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[0016] By making the blade in one piece in a closed process, the workers' exposure to possible environmentally hazardous substances in the composite material is eliminated, so that the need for personal protective
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means may be reduced to an absolute minimum. [0017] By making the blade in a sandwich construction with a core material which largely runs continuously around the cross-sectional profile of the blade, there is
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5 achieved a particularly advantageous combination of production technique and properties of the finished product. The core material may thus be used as evacuation and flow duct by a vacuum based process, and the continuous process ensures uniform cross-sectional
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10 properties without disadvantageous transitions between sandwich and solid structure in highly loaded areas. The continuous core material and the real separation of the load bearing part of the laminate in an outer and an inner section furthermore provides the construc
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15 tional advantage that a possible crack formation in one (outer or inner) laminate only implies a very small risk of propagation to the other laminate. Hereby is achieved a hitherto unknown redundancy of the structure.
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means may be reduced to an absolute minimum. [0017] By making the blade in a sandwich construction with a core material which largely runs continuously around the cross-sectional profile of the blade, there is achieved a particularly advantageous combination of production technique and properties of the finished product. The core material may thus be used as evacuation and flow duct by a vacuum based process, and the continuous process ensures uniform cross-sectional properties without disadvantageous transitions between sandwich and solid structure in highly loaded areas. The continuous core material and the real separation of the load bearing part of the laminate in an outer and an inner section furthermore provides the constructional advantage that a possible crack formation in one (outer or inner) laminate only implies a very small risk of propagation to the other laminate. Hereby is achieved a hitherto unknown redundancy of the structure.
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[0011] 本发明的目的是提供一种制造复合材料风电机组叶片的方法，以便这些叶片可以在封闭工艺中主要以一体成型的方式制造，而无需任何胶合接头。
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# 20 The Drawing
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[0012] 这通过引言中指出的方法实现，其特点在于叶片在封闭模具中一体成型，并且，根据复合材料的类型，可能还有全部或部分的基体材料，被放置在至少一个由柔性材料外部部分组成的模具型芯周围；一个外部模具部件围绕模具型芯和可能的基体材料闭合；纤维增强材料和基体材料被引入到与所选复合材料相关的结合中；并且模具型芯的内部部分至少一部分随后从制成的风电机组叶片中取出。
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[0018] In the following, the method will be explained in detail as reference is made to the Figures. Figures 1 - 2 provides examples of prior art, and Figure 3 indicates 25 a blade made in accordance with the invention. With the Figures 4 - 11, the method is explained in an embodiment where the laminate is made of thermosetting plastic by vacuum injection.
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[0013] 与现有技术方法相比，通过这种方法获得了多项优点。
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# 30 Description of Embodiments
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[0014] 通过一体成型制造叶片，其中外部的很大一部分是一个或多个外部模具部件的印模，从而获得了以下优点：通过在模具中使用胶衣或通过随后的简单表面处理，叶片表面可以在气动效率和美学印象方面呈现所需的质量。
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[0019] Fig. 1 shows a windmill blade made according to a usual method. A beam 1 is made by winding around a mandrel which later is taken out of the beam. Around 35 the beam is glued two half-shells 2 and 3. Each halfshell consists of an outer laminate 4, a sandwich core 5, which e.g. can be made in balsa wood or PVC foam, and an inner laminate 6. The half-shells are fastened by glue joints at the leading edge 7, at the trailing edge 8, 40 and against the beam 9. A blade made according to this usual method initially has three main parts, namely the beam 1 and the two half-shells 2 and 3. According to the circumstances, these main parts may be supplemented with further main parts, e.g. at the root of the blade, for 45 forming transition to pitch bearing and/or rotor hub.
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[0015] 通过一体成型制造叶片，而无需任何胶合接头，消除了现有技术中胶合接头的问题，包括胶合接头尺寸公差的问题以及随后检查胶合接头质量的困难。
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[0020] Fig. 2 shows a windmill blade made according to another usual method. Two beams 10 and 11 are made by moulding in separate moulds. The two beams are joined with two half-shells 12 and 13. The half-shells
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50 are fastened by glue joints at the leading edge 14, at the trailing edge 15, and against the beams 16 and 17. At the outset, a blade made according to this prior art method has four main parts, namely the beams 10 and 11 and the two half-shells 12 and 13. Depending on the cir
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55 cumstances, these main parts may be supplemented with further main parts, e.g. at the root of the blade, for forming transition to pitch bearing and/or rotor hub.
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[0016] 通过在封闭工艺中一体成型制造叶片，消除了工人接触复合材料中可能存在的环境有害物质的风险，从而可以将对个人防护用品的需求降至最低。
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[0017] 通过以夹层结构制造叶片，其中芯材大致连续地围绕叶片的横截面轮廓延伸，从而实现了生产技术和成品性能的特别有利组合。因此，芯材可以通过基于真空的工艺用作抽空和流动管道，并且连续工艺确保了均匀的横截面性能，在高载荷区域没有夹层结构和实体结构之间的不利过渡。连续的芯材以及层压板承载部分在外层和内层之间的实际分离，此外还提供了结构上的优点，即在一个（外层或内层）层压板中可能出现的裂纹形成仅意味着传播到另一个层压板的风险非常小。由此实现了结构前所未有的冗余性。
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# The Drawing
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[0018] In the following, the method will be explained in detail as reference is made to the Figures. Figures 1 - 2 provides examples of prior art, and Figure 3 indicates a blade made in accordance with the invention. With the Figures 4 - 11, the method is explained in an embodiment where the laminate is made of thermosetting plastic by vacuum injection.
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下文将结合附图详细解释该方法。图1-2示出了现有技术的示例，而图3示出了根据本发明制造的叶片。结合图4-11，在一个实施例中解释了该方法，其中层压件通过真空注射由热固性塑料制成。
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# Description of Embodiments实施例描述
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[0019] Fig. 1 shows a windmill blade made according to a usual method. A beam 1 is made by winding around a mandrel which later is taken out of the beam. Around the beam is glued two half-shells 2 and 3. Each halfshell consists of an outer laminate 4, a sandwich core 5, which e.g. can be made in balsa wood or PVC foam, and an inner laminate 6. The half-shells are fastened by glue joints at the leading edge 7, at the trailing edge 8, and against the beam 9. A blade made according to this usual method initially has three main parts, namely the beam 1 and the two half-shells 2 and 3. According to the circumstances, these main parts may be supplemented with further main parts, e.g. at the root of the blade, for forming transition to pitch bearing and/or rotor hub.
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[0020] Fig. 2 shows a windmill blade made according to another usual method. Two beams 10 and 11 are made by moulding in separate moulds. The two beams are joined with two half-shells 12 and 13. The half-shells are fastened by glue joints at the leading edge 14, at the trailing edge 15, and against the beams 16 and 17. At the outset, a blade made according to this prior art method has four main parts, namely the beams 10 and 11 and the two half-shells 12 and 13. Depending on the circumstances, these main parts may be supplemented with further main parts, e.g. at the root of the blade, for forming transition to pitch bearing and/or rotor hub.
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[0021] Fig. 3 shows a windmill blade made by the method according to the invention. The blade is an integrated unit, which is constituted by an outer shell 18, a sandwich core 19, an inner shell 20 and a shear web 21. In other sections, the blade may be made with plural shear webs or completely without webs.
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[0022] Fig. 4 shows a cross-section of a mould part suited for making windmill blades with the method according to the invention, where the laminate is made by vacuum injection of thermosetting plastic. The mould part 22 is made as a negative impression of a part of the external surface of the blade; as an example here is shown the section termed the pressure side, which during operation of the windmill largely faces the wind. The mould part 22 may be treated with a suited release agent on the surface 23 on which the blade in moulded. The mould part is provided with closure edges 24 with which tightness through abutment against other mould parts may be achieved. The mould part may be achieved with an integrated temperature regulating system 25 with which the temperature of the blade laminate may be changed during setting. The mould part 22 may be composed of several parts with joints that are to achieve tightness.
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[0023] Fig. 5 shows a first step in making windmill blades by the method according to the invention. An outer layer of fibre material 26 is laid in the mould part 22, e.g. mats or web of glass fibre or carbon fibre. Some of the outer layer of fibre material may e.g. extend out beyond the closure edge 24 at the leading edge 27. Upon at least a part of the outer layer of fibre material 26 there is provided a core material 28 that e.g. may be made in balsawood or PVC foam. At one or more suited places, here indicated by the leading edge 27, is provided one or more flow pipes 29, or other kinds of apertures are made along the blade. Besides the core material 28, which is placed upon the outer layer of fibre material 26, other core parts 30 may be provided, entirely or partly enclosed by the fibre material 26. At least a part of the surface of the fibre material 26, the core material 28, the possible flow pipe 29 and possible other core parts 30, are then covered by an inner layer of fibre material 31. This inner layer of fibre material 31 may in the same way as the outer layer of fibre material 26 entirely or partly extend beyond the closure edge 24. The flow pipe 29 may be provided with holes or saw grooves 32, or in other ways there may be provided flow ducts for resin from the interior of the flow pipe 29 to the core material 28, to the outer layer of fibre material 26 and to the inner layer of fibre material 31. The core material 28 and possible other core parts 30 may be provided with tracing 33, or flow paths for resin between the core material 28 and at least one of the two layers 26 and 31 may be provided. The core material 28 and possible other core parts 30 may be provided with borings or through-going cuttings 34, or flow ducts for resin between the two surfaces of core material 28 may be provided in other ways.
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[0019] 图1显示了根据常规方法制造的风电机组叶片。梁1通过缠绕在芯棒上制成，芯棒随后从梁中取出。在梁周围粘合有两个半壳体2和3。每个半壳体由外层层压板4、夹层芯材5（例如可用轻木或PVC泡沫制成）和内层层压板6组成。半壳体通过胶接接头在前缘7、后缘8以及与梁9连接处固定。根据这种常规方法制造的叶片最初有三个主要部件，即梁1和两个半壳体2和3。根据具体情况，这些主要部件可以补充其他主要部件，例如在叶片根部，用于形成与变桨轴承和/或风轮轮毂的过渡。
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[0024] Fig. 6 shows a subsequent step in the making of windmill blades with the method according to the in
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[0020] 图2显示了根据另一种常规方法制造的风电机组叶片。两根梁10和11通过在单独的模具中成型制成。这两根梁与两个半壳体12和13连接。半壳体通过胶接接头在前缘14、后缘15以及与梁16和17连接处固定。最初，根据这种现有技术方法制造的叶片有四个主要部件，即梁10和11以及两个半壳体12和13。根据具体情况，这些主要部件可以补充其他主要部件，例如在叶片根部，用于形成与变桨轴承和/或风轮轮毂的过渡。
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vention. On the inner layer of fibre material 31, the mould core 35 and possible shear webs 36 are placed. In the shown example, a mould core in two parts 37 and 38 is utilized that each may be divided into subparts. A core
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5 part 37 may e.g. consist of a firm inner part 39 that e.g. may be made of wood or composite material. The firm inner part 39 may be surrounded on at least a part of its outer side of a flexible outer part 40, which e.g. may be made in foam rubber. Each core part 37 is surrounded
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10 by a flexible, airtight membrane 41 that e.g. may be made of nylon or silicone rubber. The flexible membrane 41 may be treated with a suitable release agent. A shear web 36 may be made with an inner core part 42, which e.g. may be made of plywood, balsawood or PVC foam,
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15 and which at each side may have a core support part 43 in one or more parts, which e.g. may be made of plywood, balsawood or PVC foam. On each or both sides of the core parts 42 and 43, a fibre material 44 of e.g. glass or carbon can be placed. The fibre material 44 may
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20 advantageously extend to some extent across the inner layer of fibre material 31, as well as it may extend across the core part 37. [0025] Fig. 7 shows a subsequent step in making windmill blades with the method according to the inven
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25 tion. Across the core part 35 and the fibre material 44 from the possible shear web or webs 36, an inner layer of fibre material 45 is laid that e.g. may be mats or web of glass or carbon fibre, which advantageously may be composed in the same way as the inner layer of fibre
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30 material 31 in the lower mould part 22. On top of at least a part of the inner layer of fibre material 45 there is provided a core material 46, that e.g. may be made in balsawood or PVC foam, and which advantageously may be shaped in the same way as the core material 28 in
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35 the lower mould part 22. In some cases, it will be advantageous to postpone the laying of the flow pipe 29 as described above in step 5 to this stage of the process. At least a part of the surface of the fibre material 45, the core material 46, the possible flow pipe 29 and possible
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40 other core parts 30 are then covered by an outer layer of fibre material 47. This outer layer of fibre material 47 may e.g. be mats or web of glass or carbon fibre, and may advantageously be composed in the same way as the outer layer of fibre material 26 in the lower mould
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45 part 22. In the process of laying the inner fibre material 45, core material 46 and outer fibre material 47, the parts of the outer layer of fibre material 26 and the inner layer of fibre material 31, which extend beyond the closure edge 24 after laying of the material in the mould part 22,
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50 are put together into the inner fibre material 45 and/or the outer fibre material 47, so that overlap of fibre material across the joint face 48 occurring at the closure edge 24 is achieved. These layers of fibre materials 26 and 31 that extend beyond the closure edge 24 after
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55 laying of the material in the mould part 22 may entirely or partly extend right to the trailing edge when they are laid upon the mould core 35, the fibre material 44 from the possible shear web or webs, and/or the core material
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[0021] 图3显示了根据本发明方法制造的风电机组叶片。该叶片是一个集成单元，由外壳体18、夹层芯材19、内壳体20和剪力腹板21构成。在其他截面中，**叶片可以制成具有多个剪力腹板或完全没有腹板。**
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# 46.
