vault backup: 2025-10-15 10:46:23
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@ -280,133 +280,283 @@ Further embodiments, features and advantages of the present invention will becom
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本发明的其他实施例、特征和优点将从结合附图的后续描述和从属权利要求中显而易见，其中：
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Fig. l shows a wind turbine according to an embodiment; Fig. 2 shows a cross-section view of a pre-casted fibre layup forming a first shell of a blade of the wind turbine of
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30Fig. 1, the pre-casted fibre lay-up being manufactured in an upper mould turned upside down; Fig. 3 shows a cross-section view of a dry fibre lay-up forming, once casted and cured, a second shell of the blade of
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35the wind turbine of Fig. 1, the dry fibre lay-up being arranged in a lower mould;
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Fig. 1 shows a wind turbine according to an embodiment;
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Fig. 2 shows a cross-section view of a pre-casted fibre layup forming a first shell of a blade of the wind turbine of Fig. 1, the pre-casted fibre lay-up being manufactured in an upper mould turned upside down;
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Fig. 3 shows a cross-section view of a dry fibre lay-up forming, once casted and cured, a second shell of the blade of the wind turbine of Fig. 1, the dry fibre lay-up being arranged in a lower mould;
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Fig. 4 shows a view similar as Fig. 3 with a mould core and a web arranged on the dry fibre lay-up in the lower mould;
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Fig. 5 shows a view similar as Fig. 4 with extending portions
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5of the dry fibre lay-up being folded up onto the mould core; Fig. 6 shows the upper mould with the pre-casted fibre lay-up of Fig. 2 during arrangement on the lower mould with the dry fibre lay-up of Fig. 5;
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10 Fig. 7 shows a view similar as Fig. 6 with the upper mould being arranged on the lower mould, wherein the pre-casted fibre lay-up is overlapping with the dry fibre lay-up in an overlap region;
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15 Fig. 8 shows a view similar as Fig. 7 with resin infused; Fig. 9 shows a further embodiment of an overlap of a precasted fibre lay-up and a dry fibre lay-up;
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20 Fig. 10 shows another embodiment of an overlap of a precasted fibre lay-up and a dry fibre lay-up; and Fig. ll shows a flowchart illustrating a method for manufac
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25turing the wind turbine blade of the wind turbine of Fig. 1. In the figures, like reference numerals designate like or functionally equivalent elements, unless otherwise indicated.
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30Fig. 1 shows a wind turbine 1 according to an embodiment. The wind turbine 1 comprises a rotor 2 having one or more blades
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3 connected to a hub 4. The hub 4 is connected to a generator (not shown) arranged inside a nacelle 5. During operation of the wind turbine l, the blades 3 are driven by wind to rotate
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35 and the wind's kinetic energy is converted into electrical energy by the generator in the nacelle 5. The nacelle 5 is arranged at the upper end of a tower 6 of the wind turbine 1. The tower 6 is erected on a foundation 7 such as a monopile
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Fig. 5 shows a view similar as Fig. 4 with extending portions of the dry fibre lay-up being folded up onto the mould core;
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Fig. 6 shows the upper mould with the pre-casted fibre lay-up of Fig. 2 during arrangement on the lower mould with the dry fibre lay-up of Fig. 5;
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Fig. 7 shows a view similar as Fig. 6 with the upper mould being arranged on the lower mould, wherein the pre-casted fibre lay-up is overlapping with the dry fibre lay-up in an overlap region;
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Fig. 8 shows a view similar as Fig. 7 with resin infused;
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Fig. 9 shows a further embodiment of an overlap of a precasted fibre lay-up and a dry fibre lay-up;
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Fig. 10 shows another embodiment of an overlap of a precasted fibre lay-up and a dry fibre lay-up; and
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Fig. 11 shows a flowchart illustrating a method for manufacturing the wind turbine blade of the wind turbine of Fig. 1.
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In the figures, like reference numerals designate like or functionally equivalent elements, unless otherwise indicated.
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or tripile. The foundation 7 is connected to and/or driven into the ground or seabed.
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图1示出根据一个实施例的一种风电机组；
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图2示出图1所示风电机组的叶片的第一壳体的预铸纤维铺层的截面图，该预铸纤维铺层在上模具中倒置制造；
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图3示出图1所示风电机组的叶片的第二壳体的干纤维铺层的截面图，该干纤维铺层在浇铸和固化后形成第二壳体，该干纤维铺层布置在下模具中；
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图4示出与图3类似的视图，其中模具型芯和腹板布置在下模具中的干纤维铺层上；
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图5示出与图4类似的视图，其中干纤维铺层的延伸部分被向上折叠到模具型芯上；
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图6示出带有图2所示预铸纤维铺层的上模具在布置到带有图5所示干纤维铺层的下模具上时的视图；
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图7示出与图6类似的视图，其中上模具布置在下模具上，并且预铸纤维铺层在重叠区域与干纤维铺层重叠；
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图8示出与图7类似的视图，其中树脂已注入；
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图9示出预铸纤维铺层和干纤维铺层重叠的又一个实施例；
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图10示出预铸纤维铺层和干纤维铺层重叠的另一个实施例；以及
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图11示出一种用于制造图1所示风电机组的叶片的方法的流程图。
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在图中，除非另有说明，相同的附图标记表示相同或功能等效的元件。
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Fig. 1 shows a wind turbine 1 according to an embodiment. The wind turbine 1 comprises a rotor 2 having one or more blades connected to a hub 4. The hub 4 is connected to a generator (not shown) arranged inside a nacelle 5. During operation of the wind turbine l, the blades 3 are driven by wind to rotate and the wind's kinetic energy is converted into electrical energy by the generator in the nacelle 5. The nacelle 5 is arranged at the upper end of a tower 6 of the wind turbine 1. The tower 6 is erected on a foundation 7 such as a monopile or tripile. The foundation 7 is connected to and/or driven into the ground or seabed.
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In the following an improved method for manufacturing a wind 5turbine blade 3 is described with respect to Figs. 2 to 11.
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In step Sl of the method, and upper mould 8 is provided for pre-casting a fibre lay-up 9', as shown in Fig. 2. The precasted fibre lay-up 9", once cured and assembled, will become
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10a first shell 10 of the manufactured blade 3 (Fig. 7)．For step Sl, the upper mould 8 is turned upside down, as shown in Fig. 2. A mould cavity ll of the upper mould 8 is packed with dry fibre lay-up 9'. Since the upper mould 8 is turned upside down, the fibre lay-up 9' can be packed towards a well
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15 defined geometry, in contrast to the case in which a fibre lay-up is packed onto a flexible mould core. The fibre lay-up 9', 9" in the example of Fig. 2 comprises an outer laminate 12 and an inner laminate 13.Further, the fi
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20 bre lay-up 9', 9" comprises a core material, e.g., a balsa core, between the outer laminate 12 and the inner laminate 13. Here, it comprises a trailing edge balsa core 14 and a leading edge balsa core 15. The outer laminate 12, the respective balsa core 14, 15, and the inner laminate 13 form a
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25 sandwich structure. The fibre lay-up 9', 9" has a first tapered portion 17 and a second tapered portion 18 at its left and right edges in Fig. 2. In each of these tapered portions 17, 18, the inner lami
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30 nate 13, the respective balsa core 14, 15, and the outer laminate 12 is tapered. Hence, the tapered portions 17, 18 each have a continuous inclined surface 19, 20.
