Normalization Process Technique of a Small Composite Wind Turbine Blades

小型複材風力機葉片之標準化製程技術

張瑞榮(Rang-Rong Chang) ； 蘇承佑(Cheng-Yu Su)

《中華科技大學學報》 47期 (2011/04) Pp. 1-20

https://doi.org/10.7095/JCUST.201104.0001

摘要

由於複合材料在風力發電的應用實際上就是在風力發電機葉片上的開發，此葉片的外形流場設計、結構應力分析、材料選用、製造方法、結構性能測試及產品實驗必須緊密結合，尤其風力發電機葉片之破損更值得注意，葉片破損區易產生應力集中及疲勞強度問題，而要能預測複材破損結構疲勞強度、壽命及可能修補元件受損模式，才能確認成功可靠的修補製程。在本研究中，為了產品減重、強度增強及修補結構一致性等考量因素，我們將風力機葉片利用標準化製程技術成為輕巧之多功能型複合材料發泡三明治補強結構。結構中包括有保麗龍發泡芯材層、玻璃纖維覆蓋層及功能性嵌入物，同時將三者預成形物置於葉片模具內施以樹脂轉注成形法及模壓成形法製程技術予以一體硬化成形。其中嵌入物結構更包括具有根部補強層、I-beam補強樑、LED警示燈泡、避雷器防雷擊、金屬接頭及破損之修補片等設計為具有多重監控功能及材料機械行為，此設計最主要功能是抵抗風力機葉片懸掛運轉所承受之最大彎曲應力集中現象。最後，在理論分析方面，利用有限單元分析軟體ANSYS來分析補強結構應力分佈及應用破壞及量測實驗如彎曲破壞試驗、模態頻譜測試等來驗證說明其風力機葉片補強及修補結構體之功能性、完整性。

關鍵字

風力機葉片 ； 標準化製程 ； 樹脂轉注成形法 ； 模壓成形法 ； 發泡三明治補強結構 ； 保麗龍芯材層 ； 嵌入物 ； 修補片

並列摘要

Advancements in composite material technology have spurred an increase in the use of composites in modern wind turbine's blades structure. In addition to the desirable high strength, low-weight features of these material systems, the enhanced fatigue strength and damage tolerance has made composites particularly attractive for advanced structural applications. In this paper, the normalization process technique of the resin transfer molding (RTM) and compression molding was used to manufacture composite wind turbine blade by the stacking of pieces of glass-fiber fabrics、 expandable polystyrene (EPS) foam and insert parts in an interior pressure mold. The blade perform is a composite foam-filled sandwich structure, where the interior is an EPS foam layer while the exterior is coated with main fibre layer、root reinforcing fiber layer and insert parts. The insert parts investigated were I-beam、LED、conductor、root connection joint and repair patch. This is designed to provide the maximum bending stiffness in the flexure to resist the stress concentration of the composite wind turbine blade. This research also will be used to develop adhesive bonding repair techniques for life extension of damaged components in wind turbine blade. A number of composite foam-filled sandwich wind turbine blade constructions were fabricated to demonstrate the feasibility and applications of the proposed manufacturing method.

並列關鍵字

Wind turbine blade ； Normalization process technique ； Resin transfer molding ； Compression molding ； Composite foam-filled sandwich structure ； EPS foam ； insert parts ； repair patch