WO2024159806A1 - 一种模块化风电叶片结构及其制作方法 - Google Patents

一种模块化风电叶片结构及其制作方法 Download PDF

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Publication number
WO2024159806A1
WO2024159806A1 PCT/CN2023/124319 CN2023124319W WO2024159806A1 WO 2024159806 A1 WO2024159806 A1 WO 2024159806A1 CN 2023124319 W CN2023124319 W CN 2023124319W WO 2024159806 A1 WO2024159806 A1 WO 2024159806A1
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WO
WIPO (PCT)
Prior art keywords
shell
windward
leeward
trailing edge
blade
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/CN2023/124319
Other languages
English (en)
French (fr)
Inventor
谈昆伦
刘叶霖
杜秋萍
李宁
曹磊
张健
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Newtech Group Co Ltd
Original Assignee
Newtech Group Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Newtech Group Co Ltd filed Critical Newtech Group Co Ltd
Priority to EP23919370.9A priority Critical patent/EP4534835A4/en
Publication of WO2024159806A1 publication Critical patent/WO2024159806A1/zh
Priority to US18/827,636 priority patent/US12392319B2/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
    • F03D—WIND MOTORS
    • F03D1/00—Wind motors with rotation axis substantially parallel to the air flow entering the rotor 
    • F03D1/06—Rotors
    • F03D1/065—Rotors characterised by their construction elements
    • F03D1/0675—Rotors characterised by their construction elements of the blades
    • F03D1/0679—Load carrying structures, e.g. beams
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
    • B29C70/443—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding and impregnating by vacuum or injection
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D99/00—Subject matter not provided for in other groups of this subclass
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D99/00—Subject matter not provided for in other groups of this subclass
    • B29D99/001—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings
    • B29D99/0014—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings provided with ridges or ribs, e.g. joined ribs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D99/00—Subject matter not provided for in other groups of this subclass
    • B29D99/0025—Producing blades or the like, e.g. blades for turbines, propellers, or wings
    • B29D99/0028—Producing blades or the like, e.g. blades for turbines, propellers, or wings hollow blades
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
    • F03D—WIND MOTORS
    • F03D1/00—Wind motors with rotation axis substantially parallel to the air flow entering the rotor 
    • F03D1/06—Rotors
    • F03D1/065—Rotors characterised by their construction elements
    • F03D1/0675—Rotors characterised by their construction elements of the blades
    • F03D1/0688—Rotors characterised by their construction elements of the blades of the leading edge region, e.g. reinforcements
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
    • F03D—WIND MOTORS
    • F03D1/00—Wind motors with rotation axis substantially parallel to the air flow entering the rotor 
    • F03D1/06—Rotors
    • F03D1/065—Rotors characterised by their construction elements
    • F03D1/0675—Rotors characterised by their construction elements of the blades
    • F03D1/069—Rotors characterised by their construction elements of the blades of the trailing edge region
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/08—Blades for rotors, stators, fans, turbines or the like, e.g. screw propellers
    • B29L2031/082—Blades, e.g. for helicopters
    • B29L2031/085—Wind turbine blades
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05B—INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
    • F05B2240/00—Components
    • F05B2240/20—Rotors
    • F05B2240/30—Characteristics of rotor blades, i.e. of any element transforming dynamic fluid energy to or from rotational energy and being attached to a rotor
    • F05B2240/302—Segmented or sectional blades
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05B—INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
    • F05B2240/00—Components
    • F05B2240/20—Rotors
    • F05B2240/30—Characteristics of rotor blades, i.e. of any element transforming dynamic fluid energy to or from rotational energy and being attached to a rotor
    • F05B2240/304—Details of the trailing edge
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2240/00—Components
    • F05D2240/20—Rotors
    • F05D2240/30—Characteristics of rotor blades, i.e. of any element transforming dynamic fluid energy to or from rotational energy and being attached to a rotor
    • F05D2240/304—Characteristics of rotor blades, i.e. of any element transforming dynamic fluid energy to or from rotational energy and being attached to a rotor related to the trailing edge of a rotor blade
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/70—Wind energy
    • Y02E10/72—Wind turbines with rotation axis in wind direction
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product

Definitions

  • the present invention relates to the technical field of wind turbine blades, and in particular to a modular wind turbine blade structure and a manufacturing method thereof.
  • a Chinese utility model patent with authorization announcement number CN216767624U disclosed a large-scale wind turbine blade connection structure on June 17, 2022.
