CN102814996A - Preparing method of hybrid composite wing spar of large-scale wind power blade - Google Patents
Preparing method of hybrid composite wing spar of large-scale wind power blade Download PDFInfo
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- CN102814996A CN102814996A CN2012103044977A CN201210304497A CN102814996A CN 102814996 A CN102814996 A CN 102814996A CN 2012103044977 A CN2012103044977 A CN 2012103044977A CN 201210304497 A CN201210304497 A CN 201210304497A CN 102814996 A CN102814996 A CN 102814996A
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Abstract
The invention discloses a preparing method of a hybrid composite wing spar of a large-scale wind power blade. The preparing method comprises the following steps of firstly, preprocessing a die; then, paving and covering distribution medium, demolding cloth, a perforated isolating membrane, an enhancing material performing body, the perforated isolating membrane and the demolding cloth on the surface of the die from bottom to top; paving a first ventilated felt which is provided with multiple semi-permeable ventilating connectors; forming a first layer closing die cavity by covering a first flexible vacuum bag membrane and a flexible semi-permeable membrane on the surface of the die by a sealing tape after connecting the first flexible vacuum bag membrane and the flexible semi-permeable membrane into a whole, completely sealing and coating the first flexible vacuum bag membrane and the flexible semi-permeable membrane by using a second flexible vacuum bag membrane, and forming a second layer closing die cavity; connecting the semi-permeable ventilating connectors to a vacuum pumping system and an glue injection system for injecting glue, and controlling a flow direction of matrix resin so as to realize the complete dipping in glue injection; and finally, obtaining a wing spar through solidifying, demolding and reconditioning. The preparing method disclosed by the invention has the advantages that the cost is low, the quality is stable, the technology efficiency is high, the product quality is good, and the like.
Description
Technical field
The invention belongs to the manufacturing processing technique field of wind power plant, relate in particular to a kind of preparation method of wind power generation blade spar of special material making.
Background technology
The typical structure of larger wind turbines blade comprises pneumatic housing that two fiber-reinforced polymers are processed and the shear web that two pneumatic housing are coupled together.Between two pneumatic housing, connect through bonding way between pneumatic housing and the shear web.The typical method of preparation blade pneumatic housing and shear web is a vacuum perfusion process.When vacuum perfusion process prepared the blade pneumatic housing, sandwich materials such as reinforcing materials such as fiber and fabric, foam and cork wood were laid in the mould according to shop layer design and cover a vacuum bag.Through producing vacuum in the cavity between mould inner surface and vacuum bag, resin is inhaled into and is full of the cavity that includes fibrous material.Employed typical polymers mainly is polyester or epoxy resin, and employed typical fibers material mainly is the fabric of different shape.Fortifying fibre is often based on glass fibre, and carbon fiber also begins in the maximization composite material wind-power blade, to use as a kind of high-performance fiber.The ratio of rigidity glass fibre of carbon fiber is big, and the adding of carbon fiber can obtain higher rigidity and lighter weight.Yet, because the price of carbon fiber is expensive more than glass fibre, this drawbacks limit carbon fiber being widely used on large-scale composite material wind-power blade.
The main component of pneumatic housing is a spar, and spar is the primary load bearing parts of large-scale composite material wind-power blade, is that typical large scale, thick cross-section fibers strengthen base layer of resin plywood (thick cross section composite laminated plate) member.The various embodiments that propose the assorted fibre reinforced composite material wind electricity blade have been arranged in the prior art, but the blade cost increase that causes because of the carbon fiber increase makes it on the existing market, still be difficult to bear and promote.In addition; The power output of wind turbine receives the influence of outside natural environments such as wind speed easily; For the wind turbine of rated power, how to weaken influence, the maximization of realization power output of external environment condition, be the important topic that the wind turbine development faces.According to the power output of blower fan and square principle that is directly proportional of rotor diameter, can eliminate the influence of external condition through the length of lengthening rated power blade, increase the power output of wind turbine.But the lengthening length of blade can bring following problem: 1) leaf quality increases by the cube of length, has a strong impact on the operation and the fatigue life of blower fan; 2) the lengthening length of blade will make blade center of gravity move outward, can cause vibration frequency of blade to increase, influence operation and service life, even the danger that has the resonance of producing to destroy; 3) behind the lengthening length of blade, limit wind carries down blade-tip deflection and increases, the risk that has the collision pylon to destroy.
Distinguish and independently defined the hybrid composite spar of blade among the present invention first, the hybrid composite spar is meant that glass fibre/carbon fiber hybrid strengthens thick cross section composite material blade spar, typically applies to the extended type composite material wind-power blade.Hybrid composite spar moulding preparation has the difficult point of two aspects at least: on the one hand; Blade spars is large scale, thick cross section composite laminated plate; And the length of large-scale wind electricity blade spars rose to more than 60 meters by twenties meters over past ten years; The difficult point of thick cross section composite element moulding is that the thickness direction permeability is lower, resin is difficult to thorough impregnation, so is difficult to guarantee the even impregnation of fibers reinforcing material of resin in the whole dimension scope on the technology; On the other hand, with respect to glass fibre, the carbon fiber diameter is less; Fibre gap is little, and the fiber total surface area is big under the equal volume, and carbon fiber is difficult to dipping evenly more than glass fibre; And the thick cross-sectional layers plywood of the existing glass fibre of hybrid composite spar, the thick cross-sectional layers plywood of carbon fiber is arranged again, also have carbon fibers/fiberglass to mix thick cross-sectional layers plywood; The slipper dip speed of resin on different fibre sections is different; Cause easily flooding inhomogeneous, form defective such as starved, technology controlling and process difficulty, quality of item less stable.