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In step S1 of the method, and upper mould 8 is provided for pre-casting a fibre lay-up 9', as shown in Fig. 2. The precasted fibre lay-up 9", once cured and assembled, will become a first shell 10 of the manufactured blade 3 (Fig. 7)．For step Sl, the upper mould 8 is turned upside down, as shown in Fig. 2. A mould cavity ll of the upper mould 8 is packed with dry fibre lay-up 9'. Since the upper mould 8 is turned upside down, the fibre lay-up 9' can be packed towards a well defined geometry, in contrast to the case in which a fibre lay-up is packed onto a flexible mould core.
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The fibre lay-up 9', 9" in the example of Fig. 2 comprises an outer laminate 12 and an inner laminate 13.Further, the fibre lay-up 9', 9" comprises a core material, e.g., a balsa core, between the outer laminate 12 and the inner laminate 13. Here, it comprises a trailing edge balsa core 14 and a leading edge balsa core 15. The outer laminate 12, the respective balsa core 14, 15, and the inner laminate 13 form a sandwich structure.
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The fibre lay-up 9', 9" has a first tapered portion 17 and a second tapered portion 18 at its left and right edges in Fig. 2. In each of these tapered portions 17, 18, the inner laminate 13, the respective balsa core 14, 15, and the outer laminate 12 is tapered. Hence, the tapered portions 17, 18 each have a continuous inclined surface 19, 20.
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The fibre lay-up 9', 9" in Fig. 2 further comprises a pre35 casted beam 16. The beam 16 is, for example, a suction-side beam or a pressure-side beam of the blade 3.
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The dry fibre lay-up 9' is pre-casted by a known vacuum infusion process, as described in EP 1 310 351 Al. In this vacuum infusion process, the fibre lay-up 9' is covered with a vacuum bag (not shown), and the vacuum bag is sealed (not shown) 5 at horizontal portions 21, 22 of the upper mould 8. Further, a vacuum is generated in a space covered by the vacuum bag, resin (not shown) is infused into the fibre lay-up 9’ and cured, resulting in the pre-casted fibre lay-up 9" shown in Fig.2.
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10 In step S2 of the method, a lower mould 23 is provided, as shown in Fig. 3. The lower mould 23 is packed with a dry fibre lay-up 24'.
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15The dry fibre lay-up 24' comprises an outer laminate 25 and an inner laminate 26. Further, the dry fibre lay-up 24' comprises a core material, such as a leading edge balsa core 27 and a trailing edge balsa core 28. Hence, the fibre lay-up 24' has a sandwich structure, wherein a respective balsa core
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20 27, 28 is sandwiched in between outer and inner laminates 25, 26。 The fibre lay-up 24' further comprises a pre-casted beam 29. The beam 29 is, for example, a pressure-side beam or a suc
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25 tion-side beam of the blade 3. The lower mould 23 comprises a mould cavity 30 and horizontal portions 31, 32 extending from side edges 33, 34 of the mould cavity 30.
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30 The dry fibre lay-up 24' is packed into the lower mould 23 by arranging a main portion 35 of the dry fibre lay-up 24' inside the cavity 30. In this example, the main portion 35 comprises a first main portion 36 and a second main portion 37.
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35 The first main portion 36 is arranged to the left side in Fig. 3 of the beam 29. The second main portion 37 is arranged to the right side in Fig. 3 of the beam 29.
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The dry fibre lay-up 9' is pre-casted by a known vacuum infusion process, as described in EP 1 310 351 Al. In this vacuum infusion process, the fibre lay-up 9' is covered with a vacuum bag (not shown), and the vacuum bag is sealed (not shown) at horizontal portions 21, 22 of the upper mould 8. Further, a vacuum is generated in a space covered by the vacuum bag, resin (not shown) is infused into the fibre lay-up 9’ and cured, resulting in the pre-casted fibre lay-up 9" shown in Fig.2.
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In step S2 of the method, a lower mould 23 is provided, as shown in Fig. 3. The lower mould 23 is packed with a dry fibre lay-up 24'.
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The dry fibre lay-up 24' comprises an outer laminate 25 and an inner laminate 26. Further, the dry fibre lay-up 24' comprises a core material, such as a leading edge balsa core 27 and a trailing edge balsa core 28. Hence, the fibre lay-up 24' has a sandwich structure, wherein a respective balsa core 27, 28 is sandwiched in between outer and inner laminates 25, 26。
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The fibre lay-up 24' further comprises a pre-casted beam 29. The beam 29 is, for example, a pressure-side beam or a suction-side beam of the blade 3.
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The lower mould 23 comprises a mould cavity 30 and horizontal portions 31, 32 extending from side edges 33, 34 of the mould cavity 30.
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The dry fibre lay-up 24' is packed into the lower mould 23 by arranging a main portion 35 of the dry fibre lay-up 24' inside the cavity 30. In this example, the main portion 35 comprises a first main portion 36 and a second main portion 37.
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The first main portion 36 is arranged to the left side in Fig. 3 of the beam 29. The second main portion 37 is arranged to the right side in Fig. 3 of the beam 29.
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Further, extending portions 38, 39 of the dry fibre lay-up 24' extend from the main portion 35,i.e. from the first main portion 36 and the second main portion 37, beyond the side edges 33, 34 of the cavity 30, respectively.
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The extending portion 38 comprises a first continuation portion 40 and a first tapered portion 42. The extending portion 39 comprises a second continuation portion 4l and a second tapered portion 43.
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10 In this example, the continuation portion 40 has the same layer structure of the outer laminate 25, the leading edge balsa core 27, and the inner laminate 26 as the first main portion 36 of the fibre lay-up 24'. Further, the continuation
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15 portion 40 has the same thickness dl as the first main portion 36. Furthermore, the continuation portion 4l has the same layer structure of the outer laminate 25, the trailing edge balsa core 28, and the inner laminate 26 as the second main portion 37 of the fibre lay-up 24'. Further, the contin
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20 uation portion 41 has the same thickness d2 as the second main portion 37.
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In this example, the continuation portion 40 has the same layer structure of the outer laminate 25, the leading edge balsa core 27, and the inner laminate 26 as the first main portion 36 of the fibre lay-up 24'. Further, the continuation portion 40 has the same thickness d1 as the first main portion 36. Furthermore, the continuation portion 4l has the same layer structure of the outer laminate 25, the trailing edge balsa core 28, and the inner laminate 26 as the second main portion 37 of the fibre lay-up 24'. Further, the continuation portion 41 has the same thickness d2 as the second main portion 37.
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In each of the first and second tapered portions 42, 43, the inner laminate 26, the respective balsa core 27, 28, and the 25 outer laminate 25 are tapered. Hence, the tapered portions 42, 43 each have a continuous inclined surface 44, 45.
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In each of the first and second tapered portions 42, 43, the inner laminate 26, the respective balsa core 27, 28, and the outer laminate 25 are tapered. Hence, the tapered portions 42, 43 each have a continuous inclined surface 44, 45.
