CN103358564B - Integral wind power blade ultraviolet light/electron beam in-situ cured fiber placement shaped device and method - Google Patents
Integral wind power blade ultraviolet light/electron beam in-situ cured fiber placement shaped device and method Download PDFInfo
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Abstract
The invention discloses a kind of Integral wind power blade ultraviolet light/electron beam in-situ cured fiber placement shaped device and method, can be applicable to large-scale composite material wind-power blade automated manufacturing field.The present invention is directed to perfusion and merotype wind electricity blade manufacturing process automaticity lower, labour intensity is high, and quality is unstable, and two-piece type wind electricity blade glue-joint strength, bulk strength and rigidity are lower, blade laying can not optimal design, manufactures the problems such as wind turbine blade is more difficult; Adopt ultraviolet cure in site fiber placement manufacturing method and apparatus, the method uses ultraviolet light/electron beam in-situ solidifying technique that the shaping and solidification process of wind turbine blade is once completed, and global formation, improves the overall performance of curing efficiency and blade; Simultaneously, in conjunction with wind turbine blade fiber placement manufacturing system, comprise ultraviolet light/electron beam in-situ cured fiber placement head, prepreg tape induction system, mandrel support device, Integral wind power blade core, horizontal or vertical multiple degrees of freedom machine tool system and lay control system, to realize the automated manufacturing of monoblock type wind turbine blade.
Description
Technical field:
The invention belongs to wind electricity blade manufacturing technology field, relate to a kind of Integral wind power blade ultraviolet light/electron beam in-situ cured fiber placement shaped device and method.
Background technology:
Wind energy has more and more been subject to the attention of countries in the world as a kind of renewable and clean energy resource, therefore wind power installation create the key developing this green energy resource.In wind power generating set, the manufacturing cost of wind electricity blade accounts for 15% ~ 22% of totle drilling cost; And due to blade be catch the vital part of wind energy, also be affected by environment maximum, the most impaired part, current wind electricity blade mainly adopts perfusion and the manufacture of parting process, adopt the instillation process such as RTM respectively by upper blade face, lower blade face, crossbeam is made; Then, by crossbeam, upper and lower blade face is bonding, thus completes the manufacture of wind electricity blade main body.There is following problem in this process: 1. the bonding blade integral performance that causes of burst is lower; 2. blade laying can not optimal design thus can not give full play to composite advantage; 3. automaticity is lower, and labour intensity is high; 4. poor glue, rich glue, the perfusion such as fiber flexing defect is wayward; 5. manufacture wind turbine blade more difficult, need the auxiliary process such as mould, baking oven, filling system equipment supporting with it.
Integral wind power blade construction is complete, very close to each other between blade face and girder outside, and one integrated mass makes blade integral strength and stiffness be improved; And there are not gluing parts, thus avoid crack, moisture intrusion, these potential threats of thunder and lightning to the adverse effect of blade.Siemens adopts Integralblade technology to produce the large-scale integral formula wind electricity blade of 75 meters, substantially improves the overall performance of blade.But this technology is also that the perfusion of employing resin and molded curing are shaping, there is automaticity not high, the problems such as labour intensity is large, and resin perfusion defect is wayward.
In order to improve wind turbine blade workmanship and efficiency, increase wind electricity blade service life, reduce wind electricity blade manufacturing cost and reduce the maintenance and repair cost of wind electricity blade in running, exploitation and design novel wind power vane manufacturing technology and device become problem demanding prompt solution.
In ultraviolet light/electron beam in-situ solidifying process, energy consumption is little, solvent-free volatilization, environmental protection, and this curing process has been applied to manufacture and the reparation of wind electricity blade, and the manufacture etc. of large ship hull shows good effect.Meanwhile, when adopting ultraviolet light/electron beam layering in-situ solidifying manufacture technics composite element, component overlay thickness is unrestricted, and curing efficiency is high.
Fiber placement automated manufacturing technology is that a kind of automaticity is high, for the production of the advanced molding fabrication techniques of large-scale, that curved surface is complicated composite element, is mainly used in Aero-Space, boats and ships, in the industrial circles such as new forms of energy.The series of advantages such as manufactured resin base fiber reinforced composite material product has that specific strength is high, specific modulus is high, corrosion-resistant, endurance.
Summary of the invention:
The problem that the present invention solves is to provide a kind of Integral wind power blade ultraviolet light/electron beam in-situ cured fiber placement shaped device and method, adopts automation equipment to manufacture monoblock type wind turbine blade, to improve workmanship and the service life of blade.