The most general cost effective method of large-scale composite material wind-power blade spar moulding can adopt vacuum perfusion process equally at present; But traditional vacuum perfusion process only is suitable for moulding and prepares pure glass fibre and strengthen thick cross section blade spars; Adopt the above-mentioned hybrid composite spar of vacuum perfusion process moulding often can only guarantee that the abundant impregnated glass fiber of resin strengthens part, and can not guarantee the thorough impregnation of whole member.Therefore, the method that moulding at present prepares the hybrid composite spar adopts the prepreg forming method more, but the prepreg forming method is the multistep forming method, and prepreg needs particular surroundings to store, and cost is higher, and is also higher to the requirement of mould in addition.
Blade maximizes and the needs of high-output power in order to adapt to; How effectively to solve the low-cost moulding problem of hybrid composite spar; It is the key of carbon fiber successful Application on composite material wind-power blade; Also be the difficult problem that extended type, the development of maximization composite material wind-power blade face, the preparation moulding process program of exploitation and development hybrid composite spar will have important practical significance.
Summary of the invention
The technical problem that the present invention will solve is the deficiency that overcomes prior art; Provide that a kind of cost is low, steady quality evenly, the preparation method of the large-scale wind electricity blade hybrid composite spar of high, the good product quality of one step integral forming, process efficiency; After the spar that this preparation method makes is applied to the large-scale wind electricity blade; Can control cost and guarantee under the prerequisite of wind electricity blade quality, the length of wind electricity blade is increased, power output improves.
For solving the problems of the technologies described above; The technical scheme that the present invention proposes is a kind of preparation method of large-scale wind electricity blade hybrid composite spar; Said hybrid composite spar comprises the spar covering layer that the spar laminboard layer is outer with being coated on the spar laminboard layer; Said spar laminboard layer is mainly by near the glass fibre laminboard layer of root of blade, form near the carbon fiber laminboard layer of blade tip and transition region three parts that connect glass fibre laminboard layer and carbon fiber laminboard layer, and the preparation method of said spar mainly may further comprise the steps:
(1) mould preliminary treatment: at first clear up mould, spraying releasing agent and gel coat;
(2) shop cover material material: reinforcing material preform and the moulding auxiliary material required according to the designing requirement cutting of spar; Said reinforcing material preform is (to comprise covering layer reinforcing material and following covering layer reinforcing material by spar covering layer reinforcing material; And all adopt glass fabric) and spar laminboard layer reinforcing material composition; Spar laminboard layer reinforcing material comprises glass fabric near root of blade, forms near the carbon fibre fabric of blade tip and the assorted fibre fabric that connects glass fabric and carbon fibre fabric; The moulding auxiliary material comprise permeable medium, release cloth, barrier film with holes, airfelt and vacuum bag film, through the pretreated die surface of step (1) from lower to upper successively the shop cover permeable medium, release cloth, barrier film with holes, reinforcing material preform, barrier film with holes and release cloth; Lay first airfelt on release cloth corresponding above the glass fibre laminboard layer region then, the said first airfelt upper edge spar length direction is provided with a plurality of semi permeability ventilating joints at interval;
(3) the ground floor closed mould cavity is set: on horizontal plane, be projected as the line of demarcation with the boundary line of said glass fibre laminboard layer and said transition region; The first flexible vacuum bag film coating mould is used near a side of glass fibre laminboard layer in the line of demarcation; Flexible pellicle coating mould is used near a side of transition region in the line of demarcation; The first flexible vacuum bag film and flexible pellicle connect into whole back and cover on die surface formation ground floor closed mould cavity through sealant tape at the place, line of demarcation, said reinforcing material preform and moulding auxiliary material are covered by in the ground floor closed mould cavity;
(4) second layer closed mould cavity is set: lay second airfelt above described flexible pellicle, the said second airfelt upper edge spar length direction is provided with a plurality of ventilating joints at interval; Cover on die surface and the first flexible vacuum bag film and flexible pellicle are sealed coating fully with the second flexible vacuum bag film then, form second layer closed mould cavity, second airfelt and ventilating joint are in the second layer closed mould cavity;
(5) connect external equipment: all semi permeability ventilating joint and ventilating joint are connected to pumped vacuum systems, simultaneously the injecting glue system are connected to the gum-injecting port that is arranged in the ground floor closed mould cavity;
(6) vacuum injecting glue: close the injecting glue system; Open all semi permeability ventilating joint and ventilating joint then; Discharge the gas in ground floor closed mould cavity and the second layer closed mould cavity through pumped vacuum systems; Make and reach negative pressure of vacuum and ability stable maintenance in ground floor closed mould cavity and the second layer closed mould cavity; Open the injecting glue system again and begin to inject matrix resin and be positioned at the reinforcing material preform of ground floor closed mould cavity, close semi permeability ventilating joint and ventilating joint in the injecting glue process in succession, realize the thorough impregnation of matrix resin the reinforcing material preform with the flow direction of control matrix resin with dipping;
(7) curing molding and post processing: the vacuum injecting glue begins to be cured moulding after accomplishing; Keep vacuum in the die cavity until completion of cure in the curing molding process, solidify the large-scale wind electricity blade hybrid composite spar that carries out obtaining after the demoulding, finishing and the cleaning global formation after accomplishing.
