CN110657061A

CN110657061A - Wind power blade plate, wind power blade and manufacturing method thereof

Info

Publication number: CN110657061A
Application number: CN201810715044.0A
Authority: CN
Inventors: 宋秋香; 刘仁; 曾鸿鸣; 苏成功
Original assignee: Sinomatech Wind Power Blade Co Ltd
Current assignee: Sinomatech Wind Power Blade Co Ltd
Priority date: 2018-06-29
Filing date: 2018-06-29
Publication date: 2020-01-07
Anticipated expiration: 2038-06-29
Also published as: CN110657061B

Abstract

The invention provides a wind power blade plate, a wind power blade and a manufacturing method thereof. The main force-bearing structural part comprises at least one pair of beam caps and a web supported between the at least one pair of beam caps, each beam cap comprises at least one attached plate and at least one non-attached plate, each attached plate is provided with a first surface and a second surface which are opposite, and the non-attached plates are stacked and combined on the second surfaces of the attached plates. The blade shell is enclosed outside the at least one pair of spar caps, and the first surface of each of the conformable sheets is attached to the blade shell. The curvature radius of the circle on which the section of the first surface of each laminated plate is located is obtained through the following formula: a) sita is L/2.0/r; b) a _2 ═ r sin (sita); c) sita ═ asin (a _ 2/R); d) s ═ R (fabs (R × Sita) -a _2 × cos (Sita)) -R (R × Sita-a _2 × cos (Sita)); and selecting r corresponding to the minimum value of the gap volume as the curvature radius of the circle of the section of the first surface of each attached plate.

Description

Wind power blade plate, wind power blade and manufacturing method thereof

Technical Field

The invention relates to the technical field of wind power generation, in particular to a wind power blade and a manufacturing method thereof.

Background

With the increasing severity of the environmental pollution problem, the utilization of clean energy is more and more emphasized. Wind energy has been widely used as an important clean energy source. Wind blades are important parts of wind power plants, which usually comprise a main load-bearing structure and a blade shell. The main bearing structural member comprises an upper beam cap, a lower beam cap and a web plate between the upper beam cap and the lower beam cap. The upper and lower spar caps are respectively attached to the shell of the blade.

The spar cap may comprise a plurality of sheets bonded together, for example, with a resin, and the resulting spar cap may be bonded to the blade shell, for example, with a resin.

Because the blade shell belongs to special-shaped curved surface, current planar beam cap panel and blade shell laminating back, must have the sheet clearance under the two, and this clearance will lead to defects such as wind-powered electricity generation blade vacuole formation, bubble or rich resin district, influences wind-powered electricity generation blade's performance, increases wind-powered electricity generation blade's potential safety hazard, increases cost of maintenance.

The above information disclosed in this background section is only for enhancement of understanding of the background of the invention and therefore it may contain information that does not constitute prior art that is already known to a person of ordinary skill in the art.

Disclosure of Invention

The invention aims to overcome the defects of the prior art and provides a wind power blade plate, a wind power blade and a manufacturing method thereof, which can reduce or even avoid the gap between a beam cap and a blade shell as much as possible so as to reduce the manufacturing cost and simplify the process.

According to an aspect of the invention, a wind turbine blade panel is provided, comprising a first surface and a second surface opposite to each other, the first surface being adapted to be attached to a blade shell,

wherein the radius of curvature of the circle in which the cross section of the first surface lies is obtained by the following formula:

a)sita＝L/2.0/r；

b)a_2＝r*sin(sita)；

c)Sita＝asin(a_2/R)；

d)S＝R*(fabs(R*Sita)-a_2*cos(Sita))-r*(r*sita-a_2*cos(sita))；

wherein: r is the radius of curvature of the circle in which the cross section of the first surface lies; r is the section curvature radius of the blade shell; l is the cross-sectional arc length of the first surface; sita, a _2, Sita and S are process parameters; fabs are absolute value functions;

r and L are known, a plurality of different R are input, S is integrated, and a clearance volume corresponding to each R can be obtained, wherein the clearance volume is the volume of the clearance between the first surface and the surface of the blade shell, and R corresponding to the minimum value of the clearance volume is selected as the curvature radius of the circle on which the section of the first surface is located.

According to another aspect of the invention, a wind power blade is provided, which comprises a main load-bearing structural member and a blade shell.

