CN102814996B - 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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- CN102814996B CN102814996B CN201210304497.7A CN201210304497A CN102814996B CN 102814996 B CN102814996 B CN 102814996B CN 201210304497 A CN201210304497 A CN 201210304497A CN 102814996 B CN102814996 B CN 102814996B
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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 manufacture 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 the pneumatic housing that two fiber-reinforced polymers are made and the shear web that two pneumatic housing are coupled together.Between two pneumatic housing, connect by bonding way between pneumatic housing and shear web.The typical method of preparing blade pneumatic housing and shear web is vacuum perfusion process.When vacuum perfusion process is prepared blade pneumatic housing, the sandwich materials such as the reinforcing materials such as fiber and fabric, foam and cork wood are laid in mould and cover a vacuum bag according to laying design.By 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.The typical polymers of using is mainly polyester or epoxy resin, and the typical fibers material using is mainly the fabric of different shape.Fortifying fibre is often based on glass fibre, and carbon fiber also starts to use in maximization composite material wind-power blade as a kind of high-performance fiber.The ratio of rigidity glass fibre of carbon fiber is large, and 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 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.In prior art, had the various embodiments that propose assorted fibre reinforced composite material wind electricity blade, but the blade cost increase causing because of carbon fiber increase makes it on existing market, still be difficult to bear and promote.In addition, the power output of wind turbine is easily subject to the impact of the outside natural environments such as wind speed, for the wind turbine of rated power, how to weaken external environment condition impact, realize power output and maximize, be the important topic that wind turbine development faces.Square principle being directly proportional according to the power output of blower fan to rotor diameter, can eliminate the impact of external condition by lengthening the length of rated power blade, increase the power output of wind turbine.But lengthened blades length can be brought following problem: 1) leaf quality increases by the cube of length, has a strong impact on operation and the fatigue life of blower fan; 2) lengthened blades length will make blade center of gravity move outward, can cause vibration frequency of blade to increase, impact operation and service life, the danger that even has the resonance of producing to destroy; 3) after lengthened blades length, limit wind carries lower blade-tip deflection and increases, the risk that has collision pylon to destroy.
In the present invention, distinguish and independently defined first the hybrid composite spar of blade, hybrid composite spar refers to that glass fibre/carbon fiber hybrid strengthens thick cross section composite material blade spar, typically applies to 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 has risen to more than 60 meters by twenties meters nearly ten years, the difficult point of thick cross section composite element moulding is that thickness direction permeability is lower, resin is difficult to thorough impregnation, so in technique, is difficult to guarantee resin uniform impregnation of fiber reinforcing material in whole size range; On the other hand, with respect to glass fibre, carbon fiber diameter is less, fibre gap is little, under same volume, fiber total surface area is large, 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, there is again the thick cross-sectional layers plywood of carbon fiber, also have carbon fibers/fiberglass to mix thick cross-sectional layers plywood, the slipper dip speed of resin on different fibre sections is different, easily cause flooding inhomogeneous, form the defects 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 is only suitable for moulding and prepares pure glass fibre and strengthen thick section blades spar, 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 hybrid composite spar is prepared at present moulding adopts prepreg forming method more, but prepreg forming method is multistep forming method, and prepreg needs particular surroundings to store, and cost is higher, also higher to the requirement of mould in addition.
In order to adapt to, blade maximizes and the needs of high-output power, how effectively to solve the preporm 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 development hybrid composite spar will have important practical significance.