The present invention is achieved through the following technical solutions:
A kind of Integral wind power blade ultraviolet light/electron beam in-situ cured fiber placement shaped device, comprise and support wind electricity blade monoblock type core and its mandrel support device rotated can be driven, under multiple degrees of freedom machine tool system drives, ultraviolet light attached to it/electron beam in-situ cured fiber placement head and prepreg tape induction system carry out the automatic fibers laying forming processing of Integral wind power blade, ultraviolet light/electronic beam curing prepreg tape is delivered in ultraviolet light/electron beam in-situ cured fiber placement head by prepreg tape induction system, by ultraviolet light/electron beam in-situ cured fiber placement head by ultraviolet light/electronic beam curing prepreg tape lay, compacting, be solidificated on Integral wind power blade core, fiber placement control system and multi-shaft interlocked control system according to lay path and lay-up procedure to ultraviolet light/electron beam in-situ cured fiber placement head, prepreg tape induction system, multiple degrees of freedom machine tool system and mandrel support device Collaborative Control.
Described ultraviolet light/electron beam in-situ cured fiber placement head comprises: prepreg tape laying mechanism, hold-down mechanism, jockey, ultraviolet light/electronic beam curing light source and ultraviolet light/electronic beam curing prepreg tape; The conveying of prepreg tape laying mechanism, shearing, clamping ultraviolet light/electronic beam curing prepreg tape, ultraviolet light/electronic beam curing prepreg tape is compressed compacting at Integral wind power blade mandrel surface by hold-down mechanism, ultraviolet light/electron beam source solidification prepreg tape, is arranged on ultraviolet light/electron beam in-situ cured fiber placement head on multiple degrees of freedom machine tool system by jockey.
Described prepreg tape induction system comprises: prepreg tape storing compartment, prepreg tape winding/unwinding device, prepreg tape guiding mechanism, tension detecting apparatus and prepreg tape condition checkout gear; Prepreg tape storing compartment is installed on multiple degrees of freedom machine tool system, the temperature providing applicable prepreg tape to deposit, humidity and cleanliness factor environment, and its inside is provided with multiple prepreg tape winding/unwinding device; Prepreg tape winding/unwinding device is installed prepreg tape material volume and in laid course, is supplied prepreg tape according to depositing speeds and collect prepreg tape backing paper; Prepreg tape guiding mechanism, between prepreg tape storing compartment and ultraviolet light/electron beam in-situ cured fiber placement head, guides prepreg tape from storing compartment, be delivered to ultraviolet light/electron beam in-situ cured fiber placement head, and prevents prepreg tape from reversing, interfere with each other staggered; Tension detecting apparatus and prepreg tape condition checkout gear, in prepreg tape storing compartment or between prepreg tape storing compartment and prepreg tape guiding mechanism, detect tension force and feed status in prepreg tape course of conveying.
Described mandrel support device comprises: the headstock, tailstock, center bearing bracket, supporting guide and core electric rotating machine; Core electric rotating machine is installed on the headstock, drives the rotation of the Integral wind power blade core be supported on the headstock, center bearing bracket, tailstock; Center bearing bracket between the headstock and tailstock, supplemental support wind electricity blade core, the Integral wind power blade core preventing from large span from supporting causing distortion; Supporting guide supports installs the headstock, center bearing bracket and tailstock, adjusts distance between each support by center bearing bracket or tailstock along the slip of supporting guide.
Described Integral wind power blade core comprises: crossbeam, Ye Xin, blade root supporting mechanism, blade tip supporting mechanism and composite plys; Integral wind power blade core profile and wind electricity blade profile are consistent, and crossbeam, as skeleton, is wrapped up by the leaf core as filler; Be respectively equipped with blade root supporting mechanism and blade tip supporting mechanism at Integral wind power blade core two ends, by Integral wind power blade core location and installation in mandrel support device, when after blade laying forming, remove blade root supporting mechanism and blade tip supporting mechanism; Composite plys is in laying forming process, the ply angles formed at Integral wind power blade core outer surface according to the lay angle envelope of planning.
Described multiple degrees of freedom machine tool system is one or two horizontal multiple degrees of freedom machine tool system, comprising: longitudinal rail, column, cross slideway, crossbeam and Double swing head mechanism; Column is arranged on longitudinal rail, and can longitudinally move by guide rail; Cross slideway is arranged on column, can slide up and down along column; Crossbeam is installed on cross slideway, can slide along the direction of cross slideway perpendicular to column; Double swing head mechanism can realize two rotary freedoms of lathe, and its one end is installed on crossbeam, and the other end connects ultraviolet light/electron beam in-situ cured fiber placement head;
When employing two horizontal multiple degrees of freedom machine tool systems, respectively arrange one in Integral wind power blade core both sides.
Described multiple degrees of freedom machine tool system is vertical multiple degrees of freedom machine tool system, comprising: mobile gantry, biserial longitudinal rail, cross slideway, ram and Double swing head mechanism; Mobile gantry is installed on biserial longitudinal rail, and can move along biserial longitudinal rail; Cross slideway is installed on the side of the crossbeam of mobile gantry, can along cross beam movement; Ram is installed on cross slideway, and can move along the direction of the crossbeam perpendicular to mobile gantry; The lower end of ram is provided with Double swing head mechanism, and Double swing head mechanism can realize two rotary freedoms of lathe, and its one end is arranged on ram, and one end connects ultraviolet light/electron beam in-situ cured fiber placement head in addition.