The main force-bearing structural part comprises at least one pair of beam caps and a web supported between the at least one pair of beam caps, each beam cap comprises at least one attached plate and at least one non-attached plate, each attached plate is provided with a first surface and a second surface which are opposite, and the non-attached plates are stacked and combined on the second surfaces of the attached plates.

The blade shell is enclosed outside the at least one pair of beam caps, the first surface of each laminated plate is connected with the blade shell, and the curvature radius of a circle in which the section of the first surface of each laminated plate is located is obtained through the following formula:

a)sita＝L/2.0/r；

b)a_2＝r*sin(sita)；

c)Sita＝asin(a_2/R)；

d)S＝R*(fabs(R*Sita)-a_2*cos(Sita))-r*(r*sita-a_2*cos(sita))；

wherein: r is the curvature radius of the circle of the section of the first surface of each attaching plate; r is the section curvature radius of the blade shell; l is the arc length of the cross section of the first surface of each laminated plate; sita, a _2, Sita and S are process parameters; fabs are absolute value functions;

r and L are known, a plurality of different R are input, and S is integrated to obtain a gap volume corresponding to each R, wherein the gap volume is a volume of a gap between the first surface of each bonding plate and the surface of the connected blade shell, and R corresponding to the minimum value of the gap volume is selected as a curvature radius of a circle in which a cross section of the first surface of each bonding plate is located.

According to another aspect of the present invention, there is provided a method for manufacturing a wind turbine blade, comprising:

forming a laminated sheet and a non-laminated sheet to be stacked to form a spar cap;

providing a blade shell mould, putting a joint plate and a non-joint plate into preset positions of the blade shell mould, and pouring resin through a vacuum pouring process to cure and form at least one pair of beam caps and a blade shell; and

providing a web such that the web is connected between the at least one pair of spar caps, thereby forming a wind turbine blade;

wherein, each laminating panel has relative first surface and second surface, and non-laminating panel piles up to combine in the second surface of laminating panel, and the first surface and the blade shell of each laminating panel are connected, obtain the radius of curvature of the cross-section place circle of the first surface of each laminating panel through following formula:

a)sita＝L/2.0/r；

b)a_2＝r*sin(sita)；

c)Sita＝asin(a_2/R)；

d)S＝R*(fabs(R*Sita)-a_2*cos(Sita))-r*(r*sita-a_2*cos(sita))；

wherein: r is the curvature radius of the circle of the section of the first surface of each attaching plate; r is the section curvature radius of the blade shell mold; l is the arc length of the cross section of the first surface of each laminated plate; sita, a _2, Sita and S are process parameters; fabs are absolute value functions;

r and L are known, a plurality of different R are input, and S is integrated to obtain a gap volume corresponding to each R, wherein the gap volume is the volume of a gap between the first surface of each bonding plate and the surface of the connected blade shell mold, and R corresponding to the minimum value of the gap volume is selected as the radius of curvature of a circle in which the cross section of the first surface of each bonding plate is located.

According to the technical scheme, the method for automatically searching the optimal curvature radius of the section radian of the sheet is provided, and the plate with the arc-shaped section is used, so that the size of a gap between the plate and the blade shell is minimum, the gap between the formed beam cap plate and the blade shell is as small as possible, even no gap exists, and the risk of defects such as cavities, bubbles or resin-rich areas of the wind power blade is greatly reduced. Therefore, the efficiency of manufacturing the wind turbine blade can be improved, and the cost of manufacturing the blade can be reduced.

Drawings

The above and other features and advantages of the present invention will become more apparent by describing in detail exemplary embodiments thereof with reference to the attached drawings.

FIG. 1 is a schematic cross-sectional view of a prior art spar cap and blade shell combination;

FIG. 2 is a schematic cross-sectional view of a wind blade according to an embodiment of the invention;

FIG. 3 is a graph of radius of curvature of a circle having a cross-section of a first surface of a conformable sheet material according to one embodiment of the present invention versus gap volume;

FIG. 4 is a schematic cross-sectional view of a bond location of a spar cap to a blade shell of an embodiment of the present invention;

FIG. 5 is a schematic cross-sectional view of a spar cap and blade shell combination according to another embodiment of the present invention;

FIG. 6 is a schematic partial cross-sectional view of a spar cap of yet another embodiment of the present invention;

FIG. 7 is a schematic partial cross-sectional view of a spar cap of a further embodiment of the present invention;

FIG. 8 is a schematic partial cross-sectional view of a spar cap of yet another embodiment of the present invention;

FIG. 9 is a schematic partial cross-sectional view of a spar cap of yet another embodiment of the present invention;

FIG. 10 is a schematic partial cross-sectional view of a spar cap of yet another embodiment of the present invention;

FIG. 11 is a schematic partial cross-sectional view of a spar cap of yet another embodiment of the present invention; and

FIG. 12 is a partial cross-sectional schematic view of a spar cap of a further embodiment of the present invention.