Summary of the invention
The technical problem to be solved in the present invention is to overcome the deficiencies in the 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, the spar that this preparation method makes is applied to after 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, and 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, described hybrid composite spar comprises spar laminboard layer and is coated on the spar covering layer outside spar laminboard layer, described spar laminboard layer is mainly comprised of the carbon fiber laminboard layer of the glass fibre laminboard layer near root of blade, close blade tip and transition region three parts of connection glass fibre laminboard layer and carbon fiber laminboard layer, and the preparation method of described spar mainly comprises the following steps:
(1) mould pretreatment: first clear up mould, spraying releasing agent and gel coat;
(2) paving cover material material: according to the required reinforcing material preform of the designing requirement cutting of spar and moulding auxiliary material, described reinforcing material preform is (to comprise upper covering layer reinforcing material and lower 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 the glass fabric near root of blade, near the carbon fibre fabric of blade tip and the hybrid fabrics composition that connects glass fabric and carbon fibre fabric, moulding auxiliary material comprise permeable medium, release cloth, porous release film, airfelt and vacuum bag film, through the pretreated die surface of step (1), spreading and covering permeable medium successively from lower to upper, release cloth, porous release film, reinforcing material preform, porous release film and release cloth, then lay the first airfelt on release cloth corresponding above glass fibre laminboard layer region, arranges a plurality of semi permeability ventilating joints along spar length direction interval in described the first airfelt,
(3) ground floor closed mould cavity is set: with the boundary line of described glass fibre laminboard layer and described transition region on horizontal plane, be projected as line of demarcation, the first flexible vacuum bag film coating mould is used near a side of glass fibre laminboard layer in line of demarcation, flexible pellicle coating mould is used near a side of transition region in line of demarcation, the first flexible vacuum bag film and flexible pellicle cover on die surface by sealant tape and form ground floor closed mould cavity after place, line of demarcation connects into integral body, described reinforcing material preform and moulding auxiliary material are covered by ground floor closed mould cavity,
(4) second layer closed mould cavity is set: lay the second airfelt above described flexible pellicle, arranges a plurality of ventilating joints along spar length direction interval in described the second airfelt; Then with the second flexible vacuum bag film, cover on die surface and the first flexible vacuum bag film and flexible pellicle are sealed completely coated, form second layer closed mould cavity, the second airfelt and ventilating joint are in second layer closed mould cavity;
(5) connect external equipment: all semi permeability ventilating joint and ventilating joint are connected to pumped vacuum systems, injection system are connected to the gum-injecting port that is arranged in ground floor closed mould cavity simultaneously;
(6) vacuum injecting glue: close injection system, then open all semi permeability ventilating joint and ventilating joint, by pumped vacuum systems, discharge the gas in ground floor closed mould cavity and second layer closed mould cavity, make to reach in ground floor closed mould cavity and the second layer closed mould cavity negative pressure of vacuum can stable maintenance, open again injection system and start to inject matrix resin to flood the reinforcing material preform that is positioned at ground floor closed mould cavity, in injecting glue process, in succession close semi permeability ventilating joint and ventilating joint, to control the flow direction of matrix resin, realize the thorough impregnation of matrix resin to reinforcing material preform,
(7) curing molding and post processing: after vacuum injecting glue completes, start to be cured moulding, in curing molding process, keep vacuum in die cavity until completion of cure, after having solidified, carry out obtaining after the demoulding, finishing and cleaning the large-scale wind electricity blade hybrid composite spar of global formation.
In the preparation method of above-mentioned large-scale wind electricity blade hybrid composite spar, described 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).
In the preparation method of above-mentioned large-scale wind electricity blade hybrid composite spar, described semi permeability ventilating joint is preferably gas and can sees through but the impervious ventilating joint of matrix resin glue.The structure of described semi permeability ventilating joint preferably includes outer rigid housing, the bottom of outer rigid housing is coated by permeable medium, in shell, be provided with gas channel, the bottom section of gas channel is provided with obturator, and obturator is mainly comprised of the pellicle superposeing successively from bottom to top, permeable medium, pellicle, airfelt and permeable medium; Between obturator and the inwall of outer rigid housing, be tightly connected; In the gas channel of obturator top, be provided with valve.
In the preparation method of above-mentioned large-scale wind electricity blade hybrid composite spar, described ventilating joint is preferably all permeable ventilating joints of gas and matrix resin glue.The structure of described ventilating joint preferably includes outer rigid housing, the bottom of outer rigid housing is coated by permeable medium, in shell, be provided with gas channel, the bottom section of gas channel is provided with obturator, and obturator is mainly comprised of the permeable medium superposeing successively from bottom to top, airfelt and permeable medium; Between obturator and the inwall of outer rigid housing, be tightly connected; In the gas channel of obturator top, be provided with valve.
In the preparation method of above-mentioned large-scale wind electricity blade hybrid composite spar, described semi permeability ventilating joint is preferably 2m～3m in the spacing along on spar length direction.Described ventilating joint is preferably 1m～2m in the spacing along on spar length direction.
The preparation method of above-mentioned large-scale wind electricity blade hybrid composite spar, in described vacuum injecting glue step, in succession closing semi permeability ventilating joint and ventilating joint specifically refers to: from mould, be set to one end of root of blade to the one end that is set to blade tip, one by one closeall semi permeability ventilating joint and ventilating joint.The shut-in time interval of each semi permeability ventilating joint is preferably 1min～2min, and the shut-in time interval of each ventilating joint is preferably 2min～3min.
