CN110657061B - Wind power blade plate, wind power blade and manufacturing method thereof - Google Patents

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

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Publication number
CN110657061B
CN110657061B CN201810715044.0A CN201810715044A CN110657061B CN 110657061 B CN110657061 B CN 110657061B CN 201810715044 A CN201810715044 A CN 201810715044A CN 110657061 B CN110657061 B CN 110657061B
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CN
China
Prior art keywords
wind power
laminated
bonded
plate
blade
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Active
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CN201810715044.0A
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Chinese (zh)
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CN110657061A (en
Inventor
宋秋香
刘仁
曾鸿鸣
苏成功
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Sinomatech Wind Power Blade Co Ltd
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Sinomatech Wind Power Blade Co Ltd
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Priority to CN201810715044.0A priority Critical patent/CN110657061B/en
Publication of CN110657061A publication Critical patent/CN110657061A/en
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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
    • F03D—WIND MOTORS
    • F03D1/00—Wind motors with rotation axis substantially parallel to the air flow entering the rotor 
    • F03D1/06—Rotors
    • F03D1/0608—Rotors characterised by their aerodynamic shape
    • F03D1/0633—Rotors characterised by their aerodynamic shape of the blades
    • 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
    • B29C39/00—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
    • B29C39/02—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles
    • B29C39/10—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. casting around inserts or for coating articles
    • 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
    • B29C39/00—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
    • B29C39/22—Component parts, details or accessories; Auxiliary operations
    • B29C39/42—Casting under special conditions, e.g. vacuum
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
    • F03D—WIND MOTORS
    • F03D1/00—Wind motors with rotation axis substantially parallel to the air flow entering the rotor 
    • F03D1/06—Rotors
    • F03D1/065—Rotors characterised by their construction elements
    • F03D1/0675—Rotors characterised by their construction elements of the blades
    • 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
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/70—Wind energy
    • Y02E10/72—Wind turbines with rotation axis in wind direction
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product

Abstract

The application provides a wind power blade plate, a wind power blade and a manufacturing method thereof. The main bearing structure 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 laminated plate and at least one non-laminated plate, each laminated plate is provided with a first surface and a second surface which are opposite, and the non-laminated plates are stacked and combined on the second surface of the laminated plate. The blade shell surrounds the outside of at least a pair of roof beam cap, and the first surface of each laminating panel is connected with the blade shell. The radius of curvature of the circle where the section of the first surface of each laminated sheet material is located is obtained by the following formula: a) sita=l/2.0/r; b) a2=r.sin (sita); c) Sita=asin (a_2/R); d) S=r (fabs (R x Sita) -a_2 x cos (Sita)) -R (R x Sita-a_2 x cos (Sita)); and r corresponding to the minimum value of the clearance volume is selected as the curvature radius of the circle where the section of the first surface of each laminated plate is located.

Description

Wind power blade plate, wind power blade and manufacturing method thereof
Technical Field
The application 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 environmental pollution problems, the use of clean energy is becoming more and more important. Wind energy has been widely used as an important clean energy source. Wind power blades are important components of wind power plants, which generally comprise a main load-bearing structure and a blade shell. The main bearing structure comprises an upper beam cap and a lower beam cap and a web plate between the upper beam cap and the lower beam cap. The upper beam cap and the lower beam cap are respectively attached to the shell of the blade.
The spar cap may comprise a plurality of sheets of material that may be bonded together, for example, by a resin, and the spar cap formed may be bonded to the blade shell, for example, by a resin.
Because the blade shell belongs to special-shaped curved surface, after the existing planar beam cap plate is attached to the blade shell, a gap under the sheet necessarily exists between the beam cap plate and the blade shell, and the gap can cause defects of a cavity, bubbles or a resin-rich area and the like of the wind power blade, so that the performance of the wind power blade is affected, the potential safety hazard of the wind power blade is increased, and the maintenance cost is increased.
The above information disclosed in the background section is only for enhancement of understanding of the background of the application and therefore it may contain information that does not form the prior art that is already known to a person of ordinary skill in the art.