Detailed Description

Example embodiments will now be described more fully with reference to the accompanying drawings. Example embodiments may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the concept of example embodiments to those skilled in the art. The same reference numerals in the drawings denote the same or similar structures, and thus their detailed description will be omitted.

Although relative terms, such as "upper" and "lower," may be used in this specification to describe one element of an icon relative to another, these terms are used in this specification for convenience only, e.g., in accordance with the orientation of the examples described in the figures. It will be appreciated that if the device of the icon were turned upside down, the element described as "upper" would become the element "lower". Other relative terms, such as "high", "low", "top", "bottom", "front", "back", "left", "right", etc., are also intended to have similar meanings. When a structure is "on" another structure, it may mean that the structure is integrally formed with the other structure, or that the structure is "directly" disposed on the other structure, or that the structure is "indirectly" disposed on the other structure via another structure.

In the claims, the terms "a", "an", "the", "said" and "at least one" are used to indicate the presence of one or more elements/components/etc.; the terms "comprising," "including," and "having" are intended to be inclusive and mean that there may be additional elements/components/etc. other than the listed elements/components/etc.; the terms "first," "second," and "third," etc. are used merely as labels, and are not limiting on the number of their objects.

In the manufacturing process of the wind power blade, a girder prefabricated part, namely a girder cap, is placed in a shell mold of the wind power generation blade, resin is poured into the mold, and the girder prefabricated part and the shell material are solidified together.

As shown in fig. 1, since the blade shell is a special-shaped curved surface, the curvature radius of the blade shell is different at each position, and the spar cap plate is generally flat, a gap G under the plate inevitably exists between the flat spar cap plate and the blade shell after the flat spar cap plate is attached to the blade shell. This clearance G will lead to wind-powered electricity generation blade to form defects such as cavity, bubble or rich resin district, influences wind-powered electricity generation blade's performance, increases wind-powered electricity generation blade's operation potential safety hazard, increases cost of maintenance.

Generally, a blade shell is formed by pouring resin through a blade shell mold through a vacuum pouring process and curing, a gap between a planar plate and the blade shell mold is a plate lower gap G, and due to the existence of the plate lower gap G, the formed wind power blade has defects of a cavity, bubbles or a resin-rich area and the like.

It should be noted that the "lower plate gap" and "gap" mentioned in the present application may refer to both the gap between the plate and the blade shell and the gap between the plate and the blade shell mold. The "blade shell" referred to in the present application refers to the outer shell of the wind turbine blade surrounding the main load-bearing structural member.

Fig. 2 is a schematic cross-sectional view of a wind turbine blade according to an embodiment of the present invention, and it should be understood that fig. 2 is only one form of a plurality of wind turbine blades, the wind turbine blade in this application includes, but is not limited to, that shown in fig. 2, and the wind turbine blade sheet material provided by the present invention can be applied to various existing wind turbine blades.

As shown in fig. 2 and 4, the invention provides a wind power blade, which comprises a main force-bearing structural member and a blade shell 40.

The primary messenger includes at least one spar cap, and the present embodiment is illustrated with a pair of spar caps 10, 20. It should be understood that the number of the caps is not limited thereto, and may be a plurality of pairs

And a web 30 supported between the pair of spar caps 10, 20. Each spar cap comprises at least one attached sheet 11 and at least one non-attached sheet 12, each attached sheet 11 having first and second opposed surfaces S1, S2, the non-attached sheets 12 being stacked and bonded to the second surface S2 of the attached sheet 12.

