CN107009644B - Wind power blade manufacturing method - Google Patents
Wind power blade manufacturing method Download PDFInfo
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- CN107009644B CN107009644B CN201710311896.9A CN201710311896A CN107009644B CN 107009644 B CN107009644 B CN 107009644B CN 201710311896 A CN201710311896 A CN 201710311896A CN 107009644 B CN107009644 B CN 107009644B
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- cushion block
- bolt sleeve
- blade
- rigid control
- fiber reinforced
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 54
- 239000004744 fabric Substances 0.000 claims abstract description 155
- 239000000835 fiber Substances 0.000 claims abstract description 58
- 229920005989 resin Polymers 0.000 claims abstract description 34
- 239000011347 resin Substances 0.000 claims abstract description 34
- 239000003365 glass fiber Substances 0.000 claims description 45
- 238000000034 method Methods 0.000 claims description 33
- 239000000463 material Substances 0.000 claims description 21
- 239000003795 chemical substances by application Substances 0.000 claims description 11
- 238000001746 injection moulding Methods 0.000 claims description 10
- 238000000465 moulding Methods 0.000 claims description 9
- 238000001723 curing Methods 0.000 claims description 7
- 239000011152 fibreglass Substances 0.000 claims description 7
- 238000010438 heat treatment Methods 0.000 claims description 7
- 238000002347 injection Methods 0.000 claims description 7
- 239000007924 injection Substances 0.000 claims description 7
- 239000011148 porous material Substances 0.000 claims description 7
- 238000004080 punching Methods 0.000 claims description 7
- 238000005096 rolling process Methods 0.000 claims description 6
- 238000000748 compression moulding Methods 0.000 claims description 4
- 238000002360 preparation method Methods 0.000 claims description 4
- 238000004804 winding Methods 0.000 claims description 4
- 239000003822 epoxy resin Substances 0.000 claims description 3
- 238000013007 heat curing Methods 0.000 claims description 3
- 229920000647 polyepoxide Polymers 0.000 claims description 3
- 238000005516 engineering process Methods 0.000 claims description 2
- 238000009966 trimming Methods 0.000 claims description 2
- 239000000428 dust Substances 0.000 abstract description 2
- 238000005429 filling process Methods 0.000 abstract description 2
- 238000010030 laminating Methods 0.000 abstract description 2
- 238000003860 storage Methods 0.000 abstract description 2
- 238000001802 infusion Methods 0.000 abstract 1
- 125000006850 spacer group Chemical group 0.000 description 7
- 230000037303 wrinkles Effects 0.000 description 6
- 238000009434 installation Methods 0.000 description 4
- 230000007704 transition Effects 0.000 description 3
- 239000002131 composite material Substances 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 230000002349 favourable effect Effects 0.000 description 2
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- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
- B29C70/36—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and impregnating by casting, e.g. vacuum casting
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
- B29C70/681—Component parts, details or accessories; Auxiliary operations
- B29C70/683—Pretreatment of the preformed part, e.g. insert
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/08—Blades for rotors, stators, fans, turbines or the like, e.g. screw propellers
- B29L2031/082—Blades, e.g. for helicopters
Abstract
The invention discloses a manufacturing method of a wind power blade, which is characterized in that a rigid cushion block is embedded in a blade root layer to inhibit soft fiber reinforced fabric from deforming. The rigidity control cushion block is divided into a bolt sleeve lower cushion block and a bolt sleeve upper cushion block due to different forms, the lower rigidity control cushion block is manufactured by taking a blade root cylindrical section of a blade mould as the mould, and the obtained cushion block has good matching performance with the blade mould. The upper rigid control cushion block is manufactured by adopting a special die, and the die is reasonably designed, so that the laminating property of the cushion block and the upper paving layer of the bolt sleeve can be ensured. The cushion block is manufactured by adopting the infusion resin and the fiber reinforced fabric for producing the blade, so that the compatibility of the cushion block and the blade can be effectively ensured, and the interface problem does not occur. And the surface of the cushion block is perforated, so that resin can smoothly penetrate through the cushion block to soak the fabric layer below the cushion block, and the resin filling process of the blade is not affected. The upper surface and the lower surface of the cushion block are protected by release cloths, so that dust pollution can be effectively avoided, and long-time storage is facilitated.
Description
Technical Field
The invention relates to the field of production and manufacturing of wind power blades, in particular to a wind power blade manufacturing method which can effectively control deformation and folds possibly existing in fiber reinforced fabrics at the root of a blade in the production process, avoid reducing the bearing capacity of the fiber reinforced fabrics due to the existence of the folds and avoid causing quality hidden trouble to the operation of the wind power blade.