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[0022] 图4显示了适用于根据本发明方法制造风电机组叶片的模具部件的横截面，其中层压板通过热固性塑料的真空注射制成。模具部件22是叶片外部表面一部分的负模；此处以受压侧为例，该侧在风电机组运行期间主要面向风。模具部件22可在其上成型叶片的表面23上涂覆合适的脱模剂。模具部件设有闭合边缘24，通过与其他模具部件的对接可实现密封。模具部件可配备集成式温度调节系统25，用于在固化过程中改变叶片层压板的温度。模具部件22可由多个部件组成，这些部件之间具有旨在实现密封的接头。
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[0023] 图5显示了根据本发明方法制造风电机组叶片的第一步。将一层外层纤维材料26铺设在模具部件22中，例如玻璃纤维或碳纤维毡或网。部分外层纤维材料例如可以延伸超出前缘27处的闭合边缘24。在外层纤维材料26的至少一部分上设置有芯材28，例如可用轻木或PVC泡沫制成。在一个或多个合适的位置（此处由前缘27指示）设置有一个或多个流道管29，或沿叶片制作其他类型的孔口。除了放置在外层纤维材料26上的芯材28之外，还可以设置其他芯部件30，这些芯部件可完全或部分被纤维材料26包围。然后，纤维材料26、芯材28、可能的流道管29和可能的其他芯部件30的至少一部分表面被一层内层纤维材料31覆盖。这层内层纤维材料31可以与外层纤维材料26一样，完全或部分延伸超出闭合边缘24。流道管29可以设有孔或锯槽32，或者以其他方式提供树脂从流道管29内部流向芯材28、外层纤维材料26和内层纤维材料31的流道。芯材28和可能的其他芯部件30可以设有导流槽33，或者在芯材28与两层26和31中的至少一层之间可以提供树脂流道。芯材28和可能的其他芯部件30可以设有钻孔或贯通切口34，或者以其他方式在芯材28的两个表面之间提供树脂流道。
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[0024] Fig. 6 shows a subsequent step in the making of windmill blades with the method according to the invention. On the inner layer of fibre material 31, the mould core 35 and possible shear webs 36 are placed. In the shown example, a mould core in two parts 37 and 38 is utilized that each may be divided into subparts. A core part 37 may e.g. consist of a firm inner part 39 that e.g. may be made of wood or composite material. The firm inner part 39 may be surrounded on at least a part of its outer side of a flexible outer part 40, which e.g. may be made in foam rubber. Each core part 37 is surrounded by a flexible, airtight membrane 41 that e.g. may be made of nylon or silicone rubber. The flexible membrane 41 may be treated with a suitable release agent. A shear web 36 may be made with an inner core part 42, which e.g. may be made of plywood, balsawood or PVC foam, and which at each side may have a core support part 43 in one or more parts, which e.g. may be made of plywood, balsawood or PVC foam. On each or both sides of the core parts 42 and 43, a fibre material 44 of e.g. glass or carbon can be placed. The fibre material 44 may
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advantageously extend to some extent across the inner layer of fibre material 31, as well as it may extend across the core part 37. [0025] Fig. 7 shows a subsequent step in making windmill blades with the method according to the invention. Across the core part 35 and the fibre material 44 from the possible shear web or webs 36, an inner layer of fibre material 45 is laid that e.g. may be mats or web of glass or carbon fibre, which advantageously may be composed in the same way as the inner layer of fibre material 31 in the lower mould part 22. On top of at least a part of the inner layer of fibre material 45 there is provided a core material 46, that e.g. may be made in balsawood or PVC foam, and which advantageously may be shaped in the same way as the core material 28 in the lower mould part 22. In some cases, it will be advantageous to postpone the laying of the flow pipe 29 as described above in step 5 to this stage of the process. At least a part of the surface of the fibre material 45, the core material 46, the possible flow pipe 29 and possible other core parts 30 are then covered by an outer layer of fibre material 47. This outer layer of fibre material 47 may e.g. be mats or web of glass or carbon fibre, and may advantageously be composed in the same way as the outer layer of fibre material 26 in the lower mould part 22. In the process of laying the inner fibre material 45, core material 46 and outer fibre material 47, the parts of the outer layer of fibre material 26 and the inner layer of fibre material 31, which extend beyond the closure edge 24 after laying of the material in the mould part 22, are put together into the inner fibre material 45 and/or the outer fibre material 47, so that overlap of fibre material across the joint face 48 occurring at the closure edge 24 is achieved. These layers of fibre materials 26 and 31 that extend beyond the closure edge 24 after laying of the material in the mould part 22 may entirely or partly extend right to the trailing edge when they are laid upon the mould core 35, the fibre material 44 from the possible shear web or webs, and/or the core material
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[0026] Fig. 8 shows the next step in making windmill blades by the method according to the invention. Across the outer layer of fibre material 47 there is disposed one or more mould parts 48 that are shaped as a negative impression of a part of the outer surface of the blade, here illustrated the part termed the suction side, and which during operation of the windmill largely faces away from the wind. The mould part 48 may be treated on the surface 49 on which the blade is moulded with a suited release agent. The mould part is provided with closure edges 50 with which tightness may be achieved against the first mould part 22. The mould part may be provided with an integrated temperature regulation system 25 with which the temperature of the laminate of the blade may be changed during setting. The mould part 48 may be composed of several parts with joints that are to attain tightness.
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[0027] Fig. 9 shows the next step in making windmill blades by the method according to the invention. Between on the one hand the mould parts 22 and 48 and on the other hand the flexible membrane 41 around the mould core 35 there is a cavity 51. The cavity 51 is partly filled by the fibre materials 26, 31, 44, 45 and 47, the core materials 28, 42, 43, and 46, the flow pipe 29 and possible other core parts 30, as the cavities between the fibre and between the fibre and other parts are filled with air. Now, vacuum is applied to the cavity 51 so that at least a substantial part of the air staying between the parts in the cavity is evacuated. Thereby, fibre and core materials etc. are compressed in the cavity 51 as the flexible membrane 41 expands. In order to ensure good sealing, the surfaces between the closure edges 24 and 50 may advantageously be made with at least two sealing arrangements, an internal arrangement 52 and an external arrangement 53, so that between these arrangements there is provided a cavity 54 that may be subjected to vacuum separately from vacuum in the cavity 51, and which may advantageously be maintained at a lower absolute pressure than the cavity 51, whereby possible leakages from the surrounding air to the cavity 51 is prevented.
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[0024] 图6显示了根据本发明方法制造风电机组叶片的后续步骤。在纤维材料内层31上，放置模具芯35和可能的剪力腹板36。在所示示例中，使用了由两部分37和38组成的模具芯，每个部分又可分为若干子部分。芯部37例如可由坚固的内芯39组成，该内芯例如可由木材或复合材料制成。坚固的内芯39在其外侧的至少一部分可由柔性外芯40包围，该柔性外芯例如可由泡沫橡胶制成。每个芯部37都由柔性、气密性膜41包围，该膜例如可由尼龙或硅橡胶制成。柔性膜41可用合适的脱模剂处理。剪力腹板36可由内芯部42制成，该内芯部例如可由胶合板、轻木或PVC泡沫制成，并且其两侧可具有一个或多个芯支撑部分43，该芯支撑部分例如可由胶合板、轻木或PVC泡沫制成。在芯部42和43的每一侧或两侧，可放置例如玻璃或碳纤维的纤维材料44。纤维材料44有利地可在一定程度上延伸穿过纤维材料内层31，并且也可延伸穿过芯部37。
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[0028] Fig. 10 shows the next step in making windmill blades by the method according to the invention. The closed mould, consisting of the mould parts 22 and 48 with the entire amount of fibre and core materials, mould cores etc., is now turned about its longitudinal axis, so that the flow pipe 29 assumes a position close to the lowest point in a cross-section of the closed mould. A connection 55 is established between the flow pipe 29 and a reservoir 56 with suitable resin 57 with the right mix ratio, e.g. polyester, vinyl ester or epoxy. The connection 55 that may be a pipe or a tube or combinations thereof, may be provided with a variable flow control valve 58, or in other ways there may be established means for controlling the flow rate in connection 55 to the flow pipe 29, e.g. in the form of pressure control of the space 59 over the resin 57. The connection 55 may
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[0025] 图7显示了根据本发明方法制造风电机组叶片的后续步骤。跨越芯部35和来自可能的剪力腹板36的纤维材料44，铺设一层纤维材料内层45，该内层例如可以是玻璃或碳纤维毡或网，其有利地可以与下模具部分22中的纤维材料内层31以相同方式构成。在纤维材料内层45的至少一部分顶部，设置有芯材46，该芯材例如可由轻木或PVC泡沫制成，并且其有利地可以与下模具部分22中的芯材28以相同方式成形。在某些情况下，将如上文步骤5所述的流管29的铺设推迟到本工艺阶段将是有利的。然后，纤维材料45、芯材46、可能的流管29和可能的其他芯部30的表面至少一部分被纤维材料外层47覆盖。该纤维材料外层47例如可以是玻璃或碳纤维毡或网，并且其有利地可以与下模具部分22中的纤维材料外层26以相同方式构成。在铺设内层纤维材料45、芯材46和外层纤维材料47的过程中，在模具部分22中铺设材料后超出闭合边缘24的纤维材料外层26和纤维材料内层31的部分，被整合到内层纤维材料45和/或外层纤维材料47中，从而实现在闭合边缘24处出现的接合面48上的纤维材料重叠。这些在模具部分22中铺设材料后超出闭合边缘24的纤维材料层26和31，当它们铺设在模具芯35、来自可能的剪力腹板的纤维材料44和/或芯材上时，可以完全或部分地延伸直至后缘。
|
||||
|
||||
be provided with a stop cock 60, or in other ways there may be established possibility of blocking the flow from the reservoir 56 through the connection 55, e.g. by the flow control valve 58 being able to shut the connection
|
||||
5 off completely. When the blade has the desired position, there is opened up for the flow in the connection 55, and injection is commenced as the resin flows into the cavity 51 under action of the pressure difference between the vacuum established in the cavity and the pressure on
|
||||
10 the resin 57. During the injection, the flow is regulated with the flow control valve 58, or in other ways, so that a controlled development of the fluid front 61 of the injected resin 62 is maintained with balance between regulated inflow and gravitation. The fluid front may e.g. be
|
||||
15 tried kept approximately horizontal so that the risk of blocking and confinement of larger or lesser amounts of residual air is minimized. [0029] Fig. 11 shows the next step in making windmill blades according to the invention. The flow front 61 has
|
||||
20 now reached the trailing edge of the blade, and resin now penetrates up into one or more overflow containers 63. When there is pure resin in the relevant overflow containers, the injection is terminated by the stop cock 60, or in other ways. The temperature regulating system
|
||||
25 25 may be active during the whole or a part of the injection process, and particularly after finished injection it may be used to bring the injected laminated up to a temperature that enhances the setting process for the resin. Depending on the embodiment, the temperature regu
|
||||
30 lating system may also be used for cooling mould and laminate, if the exothermic heat of the setting process is in danger of raising the temperature of mould and laminate to an undesired level. However, one may also completely omit a temperature regulating system in the
|
||||
35 mould and perform possible final setting in a separate process afterwards.
