CN106194576A - 风轮机叶片及组装风轮机叶片的方法及翼梁缘条连接件 - Google Patents

风轮机叶片及组装风轮机叶片的方法及翼梁缘条连接件 Download PDF

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CN106194576A
CN106194576A CN201610359381.1A CN201610359381A CN106194576A CN 106194576 A CN106194576 A CN 106194576A CN 201610359381 A CN201610359381 A CN 201610359381A CN 106194576 A CN106194576 A CN 106194576A
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section
spar
connector
spar flange
blade
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CN106194576B (zh
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P.T.海登
张帆
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LM Wind Power UK Ltd
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Blade Dynamics Ltd
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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
    • 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
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • F03D—WIND MOTORS
    • F03D1/00—Wind motors with rotation axis substantially parallel to the air flow entering the rotor 
    • F03D1/06—Rotors
    • 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
    • F03D3/00—Wind motors with rotation axis substantially perpendicular to the air flow entering the rotor 
    • F03D3/06—Rotors
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    • 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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    • B29C66/51—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
    • B29C66/5241—Joining profiled elements for forming coaxial connections, i.e. the profiled elements to be joined forming a zero angle relative to each other
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract

本发明提供了一种包括沿叶片的长度端对端布置的第一和第二相邻叶片区段的风轮机叶片，各个区段均包括沿区段的长度延伸的空气动力整流罩和翼梁；各个翼梁均包括延伸跨过整流罩的抗剪腹板和一对翼梁缘条，在抗剪腹板的任一端处各有一个翼梁缘条；其中第一区段中的各个翼梁缘条具有与第二区段中的相应翼梁缘条不同的截面形状和/或材料，以及其中第一区段中的翼梁缘条经由连接件连结至第二区段中的相应翼梁缘条；各个连接件均为预先固化的构件，沿叶片的长度从构造成连接至第一叶片区段的翼梁缘条的第一互补倾斜端的第一倾斜端和构造成连接至第二叶片区段的翼梁缘条的第二互补倾斜端的第二倾斜端延伸。

Description

风轮机叶片及组装风轮机叶片的方法及翼梁缘条连接件
技术领域
本发明涉及一种风轮机叶片、组装风轮机叶片的方法及翼梁缘条连接件。
具体而言，本发明涉及包括连结在一起的至少两个区段的风轮机叶片，以及它们连接的方式。
背景技术
假定需要日益更长的风轮机叶片，现在公知的是生产以一定数目的区段的风轮机叶片，区段可运输至接近它们附接到其上的风轮机的位置的位置。叶片然后可在此位置组装，以避免需要运输完整长度的叶片。较小区段的使用进一步的优点，因为较小的构件可在更受控的过程中制作。此外，将不同区段连结在一起的能力意味着更多叶片设计可在较低成本下产生。例如，使叶片延伸来改善性能变得更容易。
在此地点可用的设施相比于工厂环境中可用的那些之间存在显著差异。因此，所需的是提供简明地在原地组装的接头。
申请人认识到使用高性能材料和高质量生产技术以便产生叶片的某些部分的构想中的优点。例如，有益的是产生高质量末梢区段，以便减小寄生质量，因为末梢区段中的任何附加质量生成了沿叶片的其余部分的显著的负载。
然而，此材料产生了这些附接到由不同材料制成的其它构件上的方式和使用不可与高性能材料相容的不同制造技术中的问题。
此外，申请人考虑了产生可配合到由第三方制作的叶片区段上的高质量末梢区段的可能性。在此情形下，有可能加重区段之间的不相容的任何问题。
这些不相容是潜在问题，因为翼梁缘条主要负责提供叶片的弯曲刚度和强度。这些高负载构件必须满足弯曲强度和刚度要求，以甚至穿过潜在不相容节段之间的过渡部分来保持叶片的结构完整性。
发明内容
根据本发明，提供了一种根据权利要求1的风轮机叶片。
通过使用可有效地提供从一个翼梁缘条构造到另一个的过渡的连接件，本发明克服了以上问题。在一些情况中，翼梁缘条可在接头附近成锥形。在这些情况中，当考虑翼梁缘条是否具有本发明所需的不同截面形状时，锥形部分可忽略。换言之，提到的不同截面形状为提到的除翼梁缘条的任何锥形部分外的形状。最重要的考虑在于，在任一端处，连接件匹配翼梁缘条的形状，使得如果翼梁缘条具有不同截面，则连接件的尺寸和形状相应地改变。连接件可为相对小的构件，其可容易且精确地在工厂环境中模制以具有所需的特征。如果需要，则该件可运输至负责制作第一区段的单独的一方。在此情况中，连接件的一端将按第三方要求制作，且它们可在其产生时将其结合到第一区段的翼梁缘条中。第二区段(例如，高质量末梢构件)的制造者然后对第二部分将附接到其上的表面有显著的控制，使得这可容易地在原地完成。
材料沿连接件的长度变化的要求可以以许多方式满足。材料可改变其化学成分。作为备选，在复合物的情况下，物理组成可改变。例如，基质中的纤维的形状和/或尺寸可从一端变到另一端，这可为纤维与基材料的相对浓度。另一个可能性在于，与上文一样或作为上文的备选，微观结构可为不同的。因此，即使纤维和基质的复合组分相同，且相同纤维在各处使用，但制造方法可意味着处理的材料的微观结构可从一端到另一端不同。
连接件可在工厂环境中连接，使得当原地组装区段时，存在两个高质量且良好限定的来制作接头的表面。
即使不涉及第三方，连接件也可用于允许在其它情况下为不相容材料的两个翼梁的连接，例如，在高质量末梢部分附接到低质量主题部分上时。
连接件可制作成具有带相同长度的两个倾斜端。然而，一个倾斜端优选比另一个更长。如果连接件提供成由第三方匹配，则供应方将没有第三方翼梁缘条的完成的更多知识或控制。通过提供用于附接到翼梁上的相对长的倾斜端，在连接件的该端处需要较低准确性。这是因为第三方具有较大的连结表面。另外，如果连接件由沿叶片的长度延伸的单轴纤维的纤维层制成，具有相对长的倾斜端面意味着纤维的各个层终止于可与相邻层合理间隔开的位置处，从而在更宽的区域上分布任何应力集中。