Background
Wind power blades are key components of wind power generators, and blade quality is critical to the reliability of wind turbine operation. At present, the wind power blade manufacturing process mainly comprises two types, namely a prepreg forming process and a vacuum infusion forming process, wherein the application of the prepreg forming process is wider. Wind power blades manufactured by vacuum infusion molding processes generally use fiber reinforced fabrics, which have a certain softness in order to maintain good conformality with the curved surface of the blade mold. However, due to the softness of the fabric, deformation and wrinkling can occur during laying and vacuuming. Because the fiber reinforced fabric is the main bearing material of the blade, the existence of deformation and folds can reduce the bearing capacity of the fiber reinforced fabric, cause quality hidden trouble to the operation of the blade, and are listed as serious quality defects in the industry. In order to make the surface of the fiber reinforced fabric flat, it is common practice to manually roll a layer of fiber reinforced fabric by using auxiliary tools every time a layer of fiber reinforced fabric is laid in the process of laying the fiber reinforced fabric, and then laying a layer of fiber reinforced fabric. The method can control the folds of the fiber reinforced fabric in partial areas to a certain extent, and improves the quality of the blade.
The method for manually rolling the fiber reinforced fabric can control the flatness of the fiber reinforced fabric on a certain distance, and has good effect on the part with less layering layers. However, for the parts with a large number of layers of fabric, usually the areas close to the root of the blade, wrinkles still occur in the processes of laying, vacuumizing and resin pouring due to the softness of the fiber reinforced fabric. In the blade produced by the embedded bolt sleeve mode, gaps between adjacent bolt sleeves are required to be filled by glass fiber reinforced plastic wedge-shaped strips, and fiber reinforced fabrics near the tips of the wedge-shaped strips are usually easy to wrinkle. In order to solve the problems, the invention provides a novel method for effectively controlling wrinkles at the root of the wind power blade.
Disclosure of Invention
Aiming at the technical problems in the prior art, the invention aims to provide a manufacturing method of a wind power blade, which can effectively control the deformation and the folds possibly existing in the fiber reinforced fabric of the blade root in the production process, avoid reducing the bearing capacity of the fiber reinforced fabric of the blade root due to the existence of the folds and avoid causing quality hidden trouble to the running of the wind power blade.
The invention adopts the technical proposal for solving the technical problems that:
the wind power blade manufacturing method is characterized in that the root of the wind power blade is provided with embedded bolt sleeves, and the gap between the adjacent bolt sleeves is filled with wedge-shaped strips,
the lower part of the bolt sleeve and the lower part of the wedge-shaped strip are paved with a rigid control cushion block at the lower part of the bolt sleeve, the upper part of the bolt sleeve is paved with a rigid control cushion block at the upper part of the bolt sleeve, the whole rigid control cushion block at the lower part of the bolt sleeve is a cylindrical surface, the front part of the rigid control cushion block at the upper part of the bolt sleeve is a cylindrical surface, the middle part of the rigid control cushion block is an approximate conical surface, the rear part of the rigid control cushion block is a cylindrical surface,
wherein the manufacturing method comprises the following steps,
SS1, manufacturing a rigid control cushion block at the lower part of a bolt sleeve:
taking a blade root section of a blade mould as a mould, preparing a cushion block main body by adopting a fiber reinforced fabric through vacuum suction injection molding, pultrusion molding, winding molding or compression molding process, and carrying out punching treatment on the whole cylindrical surface of the cushion block main body after the preparation of the cushion block main body is completed;
SS2, manufacturing a rigid control cushion block at the upper part of the bolt sleeve:
firstly, preparing an upper cushion block mold, wherein the front end of the upper cushion block mold is a cylindrical surface, the length of the cylindrical surface is not less than that of a constant section of the wedge-shaped strip, the middle of the upper cushion block mold is an approximate conical surface, the length of the approximate conical surface is consistent with that of a variable section (bevel area) of the wedge-shaped strip, the bevel angle of the approximate conical surface is consistent with the chamfer angle of the wedge-shaped strip, the rear part of the upper cushion block mold is a cylindrical surface, and the total length of the upper cushion block mold is not less than that of a blade root cylindrical section of a blade;
secondly, preparing a cushion block main body by using the upper cushion block die and adopting a fiber reinforced fabric through vacuum suction injection molding, pultrusion molding, winding molding or compression molding technology;
after the preparation of the cushion block main body is completed, punching is carried out on the whole surface of the cushion block main body;
SS3 fabric placement and rigid control pad placement
Firstly, trimming a rigid control cushion block at the upper part of a bolt sleeve and a rigid control cushion block at the lower part of the bolt sleeve so as to enable the size of the cushion block to be matched with a blade die;
secondly, laying fiber reinforced fabric according to the technological requirement of manufacturing the layer of the blade,
a) Firstly, paving glass fiber fabrics layer by layer on the surface of a blade mould coated with a release agent according to design requirements, and rolling out each layer of glass fiber fabrics by using an auxiliary tool so as to ensure the surface of the fabrics to be flat;
b) Before finishing the layering of all fiber reinforced fabrics at the lower part of the bolt sleeve, reserving at least one layer of fiber reinforced fabrics, placing a rigid control cushion block at the lower part of the bolt sleeve on the surface of the finished layering, and then laying the rest at least one layer of fiber reinforced fabrics at the lower part of the bolt sleeve;
c) After finishing the layering of the fiber reinforced fabric at the lower part of the bolt sleeve, placing the bolt sleeve and the wedge-shaped strips according to the process requirements;
d) Then, laying a layer on the upper part of the bolt sleeve, firstly laying at least one layer of fiber reinforced fabric, then placing a rigid control cushion block on the upper part of the bolt sleeve, and ensuring that the cushion block is attached to the surface of the lower glass fiber fabric everywhere in the process of placing the rigid control cushion block on the upper part of the bolt sleeve;
e) After the placement of the rigid control cushion block at the upper part of the bolt sleeve is completed, laying the rest fiber reinforced fabrics layer by layer according to the design requirement, and rolling out each layer of glass fiber fabrics laid by each layer by using an auxiliary tool to ensure the surface of each layer of fiber reinforced fabrics to be flat;
f) After finishing the layering of the fiber reinforced fabric, paving auxiliary materials such as release cloth, a porous isolating film, a diversion net, a vacuum bag film and the like in sequence.