Described fiber placement control system and multi-shaft interlocked control system can control independently to carry every a branch of prepreg tape, shear, clipping operation, and can control light exposure, thrust and tension force in real time;
The number of motion axes that fiber placement control system and multi-shaft interlocked control system control reaches more than four axles, and can realize the real-time communication of same fiber placement control system.
A kind of Integral wind power blade ultraviolet light/electron beam in-situ cured fiber placement forming method, comprises following operation:
1) CAE intensive analysis is carried out according to wind electricity blade Design CAD model and to the external load of wind electricity blade, and extract stress curve distribution according to analysis result, then carry out optimum design of laminate layup by stress curve distribution and cad model, make wind electricity blade combination property optimum; And according to Lay up design result planning automatic fibers lay path, and the routing information planned is converted to lay-up procedure;
Meanwhile, adopt conventional method to manufacture Integral wind power blade girder according to cad model, then with leaf core parcel crossbeam, and make Integral wind power blade core according to wind electricity blade aerodynamic configuration;
2) Integral wind power blade core is placed on mandrel support device, and it supports blade root supporting mechanism and blade tip supporting mechanism respectively at two ends; Then multiple degrees of freedom machine tool system, ultraviolet light/electron beam in-situ cured fiber placement head and prepreg tape induction system are installed around Integral wind power blade core, lay-up procedure are configured in fiber placement control system and multi-shaft interlocked control system;
Under fiber placement control system and multi-shaft interlocked control system control, ultraviolet light/electronic beam curing prepreg tape is delivered in ultraviolet light/electron beam in-situ cured fiber placement head by prepreg tape induction system, by ultraviolet light/electron beam in-situ cured fiber placement head by ultraviolet light/electronic beam curing prepreg tape lay, compacting, be solidificated on Integral wind power blade core and form ply angles;
3) after Integral wind power blade core laying forming completes, Integral wind power blade finished product is made through postprocessing working procedures.
Concrete, described step 1) in stress curve distribution extraction be according to CAE intensive analysis result, the data of stress curve distribution in background are extracted by the secondary development of CAE software, distributed and cad model by stress curve, according to stress direction, carry out design optimization laying angle by variation rigidity method for designing, make blade combination property optimum; According to laying angle information by CAM Software Create automatic fibers lay path, and Digit Control Machine Tool lay path data information being converted to standard processes G code as lay-up procedure, to control the motion of multiple degrees of freedom lathe
Described step 2) in lay application configuration be G code is inputted in multi-shaft interlocked control system; Control the rotation of Integral wind power blade core, and the lay of placement head moves and processing action simultaneously, and carry out the laying forming of blade in conjunction with ultraviolet light/electron beam in-situ solidifying technique, realize the processing of Integral wind power blade lay;
Described step 3) in postprocessing working procedures comprise deburring, detect, application, to complete the processing of Integral wind power blade.
Compared with prior art, the Advantageous Effects that the present invention brings is:
Integral wind power blade ultraviolet light/electron beam in-situ cured fiber placement shaped device provided by the invention and method, be a kind ofly adopt ultraviolet light/electron beam in-situ solidifying technique in conjunction with automatic fibers lay manufacturing technology to manufacture the apparatus and method of monoblock type wind turbine blade, be applicable to large-scale composite material wind-power blade automated manufacturing field.The method uses ultraviolet light/electron beam in-situ solidifying technique that the shaping and solidification process of wind turbine blade is once completed, and global formation, improves the overall performance of curing efficiency and blade; Meanwhile, in conjunction with wind turbine blade fiber placement manufacturing system, realize the high-efficient automatic manufacture of monoblock type wind turbine blade.
The invention solves perfusion and merotype wind electricity blade manufacturing process automaticity lower, labour intensity is high, and quality is unstable, and two-piece type wind electricity blade glue-joint strength, bulk strength and rigidity are lower, blade laying can not optimal design, manufactures the problems such as wind turbine blade is more difficult.
Integral wind power blade ultraviolet light/electron beam in-situ cured fiber placement shaped device provided by the invention and method, adopt automation equipment to manufacture large-scale integral formula wind electricity blade, to improve workmanship and the service life of blade.Produce in an automated fashion owing to adopting, improve manufacture efficiency, reduce manufacturing cost.
Integral wind power blade ultraviolet light/electron beam in-situ cured fiber placement shaped device provided by the invention and method, support the optimal design of blade construction, by CAE Optimal Structure Designing, increase the service life, and reduces weight, improves combination property; Effectively can mate with prior art, existing Mold Making monoblock type core can be adopted.