Disclosure of Invention
The application 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 a gap between a beam cap and a blade shell as much as possible so as to reduce manufacturing cost and simplify process.
According to an aspect of the application, there is provided a wind power blade panel comprising opposed first and second surfaces, the first surface being adapted to conform to a blade shell,
wherein the radius of curvature of the circle in which the cross section of the first surface 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 in which the cross section of the first surface is located; r is the cross-sectional 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 functions;
r and L are known, a plurality of different R are input, and S is integrated, so that a clearance volume corresponding to each R can be obtained, wherein the clearance volume is the volume of a 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 a circle where the section of the first surface is located.
According to another aspect of the application, a wind power blade is provided comprising a primary load carrying structure and a blade shell.
The main bearing structure 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 laminated plate and at least one non-laminated plate, each laminated plate is provided with a first surface and a second surface which are opposite, and the non-laminated plates are stacked and combined on the second surface of the laminated plate.
The blade shell surrounds the outside of at least a pair of roof beam cap, and the first surface and the blade shell of each laminating panel are connected, obtain the radius of curvature of the circle that the cross-section of the first surface of each laminating panel is located 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 radius of curvature of the circle where the section of the first surface of each laminated plate is located; r is the cross-sectional curvature radius of the blade shell; l is the cross-sectional arc length of the first surface of each laminated board; sita, a_2, sita and S are process parameters; fabs are absolute functions;
r and L are known, a plurality of different R are input, and S is integrated, so that a clearance volume corresponding to each R can be obtained, wherein the clearance volume is the volume of a clearance 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 clearance volume is selected as the curvature radius of a circle where the section of the first surface of each bonding plate is located.
According to still another aspect of the present application, there is provided a method of manufacturing a wind turbine blade, comprising:
forming a laminated board and a non-laminated board to be stacked to form a beam cap;
providing a blade shell mould, putting the laminated plate and the non-laminated plate into a preset position 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; a kind of electronic device with high-pressure air-conditioning system
Providing a web plate, so that the web plate is connected between the at least one pair of spar caps, thereby forming a wind power blade;
wherein, each laminating panel has relative first surface and second surface, and non-laminating panel piles up the second surface that combines in laminating panel, and the first surface and the blade casing 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 radius of curvature of the circle where the section of the first surface of each laminated plate is located; r is the section curvature radius of the blade shell mould; l is the cross-sectional arc length of the first surface of each laminated board; sita, a_2, sita and S are process parameters; fabs are absolute 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 a clearance 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 clearance volume is selected as the curvature radius of a circle where the section of the first surface of each bonding plate is located.
According to the technical scheme, the application provides the method for automatically searching the optimal curvature radius of the radian of the section of the sheet, and the plate with the arc-shaped section is used, so that the clearance volume between the plate and the blade shell is minimum, and therefore, the clearance between the beam cap plate and the blade shell after forming is as small as possible, even no clearance exists, and the risk of defects such as cavities, bubbles or resin-rich areas of the wind power blade is greatly reduced. Therefore, the manufacturing efficiency of the wind power generation blade can be improved, and the blade manufacturing cost can be reduced.
Drawings
The above and other features and advantages of the present application 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 joint;
FIG. 2 is a schematic cross-sectional view of a wind power blade according to an embodiment of the application;
FIG. 3 is a graph of radius of curvature versus interstitial volume of a circle in which a cross section of a first surface of a conformable sheet material according to an embodiment of the present application is located;
FIG. 4 is a schematic cross-sectional view of a spar cap and blade shell joint location in accordance with an embodiment of the present application;
FIG. 5 is a schematic cross-sectional view of a spar cap and blade shell joint location in accordance with another embodiment of the present application;
FIG. 6 is a schematic partial cross-sectional view of a spar cap according to yet another embodiment of the present application;
FIG. 7 is a schematic partial cross-sectional view of a spar cap according to yet another embodiment of the present application;
FIG. 8 is a schematic partial cross-sectional view of a spar cap according to yet another embodiment of the present application;
FIG. 9 is a schematic partial cross-sectional view of a spar cap according to yet another embodiment of the present application;
FIG. 10 is a schematic partial cross-sectional view of a spar cap according to yet another embodiment of the present application;
FIG. 11 is a schematic partial cross-sectional view of a spar cap according to yet another embodiment of the present application; a kind of electronic device with high-pressure air-conditioning system
Fig. 12 is a schematic partial cross-sectional view of a spar cap according to yet another embodiment of the present application.