|
||||
[0026] 图8显示了根据本发明方法制造风电机组叶片的下一步骤。跨越纤维材料外层47，设置有一个或多个模具部分48，其形状是叶片外表面一部分的负形，此处所示为被称为吸力侧的部分，并且在风电机组运行期间主要背向风。模具部分48在叶片成型的表面49上可用合适的脱模剂处理。模具部分设有闭合边缘50，通过该边缘可与第一模具部分22实现密封。模具部分可设有集成温度调节系统25，通过该系统可在固化过程中改变叶片层压件的温度。模具部分48可由多个部分组成，这些部分之间的接缝需达到密封。
|
||||
|
||||
[0027] 图9显示了根据本发明方法制造风电机组叶片的下一步骤。在模具部分22和48与模具芯35周围的柔性膜41之间，存在一个腔体51。腔体51部分地被纤维材料26、31、44、45和47、芯材28、42、43和46、流管29以及可能的其他芯部30填充，因为纤维之间以及纤维与其他部件之间的空腔都充满了空气。现在，对腔体51施加真空，以便抽空腔体中部件之间存在的至少大部分空气。因此，随着柔性膜41的膨胀，纤维和芯材等在腔体51中被压缩。为了确保良好的密封，闭合边缘24和50之间的表面有利地可设置至少两种密封装置，即内部装置52和外部装置53，以便在这些装置之间提供一个腔体54，该腔体可独立于腔体51中的真空而进行抽真空，并且有利地可保持比腔体51更低的绝对压力，从而防止周围空气可能泄漏到腔体51中。
|
||||
|
||||
[0028] Fig. 10 shows the next step in making windmill blades by the method according to the invention. The closed mould, consisting of the mould parts 22 and 48 with the entire amount of fibre and core materials, mould cores etc., is now turned about its longitudinal axis, so that the flow pipe 29 assumes a position close to the lowest point in a cross-section of the closed mould. A connection 55 is established between the flow pipe 29 and a reservoir 56 with suitable resin 57 with the right mix ratio, e.g. polyester, vinyl ester or epoxy. The connection 55 that may be a pipe or a tube or combinations thereof, may be provided with a variable flow control valve 58, or in other ways there may be established means for controlling the flow rate in connection 55 to the flow pipe 29, e.g. in the form of pressure control of the space 59 over the resin 57. The connection 55 may be provided with a stop cock 60, or in other ways there may be established possibility of blocking the flow from the reservoir 56 through the connection 55, e.g. by the flow control valve 58 being able to shut the connection off completely. When the blade has the desired position, there is opened up for the flow in the connection 55, and injection is commenced as the resin flows into the cavity 51 under action of the pressure difference between the vacuum established in the cavity and the pressure on the resin 57. During the injection, the flow is regulated with the flow control valve 58, or in other ways, so that a controlled development of the fluid front 61 of the injected resin 62 is maintained with balance between regulated inflow and gravitation. The fluid front may e.g. be tried kept approximately horizontal so that the risk of blocking and confinement of larger or lesser amounts of residual air is minimized. [0029] Fig. 11 shows the next step in making windmill blades according to the invention. The flow front 61 has now reached the trailing edge of the blade, and resin now penetrates up into one or more overflow containers 63. When there is pure resin in the relevant overflow containers, the injection is terminated by the stop cock 60, or in other ways. The temperature regulating system 25 may be active during the whole or a part of the injection process, and particularly after finished injection it may be used to bring the injected laminated up to a temperature that enhances the setting process for the resin. Depending on the embodiment, the temperature regulating system may also be used for cooling mould and laminate, if the exothermic heat of the setting process is in danger of raising the temperature of mould and laminate to an undesired level. However, one may also completely omit a temperature regulating system in the mould and perform possible final setting in a separate process afterwards.
|
||||
|
||||
[0030] After finished setting, the moulds are opened and the finished blade is taken out.
|
||||
|
||||
[0031] Before or after the blade is taken out, the mould
|
||||
40 core 35 is removed. In the shown example there is used a mould core in two core parts 37 and 38. The front core part 37 may be removed in one piece in this example, whereas the rear core part 38 may advantageously be divided into subparts that are removed in the sequence
|
||||
45 which is most convenient with regard to geometry and handling. If a core part 37 consists of a firm internal part 39 surrounded by a flexible external part 40, which e.g. may be made of foam rubber and enclosed by a flexible, airtight membrane, over at least apart of its outer side,
|
||||
50 it may advantageous to apply vacuum on the flexible external part 40, whereby the airtight membrane 41 contracts and is released in relation to the cavity in the moulded blade. For this process, it may be an advantage that the flexible, airtight membrane 41 is constitut
|
||||
55 ed by plural layers so that possible adherence between the moulded blade and the airtight membrane is limited to the outermost layer of the membrane. It may also be an advantage to provide an airtight layer between the
|
||||
|
||||
firm internal part 39 and the flexible external part 40 so that vacuum is limited to the flexible external part 40, and larger or lesser pressure loads are not applied on the firm internal part 39.
|
||||
[0031] Before or after the blade is taken out, the mould core 35 is removed. In the shown example there is used a mould core in two core parts 37 and 38. The front core part 37 may be removed in one piece in this example, whereas the rear core part 38 may advantageously be divided into subparts that are removed in the sequence which is most convenient with regard to geometry and handling. If a core part 37 consists of a firm internal part 39 surrounded by a flexible external part 40, which e.g. may be made of foam rubber and enclosed by a flexible, airtight membrane, over at least apart of its outer side, it may advantageous to apply vacuum on the flexible external part 40, whereby the airtight membrane 41 contracts and is released in relation to the cavity in the moulded blade. For this process, it may be an advantage that the flexible, airtight membrane 41 is constituted by plural layers so that possible adherence between the moulded blade and the airtight membrane is limited to the outermost layer of the membrane. It may also be an advantage to provide an airtight layer between the firm internal part 39 and the flexible external part 40 so that vacuum is limited to the flexible external part 40, and larger or lesser pressure loads are not applied on the firm internal part 39.
|
||||
|
||||
[0032] In the above, the process is described with the use of a flow pipe 29 which is integrated in the leading edge of the blade. The flow pipe may very well be disposed outside the blade itself, e.g. in a recess in the mould, and this recess may constitute the flow duct so that a separate pipe is not necessary. Versions with more flow pipes and flow ducts integrated in the blade as well as disposed externally as continuous recesses or tubes in the mould parts may also be envisaged, or partly or entirely in the shape of flow pipes with discrete inlets at the inner sides of the mould parts.
|
||||
|
||||
@ -143,16 +137,28 @@ firm internal part 39 and the flexible external part 40 so that vacuum is limite
|
||||
|
||||
[0034] Combinations of the practical embodiment of the method with fibre material laid in dry condition and where a part of laid material is in form of finished fibre reinforced parts, e.g. previously moulded part for the blade root or longitudinally pultruded profiles. Combinations of materials in the laying may also be envisaged, which otherwise in prior art methods are held separate to each other. E.g. mats in prepeg may also be envisaged where the integrated resin contributes to the injection of the surrounding dry fibre material to a certain degree, and where the amount of resin needed for complete impregnation of the laminate is provided by vacuum injection as described above.
|
||||
|
||||
[0028] 图10显示了根据本发明方法制造风电机组叶片的下一步。由模具部件22和48以及全部纤维和芯材、模具型芯等组成的闭合模具，现在绕其纵轴转动，使得流道管29在闭合模具的横截面中处于接近最低点的位置。在流道管29与装有合适配比的树脂57（例如聚酯、乙烯基酯或环氧树脂）的储液罐56之间建立连接55。连接55可以是管道或管子或其组合，可以配备可变流量控制阀58，或者以其他方式建立用于控制连接55到流道管29的流量的装置，例如通过控制树脂57上方空间59的压力。连接55可以配备截止阀60，或者以其他方式建立阻断从储液罐56通过连接55的流动的可能性，例如通过流量控制阀58能够完全关闭连接。当叶片处于所需位置时，打开连接55中的流动，并开始注射，树脂在型腔中建立的真空与树脂57上的压力之间的压差作用下流入型腔51。在注射过程中，通过流量控制阀58或其他方式调节流量，使得注入树脂62的流体前沿61的受控发展得以维持，并在受控流入和重力之间保持平衡。流体前沿例如可以尝试保持近似水平，从而最大限度地减少阻碍和滞留或多或少残余空气的风险。
|
||||
|
||||
[0029] 图11显示了根据本发明制造风电机组叶片的下一步。流动前沿61现已到达叶片的后缘，树脂现在渗透进入一个或多个溢流容器63中。当相关溢流容器中出现纯树脂时，通过截止阀60或其他方式终止注射。温度调节系统25可以在整个注射过程或部分注射过程中处于活动状态，特别是在注射完成后，它可用于将注入的层压件提升到有助于树脂固化过程的温度。根据实施方式，如果固化过程的放热热量有使模具和层压件温度升高到不希望的水平的危险，温度调节系统也可用于冷却模具和层压件。然而，也可以完全省略模具中的温度调节系统，并在之后通过单独的工艺进行可能的最终固化。
|
||||
|
||||
[0030] 固化完成后，打开模具并取出成品叶片。
|
||||
|
||||
[0031] 在取出叶片之前或之后，移除模具型芯35。在所示示例中，使用了由两个型芯部件37和38组成的模具型芯。在此示例中，前型芯部件37可以整体移除，而后型芯部件38可以有利地分成若干子部件，并按照几何形状和操作最方便的顺序移除。如果型芯部件37由坚固的内部部件39和被柔性外部部件40包围的柔性外部部件40组成，例如该柔性外部部件40可以由泡沫橡胶制成，并至少在其外侧的一部分被柔性、气密膜包围，那么对柔性外部部件40施加真空可能是有利的，从而使气密膜41收缩并相对于模制叶片中的型腔释放。对于此过程，柔性气密膜41由多层构成可能是一个优点，这样模制叶片与气密膜之间可能的粘附仅限于膜的最外层。在坚固的内部部件39和柔性外部部件40之间提供气密层也可能是一个优点，这样真空仅限于柔性外部部件40，并且不会对坚固的内部部件39施加或大或小的压力载荷。
|
||||
|
||||
[0032] 在上文中，该工艺描述了使用集成在叶片前缘的流道管29。流道管也可以很好地设置在叶片本身之外，例如在模具的凹槽中，并且该凹槽可以构成流道，从而不需要单独的管道。也可以设想具有更多流道管和流道集成在叶片中以及作为连续凹槽或管子外部设置在模具部件中的版本，或者部分或完全以在模具部件内侧具有离散入口的流道管的形式。
|
||||
|
||||
[0033] 上文描述了该方法的一种实际实施方式，其中纤维材料在干燥条件下铺设，并且树脂通过真空注射供应。在其他实际实施方式中，铺设所谓的预浸料，其中纤维材料预先用树脂浸渍，在施加真空后，通过热、紫外线照射或类似作用使其固化；或者可以铺设耐温纤维材料和热塑性材料的组合纤维材料，并且铺设后纤维材料可以被加热到热塑性材料熔化并因此在成品层压件中充当树脂的温度。
|
||||
|
||||
[0034] 该方法的实际实施方式可以与干燥条件下铺设纤维材料相结合，其中一部分铺设材料是成品纤维增强部件的形式，例如预先模制的叶片根部部件或纵向拉挤型材。也可以设想铺设材料的组合，这些材料在现有技术方法中通常是相互分离的。例如，也可以设想预浸料中的毡片，其中集成的树脂在一定程度上促进了周围干燥纤维材料的注射，并且层压件完全浸渍所需的树脂量通过如上所述的真空注射提供。
|
||||
# Claims
|
||||
|
||||
1. A method for making a windmill blade of composite materials which include a fibre reinforced matrix material, the improvement comprising that the blade is made in one piece in a closed mould and comprising steps that provide:
|
||||
|
||||
a mould core with a flexible external core part and an internal, firm or workable core part, and outer mould parts arranged to close around the mould core for formation of a mould cavity there between, that composite material and possible core inserts are laid on an outer mould part and/or the
|
||||
|
||||
mould core,
|
||||
that the outer mould parts are closed around the mould core and around the composite material placed in the mould cavity,
|
||||
that the composite material is set,
|
||||
that the outer mould parts are removed, and that the mould core is taken out of the shape permanent blade before or after removing the outer mould parts.