Integral wind power blade ultraviolet light/electron beam in-situ cured fiber placement shaped device provided by the invention and method, adopt ultraviolet light/electronic beam curing prepreg tape material system, shaping efficiency is high, is conducive to maintenance and repair.
Accompanying drawing illustrates:
Fig. 1 is Integral wind power blade ultraviolet light/electron beam in-situ solidifying automatic fibers lay manufacturing flow chart;
Fig. 2 is Integral wind power vane manufacturing schematic diagram;
Fig. 3 is ultraviolet light/electron beam in-situ cured fiber placement head structural representation;
Fig. 4 adopts horizontal automatic fibers layer to manufacture Integral wind power blade schematic diagram;
Fig. 5 is Integral wind power Leaf structure schematic diagram;
Fig. 6 adopts planer-type automatic fibers layer to manufacture Integral wind power blade schematic diagram;
Fig. 7 is that dual horizontal automatic fibers layer manufactures Integral wind power blade schematic diagram.
Detailed description of the invention:
The present invention adopts ultraviolet light/electron beam in-situ cured fiber placement manufacturing method and apparatus, the method uses ultraviolet light/electron beam in-situ solidifying technique that the shaping and solidification process of wind turbine blade is once completed, global formation, improves the overall performance of curing efficiency and blade; Simultaneously, in conjunction with wind turbine blade fiber placement manufacturing system, comprise: ultraviolet light/electron beam in-situ cured fiber placement head, prepreg tape induction system, monoblock type mandrel support device, the overall core of wind turbine blade, horizontal or vertical multiple degrees of freedom machine tool system and lay control system and multi-shaft interlocked control system, to realize the automated manufacturing of monoblock type wind turbine blade.Below in conjunction with specific embodiment, the present invention is described in further detail, and the explanation of the invention is not limited.
Composition graphs 1, a kind of Integral wind power blade ultraviolet light/electron beam in-situ cured fiber placement manufacture method, comprises following operation:
1) CAE software is adopted to carry out intensive analysis according to the external load file of wind electricity blade Design CAD model and wind electricity blade, ANSYS can be adopted, the specialty analysis softwares such as ABQUS carry out intensive analysis, and according to analysis result, stress curve distribution is extracted by data processing, then design laying angle according to stress distribution and cad model, make blade combination property optimum;
Concrete, extracted the data of stress curve distribution in background by the secondary development of CAE software, distributed and cad model by stress curve, according to stress direction, carry out design optimization laying angle by variation rigidity method for designing, make blade combination property optimum.
After laying path design completes, by the CAM module of the three-dimensional softwares such as CATIA, UG or the method by secondary development, the routing information designed is converted to the Digit Control Machine Tool processing G code control program of standard, for controlling the motion of multiple degrees of freedom lathe;
Meanwhile, adopt common manufacturing method to manufacture wind turbine blade crossbeam, Ye Xin according to cad model, and crossbeam and Ye Xin are made Integral wind power blade core;
2) Integral wind power blade core is placed on mandrel support device, and it supports blade root supporting mechanism and blade tip supporting mechanism respectively at two ends; Then multiple degrees of freedom machine tool system, ultraviolet light/electron beam in-situ cured fiber placement head and prepreg tape induction system are installed around Integral wind power blade core, lay-up procedure are configured in fiber placement control system and multi-shaft interlocked control system;
Under fiber placement control system and multi-shaft interlocked control system control, ultraviolet light/electronic beam curing prepreg tape is delivered in ultraviolet light/electron beam in-situ cured fiber placement head by prepreg tape induction system, by ultraviolet light/electron beam in-situ cured fiber placement head by ultraviolet light/electronic beam curing prepreg tape lay, compacting, be solidificated on Integral wind power blade core and form ply angles;
Concrete, G code is inputted in multi-shaft interlocked control system, as Siemens 840D etc., control the rotation of Integral wind power blade core simultaneously, and the lay of placement head moves and processing action, and the laying forming of blade is carried out in conjunction with ultraviolet light/electron beam in-situ solidifying technique, realize Integral wind power blade processing.
3) after Integral wind power blade core laying forming completes, Integral wind power blade finished product is made through postprocessing working procedures.Described postprocessing working procedures comprises deburring, and detect, the postprocessing working procedures such as application complete the processing of integral blade.
See Fig. 2 ~ Fig. 7, a kind of Integral wind power blade ultraviolet light/electron beam in-situ cured fiber placement shaped device, comprise and support wind electricity blade monoblock type core 4 and the mandrel support device 3 that it can be driven to rotate, under multiple degrees of freedom machine tool system 5 drives, ultraviolet light attached to it/electron beam in-situ cured fiber placement head 1 and prepreg tape induction system 2 carry out the automatic fibers laying forming processing of Integral wind power blade, ultraviolet light/electronic beam curing prepreg tape is delivered in ultraviolet light/electron beam in-situ cured fiber placement head 1 by prepreg tape induction system 2, by ultraviolet light/electron beam in-situ cured fiber placement head 1 by ultraviolet light/electronic beam curing prepreg tape lay, compacting, be solidificated on Integral wind power blade core 4, fiber placement control system and multi-shaft interlocked control system 6 according to lay path and lay-up procedure to ultraviolet light/electron beam in-situ cured fiber placement head 1, prepreg tape induction system 2, multiple degrees of freedom machine tool system 5 and mandrel support device 3 Collaborative Control.
