CN113286943A - 用于确保叶片闭合过程中的适当粘接物流动的粘合剂阻挡件设计 - Google Patents
用于确保叶片闭合过程中的适当粘接物流动的粘合剂阻挡件设计 Download PDFInfo
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Abstract
本发明提供了改善在风力涡轮机叶片制造过程中粘接物流动的装置、***和方法。当第一涡轮机叶片半体与第二涡轮机叶片半体对准时,在第一壳体与结合帽之间形成间隙。该组件包括对应于第一涡轮机叶片半体的第一模半体和对应于第二涡轮机叶片半体的第二模半体。当第一模半体与第二模半体对准时,形成第二间隙。第一阻挡件设置在第一间隙内,第二阻挡件设置在第二间隙内,从而流体密封由第一间隙和第二间隙限定的容积,以引导粘合粘接物在相邻前缘和后缘之间沿着叶片跨度流动。
Description
相关申请的交叉引用
本申请根据35 USC 119要求于2018年10月22日提交的临时申请US62/748,835的优先权,其全部内容在此通过引用并入本文。
背景技术
本公开的实施例涉及在风力涡轮机叶片制造期间改善粘接物的流动的装置、***和方法。特别地,本公开的装置、***和方法涉及在叶片闭合过程中确保适当的粘接物流动并防止在粘接物中形成空隙。
发明内容
所公开的主题的目的和优点将在下面的描述中阐明并且从下面的描述中显而易见,并且将通过实施所公开的主题而知晓。所公开的主题的其它优点将通过在其书面说明书和权利要求书中特别指出的方法和***以及从所附附图来实现和获得。
为了实现这些和其它优点并根据所公开的主题的目的,如所示例并广泛描述的,所公开的主题包括一种组件,该组件包括:第一涡轮机叶片半体,所述第一涡轮机叶片半体包括限定第一周边的第一壳体和沿第一周边延伸的第一界面表面;第二涡轮机叶片半体,所述第二涡轮机叶片半体包括限定第二周边的第二壳体和沿第二周边延伸的第二界面表面,所述第二涡轮机叶片半体包括从所述周边延伸的结合帽,其中,当所述第一界面表面与所述第二界面表面对准时,在所述第一壳体与所述结合帽之间形成第一间隙;第一模半体,所述第一模半体包括对应于第一壳体的第一模表面;第二模半体,所述第二模半体包括对应于第二壳体的第一模表面,当第一模半体与第二模半体对准时,在第一模半体与第二模半体之间形成第二间隙,其中第一间隙与第二间隙流体连通;第一阻挡件,所述第一阻挡件设置在所述第一间隙内;和第二阻挡件,第二阻挡件设置在所述第二间隙内,从而流体密封由所述第一间隙和所述第二间隙限定的容积。在一些实施例中,粘接物设置在第一界面表面和/或第二界面表面上。在一些实施例中,第一间隙的宽度在大约2mm和15mm之间。在一些实施例中,第二间隙的宽度在大约2mm和15mm之间。在一些实施例中,在第二阻挡件上包括通风口。在一些实施例中,通风孔是第二阻挡件上的多个通风孔之一。在一些实施例中,所述多个通风孔彼此以预定距离间隔开。在一些实施例中,多个阻挡件沿着叶片的前缘和后缘均匀地间隔开。在一些实施例中,所述第一阻挡件永久性地附接到所述第一涡轮机叶片半体和所述第二涡轮机叶片半体中的至少一者。在一些实施例中,第二阻挡件可拆卸地附接到第一模半体和第二模半体中的至少一者。