连接件可直接地连结到相邻叶片区段的翼梁缘条上。然而，作为优选，连接件与相邻区段的翼梁缘条之间存在双重嵌接构件。双重嵌接构件采用具有宽V形截面的构件形式。这连接到连接件的倾斜端和相邻翼梁缘条的倾斜端面上，其定向成与连接件的倾斜端面成相对关系。此双重嵌接的构件具有WO 2012/004571中所示的优点，其提供了高连结区域，且可就位，而不分布粘合剂(如果其为预先固化的构件)。作为备选，它可容易地在原地从薄片叠层构成。
一个区段的翼梁缘条可简单地具有相比于相邻区段的相应翼梁缘条的不同宽度或深度。然而，更可能的是，一个区段的翼梁缘条具有截面中的弯曲轮廓，以符合空气动力表面，且相邻区段的翼梁缘条具有截面中的平轮廓，以用于现场接头设计的目的。
本发明还延伸至组装根据本发明的第一方面的风轮机叶片的方法，该方法包括将连接件附接到第一区段的各个翼梁缘条上；以及随后将连接件附接到第二区段的相应翼梁缘条上。
连接件可直接地附接到第二区段的相应翼梁缘条上。然而，作为优选，第二区段中的连接件和相应的抗剪腹板呈现出沿相反方向倾斜的面向外的倾斜表面，且双重嵌接构件附接到这些表面上来完成接头。
本发明还优选延伸至根据权利要求7的翼梁缘条。
连接件的各个倾斜端可以以相同的锐角成角，使得两端平行于彼此。然而，作为优选，各个倾斜端均以不同的锐角成角。这允许了端面中的一个呈现出如上文所述的较大的连结表面。
如果需要连接件具有从一个形状沿过渡区域过渡到另一个的形状，则这可为宽度或深度的简单改变。然而，作为优选，连接件从一端处的截面的弯曲轮廓过渡至相对端处的截面的平轮廓。
本发明的第一技术方案提供了一种包括沿叶片的长度端对端布置的第一和第二相邻叶片区段的风轮机叶片，各个区段均包括沿区段的长度延伸的空气动力整流罩和翼梁；各个翼梁均包括延伸跨过整流罩的抗剪腹板和一对翼梁缘条，在所述抗剪腹板的任一端处各有一个翼梁缘条；其中第一区段中的各个翼梁缘条具有与第二区段中的相应翼梁缘条不同的截面形状和/或材料，以及其中所述第一区段中的所述翼梁缘条经由连接件连结至所述第二区段中的相应翼梁缘条；各个连接件均为预先固化的构件，沿所述叶片的长度从构造成连接至第一叶片区段的翼梁缘条的第一互补倾斜端的第一倾斜端和构造成连接至第二叶片区段的翼梁缘条的第二互补倾斜端的第二倾斜端延伸；其中所述截面形状和/或材料沿所述连接件的长度变化，以便在任一端处可与所述相邻翼梁缘条相容。
本发明的第二技术方案是在第一技术方案中，所述连接件的所述第一倾斜端比所述第二倾斜端更长。
本发明的第三技术方案是在第一技术方案或第二技术方案中，其特征在于，所述连接件由沿所述叶片的长度延伸的单轴纤维的纤维层制成。
本发明的第四技术方案是在第一至第三技术方案中的任一项中，在相邻区段的所述连接件与所述翼梁缘条之间存在双重嵌接构件。
本发明的第五技术方案是在第四技术方案中，所述双重嵌接构件连接至所述连接件的倾斜端和所述相邻翼梁缘条的倾斜端面，其定向成与所述连接件的倾斜端面相对。
本发明的第六技术方案是在上述任一技术方案中，一个区段的所述翼梁缘条具有截面中的弯曲轮廓，且所述相邻区段的所述翼梁缘条具有截面中的平轮廓。
本发明的第七技术方案提供了一种翼梁缘条连接件，其包括预先固化的复合构件，该构件包括单轴纤维，其沿所述构件的长度沿在使用中对应于其所固定至的翼梁的纵向方向的纵向方向从第一端行进至第二端，所述第一端和所述第二端各自以相应的锐角与所述纵向方向相同地倾斜；所述连接件具有过渡区域，其中所述连接件的截面形状和/或材料沿所述过渡区域从一个形式过渡至另一个，使得在使用中，其能够连接具有不同截面形状和/或材料的两个翼梁缘条。
本发明的第八技术方案是在第七技术方案中，各个倾斜端以不同锐角成角。
本发明的第九技术方案是在第七技术方案或第八技术方案中，所述连接件从一端处的截面中的弯曲轮廓过渡至相对端处的截面中的平轮廓。
本发明的第十技术方案提供了一种形成根据第一技术方案至第六技术方案中的任一项所述的风轮机叶片的方法，所述方法包括将连接件附接至第一区段中的翼梁缘条中的每一个；以及将所述连接件随后附接至第二区段的相应翼梁缘条。
本发明的第十一技术方案是在第十技术方案中，所述第二区段中的所述连接件和相应抗剪腹板呈现为沿相反方向倾斜的面向外的倾斜表面，且双重嵌接构件附接至这些表面以完成接头。