The blade shell 40 is enclosed outside the pair of spar caps 10, 20, and the first surface S1 of each of the bonded sheets 11 is connected to the blade shell 40. The radius of curvature of the circle in which the cross section of the first surface S1 of each laminated sheet material 11 lies is obtained by the following formula:

a)sita＝L/2.0/r；

b)a_2＝r*sin(sita)；

c)Sita＝asin(a_2/R)；

d)S＝R*(fabs(R*Sita)-a_2*cos(Sita))-r*(r*sita-a_2*cos(sita))；

wherein: r is the radius of curvature of the circle on which the cross section of the first surface S1 of each bonded panel 11 is located; r is the cross-sectional radius of curvature of the blade shell 40; l is the cross-sectional arc length of the first surface S1 of each bonded panel 11; sita, a _2, Sita and S are process parameters; fabs are absolute value functions;

r and L are known, and a plurality of different R are input, and S is integrated to obtain a gap volume corresponding to each R, where the gap volume is the volume of the gap between the first surface S1 of each bonded plate material 11 and the surface of the blade shell 40 to which it is connected, and R corresponding to the minimum value of the gap volume is selected as the radius of curvature of the circle in which the cross section of the first surface of each bonded plate material lies.

Specifically, since the blade shell 40 belongs to the irregular curved surface and the curvature radius thereof is different at each position, a specific position on the blade shell 40 corresponds to a specific curvature radius, that is, the curvature radius R of the circle where the cross section of the blade shell 40 is located is set to a specific value at a specific position.

When the position of the plate material with respect to the blade shell 40 is determined and the arc length of the plate material is determined, R and L are input, and a plurality of different R are input, respectively, and a plurality of clearance volumes corresponding to R can be obtained by the above formula. R corresponding to the minimum value of the gap volume, which is preferably 0, is selected as the radius of curvature of the circle in which the cross section of the first surface S1 lies. Therefore, an optimal curvature radius r can be obtained, and after the beam cap plate with the curvature radius is placed into the blade shell mold, the size of a gap between the first surface of the beam cap plate and the blade shell is the smallest, so that the gap between the formed beam cap plate and the blade shell is as small as possible, even the gap does not exist, and the risk of defects such as a cavity, bubbles or a resin-rich area of the wind power blade is greatly reduced.

In this embodiment, a plate is placed at a designated position of a shell (mold) according to a structural design requirement of the wind turbine blade, however, a specific curvature radius on the shell of the blade corresponding to the plate located at the designated position can be obtained by inputting coordinate data of a relative position between the plate and the shell (mold).

It should be understood that the method of determining the specific curvature radius is not limited thereto, and other position data of the plate material may be in other relations with the curvature radius of the blade shell 40, and the curvature radius R of the circle in which the section of the blade shell 40 is located is derived by inputting the position data.

In the embodiment, a 65-meter leaf profile is selected, a 200mm wide plate (i.e., L is 200mm) is used, and the plate laying position is 0mm in chord coordinate; under this condition, a plurality of different r are inputted, and the gap volume corresponding to each r can be obtained, and fig. 3 shows a graph of r and the gap volume, with the abscissa representing r and the ordinate representing the gap volume. As shown in fig. 3, when r is about 2000mm, the corresponding gap volume is 0, so 2000mm is the optimum curvature radius, and the plate material with the above size is placed at the position of the blade shell 40, so that the gap between the two can be minimized.

It should be understood that the above values are merely examples, and the value of the radius of curvature r is not limited thereto, and may range from not less than 100 mm. The plates corresponding to the positions of the blade shell 40 are designed in the mode, the plates are arranged side by side in the second direction to form a plurality of groups, and the number and the size of gaps are greatly reduced.

Therefore, the present invention provides a method for automatically searching for the optimum curvature radius of the section radian of the sheet material, compared with the existing planar spar cap plate shown in fig. 1, the gap volume can be reduced by about 2/3 by using the plate material with the arc-shaped section designed by the present invention, so that the amount of the filling material can be greatly reduced, the process is simplified, and the formation of cavities, bubbles or resin-rich layers between the blade shell 40 and the spar cap plate can be reduced or even avoided as much as possible.

In this embodiment, as shown in FIG. 4, each

spar cap

10, 20 includes a plurality of attached sheets 11 and non-attached sheets 12 stacked and bonded along a first direction D1, each of the attached sheets 11 and non-attached sheets 12 being formed by a pultrusion process.