  • a sandwich structure with an inner core and a reinforcement layer is set in the middle part to improve the structural strength of the product;
  • the present invention provides a modular wind turbine blade structure and a manufacturing method thereof, and improves the structure and the manufacturing method to improve the structural strength and processing efficiency of the modular wind turbine blade.
  • a modular wind turbine blade structure comprising a windward shell, a leeward shell, a T-shaped rib and a support member, wherein the windward shell and the leeward shell are relatively assembled to form a complete blade cross-sectional structure, wherein the T-shaped rib is fixed to the windward shell and the leeward shell along the length direction of the blade, and a plurality of T-shaped ribs are arranged at intervals in the width direction of the blade; wherein the support member comprises a web and a spar cap connected to both ends of the web, wherein the two spar caps are respectively connected and fixed to the inner walls of the windward shell and the leeward shell;
  • the T-shaped ribs and beam caps are pultruded profiles, and the windward shell and the leeward shell are formed by layering through an automatic tape laying process.
  • a trailing edge beam is further included, which is arranged at the trailing edge position where the windward surface shell and the leeward surface shell are connected, the top surface of the trailing edge beam is fitted and connected to the shell at the trailing edge of the windward surface shell, and the bottom surface of the trailing edge beam is fitted and connected to the shell at the trailing edge of the leeward surface shell.
  • the windward surface shell and the leeward surface shell are bent inward at the trailing edge and are closely connected to the side wall of the trailing edge beam.
  • the trailing edge beam includes a U-shaped beam and a sealing plate connected to an opening of the U-shaped beam.
  • the windward surface shell and the leeward surface shell both have an inwardly bent flange structure at the leading edge, and the flange structure of the windward surface shell and the flange structure of the leeward surface shell are parallel and oppositely arranged, with an adhesive structural glue layer between the two.
  • connection of the flange structure is covered with an inner reinforcement layer inside the shell, and the flange structure is covered with an outer reinforcement layer outside.
  • the adhesive structure adhesive layer overflows at both ends of the two flange structures to form an inverted structure, and the inverted structure is respectively covered by the inner reinforcement layer and the outer reinforcement layer, and both ends of the inner reinforcement layer and the outer reinforcement layer are respectively connected and fixed to the windward shell and the leeward shell.
  • the T-shaped rib includes a bottom plate and a vertical plate, the vertical plate is vertically connected to the center line of the bottom plate, the bottom plate is connected and fixed to the inner wall of the windward shell or the leeward shell, and the bottom plate parts on both sides of the vertical plate are also covered with a reinforcement layer.
  • the tape laying material of the windward shell and the leeward shell is a multi-layer biaxial glass fiber cloth, and the web is composed of glass fiber cloth sandwiched with PET foam.
  • a method for manufacturing a modular wind turbine blade structure comprising the following steps:
  • the windward shell and the leeward shell that have been laid are respectively subjected to integral vacuum infusion molding;
  • the windward shell and the leeward shell are integrally butt-jointed and fixed, and the windward shell and the leeward shell are connected at the trailing edge by a trailing edge beam, bonded at the leading edge by a flanging structure, and reinforced at the leading edge bonding point by an inner reinforcement layer and an outer reinforcement layer.
  • the present invention adopts an automatic tape laying process to manufacture the windward surface shell and the leeward surface shell, which has higher processing efficiency and better structural strength than the sandwich wind turbine blade shell structure in the prior art, and further improves manufacturing efficiency and quality by adopting pultruded profiles for T-shaped ribs and beam caps in the support members.
  • FIG1 is a schematic cross-sectional view of a modular wind turbine blade structure according to an embodiment of the present invention.
  • FIG2 is a schematic diagram of the installation structure of a modular wind turbine blade structure according to an embodiment of the present invention.
  • FIG. 3 is a schematic diagram of the structure of installing T-shaped ribs and support members on the leeward shell in an embodiment of the present invention
  • FIG4 is a partial enlarged view of point A in FIG1 according to an embodiment of the present invention.
  • FIG5 is a schematic diagram of the structure of a trailing edge beam in an embodiment of the present invention.
  • FIG6 is a partial enlarged view of point B in FIG1 according to an embodiment of the present invention.
  • FIG7 is a partial enlarged view of point C in FIG3 according to an embodiment of the present invention.