附图说明
现在将参照附图来描述风轮机叶片翼梁缘条连接件的实例，在附图中：
图1为两个翼梁区段之间的部分地组装的翼梁的透视图；
图2为图1中来自下翼梁缘条的翼梁缘条连接件的透视图；
图3为组装之前穿过翼梁的顶部的截面视图；
图4为完成连接过程之后的穿过图1中所示的翼梁的截面视图；
图5a示出了类似于图4的布置，示出了在沿叶片的长度的一定数目的标记位置处的穿过翼梁缘条/连接件/双重嵌接构件的截面，示出了从弯曲翼梁缘条到平翼梁缘条的过渡，其中过渡发生在连接件的倾斜端之间；
图5b为过渡区域延伸到连接件的锥形部分中的类似于图5a的视图；
图6a-6c为备选的连接件的透视图；以及
图7a和7b为示出组装之前和之后的整个叶片的透视图。
具体实施方式
风轮机叶片由端对端连接的一定数目的区段构成。例如，叶片的基本结构在WO 2012/004571和WO 2009/034291中公开。本发明提供了一种提供相邻区段的翼梁缘条之间的连接的新方法，且以下描述将聚焦于此。
第一区段具有沿区段的长度延伸的第一翼梁区段10，以提供叶片的结构完整性，且具体而言，阻止可在叶片上出现的高弯曲负载。第二区段具有类似的翼梁区段11。各个翼梁区段均具有抗剪腹板12。这沿横向行进跨过叶片区段，且大体上包括多轴纤维的复合材料。
各个翼梁区段由沿抗剪腹板的顶缘和底缘行进的翼梁缘条14完成。翼梁缘条14为复合材料，其大体上包括沿叶片的长度行进的单轴纤维。
在该特定实例中，第一区段可为低质量构件，其形成叶片的中心部分或内部，而第二部分可为高质量末梢区段。末梢区段可使用较高质量的预浸料坯材料，而第一区段为成本效益更划算的真空协助的树脂传递模制。由于翼梁缘条的质量和性质的差异，故制造方法的差异使得翼梁区段之间的接头更难。树脂的处理温度可对于此接头不相容。例如，传递模制树脂需要低于80℃的温度，而预浸料坯树脂需要高于100℃的温度。
另一个可能在于，第二区段可为具有碳纤维翼梁缘条的末梢，碳纤维翼梁缘条连结到第一区段的翼梁中的玻璃纤维上，以便延长叶片长度，同时保持相同的叶片质量。用于薄片中的板层的刚度、强度和厚度之间的翼梁缘条材料的差异在匹配接头区域中的翼梁缘条中的性质中产生了困难。还有可能的是，翼梁区段中的一个(例如，在此情况下，第一翼梁区段12)可具有如图1中的线15绘出的弯曲区段，而第二区段可具有带平翼梁缘条轮廓的翼梁缘条。
翼梁缘条连接件20提供成解决这些问题。如图1中所示，存在一个此类翼梁缘条连接件20来用于第一翼梁区段12中的各个翼梁缘条。
图2更详细地示出了图1中的下翼梁缘条连接件20。如可见，这设计成大体上配合在与周围的翼梁缘条相同的封套内，但在不相容的相邻翼梁缘条形状的情况中，连接件设计成从一个形状过渡到另一个。连接件具有上表面21和下表面22，其在使用中形成翼梁缘条的相应上表面和下表面的继续部分。它还具有用于连接到第一区段的翼梁缘条上的第一倾斜端23，以及用于(直接地或间接地)连接到第二翼梁区段11上的第二倾斜端24。
如图2中所示最佳所示，第一倾斜端23具有弯曲形状，以便匹配第一翼梁区段10的翼梁缘条14的弯曲形状15。翼梁缘条连接件20的形状然后过渡到如图2中所示的第二端表面24处的平面形状。
第一翼梁区段10可为由第三方制造的构件。在此情况下，它们可在第一翼梁区段10产生之前供有翼梁缘条连接件20。当产生第一翼梁区段10时，连接件20可置于模具中，由此翼梁缘条的材料置于连接件上。这提供了对第一翼梁区段10的最小干扰，但出现的是具有端面24的翼梁区段，其不但准确地限定，而且对于第二翼梁区段11的制造是公知的。
图2中所示的翼梁缘条连接件20具有端面23和24，其相同地倾斜。然而，这些面有可能在相对端中倾斜，且连接件直接地连结到相邻节段的翼梁缘条14上。然而，作为优选，接头还结合了双重嵌接接头，这是WO 2012/004571的主题。这采用了如图1,3和4中所示的双重嵌接构件30的形式。这具有宽V形截面，其中第一倾斜表面21构造成匹配翼梁缘条连接件20的第一倾斜端24。双重嵌接构件30具有第二倾斜表面32，其匹配第二翼梁缘条区段11中的翼梁缘条14的倾斜端面。
如附图中所示，双重嵌接构件30为单个预先固化的构件，其可连结到表面24,33上。作为备选，其可在原地构成在这些倾斜表面上。