The preparation method of above-mentioned large-scale wind electricity blade hybrid composite spar, reinforcing material in described transition region is hybrid fabrics, and its arrangement in reinforcing material preform is preferably: the direction from described glass fabric to carbon fibre fabric, by whole glass fibres enhancing gradual change types, be transitioned into whole carbon fibers and strengthen.Described gradual change type transition specifically refers to following any transient mode:
(1) described glass fabric forms a transition tip and wedges in the V-shaped groove forming in transition region into described carbon fibre fabric in described transition region; Or,
(2) described carbon fibre fabric forms a transition tip and wedges in the V-shaped groove forming in transition region into described glass fabric in described transition region.
The preparation method of above-mentioned large-scale wind electricity blade hybrid composite spar, the glass fabric in described transition region and carbon fibre fabric can also be by weaving manner in layer, to realize transition to join.In described layer, weaving manner refers to: the glass fabric termination in transition region and carbon fibre fabric termination are adopted to the alternately mode of braiding of interlaminar hybrid, make to extend in glass fibre laminboard layer the carbon fiber that extends into transition region in the glass fibre of transition region and carbon fiber laminboard layer and link together.
The preparation method of above-mentioned large-scale wind electricity blade hybrid composite spar, glass fabric in described transition region and carbon fibre fabric are preferably realized transition by interlayer suture way and are joined, and make to extend in glass fibre laminboard layer the glass fabric of transition region together with extending into the carbon fibre fabric fixed overlay of transition region in carbon fiber laminboard layer.The suture that described interlayer stitching adopts is preferably one or more in aramid fiber yarn, quartz fibre yarn, glass fiber yarn.
The preparation method of above-mentioned large-scale wind electricity blade hybrid composite spar, the thickness of described spar covering layer is preferably 2mm～3mm, and spar covering layer reinforcing material used is preferably glass fibre single shaft to cloth, the axial cloth of Glass Fibre Double and/or the axial cloth of glass fibre three.Glass fabric in described spar laminboard layer is preferably surface density at 1000g/m
2above single axial fabrics, the carbon fibre fabric in described spar laminboard layer is preferably surface density at 600g/m
2above single axial fabrics.
Compared with prior art, the invention has the advantages that: 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 for composite liquid moulding technology is provided by a kind of simple and effective method that provides; Secondly, by resin liquid flow control method of the present invention, it can be realized low-permeability multi-layer fiber fabric preform (for example thick cross section pure carbon fiber spar) and become the one step integral forming of permeability multi-layer fiber fabric preform (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 not only easy and simple to handle, environmental protection property good, and cost is low.
Preparation method of the present invention is applied to after the preparation of large-scale wind electricity blade, reduced on the one hand the production cost of application of carbon fibres, the ability to bear that meets current market, (being also prior aspect) efficiently solves the stability of wind electricity blade work on the other hand, extended the service life of blade.Generally speaking, under the prerequisite that the lengthened large-scale composite material wind-power blade that preparation method of the present invention makes is unchanged at pneumatic structure, weight does not increase, position of centre of gravity does not change, blade-tip deflection does not increase, cost does not increase, the length of blade of rated power can be lengthened to 5%～20%, and can keep same power (rated power), same aerofoil profile (pneumatic wing type); Square principle being directly proportional according to the power output of blower fan to rotor diameter, can improve 10%～20% by the power output of wind turbine.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; By changing and adjust content and the distribution of carbon fiber in transition region and outer end, can make rigidity and the natural frequency respective change of blade, thereby the rigidity of realization and natural frequency, corresponding to being optimum under specified conditions, have improved applicability, flexibility and the operability of blade of the present invention greatly.Visible, large-scale wind electricity blade prepared by the present invention has good market application foreground.
Accompanying drawing explanation
Fig. 1 is the structural representation of the wind turbine blade in the embodiment of the present invention.
Fig. 2 is the profile at A-A place in Fig. 1.
Fig. 3 is the interval distribution schematic diagram of embodiment of the present invention central spar laminboard layer in length of blade direction.
Fig. 4 is the structural representation of embodiment of the present invention central spar laminboard layer transition region gradual change type transient mode one.
Fig. 5 is the structural representation of embodiment of the present invention central spar laminboard layer transition region gradual change type transient mode two.
Fig. 6 adopts the principle sketch of weaving manner in layer in the embodiment of the present invention.
Fig. 7 is the principle sketch that adopts interlayer suture way in the embodiment of the present invention.