  • FIG8 is a flowchart of the steps of a method for manufacturing a modular wind turbine blade structure according to an embodiment of the present invention.
  • the modular wind turbine blade structure as shown in Figures 1 to 7 includes a windward shell 1, a leeward shell 2, T-shaped ribs 3 and a support member 4.
  • the windward shell 1 and the leeward shell 2 are relatively assembled to form a complete blade cross-sectional structure. It should be pointed out here that in the embodiment of the present invention, the blade is divided into a blade root module, a blade middle module and a blade tip module along the length direction.
  • the blade cross-sectional structure formed by the relative assembly of the windward shell 1 and the leeward shell 2 is a closed shape of the blade root, blade middle or blade tip part; the T-shaped ribs 3 are fixed to the windward shell 1 and the leeward shell 2 along the length direction of the blade, and a plurality of them are arranged at intervals in the width direction of the blade; as shown in Figures 1 and 2, the T-shaped ribs 3 are attached to the windward shell 1 and the inner wall of the leeward shell 2 and extending along the length direction of the blade.
  • the support member 4 includes a web 41 and a beam cap 42 connected to both ends of the web 41, and the two beam caps 42 are respectively connected and fixed to the inner walls of the windward shell 1 and the leeward shell 2; it should also be pointed out here that in the embodiments of the present invention, different numbers of support members 4 and T-shaped ribs 3 are set according to the different widths of the blade root, the middle of the blade and the tip of the blade.
  • the blade tip adopts a double support member 4 and a T-shaped rib 3 structure
  • the blade middle module adopts a five support member 4 and six T-shaped ribs 3 structure
  • the blade root adopts a five support member 4 and six T-shaped ribs 3 structure.
  • the specific arrangement quantity can be determined in the form of simulation analysis to determine the number of T-shaped ribs 3 and support members 4 required to meet the strength requirements;
  • the T-shaped rib 3 and the beam cap 42 are pultruded profiles, and the windward shell 1 and the leeward shell 2 are formed by automatic tape laying.
  • the automatic tape laying machine is used to lay the windward shell 1 and the leeward shell 2 molds.
  • the automatic processing of the tape laying machine ensures the structural strength; and the T-shaped rib 3 and the beam cap 42 are processed by pultrusion, which also improves the processing efficiency.
  • the windward shell 1 and the leeward shell 2 are manufactured by using the automatic tape laying process, which has higher processing efficiency and better structural strength than the sandwich structure in the prior art, and the T-shaped ribs 3 and the beam caps 42 in the support 4 are made of pultruded profiles, which further improves the manufacturing efficiency and quality.
  • the shell is made of carbon fiber reinforced composite material or fiber reinforced composite material, the manufacturing process quality control is simplified, the manufacturing cost is low, the structural stability is good, and the strength is higher.
  • a trailing edge beam 5 is also included.
  • the trailing edge beam 5 is arranged at the trailing edge position where the windward shell 1 and the leeward shell 2 are connected.
  • the top surface of the trailing edge beam 5 is fitted and connected to the shell at the trailing edge of the windward shell 1, and the bottom surface of the trailing edge beam 5 is fitted and connected to the shell at the trailing edge of the leeward shell 2. Further, as shown in FIG.
  • the windward shell 1 and the leeward shell 2 are bent inward at the trailing edge and are fitted and connected to the side wall of the trailing edge beam 5.
  • the upper and lower surfaces and the outer side surface of the trailing edge beam 5 are all connected to the windward shell 1 or the leeward shell 2, thereby playing the effect of strengthening support and improving connection strength.
  • the trailing edge beam 5 includes a U-shaped beam 51 and a sealing plate 52 connected to the opening of the U-shaped beam 51.
  • the U-shaped beam 51 is provided to facilitate the side wall of the U-shaped beam 51 to follow the shape of the windward shell 1 or the leeward shell 2, thereby achieving a closer contact to improve the connection effect.
  • the windward shell 1 and the leeward shell 2 both have an inwardly bent flange structure 11 at the leading edge, and the flange structure 11 of the windward shell 1 and the flange structure 11 of the leeward shell 2 are arranged parallel and opposite to each other, with an adhesive layer 12 of bonding structure between the two.
  • the flange structure 11 increases the connection area of the windward shell 1 and the leeward shell 2 at the leading edge, and the inwardly folded form has no effect on the shape of the blade, and the above-mentioned structural form increases the bonding area, thereby enhancing the strength of the connection type structure.