Compared with the vacuum introduction molding technology, the beam cap prepared by pultrusion of the plate has higher fiber volume content, more uniformity and higher fiber direction consistency, can reduce the defects of wrinkles, whitening and the like, obtains higher mechanical property, improves the fiber content of the main beam cap, and reduces the weight of the main bearing structural part of the wind power blade; in addition, the manufacturing cost of the wind power generation blade can be reduced, and the manufacturing efficiency of the wind power generation blade is improved; meanwhile, the number of main beam molds can be reduced, and a large amount of factory space does not need to be occupied.

It should be understood that the forming method of the sheet material is not limited thereto, and any existing process can be applied to the present application and is covered by the protection scope of the present application.

In this embodiment, as shown in fig. 4, each

spar cap

10, 20 includes a plurality of adjacent panel units arranged side by side along the second direction D2, each panel unit includes a plurality of attached panels 11 and non-attached panels 12 stacked and combined along the first direction D1, and the first direction D1 is perpendicular to the second direction D2.

Hereinafter, detailed description will be given of specific structures of the

caps

10 and 20, and since the

caps

10 and 20 have the same structure, only the cap 10 will be described, and the structure of the cap 20 will not be described in detail.

As shown in fig. 4, in the present embodiment, the curvature radius of the attached sheet material 11 and the curvature radius of the plurality of non-attached sheet materials 12 of each group of sheet material units are the same. That is, each plate of each group of plate units is a curved plate, the upper and lower surfaces of each group of plate units have radians, the shapes of the plates are the same, and two opposite surfaces of each plate have the same curvature radius.

In other embodiments, the second surface of the bonded panel is a flat surface, and the plurality of non-bonded panels are all flat panels. That is, among the multiple sheets of plates, only the surface connected with the blade shell is a curved surface, and other surfaces are planes, and stacking is performed between the planes of the multiple sheets of plates, and the surfaces in contact with the web 30 are planes, so that the connection between the plates and the web 30 is tighter.

In this embodiment, each of the attached plates 11 and the non-attached plates 12 further has a fastening portion, and the adjacent attached plates 11 and the non-attached plates 12 are in matching butt joint through the fastening portions.

The clamping part can be an area outside the area with the maximum thickness of the plate, wherein the connecting line of the maximum thickness parts of the upper surface and the lower surface of the plate is a boundary.

As shown in fig. 4, each plate has a circular arc-shaped cross section, and the convex-concave shapes of the opposite surfaces of the circular arc-shaped plates are used as the engaging portions 13, and when the plates are stacked in the first direction, the engaging portions 13 of the adjacent plates are matched with each other, so that the plates are tightly attached to each other and the plates are prevented from being displaced.

As shown in fig. 5, the two ends of the second and fourth groups of plates have cambered surfaces protruding outwards, the two ends of the third group of plates have cambered surfaces recessed inwards, one ends of the first and fifth groups of plates have cambered surfaces recessed inwards, and the adjacent groups of plates are matched and butted with each other to form interlocking, so that the adjacent plates are combined more accurately and tightly.

It should be understood that the number and arrangement of the plates are only illustrative, and the outer peripheries of the plates on both sides may have engaging portions or may be flush.

Fig. 6 to 12 show various forms of sheet material. In fig. 6 and 10, the cross section of the plates is isosceles trapezoid, and the shapes of the two adjacent groups of plates are reversed, so that the plates are matched and aligned. The cross-section of the sheet material on both sides is right trapezoid, forming a flush periphery.

In fig. 9, each sheet is right-angled trapezoidal in cross-section, with two adjacent sets of sheets inverted so as to match in alignment, and the periphery of the spar cap is flush.

In fig. 11, the cross-section of the sheets includes a right trapezoid and a parallelogram, and in the second direction, the sheets having a parallelogram cross-section overlap each other to form an interlock, and the sheets having a right trapezoid cross-section are located at both sides to form a flush periphery.

In fig. 7, the plate member has a zigzag cross section, and an engaging portion 13 is formed at each of both ends of the plate member. Along the second direction, the plates are oriented in the same direction and overlap each other to form an interlock. In this embodiment, the periphery of the panel that is located both sides is for flushing, promptly, includes two kinds of pultrusion panels, and the cross section of a pultrusion panel is foretell zigzag, and the block shape of zigzag is square, and the cross section of another kind of pultrusion panel is square, and two kinds of pultrusion panels buckle together and form the girder prefab that the cross section is the rectangle. The thickness of the square pultrusion plate is 2-3mm, the width is 5-40 mm, the maximum thickness of the Z-shaped plate is 5mm, the minimum thickness is 2-3mm, the total width is 120mm, the thickness of the clamping part is 2-3mm, and the width is 5-40 mm; the cross section of the square pultruded plate is the same as or complementary to the cross section of the clamping part of the Z-shaped plate. The two types of pultruded panels are combined together to form a rectangular or quasi-rectangular spar cap cross section with uniform upper and lower surface thickness and width.