|
||||
- a mould core with a flexible external core part and an internal, firm or workable core part, and outer mould parts arranged to close around the mould core for formation of a mould cavity there between,
|
||||
- that composite material and possible core inserts are laid on an outer mould part and/or the mould core,
|
||||
- that the outer mould parts are closed around the mould core and around the composite material placed in the mould cavity,
|
||||
- that the composite material is set,
|
||||
- that the outer mould parts are removed, and that the mould core is taken out of the shape permanent blade before or after removing the outer mould parts.
|
||||
|
||||
2. A method according to claim 1, wherein some of the required matrix material is used in connection with the reinforcing fibre when laying the composite material and where additional matrix material is added after closing the mould.
|
||||
|
||||
@ -162,13 +168,37 @@ that the outer mould parts are removed, and that the mould core is taken out of
|
||||
|
||||
5. A method according to claim 3 or 4, wherein an outer layer of fibre material extending beyond a side edge of the mould cavity is laid on a first outer mould part, where at least one flow pipe is placed at the said side edge for injecting matrix material, where a layer of core material and possible other core parts are placed, where an inner layer of fibre material extending beyond the said side edge is laid, where the mould core is placed in the layers that are laid, where the fibre material extending beyond the side edge is folded in over the mould core and the flow pipe, where a layer of core material and an outer layer of fibre material are laid on the mould core, where a second outer mould part is placed in close contact with the first outer mould part, where vacuum is applied to the mould cavity and where the matrix material is injected via the flow pipe.
|
||||
|
||||
5 6. A method according to any preceding claim, wherein core inserts are disposed between the layers of fibre material and are taken out of the mould together with the composite material for making a blade in which such inserts constitute structural elements in the finished blade.
|
||||
6. A method according to any preceding claim, wherein core inserts are disposed between the layers of fibre material and are taken out of the mould together with the composite material for making a blade in which such inserts constitute structural elements in the finished blade.
|
||||
|
||||
7. A method according to any preceding claim, wherein thermal setting is used, and wherein the temper- 5 ature in the composite materials of the blade are changed during the setting by using a temperature control system in at least one of the mould parts.
|
||||
8. A method according to any of claims 3 - 7, wherein 10 the core material is provided with through-going passages used as ducts for fluid matrix material between the two layers of fibre material.
|
||||
9. A method according to any preceding claim, where- 15 in injection of the matrix material is terminated when fluid matrix material is pressed out of apertures at the upwardly facing side edge of the blade.
|
||||
10. A method according to any preceding claim, where- 20 in the mould core is provided as a plurality of separate sections.
|
||||
一种制造包含纤维增强基体材料的复合材料风力机叶片的方法，其改进之处在于，该叶片在闭合模具中一体成型，并且包括以下步骤：
|
||||
|
||||
- 提供一个模具型芯，其具有柔性外部型芯部分和内部坚固或可加工的型芯部分，以及围绕模具型芯闭合以在其间形成模腔的外部模具部分；
|
||||
- 将复合材料和可能的型芯嵌件铺设在外部模具部分和/或模具型芯上；
|
||||
- 外部模具部分围绕模具型芯和放置在模腔中的复合材料闭合；
|
||||
- 复合材料固化；
|
||||
- 外部模具部分被移除，并且在移除外部模具部分之前或之后，将模具型芯从形状永久的叶片中取出。
|
||||
|
||||
2. 根据权利要求1所述的方法，其中，在铺设复合材料时，将部分所需基体材料与增强纤维一起使用，并且在模具闭合后添加额外的基体材料。
|
||||
|
||||
3. 根据权利要求1或2所述的方法，其中，复合材料围绕芯材铺设以将叶片形成为夹层结构，其中，当模腔受到真空时，芯材用于叶片真空成型时的排气和流动，从而由于模具型芯的柔性外部型芯部分，空气在复合材料和可能的型芯嵌件被压向外部模具部分内侧的同时被排出，并且基体材料通过真空注入模腔。
|
||||
|
||||
4. 根据权利要求3所述的方法，其中，材料通过设置在模腔垂直下侧的管道注入，并且流速受到调节，以控制基体材料向上推进的流体前沿，从而避免空气滞留在模腔中。
|
||||
|
||||
5. 根据权利要求3或4所述的方法，其中，将超出模腔侧边缘的纤维材料外层铺设在第一外部模具部分上，其中，至少一根流体管道放置在该侧边缘处用于注入基体材料，其中，放置一层芯材和可能的其他芯材部分，其中，铺设一层超出该侧边缘的纤维材料内层，其中，模具型芯放置在已铺设的层中，其中，超出侧边缘的纤维材料折叠在模具型芯和流体管道上方，其中，一层芯材和一层纤维材料外层铺设在模具型芯上，其中，第二外部模具部分与第一外部模具部分紧密接触放置，其中，对模腔施加真空，并且基体材料通过流体管道注入。
|
||||
|
||||
6. 根据前述任一权利要求所述的方法，其中，型芯嵌件设置在纤维材料层之间，并且与复合材料一起从模具中取出，以制造一个叶片，其中此类嵌件在成品叶片中构成结构元件。
|
||||
|
||||
7. 根据前述任一权利要求所述的方法，其中，采用热固化，并且在固化过程中，通过在至少一个模具部分中使用温度控制系统来改变叶片复合材料的温度。
|
||||
|
||||
8. 根据权利要求3至7中任一项所述的方法，其中，芯材设有贯通通道，用作两层纤维材料之间流体基体材料的管道。
|
||||
|
||||
9. 根据前述任一权利要求所述的方法，其中，当流体基体材料从叶片向上侧边缘的孔口中挤出时，基体材料的注入终止。
|
||||
|
||||
10. 根据前述任一权利要求所述的方法，其中，模具型芯以多个独立部分的形式提供。
|
||||
|
||||
|
||||
|
||||
|
||||
@ -19,7 +19,11 @@
|
||||
|
||||
(54) Title: METHOD FOR MANUFACTURING A WIND TURBINE BLADE
|
||||
(57) Abstract: A method for manufacturing a wind turbine blade, comprising the steps of: - arranging an upper mould (8) comprising a pre-casted fibre lay-up $(9")$ on a lower mould (23) comprising a dry fibre lay-up (24) and a mould core (46), - applying vacuum to a space (63) between the upper and lower moulds (8, 23) and the mould core (46), - infusing 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 the resin (65). By having the pre-casted fibre lay-up in the upper mould, the packing and positioning of dry composite materials on top of themouldcoreis avoided.
|
||||
|
||||
一种制造风电机组叶片的方法，包括以下步骤：
|
||||
- 将包括预铸造纤维铺层 $(9")$ 的上模具 (8) 布置在包括干纤维铺层 (24) 和模具芯 (46) 的下模具 (23) 上，
|
||||
- 对上模具和下模具 (8, 23) 以及模具芯 (46) 之间的空间 (63) 施加真空，
|
||||
- 用树脂 (65) 注入至少干纤维铺层 (24') 以及干纤维铺层 (24') 和预铸造纤维铺层 $(9")$ 之间的连接区域 (66, 67)，并固化树脂 (65)。
|
||||
通过将预铸造纤维铺层设置在上模具中，避免了在模具芯顶部堆叠和定位干复合材料。
|
||||
SA, SC, SD, SE, SG, SK, SL, ST, SV, SY,TH, TJ, TM, TN, TR, TT, TZ, UA, UG, US, UZ, VC, VN, WS, ZA, ZM, ZW.
|
||||
|
||||
(84) Designated States (unless otherwise indicated, for every kind of regional protection available): ARIPO (BW, GH, GM, KE,LR, LS, MW, MZ, NA, RW, SD, SL, ST, SZ, TZ, UG, ZM, ZW), Eurasian (AM, AZ, BY, KG, KZ, RU, TJ, TM), European (AL, AT, BE, BG, CH, CY, CZ, DE, DK, EE, ES, FI, FR, GB, GR, HR, HU, IE, IS, IT, LT, LU, LV, MC, MK, MT, NL, NO, PL, PT, RO, RS, SE, SI, SK, SM, TR), OAPI (BF, BJ, CF, CG, CI, CM, GA, GN, GQ, GW, KM, ML, MR, NE, SN, TD, TG).
|
||||
@ -28,21 +32,18 @@ SA, SC, SD, SE, SG, SK, SL, ST, SV, SY,TH, TJ, TM, TN, TR, TT, TZ, UA, UG, US, U
|
||||
|
||||
with international search report (Art. 21(3)
|
||||
|
||||
Description
|
||||
# Description
|
||||
|
||||
Method for manufacturing a wind turbine blade
|
||||
|
||||
5The present invention relates to a method for manufacturing a wind turbine blade. One way to produce more power using a wind turbine under given wind conditions is to increase the size of the blades.
|
||||
10 However, the manufacture of wind turbine blades is becoming increasingly difficult with increasing blade sizes. Currently, many wind turbine blades are made by premanufacturing parts of the blade separately, such as a pres
|
||||
15 sure-side shell and a suction-side shell, and gluing the parts to each other. The parts are, for example, premanufactured by infusing composite materials such as glass fibres with a resin and curing the resin. However, the gluing process has many disadvantages. It is, for example, difficult
|
||||
20 to achieve a sufficient strength and robustness of the glueline. Furthermore, the method requires an exact positioning of very large parts within limited time, i.e. before the applied glue hardens.
|
||||
25In another method, disclosed in EP 1 310 351 Al， the blade is manufactured by packing composite materials for the entire blade, or for a lengthwise blade section, on a mandrel and by infusing and curing resin. Thereby, glue joints are avoided. However, packing and positioning of dry composite material on
|
||||
30top of the - usually flexible - mandrel is challenging, in particular for very large blades. Furthermore, with increasing blade sizes, the volume required to be filled with resin by vacuum infusion is also increased, making the resin infusion more difficult.
|
||||
35 It is one object of the present invention to provide an improved method for manufacturing a wind turbine blade.
|
||||
The present invention relates to a method for manufacturing a wind turbine blade. One way to produce more power using a wind turbine under given wind conditions is to increase the size of the blades.
|
||||
However, the manufacture of wind turbine blades is becoming increasingly difficult with increasing blade sizes. Currently, many wind turbine blades are made by premanufacturing parts of the blade separately, such as a pressure-side shell and a suction-side shell, and gluing the parts to each other. The parts are, for example, premanufactured by infusing composite materials such as glass fibres with a resin and curing the resin. However, the gluing process has many disadvantages. It is, for example, difficult to achieve a sufficient strength and robustness of the glueline. Furthermore, the method requires an exact positioning of very large parts within limited time, i.e. before the applied glue hardens.