Detailed Description
Example embodiments will now be described more fully with reference to the accompanying drawings. However, the exemplary embodiments can be embodied in many 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 the example embodiments to those skilled in the art. The same reference numerals in the drawings denote the same or similar structures, and thus detailed descriptions thereof will be omitted.
Although relative terms such as "upper" and "lower" are used in this specification to describe the relative relationship of one component of an icon to another component, these terms are used in this specification for convenience only, such as in terms of the orientation of the examples described in the figures. It will be appreciated that if the device of the icon is flipped upside down, the recited "up" component will become the "down" component. 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 through 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., in addition to the listed elements/components/etc.; the terms "first," "second," and "third," etc. are used merely as labels, and do not limit the number of their objects.
In the manufacturing process of the wind power blade, a main beam prefabricated member, namely a beam cap, is placed into a shell mould of the wind power blade, resin is poured into the mould, and the main beam prefabricated member and a shell material are solidified together.
As shown in fig. 1, since the blade shell is a special-shaped curved surface, and the curvature radius of the blade shell at each position is different, the beam cap plate is generally flat, and therefore, after the flat beam cap plate is attached to the blade shell, a plate lower gap G is necessarily present between the two. The gap G can cause defects such as a cavity, bubbles or a resin-rich region and the like of the wind power blade, influence the performance of the wind power blade, increase the operation potential safety hazard of the wind power blade and increase the maintenance cost.
In general, the blade shell is formed by pouring resin into a blade shell mold through a vacuum pouring process, and the gap between a planar plate and the blade shell mold is the plate lower gap G, so that the formed wind power blade forms defects such as a cavity, bubbles or a resin-rich region due to the existence of the plate lower gap G.
It should be noted that the "under-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 term "blade shell" as used herein refers to the outer shell of a wind power blade that encloses the primary load carrying structure.
FIG. 2 is a schematic cross-sectional view of a wind turbine blade in accordance with an embodiment of the present application, it being understood that FIG. 2 is only one version of a plurality of wind turbine blades, and that the wind turbine blade of this application includes, but is not limited to, the wind turbine blade sheet material of FIG. 2, and that the present application is applicable to a variety of wind turbine blades in the prior art.
As shown in fig. 2 and 4, the present application provides a wind power blade comprising a primary load carrying structure and a blade shell 40.
The primary load bearing structure includes at least a spar cap, the present embodiment being described by way of example as a pair of spar caps 10, 20. It should be understood that the number of spar 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 includes at least one conformable sheet 11 and at least one non-conformable sheet 12, each conformable sheet 11 having opposing first and second surfaces S1, 12 being stacked and bonded to the second surface of the conformable sheet 11.
The blade shell 40 surrounds the outside of the pair of spar caps 10, 20, and the first surface S1 of each bonding sheet 11 is connected to the blade shell 40. The radius of curvature of the circle in which the section of the first surface S1 of each laminated 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 in which the cross section of the first surface S1 of each laminated board 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 laminated board 11; sita, a_2, sita and S are process parameters; fabs are absolute functions;
r and L are known, a plurality of different R are input, and the 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 S1 of each bonding sheet 11 and the surface of the connected blade housing 40, and R corresponding to the minimum value of the gap volume is selected as a radius of curvature of a circle where the cross section of the first surface of each bonding sheet is located.
Specifically, since the blade shell 40 belongs to a special-shaped curved surface, the curvature radius of each position is different, and thus 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 section of the blade shell 40 is located is a specific value at a specific position.