The embodiment shown in fig. 8 is similar to the embodiment shown in fig. 7, in this embodiment, the cross section of the plate material is zigzag, and the engaging portions 13 at both ends of the plate material are triangular and formed into a hook shape, so that the adjacent plate materials are more closely aligned and combined.

The embodiment shown in fig. 12 is similar to the embodiment shown in fig. 7, and includes two sections of sheet material. The difference is that in this embodiment, at least two adjacent plates arranged along the second direction are oppositely disposed, the engaging portions 13 at the upper ends of the two plates are butted, and the engaging portions 13 at the lower ends of the two plates are far away from each other, so that a gap exists between the two plates. And filling the gap in the next layer of plate material through the upper end of one plate material and filling the gap between the next layer of plate material through the plate material. Therefore, the plates arranged side by side are interlocked in the second direction, and the stacked plates are also interlocked in the first direction, namely, the plates are clamped and locked in the two directions simultaneously, so that the overall structure of the beam cap is more stable.

The shapes mentioned in the above embodiments are not strictly defined and encompass similar shapes, for example, where the upper and lower surfaces of the sheet have a curvature, and the cross-section is generally in the shape of a zigzag, parallelogram, triangle, circular arc or trapezoid.

The plate materials described in the above embodiments are merely illustrative, and the shape and arrangement of the plate materials are not limited thereto, and for example, the outer periphery of the spar cap may have other shapes, and the corners of the plate materials may have circular arc-shaped or wedge-shaped chamfers, or may not have chamfers. In other embodiments, a combination of shapes of the sheet material may be included.

The invention also provides a manufacturing method of the wind power blade, which comprises the following steps:

forming a conformable sheet 11 and a non-conformable sheet 12 to stack to form the spar caps 10, 20, wherein the conformable sheet 11 and the non-conformable sheet 12 may be formed by a pultrusion process;

providing a blade shell mould (not shown), placing the attached plate 11 and the non-attached plate 12 into preset positions of the blade shell mould, and pouring resin through a vacuum pouring process to cure and form at least one pair of beam caps 10 and 20 and a blade shell 40; and

providing a web 30 such that the web 30 is connected between the at least one pair of spar caps 10, 20, thereby forming a wind turbine blade;

wherein, each attaching plate 11 has a first surface S1 and a second surface S2 which are opposite to each other, the non-attaching plate 12 is stacked and combined on the second surface S2 of the attaching plate 11, the first surface S1 of each attaching plate 11 is connected with the blade shell 40, and the curvature radius of the circle on which the section of the first surface S1 of each attaching plate 11 is located is obtained by the following formula:

a)sita＝L/2.0/r；

b)a_2＝r*sin(sita)；

c)Sita＝asin(a_2/R)；

d)S＝R*(fabs(R*Sita)-a_2*cos(Sita))-r*(r*sita-a_2*cos(sita))；

wherein: r is the radius of curvature of the circle on which the cross section of the first surface S1 of each bonded panel 11 is located; r is the section curvature radius of the blade shell mold; l is the cross-sectional arc length of the first surface S1 of each bonded panel 11; sita, a _2, Sita and S are process parameters; fabs are absolute value functions;

According to the wind power blade manufactured by the method, the curved beam cap plate has the optimal curvature radius, so that the size of a gap between the first surface of the beam cap plate and the blade shell is the smallest, the gap between the formed beam cap plate and the blade shell is as small as possible, even the gap does not exist, and the risk of defects such as a cavity, bubbles or a resin-rich area of the wind power blade is greatly reduced.

Wherein, the plate can be formed with the clamping part. The form of the engaging portion is as described above, and thus, the description thereof is omitted.

Wherein the step of forming the spar cap comprises:

and providing a girder mould, and laying the attached plate and the non-attached plate in the girder mould to form the beam cap.