Among the preparation method of above-mentioned large-scale wind electricity blade hybrid composite spar; Said flexible pellicle is preferably that gas can see through but the impervious thin-film material of matrix resin glue (this thin-film material is generally double-layer structure, belongs to the product that those skilled in the art can commercial and conventional selection).
Among the preparation method of above-mentioned large-scale wind electricity blade hybrid composite spar, said semi permeability ventilating joint is preferably gas and can sees through but the impervious ventilating joint of matrix resin glue.The structure optimization of said semi permeability ventilating joint comprises outer rigid housing; The bottom of outer rigid housing is coated by permeable medium; Be provided with gas channel in the shell; The bottom section of gas channel is provided with obturator, and obturator is mainly by pellicle, permeable medium, pellicle, airfelt and the permeable medium of stack are formed successively from bottom to top; Be tightly connected between the inwall of obturator and outer rigid housing; Be provided with valve in the gas channel of obturator top.
Among the preparation method of above-mentioned large-scale wind electricity blade hybrid composite spar, said ventilating joint is preferably gas and all permeable ventilating joint of matrix resin glue.The structure optimization of said ventilating joint comprises outer rigid housing; The bottom of outer rigid housing is coated by permeable medium; Be provided with gas channel in the shell, the bottom section of gas channel is provided with obturator, and obturator is mainly by permeable medium, airfelt and the permeable medium of stack are formed successively from bottom to top; Be tightly connected between the inwall of obturator and outer rigid housing; Be provided with valve in the gas channel of obturator top.
Among the preparation method of above-mentioned large-scale wind electricity blade hybrid composite spar, said semi permeability ventilating joint is being preferably 2m～3m along the spacing on the spar length direction.Said ventilating joint is being preferably 1m～2m along the spacing on the spar length direction.
The preparation method of above-mentioned large-scale wind electricity blade hybrid composite spar; In the said vacuum injecting glue step; Closing semi permeability ventilating joint and ventilating joint in succession specifically is meant: an end that from mould, is set to root of blade is to an end that is set to blade tip, closeall one by one semi permeability ventilating joint and ventilating joint.The shut-in time of each semi permeability ventilating joint is preferably 1min～2min at interval, and the shut-in time of each ventilating joint is preferably 2min～3min at interval.
The preparation method of above-mentioned large-scale wind electricity blade hybrid composite spar; Reinforcing material in the said transition region is the assorted fibre fabric, and its arrangement in the reinforcing material preform is preferably: strengthen gradual change type by whole glass fibres on the direction from said glass fabric to carbon fibre fabric and carry out the transition to whole carbon fibers enhancings.Said gradual change type transition specifically is meant following any transient mode:
(1) said glass fabric forms the most advanced and sophisticated and wedging of a transition and advances in the V-shaped groove that said carbon fibre fabric forms in transition region in said transition region; Perhaps,
(2) said carbon fibre fabric forms the most advanced and sophisticated and wedging of a transition and advances in the V-shaped groove that said glass fabric forms in transition region in said transition region.
Glass fabric in the preparation method of above-mentioned large-scale wind electricity blade hybrid composite spar, said transition region and carbon fibre fabric can also be to realize the transition handing-over through weaving manner in the layer.Weaving manner is meant in the said layer: with the mode that glass fabric termination in the transition region and carbon fibre fabric termination adopt interlaminar hybrid alternately to weave, the carbon fiber that extends into transition region in the glass fibre that extends into transition region in the glass fibre laminboard layer and the carbon fiber laminboard layer is linked together.
The preparation method of above-mentioned large-scale wind electricity blade hybrid composite spar; Glass fabric in the said transition region preferably realizes that through the interlayer suture way transition joins with carbon fibre fabric, make extend into transition region in the glass fabric that extends into transition region in the glass fibre laminboard layer and the carbon fiber laminboard layer the carbon fibre fabric fixed overlay together.The suture that said interlayer stitching is adopted is preferably one or more in aramid fiber yarn, quartz fibre yarn, the glass fiber yarn.
The preparation method of above-mentioned large-scale wind electricity blade hybrid composite spar; The thickness of said spar covering layer is preferably 2mm～3mm, and the used reinforcing material of spar covering layer is preferably the glass fibre single shaft to cloth, the axial cloth of Glass Fibre Double and/or glass fibre three axial cloth.Glass fabric in the said spar laminboard layer is preferably surface density at 1000g/m
2Above single shaft is to fabric, and the carbon fibre fabric in the said spar laminboard layer is preferably surface density at 600g/m
2Above single shaft is to fabric.
Compared with prior art; The invention has the advantages that: at first; The vacuum impregnating colloid system that the present invention adopts vacuum bag film, pellicle, semi permeability ventilating joint and ventilating joint to form; Can realize effective control of resin liquid flow direction, this resin flows control for the composite liquid moulding technology provides a kind of simple and effective method; Secondly; Through resin liquid flow control method of the present invention; It can realize low-permeability multi-layer fiber Fabric preform body (for example thick cross section pure carbon fiber spar) and become the one step integral forming of permeability multi-layer fiber Fabric preform body (for example thick cross section assorted fibre strengthens spar), for low-permeability or the one step integral forming that becomes permeability large-sized composite material structural member provide effective ways.In addition, preparation method of the present invention is not only easy and simple to handle, environmental protection property is good, and cost is low.