  • connection of the flange structure 11 is covered with an inner reinforcement layer 13 inside the shell, and the flange structure 11 is covered with an outer reinforcement layer 14 outside.
  • the adhesive structure adhesive layer 12 overflows at both ends of the two flange structures 11 to form an undercut structure 12a, and the undercut structure 12a is respectively covered by the inner reinforcement layer 13 and the outer reinforcement layer 14, and both ends of the inner reinforcement layer 13 and the outer reinforcement layer 14 are respectively connected and fixed to the windward shell 1 and the leeward shell 2.
  • the two ends of the adhesive structure adhesive layer 12 form a cap structure, which not only increases the bonding stability of the two-layer flange structure 11, but also improves the bonding strength of the inner reinforcement layer and the outer reinforcement layer.
  • the T-shaped rib 3 includes a bottom plate 31 and a vertical plate 32.
  • the vertical plate 32 is vertically connected to the center line of the bottom plate 31.
  • the bottom plate 31 is connected and fixed to the inner wall of the windward shell 1 or the leeward shell 2.
  • the bottom plate 31 on both sides of the vertical plate 32 is also covered with a reinforcing layer 33.
  • the tape laying material of the windward shell 1 and the leeward shell 2 is a multi-layer biaxial glass fiber cloth, and the web 41 is composed of a glass fiber cloth sandwich PET foam.
  • a method for manufacturing a modular wind turbine blade structure as shown in FIG8 comprising the following steps:
  • T-shaped ribs 3 Laying T-shaped ribs 3 on the inner walls of the windward shell 1 and the leeward shell 2 at set positions; during the specific laying, laser positioning is used to ensure the laying accuracy, and specifically, the specific area where the T-shaped ribs 3 or the beam caps 42 need to be laid can be projected on the inner walls of the windward shell 1 and the leeward shell 2 by laser, and then the T-shaped ribs 3 are fixed in the laser projection area; in addition, it should be pointed out here that in some embodiments of the present invention, in order to further improve the positioning accuracy, two web 41 bonding groove structures are also provided on the beam cap 42.