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In step S3 of the method, a mould core 46 is arranged on the dry fibre lay-up 24', as shown in Fig. 4. The mould core 46 30 comprises a first mould core portion 47 and a second mould core portion 48. Each of the first and second mould core portions 47， 48 comprises，for example, a firm inner core 49, 50, and a flexible external portion 5l, 52. The flexible external portions 51, 52 comprise, for example, a foam material 35 which Can be compressed.
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In step S3 of the method, a mould core 46 is arranged on the dry fibre lay-up 24', as shown in Fig. 4. The mould core 46 comprises a first mould core portion 47 and a second mould core portion 48. Each of the first and second mould core portions 47， 48 comprises，for example, a firm inner core 49, 50, and a flexible external portion 5l, 52. The flexible external portions 51, 52 comprise, for example, a foam material which Can be compressed.
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Before arranging the mould core portions 47, 48, each of them is covered with a vacuum bag 53, 54, as shown in Fig. 4. The vacuum bags 53, 54 are sealed.
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5In step S4 of the method, a shear web 55 is provided on the dry fibre lay-up 24' and in between the first and second mould core portions 47 and 48. In the example shown in the figures, the web 55 is a dry lay-up. In other examples, the web 55 may also be pre-casted.
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10 Step S4 may be performed simultaneously with step S3 of arranging the mould core portions 47, 48. In step S5 of the method, the extending portions 38, 39 of
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15 the dry fibre lay-up 24' are folded up onto the respective first and second mould core portions 47, 48 of the mould core 46, as shown in Fig. 5. In step S6 of the method, the extending portions 38, 39 are
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20 fixed to the respective first and second mould core portions 47, 48. In detail, the extending portion 38 is fixed to the first mould core portion 47 covered with the vacuum bag 53 by means of a first adhesive tape 56. Further, the extending portion 39 is fixed to the second mould core portion 48 cov
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25 ered with the vacuum bag 54 by means of a second adhesive tape 57 . In step S7 of the method, the pre-casted fibre lay-up 9", which was pre-casted in the upper mould 8 in step Sl (Fig.
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30 2), is fixed to the upper mould 8. The pre-casted fibre layup 9" is, for example and as shown in Fig. 6, fixed to the upper mould 8 by means of attaching a first foil 58 and a second foil 59 each to the pre-casted fibre lay-up 9" and the
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In step S4 of the method, a shear web 55 is provided on the dry fibre lay-up 24' and in between the first and second mould core portions 47 and 48. In the example shown in the figures, the web 55 is a dry lay-up. In other examples, the web 55 may also be pre-casted.
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upper mould 8. The foils 58, 59 are sealed. Fig. 6 shows as 35 example sealings 6o. A vacuum is generated in a space covered by the foils 58, 59 which holds the pre-casted fibre lay-up 9" in the upper mould 8 while turning it and lowering it onto the lower mould 23 in the next step.
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Step S4 may be performed simultaneously with step S3 of arranging the mould core portions 47, 48.
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Step Sl and S7 may be performed before steps S2 to S6, simultaneously with steps S2 to S6, or after steps S2 to S6.
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In step S5 of the method, the extending portions 38, 39 of the dry fibre lay-up 24' are folded up onto the respective first and second mould core portions 47, 48 of the mould core 46, as shown in Fig. 5.
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5In step S8 of the method, the upper mould 8 is arranged on the lower mould 23, as shown in Fig. 6. Arranging the upper mould 8 on the lower mould 23 includes turning the upper mould 8 from the position in Fig. 2 to the position in Fig. 6. Fig. 6 shows a state in which the fibre lay-up 9" is al
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10 ready fixed to the upper mould 8, and the upper mould 8 is lifted, turned around and is being lowered onto the lower mould 23. Fig. 7 shows a state in which the upper mould 8 has been ar
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15 ranged on the lower mould 23. The pre-casted fibre lay-up 9" and the dry fibre lay-up 24' overlap each other in both a first and a second overlap region 6l, 62. Fig. 7 shows an insert with an enlarged view of the overlap region 61. In particular, the tapered portion 18 of the pre-casted fibre lay
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20 up 9" and the tapered portion 42 of the dry fibre lay-up 24' are overlapping each other in the overlap region 6l. Thereby, the inclined surface 20 of the tapered portion 18 and the inclined surface 44 of the tapered portion 42 are in direct contact with each.
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25 Similar, the tapered portion 17 of the pre-casted fibre layup 9" and the tapered portion 43 of the dry fibre lay-up 24' are overlapping each other in the overlap region 62. Thereby, the inclined surface 19 of the tapered portion 17 and the in
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30 clined surface 45 of the tapered portion 43 are in direct Contact with each. In this example, as can be seen in the insert of Fig. 7, the layer structure of the pre-casted fibre lay-up 9" including
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In step S6 of the method, the extending portions 38, 39 are fixed to the respective first and second mould core portions 47, 48. In detail, the extending portion 38 is fixed to the first mould core portion 47 covered with the vacuum bag 53 by means of a first adhesive tape 56. Further, the extending portion 39 is fixed to the second mould core portion 48 covered with the vacuum bag 54 by means of a second adhesive tape 57 .
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35 the outer and inner laminates 12, 13 and the respective core material 14, 15 match the layer structure of the dry fibre lay-up 24' including the outer and inner laminates 25, 26 and the respective core material 27, 28.
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In step S7 of the method, the pre-casted fibre lay-up 9", which was pre-casted in the upper mould 8 in step S1 (Fig. 2), is fixed to the upper mould 8. The pre-casted fibre layup 9" is, for example and as shown in Fig. 6, fixed to the upper mould 8 by means of attaching a first foil 58 and a second foil 59 each to the pre-casted fibre lay-up 9" and the upper mould 8. The foils 58, 59 are sealed. Fig. 6 shows as example sealings 60. A vacuum is generated in a space covered by the foils 58, 59 which holds the pre-casted fibre lay-up 9" in the upper mould 8 while turning it and lowering it onto the lower mould 23 in the next step.
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Step S1 and S7 may be performed before steps S2 to S6, simultaneously with steps S2 to S6, or after steps S2 to S6.
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In step S8 of the method, the upper mould 8 is arranged on the lower mould 23, as shown in Fig. 6. Arranging the upper mould 8 on the lower mould 23 includes turning the upper mould 8 from the position in Fig. 2 to the position in Fig. 6. Fig. 6 shows a state in which the fibre lay-up 9" is already fixed to the upper mould 8, and the upper mould 8 is lifted, turned around and is being lowered onto the lower mould 23.
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Fig. 7 shows a state in which the upper mould 8 has been arranged on the lower mould 23. The pre-casted fibre lay-up 9" and the dry fibre lay-up 24' overlap each other in both a first and a second overlap region 61, 62. Fig. 7 shows an insert with an enlarged view of the overlap region 61. In particular, the tapered portion 18 of the pre-casted fibre layup 9" and the tapered portion 42 of the dry fibre lay-up 24' are overlapping each other in the overlap region 6l. Thereby, the inclined surface 20 of the tapered portion 18 and the inclined surface 44 of the tapered portion 42 are in direct contact with each.
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Similar, the tapered portion 17 of the pre-casted fibre layup 9" and the tapered portion 43 of the dry fibre lay-up 24' are overlapping each other in the overlap region 62. Thereby, the inclined surface 19 of the tapered portion 17 and the in
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30 clined surface 45 of the tapered portion 43 are in direct Contact with each.