图4中的截面中示出了完成的接头。
从一个构件上的弯曲翼梁缘条14过渡到相邻构件中的平翼梁缘条14可以以图5a和5b中所示的不同方式实现。在图5a中，将认识到的是，在如由截面B-B呈现的连接部分20的锥形部分中，相比于过渡的显著部分已经完成(因此截面中略微弯曲)的图5b，过渡至较平的截面并未开始。朝图5a中的连接件20的非锥形部分的中部(截面C-C)，相比于已经完成大部分过渡的图5b中，已经完成了大约一半的过渡。
图6a到6c示出了翼梁缘条连接件的不同构造。
图6a中示出的连接件20A呈现出了左手端处的弯曲翼梁缘条过渡到右手端上的平翼梁缘条，但这仅具有两个锥形部分，它并不具有之前实例的非锥形中心部分。在此情况下，锥形部分可对应地较长，或过渡可更突然，以允许缺少中心部分。
在图6b中，连接件20B呈现出左手侧上的平翼梁缘条到右手侧上的较窄翼梁平翼梁缘条的过渡。中心过渡区域提供了该宽度减小。减小的宽度可通过厚度增大来实现，以控制翼梁缘条的截面面积。
图6c示出了相同形状和尺寸的两个翼梁缘条之间的过渡。与图6a共同的是，该翼梁缘条没有中心非锥形部分。然而，它具有显著更长的锥形部分，其可良好适于产生与不太好或未知质量的第三方翼梁缘条的连接。
图7a和7b示出了接头如何容纳在具有毂端41和末梢端42的叶片40中。叶片由主体43形成，主体43沿叶片的大部分长度延伸。如可见，连接件20从根部端的空气动力整流罩44延伸，同时翼梁缘条14从末梢构件45延伸。两者合到一起，且如上文参照上图所述连接，且整流罩桥接部分46覆盖该区域中的接头。

Claims (10)

1. 一种包括沿叶片的长度端对端布置的第一和第二相邻叶片区段的风轮机叶片，各个区段均包括沿区段的长度延伸的空气动力整流罩和翼梁；各个翼梁均包括延伸跨过整流罩的抗剪腹板和一对翼梁缘条，在所述抗剪腹板的任一端处各有一个翼梁缘条；其中第一区段中的各个翼梁缘条具有与第二区段中的相应翼梁缘条不同的截面形状和/或材料，以及其中所述第一区段中的所述翼梁缘条经由连接件连结至所述第二区段中的相应翼梁缘条；各个连接件均为预先固化的构件，沿所述叶片的长度从构造成连接至第一叶片区段的翼梁缘条的第一互补倾斜端的第一倾斜端和构造成连接至第二叶片区段的翼梁缘条的第二互补倾斜端的第二倾斜端延伸；其中所述截面形状和/或材料沿所述连接件的长度变化，以便在任一端处可与所述相邻翼梁缘条相容。
2. 根据权利要求1所述的叶片，其特征在于，所述连接件的所述第一倾斜端比所述第二倾斜端更长。
3. 根据权利要求1或权利要求2所述的叶片，其特征在于，所述连接件由沿所述叶片的长度延伸的单轴纤维的纤维层制成。
4. 根据权利要求1至3中的任一项所述的叶片，其特征在于，在相邻区段的所述连接件与所述翼梁缘条之间存在双重嵌接构件。
5. 根据权利要求4所述的叶片，其特征在于，所述双重嵌接构件连接至所述连接件的倾斜端和所述相邻翼梁缘条的倾斜端面，其定向成与所述连接件的倾斜端面相对。
6. 根据前述权利要求中的任一项所述的叶片，其特征在于，一个区段的所述翼梁缘条具有截面中的弯曲轮廓，且所述相邻区段的所述翼梁缘条具有截面中的平轮廓。
7. 一种翼梁缘条连接件，其包括预先固化的复合构件，该构件包括单轴纤维，其沿所述构件的长度沿在使用中对应于其所固定至的翼梁的纵向方向的纵向方向从第一端行进至第二端，所述第一端和所述第二端各自以相应的锐角与所述纵向方向相同地倾斜；所述连接件具有过渡区域，其中所述连接件的截面形状和/或材料沿所述过渡区域从一个形式过渡至另一个，使得在使用中，其能够连接具有不同截面形状和/或材料的两个翼梁缘条。
8. 根据权利要求7所述的翼梁缘条连接件，其特征在于，各个倾斜端以不同锐角成角。
9. 根据权利要求7或权利要求8所述的翼梁缘条连接件，其特征在于，所述连接件从一端处的截面中的弯曲轮廓过渡至相对端处的截面中的平轮廓。
10. 一种形成根据权利要求1至6中的任一项所述的风轮机叶片的方法，所述方法包括将连接件附接至第一区段中的翼梁缘条中的每一个；以及将所述连接件随后附接至第二区段的相应翼梁缘条。
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