根据本公开的另一方面,提供了一种形成风力涡轮机叶片的方法,该方法包括:提供第一涡轮机叶片半体,所述第一涡轮机叶片半体包括限定第一周边的第一壳体和沿第一周边延伸的第一界面表面;提供第二涡轮机叶片半体,所述第二涡轮机叶片半体包括限定第二周边的第二壳体和沿所述第二周边延伸的第二界面表面,所述第二涡轮机叶片半体包括从所述第二周边延伸的结合帽,其中,当所述第一界面表面与所述第二界面表面对准时,在所述第一壳体与所述结合帽之间形成第一间隙;提供第一模半体,所述第一模半体包括对应于所述第一壳体的第一模表面,所述第一涡轮机叶片半体设置在所述第一模半体内;提供第二模半体,所述第二模半体包括对应于所述第二壳体的第一模表面,当所述第一模半体与所述第二模半体对准时,在所述第一模半体与所述第二模半体之间形成第二间隙,其中所述第一间隙与所述第二间隙流体连通,所述第二涡轮机叶片半体设置在所述第二模半体内;将粘接物施加到第一界面表面和/或第二界面表面上;将第一阻挡件定位在结合帽上,并将第二阻挡件定位在第二模半体上;使第一周边和第二周边接触;以及使所述第一模半体与所述第二模半体接触,从而流体密封由所述第一间隙和所述第二间隙限定的容积。
附图说明
图1A示出了根据本公开的实施例的示例性风力涡轮机叶片。
图1B示出了根据本公开的实施例的图1A的风力涡轮机叶片的横截面。
图2A示出了根据本公开的实施例在叶片闭合期间的示例性风力涡轮机叶片的横截面。
图2B示出了根据本公开的实施例在叶片闭合期间图2A的风力涡轮机叶片的前缘的横截面。
图2C示出了根据本公开的实施例在叶片闭合期间图2A的风力涡轮机叶片的前缘的横截面。
图3示出了根据本公开的实施例的在叶片闭合期间示例性风力涡轮机叶片的前缘的横截面的放大部分。
图4示出了根据本公开的实施例在叶片闭合期间的示例性风力涡轮机叶片的俯视图。
图4A示出了根据本公开的实施例的外部阻挡件和通风口设计的横截面。
图5示出了根据本公开的实施例的风力涡轮机叶片根部附接的方法。
具体实施方式
现代风力涡轮机转子叶片由纤维增强塑料制成,因为纤维增强塑料具有高的强度-重量比。转子叶片通常包括具有圆形前缘和尖锐后缘的翼型形状,并且叶片包括连接到涡轮的毂形件的叶片根部。多个转子叶片在相应的叶片根部处连接到毂形件以形成风力涡轮机。叶片根部包括设置在纤维增强聚合物内的多个根部衬套,所述纤维增强聚合物向叶片提供增强部。螺栓与根部衬套中的螺纹接合以将叶片根部连接到毂形件。
通过在一对模具中模制两个半壳体来制造典型的涡轮机叶片。翼梁帽(类似于飞机机翼中的翼梁),腹板加强件(肋)和其它细节可以可选地安装在叶片半体之一中。粘合剂例如以等距间隔开的珠状物形式施加到第一壳体的结合周边/边缘上。然后,使第二半壳体仍然在其模具中地翻转,并且下降到第一半壳体上。将模具压在一起,并使粘合剂固化,从而将叶片的两个半体连接在一起。两个叶片半体通过粘接物连接在一起的过程被称作叶片闭合。
两个叶片半体连接所沿的接缝是整个涡轮机叶片的结构完整性的关键连接点。在叶片闭合期间,粘接物(通常以沿叶片半体的周边间隔开的珠状物的形式施加)必须填充两个叶片半体之间的所有空隙空间,以避免任何制造缺陷。然而,当两个叶片半体被压在一起时,由于粘接物通常是粘性液体,因此粘接物可能不会填充两个叶片半体之间的整个空间,从而在结合接缝中形成可能损害结构完整性的空气空隙。超声测试可以实现为质量控制器,以确保不存在空气空隙,并且如果确定存在空气空隙,则可以将额外的粘接物注入空隙空间中以填充空隙。然而,这种筛选整个结合接缝的方法费用高(需要技术人员的时间和昂贵的测试设备)并且耗时长。因此,需要一种***来改善叶片闭合期间的粘接物流动并防止在粘接物中形成空气空隙。