SS4 injection resin
After the arrangement of the layering and auxiliary materials used for the blade is completed, a vacuum system is started to remove air in the layering, and then the resin is sucked and infused. Because the surfaces of the lower cushion block and the upper cushion block are provided with openings, resin can penetrate into the lower fabric layer through the cushion block, and the poor infiltration is avoided.
SS5 heat curing
After the resin suction injection is completed, a mold heating system is started, and the temperature is gradually increased and solidified according to the requirements of the blade manufacturing process; after the curing is completed, the laying material is removed, the subsequent manufacturing procedures such as web installation, die assembly and the like are started, and finally the blade manufacturing is completed.
Preferably, the wedge-shaped strip is a glass fiber reinforced plastic wedge-shaped strip.
Preferably, the upper rigid control cushion block of the bolt sleeve and the lower rigid control cushion block of the bolt sleeve are prepared through a vacuum suction injection molding process.
Further, the upper rigid control cushion block of the bolt sleeve and the lower rigid control cushion block of the bolt sleeve are made of the same material, and the resin is the same as the main body of the blade; the fiber reinforced fabric is glass fiber fabric which is the same as the blade body. Preferably, the glass fiber fabric is a uniaxial glass fiber fabric, a biaxial glass fiber fabric or a triaxial glass fiber fabric. Preferably, the rigid control cushion block at the upper part of the bolt sleeve and the rigid control cushion block at the lower part of the bolt sleeve adopt triaxial glass fiber fabrics.
Preferably, the thicknesses of the upper rigid control cushion block of the bolt sleeve and the lower rigid control cushion block of the bolt sleeve are not too thick, and larger steps or gaps are formed between the upper layer of fabric and the lower layer of fabric at the edge of the too thick cushion block, so that the comprehensive performance of the finally formed composite material is affected. In addition, too thick shims increase the actual thickness of the blade root layer, which may cause inconvenience in the installation of the bolt housing at a later stage.
Preferably, the lower rigid control cushion block of the bolt sleeve is a cylindrical surface, and the blade die She Genduan is a die and is manufactured through a vacuum suction injection molding process.
Preferably, the upper rigid control cushion block of the bolt sleeve and the lower rigid control cushion block of the bolt sleeve are manufactured according to the following steps:
firstly, paving release cloth on the surface of a mould coated with release agent, paving glass fiber fabric on the surface of the release cloth, paving release cloth on the surface of the glass fiber fabric, paving a porous isolating film on the surface of the release cloth, paving a flow guide net on the surface of the porous isolating film, and paving a vacuum bag film on the surface of the flow guide net;
after finishing the layering of the glass fiber fabric, vacuumizing to remove air in the layering, then sucking and injecting resin, and heating the die for curing after the sucking and injection are finished;
after the resin is solidified, auxiliary materials such as a vacuum bag film, a diversion net and the like are removed, the cushion block is removed from the die, and demolding cloth on the upper surface and the lower surface of the cushion block is reserved; the release cloths on the upper surface and the lower surface of the cushion block are favorable for protecting the surface of the cushion block, and the release cloth on the lower surface of the cushion block also plays a role in isolating the cushion block and the release agent on the surface of the die. If the lower surface of the cushion block is not provided with release cloth, the surface is polished to remove the release agent before the cushion block is used.
And then, punching flow holes on the surface of the cushion block. In order to facilitate resin to flow through the pad and soak the glass fiber fabric layer below the pad in the process of manufacturing the blade in the later stage, holes are required to be punched on the pad, and the density and the size of the holes are determined according to actual needs.