|
||||
In another method, disclosed in EP 1 310 351 Al， the blade is manufactured by packing composite materials for the entire blade, or for a lengthwise blade section, on a mandrel and by infusing and curing resin. Thereby, glue joints are avoided. However, packing and positioning of dry composite material on top of the - usually flexible - mandrel is challenging, in particular for very large blades. Furthermore, with increasing blade sizes, the volume required to be filled with resin by vacuum infusion is also increased, making the resin infusion more difficult.
|
||||
It is one object of the present invention to provide an improved method for manufacturing a wind turbine blade.
|
||||
|
||||
Accordingly, a method for manufacturing a wind turbine blade is proposed. The method comprises the steps of:
|
||||
|
||||
- arranging an upper mould comprising a pre-casted fibre lay-up on a lower mould comprising a dry fibre lay-up and a mouldcore,
|
||||
- arranging an upper mould comprising a pre-casted fibre lay-up on a lower mould comprising a dry fibre lay-up and a mould core,
|
||||
|
||||
- applying vacuum to a space between the upper and lower moulds and the mould core,
|
||||
|
||||
@ -50,111 +51,236 @@ Accordingly, a method for manufacturing a wind turbine blade is proposed. The me
|
||||
|
||||
By having the pre-casted fibre lay-up in the upper mould, the packing and positioning of dry composite materials on top of the mould core is avoided.
|
||||
|
||||
15 Further, pre-casting the fibre lay-up in the upper mould is preferably done by packing a dry fibre lay-up in the upper mould turned upside down, infusing resin and curing. Since the upper mould is turned upside down, packing the fibre ma
|
||||
20 terial is done also in the upper mould towards a mould with a well-defined geometry instead of towards a flexible mould core. Furthermore, having the pre-casted fibre lay-up in the upper
|
||||
25 mould, the volume the resin has to fill during the vacuum infusion of the dry fibre lay-up in the lower mould and the connection region is smaller for the same blade size compared to the case in which the fibre lay-up for the upper part is not pre-casted. Further, the path the resin has to travel
|
||||
Further, pre-casting the fibre lay-up in the upper mould is preferably done by packing a dry fibre lay-up in the upper mould turned upside down, infusing resin and curing. Since the upper mould is turned upside down, packing the fibre ma
|
||||
terial is done also in the upper mould towards a mould with a well-defined geometry instead of towards a flexible mould core. Furthermore, having the pre-casted fibre lay-up in the upper mould, the volume the resin has to fill during the vacuum infusion of the dry fibre lay-up in the lower mould and the connection region is smaller for the same blade size compared to the case in which the fibre lay-up for the upper part is not pre-casted. Further, the path the resin has to travel
|
||||
30 during the vacuum infusion is shorter for the same blade size compared to the case in which the fibre lay-up for the upper part is not pre-casted. The resin has, for example, to rise to a lower height above a floor level of a manufacturing site compared to the case in which the fibre lay-up for the upper
|
||||
35 part is not pre-casted. Therefore, it is easier to infuse the fibre lay-up in a resin infusion process with a good quality, even in the case of larger blade sizes.
|
||||
|
||||
An advantage over the method in which blade parts are glued
|
||||
|
||||
together is that here a laminate joint is provided connecting the upper pre-casted fibre lay-up and the dry fibre lay-up in the lower mould, once cured. Compared to a connection using
|
||||
5 an adhesive, the laminate joint formed by resin infusion is a lighter and at the same time stronger joint. It is lighter because in the case of an adhesive, the weight of the adhesive is added in the bond line. Further, the strength of the laminate joint formed by vacuum infusion is comparable to the
|
||||
10 strength of the pristine laminate. In addition, the laminate joint formed by vacuum infusion avoids the problem of glue joints of having a different material in the glue than in the rest of the blade.
|
||||
15 The wind turbine blade is part of a rotor of a wind turbine. The wind turbine is an apparatus to convert the wind's kinetic energy into electrical energy. The wind turbine comprises, for example, the rotor having one or more of the blades connected each to a hub, a nacelle including a generator, and a
|
||||
20 tower holding, at its top end, the nacelle. The tower of the wind turbine may be connected via a transition piece to a foundation of the wind turbine, such as a monopile in the seabed.
|
||||
together is that here a laminate joint is provided connecting the upper pre-casted fibre lay-up and the dry fibre lay-up in the lower mould, once cured. Compared to a connection using an adhesive, the laminate joint formed by resin infusion is a lighter and at the same time stronger joint. It is lighter because in the case of an adhesive, the weight of the adhesive is added in the bond line. Further, the strength of the laminate joint formed by vacuum infusion is comparable to the strength of the pristine laminate. In addition, the laminate joint formed by vacuum infusion avoids the problem of glue joints of having a different material in the glue than in the rest of the blade.
|
||||
The wind turbine blade is part of a rotor of a wind turbine. The wind turbine is an apparatus to convert the wind's kinetic energy into electrical energy. The wind turbine comprises, for example, the rotor having one or more of the blades connected each to a hub, a nacelle including a generator, and a tower holding, at its top end, the nacelle. The tower of the wind turbine may be connected via a transition piece to a foundation of the wind turbine, such as a monopile in the seabed.
|
||||
|
||||
25 The pre-casted fibre lay-up in the upper mould becomes, in the manufactured blade, a first shell of the blade. In particular, it becomes a first half shell of the blade.
|
||||
The pre-casted fibre lay-up in the upper mould becomes, in the manufactured blade, a first shell of the blade. In particular, it becomes a first half shell of the blade.
|
||||
|
||||
The dry fibre lay-up in the lower mould becomes, once infused 30and cured, in the manufactured blade a second shell of the blade. In particular, it becomes a second half shell of the blade.
|
||||
The dry fibre lay-up in the lower mould becomes, once infused and cured, in the manufactured blade a second shell of the blade. In particular, it becomes a second half shell of the blade.
|
||||
|
||||
The first and second shells are, in particular, fibre35 reinforced resin laminates.
|
||||
The first and second shells are, in particular, fibre reinforced resin laminates.
|
||||
|
||||
The first shell may comprise a pressure side (upwind side) of the blade and the second shell may comprise a suction side (downwind side) of the blade or vice versa.
|
||||
|
||||
5The first and the second shells may each comprise the entire length of the blade from a blade root to a blade tip. Alternatively, the wind turbine blade may be split in a lengthwise direction. In this case, each of the first and second shells comprises a fraction of the total length of the blade.
|
||||
10 The wind turbine blade, e.g., its root section, is, for example, fixedly connected to the hub. The wind turbine blade is, for example, directly bolted to the hub.
|
||||
15 Alternatively, the wind turbine blade, e.g., the root section, is rotatably connected to the hub. For example, the wind turbine blade is connected to a pitch bearing of the wind turbine, and the pitch bearing is connected to the hub. The pitch bearing is configured to adjust the angle of attack
|
||||
20 of the blade according to the wind speed to control the rotational speed of the blade. Apart from the (cylindrical) root section connected with the hub, the wind turbine blade is formed aerodynamically. The
|
||||
25 wind turbine blade comprises, for example, the pressure side (upwind side) and the suction side (downwind side). The pressure side and the suction side are connected with each other at a leading edge and a trailing edge. The pressure and suctions sides and the leading and trailing edges define an in
|
||||
30 terior cavity of the wind turbine blade. The mould core (or mandrel) comprises, for example, an inner firm core and an external flexible portion surrounding the inner firm core.
|
||||
35 The mould core may comprise two or more mould core portions. Each of the two or more mould core portions may comprise an inner firm core and a flexible external portion.
|
||||
The first and the second shells may each comprise the entire length of the blade from a blade root to a blade tip. Alternatively, the wind turbine blade may be split in a lengthwise direction. In this case, each of the first and second shells comprises a fraction of the total length of the blade.
|
||||
|
||||
The wind turbine blade, e.g., its root section, is, for example, fixedly connected to the hub. The wind turbine blade is, for example, directly bolted to the hub.
|
||||
|
||||
Alternatively, the wind turbine blade, e.g., the root section, is rotatably connected to the hub. For example, the wind turbine blade is connected to a pitch bearing of the wind turbine, and the pitch bearing is connected to the hub. The pitch bearing is configured to adjust the angle of attack of the blade according to the wind speed to control the rotational speed of the blade. Apart from the (cylindrical) root section connected with the hub, the wind turbine blade is formed aerodynamically. The wind turbine blade comprises, for example, the pressure side (upwind side) and the suction side (downwind side). The pressure side and the suction side are connected with each other at a leading edge and a trailing edge. The pressure and suctions sides and the leading and trailing edges define an in terior cavity of the wind turbine blade. The mould core (or mandrel) comprises, for example, an inner firm core and an external flexible portion surrounding the inner firm core.
|
||||
|
||||
The mould core may comprise two or more mould core portions. Each of the two or more mould core portions may comprise an inner firm core and a flexible external portion.
|
||||
|
||||
The upper and lower moulds and the mould core define the space in which the vacuum for the vacuum infusion process is applied. Resin is infused into this space and fills it partly So as to infuse at least the dry fibre lay-up and the connection region. Thus, the pre-casted fibre lay-up is infused with resin only in the connection region, while the remaining portion of the pre-casted fibre lay-up is - apart from the pre-casting process itself - not infused with resin.
|
||||
|
||||
10 The dry fibre lay-up and/or the pre-casted fibre lay-up includes, in particular, glass fibres, carbon fibres, aramid fibres and/or natural fibres.
|
||||
15 The pre-casted fibres are, in particular, fibres infused with resin and cured before the step of infusing the dry fibre lay-up in the lower mould and the connection regions with resin. In other words, the pre-casted fibres in the upper mould are pre-casted in a first wet process (first resin in
|
||||
20 fusion process) and cured, and the dry fibre lay-up in the lower mould and the connection regions are infused with resin in a second wet process (second resin infusion process), wherein the first wet process (including curing) and second wet process are spaced apart in time.
|
||||
25 The dry fibre lay-up comprises (only) fibres in dry condition, in particular, fibres without a resin. Fibres in dry condition are more flexible compared to fibres with resin such as fibres casted in resin or pre-impregnated fibres
|
||||
30(prepreg). Packing fibres in dry condition into the lower or upper mould allows to match the shape of the respective mould. The resin includes, for example, thermosets, thermoplastics,
|
||||
35 epoxy, polyurethane, vinyl ester and/or polyester. The resin is, in particular, infused due to the generated
|
||||
The dry fibre lay-up and/or the pre-casted fibre lay-up includes, in particular, glass fibres, carbon fibres, aramid fibres and/or natural fibres.
|
||||
|
||||
vacuum in the space between the upper and lower moulds and the mould core. The resin is, for example, cured by applying heat.
|
||||
The pre-casted fibres are, in particular, fibres infused with resin and cured before the step of infusing the dry fibre lay-up in the lower mould and the connection regions with resin. In other words, the pre-casted fibres in the upper mould are pre-casted in a first wet process (first resin in fusion process) and cured, and the dry fibre lay-up in the lower mould and the connection regions are infused with resin in a second wet process (second resin infusion process), wherein the first wet process (including curing) and second wet process are spaced apart in time.
|
||||
|
||||
According to an embodiment, the dry fibre lay-up and/or the 5 pre-casted fibre lay-up includes a fibre core material. The fibre core material comprises, for example, wood, balsa, PET foam and/or PVc foam.
|
||||
10When the fibre lay-up including the core material is infused and cured with the resin, a fibre-reinforced resin laminate with a core structure made from the core material is obtained. For example, a sandwich-structured fibre-reinforced resin laminate may be obtained in which a layer of the core
|
||||
15 material is arranged between layers of fibre-reinforced resin. The dry fibre lay-up and/or the pre-casted fibre lay-up includes, for example, an inner laminate and an outer laminate
|
||||
20 and in between the core material. Having the fibre core material allows to reduce the weight of the final fibre-reinforced resin laminate while maintaining a sufficient rigidity and/or strength of the blade.