Fig. 8 is that between embodiment of the present invention Leaf gradual change type transient mode one binder course, suture way is realized the structural representation that transition connects.
Fig. 9 is that between embodiment of the present invention Leaf gradual change type transient mode two binder courses, suture way is realized the structural representation that transition connects.
Figure 10 is the location map of embodiment of the present invention Leaf transition region on blade.
Figure 11 is embodiment of the present invention Leaf preparation method's schematic diagram.
Figure 12 is the structural representation of semi permeability ventilating joint in the embodiment of the present invention.
Figure 13 is the structural representation of ventilating joint in the embodiment of the present 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, hybrid fabrics; 333, carbon fibre fabric; 334, spar covering layer reinforcing material; 34, permeable medium; 35, release cloth; 36, porous release film; 37, the first airfelt; 371, the 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, injection system; 81, gum-injecting port; 82, resin barrel.
The specific embodiment
Below in conjunction with Figure of description and specific embodiment, the invention will be further described.
embodiment:
A kind of lengthened large-scale composite material wind turbine blade as shown in Figure 1 and Figure 2, the monnolithic case of this blade as shown in Figure 1, as seen from Figure 2, blade includes pneumatic housing 1 and is located at the shear web 2 in pneumatic housing 1 inner chamber, pneumatic housing 1 mainly by be arranged in the upper and lower spar 3 at middle part and obturator 12(the present embodiment obturator of spar 3 both sides for the density that Mead China composite Co., Ltd provides be 63.0 ± 6 kg/m
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 by shear web 2.
Spar 3 in the present embodiment comprises spar laminboard layer 31 and is coated on the spar covering layer 32 outside spar laminboard layer 31, as shown in Figure 3, spar laminboard layer 31 is mainly by the glass fibre laminboard layer 311 near root of blade, near the carbon fiber laminboard layer 313 of blade tip and the transition region 312 3 parts compositions that connect glass fibre laminboard layer 311 and carbon fiber laminboard layer 313, glass fibre laminboard layer 311 is mainly by glass fiber reinforced polymer (GFRP, Glass Fiber Reinforced Polymer) make, carbon fiber laminboard layer 313 is mainly by carbon fiber reinforced polymer (CFRP, Carbon Fiber Reinforced Polymer) make, transition region 312 mainly strengthens polymer by glass-carbon assorted fibre and makes, the concrete arrangement of the glass-carbon assorted fibre in transition region 312 is: the direction from glass fibre laminboard layer 311 to carbon fiber laminboard layer 313, by whole glass fibres enhancing gradual change types, be transitioned into whole carbon fibers and strengthen.Due to carbon fiber than glass fibre general hard 3～4 times, the stress of transition region 312 is concentrated the risk that often easily causes that whole blade destroys, 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 glass fibre to be in bearing larger dynamically or occur that stress concentrates during static stress.
As shown in figure 10, in the wind electricity blade of the present embodiment, the length of glass fibre laminboard layer 311 be whole spar 3 length L 50%(45%～55% all can, the length L of the present embodiment central spar is 55m); The length of transition region 312 be whole spar 3 length L 20%(15%～25% all can); The length of carbon fiber laminboard layer 313 be whole spar 3 length 30%(25%～35% all can).Wherein, the position of transition region 312 is laid in apart from root of blade 3
l/ 2 to 5
l/ 2 region, wherein,
lfor the distance of 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 spar laminboard layer 31, important improvement and the optimization that we have done through repetition test, under this kind of preferred condition, not only be conducive to improve 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 comprises the following steps:
(1) mould pretreatment: first clear up mould, repair smoothly, then spray releasing agent, then spray gel coat.