After preparation method of the present invention being applied to the preparation of large-scale wind electricity blade; Reduced the production cost of application of carbon fibres on the one hand; The ability to bear that meets current market; (also being prior aspect) efficiently solves the stability of wind electricity blade work on the other hand, prolonged the service life of blade.Generally speaking; The extended large-scale composite material wind-power blade that preparation method of the present invention makes is under the prerequisite that pneumatic structure no change, weight do not increase, position of centre of gravity does not change, blade-tip deflection does not increase, cost does not increase; Can the length of blade of rated power be extended 5%～20%, and can keep same power (rated power), same aerofoil profile (pneumatic aerofoil profile); According to the power output of blower fan and square principle that is directly proportional of rotor diameter, can the power output of wind turbine be improved 10%～20%.Under certain stiffness, technical scheme of the present invention can also reduce the dead load of wind electricity blade, reduces the dynamic load of blade pneumatic housing and root of blade simultaneously; Through changing and adjust the content and the distribution of carbon fiber in transition region and the outer end; Can make the rigidity and the natural frequency respective change of blade; Thereby realize that rigidity and natural frequency are optimum down corresponding to specified conditions, have improved applicability, flexibility and the operability of blade of the present invention greatly.It is thus clear that the large-scale wind electricity blade of the present invention's preparation has better market prospect.
Description of drawings
Fig. 1 is the structural representation of the wind turbine blade in the embodiment of the invention.
Fig. 2 is the profile at A-A place among Fig. 1.
Fig. 3 is the interval distribution schematic diagram of embodiment of the invention central spar laminboard layer on the length of blade direction.
Fig. 4 is the structural representation of embodiment of the invention central spar laminboard layer transition region gradual change type transient mode one.
Fig. 5 is the structural representation of embodiment of the invention central spar laminboard layer transition region gradual change type transient mode two.
Fig. 6 is the principle sketch that adopts weaving manner in the layer in the embodiment of the invention.
Fig. 7 is the principle sketch that adopts the interlayer suture way in the embodiment of the invention.
Fig. 8 realizes the structural representation that transition connects for stitching mode between blade gradual change type transient mode one binder course in the embodiment of the invention.
Fig. 9 realizes the structural representation that transition connects for stitching mode between blade gradual change type transient mode two binder courses in the embodiment of the invention.
Figure 10 is the location map of blade transition region on blade in the embodiment of the invention.
Figure 11 is the schematic diagram of embodiment of the invention middle period piece preparation method.
Figure 12 is the structural representation of semi permeability ventilating joint in the embodiment of the invention.
Figure 13 is the structural representation of ventilating joint in the embodiment of the invention.
Marginal data:
1, pneumatic housing; 11, covering layer; 12, obturator; 2, shear web; 3, spar; 31, spar laminboard layer; 311, glass fibre laminboard layer; 312, transition region; 313, carbon fiber laminboard layer; 32, spar covering layer; 33, reinforcing material preform; 331, glass fabric; 332, assorted fibre fabric; 333, carbon fibre fabric; 334, spar covering layer reinforcing material; 34, permeable medium; 35, release cloth; 36, barrier film with holes; 37, first airfelt; 371, second airfelt; 38, the first flexible vacuum bag film; 381, flexible pellicle; 382, the second flexible vacuum bag film; 39, sealant tape; 4, glass fibre; 5, carbon fiber; 6, mould; 61, semi permeability ventilating joint; 62, ventilating joint; 63, outer rigid housing; 64, pellicle; 65, airfelt; 66, valve; 7, pumped vacuum systems; 71, vavuum pump; 8, injecting glue system; 81, gum-injecting port; 82, resin bucket.
The specific embodiment
Below in conjunction with Figure of description and specific embodiment the present invention is further described.
Embodiment:
A kind of like Fig. 1, extended large-scale composite material wind turbine blade shown in Figure 2; The monnolithic case of this blade is as shown in Figure 1; Visible by Fig. 2; Blade includes pneumatic housing 1 and is located at the shear web 2 in pneumatic housing 1 inner chamber, and (the present embodiment obturator is that the density that Mead China composite Co., Ltd provides is 63.0 ± 6 kg/m to pneumatic housing 1 main obturator 12 by upper and lower spar that is arranged in the middle part 3 and spar 3 both sides
3PVC foam and density be 150 ± 20 kg/m
3Balsa wood) form, pneumatic housing 1 periphery is coated with covering layer 11, upper and lower spar 3 connects through shear web 2.
Spar 3 in the present embodiment comprises spar laminboard layer 31 and the spar covering layer 32 that is coated on outside the spar laminboard layer 31; As shown in Figure 3; Spar laminboard layer 31 is mainly by near the glass fibre laminboard layer 311 of root of blade, near the carbon fiber laminboard layer 313 of blade tip and connect glass fibre laminboard layer 311 and form with transition region 312 3 parts of carbon fiber laminboard layer 313; Glass fibre laminboard layer 311 is mainly by glass fiber reinforced polymer (GFRP; Glass Fiber Reinforced Polymer) processes; Carbon fiber laminboard layer 313 is mainly by carbon fiber reinforced polymer (CFRP; Carbon Fiber Reinforced Polymer) process, transition region 312 mainly strengthens polymer by glass-carbon assorted fibre to be processed, and the concrete arrangement of the glass-carbon assorted fibre in the transition region 312 is: strengthen gradual change type by whole glass fibres on the direction from glass fibre laminboard layer 311 to carbon fiber laminboard layer 313 and carry out the transition to whole carbon fibers enhancings.Because general hard 3～4 times on carbon fiber than glass fibre; The stress of transition region 312 is concentrated the risk that often causes easily that whole blade is destroyed; The transition region of the application of the invention design; Can avoid undergoing mutation in the transition region of blade stiffness between glass fibre and carbon fiber, so avoid border surface between carbon fiber and the glass fibre to be in bearing bigger dynamically or stress occurs during static stress and concentrate.