|
||||
25 According to a further embodiment, the connection region comprises an overlap region in which the pre-casted fibre lay-up and the dry fibre lay-up overlap each other.
|
||||
30Having the overlap region allows to better join the precasted fibre lay-up and the dry fibre lay-up with each other by infusing and curing the resin. The resulting joint can better transfer loads in the blade shell.
|
||||
35 The overlap region may be smaller than the connection region. Alternatively, the connection region may concur with the overlap region.
|
||||
The dry fibre lay-up comprises (only) fibres in dry condition, in particular, fibres without a resin. Fibres in dry condition are more flexible compared to fibres with resin such as fibres casted in resin or pre-impregnated fibres(prepreg). Packing fibres in dry condition into the lower or upper mould allows to match the shape of the respective mould.
|
||||
|
||||
The resin includes, for example, thermosets, thermoplastics, epoxy, polyurethane, vinyl ester and/or polyester.
|
||||
|
||||
The resin is, in particular, infused due to the generated vacuum in the space between the upper and lower moulds and the mould core. The resin is, for example, cured by applying heat.
|
||||
|
||||
According to an embodiment, the dry fibre lay-up and/or the 5 pre-casted fibre lay-up includes a fibre core material.
|
||||
The fibre core material comprises, for example, wood, balsa, PET foam and/or PVc foam.
|
||||
When the fibre lay-up including the core material is infused and cured with the resin, a fibre-reinforced resin laminate with a core structure made from the core material is obtained. For example, a sandwich-structured fibre-reinforced resin laminate may be obtained in which a layer of the core material is arranged between layers of fibre-reinforced resin.
|
||||
The dry fibre lay-up and/or the pre-casted fibre lay-up includes, for example, an inner laminate and an outer laminate and in between the core material.
|
||||
Having the fibre core material allows to reduce the weight of the final fibre-reinforced resin laminate while maintaining a sufficient rigidity and/or strength of the blade.
|
||||
According to a further embodiment, the connection region comprises an overlap region in which the pre-casted fibre lay-up and the dry fibre lay-up overlap each other.
|
||||
Having the overlap region allows to better join the precasted fibre lay-up and the dry fibre lay-up with each other by infusing and curing the resin. The resulting joint can better transfer loads in the blade shell.
|
||||
The overlap region may be smaller than the connection region. Alternatively, the connection region may concur with the overlap region.
|
||||
|
||||
According to a further embodiment, the pre-casted fibre layup and/or the dry fibre lay-up comprises the fibre core material in the overlap region.
|
||||
|
||||
5 Having the same structure of the fibre-reinforced resin laminate with core material throughout the overlap and connection region allows to obtain a blade shell with homogenous properties, such as homogenous strength and weight, across the overlap and connection region.
|
||||
10 According to a further embodiment, both the dry fibre lay-up and the pre-casted fibre lay-up comprise at least one tapered edge portion overlapping each other in the overlap region.
|
||||
15 Having the tapered edge portions allows a good overlap of the dry fibre lay-up and the pre-casted fibre lay-up and a smooth transition from one to the other. According to a further embodiment, the pre-casted fibre lay
|
||||
20up and the dry fibre lay-up are in direct contact with each other in the connection region. In particular, a surface of the pre-casted fibre lay-up and a surface of the dry fibre lay-up are in direct contact with
|
||||
25 each other. In the case of tapered edge portions overlapping each other, inclined surfaces of the tapered edge portions may be in direct contact with each other. According to a further embodiment, an auxiliary material is
|
||||
30 disposed between a surface of at least one edge portion of the pre-casted fibre lay-up and a surface of at least one edge portion of the dry fibre lay-up. The auxiliary material is, for example, a non-fibre material.
|
||||
35 The auxiliary material is, for example, a PUR material. Having the auxiliary material allows, in particular, more
|
||||
Having the same structure of the fibre-reinforced resin laminate with core material throughout the overlap and connection region allows to obtain a blade shell with homogenous properties, such as homogenous strength and weight, across the overlap and connection region.
|
||||
According to a further embodiment, both the dry fibre lay-up and the pre-casted fibre lay-up comprise at least one tapered edge portion overlapping each other in the overlap region.
|
||||
Having the tapered edge portions allows a good overlap of the dry fibre lay-up and the pre-casted fibre lay-up and a smooth transition from one to the other.
|
||||
According to a further embodiment, the pre-casted fibre lay up and the dry fibre lay-up are in direct contact with each other in the connection region.
|
||||
In particular, a surface of the pre-casted fibre lay-up and a surface of the dry fibre lay-up are in direct contact with each other. In the case of tapered edge portions overlapping each other, inclined surfaces of the tapered edge portions may be in direct contact with each other.
|
||||
According to a further embodiment, an auxiliary material is disposed between a surface of at least one edge portion of the pre-casted fibre lay-up and a surface of at least one edge portion of the dry fibre lay-up.
|
||||
The auxiliary material is, for example, a non-fibre material.
|
||||
The auxiliary material is, for example, a PUR material.
|
||||
Having the auxiliary material allows, in particular, more freedom in configuring different blade cross-section profiles to obtain different aerodynamic profiles (airfoils). For example, the auxiliary material may be applied to form a sharp edge of an aerodynamic profile, e.g. at the trailing edge of the air foil.
|
||||
|
||||
freedom in configuring different blade cross-section profiles to obtain different aerodynamic profiles (airfoils). For example, the auxiliary material may be applied to form a sharp edge of an aerodynamic profile, e.g. at the trailing edge of the air foil.
|
||||
According to a further embodiment, the dry fibre lay-up in the lower mould has a main portion inside a cavity of the lower mould and at least one extending portion extending from the main portion beyond a side edge of the cavity of the lower mould, and wherein the method comprises, before the step of arranging the upper mould on the lower mould, the steps of arranging the mould core on the dry fibre lay-up in the lower mould and folding up the at least one extending portion of the dry fibre lay-up onto the mould core.
|
||||
|
||||
5 According to a further embodiment, the dry fibre lay-up in the lower mould has a main portion inside a cavity of the lower mould and at least one extending portion extending from the main portion beyond a side edge of the cavity of the low
|
||||
10 er mould, and wherein the method comprises, before the step of arranging the upper mould on the lower mould, the steps of arranging the mould core on the dry fibre lay-up in the lower mould and folding up the at least one extending portion of the dry fibre lay-up onto the mould core.
|
||||
15 Having the extending portion and folding it up onto the mould core allows to configure the connection region offset from a region where the upper and lower mould edges are coming into Contact with each other. Hence, the pre-casted fibre lay-up can be better arranged and positioned on the dry fibre layup. Further, the connection region can be configured, for example, offset from the leading edge and/or the trailing edge. Hence, the connection region can be configured, for example, offset from the maximum curvature of the airfoil.
|
||||
25 The lower mould comprises, in particular, the mould cavity for forming and casting the dry fibre lay-up. Further, the lower mould comprises horizontal portions extending from the side edges of the mould cavity to the right and left, as seen
|
||||
Having the extending portion and folding it up onto the mould core allows to configure the connection region offset from a region where the upper and lower mould edges are coming into Contact with each other. Hence, the pre-casted fibre lay-up can be better arranged and positioned on the dry fibre layup. Further, the connection region can be configured, for example, offset from the leading edge and/or the trailing edge. Hence, the connection region can be configured, for example, offset from the maximum curvature of the airfoil.
|
||||
|
||||
The lower mould comprises, in particular, the mould cavity for forming and casting the dry fibre lay-up. Further, the lower mould comprises horizontal portions extending from the side edges of the mould cavity to the right and left, as seen
|
||||
30 in a cross-sectional view. The mould cavity accommodates, in particular, the main portion of the dry fibre lay-up. The at least one extending portion of the dry fibre lay-up is, for example, laid, before folding it up, on the horizontal portion(s) of the lower mould.
|
||||
35 According to a further embodiment, a continuation portion of
|
||||
|
||||
the at least one extending portion has the same layer structure and/or the same thickness as the main portion, the continuation portion being continuous with the main portion.
|
||||
According to a further embodiment, a continuation portion of the at least one extending portion has the same layer structure and/or the same thickness as the main portion, the continuation portion being continuous with the main portion.
|
||||
|
||||
Having said continuity in layer structure and/or thickness
|
||||
5from the main portion to the continuation portion of the dry fibre lay-up allows, in particular, to ensure homogenous properties, such as homogenous strength and/or weight, of the main portion and the continuation portion. The continuation portion may cover the leading edge and/or trailing edge of
|
||||
10 the airfoil. In this way, homogenous strength and/or weight of the blade can be ensured, for example, across the leading edge and/or the trailing edge. According to a further embodiment, the method comprises, af
|
||||
15ter the step of folding up the at least one extending portion onto the mould core, the step of fixing the at least one folded-up extending portion at the mould core. With the extending portion fixed at the mould core, the upper
|
||||
20mould can be more easily arranged on the lower mould and the mould core. The extending portion is, for example, fixed at the mould core by applying a tape, e.g., an adhesive tape and/or a
|
||||
25 glass tape. The dry fibre lay-up may comprise two extending portions. Each of the two extending portions may be fixed at the mould core by an adhesive tape. Alternatively, the two extending
|
||||
30 portions may be fixed to each other, e.g., with a tape laid across the mould core. According to a further embodiment, the method comprises, before the step of arranging the upper mould comprising the
|
||||
35 pre-casted fibre lay-up on the lower mould, the step of fixing the pre-casted fibre lay-up to the upper mould.
|
||||
Having said continuity in layer structure and/or thickness from the main portion to the continuation portion of the dry fibre lay-up allows, in particular, to ensure homogenous properties, such as homogenous strength and/or weight, of the main portion and the continuation portion. The continuation portion may cover the leading edge and/or trailing edge of the airfoil. In this way, homogenous strength and/or weight of the blade can be ensured, for example, across the leading edge and/or the trailing edge.
|
||||
|
||||
According to a further embodiment, the method comprises, after the step of folding up the at least one extending portion onto the mould core, the step of fixing the at least one folded-up extending portion at the mould core.
|
||||
|
||||
With the extending portion fixed at the mould core, the upper mould can be more easily arranged on the lower mould and the mould core.
|
||||
|
||||
The extending portion is, for example, fixed at the mould core by applying a tape, e.g., an adhesive tape and/or a glass tape.
|
||||
The dry fibre lay-up may comprise two extending portions. Each of the two extending portions may be fixed at the mould core by an adhesive tape. Alternatively, the two extending portions may be fixed to each other, e.g., with a tape laid across the mould core.
|
||||
|
||||
According to a further embodiment, the method comprises, before the step of arranging the upper mould comprising the pre-casted fibre lay-up on the lower mould, the step of fixing the pre-casted fibre lay-up to the upper mould.
|
||||
|
||||
The upper mould comprising the fixed pre-casted fibre lay-up can be easier arranged on the lower mould. This is in particular the case as the upper mould is turned around.
|
||||
|
||||
5Fixation of the pre-casted fibre lay-up may be done by attaching a foil to each of the edges of the pre-casted fibre lay-up and the upper mould and applying vacuum to a space covered by the foil. Fixation may also be done by using an elongated element, e.g. a bar and/or (wooden) stick clamped
|
||||
10to the upper mould, e.g., to the horizontal portions of the upper mould. Fixation may also be done by bolting the precasted fibre lay-up to the upper mould. According to a further embodiment, the method comprises, be
|
||||
15fore the step of applying vacuum, the step of covering the mould core with a vacuum bag, and wherein the vacuum is applied to a space between the upper and lower moulds and the vacuum bag.