  • the windward shell 1 and the leeward shell 2 that have been laid are respectively subjected to integral vacuum infusion molding;
  • the integral vacuum infusion is to first set a vacuum bag that follows the shell shape, and then perform vacuuming while infusing resin glue, so that the resin glue penetrates into every corner, and then performs curing and drying. This arrangement improves the bonding strength and the overall structural strength of the shell;

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Sustainable Energy (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Combustion & Propulsion (AREA)
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  • General Engineering & Computer Science (AREA)
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Abstract

本发明涉及风电叶片技术领域，尤其涉及一种模块化风电叶片结构及其制作方法，该结构包括迎风面壳体、背风面壳体、T型筋和支撑件，迎风面壳体和背风面壳体相对拼合构成完整的叶片截面结构，T型筋沿叶片长度方向固定在迎风面壳体和背风面壳体上，并且在叶片宽度方向间隔布置有多条；支撑件包括腹板和连接在腹板两端的梁帽，两梁帽分别与迎风面壳体以及背风面壳体的内壁连接固定；其中，T型筋和梁帽为拉挤型材，迎风面壳体和背风面壳体通过自动铺带工艺铺层成型。本发明通过将迎风面壳体和背风面壳体改用自动铺带工艺制作的方法，与现有技术中的夹心风电叶片壳体结构相比，制造工艺质量控制简单化，制造成本低，结构稳定性好，强度更高。

Description

一种模块化风电叶片结构及其制作方法 技术领域
本发明涉及风电叶片技术领域，尤其涉及一种模块化风电叶片结构及其制作方法。
 背景技术
随着风电叶片的发展，开始逐步朝向大型化也分段化的方向推广，现有技术中，如何提高模块化风电叶片的安装结构强度成为了当前亟待解决的问题；
现有技术中，为了提高模块化风电叶片的结构强度，如授权公告号为CN216767624U的中国实用新型专利于2022年6月17日公开了一种大型化风电叶片连接结构，其为了在宽度方向增加原片的尺寸，将中间部设置具有内芯和加强层的夹心结构，以提高产品的结构强度；
然而发明人在实施上述方案时发现，上述夹心结构风电叶片壳体的制作和连接较为繁琐，使得叶片的加工效率大为降低，而且模块化的连接处的结构强度也无法得到保障。
 发明内容
鉴于以上技术问题中的至少一项，本发明提供了一种模块化风电叶片结构及其制作方法，采用结构和制作方法的改进以提高模块化风电叶片的结构强度和加工效率。
根据本发明的第一方面，提供一种模块化风电叶片结构，包括迎风面壳体、背风面壳体、T型筋和支撑件，所述迎风面壳体和背风面壳体相对拼合构成完整的叶片截面结构，所述T型筋沿叶片长度方向固定在所述迎风面壳体和背风面壳体上，并且在叶片宽度方向间隔布置有多条；所述支撑件包括腹板和连接在所述腹板两端的梁帽，两所述梁帽分别与所述迎风面壳体以及背风面壳体的内壁连接固定；
其中，所述T型筋和梁帽为拉挤型材，所述迎风面壳体和背风面壳体通过自动铺带工艺铺层成型。