Shown in figure 10, in the wind electricity blade of present embodiment, the length of glass fibre laminboard layer 311 is 50% (45%～55% all can, the length L of present embodiment central spar is 55m) of whole spar 3 length L; The length of transition region 312 is 20% (15%～25% all can) of whole spar 3 length L; The length of carbon fiber laminboard layer 313 is 30% (25%～35% all can) of whole spar 3 length.Wherein, the position of transition region 312 is laid in apart from root of blade 3
l/ 2 to 5
l/ 2 zone, wherein,
lDistance for root of blade to blade center of gravity.The length ratio of each part and the each several part position distribution relation in whole spar 3 in the spar laminboard layer 31; Be important improvement and the optimization that we have done through repetition test; Under the preferred condition of this kind; Not only help improving blade integral intensity and performance, and can farthest reduce cost.
Figure 11 shows the one step integral forming method of above-mentioned large-scale wind electricity blade assorted fibre enhancing spar in the present embodiment, specifically may further comprise the steps:
(1) mould preliminary treatment: at first clear up mould, repair smoothly, spray releasing agent then, spray gel coat again.
(2) shop cover material material: the reinforcing material preform 33 and moulding auxiliary material required according to the designing requirement cutting spar in the present embodiment 3; Reinforcing material preform 33 is made up of spar covering layer reinforcing material 334 and spar laminboard layer reinforcing material, and spar laminboard layer reinforcing material comprises that (present embodiment is selected surface density 1200g/m for use for glass fabric 331 near root of blade
2The glass single shaft to woven cloth), (present embodiment is selected surface density 600g/m for use near the carbon fibre fabric 333 of blade tip
2The carbon fiber single shaft is to woven cloth) and the assorted fibre fabric 332 that connects glass fabric 331 and carbon fibre fabric 333 form; The moulding auxiliary material comprise that ((the R85PA66 type release cloth that drop High Seience Technology Co., Ltd. in Shanghai produces, surface density is 85g/m for permeable medium 34 (being the water conservancy diversion net), release cloth 35
2)), barrier film with holes 36, airfelt (comprising first airfelt and second airfelt) and vacuum bag film (the vacuum bag film of present embodiment is the Vacfilm400Y26100 type vacuum bag film that French Aerorac company produces, and comprises the first flexible vacuum bag film and the second flexible vacuum bag film); Through the pretreated mould of step (1) 6 surfaces from lower to upper successively the shop cover permeable medium 34, release cloth 35, barrier film with holes 36, reinforcing material preform 33, barrier film with holes 36 and release cloth 35; Wherein reinforcing material preform 33 is from lower to upper successively by covering layer reinforcing material, spar laminboard layer reinforcing material and last covering layer reinforcing material are formed down; Lay first airfelt 37, the first airfelt 37 upper edge spars 3 length directions are provided with a plurality of semi permeability ventilating joints 61 at interval (spacing are 2m～3m) on release cloth 35 corresponding above glass fibre laminboard layer 311 regions then.
(3) the ground floor closed mould cavity is set: on horizontal plane, be projected as the line of demarcation with the boundary line of glass fibre laminboard layer 311 and transition region 312; The first flexible vacuum bag film, 38 coating moulds 6 are used near a side of glass fibre laminboard layer 311 in the line of demarcation; Flexible pellicle 381 coating moulds (the QL836 pellicle that the pellicle of present embodiment provides as Shanghai drop High Seience Technology Co., Ltd. is used near a side of transition region 312 in the line of demarcation; Thickness is 0.35mm); The first flexible vacuum bag film 38 uses sealant tape 39 to glued joint with flexible pellicle 381 at joint and forms a hybrid films integral body that covers the spar enhancement region fully; Cover on mould 6 surfaces through sealant tape 39 then and form the ground floor closed mould cavity, reinforcing material preform 33 all is covered by in the ground floor closed mould cavity with the moulding auxiliary material.In the present embodiment, the first flexible vacuum bag film 38 is thin-film materials that liquids and gases all can't see through, flexible pellicle 381 then be gas can through but thin-film material that liquid can't see through; The first flexible vacuum bag film 38 can make the matrix resin glue flow to transition region 312 and carbon fiber laminboard layer 313 along glass fibre laminboard layer 311; Flexible pellicle 381 then is that guiding matrix resin glue flows and even lay-up preform 33 along thickness direction, avoids the formation of defective; Therefore, just can guide resin to flow through being used in combination the first flexible vacuum bag film 38 with flexible pellicle 381 along the direction of design.
(4) second layer closed mould cavity is set: at interval (spacing is that 1m～2m) is provided with a plurality of ventilating joints 62 to lay second airfelt 371, the second airfelt 371 upper edge spars 3 length directions above flexible pellicle 381; Cover on mould 6 surfaces and use sealant tape 39 that the first flexible vacuum bag film 38 is sealed coating fully with flexible pellicle 381 with the second flexible vacuum bag film 382 then; Form second layer closed mould cavity, second airfelt 371 is in the second layer closed mould cavity with ventilating joint 62.
(5) connect external equipment: all semi permeability ventilating joints 61 and ventilating joint 62 are connected to pumped vacuum systems 7 (being connected to vavuum pump 71 by vacuum lead), injecting glue system 8 (being communicated to resin bucket 82 by the injecting glue pipeline) are connected to are arranged in ground floor closed mould cavity gum-injecting port 81 places simultaneously.The matrix resin that spar 3 injecting glues adopt is generally selected epoxy-resin systems, and epoxy-resin systems can satisfy the interface performance requirement of glass fibre 4 and carbon fiber 5 well.