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In this example, as can be seen in the insert of Fig. 7, the layer structure of the pre-casted fibre lay-up 9" including the outer and inner laminates 12, 13 and the respective core material 14, 15 match the layer structure of the dry fibre lay-up 24' including the outer and inner laminates 25, 26 and the respective core material 27, 28.
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In step S9 of the method, a vacuum is generated in a space 63 defined by the upper and lower moulds 8, 23 and the vacuum bags 53, 54 covering the mould core portions 47, 48, as shown in Fig . 8 .
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In step S10, resin 65 is introduced in the space 63. In particular, the resin 65 is introduced in that part of the space 63 comprising the dry fibre lay-up 24', the connection re
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10 gions 66, 67, and the web 55. The resin 65 is, for example, introduced by a vacuum infusion process such as Vacuum Assisted Resin Transfer Moulding (VARTM). For further details of the generation of the vacuum, the infusion and curing of the resin 65, it is referred to EP 1 310 351 Al.
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15 The example illustrated in the figures shows a case where the web 55 is a dry lay-up. In this case, the web 55 is entirely infused with the resin 65, as shown.
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20 In other examples, a pre-casted web instead of the web 55 may be used. Then, the resin 65 would only be infused in an upper and lower connection portion of such a web (i.e. in a region where such a web would be connected with the beam 16 and in a region where such a web would be connected with the beam
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25 29) but not in a vertical portion of such a web. Fig. 8 shows exemplary inlet channels 64 through which the resin 65 is infused. With the drawn-in resin 65, the dry fibre lay-up 24', the connection regions 66, 67 (between the
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30dry fibre lay-up 24' and the pre-casted fibre lay-up 9"), and the web 55 are casted in a single process step. Each of the connection regions 66, 67 includes, in particularly, the respective overlap region 6l, 62. In this example,
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35 the connection regions 66, 67 are larger than the overlap regions 61, 62, respectively. In another embodiment, the connection regions 66, 67 and overlap regions 61, 62 may be the same, respectively.
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In step S10, resin 65 is introduced in the space 63. In particular, the resin 65 is introduced in that part of the space 63 comprising the dry fibre lay-up 24', the connection regions 66, 67, and the web 55. The resin 65 is, for example, introduced by a vacuum infusion process such as Vacuum Assisted Resin Transfer Moulding (VARTM). For further details of the generation of the vacuum, the infusion and curing of the resin 65, it is referred to EP 1 310 351 A1.
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The example illustrated in the figures shows a case where the web 55 is a dry lay-up. In this case, the web 55 is entirely infused with the resin 65, as shown.
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In other examples, a pre-casted web instead of the web 55 may be used. Then, the resin 65 would only be infused in an upper and lower connection portion of such a web (i.e. in a region where such a web would be connected with the beam 16 and in a region where such a web would be connected with the beam 29) but not in a vertical portion of such a web.
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Fig. 8 shows exemplary inlet channels 64 through which the resin 65 is infused. With the drawn-in resin 65, the dry fibre lay-up 24', the connection regions 66, 67 (between the dry fibre lay-up 24' and the pre-casted fibre lay-up 9"), and the web 55 are casted in a single process step.
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Each of the connection regions 66, 67 includes, in particularly, the respective overlap region 6l, 62. In this example, the connection regions 66, 67 are larger than the overlap regions 61, 62, respectively. In another embodiment, the connection regions 66, 67 and overlap regions 61, 62 may be the same, respectively.
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As the fibre lay-up 9" in the upper mould 8 is pre-casted, the resin 65 has to only fill the dry fibre lay-up 24', the connection regions 66, 67 and the web 55 but not the remaining portion of the pre-casted fibre lay-up 9" during the vacuum infusion process in step S9. Thus, the resin 65 has to travel a shorter path and fill a smaller volume compared to the case in which a fibre lay-up in the upper mould 8 is in a dry condition, i.e. without resin.
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10 In step Sll, the infused resin 65 is cured by a known process to obtain a cured and assembled blade shell. As shown in Fig. 8, the pre-casted fibre lay-up 9" in the upper mould 8 beComes in the manufactured blade 3 the first half shell 10.
|
||||
15Further, the fibre lay-up 24" in the lower mould 23 becomes, once infused and cured, in the manufactured blade 3 a second half shell 68. The web 55, once cured, transversally connects the first half shell 10 and the second half shell 68 within an interior cavity 7l of the blade 3.
|
||||
20 In this example, the resulting fibre-reinforced resin laminate of the shells 10, 68 has the same structure comprising the inner laminates 13, 26, the core materials 14, 15, 27, 28, and the outer laminates 12, 25 throughout the overlap re
|
||||
25 gions 61, 62 and the connection regions 66, 67. Therefore, a blade 3 having a shell with homogenous properties, such as homogenous strength and weight, across the overlap and connection regions 61, 62, 66, 67 is obtained.
|
||||
30In step S12 (not shown), the mould core portions 47, 48 and the vacuum bags 53, 54 are removed from the blade 3, e.g., through a root section of the blade 3. With this method, a blade is manufactured in which the first
|
||||
35 and second shells 10, 68 are connected with each other by a laminate joint which is a light and at the same time strong joint.
|
||||
In step S11, the infused resin 65 is cured by a known process to obtain a cured and assembled blade shell. As shown in Fig. 8, the pre-casted fibre lay-up 9" in the upper mould 8 beComes in the manufactured blade 3 the first half shell 10.
|
||||
|
||||
In a further embodiment, as shown in Fig.9, an overlap region 16l of a pre-casted fibre lay-up 109" in an upper mould 108 and a dry fibre lay-up 124' in a lower mould 123 does not contain a core material 115, 127. Thus, in the overlap region 5 161, the outer and inner laminates 112, 1l3 of the pre-casted lay-up 109" overlap with the outer and inner laminates 125, 126 of the fibre lay-up 124', 124" in the lower mould 123. However, the core material 1l5 of the pre-casted fibre lay-up 109" does not overlap with the core material 127 of the fibre O lay-up 124', 124" in the lower mould 123.
|
||||
Further, the fibre lay-up 24" in the lower mould 23 becomes, once infused and cured, in the manufactured blade 3 a second half shell 68. The web 55, once cured, transversally connects the first half shell 10 and the second half shell 68 within an interior cavity 7l of the blade 3.
|
||||
|
||||
In a further embodiment, as shown in Fig. 1o, an auxiliary material 69 is disposed in an overlap region 262 of a precasted fibre lay-up 209" in an upper mould 208 and a fibre 15 lay-up 224', 224" in a lower mould 223. The auxiliary material 69 is, for example, a PUR material. It is applied in the example of Fig. 10 to form a sharp edge 70 of an aerodynamic profile of the blade 3, e.g. at a trailing edge of the airfoil.
|
||||
In this example, the resulting fibre-reinforced resin laminate of the shells 10, 68 has the same structure comprising the inner laminates 13, 26, the core materials 14, 15, 27, 28, and the outer laminates 12, 25 throughout the overlap regions 61, 62 and the connection regions 66, 67. Therefore, a blade 3 having a shell with homogenous properties, such as homogenous strength and weight, across the overlap and connection regions 61, 62, 66, 67 is obtained.