Concrete, comprise see Fig. 2, Fig. 3 ultraviolet light/electron beam in-situ cured fiber placement head 1: prepreg tape laying mechanism 1-1, hold-down mechanism 1-2, jockey 1-3, ultraviolet light/electronic beam curing light source 1-4, ultraviolet light/electronic beam curing prepreg tape 1-5.
Prepreg tape laying mechanism 1-1 is used for conveying, shears, clamping ultraviolet light/electronic beam curing prepreg tape, and concrete structure can with reference to disclosed patent document CN1911638A or data of literatures.Ultraviolet light/electronic beam curing prepreg tape is compressed compacting on Integral wind power blade core 4 surface by hold-down mechanism 1-2, such as adopt the method that cylinder is exerted pressure, the end of cylinder is connected and installed with flexible compression roller, stretching out and retrieving to make flexible compression roller press on Integral wind power blade mandrel surface by cylinder, thrust can adjust its size by changing air pressure.Ultraviolet light/electron beam source 1-4 solidifies prepreg tape, is arranged on multiple degrees of freedom machine tool system 5 by ultraviolet light/electron beam in-situ cured fiber placement head 1 by jockey 1-3.Concrete, jockey 1-3, for fiber placement head is arranged on multiple degrees of freedom lathe, adopts the mode of Flange joint, for convenience detach.Ultraviolet light/electron beam source 1-4 is for solidifying prepreg tape, and ultraviolet light/electron beam wavelength is 365nm, and ultraviolet light/electronic beam curing prepreg tape uses the light-cured resin of advanced manufacturing technology research institute of Xi'an Communications University research and development.
See Fig. 2, Fig. 4, prepreg tape induction system comprises: prepreg tape storing compartment 2-1, prepreg tape winding/unwinding device 2-2, prepreg tape guiding mechanism 2-3, tension detecting apparatus 2-4, and prepreg tape condition checkout gear 2-5.
Prepreg tape storing compartment 2-1 is arranged on multiple degrees of freedom lathe, and conveniently machine design method designs, and manufactures processing.Prepreg tape storing compartment has good sealing, and inside is provided with aircondition, to ensure suitable temperature, humidity and purity requirements.
The temperature that prepreg tape storing compartment 2-1 provides applicable prepreg tape to deposit, humidity and cleanliness factor environment, its inside is provided with multiple prepreg tape winding/unwinding device 2-2; Prepreg tape winding/unwinding device 2-2 installs prepreg tape material volume and in laid course, supplies prepreg tape according to depositing speeds and collect prepreg tape backing paper.Prepreg tape winding/unwinding device 2-2 can refer to unwinding and rewinding mechanism in textile industry or Filament-wound Machine technology and carries out conventional mechanical design.
Prepreg tape guiding mechanism 2-3 is between prepreg tape storing compartment 2-1 and ultraviolet light/electron beam in-situ cured fiber placement head 1, guide prepreg tape from storing compartment 2-1, be delivered to ultraviolet light/electron beam in-situ cured fiber placement head 1, specifically can be made up of one group of guide roller, reduce the resistance of prepreg tape in course of conveying, and by the adjustment in guide wheel gap, reach and prevent prepreg tape torsional deflection, interfere with each other staggered object.
Tension detecting apparatus 2-4 and prepreg tape condition checkout gear 2-5, in prepreg tape storing compartment 2-1 or between prepreg tape storing compartment 2-1 and prepreg tape guiding mechanism 2-3, detects tension force and feed status in prepreg tape course of conveying; Tension detecting apparatus 2-4 can select German Schmidt TS1-50 line tension sensor.Infrared photoelectric sensor can be used to the coil diameter detecting prepreg tape, as selected Omron E32-DC200 type photoelectric sensor etc.
See Fig. 6, mandrel support device 3 comprises: headstock 3-1, tailstock 3-2, center bearing bracket 3-3, supporting guide 3-4, core electric rotating machine 3-5.Wherein, core electric rotating machine 3-5 is installed on the headstock, center bearing bracket 3-3 is between headstock 3-1 and tailstock 3-2, supporting guide 3-4 supports and installs headstock 3-1, center bearing bracket 3-3 and tailstock 3-2, adjusts distance between each support by center bearing bracket 3-3 or tailstock 3-2 along the slip of supporting guide 3-4.