In one embodiment, specifically, the attached plates and the non-attached plates are laid in a girder mold, fibers are laid between the attached plates and the non-attached plates of adjacent layers, and then the attached plates, the non-attached plates and the fibers are bound and fixed by using fiber tapes to form a girder cap.

In this embodiment, the manufacturing method of the wind turbine blade may include:

cutting and surface treating the plate according to the design requirement, wherein the plate is designed into a specific curvature radius and a clamping part through the method; for example, the cross-section of the sheet material is circular. The thickness of the pultruded panel is 5mm, the arc length is 150mm or 50mm, and the curvature radius is 2000 mm.

Laying the sheet material in a main beam mold; the clamping parts of the plates on each layer are connected with the clamping parts of the adjacent plates, and the fibers are laid between the stacked plates along the first direction, so that the wind power blade main beam prefabricated member is laid in a circulating mode. And then binding and fixing the girder prefabricated member by using the fiber strip for later use.

And after the main beam prefabricated part is placed at the position of the main beam in the blade shell mold, resin is poured into the area between the pultrusion plates and the fiber area according to the vacuum infusion process of the wind power blade or the main beam, and the resin is cured to finish the manufacture of the wind power blade main beam or the wind power blade shell 40.

In one embodiment, referring to fig. 7, the step of laying the plate in the girder mold is specifically:

first layer laying sequence: along the second direction, a plurality of Z-shaped plates are mutually adjacent and interlocked together, and the connection is repeated until the total width of the plates is consistent with the width of the main beam; then, the two ends of the plate are respectively connected with a plate with a square section, so that the periphery of the main beam is flush.

According to the mode, plates of other layers are sequentially laid, fiber fabrics are laid between the plates of each layer and between the plates of adjacent layers, and the wind power blade main beam prefabricated member is laid in a circulating mode. And then binding and fixing the girder prefabricated member by using the fiber strip for later use.

The fiber fabric can be glass fiber fabric or carbon fiber fabric, and the type of the fiber fabric is consistent with or inconsistent with the type of the fiber used by the plate.

The fiber fabric can be a uniaxial fabric with a 90-degree direction or a biaxial fabric with 0/90 degrees or +/-45 degrees.

For example, the plate may be made of 0-degree glass fiber or carbon fiber by a pultrusion process, and a layer of fiber fabric in the ± 45-degree direction may or may not be added in the middle layer of the 0-degree glass fiber yarn during the plate making process. The gram weight of the fiber fabric can be 100 plus 300g per square meter.

In some embodiments, laying glass fibers between the sheets may be omitted.

In summary, the invention provides a method for automatically searching for an optimal curvature radius of a section radian of a sheet, and the sheet with an arc-shaped section designed by the invention is used, so that the size of a gap between the sheet and a blade shell is minimum, and therefore, the gap between the formed beam cap sheet and the blade shell is as small as possible, even no gap exists, and the risk of defects such as a cavity, bubbles or a resin-rich area of the wind power blade is greatly reduced. Therefore, the efficiency of manufacturing the wind turbine blade can be improved, and the cost of manufacturing the blade can be reduced.

It is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the description. The invention is capable of other embodiments and of being practiced and carried out in various ways. The foregoing variations and modifications fall within the scope of the present invention. It will be understood that the invention disclosed and defined in this specification extends to all alternative combinations of two or more of the individual features mentioned or evident from the text and/or drawings. All of these different combinations constitute alternative aspects of the present invention. The embodiments described in this specification illustrate the best mode known for carrying out the invention and will enable those skilled in the art to utilize the invention.

Claims

1. A wind power blade plate comprises a first surface and a second surface which are opposite, wherein the first surface is used for being attached to a blade shell,

a)sita＝L/2.0/r；

b)a_2＝r*sin(sita)；

c)Sita＝asin(a_2/R)；

d)S＝R*(fabs(R*Sita)-a_2*cos(Sita))-r*(r*sita-a_2*cos(sita))；

2. A wind turbine blade comprising:

the main force-bearing structural part comprises at least one pair of beam caps and a web plate supported between the at least one pair of beam caps, each beam cap comprises at least one jointed plate and at least one non-jointed plate, each jointed plate is provided with a first surface and a second surface which are opposite, and the non-jointed plates are stacked and combined on the second surfaces of the jointed plates; and

a blade shell surrounding the at least one pair of spar caps, the first surface of each of the bonded sheets being joined to the blade shell, the radius of curvature of the circle in which the cross-section of the first surface of each of the bonded sheets lies being obtained by the following formula:

a)sita＝L/2.0/r；

b)a_2＝r*sin(sita)；

c)Sita＝asin(a_2/R)；

d)S＝R*(fabs(R*Sita)-a_2*cos(Sita))-r*(r*sita-a_2*cos(sita))；

3. The wind blade of claim 2, wherein each spar cap comprises a plurality of attached and unattached panels stacked in a first direction, each attached and unattached panel formed by a pultrusion process.