|
||||
|
||||
ZU The auxiliary material 69 is arranged in the example of Fig. 10 between an inclined surface 219 of a tapered edge portion 217 of the pre-casted fibre lay-up 209" and an inclined surface 245 of a tapered edge portion 243 of the fibre lay-up
|
||||
25 224', 224" in the lower mould 223. Furthermore, a mini-web 229 is arranged connecting the pre-casted fibre lay-up 209", the auxiliary material 69 and the fibre lay-up 224', 224".
|
||||
In step S12 (not shown), the mould core portions 47, 48 and the vacuum bags 53, 54 are removed from the blade 3, e.g., through a root section of the blade 3.
|
||||
|
||||
Although the present invention has been described in accord30 ance with preferred embodiments, it is obvious for the person skilled in the art that modifications are possible in all embodiments.
|
||||
With this method, a blade is manufactured in which the first and second shells 10, 68 are connected with each other by a laminate joint which is a light and at the same time strong joint.
|
||||
|
||||
In a further embodiment, as shown in Fig.9, an overlap region 161 of a pre-casted fibre lay-up 109" in an upper mould 108 and a dry fibre lay-up 124' in a lower mould 123 does not contain a core material 115, 127. Thus, in the overlap region 161, the outer and inner laminates 112, 113 of the pre-casted lay-up 109" overlap with the outer and inner laminates 125, 126 of the fibre lay-up 124', 124" in the lower mould 123.
|
||||
However, the core material 1l5 of the pre-casted fibre lay-up 109" does not overlap with the core material 127 of the fibre lay-up 124', 124" in the lower mould 123.
|
||||
|
||||
In a further embodiment, as shown in Fig. 1o, an auxiliary material 69 is disposed in an overlap region 262 of a precasted fibre lay-up 209" in an upper mould 208 and a fibre lay-up 224', 224" in a lower mould 223. The auxiliary material 69 is, for example, a PUR material. It is applied in the example of Fig. 10 to form a sharp edge 70 of an aerodynamic profile of the blade 3, e.g. at a trailing edge of the airfoil.
|
||||
|
||||
The auxiliary material 69 is arranged in the example of Fig. 10 between an inclined surface 219 of a tapered edge portion 217 of the pre-casted fibre lay-up 209" and an inclined surface 245 of a tapered edge portion 243 of the fibre lay-up 224', 224" in the lower mould 223. Furthermore, a mini-web 229 is arranged connecting the pre-casted fibre lay-up 209", the auxiliary material 69 and the fibre lay-up 224', 224".
|
||||
|
||||
Although the present invention has been described in accord ance with preferred embodiments, it is obvious for the person skilled in the art that modifications are possible in all embodiments.
|
||||
|
||||
图1示出了根据一个实施例的风电机组1。风电机组1包括风轮2，风轮2具有连接到轮毂4的一个或多个叶片。轮毂4连接到布置在机舱5内部的发电机（未示出）。在风电机组1运行期间，叶片3由风驱动旋转，并且风的动能由机舱5中的发电机转换为电能。机舱5布置在风电机组1的塔架6的上端。塔架6竖立在基础7上，例如单桩或三桩。基础7连接到陆地或海床和/或打入陆地或海床。
|
||||
|
||||
下文将参照图2至图11描述一种改进的叶片3制造方法。
|
||||
|
||||
在该方法的步骤S1中，提供上模具8以预铸纤维铺层9'，如图2所示。预铸纤维铺层9"一旦固化并组装，将成为所制造叶片3的第一壳体10（图7）。对于步骤S1，上模具8被倒置，如图2所示。上模具8的模腔11填充有干纤维铺层9'。由于上模具8被倒置，纤维铺层9'可以被填充成明确的几何形状，这与将纤维铺层填充到柔性模芯上的情况不同。
|
||||
图2示例中的纤维铺层9'、9"包括外层层压板12和内层层压板13。此外，纤维铺层9'、9"包括芯材，例如，在外层层压板12和内层层压板13之间的轻木芯。在此，其包括后缘轻木芯14和前缘轻木芯15。外层层压板12、相应的轻木芯14、15和内层层压板13形成夹层结构。
|
||||
|
||||
图2中的纤维铺层9'、9"在其左边缘和右边缘处具有第一锥形部分17和第二锥形部分18。在这些锥形部分17、18中的每一个中，内层层压板13、相应的轻木芯14、15和外层层压板12是锥形的。因此，锥形部分17、18各自具有连续的倾斜表面19、20。
|
||||
|
||||
图2中的纤维铺层9'、9"还包括预铸梁16。梁16例如是叶片3的吸力侧梁或压力侧梁。
|
||||
|
||||
干纤维铺层9'通过已知的真空灌注工艺进行预铸，如EP 1 310 351 A1中所述。在该真空灌注工艺中，纤维铺层9'被真空袋（未示出）覆盖，并且真空袋在上模具8的水平部分21、22处被密封（未示出）。此外，在真空袋覆盖的空间中产生真空，树脂（未示出）被灌注到纤维铺层9'中并固化，从而得到图2所示的预铸纤维铺层9"。
|
||||
|
||||
在该方法的步骤S2中，提供下模具23，如图3所示。下模具23填充有干纤维铺层24'。
|
||||
|
||||
干纤维铺层24'包括外层层压板25和内层层压板26。此外，干纤维铺层24'包括芯材，例如前缘轻木芯27和后缘轻木芯28。因此，纤维铺层24'具有夹层结构，其中相应的轻木芯27、28夹在外层和内层层压板25、26之间。
|
||||
|
||||
纤维铺层24'还包括预铸梁29。梁29例如是叶片3的压力侧梁或吸力侧梁。
|
||||
|
||||
下模具23包括模腔30和从模腔30的侧边缘33、34延伸的水平部分31、32。
|
||||
|
||||
通过将干纤维铺层24'的主体部分35布置在模腔30内部，将干纤维铺层24'填充到下模具23中。在该示例中，主体部分35包括第一主体部分36和第二主体部分37。
|
||||
|
||||
第一主体部分36布置在图3中梁29的左侧。第二主体部分37布置在图3中梁29的右侧。
|
||||
|
||||
此外，干纤维铺层24'的延伸部分38、39分别从主体部分35，即从第一主体部分36和第二主体部分37，延伸超出模腔30的侧边缘33、34。
|
||||
|
||||