Headstock 3-1 is provided with scroll chuck for fixing core, core electric rotating machine 3-5 is installed on the headstock, rotates for driving the rotation of the Integral wind power blade core 4 be supported on headstock 3-1, center bearing bracket 3-3, tailstock 3-2.Tailstock 3-2 adopts heavy live center to support one end of monoblock type core 4.Stablizing in order to ensure core, Reducing distortion, is provided with center bearing bracket 3-3 between headstock 3-1 and tailstock 3-2, for supplemental support wind electricity blade core, prevents because large span supports the blade core distortion caused.Supporting guide 3-4 adopts splicing structure, installing the headstock, center bearing bracket and tailstock, adjusting the distance between each support by making center bearing bracket or tailstock along slide for supporting.
See Fig. 2, Fig. 5, wind electricity blade monoblock type core 4 comprises: crossbeam 4-1, Ye Xin 4-2, blade root supporting mechanism 4-3, blade tip supporting mechanism 4-4, composite plys 4-5; Integral wind power blade core 4 profile and wind electricity blade profile are consistent, and crossbeam 4-1, as skeleton, is wrapped up by the leaf core 4-2 as filler; Blade root supporting mechanism 4-3 and blade tip supporting mechanism 4-4 is respectively equipped with at Integral wind power blade core 4 two ends, by Integral wind power blade core 4 location and installation in mandrel support device 3, when after blade laying forming, remove blade root supporting mechanism 4-3 and blade tip supporting mechanism 4-4; Composite plys 4-5 is in laying forming process, the ply angles formed at Integral wind power blade core 4 outer surface according to the lay angle envelope of planning.
Concrete, crossbeam adopts composite material pultrusion technique to make, and after making, its two ends increase blade root supporting mechanism and blade tip supporting mechanism again, are then made into as a whole by the mode of mold pressing by crossbeam and Ye Xin, wind electricity blade core to form a monolithic, Ye Xin adopts foamed material.After Integral wind power blade core is made, be arranged on mandrel support device, by automatic fibers lay system by composite plys lay to mandrel surface, through the laying forming of multilayer, finally produce Integral wind power blade.
See Fig. 2, Fig. 4, horizontal multiple degrees of freedom machine tool system 5 comprises: longitudinal rail 5-1, column 5-2, cross slideway 5-3, crossbeam 5-4, Double swing head mechanism 5-5.
Column 5-2 is arranged on longitudinal rail 5-1, and can longitudinally move by guide rail 5-1; Cross slideway 5-3 is arranged on column 5-2, can slide up and down along column 5-2; Crossbeam 5-4 is installed on cross slideway 5-3, can slide along cross slideway 5-3 perpendicular to the direction of column 5-2; Double swing head mechanism 5-5 can realize two rotary freedoms of lathe, and its one end is installed on crossbeam 5-4, and the other end connects ultraviolet light/electron beam in-situ cured fiber placement head 1.
Concrete, horizontal multiple degrees of freedom machine tool system with reference to associated machine tool design manual, can select guide rail, drive motors and other annexes.Prepreg tape induction system is arranged on column, with column along the longitudinal guide rail move, guiding mechanism, tension detecting apparatus etc. are arranged in crossbeam and placement head.
See composition graphs 6, vertical multiple degrees of freedom machine tool system 5 comprises: mobile gantry 5-6, biserial longitudinal rail 5-7, cross slideway 5-8, ram 5-9, Double swing head mechanism 5-10;
Mobile gantry 5-6 is installed on biserial longitudinal rail 5-7, and can move along biserial longitudinal rail 5-7; Cross slideway 5-8 is installed on the side of the crossbeam of mobile gantry 5-6, can along cross beam movement; Ram 5-9 is installed on cross slideway 5-8, and can move along the direction of the crossbeam perpendicular to mobile gantry 5-6; The lower end of ram 5-9 is provided with Double swing head mechanism 5-10, and Double swing head mechanism 5-10 can realize two rotary freedoms of lathe, and its one end is arranged on ram, and one end connects ultraviolet light/electron beam in-situ cured fiber placement head in addition.
Concrete, movable gantry multiple degrees of freedom lathe with reference to associated machine tool design manual, can select guide rail, drive motors and other annexes.Ram can be used for installing prepreg tape storing compartment, to shorten the fed distance of prepreg tape.
See Fig. 7, horizontal multiple degrees of freedom machine tool system according to laying forming requirement, can respectively arrange one in Integral wind power blade core both sides, to improve lay working (machining) efficiency.Two horizontal fiber placement machines adopt identical configuration, independently control, and input different lay procedures, and lay path is not identical yet.
Fiber placement control system and multi-shaft interlocked control system 6 can control independently to carry every a branch of prepreg tape, shear, clipping operation, and the technological parameters such as light exposure, thrust, tension force can be controlled in real time, digital control system in open type such as admittedly high kinetic control system GTS800 can be adopted to realize the control of each lay action and the collection of technological parameter and control; And the number of motion axes that multi-shaft interlocked control system controls reaches more than four axles, Siemens 840D control system can be adopted, and by Ethernet interface or RS232 interface with open type movement-control system real-time communication.