(2) paving cover material material: reinforcing material preform 33 and the moulding auxiliary material required according to the designing requirement cutting spar 3 in the present embodiment, reinforcing material preform 33 is comprised of spar covering layer reinforcing material 334 and spar laminboard layer reinforcing material, and spar laminboard layer reinforcing material comprises near glass fabric 331(the present embodiment of root of blade selects surface density 1200g/m
2glass single shaft to woven cloth), near carbon fibre fabric 333(the present embodiment of blade tip, select surface density 600g/m
2carbon fiber single shaft is to woven cloth) and the hybrid fabrics 332 that connects glass fabric 331 and carbon fibre fabric 333 form, moulding auxiliary material comprise that permeable medium 34(is flow-guiding screen), the R85PA66 type release cloth produced of release cloth 35((Shanghai drop High Seience Technology Co., Ltd., surface density is 85g/m
2)), porous release film 36, airfelt (comprising the first airfelt and the second airfelt) and vacuum bag film (the vacuum bag film of the 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, spreading and covering permeable medium 34 successively from lower to upper, release cloth 35, porous release film 36, reinforcing material preform 33, porous release film 36 and release cloth 35, wherein reinforcing material preform 33 is from lower to upper successively by lower covering layer reinforcing material, spar laminboard layer reinforcing material and upper covering layer reinforcing material form, then lay the first airfelt 37 on release cloth 35 corresponding above glass fibre laminboard layer 311 regions, in the first airfelt 37, along spar 3 length direction intervals, a plurality of semi permeability ventilating joint 61(spacing being set is 2m～3m).
(3) ground floor closed mould cavity is set: with the boundary line of glass fibre laminboard layer 311 and transition region 312 on horizontal plane, be projected as line of demarcation, the first flexible vacuum bag film 38 coating moulds 6 are used near a side of glass fibre laminboard layer 311 in line of demarcation, flexible pellicle 381 coating moulds (the QL836 pellicle that the pellicle of the present embodiment provides for Shanghai drop High Seience Technology Co., Ltd. is used near a side of transition region 312 in line of demarcation, thickness is 0.35mm), the first flexible vacuum bag film 38 and flexible pellicle 381 are used sealant tape 39 to glued joint at joint and form a hybrid films integral body that covers spar enhancement region completely, then by sealant tape 39, cover on mould 6 surfaces and form ground floor closed mould cavity, reinforcing material preform 33 and moulding auxiliary material are all covered by ground floor closed mould cavity.In the present embodiment, the first flexible vacuum bag film 38 is thin-film materials that liquids and gases all cannot see through, flexible pellicle 381 be gas can by but thin-film material that liquid cannot see through; The first flexible vacuum bag film 38 can make matrix resin glue along glass fibre laminboard layer 311 to transition region 312 and carbon fiber laminboard layer 313 flows, flexible pellicle 381 is that guiding matrix resin glue through-thickness flows and even lay-up preform 33, avoids the formation of defect; Therefore, by being combined with the first flexible vacuum bag film 38 and flexible pellicle 381, just can guide resin to flow along the direction of design.
(4) second layer closed mould cavity is set: in the second airfelt 371, the second airfelt 371 of lay above flexible pellicle 381, along spar 3 length direction intervals (spacing is 1m～2m), a plurality of ventilating joints 62 are set; Then with the second flexible vacuum bag film 382, cover on mould 6 surfaces and use sealant tape 39 that the first flexible vacuum bag film 38 and flexible pellicle 381 are sealed coated completely, form second layer closed mould cavity, the second airfelt 371 and ventilating joint 62 are in second layer closed mould cavity.
(5) connect external equipment: all semi permeability ventilating joints 61 and ventilating joint 62 are connected to pumped vacuum systems 7(and by vacuum lead, are connected to vavuum pump 71), injection system 8(is communicated to resin barrel 82 by injecting glue pipeline simultaneously) be connected to and be arranged in ground floor closed mould cavity gum-injecting port 81 places.The matrix resin that spar 3 injecting glues adopt is generally selected epoxy-resin systems, and epoxy-resin systems can meet the interface performance requirement of glass fibre 4 and carbon fiber 5 well.
(6) vacuum injecting glue: close injection system 8, then open all semi permeability ventilating joints 61 and ventilating joint 62, the gas of discharging in ground floor closed mould cavity and second layer closed mould cavity by pumped vacuum systems 7, make to reach in ground floor closed mould cavity and the second layer closed mould cavity negative pressure of vacuum (0.098MPa) can stable maintenance 20min～30min, open again injection system 8 and start to inject matrix resin to flood the reinforcing material preform 33 that is positioned at ground floor closed mould cavity, in injecting glue process, in succession close semi permeability ventilating joint 61 and ventilating joint 62, to control the flow direction of matrix resin, realize the thorough impregnation of matrix resin to reinforcing material preform, in succession close semi permeability ventilating joint 61 and ventilating joint 62 specifically refers to: from mould 6, be set to one end of root of blade to the one end that is set to blade tip, closeall semi permeability ventilating joint 61 and ventilating joint 62 one by one, 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: after vacuum injecting glue completes, start to be cured moulding, in curing molding process, keep vacuum in die cavity until completion of cure, after having solidified, carry out obtaining after the demoulding, finishing and cleaning the large-scale wind electricity blade hybrid composite spar 3 of the present embodiment.Adopt the forming method of above-mentioned spar 3, both spar 3 structural entity continuitys can have been realized, while being conducive to again spar 3 vacuum perfusion process moulding, resinous polymer fully floods fortifying fibre, and the continuous fiber number of plies of the whole length of the upper and lower surface coverage of spar 3 can need to be selected according to specific design (the present embodiment is 3 layers).