Preferably, when preparing the upper rigid control cushion block of the bolt sleeve and the lower rigid control cushion block of the bolt sleeve, the glass fiber fabric is laid flat, no wrinkles appear, and particularly, at the transition positions from the cylindrical section to the conical section and from the conical section to the cylindrical section, each layer of material is laid flat by using an auxiliary tool.
Preferably, the flow pore diameters of the upper rigid control cushion block of the bolt sleeve and the lower rigid control cushion block of the bolt sleeve are not too large, preferably 2-3mm, the pore number is not too large and too dense, preferably the pore spacing is 20mm multiplied by 20mm, so that the strength of the cushion blocks is not affected, and damage or destroy is caused due to stress in the process of taking and placing.
Preferably, the strength and thickness requirements of the cushion block are comprehensively considered, and the upper rigid control cushion block of the bolt sleeve and the lower rigid control cushion block of the bolt sleeve are preferably two layers with the gram weight of 1200g/m 2 Is manufactured by the three-axial glass fiber fabric.
According to another aspect of the invention, a wind power blade prepared by the method is also provided.
Compared with the prior art, the wind power blade manufacturing method has the following technical advantages: 1) The rigid spacer blocks are embedded in the fabric layers, so that the reliability of controlling the folds of the final blade root layer is better than that of manually rolling each layer of fabric. The number of the cushion blocks and the placement positions can be flexibly adjusted, and the optimal control effect can be obtained. 2) The cushion block is made of transparent glass fiber reinforced plastic material, and the fitting condition of the cushion block and the surface of the fabric can be clearly observed in the placing process, especially the placing of the cushion block is rigidly controlled at the upper part, so that the implementation reliability of the scheme is ensured. The manufacturing method of the wind power blade can effectively control the deformation and the folds possibly existing in the fiber reinforced fabric of the blade root in the production process, avoid reducing the bearing capacity of the fiber reinforced fabric of the blade root due to the existence of the folds, and avoid causing quality hidden trouble to the running of the wind power blade.
Drawings
FIG. 1 is a schematic diagram of a layering structure made of a rigid control pad at the lower part of a bolt sleeve, wherein (A) is a schematic perspective view; (B) is an oy-direction cross-sectional view of the graph (A);
FIG. 2 is a schematic view of a rigid control pad at the lower part of a bolt housing after punching;
FIG. 3 is a schematic diagram of a layering structure made of a rigid control pad at the upper part of a bolt sleeve, wherein (A) is a schematic perspective view; (B) is an oy-direction cross-sectional view of the graph (A);
FIG. 4 is a schematic view of a rigid control pad at the upper part of a perforated bolt sleeve;
FIG. 5 is a schematic structural view of a wind turbine blade root, wherein (A) is a schematic perspective view; (B) is a cross-sectional view in the oy direction of the drawing (A).
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention will be further described in detail below by referring to the accompanying drawings and examples.
As shown in fig. 1-5, the blade root of a fan blade is generally cylindrical, with a length of between 1-2 m. For the blade produced in the pre-buried mode, as shown in fig. 5, the root of the wind power blade is provided with pre-buried bolt sleeves 70, and gaps between adjacent bolt sleeves 70 are filled with glass fiber reinforced plastic wedge-shaped strips 80. Because the glass fiber reinforced plastic wedge-shaped strips 80 with oblique angles are used between the embedded bolt sleeves 70, the form of the layer below the bolt sleeve 70 at the root of the blade is different from that of the layer above the bolt sleeve at the root of the blade. The layering shape under the blade root bolt sleeve 70 is the same as the surface shape of the blade mould and is a cylindrical surface; the upper surface of the bolt sleeve 70 of the blade root is a cylindrical surface on the side close to the flange, and the bevel area of the wedge-shaped glass fiber reinforced plastic strip 80 is an approximate conical surface.
In order to control possible deformation and wrinkling of the fiber reinforced fabric at the root of the blade, avoid reducing the bearing capacity of the fiber reinforced fabric at the root of the blade due to the existence of wrinkling and cause quality hidden trouble to the operation of the wind power blade, the invention respectively places rigid control cushion blocks 31 and 32 in the fiber reinforced fabric layers below and above the bolt sleeve 70, thereby inhibiting the deformation of the soft fiber reinforced fabric. Because of different forms, two rigid cushion blocks are required to be manufactured respectively.
Specifically, the wind power blade is prepared by adopting the following method to inhibit root wrinkles:
SS1 manufacture of rigid control cushion block 31 at lower part of bolt sleeve
The lower rigid control cushion block of the bolt sleeve is a cylindrical surface, and the blade die She Genduan is used as a die and manufactured by a vacuum suction injection molding process. The gasket is made of a material, and the resin is poured epoxy resin for producing the blade; the fiber fabric is glass fiber fabric for producing blades, and is commonly used as uniaxial glass fiber fabric, biaxial glass fiber fabric and triaxial glass fiber fabric, preferably triaxial glass fiber fabric adopted for blade root layering. The thickness of the cushion block is not too thick, and larger steps or gaps exist between the upper layer of fabric and the lower layer of fabric at the edge of the too thick cushion block, so that the comprehensive performance of the finally formed composite material is affected. In addition, too thick shims increase the actual thickness of the blade root layer, which may cause inconvenience in the installation of the bolt housing at a later stage.