延伸部分38包括第一连续部分40和第一锥形部分42。延伸部分39包括第二连续部分41和第二锥形部分43。
|
||||
|
||||
在该示例中，连续部分40具有与纤维铺层24'的第一主体部分36相同的外层层压板25、前缘轻木芯27和内层层压板26的层结构。此外，连续部分40具有与第一主体部分36相同的厚度d1。此外，连续部分41具有与纤维铺层24'的第二主体部分37相同的外层层压板25、后缘轻木芯28和内层层压板26的层结构。此外，连续部分41具有与第二主体部分37相同的厚度d2。
|
||||
|
||||
在第一和第二锥形部分42、43中的每一个中，内层层压板26、相应的轻木芯27、28和外层层压板25是锥形的。因此，锥形部分42、43各自具有连续的倾斜表面44、45。
|
||||
|
||||
在该方法的步骤S3中，将模芯46布置在干纤维铺层24'上，如图4所示。模芯46包括第一模芯部分47和第二模芯部分48。第一和第二模芯部分47、48中的每一个例如包括坚固的内芯49、50和柔性外部部分51、52。柔性外部部分51、52例如包括可被压缩的泡沫材料。
|
||||
|
||||
在布置模芯部分47、48之前，每个模芯部分都用真空袋53、54覆盖，如图4所示。真空袋53、54被密封。
|
||||
|
||||
在该方法的步骤S4中，在干纤维铺层24'上以及在第一和第二模芯部分47和48之间提供剪力腹板55。在图中所示的示例中，腹板55是干铺层。在其他示例中，腹板55也可以是预铸的。
|
||||
|
||||
步骤S4可以与布置模芯部分47、48的步骤S3同时执行。
|
||||
|
||||
在该方法的步骤S5中，干纤维铺层24'的延伸部分38、39被向上折叠到模芯46的相应第一和第二模芯部分47、48上，如图5所示。
|
||||
|
||||
在该方法的步骤S6中，延伸部分38、39被固定到相应的第一和第二模芯部分47、48上。具体地，延伸部分38通过第一胶带56固定到被真空袋53覆盖的第一模芯部分47上。此外，延伸部分39通过第二胶带57固定到被真空袋54覆盖的第二模芯部分48上。
|
||||
|
||||
在该方法的步骤S7中，在步骤S1中（图2）在上模具8中预铸的预铸纤维铺层9"被固定到上模具8上。预铸纤维铺层9"例如如图6所示，通过将第一箔片58和第二箔片59分别连接到预铸纤维铺层9"和上模具8上来固定到上模具8上。箔片58、59被密封。图6示出了示例性密封件60。在箔片58、59覆盖的空间中产生真空，该真空将预铸纤维铺层9"保持在上模具8中，同时在下一步中将其翻转并降低到下模具23上。
|
||||
|
||||
步骤S1和S7可以在步骤S2至S6之前、与步骤S2至S6同时或在步骤S2至S6之后执行。
|
||||
|
||||
在该方法的步骤S8中，上模具8布置在下模具23上，如图6所示。将上模具8布置在下模具23上包括将上模具8从图2中的位置翻转到图6中的位置。图6示出了纤维铺层9"已经固定到上模具8上，并且上模具8被抬起、翻转并正在降低到下模具23上的状态。
|
||||
|
||||
图7示出了上模具8已经布置在下模具23上的状态。预铸纤维铺层9"和干纤维铺层24'在第一和第二重叠区域61、62中彼此重叠。图7示出了具有重叠区域61放大视图的插图。具体地，预铸纤维铺层9"的锥形部分18和干纤维铺层24'的锥形部分42在重叠区域61中彼此重叠。因此，锥形部分18的倾斜表面20和锥形部分42的倾斜表面44彼此直接接触。
|
||||
|
||||
类似地，预铸纤维铺层9"的锥形部分17和干纤维铺层24'的锥形部分43在重叠区域62中彼此重叠。因此，锥形部分17的倾斜表面19和锥形部分43的倾斜表面45彼此直接接触。
|
||||
|
||||
在该示例中，如图7的插图所示，预铸纤维铺层9"的层结构，包括外层和内层层压板12、13以及相应的芯材14、15，与干纤维铺层24'的层结构，包括外层和内层层压板25、26以及相应的芯材27、28相匹配。
|
||||
|
||||
在该方法的步骤S9中，在由上模具8、23和覆盖模芯部分47、48的真空袋53、54限定的空间63中产生真空，如图8所示。
|
||||
|
||||
在步骤S10中，树脂65被引入空间63中。具体地，树脂65被引入空间63中包括干纤维铺层24'、连接区域66、67和腹板55的部分。树脂65例如通过真空灌注工艺引入，例如真空辅助树脂传递模塑（VARTM）。关于真空的产生、树脂65的灌注和固化的更多细节，请参阅EP 1 310 351 A1。
|
||||
|
||||
图中所示的示例示出了腹板55是干铺层的情况。在这种情况下，腹板55完全被树脂65灌注，如图所示。
|
||||
|
||||
在其他示例中，可以使用预铸腹板而不是腹板55。那么，树脂65将仅灌注到这种腹板的上下连接部分（即，这种腹板将与梁16连接的区域以及这种腹板将与梁29连接的区域），而不是这种腹板的垂直部分。
|
||||
|
||||
图8示出了树脂65通过其灌注的示例性入口通道64。随着树脂65的吸入，干纤维铺层24'、连接区域66、67（在干纤维铺层24'和预铸纤维铺层9"之间）和腹板55在单个工艺步骤中被铸造。
|
||||
|
||||
每个连接区域66、67特别包括相应的重叠区域61、62。在该示例中，连接区域66、67分别大于重叠区域61、62。在另一个实施例中，连接区域66、67和重叠区域61、62可以分别相同。
|
||||
|
||||
由于上模具8中的纤维铺层9"是预铸的，因此在步骤S9的真空灌注过程中，树脂65只需填充干纤维铺层24'、连接区域66、67和腹板55，而无需填充预铸纤维铺层9"的剩余部分。因此，与上模具8中的纤维铺层处于干燥状态（即没有树脂）的情况相比，树脂65必须行进更短的路径并填充更小的体积。
|
||||
|
||||
在步骤S11中，灌注的树脂65通过已知工艺固化，以获得固化并组装的叶片壳体。如图8所示，上模具8中的预铸纤维铺层9"在所制造的叶片3中成为第一半壳体10。
|
||||
|
||||
此外，下模具23中的纤维铺层24"一旦灌注并固化，在所制造的叶片3中成为第二半壳体68。腹板55一旦固化，在叶片3的内部腔体71内横向连接第一半壳体10和第二半壳体68。
|
||||
|
||||
在该示例中，壳体10、68的所得纤维增强树脂层压板在整个重叠区域61、62和连接区域66、67中具有相同的结构，包括内层层压板13、26、芯材14、15、27、28和外层层压板12、25。因此，获得了在重叠和连接区域61、62、66、67上具有均匀特性（例如均匀强度和重量）的壳体的叶片3。
|
||||
|
||||
在步骤S12（未示出）中，模芯部分47、48和真空袋53、54从叶片3中移除，例如通过叶片3的根部。
|
||||
|
||||
通过这种方法，制造出一种叶片，其中第一和第二壳体10、68通过层压接头彼此连接，该接头是轻质且同时坚固的接头。
|
||||
|
||||
在另一个实施例中，如图9所示，上模具108中的预铸纤维铺层109"和下模具123中的干纤维铺层124'的重叠区域161不包含芯材115、127。因此，在重叠区域161中，预铸铺层109"的外层和内层层压板112、113与下模具123中的纤维铺层124'、124"的外层和内层层压板125、126重叠。
|
||||
|
||||
然而，预铸纤维铺层109"的芯材115不与下模具123中的纤维铺层124'、124"的芯材127重叠。
|
||||
|
||||
在另一个实施例中，如图10所示，辅助材料69布置在上模具208中的预铸纤维铺层209"和下模具223中的纤维铺层224'、224"的重叠区域262中。辅助材料69例如是PUR材料。在图10的示例中，其被施加以形成叶片3的气动轮廓的锐边70，例如在翼型的后缘处。
|
||||
|
||||
在图10的示例中，辅助材料69布置在预铸纤维铺层209"的锥形边缘部分217的倾斜表面219和下模具223中的纤维铺层224'、224"的锥形边缘部分243的倾斜表面245之间。此外，布置有迷你腹板229，连接预铸纤维铺层209"、辅助材料69和纤维铺层224'、224"。
|
||||
|
||||
尽管本发明已根据优选实施例进行了描述，但对于本领域技术人员而言，所有实施例中都可能进行修改是显而易见的。
|
||||
Patent claims
|
||||
|
||||
1. A method for manufacturing a wind turbine blade (3), comprising the steps of: 5 - arranging (S8) an upper mould (8) comprising a precasted fibre lay-up (9") on a lower mould (23) comprising a dry fibre lay-up (24') and a mould core (46), - applying vacuum (S9) to a space (63) between the upper and lower moulds (8, 23) and the mould core (46),
|
||||
10 - infusing (S10) at least the dry fibre lay-up (24') and a connection region (66, 67） between the dry fibre lay-up (24') and the pre-casted fibre lay-up (9") with a resin (65), and curing (S1l) the resin (65).