在各种实施例中,模具和/或阻挡件可以由本领域已知的任何合适的金属制成。在各种实施例中,模具和/或阻挡件可以包括金属,例如铝、钢、不锈钢、钛、钽、钨、或金属的任何合适组合(例如,金属合金)。在各种实施例中,模具和/或阻挡件可以包括聚合物,例如,聚乙烯、聚氨酯、聚对苯二甲酸乙二醇酯、聚氯乙烯等。在各种实施例中,模具和/或阻挡件可以通过机加工(例如,CNC机加工)、3D打印(例如,使用直接金属激光烧结(DMLS)和熔融沉积成型(FDM))、开放成型、封闭成型、树脂灌注、压缩成型、复合手工铺贴、注塑成型、拉挤、自动纤维放置、管轧制、自动带铺设、纤维缠绕、树脂转移成型或本领域已知的任何合适的制造技术。本领域技术人员将认识到,可以使用任何合适的3D打印技术来制造本文所述的部件。
图1A示出了根据本公开的实施例的示例性风力涡轮机叶片102。风力涡轮机叶片102包括具有前缘104和后缘106的壳体。任何适当数量的叶片102(例如,三个)可以在叶片根部108处连接到风力涡轮机的毂形件,使得当风经过叶片102时,叶片102使毂形件旋转,从而产生电力。
图1B示出了根据本公开的实施例的图1A的风力涡轮机叶片102的横截面。风力涡轮机叶片102的横截面通常成形为翼型并且包括如上所述的前缘204和后缘206。
图2A示出了根据本公开的实施例在叶片闭合期间的示例性风力涡轮机叶片202的横截面。风力涡轮机叶片202通常成形为具有前缘204和后缘206的翼型,并且由聚合物增强复合材料制造。在制造叶片202的过程中,叶片202可以被制造为两个半体(第一半体202a和第二半体202b),并且随后通过例如施加在界面处的粘合粘接物而彼此固定。为了将第一叶片半体202a粘附到第二叶片半体202b,将粘接物施加到一个或两个叶片半体202a、202b的周边上。在一些实施例中,在沿着叶片跨度的选定位置处施加粘合剂;在一些实施例中,沿着整个叶片跨度连续施加粘合剂。每个叶片半体202a、202b定位于相应的模具半体210a、210b的内部,并且将模具半体210a、210b和叶片半体202a、202b带到一起。
如图2A所示,本公开可应用于各种叶片设计,包括具有剪切腹板250和相应翼梁帽260的叶片设计。上模表皮和下模表皮还可以包括芯材料,例如具有从叶片的中点到后缘逐渐增加的厚度。
图2B示出了根据本公开的实施例在叶片闭合期间图2A的风力涡轮机叶片202的前缘204的横截面。窗口A示出了风力涡轮机叶片202的前缘204的放大部分。如图2B所示,叶片半体202a包括外壳体203a、芯203b和内壳体203c。内壳体203a和外壳体203c由纤维增强的聚合物(诸如,玻璃纤维增强的环氧树脂)制成。其它合适的纤维增强物可以与其它纤维一起结合或者独立地结合,其它纤维诸如是碳纤维(单向和/或双向的)、Kevlar纤维、玻璃纤维(单向和/或双向的)等。此外,内壳体203a和外壳体203c可以包括针对部件的期望厚度和性能的任何适当数量的纤维增强层。芯203b由任何合适材料制成,任何合适材料诸如是聚合物泡沫(例如聚氨酯、二乙烯基单元、聚异氰脲酸酯等),夹层芯(例如NOMEX蜂窝、铝蜂窝、BALSA等),和/或聚合物蜂窝材料。
类似于第一叶片半体202a,第二叶片半体202b包括外壳体205a、芯205b和内壳体205c。内壳体205a和外壳体205c类似地由纤维增强聚合物制成,芯205b类似地由合适的芯材料(例如聚合物泡沫)制成。第二叶片半体202b还包括从叶片半体202b的周边/边缘延伸的结合帽207,使得当第一叶片半体202a和第二叶片半体202b被带到一起时(在将粘接物212施加到周边之后),在结合帽207和第一叶片半体202a之间形成间隙209a。结合帽的长度取决于特定的叶片类型(尺寸、材料等),在一些实施例中,结合帽207沿着前缘长度的大部分(如果不是全部)定位;而在后缘侧,结合帽从根部延伸到叶片跨度的约20米标记处。而且,当第一模半体210a和第二模半体210b被带到在一起时,在两个模半体210a、210b之间形成间隙209b,当施加压力以将两个模半体210a、210b压在一起时,粘接物212可流到间隙209b中。