The manufacturing process of the rigidity control cushion block at the lower part of the bolt sleeve is shown in fig. 1, a release cloth 20 is paved on the surface of a blade root cylindrical section 10 of the blade mould coated with release agent, a glass fiber fabric 30 is paved on the surface of the release cloth, the release cloth 20 is paved on the surface of the glass fiber fabric, a porous isolating film 40 is paved on the surface of the release cloth, a flow guide net 50 is paved on the surface of the porous isolating film, and a vacuum bag film 60 is paved on the surface of the flow guide net. Considering the strength and thickness requirements of the cushion block, 2 layers of cushion block with the gram weight of 1200g/m are preferably adopted 2 Is manufactured by the three-axial glass fiber fabric.
And vacuumizing after layering, removing air in the layering, sucking and injecting resin, and heating the die for curing after sucking and injecting. After the resin is solidified, auxiliary materials such as a vacuum bag film, a diversion net and the like are removed, the cushion block is removed from the die, and demolding cloth on the upper surface and the lower surface of the cushion block is reserved. In order to facilitate resin to flow through the pad and soak the glass fiber fabric layer below the pad in the process of manufacturing the blade in the later stage, holes are required to be punched on the pad, and the density and the size of the holes are determined according to actual needs. The aperture is not too large, preferably 2-3mm, the aperture number is not too large and too dense, preferably the aperture spacing is 20mm x 20mm, so as not to influence the strength of the cushion block, and damage or destroy is caused by stress in the process of taking and placing. The release cloths on the upper surface and the lower surface of the cushion block are favorable for protecting the surface of the cushion block, and the release cloth on the lower surface of the cushion block also plays a role in isolating the cushion block and the release agent on the surface of the die. If the lower surface of the cushion block is not provided with release cloth, the surface is polished to remove the release agent before the cushion block is used. The lower rigid control pad 31 of the perforated bolt housing is shown in fig. 2.
SS2 manufacture of rigid control cushion block 32 at upper part of bolt sleeve
The front part of the rigid control cushion block at the upper part of the bolt sleeve is a cylindrical surface, the middle part is an approximate conical surface, the rear part is a cylindrical surface, the shape of the bolt sleeve is different from that of the blade root cylindrical section of the blade mould, the bolt sleeve cannot be directly manufactured on the blade mould, and a special mould 11 (shown in figure 3) is needed. The front end of the upper cushion block mould 11 is a cylindrical surface, and the length of the cylindrical section is not smaller than that of the equal section of the wedge-shaped strip for blade production. The middle is an approximate conical surface, and the length of the conical section is consistent with the length of a wedge-shaped strip variable section (bevel area) for blade production. The angle of inclination alpha of the conical section is consistent with the chamfer alpha (as shown in fig. 5) of the wedge-shaped strip. The rear part is a cylindrical surface, and the total length of the die is not smaller than the length of the cylindrical section of the blade root.
The manufacturing method of the rigid control cushion block at the upper part of the bolt sleeve is the same as that of the rigid control cushion block at the lower part of the bolt sleeve, and a vacuum suction injection molding process is adopted. The resin of the manufacturing material is epoxy resin for pouring in the production of the blade, the fiber fabric is glass fiber fabric for producing the blade, preferably triaxial glass fiber fabric for paving the blade root of the blade, the layer number is 2, and the gram weight is 1200g/m 2 。
The manufacturing process of the upper rigid control cushion block of the bolt sleeve is similar to that of the lower cushion block, as shown in fig. 3, a release cloth 20 is paved on the surface of a special cushion block mold 11 coated with release agent, a glass fiber fabric 30 is paved on the surface of the release cloth, the release cloth 20 is paved on the surface of the glass fiber fabric, a porous isolating film 40 is paved on the surface of the release cloth, a diversion net 50 is paved on the surface of the porous isolating film, and a vacuum bag film 60 is paved on the surface of the diversion net. Considering the strength and thickness requirements of the cushion block, 2 layers of cushion block with the gram weight of 1200g/m are preferably adopted 2 Is manufactured by the three-axial glass fiber fabric. The material is laid with care that the material remains flat and no wrinkles appear, especially at the transition from cylindrical section to conical section and from conical section to cylindrical section, and each layer of material should be rolled with an auxiliary tool.
And vacuumizing after layering, removing air in the layering, sucking and injecting resin, and heating the die for curing after sucking and injecting. After the resin is solidified, auxiliary materials such as a vacuum bag film, a diversion net and the like are removed, the cushion block is removed from the die, and demolding cloth on the upper surface and the lower surface of the cushion block is reserved. Similar to the lower spacer, the upper spacer also requires perforation, and the pore size and pore density are consistent with those of the lower spacer, and the perforated spacer 32 is shown in fig. 4.
