
该***还包括粘合材料，该粘合材料使所述第一叶片壳粘合至所述第二叶片壳，其中，所述温度传感器嵌入在所述粘合材料中，所述温度传感器是光学温度传感器。
14.根据权利要求13所述的***，其中，所述光学温度传感器是光纤内的光纤布拉格光栅。
15.根据权利要求14所述的***，该***还包括沿所述光纤的长度的多个光纤布拉格光栅。
16.根据权利要求13所述的***，其中，所述光学温度传感器是光纤内的长周期光栅。
17.根据权利要求13所述的***，该***包括位于所述第一叶片壳与所述第二叶片壳要被粘合在一起的所述粘合区中在所述第一叶片壳和所述第二叶片壳之间的多个光学温度传感器，这些光学温度传感器包括多根光纤，每根光纤包括一个或多个光纤布拉格光栅。
18.一种风轮机叶片，该风轮机叶片包括：多个部件，这些部件中的至少两个部件在粘合区中粘合在一起；以及在这两个部件之间置于所述粘合区中的温度传感器，该风轮机叶片还包括粘合材料，该粘合材料使所述这两个部件彼此粘合，其中，所述温度传感器嵌入在所述粘合材料中，所述温度传感器是光学温度传感器。
19.根据权利要求18所述的风轮机叶片，其中，所述两个部件是第二叶片壳、翼梁以及腹板之一与第一叶片壳。
20.一种风轮机叶片，该风轮机叶片包括：具有第一粘合区的第一壳以及具有第二粘合区的翼梁，其中，所述翼梁的所述第二粘合区粘合至所述第一壳的所述第一粘合区；以及置于所述第一粘合区与所述第二粘合区之间的温度传感器，该风轮机叶片还包括粘合材料，该粘合材料使所述第一壳粘合至所述翼梁，其中，所述温度传感器嵌入在所述粘合材料中，所述温度传感器是光学温度传感器。
21.一种风轮机叶片，该风轮机叶片包括：具有第一粘合区的第一壳以及具有第二粘合区的腹板，其中，所述腹板的所述第二粘合区粘合至所述第一壳的所述第一粘合区；以及置于所述第一粘合区与所述第二粘合区之间的温度传感器，该风轮机叶片还包括粘合材料，该粘合材料使所述第一壳粘合至所述腹板，其中，所述温度传感器嵌入在所述粘合材料中，所述温度传感器是光学温度传感器。
22.一种装配风轮机叶片的方法，该方法包括：
形成所述风轮机叶片的第一部件与第二部件；
将热固化粘合材料施加至这些部件中的一者或两者；
设置温度传感器，所述温度传感器是光学温度传感器；
将所述第一部件放置成与所述第二部件接触，使得所述粘合材料与所述温度传感器夹在所述第一部件与所述第二部件之间；以及
使所述粘合材料固化，其中固化步骤包括监控由所述光学温度传感器检测到的温度，并基于检测到的温度控制施加至所述粘合材料的热。
23.根据权利要求22所述的方法，其中，所述第一部件和所述第二部件是第二叶片壳、翼梁以及腹板之一与第一叶片壳。
24.一种装配风轮机叶片的方法，该方法包括：
形成第一壳与翼梁；
将热固化粘合材料施加至所述第一壳或所述翼梁，或者施加至所述第一壳与所述翼梁二者；
设置温度传感器，所述温度传感器是光学温度传感器；
将所述第一壳放置成与所述翼梁接触，使得所述粘合材料与所述温度传感器夹在所述第一壳与所述翼梁之间；以及
使所述粘合材料固化，其中固化步骤包括监控由所述光学温度传感器检测到的温度，并基于检测到的温度控制施加至所述粘合材料的热。
25.一种装配风轮机叶片的方法，该方法包括：
形成第一壳与腹板；
将热固化粘合材料施加至所述第一壳或所述腹板，或者施加至所述第一壳与所述腹板二者；
设置温度传感器，所述温度传感器是光学温度传感器；
将所述第一壳放置成与所述腹板接触，使得所述粘合材料与所述温度传感器夹在所述第一壳与所述腹板之间；以及
使所述粘合材料固化，其中固化步骤包括监控由所述光学温度传感器检测到的温度，并基于检测到的温度控制施加至所述粘合材料的热。
26.一种用于制造风轮机叶片的***，该***包括：
炉，所述炉保持第一叶片部件与第二叶片部件；
温度传感器，所述温度传感器在所述第一叶片部件与所述第二叶片部件要被粘合在一起的粘合区中置于这些叶片部件之间；
处理电子设备，所述处理电子设备连接至所述温度传感器，以基于来自所述温度传感器的信号确定所述第一叶片部件与所述第二叶片部件要被粘合在一起的所述粘合区中的温度；以及
炉控制器，所述炉控制器连接至所述处理电子设备，所述炉控制器基于由所述处理电子设备确定的所述粘合区的温度来控制供给至所述炉的热，
该***还包括粘合材料，该粘合材料使所述第一叶片部件粘合至所述第二叶片部件，其中，所述温度传感器嵌入在所述粘合材料中，所述温度传感器是光学温度传感器。
27.根据权利要求26所述的***，其中，所述第一叶片部件与所述第二叶片部件是第二叶片壳、翼梁以及腹板之一与第一叶片壳。
28.一种用于制造风轮机叶片的***，该***包括：
炉，所述炉保持第一叶片壳与翼梁；
温度传感器，所述温度传感器在所述第一叶片壳与所述翼梁要被粘合在一起的粘合区中置于所述第一叶片壳与所述翼梁之间；
处理电子设备，所述处理电子设备连接至所述温度传感器，以基于来自所述温度传感器的信号确定所述第一叶片壳与所述翼梁要被粘合在一起的所述粘合区中的温度；以及
炉控制器，所述炉控制器连接至所述处理电子设备，所述炉控制器基于由所述处理电子设备确定的所述粘合区的温度来控制供给至所述炉的热，
该***还包括粘合材料，该粘合材料使所述第一叶片壳粘合至所述翼梁，其中，所述温度传感器嵌入在所述粘合材料中，所述温度传感器是光学温度传感器。
29.一种用于制造风轮机叶片的***，该***包括：
炉，所述炉保持第一叶片壳与腹板；
温度传感器，所述温度传感器在所述第一叶片壳与所述腹板要被粘合在一起的粘合区中置于所述第一叶片壳与所述腹板之间；
处理电子设备，所述处理电子设备连接至所述温度传感器，以基于来自所述温度传感器的信号确定所述第一叶片壳与所述腹板要被粘合在一起的所述粘合区中的温度；以及
炉控制器，所述炉控制器连接至所述处理电子设备，所述炉控制器基于由所述处理电子设备确定的所述粘合区的温度来控制供给至所述炉的热，
该***还包括粘合材料，该粘合材料使所述第一叶片壳粘合至所述腹板，其中，所述温度传感器嵌入在所述粘合材料中，所述温度传感器是光学温度传感器。
30.一种包括根据权利要求1至7中任一项所述的风轮机叶片的风轮机。
31.一种叶片脱层检测***，所述叶片脱层检测***包括根据权利要求1至7中任一项所述的风轮机叶片、以及连接至所述光学温度传感器的光学检测器，其中，所述光学检测器构造成检测所述光学温度传感器的输出中的指示叶片脱层的阶跃变化。
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