图2C示出了根据本公开的实施例在叶片闭合期间图2A的风力涡轮机叶片的前缘的横截面。当模半体210a、210b在叶片闭合期间被带到一起时,粘接物212自由地流入结合帽207和第一模半体202a之间以及两个模半体210a、210b之间的间隙209a中。然而,在各种情况下,内部空气空隙214b和/或外部空气空隙可在粘接物212中形成,并在粘接物固化时保留在粘接物中。虽然存在许多空气空隙成因,但是一个共同的原因是两个叶片半体202a、202b之间的粘接物流动不完全。这样的空气空隙214b的存在会危害叶片的结构完整性并对叶片性能产生不利影响。如图所示,这些空气空隙可以存在于施加在叶片内部214a和外部214b的粘接物部分内。
图3示出了根据本公开的实施例在叶片闭合期间示例性风力涡轮机叶片的前缘的横截面的放大部分300。类似于上面的图2A-图2C,风力涡轮机叶片包括在第一模半体310a内的第一叶片半体302a和在第二模半体310b内的第二叶片半体302b。第二叶片半体302b包括从第二叶片半体302b的周边延伸的结合帽307,使得当第一叶片半体302a和第二叶片半体彼此对准时,在它们之间形成间隙309a。而且,当第一模半体310a和第二模半体310b对准时,在它们之间形成间隙309b,间隙309b与间隙309a流体连通。在一个示例性实施例中,间隙309b的尺寸可以是大约2mm到15mm。
在图3中,第一阻挡件316a***由结合帽307和第一叶片半体309限定的间隙309a中,第二阻挡件316b***由第一模半体310a和第二模半体310b限定的间隙309b中。第一阻挡件316a位于叶片内部,而第二阻挡件316b位于叶片外部。第一阻挡件316a和第二阻挡件316b将粘接物流体密封在间隙309a、309b内,并防止粘接物从间隙309a、309b的任何漏出。提供这些阻挡件316a、316b允许粘接物的受控流动,使得粘接物填充围绕两个叶片半体302a、302b的周边的空间,从而防止在粘接物中形成空隙(外部空隙和内部空隙两者)。换言之,粘接物在内部/外部方向上流动被限制,而是沿着叶片的跨度被引导。在各种实施例中,第一阻挡件316a可以安装在第一叶片半体302a的表皮表面上。附加地或可替代地,第一阻挡件316a可安装在结合帽307上。在各种实施例中,第二阻挡件316b可以安装在模具凸缘310a、310b上。另外,第一阻挡件316a可以永久性地附接(例如,粘接)到叶片内部,而外部阻挡件316b可以可拆卸地附接(诸如通过紧固件(例如螺钉)等)到模具表面310a或310b上,以用于其重复使用。
第一阻挡件和第二阻挡件可以由任何合适的塑料或泡沫(例如聚乙烯泡沫塑料)制成。第一阻挡件316a可被定位成使得阻挡件316a的前缘延伸超过结合帽以产生重叠区域,如图3所示。将阻挡件316a定位在该位置处是有利的,因为它防止粘接物流动超出结合帽307并且如图2B所示以球状物/珠状物积聚——这不希望地增加了叶片设计的重量,并且会不利地影响叶片性能。
如图3所示,第二外部阻挡件316b可以安装成离叶片的前缘一距离“D”。如图所示地定位阻挡件316b的优点在于:它减小所施加的粘接物的量,因为它消除了在模半体210a、210b之间形成球状物/珠状物212。因此,阻挡件316b可以定位成尽可能靠近前缘。因此,本文公开的装置和技术改善了制造周期时间并减小浪费/成本。阻挡件316b可延伸以填充上模半体310a和下模半体310b之间的空间。因此,在一些实施例中,施加在叶片内侧上的粘接物的量大于施加在叶片外侧上的粘接物的量。