在本发明的一些实施例中，还包括后缘梁，所述后缘梁设置在所述迎风面壳体和背风面壳体对接的后缘位置处，所述后缘梁的顶面与所述迎风面壳体后缘处的壳体贴合连接，所述后缘梁的底面与所述背风面壳体后缘处的壳体贴合连接。
在本发明的一些实施例中，所述迎风面壳体与背风面壳体在后缘处朝内弯折，并且与所述后缘梁的侧壁贴合连接。
在本发明的一些实施例中，所述后缘梁包括U型梁和连接在所述U型梁开口处的封板。
在本发明的一些实施例中，所述迎风面壳体和背风面壳体在前缘处均具有朝内弯折的翻边结构，且所述迎风面壳体的翻边结构和所述背风面壳体的所述翻边结构平行且相对设置，二者之间具有粘接结构胶层。
在本发明的一些实施例中，所述翻边结构的连接处在壳体内部覆盖有内增强层，所述翻边结构在外部覆盖有外增强层。
在本发明的一些实施例中，所述粘接结构胶层在两所述翻边结构的两端处溢出形成倒扣结构，且所述倒扣结构分别被所述内增强层和外增强层覆盖，所述内增强层和外增强层的两端均分别与所述迎风面壳体和背风面壳体连接固定。
在本发明的一些实施例中，所述T型筋包括底板和竖板，所述竖板垂直连接在所述底板的中心线上，所述底板与所述迎风面壳体或背风面壳体的内壁连接固定，所述竖板两侧的所述底板部分还覆盖有补强层。
在本发明的一些实施例中，所述迎风面壳体和背风面壳体的铺带材料为多层双轴玻纤布，所述腹板由玻纤布夹层PET泡沫构成。
根据本发明的第二方面，还提供了一种模块化风电叶片结构的制作方法，包括以下步骤：
在风电叶片模具中自动铺带成型迎风面壳体和背风面壳体，所述迎风面壳体和背风面壳体构成完整的叶片截面；
按设定位置铺放T型筋于所述迎风面壳体和背风面壳体的内壁上；
在所述迎风面壳体和背风面壳体二者中的一者上铺设支撑件和后缘梁；
在所述迎风面壳体和背风面壳体上铺设覆盖部分所述T型筋侧翼的补强层；
对铺设完成的迎风面壳体和背风面壳体分别进行整体真空灌注成型；
成型脱模后，将迎风面壳体和背风面壳体整体对接固定，且迎风面壳体和背风面壳体在后缘处通过后缘梁连接，在前缘处通过翻边结构粘接，且在前缘粘接处通过内增强层和外增强层补强。
本发明的有益效果为：本发明通过将迎风面壳体和背风面壳体改用自动铺带工艺制作的方法，与现有技术中的夹心风电叶片壳体结构相比，加工效率更高，结构强度更好，并且通过T型筋和支撑件中的梁帽采用拉挤型材的方式，进一步提高了制造效率和质量。
 附图说明
为了更清楚地说明本发明实施例或现有技术中的技术方案，下面将对实施例或现有技术描述中所需要使用的附图作简单地介绍，显而易见地，下面描述中的附图仅仅是本发明中记载的一些实施例，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据这些附图获得其他的附图。
图1为本发明实施例中模块化风电叶片结构的截面结构示意图；
图2为本发明实施例中模块化风电叶片结构的安装结构示意图；
图3为本发明实施例中在背风面壳体上安装T型筋和支撑件的结构示意图；
图4为本发明实施例中图1中的A处局部放大图；
图5为本发明实施例中后缘梁的结构示意图；
图6为本发明实施例中图1中的B处局部放大图；
图7为本发明实施例中图3中的C处局部放大图；
图8为本发明实施例中模块化风电叶片结构的制作方法步骤流程图。
 具体实施方式
下面将结合本发明实施例中的附图，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。
需要说明的是，当元件被称为“固定于”另一个元件，它可以直接在另一个元件上或者也可以存在居中的元件。当一个元件被认为是“连接”另一个元件，它可以是直接连接到另一个元件或者可能同时存在居中元件。本文所使用的术语“垂直的”、“水平的”、“左”、“右”以及类似的表述只是为了说明的目的，并不表示是唯一的实施方式。
除非另有定义，本文所使用的所有的技术和科学术语与属于本发明的技术领域的技术人员通常理解的含义相同。在本发明的说明书中所使用的术语只是为了描述具体的实施例的目的，不是旨在于限制本发明。本文所使用的术语“及/或”包括一个或多个相关的所列项目的任意的和所有的组合。
如图1至图7所示的模块化风电叶片结构，包括迎风面壳体1、背风面壳体2、T型筋3和支撑件4，迎风面壳体1和背风面壳体2相对拼合构成完整的叶片截面结构，这里需要指出的是，在本发明实施例中，叶片沿长度方向分为叶根模块、叶中模块和叶尖模块，迎风面壳体1和背风面壳体2相对拼合后构成的叶片截面结构为叶根、叶中或者叶尖部分的闭合形状；T型筋3沿叶片长度方向固定在迎风面壳体1和背风面壳体2上，并且在叶片宽度方向间隔布置有多条；如图1和图2中所示，T型筋3贴合在迎风面壳体1和背风面壳体2的内壁上并且沿着叶片的长度方向延伸，通过这种形式的设置，可以进一步提高叶片的结构强度；支撑件4包括腹板41和连接在腹板41两端的梁帽42，两梁帽42分别与迎风面壳体1以及背风面壳体2的内壁连接固定；这里还需要指出的是，在本发明实施例中，根据叶根、叶中和叶尖宽度的不同，设置不同数量的支撑件4和T型筋3，在本发明一些实施例中，叶尖采用双支撑件4一T型筋3的结构形式、叶中模块采用五支撑件4六T型筋3的结构、叶根采用五支撑件4六T型筋3的结构形式。具体的布置数量可以采用仿真分析的形式，来确定在满足强度需求时所需T型筋3和支撑件4的数量；