4. The wind blade of claim 3, wherein each spar cap comprises a plurality of sets of plate units arranged side-by-side and adjacent to each other along the second direction, each set of plate units comprising a plurality of attached plates and non-attached plates stacked and bonded along the first direction, the first direction being perpendicular to the second direction.

5. The wind blade of claim 4, wherein the second surface of the attached sheet is planar and the plurality of non-attached sheets are planar sheets.

6. The wind blade of claim 4, wherein the second surface of the attached sheet is a curved surface and the plurality of non-attached sheets are curved surface sheets.

7. The wind blade of claim 6 wherein the radius of curvature of the conforming sheet and non-conforming sheet of each set of sheet units is the same.

8. The wind blade of claim 2 wherein each of the attached and unattached panels have a snap fit, and adjacent attached and unattached panels are mated and butted via the snap fit.

9. The wind blade of claim 8 wherein adjacent ones of the plurality of attached and unattached panels of each layer are mated and mated by a snap fit.

10. The wind blade of claim 8 wherein adjacent attached and unattached panels of each set of the plurality of attached and unattached panels are mated and mated by a snap fit.

11. The wind blade of claim 9 or 10 wherein opposing sides of each of the conformable and non-conformable sheets project away from each other forming a pair of snap-fit portions.

12. The wind blade of claim 11 wherein each of the conformable and non-conformable sheets has a cross-section that is zigzag, parallelogram, triangular, circular arc or trapezoidal.

13. The wind blade of claim 9 or 10 wherein each of the conformable and non-conformable sheets has a right trapezoid cross-section.

14. The wind turbine blade of claim 9 or 10, wherein the cross section of one of the two adjacent attached plates or non-attached plates is a right trapezoid, and the cross section of the other attached plate or non-attached plate is an isosceles trapezoid.

15. A method for manufacturing a wind power blade, comprising:

a)sita＝L/2.0/r；

b)a_2＝r*sin(sita)；

c)Sita＝asin(a_2/R)；

d)S＝R*(fabs(R*Sita)-a_2*cos(Sita))-r*(r*sita-a_2*cos(sita))；

16. The method of manufacturing a wind blade of claim 15,

the step of forming the spar cap comprises:

17. The method of manufacturing a wind blade of claim 16,

the step of forming the spar cap further comprises:

and paving the attached plates and the non-attached plates in a girder mold, and then binding and fixing the attached plates, the non-attached plates and the fibers by using fiber strips to form a girder cap.

18. The method of manufacturing a wind blade of claim 15, wherein each spar cap comprises a plurality of bonded and non-bonded sheets stacked in a first direction.

19. The method of claim 18, wherein each spar cap comprises a plurality of sets of plate units arranged side-by-side and adjacent to each other along the second direction, each set of plate units comprising a plurality of attached plates and non-attached plates stacked and bonded along the first direction, and the first direction is perpendicular to the second direction.

20. The method of manufacturing a wind blade as defined in claim 19, wherein each of the attached sheet material and the non-attached sheet material has a snap-fit portion, and adjacent attached sheet materials and non-attached sheet materials are in matching butt joint through the snap-fit portions.

21. The method of manufacturing a wind blade as defined in claim 19, wherein adjacent ones of the plurality of attached sheets and non-attached sheets of each layer are mated and butted by a snap-fit portion.

22. The method of manufacturing a wind blade as defined in claim 19, wherein adjacent attached sheets and non-attached sheets of each group of the plurality of attached sheets and non-attached sheets are in mating abutment via a snap-fit portion.

23. The method of manufacturing a wind blade according to claim 21 or 22, wherein the opposing sides of each of the conformable and non-conformable sheets project away from each other to form a pair of engaging portions.

24. The method of claim 23, wherein each of the attached sheet material and the unattached sheet material has a zigzag, parallelogram, triangle, arc or trapezoid cross-section.