在一些实施例中,阻挡件可以围绕叶片的整个周边延伸。在一些实施例中,阻挡件可以沿着结合帽延伸。在叶片的一些部分(例如后缘)中不存在结合帽。因此,内部阻挡件316a与叶片的上侧/吸入侧以及叶片的下侧/压力侧两者的内表面接触。假若阻挡件具有足够的质量/刚度以防止粘合剂流动超出其位置,阻挡件的尺寸和形状可以变化。
图4示出了根据本公开的实施例在叶片闭合期间的示例性风力涡轮机叶片402。风力涡轮机叶片402可以类似于图1-图3所示的叶片,并且包括前缘404、后缘406和如上所述设置在相应模半体中的两个叶片半体。叶片402的每个半体包括基本上围绕整个叶片延伸的周边,当叶片半体彼此对准时,其形成完整叶片。叶片402还可以包括设置在结合帽和第一叶片半体之间的第一阻挡件416a,以及如上所述的第二阻挡件416b。在图4中,第二阻挡件416b(即,两个模半体之间的外部阻挡件)包括沿着叶片402的长度设置的多个通风孔418a、418b。所述通风孔可操作以选择性地打开/闭合,使得操作者可独立地操作每个通风孔以根据需要调节压力,例如将粘接物从根部向尖端抽吸以促进固结。通风孔418a、418b可以具有任何合适的形状(例如圆形)。在一些实施例中,通风口允许粘接物迁移到通风口中并填充通风口,并且包括检查特征部(例如,窗口、孔口、易碎膜),该检查特征部提供施加到其中(即从内部阻挡件直到该特定的通风口)的粘接物没有任何气囊/空隙的视觉确认。另外地或可替代地,通风口可以是阻挡件本身中的开口,如图4A所示。
通风孔418a、418b可以定位在第二阻挡件内的任何适当位置处,从而在闭合过程中将空气(和/或粘接物)排出。多个通风孔418a、418b中的每一个可以沿着叶片的周边以预定距离间隔开,该预定距离可以根据需要基于叶片尺寸而均匀地间隔开或者不均匀地间隔开。例如,更多通风孔可以位于叶片的需要更多粘接物以将两个叶片半体粘合在一起的区域中。如图4的放大视图所示的,通风孔418可以位于阻挡件416的任一侧。
根据本公开的一个方面,离开通风孔的粘接物的形状可以揭示在挤压两个叶片半体的过程中是否已填充了任何内部空气空隙。例如,在离开通风口的粘接物如图4所示在接近通风孔418a处具有均匀(例如,圆柱形)形状的情况下,可以确定在粘接物从其施加点行进到离开通风孔的过程中没有遇到内部空隙。相反地,在离开通风口的粘接物如图所示在接近通风孔418b处具有非均匀(例如,不对称)的形状的情况下,可以确定在粘接物从其施加点行进到离开通风孔的过程中遇到内部空隙(多个)。
图5示出了根据本公开的实施例的改善在风力涡轮机叶片制造期间粘接物流动的方法500。在步骤502,提供第一涡轮机叶片半体,第一涡轮机叶片半体具有限定第一周边的第一壳体和沿第一周边延伸的第一界面表面。在步骤504,提供第二涡轮机叶片半体,第二涡轮机叶片半体具有限定第二周边的第二壳体和沿第二周边延伸的第二界面表面。第二叶片半体包括从第二周边延伸的结合帽。当第一界面表面与第二界面表面对准时,在第一壳体与结合帽之间形成第一间隙。在步骤506,提供第一模半体,第一模半体具有对应于第一壳体的第一模表面,第一涡轮机叶片半体设置在第一模半体内。在步骤508,提供第二模半体,第二模半体具有对应于第二壳体的第一模表面,其中,当第一模半体与第二模半体对准时,在所述第一模半体和所述第二模半体之间形成第二间隙,其中所述第一间隙与所述第二间隙流体连通,所述第二涡轮机叶片半体设置在所述第二模半体内。在步骤510,将粘接物施加到第一周边和/或第二周边。在步骤512,将第一阻挡件定位在结合帽上,将第二阻挡件定位在第二模半体上。在步骤514,使第一模半体与第二模半体接触,并且使第一周边与第二周边接触,从而流体密封由第一间隙和第二间隙限定的容积。