In the above-mentioned preparation method of the present embodiment, the gradual change type transition that is positioned at the hybrid fabrics 332 of transition region 312 has adopted respectively following two kinds of modes to realize:
As shown in Figure 4, glass fibre laminboard layer 311 is most advanced and sophisticated and wedge into carbon fiber laminboard layer 313 in the V-shaped groove of transition region 312 interior formation in the interior formation of transition region 312 one transition; Or as shown in Figure 5, carbon fiber laminboard layer 313 is most advanced and sophisticated and wedge into glass fibre laminboard layer 311 in the V-shaped groove of transition region 312 interior formation in the interior formation of transition region 312 one transition.
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 blade integral performance.Glass fibre 4 in the transition region 312 of the present embodiment blade can be by weaving manner in layer as shown in Figure 6, to be realized transition handing-over or realized transition by interlayer suture way as shown in Figure 7 joining with carbon fiber 5.In the present embodiment, adopt interlayer suture way to realize the connectivity of fortifying fibre, this interlayer is sewed up connected mode and is applied to after above-mentioned two kinds of gradual change type transition regions of the present embodiment, and its effect respectively as shown in Figure 8, Figure 9.It is aramid fiber yarn, quartz fibre yarn or glass fiber yarn that interlayer is sewed up the suture adopting.In transition region 312, the length range of the transition handover region of the glass fabric in same aspect and carbon fibre fabric is generally 0.6m～1.4m.
In the preparation method of the above-mentioned hybrid composite spar of the 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 as shown in figure 12, comprise outer rigid housing 63, the bottom of outer rigid housing 63 is flow-guiding screen by permeable medium 34() coated, in shell, be provided with gas channel, the bottom section of gas channel is provided with obturator, and obturator is mainly comprised of the pellicle 64 superposeing successively from bottom to top, permeable medium 34, pellicle 64, airfelt 65 and permeable medium 34; Between the inwall of obturator and outer rigid housing 63, by sealant tape 39, be connected; In the gas channel of obturator top, be provided with valve 66.Ventilating joint 62 is all permeable ventilating joints of gas and matrix resin glue, its structure as shown in figure 13, the structure of ventilating joint 62 comprises outer rigid housing 63, the bottom of outer rigid housing 63 is coated by permeable medium 34, in shell, be provided with gas channel, the bottom section of gas channel is provided with obturator, and obturator is mainly comprised of the permeable medium 34 superposeing successively from bottom to top, airfelt 65 and permeable medium 34; Between the inwall of obturator and outer rigid housing 63, be tightly connected; In the gas channel of obturator top, be provided with valve 66.
In the above-mentioned wind electricity blade spar 3 of the present embodiment, the thickness of spar covering layer 32 be 3mm(2mm～3mm all can), spar covering layer 32 reinforcing material used are that to cloth, the axial cloth of Glass Fibre Double or the axial cloth of glass fibre three, (surface density that in the present embodiment, reinforcing material used provides for Chongqing Polycomp International Co., Ltd is 1250g/m to glass fibre single shaft
2single shaft to cloth, surface density 808g/m
2± 45 ° braiding twin shafts to cloth and surface density 1215g/m
20 °, ± 45 ° braiding three axial cloth).Because spar 3 is outer, be trapped among and in whole length of blade direction, be coated with spar covering layer, this spar covering layer is to using continuous glass fibre laying as surperficial reinforcement, and the meaning of laying design has three aspects at least like this: 1) this is further to realize the successional a kind of mode of spar structural entity; 2) when this is conducive to the moulding of spar vacuum perfusion process, resinous polymer fully floods fortifying fibre (particularly carbon fiber); 3) this is conducive to the layer to layer transition between spar and pneumatic housing.