具体的，在本发明实施例中，T型筋3和梁帽42为拉挤型材，迎风面壳体1和背风面壳体2通过自动铺带工艺铺层成型。在具体进行加工时，在迎风面壳体1的模具和背风面壳体2的模具中通过自动铺带机进行铺设，通过这种形式的铺设，一方面取消了现有技术中的夹层结构，另一方面通过铺带机自动加工的方式，使得结构强度能够得到保障；而T型筋3与梁帽42采用拉挤的形式加工，也提高了加工的效率。
在上述实施例中，通过将迎风面壳体1和背风面壳体2改用自动铺带工艺制作的方法，与现有技术中的夹心结构相比，加工效率更高，结构强度更好，并且通过T型筋3和支撑件4中的梁帽42采用拉挤型材的方式，进一步提高了制造效率和质量。在进行加工是，所有的结构件和铺层均为提前预制，提高生产效率，通过模块化制造，缩短的了制造的周期，在本发明实施例中壳体为碳纤维增强基复合材料或者纤维增强复合材料，制造工艺质量控制简单化，制造成本低，结构稳定性好，强度更高。
如图1至图4中所示，在本发明实施例中，为了提高背风面壳体2和迎风面壳体1的连接强度并加强风电叶片在挥舞方向上的承载能力，还包括后缘梁5，后缘梁5设置在迎风面壳体1和背风面壳体2对接的后缘位置处，后缘梁5的顶面与迎风面壳体1后缘处的壳体贴合连接，后缘梁5的底面与背风面壳体2后缘处的壳体贴合连接。进一步地，如图4中所示，迎风面壳体1与背风面壳体2在后缘处朝内弯折，并且与后缘梁5的侧壁贴合连接。通过这种设置，使得后缘梁5的上下面以及外侧面均与迎风面壳体1或者背风面壳体2连接，进而起到了加强支撑和提高连接强度的效果。
为了便于后缘梁5的加工，如图5中所示，后缘梁5包括U型梁51和连接在U型梁51开口处的封板52。通过U型梁51的设置，便于U型梁51的侧壁与迎风面壳体1或者背风面壳体2的随型，进而实现更加紧密的接触以提高连接效果。
在本发明实施例中，为了提高壳体在前缘部分的连接强度，如图6中所示，迎风面壳体1和背风面壳体2在前缘处均具有朝内弯折的翻边结构11，且迎风面壳体1的翻边结构11和背风面壳体2的翻边结构11平行且相对设置，二者之间具有粘接结构胶层12。通过翻边结构11的设置，使得迎风面壳体1和背风面壳体2在前缘处的连接面积增加，并且通过朝内翻折的形式，对叶片的外形没有影响，通过上述结构形式的设置，使得粘接面积增加，进而增强了连接型结构强度。
请继续参照图6，在本发明实施例中，为了进一步提高迎风面壳体1和背风面壳体2在前缘位置时的连接结构强度，翻边结构11的连接处在壳体内部覆盖有内增强层13，翻边结构11在外部覆盖有外增强层14。通过内增强层和外增强层的设置，可以提高翻边结构11的连接可靠性，减少二者之间开裂的可能。
在本发明实施例中，为了进一步提高内增强层13和外增强层14的连接可靠性，如图6中所示，粘接结构胶层12在两翻边结构11的两端处溢出形成倒扣结构12a，且倒扣结构12a分别被内增强层13和外增强层14覆盖，内增强层13和外增强层14的两端均分别与迎风面壳体1和背风面壳体2连接固定。通过这种结构的设置，使得粘接结构胶层12的两端形成帽盖结构，既增加了两层翻边结构11的粘接稳定性，又提高了内加强层和外加强层的粘接强度。
在本发明实施例中，关于T型筋3的具体结构如图7中所示，T型筋3包括底板31和竖板32，竖板32垂直连接在底板31的中心线上，底板31与迎风面壳体1或背风面壳体2的内壁连接固定，竖板32两侧的底板31部分还覆盖有补强层33。在具体进行连接时，首先使用激光定位将T型筋3的底板31贴合在迎风面壳体1和背风面壳体2上，然后再铺放补强层33，如图7中所示，在具体进行补强层33的铺放时，将补强层33的两侧搭接在T型筋3的底板31上，在通过铺放真空袋进行抽真空灌注树脂胶的方式使得壳体固化成型。此外，这里还需要指出的是，在本发明一些实施例中，迎风面壳体1和背风面壳体2的铺带材料为多层双轴玻纤布，腹板41由玻纤布夹层PET泡沫构成。
在本发明实施例中，还提供了一种如图8中所示的模块化风电叶片结构的制作方法，包括以下步骤：
S10：在风电叶片模具中自动铺带成型迎风面壳体1和背风面壳体2，迎风面壳体1和背风面壳体2构成完整的叶片截面；在具体铺放时，通过自动铺带机在迎风面壳体1和背风面壳体2的模具上铺设成型；在本发明实施例中，通过自动铺带机铺设的方式，替代了现有技术中的夹层结构，大大提高了壳体的加工效率和结构强度；