|
||||
20 Covering the mould core with a vacuum bag may include sealing the vacuum bag. The mould core may also be covered with two or more vacuum bags to increase tightness. In the case, the mould core comprises more than one mould
|
||||
25 core portion, each mould core portion may be covered with one or more vacuum bags. In embodiments, the method may comprise the step of removing the vacuum bag and/or the mould core, after infusing and cur
|
||||
30ing the resin. The mould core and/or the vacuum bag is, for example, removed through the blade root section. In the case the mould core comprises the flexible external portion, this flexible external portion may be compressed before removing the mould core. For example, vacuum may be generated in a space between the vacuum bag and the mould core, thereby compressing the flexible external portion and reducing the size of the mould core.
|
||||
Fixation of the pre-casted fibre lay-up may be done by attaching a foil to each of the edges of the pre-casted fibre lay-up and the upper mould and applying vacuum to a space covered by the foil. Fixation may also be done by using an elongated element, e.g. a bar and/or (wooden) stick clamped to the upper mould, e.g., to the horizontal portions of the upper mould. Fixation may also be done by bolting the precasted fibre lay-up to the upper mould.
|
||||
According to a further embodiment, the method comprises, before the step of applying vacuum, the step of covering the mould core with a vacuum bag, and wherein the vacuum is applied to a space between the upper and lower moulds and the vacuum bag.
|
||||
Covering the mould core with a vacuum bag may include sealing the vacuum bag. The mould core may also be covered with two or more vacuum bags to increase tightness.
|
||||
In the case, the mould core comprises more than one mould core portion, each mould core portion may be covered with one or more vacuum bags.
|
||||
|
||||
In embodiments, the method may comprise the step of removing the vacuum bag and/or the mould core, after infusing and curing the resin. The mould core and/or the vacuum bag is, for example, removed through the blade root section. In the case the mould core comprises the flexible external portion, this flexible external portion may be compressed before removing the mould core. For example, vacuum may be generated in a space between the vacuum bag and the mould core, thereby compressing the flexible external portion and reducing the size of the mould core.
|
||||
|
||||
According to a further embodiment, the method comprises, before the step of arranging the upper mould on the lower mould, the step of arranging one or more reinforcement beams on the dry fibre lay-up.
|
||||
|
||||
5 Thus, the one or more reinforcement beams can be casted together with the dry fibre lay-up in one wet process, i.e. one infusion and curing process.
|
||||
10The one or more reinforcement beams comprise, for example, a pressure-side beam, a suction-side beam, a leading edge beam and/or a trailing edge beam. A reinforcement beam can be a dry layup, a pre-casted element or a combination of the two.
|
||||
15 A pressure-side beam is, in particular, a beam on the pressure side of the wind turbine blade. A suction-side beam is, in particular, a beam on the suction side of the wind turbine blade. A leading edge beam is, in particular, a beam on the leading edge of the wind turbine blade. A trailing edge beam
|
||||
20is, in particular, a beam on the trailing edge of the wind turbine blade. According to a further embodiment, the method comprises, before the step of arranging the upper mould on the lower
|
||||
25mould, the step of arranging a web, and wherein at least the dry fibre lay-up, the connection region and/or the web is/are infused with resin. One or more webs, e.g., two webs may be arranged. In embodiments, arranging a web includes arranging a pre-casted web.
|
||||
30 Thus, the web can be casted together with the fibres in one wet process. The web provides, for example, strength to the blade.
|
||||
35 According to a further embodiment, the web is configured to transversally connect the pre-casted fibre lay-up and the dry fibre lay-up, once cured, within an interior cavity of the blade.
|
||||
Thus, the one or more reinforcement beams can be casted together with the dry fibre lay-up in one wet process, i.e. one infusion and curing process.
|
||||
|
||||
The one or more reinforcement beams comprise, for example, a pressure-side beam, a suction-side beam, a leading edge beam and/or a trailing edge beam. A reinforcement beam can be a dry layup, a pre-casted element or a combination of the two.
|
||||
|
||||
A pressure-side beam is, in particular, a beam on the pressure side of the wind turbine blade. A suction-side beam is, in particular, a beam on the suction side of the wind turbine blade. A leading edge beam is, in particular, a beam on the leading edge of the wind turbine blade. A trailing edge beam is, in particular, a beam on the trailing edge of the wind turbine blade.
|
||||
|
||||
According to a further embodiment, the method comprises, before the step of arranging the upper mould on the lower mould, the step of arranging a web, and wherein at least the dry fibre lay-up, the connection region and/or the web is/are infused with resin. One or more webs, e.g., two webs may be arranged. In embodiments, arranging a web includes arranging a pre-casted web.
|
||||
|
||||
Thus, the web can be casted together with the fibres in one wet process. The web provides, for example, strength to the blade.
|
||||
|
||||
According to a further embodiment, the web is configured to transversally connect the pre-casted fibre lay-up and the dry fibre lay-up, once cured, within an interior cavity of the blade.
|
||||
|
||||
The web is, in particular, a shear web. The web connects, in particular, the blade shells of the pressure side and the suction side in the interior cavity of the blade. The web provides shear strength to the blade.
|
||||
|
||||
Arranging the shear web and infusing the dry fibre lay-up, the connection region and the shear web with resin allows to join the shear web and the upper and lower shells in a single
|
||||
10 process step by infusing and curing the resin. The shear web can be a dry layup, a pre-casted element or a combination of the two. Further possible implementations or alternative solutions of
|
||||
15 the invention also encompass combinations - that are not explicitly mentioned herein - of features described above or below with regard to the embodiments. The person skilled in the art may also add individual or isolated aspects and features to the most basic form of the invention.
|
||||
20 Further embodiments, features and advantages of the present invention will become apparent from the subsequent description and dependent claims, taken in conjunction with the accompanying drawings, in which:
|
||||
25 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
|
||||
Arranging the shear web and infusing the dry fibre lay-up, the connection region and the shear web with resin allows to join the shear web and the upper and lower shells in a single process step by infusing and curing the resin. The shear web can be a dry layup, a pre-casted element or a combination of the two.
|
||||
|
||||
Further possible implementations or alternative solutions of the invention also encompass combinations - that are not explicitly mentioned herein - of features described above or below with regard to the embodiments. The person skilled in the art may also add individual or isolated aspects and features to the most basic form of the invention.
|
||||
|
||||
Further embodiments, features and advantages of the present invention will become apparent from the subsequent description and dependent claims, taken in conjunction with the accompanying drawings, in which:
|
||||
|
||||
本发明涉及一种风电机组叶片的制造方法。在给定风况下，利用风电机组产生更多电能的一种方式是增加叶片尺寸。
|
||||
然而，随着叶片尺寸的增加，风电机组叶片的制造变得越来越困难。目前，许多风电机组叶片是通过预先单独制造叶片部件（例如压力侧壳体和吸力侧壳体），然后将这些部件相互粘合来制造的。例如，这些部件是通过将玻璃纤维等复合材料注入树脂并固化树脂来预先制造的。然而，**粘合过程存在许多缺点。例如，难以实现胶合线足够的强度和坚固性**。此外，该方法需要在有限的时间内（即在所施加的胶水硬化之前）精确地定位非常大的部件。
|
||||
在EP 1 310 351 Al中公开的另一种方法中，叶片是通过将整个叶片或沿长度方向的叶片部分的复合材料堆叠在芯模上，并通过注入和固化树脂来制造的。从而避免了胶合接头。然而，将干燥复合材料堆叠并定位在通常是柔性的芯模顶部是具有挑战性的，特别是对于非常大的叶片。此外，随着叶片尺寸的增加，通过真空灌注需要填充树脂的体积也随之增加，使得树脂灌注更加困难。
|
||||
本发明的一个目的是提供一种改进的风电机组叶片制造方法。
|
||||
|
||||
因此，提出了一种风电机组叶片的制造方法。该方法包括以下步骤：
|
||||
|
||||
- 将包含预铸纤维铺层件的上模具布置在包含干燥纤维铺层件和模具芯的下模具上；
|
||||
|
||||
- 对上模具、下模具和模具芯之间的空间施加真空；
|
||||
|
||||
- 用树脂灌注至少干燥纤维铺层件以及干燥纤维铺层件与预铸纤维铺层件之间的连接区域，并固化树脂。
|
||||
|
||||
通过在上模具中设置预铸纤维铺层件，避免了将干燥复合材料堆叠和定位在模具芯顶部。
|
||||
|
||||
此外，优选地，**通过将干燥纤维铺层件堆叠在倒置的上模具中，注入树脂并固化来完成上模具中的纤维铺层件的预铸**。由于上模具是倒置的，因此纤维材料的堆叠也是在上模具中朝向具有明确几何形状的模具进行，而不是朝向柔性模具芯。此外，在上模具中设置预铸纤维铺层件，与上部纤维铺层件未预铸的情况相比，在相同叶片尺寸下，树脂在下模具中干燥纤维铺层件和连接区域的真空灌注过程中需要填充的体积更小。此外，与上部纤维铺层件未预铸的情况相比，在相同叶片尺寸下，树脂在真空灌注过程中需要流动的路径更短。例如，与上部纤维铺层件未预铸的情况相比，树脂需要上升到制造现场地面以上的高度更低。因此，即使在叶片尺寸较大的情况下，也更容易在树脂灌注过程中高质量地灌注纤维铺层件。
|
||||
|
||||
与叶片部件相互粘合的方法相比，本发明的一个优点是，一旦固化，这里提供了一个层压接头，连接上部预铸纤维铺层件和下模具中的干燥纤维铺层件。与使用粘合剂的连接相比，通过树脂灌注形成的层压接头更轻，同时更坚固。它更轻，因为在使用粘合剂的情况下，粘合剂的重量会增加到粘合线中。此外，通过真空灌注形成的层压接头的强度与原始层压件的强度相当。此外，通过真空灌注形成的层压接头避免了胶合接头中胶水材料与叶片其余部分材料不同的问题。
|
||||
风电机组叶片是风电机组风轮的一部分。风电机组是一种将风的动能转换为电能的装置。例如，风电机组包括：具有一个或多个叶片（每个叶片连接到一个轮毂）的风轮；包括发电机的机舱；以及在其顶端支撑机舱的塔架。风电机组的塔架可以通过过渡件连接到风电机组的基础，例如海床中的单桩。
|
||||
|
||||
上模具中的预铸纤维铺层件在制成的叶片中成为叶片的第一壳体。特别地，它成为叶片的第一半壳体。
|
||||
|
||||
下模具中的干燥纤维铺层件一旦灌注并固化，在制成的叶片中成为叶片的第二壳体。特别地，它成为叶片的第二半壳体。
|
||||
|
||||
第一和第二壳体特别地是纤维增强树脂层压件。
|
||||
|
||||
第一壳体可以包括叶片的压力侧（迎风侧），第二壳体可以包括叶片的吸力侧（背风侧），反之亦然。
|
||||
|
||||
第一和第二壳体可以各自包括从叶片根部到叶尖的整个叶片长度。或者，风电机组叶片可以沿长度方向分开。在这种情况下，第一和第二壳体中的每一个都包括叶片总长度的一部分。
|
||||
|
||||
例如，风电机组叶片（例如其根部）固定连接到轮毂。例如，风电机组叶片直接用螺栓固定到轮毂。
|
||||
|
||||
或者，风电机组叶片（例如根部）可旋转地连接到轮毂。例如，风电机组叶片连接到风电机组的变桨轴承，并且变桨轴承连接到轮毂。变桨轴承配置为根据风速调整叶片的攻角，以控制叶片的转速。除了与轮毂连接的（圆柱形）根部之外，风电机组叶片是气动成形的。例如，风电机组叶片包括压力侧（迎风侧）和吸力侧（背风侧）。压力侧和吸力侧在导边和尾缘处相互连接。压力侧和吸力侧以及导边和尾缘限定了风电机组叶片的内部空腔。模具芯（或芯棒）例如包括一个内部坚固芯和一个围绕内部坚固芯的外部柔性部分。
|
||||
|
||||
模具芯可以包括两个或更多个模具芯部分。两个或更多个模具芯部分中的每一个可以包括一个内部坚固芯和一个柔性外部部分。
|
||||
|
||||
上模具、下模具和模具芯限定了用于真空灌注过程施加真空的空间。树脂被灌注到该空间中并部分填充，以灌注至少干燥纤维铺层件和连接区域。因此，预铸纤维铺层件仅在连接区域被树脂灌注，而预铸纤维铺层件的其余部分——除了预铸过程本身之外——未被树脂灌注。
|
||||
|
||||
干燥纤维铺层件和/或预铸纤维铺层件特别地包括玻璃纤维、碳纤维、芳纶纤维和/或天然纤维。
|
||||
|
||||
预铸纤维特别地是在用树脂灌注下模具中的干燥纤维铺层件和连接区域的步骤之前，用树脂灌注并固化的纤维。换句话说，上模具中的预铸纤维在第一湿法工艺（第一树脂灌注工艺）中预铸并固化，而下模具中的干燥纤维铺层件和连接区域在第二湿法工艺（第二树脂灌注工艺）中用树脂灌注，其中第一湿法工艺（包括固化）和第二湿法工艺在时间上是分开的。
|
||||
|
||||
干燥纤维铺层件包括（仅）干燥状态的纤维，特别是不含树脂的纤维。与含有树脂的纤维（例如铸造在树脂中的纤维或预浸渍纤维（预浸料））相比，干燥状态的纤维更具柔性。将干燥状态的纤维堆叠到下模具或上模具中，可以使其与相应模具的形状匹配。
|
||||
|
||||
树脂例如包括热固性塑料、热塑性塑料、环氧树脂、聚氨酯、乙烯基酯和/或聚酯。
|
||||
|
||||
树脂特别地是由于上模具、下模具和模具芯之间空间中产生的真空而灌注的。例如，树脂通过施加热量来固化。
|
||||
|
||||
根据一个实施例，干燥纤维铺层件和/或预铸纤维铺层件包括纤维芯材。
|
||||
纤维芯材例如包括木材、轻木、PET泡沫和/或PVC泡沫。
|
||||
当包含芯材的纤维铺层件用树脂灌注并固化时，获得具有由芯材制成的芯结构的纤维增强树脂层压件。例如，可以获得一种夹层结构的纤维增强树脂层压件，其中芯材层布置在纤维增强树脂层之间。
|
||||
干燥纤维铺层件和/或预铸纤维铺层件例如包括内层层压件和外层层压件，以及介于两者之间的芯材。
|
||||
设置纤维芯材可以减轻最终纤维增强树脂层压件的重量，同时保持叶片足够的刚度和/或强度。
|
||||
根据另一实施例，连接区域包括一个重叠区域，其中预铸纤维铺层件和干燥纤维铺层件相互重叠。
|
||||
设置重叠区域可以通过灌注和固化树脂，更好地将预铸纤维铺层件和干燥纤维铺层件相互连接。所形成的接头可以更好地传递叶片壳体中的载荷。
|
||||
重叠区域可以小于连接区域。或者，连接区域可以与重叠区域重合。
|
||||
|
||||
根据另一实施例，预铸纤维铺层件和/或干燥纤维铺层件在重叠区域中包含纤维芯材。
|
||||
|
||||
在整个重叠和连接区域中具有相同芯材的纤维增强树脂层压件结构，可以获得在重叠和连接区域具有均匀特性（例如均匀强度和重量）的叶片壳体。
|
||||
根据另一实施例，干燥纤维铺层件和预铸纤维铺层件都包括至少一个在重叠区域中相互重叠的锥形边缘部分。
|
||||
设置锥形边缘部分可以使干燥纤维铺层件和预铸纤维铺层件良好重叠，并实现从一个到另一个的平滑过渡。
|
||||
根据另一实施例，预铸纤维铺层件和干燥纤维铺层件在连接区域中相互直接接触。
|
||||
特别地，预铸纤维铺层件的表面和干燥纤维铺层件的表面相互直接接触。在锥形边缘部分相互重叠的情况下，锥形边缘部分的倾斜表面可以相互直接接触。
|
||||
根据另一实施例，辅助材料布置在预铸纤维铺层件的至少一个边缘部分的表面与干燥纤维铺层件的至少一个边缘部分的表面之间。
|
||||
辅助材料例如是非纤维材料。
|
||||
辅助材料例如是PUR材料。
|
||||
设置辅助材料特别地允许在配置不同叶片横截面轮廓以获得不同气动轮廓（翼型）方面具有更大的自由度。例如，辅助材料可以用于形成气动轮廓的锐边，例如在翼型的尾缘处。
|
||||
|
||||
根据另一实施例，下模具中的干燥纤维铺层件具有位于下模具型腔内部的主体部分，以及至少一个从主体部分延伸超出下模具型腔侧边缘的延伸部分，并且该方法包括，在将上模具布置在下模具上的步骤之前，将模具芯布置在下模具中的干燥纤维铺层件上，并将干燥纤维铺层件的至少一个延伸部分向上折叠到模具芯上的步骤。
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设置延伸部分并将其向上折叠到模具芯上，可以使连接区域配置成偏离上模具和下模具边缘相互接触的区域。因此，预铸纤维铺层件可以更好地布置和定位在干燥纤维铺层件上。此外，连接区域可以配置成例如偏离导边和/或尾缘。因此，连接区域可以配置成例如偏离翼型的最大曲率。
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下模具特别地包括用于形成和铸造干燥纤维铺层件的模具型腔。此外，从横截面图来看，下模具包括从模具型腔的侧边缘向右和向左延伸的水平部分。模具型腔特别地容纳干燥纤维铺层件的主体部分。干燥纤维铺层件的至少一个延伸部分例如在向上折叠之前，铺设在下模具的水平部分上。
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根据另一实施例，至少一个延伸部分的延续部分具有与主体部分相同的层结构和/或相同的厚度，该延续部分与主体部分是连续的。
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干燥纤维铺层件从主体部分到延续部分在层结构和/或厚度上的这种连续性，特别地可以确保主体部分和延续部分具有均匀的特性，例如均匀的强度和/或重量。延续部分可以覆盖翼型的导边和/或尾缘。通过这种方式，可以确保叶片具有均匀的强度和/或重量，例如在导边和/或尾缘处。
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根据另一实施例，该方法包括，在将至少一个延伸部分向上折叠到模具芯上的步骤之后，将至少一个向上折叠的延伸部分固定在模具芯上的步骤。
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随着延伸部分固定在模具芯上，上模具可以更容易地布置在下模具和模具芯上。
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例如，延伸部分通过施加胶带（例如粘合胶带和/或玻璃胶带）固定在模具芯上。
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干燥纤维铺层件可以包括两个延伸部分。两个延伸部分中的每一个可以通过粘合胶带固定在模具芯上。或者，两个延伸部分可以相互固定，例如用一条横跨模具芯的胶带。
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根据另一实施例，该方法包括，在将包含预铸纤维铺层件的上模具布置在下模具上的步骤之前，将预铸纤维铺层件固定到上模具上的步骤。
|
||||
|
||||
包含固定预铸纤维铺层件的上模具可以更容易地布置在下模具上。当上模具翻转时，情况尤其如此。
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||||
|
||||
预铸纤维铺层件的固定可以通过将箔片连接到预铸纤维铺层件和上模具的每个边缘，并对箔片覆盖的空间施加真空来完成。固定也可以通过使用细长元件（例如夹紧到上模具（例如上模具的水平部分）的杆和/或（木制）棒）来完成。固定也可以通过将预铸纤维铺层件用螺栓固定到上模具上来完成。
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||||
根据另一实施例，该方法包括，在施加真空的步骤之前，用真空袋覆盖模具芯的步骤，并且真空施加到上模具、下模具和真空袋之间的空间。
|
||||
用真空袋覆盖模具芯可以包括密封真空袋。模具芯也可以用两个或更多个真空袋覆盖以增加密封性。
|
||||
在模具芯包含多个模具芯部分的情况下，每个模具芯部分可以用一个或多个真空袋覆盖。
|
||||
|
||||
在实施例中，该方法可以包括在灌注和固化树脂之后，移除真空袋和/或模具芯的步骤。例如，模具芯和/或真空袋通过叶片根部移除。在模具芯包含柔性外部部分的情况下，该柔性外部部分可以在移除模具芯之前被压缩。例如，可以在真空袋和模具芯之间的空间中产生真空，从而压缩柔性外部部分并减小模具芯的尺寸。
|
||||
|
||||
根据另一实施例，该方法包括，在将上模具布置在下模具上的步骤之前，在干燥纤维铺层件上布置一个或多个加强梁的步骤。
|
||||
|
||||
因此，一个或多个加强梁可以与干燥纤维铺层件在一个湿法工艺中（即一个灌注和固化工艺中）一起铸造。
|
||||
|
||||
一个或多个加强梁例如包括压力侧梁、吸力侧梁、导边梁和/或尾缘梁。加强梁可以是干燥铺层件、预铸元件或两者的组合。
|
||||
|
||||
压力侧梁特别地是风电机组叶片压力侧上的梁。吸力侧梁特别地是风电机组叶片吸力侧上的梁。导边梁特别地是风电机组叶片导边上的梁。尾缘梁特别地是风电机组叶片尾缘上的梁。
|
||||
|
||||
根据另一实施例，该方法包括，在将上模具布置在下模具上的步骤之前，布置腹板的步骤，并且至少干燥纤维铺层件、连接区域和/或腹板被树脂灌注。可以布置一个或多个腹板，例如两个腹板。在实施例中，布置腹板包括布置预铸腹板。
|
||||
|
||||
因此，腹板可以与纤维在一个湿法工艺中一起铸造。例如，腹板为叶片提供强度。
|
||||
|
||||
根据另一实施例，腹板配置为在叶片的内部空腔内，一旦固化，横向连接预铸纤维铺层件和干燥纤维铺层件。
|
||||
|
||||
腹板特别地是剪力腹板。腹板特别地连接叶片内部空腔中压力侧和吸力侧的叶片壳体。腹板为叶片提供剪切强度。
|
||||
|
||||
布置剪力腹板并用树脂灌注干燥纤维铺层件、连接区域和剪力腹板，可以通过灌注和固化树脂，在一个工艺步骤中将剪力腹板与上壳体和下壳体连接起来。剪力腹板可以是干燥铺层件、预铸元件或两者的组合。
|
||||
|
||||
本发明的其他可能的实施方式或替代解决方案还包括本文未明确提及的、关于上述或下述实施例中描述的特征的组合。本领域技术人员还可以将单个或独立的方面和特征添加到本发明最基本的形式中。
|
||||
|
||||
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：
|
||||
|
||||
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
|
||||
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
|
||||
35the wind turbine of Fig. 1, the dry fibre lay-up being arranged in a lower mould;
|
||||
|
||||
|
||||
@ -288,8 +288,7 @@ fast
|
||||
| 10 | Nacelle roll velocity [rad/s] | YawBrRVxp Tower-top / yaw bearing angular (rotational) roll velocity (absolute) | ? |
|
||||
| 11 | Nacelle nod velocity [rad/s] | YawBrRVyp Tower-top / yaw bearing angular (rotational) pitch velocity (absolute) | ? |
|
||||
| 12 | Nacelle yaw velocity [rad/s] | YawBrRVzp | × in ADAMS |
|
||||
| | | YawBrTAxp Tower-top / yaw bearing fore-aft (translational) **acceleration** (absolute) | |
|
||||
| 13 | Nacelle fore-aft acceleration [m/s^2] | | |
|
||||
| 13 | Nacelle fore-aft acceleration [m/s^2] | YawBrTAxp Tower-top / yaw bearing fore-aft (translational) **acceleration** (absolute) | ? |
|
||||
| 14 | Nacelle side-side acceleration [m/s^2] | YawBrTAyp | ? |
|
||||
| 15 | Nacelle vertical acceleration [m/s^2] | YawBrTAzp | ? |
|
||||
| 16 | Nacelle roll acceleration [rad/s^2] | YawBrRAxp | × in ADAMS |
|
||||
|
||||
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