Above content is in conjunction with concrete preferred embodiment further description made for the present invention; can not assert that the specific embodiment of the present invention is only limitted to this; for general technical staff of the technical field of the invention, made some simple deduction or replace all should be considered as belonging to the present invention by submitted to claims determination scope of patent protection without departing from the inventive concept of the premise.
Claims (7)
1. Integral wind power blade ultraviolet light/electron beam in-situ cured fiber placement shaped device, it is characterized in that, comprise and support wind electricity blade monoblock type core (4) and its mandrel support device rotated (3) can be driven, under multiple degrees of freedom machine tool system (5) drives, ultraviolet light attached to it/electron beam in-situ cured fiber placement head (1) and prepreg tape induction system (2) carry out the automatic fibers laying forming processing of Integral wind power blade, ultraviolet light/electronic beam curing prepreg tape is delivered in ultraviolet light/electron beam in-situ cured fiber placement head (1) by prepreg tape induction system (2), by ultraviolet light/electron beam in-situ cured fiber placement head (1) by ultraviolet light/electronic beam curing prepreg tape lay, compacting, be solidificated on Integral wind power blade core (4), fiber placement control system and multi-shaft interlocked control system (6) according to lay path and lay-up procedure to ultraviolet light/electron beam in-situ cured fiber placement head (1), prepreg tape induction system (2), multiple degrees of freedom machine tool system (5) and mandrel support device (3) Collaborative Control,
Wherein said multiple degrees of freedom machine tool system (5) is one or two horizontal multiple degrees of freedom machine tool system, comprise: longitudinal rail (5-1), column (5-2), cross slideway (5-3), crossbeam (5-4) and Double swing head mechanism (5-5); Column (5-2) is arranged on longitudinal rail (5-1), and can longitudinally move by guide rail (5-1); Cross slideway (5-3) is arranged on column (5-2), can slide up and down along column (5-2); Crossbeam (5-4) is installed on cross slideway (5-3), can slide along the direction of cross slideway (5-3) perpendicular to column (5-2); Double swing head mechanism (5-5) can realize two rotary freedoms of lathe, and its one end is installed on crossbeam (5-4), and the other end connects ultraviolet light/electron beam in-situ cured fiber placement head (1); When employing two horizontal multiple degrees of freedom machine tool systems, respectively arrange one in Integral wind power blade core (4) both sides.
2. Integral wind power blade ultraviolet light/electron beam in-situ cured fiber placement shaped device as claimed in claim 1, it is characterized in that, described ultraviolet light/electron beam in-situ cured fiber placement head (1) comprising: prepreg tape laying mechanism (1-1), hold-down mechanism (1-2), jockey (1-3), ultraviolet light/electronic beam curing light source (1-4) and ultraviolet light/electronic beam curing prepreg tape (1-5); Prepreg tape laying mechanism (1-1) conveying, shearing, clamping ultraviolet light/electronic beam curing prepreg tape, ultraviolet light/electronic beam curing prepreg tape is compressed compacting on Integral wind power blade core (4) surface by hold-down mechanism (1-2), ultraviolet light/electron beam source (1-4) solidifies prepreg tape, is arranged on multiple degrees of freedom machine tool system (5) by ultraviolet light/electron beam in-situ cured fiber placement head (1) by jockey (1-3).
3. Integral wind power blade ultraviolet light/electron beam in-situ cured fiber placement shaped device as claimed in claim 1, it is characterized in that, described prepreg tape induction system (2) comprising: prepreg tape storing compartment (2-1), prepreg tape winding/unwinding device (2-2), prepreg tape guiding mechanism (2-3), tension detecting apparatus (2-4) and prepreg tape condition checkout gear (2-5); Prepreg tape storing compartment (2-1) is installed on multiple degrees of freedom machine tool system (5), the temperature providing applicable prepreg tape to deposit, humidity and cleanliness factor environment, and its inside is provided with multiple prepreg tape winding/unwinding device (2-2); Prepreg tape winding/unwinding device (2-2) is installed prepreg tape material volume and in laid course, is supplied prepreg tape according to depositing speeds and collect prepreg tape backing paper; Prepreg tape guiding mechanism (2-3) is positioned between prepreg tape storing compartment (2-1) and ultraviolet light/electron beam in-situ cured fiber placement head (1), guide prepreg tape from storing compartment (2-1), be delivered to ultraviolet light/electron beam in-situ cured fiber placement head (1), and prevent prepreg tape from reversing, interfere with each other staggered; Tension detecting apparatus (2-4) and prepreg tape condition checkout gear (2-5) are arranged in prepreg tape storing compartment (2-1) or are positioned between prepreg tape storing compartment (2-1) and prepreg tape guiding mechanism (2-3), detect tension force and feed status in prepreg tape course of conveying.