(6) vacuum injecting glue: close injecting glue system 8; Open all semi permeability ventilating joints 61 and ventilating joint 62 then; Through the gas in pumped vacuum systems 7 discharge ground floor closed mould cavity and the second layer closed mould cavity; Make and reach negative pressure of vacuum (0.098MPa) and ability stable maintenance 20min～30min in ground floor closed mould cavity and the second layer closed mould cavity; Open injecting glue system 8 again and begin to inject matrix resin is positioned at the ground floor closed mould cavity with dipping reinforcing material preform 33; Close semi permeability ventilating joint 61 and ventilating joint 62 in the injecting glue process in succession, realize the thorough impregnation of matrix resin the reinforcing material preform with the flow direction of control matrix resin; Closing semi permeability ventilating joint 61 in succession specifically is meant with ventilating joint 62: an end that from mould 6, is set to root of blade is to an end that is set to blade tip; Closeall one by one semi permeability ventilating joint 61 and ventilating joint 62; The shut-in time of each semi permeability ventilating joint 61 is spaced apart 1min～2min, and the shut-in time of each ventilating joint 62 is spaced apart 2min～3min.
(7) curing molding and post processing: the vacuum injecting glue begins to be cured moulding after accomplishing; Keep vacuum in the die cavity until completion of cure in the curing molding process, solidify the large-scale wind electricity blade hybrid composite spar 3 that carries out obtaining after the demoulding, finishing and the cleaning present embodiment after accomplishing.Adopt the forming method of above-mentioned spar 3; Spar 3 structural entity continuitys both can have been realized; Resinous polymer fully floods fortifying fibre when helping spar 3 vacuum perfusion process moulding again, and the continuous fiber number of plies of the whole length of spar 3 upper and lower surface coverage can be selected (present embodiment is 3 layers) according to concrete design demand.
Among the above-mentioned preparation method of present embodiment, the gradual change type transition that is positioned at the assorted fibre fabric 332 of transition region 312 has adopted following dual mode to realize respectively:
As shown in Figure 4, glass fibre laminboard layer 311 forms the most advanced and sophisticated and wedging of a transition and advances in the V-shaped groove that carbon fiber laminboard layer 313 forms in transition region 312 in transition region 312; Perhaps as shown in Figure 5, carbon fiber laminboard layer 313 forms the most advanced and sophisticated and wedging of a transition and advances in the V-shaped groove that glass fibre laminboard layer 311 forms in transition region 312 in transition region 312.
Because spar 3 is primary load bearing parts of blade, so the continuity of fortifying fibre is the key that keeps spar 3 overall performances and then guarantee the blade integral performance.Glass fibre 4 in the transition region 312 of present embodiment blade can be to realize the transition handing-over or realize the transition handing-over through interlayer suture way as shown in Figure 7 through weaving manner in the layer as shown in Figure 6 with carbon fiber 5.Adopt the interlayer suture way to realize the connectivity of fortifying fibre in the present embodiment, after this interlayer stitching connected mode was applied to above-mentioned two kinds of gradual change type transition regions of present embodiment, its effect was respectively like Fig. 8, shown in Figure 9.It is aramid fiber yarn, quartz fibre yarn or glass fiber yarn that interlayer is sewed up the suture that adopts.In transition region 312, the length range in glass fabric on the same aspect and the transition of carbon fibre fabric handing-over zone is generally 0.6m～1.4m.
Among the preparation method of the above-mentioned hybrid composite spar of present embodiment, flexible pellicle 381 can see through but the impervious thin-film material of matrix resin glue for gas.61 of semi permeability ventilating joints can see through but the impervious ventilating joint of matrix resin glue for gas; Its structure is shown in figure 12; Comprise outer rigid housing 63, the bottom of outer rigid housing 63 is coated by permeable medium 34 (being the water conservancy diversion net), is provided with gas channel in the shell; The bottom section of gas channel is provided with obturator, and obturator is mainly by pellicle 64, permeable medium 34, pellicle 64, airfelt 65 and the permeable medium 34 of stack are formed successively from bottom to top; Be connected through sealant tape 39 between the inwall of obturator and outer rigid housing 63; Be provided with valve 66 in the gas channel of obturator top.Ventilating joint 62 is all permeable ventilating joint of gas and matrix resin glue; Its structure is shown in figure 13; The structure of ventilating joint 62 comprises outer rigid housing 63, and the bottom of outer rigid housing 63 is coated by permeable medium 34, is provided with gas channel in the shell; The bottom section of gas channel is provided with obturator, and obturator is mainly by permeable medium 34, airfelt 65 and the permeable medium 34 of stack are formed successively from bottom to top; Be tightly connected between the inwall of obturator and outer rigid housing 63; Be provided with valve 66 in the gas channel of obturator top.