SS3 fabric placement and control pad placement
Before the fabric is laid, the perforated upper and lower cushion blocks 31 and 32 are taken out, and the release cloth on the surfaces of the cushion blocks is removed for standby. If the spacer is oversized, it should be trimmed appropriately to allow the size of the spacer to match the blade mold. For the upper cushion block, as three parts with different forms are arranged, the front cylindrical section is properly trimmed, so that the length of the front cylindrical section is consistent with the length of the equal section of the wedge-shaped strip, and if the length exceeds the length of the equal section of the wedge-shaped strip, a gap can be formed at a corner, so that a resin-rich area is caused, and the performance of the final blade is influenced. If the thickness of the cushion block is larger, the corners of the cushion block should be properly polished with a certain bevel angle so as not to cause local gaps between the upper and lower adjacent layers of fabrics, thereby causing resin enrichment and affecting the performance of the final blade.
The fabric laying is carried out according to the process requirements of manufacturing the layers of the blades (as shown in figure 5), firstly, the glass fiber fabrics 30-1 are laid layer by layer on the surface of the blade mould 10 coated with the release agent according to the design requirements, and each layer of glass fiber fabrics is rolled by an auxiliary tool so as to ensure the surface smoothness of the fabrics. Before all the layers below the bolt housing 70 are completed, 1 to 2 layers of glass fiber fabrics 30-2 are left, and a rigid control pad 31 below the bolt housing is placed on the surface of the completed layer 30-1, and then the remaining 1 to 2 layers of glass fiber fabrics 30-2 below the bolt housing are laid. After the lower layering of the bolt housing is completed, the bolt housing 70 and wedge bar 80 are placed as required by the process. Then, the upper layer of the bolt sleeve is laid, 1 to 2 layers of glass fiber fabrics 30-3 are laid first, and then the upper rigid control cushion block 32 of the bolt sleeve is placed. In the process of placing the upper cushion block 32, the cushion block is guaranteed to be attached to the surface of the lower glass fiber fabric everywhere, particularly, gaps cannot occur at the transition positions from the cylindrical section to the conical section and from the conical section to the cylindrical section of the cushion block. After the placement of the upper pad 32 is completed, the remaining glass fiber fabrics 30-4 are laid layer by layer according to the design requirements, and the surface of each layer of fabric is ensured to be flat. After the fabric is paved, auxiliary materials such as the release cloth 20, the perforated isolating film 40, the diversion net 50, the vacuum bag film 60 and the like are sequentially paved.
SS4 injection resin
After the layering and auxiliary material arrangement for the blades are completed, a vacuum system is started to remove air in the layering. And then resin is sucked and infused, and the resin can penetrate through the cushion blocks to the lower fabric layer due to the openings on the surfaces of the lower cushion blocks and the upper cushion blocks, so that the bad infiltration is avoided.
SS5 heat curing
After the resin is sucked and injected, a mold heating system is started, and the temperature is gradually increased and solidified according to the requirements of the blade manufacturing process. After the curing is completed, the laying material is removed, the subsequent manufacturing procedures such as web installation, die assembly and the like are started, and finally the blade manufacturing is completed.
According to the wind power blade manufacturing method, the soft fiber fabric deformation is restrained by embedding the rigid cushion block in the blade root layer. The rigidity control cushion block is divided into a bolt sleeve lower rigidity control cushion block and a bolt sleeve upper rigidity control cushion block according to different forms, the lower cushion block is manufactured by taking a blade root cylindrical section of a blade mould as the mould, and the obtained cushion block has good matching performance with the blade mould. The upper cushion block is manufactured by adopting a special die, and the die is reasonably designed, so that the laminating property of the cushion block and the upper layer of the bolt sleeve can be ensured. The cushion block is manufactured by adopting the pouring resin and the glass fiber fabric for producing the blade, so that the compatibility of the cushion block and the blade can be effectively ensured, and the interface problem does not occur. And the surface of the cushion block is perforated, so that resin can smoothly penetrate through the cushion block to soak the fabric layer below the cushion block, and the resin filling process of the blade is not affected. The upper surface and the lower surface of the cushion block are protected by release cloths, so that dust pollution can be effectively avoided, and long-time storage is facilitated.
In addition, the specific embodiments described in the present specification may differ in terms of parts, shapes of components, names, and the like. All equivalent or simple changes of the structure, characteristics and principle according to the inventive concept are included in the protection scope of the present invention. Those skilled in the art may make various modifications or additions to the described embodiments or substitutions in a similar manner without departing from the scope of the invention as defined in the accompanying claims.