|
||||
152.The method according to claim 1, wherein the dry fibre lay-up (24') and/or the pre-casted fibre lay-up (9") includes a core material (14, 15, 27, 28). 3. The method according to claim 1 or 2, wherein the connec
|
||||
20tion region (66, 67） comprises an overlap region (61,62）in which the pre-casted fibre lay-up (9") and the dry fibre layup (24') overlap each other. 4. The method according to claim 2 and 3, wherein the pre
|
||||
25casted fibre lay-up (9") and/or the dry fibre lay-up (24') Comprises the core material (14, 15, 27, 28) in the overlap region (61， 62). 5．The method according to claim 3 or 4, wherein both the
|
||||
30dry fibre lay-up (24') and the pre-casted fibre lay-up (9") comprise at least one tapered edge portion (17, 18, 42, 43) overlapping each other in the overlap region (61, 62). 6. The method according to one of claims 1 to 5, wherein the
|
||||
35pre-casted fibre lay-up (9") and the dry fibre lay-up (24') are in direct contact with each other in the connection region (66, 67).
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||||
1. A method for manufacturing a wind turbine blade (3), comprising the steps of:
|
||||
- arranging (S8) an upper mould (8) comprising a precasted fibre lay-up (9") on a lower mould (23) comprising a dry fibre lay-up (24') and a mould core (46),
|
||||
- applying vacuum (S9) to a space (63) between the upper and lower moulds (8, 23) and the mould core (46),
|
||||
- infusing (S10) at least the dry fibre lay-up (24') and a connection region (66, 67） between the dry fibre lay-up (24') and the pre-casted fibre lay-up (9") with a resin (65), and curing (S1l) the resin (65).
|
||||
|
||||
7． The method according to one of claims 1 to 5, wherein an auxiliary material (69) is disposed between a surface (219) of at least one edge portion (2i7) of the pre-casted fibre lay-up (9") and a surface (245) of at least one edge portion ;(243） of the dry fibre lay-up (24').
|
||||
2. The method according to claim 1, wherein the dry fibre lay-up (24') and/or the pre-casted fibre lay-up (9") includes a core material (14, 15, 27, 28).
|
||||
|
||||
8． The method according to one of claims 1 to 7, wherein the dry fibre lay-up (24') in the lower mould (23) has a main portion (35) inside a cavity (30) of the lower mould (23) and
|
||||
10at least one extending portion (38, 39) extending from the main portion (35) beyond a side edge (33, 34) of the cavity (30) of the lower mould (23), and wherein the method comprises, before the step of arranging (S8) the upper mould (8) on the lower mould (23), the steps of arranging (S3) the mould
|
||||
15 Core (46) on the dry fibre lay-up (24'） in the lower mould (23) and folding up (s5) the at least one extending portion (38, 39) of the dry fibre lay-up (24') onto the mould core (46) 。
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||||
20 9. The method according to claim 8, wherein a continuation portion (40, 4l） of the at least one extending portion (38, 39) has the same layer structure and/or the same thickness (dl, d2) as the main portion (35), the continuation portion (40, 4l) being continuous with the main portion (35).
|
||||
25 10. The method according to claim 8 or 9, comprising, after the step of folding up (S5) the at least one extending portion (38, 39) onto the mould core (46)， the step of fixing (S6) the at least one folded-up extending portion (38, 39) at
|
||||
30 the mould core (46). 11. The method according to one of claims 1 to 1o, comprising, before the step of arranging (S8) the upper mould (8) comprising the pre-casted fibre lay-up (9") on the lower
|
||||
35mould (23), the step of fixing (S7) the pre-casted fibre layup (9") to the upper mould (8).
|
||||
3. The method according to claim 1 or 2, wherein the connection region (66, 67） comprises an overlap region (61,62）in which the pre-casted fibre lay-up (9") and the dry fibre layup (24') overlap each other.
|
||||
|
||||
12. The method according to one of claims 1 to 1l, comprising, before the step of applying vacuum (S9), the step of covering the mould core (46) with a vacuum bag (53, 54), and wherein the vacuum is applied to a space (63) between the up5 per and lower moulds (8, 23) and the vacuum bag (53, 54).
|
||||
4. The method according to claim 2 and 3, wherein the precasted fibre lay-up (9") and/or the dry fibre lay-up (24') Comprises the core material (14, 15, 27, 28) in the overlap region (61， 62).
|
||||
5. The method according to claim 3 or 4, wherein both the dry fibre lay-up (24') and the pre-casted fibre lay-up (9") comprise at least one tapered edge portion (17, 18, 42, 43) overlapping each other in the overlap region (61, 62).
|
||||
6. The method according to one of claims 1 to 5, wherein the pre-casted fibre lay-up (9") and the dry fibre lay-up (24') are in direct contact with each other in the connection region (66, 67).
|
||||
|
||||
7. The method according to one of claims 1 to 5, wherein an auxiliary material (69) is disposed between a surface (219) of at least one edge portion (2i7) of the pre-casted fibre lay-up (9") and a surface (245) of at least one edge portion (243）of the dry fibre lay-up (24').
|
||||
|
||||
8. The method according to one of claims 1 to 7, wherein the dry fibre lay-up (24') in the lower mould (23) has a main portion (35) inside a cavity (30) of the lower mould (23) and at least one extending portion (38, 39) extending from the main portion (35) beyond a side edge (33, 34) of the cavity (30) of the lower mould (23), and wherein the method comprises, before the step of arranging (S8) the upper mould (8) on the lower mould (23), the steps of arranging (S3) the mould Core (46) on the dry fibre lay-up (24'） in the lower mould (23) and folding up (s5) the at least one extending portion (38, 39) of the dry fibre lay-up (24') onto the mould core (46) 。
|
||||
|
||||
9. The method according to claim 8, wherein a continuation portion (40, 4l） of the at least one extending portion (38, 39) has the same layer structure and/or the same thickness (dl, d2) as the main portion (35), the continuation portion (40, 4l) being continuous with the main portion (35).
|
||||
|
||||
10. The method according to claim 8 or 9, comprising, after the step of folding up (S5) the at least one extending portion (38, 39) onto the mould core (46)， the step of fixing (S6) the at least one folded-up extending portion (38, 39) at the mould core (46).