In the wind electricity blade spar that the present embodiment finally makes, blade spars 3 adopts GFRP to make near the glass fibre laminboard layer 311 of root of blade, 313 of the carbon fiber laminboard layers near blade tip adopt CFRP to make, because the specific strength (strength/density) of carbon fiber reinforced polymer laminate is approximately 2 times of glass fiber reinforced polymer laminate, specific modulus (modulus/density) is approximately 3 times of GFRP, by only adopt carbon fiber at most critical position, as the mode of reinforcing material, can not only give full play to the advantage of the high-elastic lightweight of carbon fiber, greatly improve the Rigidity and strength of blade tip, increase the critical length (in Table 1) of blade, and cost ratio adopts carbon fiber to prepare blade or adopt carbon fiber to prepare whole spars 3 as reinforcing material as reinforcing material will greatly to reduce entirely, more be conducive to carbon fiber in the promotion and application in wind electricity blade field, can effectively reduce the amount of deflection of blade tip again, prevent blade tip touching pylon in blade running simultaneously, and can realize 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 present embodiment blade and existing vaned technical parameter contrast
| 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 |
| Existence wind speed/(m/s) | 59.5 | 52.5 |
| Maximum chord length/m | 3.98 | 3.98 |
| Applicable wind field | III class | II class and III class |
| Single piece of material cost/ten thousand yuan | Approximately 60 | Approximately 60 |
Claims (10)
1. the preparation method of a large-scale wind electricity blade hybrid composite spar, it is characterized in that: described hybrid composite spar comprises spar laminboard layer and is coated on the spar covering layer outside spar laminboard layer, described spar laminboard layer is mainly comprised of the carbon fiber laminboard layer of the glass fibre laminboard layer near root of blade, close blade tip and transition region three parts of connection glass fibre laminboard layer and carbon fiber laminboard layer, and the preparation method of described spar mainly comprises the following steps:
(1) mould pretreatment: first clear up mould, spraying releasing agent and gel coat;
(2) paving cover material material: according to the required reinforcing material preform of the designing requirement cutting of spar and moulding auxiliary material, described reinforcing material preform is comprised of spar covering layer reinforcing material and spar laminboard layer reinforcing material, spar laminboard layer reinforcing material comprises the glass fabric near root of blade, near the carbon fibre fabric of blade tip and the hybrid fabrics composition that connects glass fabric and carbon fibre fabric, moulding auxiliary material comprise permeable medium, release cloth, porous release film, airfelt and vacuum bag film, through the pretreated die surface of step (1), spreading and covering permeable medium successively from lower to upper, release cloth, porous release film, reinforcing material preform, porous release film and release cloth, then lay the first airfelt on release cloth corresponding above glass fibre laminboard layer region, arranges a plurality of semi permeability ventilating joints along spar length direction interval in described the first airfelt,
(3) ground floor closed mould cavity is set: with the boundary line of described glass fibre laminboard layer and described transition region on horizontal plane, be projected as line of demarcation, the first flexible vacuum bag film coating mould is used near a side of glass fibre laminboard layer in line of demarcation, flexible pellicle coating mould is used near a side of transition region in line of demarcation, the first flexible vacuum bag film and flexible pellicle cover on die surface formation ground floor closed mould cavity by sealant tape after connecting into integral body, and described reinforcing material preform and moulding auxiliary material are covered by ground floor closed mould cavity;
(4) second layer closed mould cavity is set: lay the second airfelt above described flexible pellicle, arranges a plurality of ventilating joints along spar length direction interval in described the second airfelt; Then with the second flexible vacuum bag film, cover on die surface and the first flexible vacuum bag film and flexible pellicle are sealed completely coated, form second layer closed mould cavity, the second airfelt and ventilating joint are in second layer closed mould cavity;
(5) connect external equipment: all semi permeability ventilating joint and ventilating joint are connected to pumped vacuum systems, injection system are connected to the gum-injecting port that is arranged in ground floor closed mould cavity simultaneously;
(6) vacuum injecting glue: close injection system, then open all semi permeability ventilating joint and ventilating joint, by pumped vacuum systems, discharge the gas in ground floor closed mould cavity and second layer closed mould cavity, make to reach in ground floor closed mould cavity and the second layer closed mould cavity negative pressure of vacuum can stable maintenance, open again injection system and start to inject matrix resin to flood the reinforcing material preform that is positioned at ground floor closed mould cavity, in injecting glue process, from mould, be set to one end of root of blade to the one end that is set to blade tip, closeall semi permeability ventilating joint and ventilating joint one by one, to control the flow direction of matrix resin, realize the thorough impregnation of matrix resin to reinforcing material preform,
(7) curing molding and post processing: after vacuum injecting glue completes, start to be cured moulding, in curing molding process, keep vacuum in die cavity until completion of cure, after having solidified, carry out obtaining after the demoulding, finishing and cleaning the large-scale wind electricity blade hybrid composite spar of global formation.