Claims (11)
1. The wind power blade manufacturing method is characterized in that the root of the wind power blade is provided with embedded bolt sleeves, and the gap between the adjacent bolt sleeves is filled with wedge-shaped strips,
the lower part of the bolt sleeve and the lower part of the wedge-shaped strip are paved with a rigid control cushion block at the lower part of the bolt sleeve, the upper part of the bolt sleeve is paved with a rigid control cushion block at the upper part of the bolt sleeve, the whole rigid control cushion block at the lower part of the bolt sleeve is a cylindrical surface, the front part of the rigid control cushion block at the upper part of the bolt sleeve is a cylindrical surface, the middle part of the rigid control cushion block is an approximate conical surface, the rear part of the rigid control cushion block is a cylindrical surface,
wherein the manufacturing method comprises the following steps:
SS1 manufacture of rigid control cushion block at lower part of bolt sleeve
Taking a blade root section of a blade mould as a mould, preparing a cushion block main body by adopting a fiber reinforced fabric through vacuum suction injection molding, pultrusion molding, winding molding or compression molding process, and carrying out punching treatment on the whole cylindrical surface of the cushion block main body after the preparation of the cushion block main body is completed;
SS2 manufacture of rigid control cushion block at upper part of bolt sleeve
Firstly, preparing an upper cushion block mold, wherein the total length of the upper cushion block mold is not smaller than the length of a blade root cylindrical section, the front section of the upper cushion block mold is a cylindrical surface, the length of the cylindrical surface is not smaller than the length of a constant section of the wedge-shaped strip, the middle section of the upper cushion block mold is an approximate conical surface, the length of the approximate conical surface is consistent with the length of a variable section of the wedge-shaped strip, the inclination angle of the approximate conical surface is consistent with the chamfer angle of the wedge-shaped strip, and the rear section of the upper cushion block mold is a cylindrical surface;
secondly, preparing a cushion block main body by using the upper cushion block die and adopting a fiber reinforced fabric through vacuum suction injection molding, pultrusion molding, winding molding or compression molding technology;
thirdly, after the preparation of the pad body is completed, the punching site SS3 is performed on the whole surface thereof, the fabric is laid and the pad is rigidly controlled to be placed
Firstly, trimming the upper rigid control cushion block of the bolt sleeve and the lower rigid control cushion block of the bolt sleeve to enable the size of the rigid control cushion block to be matched with that of a blade mould;
secondly, laying fiber reinforced fabric according to the technological requirement of manufacturing the layer of the blade,
a) Firstly, laying fiber reinforced fabrics layer by layer on the surface of a blade mould coated with a release agent, and rolling out each layer of fiber reinforced fabrics by using an auxiliary tool so as to ensure the surface of the fabrics to be flat;
b) Before finishing the layering of all fiber reinforced fabrics at the lower part of the bolt sleeve, reserving at least one layer of fiber reinforced fabrics, placing a rigid control cushion block at the lower part of the bolt sleeve on the surface of the finished layering, and then laying the rest at least one layer of fiber reinforced fabrics at the lower part of the bolt sleeve on the rigid control cushion block at the lower part of the bolt sleeve;
c) After finishing the layering of the fiber reinforced fabric at the lower part of the bolt sleeve, placing the bolt sleeve and the wedge-shaped strips according to the process requirements;
d) Then, laying a layer on the upper part of the bolt sleeve, firstly laying at least one layer of fiber reinforced fabric, then placing a rigid control cushion block on the upper part of the bolt sleeve, and ensuring that the cushion block is attached to the surface of the lower fiber reinforced fabric everywhere in the process of placing the rigid control cushion block on the upper part of the bolt sleeve;
e) After the placement of the rigid control cushion block at the upper part of the bolt sleeve is completed, laying the rest fiber reinforced fabrics layer by layer according to the design requirement, and rolling out each layer of glass fiber fabrics laid by each layer by using an auxiliary tool to ensure the surface of each layer of fiber reinforced fabrics to be flat;
f) After finishing the layering of the fiber reinforced fabric, paving a demolding cloth, a porous isolating film, a diversion net and a vacuum bag film in sequence;
SS4 injection resin
After the arrangement of the layers and auxiliary materials used by the blade is completed, starting a vacuum system to remove air in the layers, and then sucking and pouring resin;
SS5 heat curing
After the resin suction injection is completed, a mold heating system is started, and the temperature is gradually increased and solidified according to the requirements of the blade manufacturing process; and after the curing is finished, removing auxiliary materials, and carrying out subsequent web plate mounting and die assembly procedures to finally finish the blade manufacturing.
2. The method of manufacturing a wind power blade according to claim 1, wherein the wedge bar is a glass fiber reinforced plastic wedge bar.
3. The method for manufacturing the wind power blade according to claim 2, wherein the upper rigid control cushion block of the bolt sleeve and the lower rigid control cushion block of the bolt sleeve are prepared through a vacuum suction injection molding process.