In the above-mentioned wind electricity blade spar 3 of present embodiment; The thickness of spar covering layer 32 is 3mm (2mm～3mm all can), and spar covering layer 32 used reinforcing material are that (used reinforcing material is that the surface density that Chongqing international composite Co., Ltd provides is 1250g/m to the glass fibre single shaft in the present embodiment to cloth, the axial cloth of Glass Fibre Double or glass fibre three axial cloth
2Single shaft to cloth, surface density 808g/m
2± 45 ° the braiding twin shafts to cloth and surface density 1215g/m
20 °, ± 45 ° the braiding three axial cloth).Because spar 3 outer being trapped among are coated with spar covering layer on the whole blade length direction; This spar covering layer is to strengthen body with continuous glass fibre shop layer as the surface, and the meaning of shop layer design has three aspects at least like this: 1) this is further to realize the successional a kind of mode of spar structural entity; Resinous polymer fully flooded fortifying fibre (particularly carbon fiber) when 2) this helped the moulding of spar vacuum perfusion process; 3) this helps the layer to layer transition between spar and the pneumatic housing.
In the wind electricity blade spar that present embodiment makes at last; Blade spars 3 adopts GFRP to process near the glass fibre laminboard layer 311 of root of blade; 313 of carbon fiber laminboard layers near blade tip adopt CFRP to process; Because the specific strength (strength/density) of carbon fiber reinforced polymer laminate approximately is 2 times of the glass fiber reinforced polymer laminate; Specific modulus (modulus/density) is 3 times of GFRP approximately; Through only adopting carbon fiber can not only give full play to the advantage of the high-elastic lightweight of carbon fiber as the mode of reinforcing material at the most critical position, improve the rigidity and the intensity of blade tip greatly, increase the critical length (seeing table 1) of blade; And price more helps the promotion and application of carbon fiber in the wind electricity blade field than adopting carbon fiber to prepare blade as reinforcing material entirely or adopting carbon fiber to prepare whole spars 3 as reinforcing material and will reduce greatly; Can effectively reduce simultaneously the amount of deflection of blade tip again, prevent blade tip touching pylon in the blade running; And can realize the length of blade lengthening, power output improves, but leaf weight does not increase and center of gravity is not moved outward, the immovable integration objective of leaf natural frequency.
Table 1: the technical parameter contrast of present embodiment blade and existing blade
| Blade | Existing blade | The present embodiment blade |
| Length/m | 50 | 55 |
| Rated power/MW | 2.5 | 2.5 |
| Weight/t | 11.56 | 11.57 |
| Position of centre of gravity/m | 16.56 | 16.58 |
| Single order is waved natural frequency/Hz | 0.665 | 0.667 |
| Second order is waved natural frequency/Hz | 1.913 | 1.918 |
| Shimmy natural frequency/the Hz of single order | 1.178 | 1.174 |
| Shimmy natural frequency/the Hz of second order | 3.521 | 3.526 |
| Blade tip maximum defluxion/m | 11.25 | 11.29 |
| Rated wind speed/(m/s) | 10.5 | 10 |
| The existence wind speed/(m/s) | 59.5 | 52.5 |
| Maximum chord length/m | 3.98 | 3.98 |
| Be suitable for wind field | The III class | II class and III class |
| Single piece of material cost/ten thousand yuan | About 60 | About 60 |
Claims (10)
1. the preparation method of a large-scale wind electricity blade hybrid composite spar; It is characterized in that: said hybrid composite spar comprises the spar covering layer that the spar laminboard layer is outer with being coated on the spar laminboard layer; Said spar laminboard layer is mainly by near the glass fibre laminboard layer of root of blade, form near the carbon fiber laminboard layer of blade tip and transition region three parts that connect glass fibre laminboard layer and carbon fiber laminboard layer, and the preparation method of said spar mainly may further comprise the steps:
(1) mould preliminary treatment: at first clear up mould, spraying releasing agent and gel coat;
(2) shop cover material material: reinforcing material preform and the moulding auxiliary material required according to the designing requirement cutting of spar; Said reinforcing material preform is made up of spar covering layer reinforcing material and spar laminboard layer reinforcing material; Spar laminboard layer reinforcing material comprises glass fabric near root of blade, forms near the carbon fibre fabric of blade tip and the assorted fibre fabric that connects glass fabric and carbon fibre fabric; The moulding auxiliary material comprise permeable medium, release cloth, barrier film with holes, airfelt and vacuum bag film, through the pretreated die surface of step (1) from lower to upper successively the shop cover permeable medium, release cloth, barrier film with holes, reinforcing material preform, barrier film with holes and release cloth; Lay first airfelt on release cloth corresponding above the glass fibre laminboard layer region then, the said first airfelt upper edge spar length direction is provided with a plurality of semi permeability ventilating joints at interval;
(3) the ground floor closed mould cavity is set: on horizontal plane, be projected as the line of demarcation with the boundary line of said glass fibre laminboard layer and said transition region; The first flexible vacuum bag film coating mould is used near a side of glass fibre laminboard layer in the line of demarcation; Flexible pellicle coating mould is used near a side of transition region in the line of demarcation; The first flexible vacuum bag film and flexible pellicle connect into whole back and cover on die surface formation ground floor closed mould cavity through sealant tape, and said reinforcing material preform and moulding auxiliary material are covered by in the ground floor closed mould cavity;
(4) second layer closed mould cavity is set: lay second airfelt above described flexible pellicle, the said second airfelt upper edge spar length direction is provided with a plurality of ventilating joints at interval; Cover on die surface and the first flexible vacuum bag film and flexible pellicle are sealed coating fully with the second flexible vacuum bag film then, form second layer closed mould cavity, second airfelt and ventilating joint are in the second layer closed mould cavity;
(5) connect external equipment: all semi permeability ventilating joint and ventilating joint are connected to pumped vacuum systems, simultaneously the injecting glue system are connected to the gum-injecting port that is arranged in the ground floor closed mould cavity;
(6) vacuum injecting glue: close the injecting glue system; Open all semi permeability ventilating joint and ventilating joint then; Discharge the gas in ground floor closed mould cavity and the second layer closed mould cavity through pumped vacuum systems; Make and reach negative pressure of vacuum and ability stable maintenance in ground floor closed mould cavity and the second layer closed mould cavity; Open the injecting glue system again and begin to inject matrix resin and be positioned at the reinforcing material preform of ground floor closed mould cavity, close semi permeability ventilating joint and ventilating joint in the injecting glue process in succession, realize the thorough impregnation of matrix resin the reinforcing material preform with the flow direction of control matrix resin with dipping;
(7) curing molding and post processing: the vacuum injecting glue begins to be cured moulding after accomplishing; Keep vacuum in the die cavity until completion of cure in the curing molding process, solidify the large-scale wind electricity blade hybrid composite spar that carries out obtaining after the demoulding, finishing and the cleaning global formation after accomplishing.