S20：按设定位置铺放T型筋3于迎风面壳体1和背风面壳体2的内壁上；在具体进行铺放时，通过激光定位的方式进行，进而可以保证铺放的精度，具体可以是通过激光在迎风面壳体1和背风面壳体2的内壁上投射出需要铺放T型筋3或者梁帽42的具体区域，然后将T型筋3固定在激光投射区域内；此外，这里还需要指出的是，在本发明一些实施例中，为了进一步提高定位精度，在梁帽42上还设置两腹板41粘接凹槽结构。
S30：在迎风面壳体1和背风面壳体2二者中的一者上铺设支撑件4和后缘梁5；在具体进行铺放时，后缘梁5可以粘接在迎风面壳体1上，也可以粘接在背风面壳体2上，本领域技术人员可以根据需要进行选择。
S40：在迎风面壳体1和背风面壳体2上铺设覆盖部分T型筋3侧翼的补强层33；如图7中所示，在具体进行补强层33的铺放时，需要将补强层33的两侧搭接在T型筋3的底板31上，并且抵接在T型筋3的竖板32底部；
S50：对铺设完成的迎风面壳体1和背风面壳体2分别进行整体真空灌注成型；整体真空灌注就是先套设与壳体随型的真空袋，然后一边灌注树脂胶一边进行抽真空，从而使得树脂胶渗透至各个角落，然后进行固化烘干，通过这种方式的设置，提高了粘接强度和壳体的整体结构强度；
S60：成型脱模后，将迎风面壳体1和背风面壳体2整体对接固定，且迎风面壳体1和背风面壳体2在后缘处通过后缘梁5连接，在前缘处通过翻边结构11粘接，且在前缘粘接处通过内增强层13和外增强层14补强。在连接完成以后，在对前后缘进行修型、刮腻子、打磨、喷漆等作业，然后等待转运。
本行业的技术人员应该了解，本发明不受上述实施例的限制，上述实施例和说明书中描述的只是说明本发明的原理，在不脱离本发明精神和范围的前提下，本发明还会有各种变化和改进，这些变化和改进都落入要求保护的本发明范围内。本发明要求保护范围由所附的权利要求书及其等效物界定。

Claims (5)

  1.  一种模块化风电叶片结构，其特征在于，该叶片在长度方向分为叶根模块、叶中模块和叶尖模块，该结构包括迎风面壳体、背风面壳体、T型筋和支撑件，所述迎风面壳体和背风面壳体相对拼合构成完整的叶片截面结构，所述T型筋沿叶片长度方向固定在所述迎风面壳体和背风面壳体上，并且在叶片宽度方向间隔布置有多条，所述T型筋贴合在所述迎风面壳体和背风面壳体的内壁上；所述支撑件包括腹板和连接在所述腹板两端的梁帽，两所述梁帽分别与所述迎风面壳体以及背风面壳体的内壁连接固定；
    其中，所述T型筋和梁帽为拉挤型材，所述迎风面壳体和背风面壳体通过自动铺带工艺铺层成型；
    还包括后缘梁，所述后缘梁设置在所述迎风面壳体和背风面壳体对接的后缘位置处，所述后缘梁的顶面与所述迎风面壳体后缘处的壳体贴合连接，所述后缘梁的底面与所述背风面壳体后缘处的壳体贴合连接；所述迎风面壳体与背风面壳体在后缘处朝内弯折，并且与所述后缘梁的侧壁贴合连接；
    所述迎风面壳体和背风面壳体在前缘处均具有朝内弯折的翻边结构，且所述迎风面壳体的翻边结构和所述背风面壳体的所述翻边结构平行且相对设置，二者之间具有粘接结构胶层；
    所述翻边结构的连接处在壳体内部覆盖有内增强层，所述翻边结构在外部覆盖有外增强层；
    所述粘接结构胶层在两所述翻边结构的两端处溢出形成倒扣结构，且所述倒扣结构分别被所述内增强层和外增强层覆盖，所述内增强层和外增强层的两端均分别与所述迎风面壳体和背风面壳体连接固定。
  2.  根据权利要求1所述的模块化风电叶片结构，其特征在于，所述后缘梁包括U型梁和连接在所述U型梁开口处的封板。
  3.  根据权利要求1所述的模块化风电叶片结构，其特征在于，所述T型筋包括底板和竖板，所述竖板垂直连接在所述底板的中心线上，所述底板与所述迎风面壳体或背风面壳体的内壁连接固定，所述竖板两侧的所述底板部分还覆盖有补强层。
  4.  根据权利要求1所述的模块化风电叶片结构，其特征在于，所述迎风面壳体和背风面壳体的铺带材料为多层双轴玻纤布，所述腹板由玻纤布夹层PET泡沫构成。
  5.  一种如权利要求1至4中任一项所述的模块化风电叶片结构的制作方法，其特征在于，包括以下步骤：
    在风电叶片模具中自动铺带成型迎风面壳体和背风面壳体，所述迎风面壳体和背风面壳体构成完整的叶片截面；
    按设定位置铺放T型筋于所述迎风面壳体和背风面壳体的内壁上；
    在所述迎风面壳体和背风面壳体二者中的一者上铺设支撑件和后缘梁；
    在所述迎风面壳体和背风面壳体上铺设覆盖部分所述T型筋侧翼的补强层；
    对铺设完成的迎风面壳体和背风面壳体分别进行整体真空灌注成型；
    成型脱模后，将迎风面壳体和背风面壳体整体对接固定，且迎风面壳体和背风面壳体在后缘处通过后缘梁连接，在前缘处通过翻边结构粘接，且在前缘粘接处通过内增强层和外增强层补强。
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