|
||||
|
||||
11. The method according to one of claims 1 to 1o, comprising, before the step of arranging (S8) the upper mould (8) comprising the pre-casted fibre lay-up (9") on the lower mould (23), the step of fixing (S7) the pre-casted fibre layup (9") to the upper mould (8).
|
||||
|
||||
12. The method according to one of claims 1 to 11, comprising, before the step of applying vacuum (S9), the step of covering the mould core (46) with a vacuum bag (53, 54), and wherein the vacuum is applied to a space (63) between the up5 per and lower moulds (8, 23) and the vacuum bag (53, 54).
|
||||
|
||||
13. The method according to one of claims 1 to 12, comprising, before the step of arranging (S8) the upper mould (8) on the lower mould (23), the step of arranging one or more rein10 forcement beams (29) on the dry fibre lay-up (24').
|
||||
|
||||
14. The method according to one of claims 1 to 13, comprising, before the step of arranging (S8) the upper mould (8) on the lower mould (23)， the step of arranging (S4) a web (55),
|
||||
15 and wherein at least the dry fibre lay-up (24'), the connection region (66,67) and the web (55) is infused (S10) with resin (65) . 15. The method according to claim 14, wherein the web (55) is
|
||||
20 configured to transversally connect the pre-casted fibre layup (9") and the dry fibre lay-up (24', 24"), once cured, within an interior cavity (7l) of the blade (3).
|
||||
|
||||
15. and wherein at least the dry fibre lay-up (24'), the connection region (66,67) and the web (55) is infused (S10) with resin (65) . 15. The method according to claim 14, wherein the web (55) is configured to transversally connect the pre-casted fibre layup (9") and the dry fibre lay-up (24', 24"), once cured, within an interior cavity (7l) of the blade (3).
|
||||
|
||||
一种制造风电机组叶片 (3) 的方法，包括以下步骤：
|
||||
- 布置 (S8) 包括预铸纤维铺层 (9") 的上模具 (8) 在包括干纤维铺层 (24') 和模具型芯 (46) 的下模具 (23) 上；
|
||||
- 施加真空 (S9) 至上模具 (8)、下模具 (23) 和模具型芯 (46) 之间的空间 (63)；
|
||||
- 用树脂 (65) 灌注 (S10) 至少干纤维铺层 (24') 以及干纤维铺层 (24') 和预铸纤维铺层 (9") 之间的连接区域 (66, 67)，并固化 (S11) 该树脂 (65)。
|
||||
|
||||
2. 根据权利要求 1 所述的方法，其中所述干纤维铺层 (24') 和/或所述预铸纤维铺层 (9") 包括芯材 (14, 15, 27, 28)。
|
||||
|
||||
3. 根据权利要求 1 或 2 所述的方法，其中所述连接区域 (66, 67) 包括重叠区域 (61, 62)，在该重叠区域中，所述预铸纤维铺层 (9") 和所述干纤维铺层 (24') 相互重叠。
|
||||
|
||||
4. 根据权利要求 2 和 3 所述的方法，其中所述预铸纤维铺层 (9") 和/或所述干纤维铺层 (24') 在所述重叠区域 (61, 62) 中包括所述芯材 (14, 15, 27, 28)。
|
||||
|
||||
5. 根据权利要求 3 或 4 所述的方法，其中所述干纤维铺层 (24') 和所述预铸纤维铺层 (9") 两者包括至少一个锥形边缘部分 (17, 18, 42, 43)，在所述重叠区域 (61, 62) 中相互重叠。
|
||||
|
||||
6. 根据权利要求 1 至 5 中任一项所述的方法，其中所述预铸纤维铺层 (9") 和所述干纤维铺层 (24') 在所述连接区域 (66, 67) 中相互直接接触。
|
||||
|
||||
7. 根据权利要求 1 至 5 中任一项所述的方法，其中辅助材料 (69) 布置在所述预铸纤维铺层 (9") 的至少一个边缘部分 (217) 的表面 (219) 和所述干纤维铺层 (24') 的至少一个边缘部分 (243) 的表面 (245) 之间。
|
||||
|
||||
8. 根据权利要求 1 至 7 中任一项所述的方法，其中下模具 (23) 中的所述干纤维铺层 (24') 在所述下模具 (23) 的型腔 (30) 内部具有主体部分 (35) 并且具有至少一个延伸部分 (38, 39)，该延伸部分从所述主体部分 (35) 延伸超出所述下模具 (23) 的型腔 (30) 的侧边缘 (33, 34)，并且其中所述方法包括，在布置 (S8) 所述上模具 (8) 在所述下模具 (23) 上的步骤之前，布置 (S3) 所述模具型芯 (46) 在所述下模具 (23) 中的所述干纤维铺层 (24') 上，以及将所述干纤维铺层 (24') 的所述至少一个延伸部分 (38, 39) 折叠 (S5) 到所述模具型芯 (46) 上的步骤。
|
||||
|
||||
9. 根据权利要求 8 所述的方法，其中所述至少一个延伸部分 (38, 39) 的延续部分 (40, 41) 具有与所述主体部分 (35) 相同的层结构和/或相同的厚度 (d1, d2)，所述延续部分 (40, 41) 与所述主体部分 (35) 连续。
|
||||
|
||||
10. 根据权利要求 8 或 9 所述的方法，包括，在将所述至少一个延伸部分 (38, 39) 折叠 (S5) 到所述模具型芯 (46) 上的步骤之后，将所述至少一个折叠的延伸部分 (38, 39) 固定 (S6) 在所述模具型芯 (46) 上的步骤。
|
||||
|
||||
11. 根据权利要求 1 至 10 中任一项所述的方法，包括，在布置 (S8) 包括所述预铸纤维铺层 (9") 的所述上模具 (8) 在所述下模具 (23) 上的步骤之前，将所述预铸纤维铺层 (9") 固定 (S7) 到所述上模具 (8) 上的步骤。
|
||||
|
||||
12. 根据权利要求 1 至 11 中任一项所述的方法，包括，在施加真空 (S9) 的步骤之前，用真空袋 (53, 54) 覆盖所述模具型芯 (46) 的步骤，并且其中所述真空施加至所述上模具 (8)、所述下模具 (23) 和所述真空袋 (53, 54) 之间的空间 (63)。
|
||||
|
||||
13. 根据权利要求 1 至 12 中任一项所述的方法，包括，在布置 (S8) 所述上模具 (8) 在所述下模具 (23) 上的步骤之前，布置一个或多个加强梁 (29) 在所述干纤维铺层 (24') 上的步骤。
|
||||
|
||||
14. 根据权利要求 1 至 13 中任一项所述的方法，包括，在布置 (S8) 所述上模具 (8) 在所述下模具 (23) 上的步骤之前，布置 (S4) 腹板 (55) 的步骤，并且其中至少所述干纤维铺层 (24')、所述连接区域 (66, 67) 和所述腹板 (55) 用树脂 (65) 灌注 (S10)。
|
||||
|
||||
15. 根据权利要求 14 所述的方法，其中所述腹板 (55) 被配置成在固化后，在所述叶片 (3) 的内部型腔 (71) 内横向连接所述预铸纤维铺层 (9") 和所述干纤维铺层 (24', 24")。
|
||||
# 1/11
|
||||
|
||||
|
||||
|
||||
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Reference in New Issue
Block a user