2. the preparation method of large-scale wind electricity blade hybrid composite spar according to claim 1 is characterized in that: said flexible pellicle is that gas can see through but the impervious thin-film material of matrix resin glue.
3. the preparation method of large-scale wind electricity blade hybrid composite spar according to claim 1 and 2; It is characterized in that: said semi permeability ventilating joint is that gas can see through but the impervious ventilating joint of matrix resin glue; Said semi permeability ventilating joint comprises outer rigid housing; The bottom of outer rigid housing is coated by permeable medium; Be provided with gas channel in the shell, the bottom section of gas channel is provided with obturator, and obturator is mainly by pellicle, permeable medium, pellicle, airfelt and the permeable medium of stack are formed successively from bottom to top; Be tightly connected between the inwall of obturator and outer rigid housing; Be provided with valve in the gas channel of obturator top.
4. the preparation method of large-scale wind electricity blade hybrid composite spar according to claim 1 and 2; It is characterized in that: said ventilating joint is all permeable ventilating joint of gas and matrix resin glue; Said ventilating joint comprises outer rigid housing, and the bottom of outer rigid housing is coated by permeable medium, is provided with gas channel in the shell; The bottom section of gas channel is provided with obturator, and obturator is mainly by permeable medium, airfelt and the permeable medium of stack are formed successively from bottom to top; Be tightly connected between the inwall of obturator and outer rigid housing; Be provided with valve in the gas channel of obturator top.
5. the preparation method of large-scale wind electricity blade hybrid composite spar according to claim 1 and 2; It is characterized in that: said semi permeability ventilating joint is being 2m～3m along the spacing on the spar length direction, and said ventilating joint is being 1m～2m along the spacing on the spar length direction.
6. the preparation method of large-scale wind electricity blade hybrid composite spar according to claim 1 and 2; It is characterized in that; In the said vacuum injecting glue step; Closing semi permeability ventilating joint and ventilating joint in succession specifically is meant: an end that from mould, is set to root of blade is to an end that is set to blade tip, closeall one by one semi permeability ventilating joint and ventilating joint; The shut-in time of each semi permeability ventilating joint is spaced apart 1min～2min, and the shut-in time of each ventilating joint is spaced apart 2min～3min.
7. the preparation method of large-scale wind electricity blade hybrid composite spar according to claim 1; It is characterized in that; Reinforcing material in the said transition region is the assorted fibre fabric, and its arrangement in the reinforcing material preform is: strengthen gradual change type by whole glass fibres on the direction from said glass fabric to carbon fibre fabric and carry out the transition to whole carbon fibers enhancings;
Said gradual change type transition specifically is meant following any transient mode:
(1) said glass fabric forms the most advanced and sophisticated and wedging of a transition and advances in the V-shaped groove that said carbon fibre fabric forms in transition region in said transition region; Perhaps,
(2) said carbon fibre fabric forms the most advanced and sophisticated and wedging of a transition and advances in the V-shaped groove that said glass fabric forms in transition region in said transition region.
8. the preparation method of large-scale wind electricity blade hybrid composite spar according to claim 7 is characterized in that, glass fabric in the said transition region and carbon fibre fabric are to realize the transition handing-over through weaving manner in the layer;
Weaving manner is meant in the said layer: with the mode that glass fabric termination in the transition region and carbon fibre fabric termination adopt interlaminar hybrid alternately to weave, the carbon fiber that extends into transition region in the glass fibre that extends into transition region in the glass fibre laminboard layer and the carbon fiber laminboard layer is linked together.
9. the preparation method of large-scale wind electricity blade hybrid composite spar according to claim 7; It is characterized in that; Glass fabric in the said transition region is to realize that through the interlayer suture way transition joins with carbon fibre fabric, make extend into transition region in the glass fabric that extends into transition region in the glass fibre laminboard layer and the carbon fiber laminboard layer the carbon fibre fabric fixed overlay together;
The suture that said interlayer stitching is adopted is one or more in aramid fiber yarn, quartz fibre yarn, the glass fiber yarn.
10. according to the preparation method of each described large-scale wind electricity blade hybrid composite spar in the claim 1,7～9; It is characterized in that; The thickness of said spar covering layer is 2mm～3mm, and the used reinforcing material of spar covering layer is that the glass fibre single shaft is to cloth, the axial cloth of Glass Fibre Double and/or glass fibre three axial cloth; Glass fabric in the said spar laminboard layer is that surface density is at 1000g/m
2Above single shaft is to fabric, and the carbon fibre fabric in the said spar laminboard layer is that surface density is at 600g/m
2Above single shaft is to fabric.
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