已经给出了本发明的各种实施例的描述,以用于举例说明,但并不旨在于对所公开的实施例进行穷举或限制。在不脱离所述实施例的范围和精神的情况下,对于本领域普通技术人员来说,许多修改和改变是显而易见的。选择本文使用的术语是为了最好地解释实施例的原理、对在市场上发现的技术的实际应用或技术改进,或者使本领域普通技术人员能够理解本文公开的实施例。
Claims (11)
1.一种组件,包括:
第一涡轮机叶片半体,所述第一涡轮机叶片半体包括限定第一周边的第一壳体和沿第一周边延伸的第一界面表面;
第二涡轮机叶片半体,所述第二涡轮机叶片半体包括限定第二周边的第二壳体和沿第二周边延伸的第二界面表面,所述第二涡轮机叶片半体包括从所述第二周边延伸的结合帽,其中,当所述第一界面表面与所述第二界面表面对准时,在所述第一壳体与所述结合帽之间形成第一间隙;
第一模半体,所述第一模半体包括对应于第一壳体的第一模表面;
第二模半体,所述第二模半体包括对应于第二壳体的第一模表面,当第一模半体与第二模半体对准时,在第一模半体与第二模半体之间形成第二间隙,其中第一间隙与第二间隙流体连通;
第一阻挡件,所述第一阻挡件设置在所述第一间隙内;和
第二阻挡件,第二阻挡件设置在所述第二间隙内,从而流体密封由所述第一间隙和所述第二间隙限定的容积。
2.如权利要求1所述的组件,所述组件还包括设置在所述第一界面表面和/或所述第二界面表面上的粘接物。
3.如权利要求1所述的组件,其中,所述第一间隙的宽度在大约2mm和15mm之间。
4.如权利要求1所述的组件,其中,所述第二间隙的宽度在大约2mm和15mm之间。
5.如权利要求1所述的组件,其中,所述组件还包括在所述第二阻挡件上的通风口。
6.如权利要求5所述的组件,其中,所述通风口是所述第二阻挡件上的多个通风口之一。
7.如权利要求6所述的组件,其中,所述多个通风口彼此以预定距离间隔开。
8.如权利要求1所述的组件,其中,多个阻挡件沿涡轮机叶片的前缘和后缘均匀地间隔开。
9.如权利要求1所述的组件,其中,所述第一阻挡件永久性地附接到所述第一涡轮机叶片半体和所述第二涡轮机叶片半体中的至少一者。
10.如权利要求1所述的组件,其中,所述第二阻挡件可拆卸地附接到所述第一模半体和所述第二模半体中的至少一者。
11.一种形成风力涡轮机叶片的方法,所述方法包括:
提供第一涡轮机叶片半体,所述第一涡轮机叶片半体包括限定第一周边的第一壳体和沿第一周边延伸的第一界面表面;
提供第二涡轮机叶片半体,所述第二涡轮机叶片半体包括限定第二周边的第二壳体和沿所述第二周边延伸的第二界面表面,所述第二涡轮机叶片半体包括从所述第二周边延伸的结合帽,其中,当所述第一界面表面与所述第二界面表面对准时,在所述第一壳体与所述结合帽之间形成第一间隙;
提供第一模半体,所述第一模半体包括对应于所述第一壳体的第一模表面,所述第一涡轮机叶片半体设置在所述第一模半体内;
提供第二模半体,所述第二模半体包括对应于所述第二壳体的第一模表面,当所述第一模半体与所述第二模半体对准时,在所述第一模半体与所述第二模半体之间形成第二间隙,其中所述第一间隙与所述第二间隙流体连通,所述第二涡轮机叶片半体设置在所述第二模半体内;
将粘接物施加到第一界面表面和/或第二界面表面上;
将第一阻挡件定位在结合帽上,并将第二阻挡件定位在第二模半体上;
使第一周边和第二周边接触;并且
使所述第一模半体与所述第二模半体接触,从而流体密封由所述第一间隙和所述第二间隙限定的容积。
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