2. the preparation method of large-scale wind electricity blade hybrid composite spar according to claim 1, is characterized in that: described 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: described semi permeability ventilating joint is that gas can see through but the impervious ventilating joint of matrix resin glue, described semi permeability ventilating joint comprises outer rigid housing, the bottom of outer rigid housing is coated by permeable medium, in shell, be provided with gas channel, the bottom section of gas channel is provided with obturator, and obturator is mainly comprised of the pellicle superposeing successively from bottom to top, permeable medium, pellicle, airfelt and permeable medium; Between obturator and the inwall of outer rigid housing, be tightly connected; In the gas channel of obturator top, be provided with valve.
4. the preparation method of large-scale wind electricity blade hybrid composite spar according to claim 1 and 2, it is characterized in that: described ventilating joint is all permeable ventilating joints of gas and matrix resin glue, described ventilating joint comprises outer rigid housing, the bottom of outer rigid housing is coated by permeable medium, in shell, be provided with gas channel, the bottom section of gas channel is provided with obturator, and obturator is mainly comprised of the permeable medium superposeing successively from bottom to top, airfelt and permeable medium; Between obturator and the inwall of outer rigid housing, be tightly connected; In the gas channel of obturator top, be provided with valve.
5. the preparation method of large-scale wind electricity blade hybrid composite spar according to claim 1 and 2, it is characterized in that: described semi permeability ventilating joint is 2m～3m in the spacing along on spar length direction, described ventilating joint is 1m～2m in the spacing along on 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 described vacuum injecting glue step, 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 described transition region is hybrid fabrics, and its arrangement in reinforcing material preform is: the direction from described glass fabric to carbon fibre fabric, by whole glass fibres enhancing gradual change types, be transitioned into whole carbon fibers and strengthen;
Described gradual change type transition specifically refers to following any transient mode:
(1) described glass fabric forms a transition tip and wedges in the V-shaped groove forming in transition region into described carbon fibre fabric in described transition region; Or,
(2) described carbon fibre fabric forms a transition tip and wedges in the V-shaped groove forming in transition region into described glass fabric in described transition region.
8. the preparation method of large-scale wind electricity blade hybrid composite spar according to claim 7, is characterized in that, the glass fabric in described transition region and carbon fibre fabric are by weaving manner in layer, to realize transition to join;
In described layer, weaving manner refers to: the glass fabric termination in transition region and carbon fibre fabric termination are adopted to the alternately mode of braiding of interlaminar hybrid, make to extend in glass fibre laminboard layer the carbon fiber that extends into transition region in the glass fibre of transition region and carbon fiber laminboard layer and link 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 described transition region and carbon fibre fabric are by interlayer suture way, to realize transition to join, and make to extend in glass fibre laminboard layer the glass fabric of transition region together with extending into the carbon fibre fabric fixed overlay of transition region in carbon fiber laminboard layer;
The suture that described interlayer stitching adopts is one or more in aramid fiber yarn, quartz fibre yarn, glass fiber yarn.
10. according to the preparation method of the large-scale wind electricity blade hybrid composite spar described in any one in claim 1,7～9, it is characterized in that, the thickness of described spar covering layer is 2mm～3mm, and spar covering layer reinforcing material used is that glass fibre single shaft is to cloth, the axial cloth of Glass Fibre Double and/or the axial cloth of glass fibre three; Glass fabric in described spar laminboard layer is that surface density is at 1000g/m
2above single axial fabrics, the carbon fibre fabric in described spar laminboard layer is that surface density is at 600g/m
2above single axial fabrics.
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| CN104029398A (en) * | 2014-06-16 | 2014-09-10 | 江苏恒神纤维材料有限公司 | Prepressing method in composite material preparation process |
| CN104234944B (en) * | 2014-07-22 | 2017-09-15 | 株洲时代新材料科技股份有限公司 | Blade of wind-driven generator and wind-driven generator |
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| CN105415701B (en) * | 2015-12-30 | 2018-05-22 | 四川德源石油天然气工程有限公司 | For the device and its implementation of the quick impregnation of fiber cloth composite material |
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| CN108656417B (en) * | 2018-05-03 | 2020-07-10 | 国电联合动力技术有限公司 | Coating method of wind power blade surface coating |
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