4. Integral wind power blade ultraviolet light/electron beam in-situ cured fiber placement shaped device as claimed in claim 1, it is characterized in that, described mandrel support device (3) comprising: the headstock (3-1), tailstock (3-2), center bearing bracket (3-3), supporting guide (3-4) and core electric rotating machine (3-5); Core electric rotating machine (3-5) is installed on the headstock, drives the rotation of the Integral wind power blade core (4) be supported on the headstock (3-1), center bearing bracket (3-3), tailstock (3-2); Center bearing bracket (3-3) is positioned between the headstock (3-1) and tailstock (3-2), supplemental support wind electricity blade core, Integral wind power blade core (4) distortion preventing from large span from supporting causing; Supporting guide (3-4) supports installs the headstock (3-1), center bearing bracket (3-3) and tailstock (3-2), adjusts distance between each support by center bearing bracket (3-3) or tailstock (3-2) along the slip of supporting guide (3-4).
5. Integral wind power blade ultraviolet light/electron beam in-situ cured fiber placement shaped device as claimed in claim 1, it is characterized in that, described Integral wind power blade core (4) comprising: crossbeam (4-1), Ye Xin (4-2), blade root supporting mechanism (4-3), blade tip supporting mechanism (4-4) and composite plys (4-5); Integral wind power blade core (4) profile and wind electricity blade profile are consistent, and crossbeam (4-1), as skeleton, is wrapped up by the leaf core (4-2) as filler; Blade root supporting mechanism (4-3) and blade tip supporting mechanism (4-4) is respectively equipped with at Integral wind power blade core (4) two ends, by Integral wind power blade core (4) location and installation in mandrel support device (3), when after blade laying forming, remove blade root supporting mechanism (4-3) and blade tip supporting mechanism (4-4); Composite plys (4-5) is in laying forming process, the ply angles formed at Integral wind power blade core (4) outer surface according to the lay angle envelope of planning.
6. Integral wind power blade ultraviolet light/electron beam in-situ cured fiber placement shaped device as claimed in claim 1, it is characterized in that, described fiber placement control system and multi-shaft interlocked control system (6) can control independently to carry every a branch of prepreg tape, shear, clipping operation, and can control light exposure, thrust and tension force in real time;
The number of motion axes that fiber placement control system and multi-shaft interlocked control system (6) control reaches more than four axles, and can realize the real-time communication of same fiber placement control system.
7. Integral wind power blade ultraviolet light/electron beam in-situ cured fiber placement forming method, is characterized in that, comprise following operation:
1) CAE intensive analysis is carried out according to wind electricity blade Design CAD model and to the external load of wind electricity blade, and extract stress curve distribution according to analysis result, then carry out optimum design of laminate layup by stress curve distribution and cad model, make wind electricity blade combination property optimum; And according to Lay up design result planning automatic fibers lay path, and the routing information planned is converted to lay-up procedure;
Meanwhile, adopt conventional method to manufacture Integral wind power blade girder according to cad model, then with leaf core parcel crossbeam, and make Integral wind power blade core according to wind electricity blade aerodynamic configuration;
Wherein the extraction of stress curve distribution is according to CAE intensive analysis result, the data of stress curve distribution in background are extracted by the secondary development of CAE software, distributed and cad model by stress curve, according to stress direction, carry out design optimization laying angle by variation rigidity method for designing, make blade combination property optimum; According to laying angle information by CAM Software Create automatic fibers lay path, and Digit Control Machine Tool lay path data information being converted to standard processes G code as lay-up procedure, to control the motion of multiple degrees of freedom lathe;
2) Integral wind power blade core is placed on mandrel support device, and it supports blade root supporting mechanism and blade tip supporting mechanism respectively at two ends; Then multiple degrees of freedom machine tool system, ultraviolet light/electron beam in-situ cured fiber placement head and prepreg tape induction system are installed around Integral wind power blade core, lay-up procedure are configured in fiber placement control system and multi-shaft interlocked control system;
Under fiber placement control system and multi-shaft interlocked control system control, ultraviolet light/electronic beam curing prepreg tape is delivered in ultraviolet light/electron beam in-situ cured fiber placement head by prepreg tape induction system, by ultraviolet light/electron beam in-situ cured fiber placement head by ultraviolet light/electronic beam curing prepreg tape lay, compacting, be solidificated on Integral wind power blade core and form ply angles;
Wherein lay-up procedure configuration is inputted by G code in multi-shaft interlocked control system; Control the rotation of Integral wind power blade core, and the lay of placement head moves and processing action simultaneously, and carry out the laying forming of blade in conjunction with ultraviolet light/electron beam in-situ solidifying technique, realize the processing of Integral wind power blade lay;
3) after Integral wind power blade core laying forming completes, make Integral wind power blade finished product through postprocessing working procedures, wherein postprocessing working procedures comprises deburring, and detect, application, to complete the processing of Integral wind power blade.
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