4. The method for manufacturing a wind power blade according to claim 3, wherein the upper rigid control cushion block of the bolt sleeve and the lower rigid control cushion block of the bolt sleeve are made of the same material, the resin is the same as the blade body, the epoxy resin is poured, and the fiber reinforced fabric is the same as the blade body.
5. The method for manufacturing a wind power blade according to claim 4, wherein the glass fiber fabric is a uniaxial glass fiber fabric, a biaxial glass fiber fabric or a triaxial glass fiber fabric.
6. The method for manufacturing a wind power blade according to claim 5, wherein the rigid control cushion block at the upper part of the bolt sleeve and the rigid control cushion block at the lower part of the bolt sleeve are made of triaxial glass fiber fabrics.
7. The method of manufacturing a wind power blade according to claim 6, wherein the rigid control pad at the lower part of the bolt sleeve is a cylindrical surface, and the blade die She Genduan is a die, and the wind power blade is manufactured by a vacuum suction injection molding process.
8. The method for manufacturing a wind power blade according to claim 7, wherein the bolt sleeve upper rigid control cushion block and the bolt sleeve lower rigid control cushion block are manufactured according to the following steps:
firstly, paving release cloth on the surface of a mould coated with release agent, paving fiber reinforced fabric on the surface of the release cloth, paving release cloth on the surface of the fiber reinforced fabric, paving a porous isolating film on the surface of the release cloth, paving a flow guide net on the surface of the porous isolating film, and paving a vacuum bag film on the surface of the flow guide net;
after finishing the layering of the fiber reinforced fabric, vacuumizing to remove air in the layering, then sucking and injecting resin, and heating the die for curing after the sucking and injection are finished;
after the resin is solidified, removing the vacuum bag film and the diversion net, removing the cushion block from the die, and reserving demolding cloth on the upper surface and the lower surface of the cushion block;
and then, punching flow holes on the surface of the cushion block.
9. The method for manufacturing a wind power blade according to claim 8, wherein the flow pore diameter of the upper rigid control cushion block of the bolt sleeve and the lower rigid control cushion block of the bolt sleeve is 2-3mm, and the pore spacing is 20mm multiplied by 20mm.
10. The method for manufacturing a wind power blade according to claim 9, wherein the bolt sleeve upper rigid control cushion block and the bolt sleeve lower rigid control cushion block adopt two layers with gram weights of 1200g/m 2 Is manufactured by the three-axial glass fiber fabric.
11. A wind power blade prepared according to the wind power blade manufacturing method of any one of the preceding claims 1 to 10.
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| EP3501809A1 (en) * | 2017-12-22 | 2019-06-26 | Siemens Gamesa Renewable Energy A/S | Pultruded fibrous composite strips having non-planar profiles cross-section for wind turbine blade spar caps |
| CN107972290B (en) * | 2017-12-25 | 2020-04-21 | 江苏金风科技有限公司 | Blade manufacturing method and blade |
| CN109760334B (en) * | 2019-01-22 | 2022-01-07 | 远景能源有限公司 | Anti-wrinkle prefabricated part and manufacturing method thereof |
| CN110328866B (en) * | 2019-07-05 | 2021-02-02 | 国电联合动力技术(连云港)有限公司 | Manufacturing method of blade tip sleeve for lengthening large wind power blade |
| CN110483951B (en) * | 2019-09-02 | 2020-06-19 | 国电联合动力技术有限公司 | Damping noise reduction wind power blade and preparation method thereof |
| CN113043624B (en) * | 2021-04-29 | 2023-05-30 | 中复连众（哈密）复合材料有限公司 | Method for solving root wrinkles of embedded bolt blades of megawatt wind driven generator |
| CN114905769B (en) * | 2022-07-19 | 2022-10-25 | 成都泰格尔航天航空科技股份有限公司 | Fabric honeycomb forming device and fabric honeycomb forming process |
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| DE112010000004B4 (en) * | 2010-06-13 | 2016-03-03 | Lianyungang Zhongfu Lianzhong Composites Group Co., Ltd. | Method for producing a turbine blade foot of a megawatt wind turbine |
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| CN102358047A (en) * | 2011-11-08 | 2012-02-22 | 保定华翼风电叶片研究开发有限公司 | Method for manufacturing wind wheel blade by vacuum suction and injection |
| CN104015375A (en) * | 2014-06-04 | 2014-09-03 | 洛阳双瑞风电叶片有限公司 | Filling molding method of large-thickness area composite product |
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Effective date of registration: 20240307 Address after: 071051 No. 2011 Xiangyang North Street, Hebei, Baoding Patentee after: BAODING HUAYI WIND TURBINE BLADE AND DEVELOPMENT CO.,LTD. Country or region after: China Patentee after: Baoding Zhongke Yuneng new energy technology research and Development Co.,Ltd. Address before: 071051 No. 2011 Xiangyang North Street, Hebei, Baoding Patentee before: BAODING HUAYI WIND TURBINE BLADE AND DEVELOPMENT CO.,LTD. Country or region before: China |