In the case of a position determination of the sheet metal relative to the blade housing 40 and an arc length determination of the sheet metal, R, L and a plurality of different R are respectively input, a plurality of gap volumes corresponding to R can be obtained by the above formula. R corresponding to the minimum value of the interstitial volume is selected as the radius of curvature of the circle in which the cross section of the first surface S1 is located, and the minimum value of the interstitial volume is preferably 0. Therefore, the optimal curvature radius r can be obtained, and after the beam cap plate with the curvature radius is placed in the blade shell die, the gap volume between the first surface of the beam cap plate and the blade shell is minimum, so that the gap between the beam cap plate after molding 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.
In this embodiment, the plate is placed at a specified position of the shell (mold) according to the structural design requirement of the wind power blade, however, the specific radius of curvature of the blade shell corresponding to the plate at the specified position can be obtained by inputting the coordinate data of the relative position of the plate and the shell (mold).
It should be appreciated that the method of determining the particular radius of curvature is not limited thereto and that other positional data of the sheet material may be in other relation to the radius of curvature of the blade shell 40 and the radius of curvature R of the circle in which the cross section of the blade shell 40 is located may be derived by inputting the positional data.
In the embodiment, a blade profile of about 65 meters is selected, a plate with the width of 200mm (namely, L is 200 mm) is used, and the laying position of the plate is the chord coordinate of 0mm; under this condition, a plurality of different r are inputted, and a 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 clearance volume is 0, so 2000mm is the optimal radius of curvature, and the clearance between the two plates having the above-mentioned dimensions can be minimized by placing the plates having the above-mentioned dimensions at this position of the blade shell 40.
It should be understood that the above values are only examples, and the value of the radius of curvature r is not limited thereto, and may be in a range of not less than 100mm. In this way, the plates corresponding to the positions of the blade shells 40 are designed, and the plates are arranged side by side in the second direction to form a plurality of groups, so that the number and the volume of gaps are greatly reduced.
Therefore, compared with the prior planar beam cap plate shown in fig. 1, the plate with the arc-shaped cross section designed by the application can reduce the clearance volume by about 2/3, thereby greatly reducing the consumption of filling materials, simplifying the process, and reducing or even avoiding the formation of a cavity, bubbles or a resin-rich layer between the blade shell 40 and the beam cap plate as much as possible.
In this embodiment, as shown in fig. 4, each of the spar caps 10, 20 includes a plurality of laminated plates 11 and non-laminated plates 12 stacked and combined along the first direction D1, and each of the laminated plates 11 and non-laminated plates 12 is formed by a pultrusion process.
Compared with the vacuum guide-in forming technology, the girder cap prepared by the pultrusion plate in the embodiment has higher fiber volume content, more uniformity and higher fiber direction consistency, can reduce the defects of wrinkling, blushing and the like, obtain higher mechanical property, improve the fiber content of the girder cap and reduce the weight of a main bearing structural member 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 girder die can be reduced, and a large amount of factory building space is not required to be occupied.
It should be understood that the forming manner of the sheet material is not limited thereto, and any existing process can be applied to the present application and is included in the protection scope of the present application.
In this embodiment, as shown in fig. 4, each of the spar caps 10, 20 includes a plurality of sets of adjacent plate units arranged side by side along the second direction D2, each set of plate units includes a plurality of laminated plates 11 and non-laminated plates 12 stacked and combined along the first direction D1, and the first direction D1 is perpendicular to the second direction D2.
Hereinafter, the specific structures of the spar caps 10, 20 will be described in detail, and since the spar caps 10 and 20 have the same structure, only the spar cap 10 will be described, and the structure of the spar cap 20 will not be described in detail.
As shown in fig. 4, in the present embodiment, the curvature radius of the laminated sheet 11 and the non-laminated sheet 12 of each group of sheet units is the same. That is, each plate of each group of plate units is a curved plate, the upper surface and the lower surface have radians, the shapes of the plates are the same, and the two opposite surfaces of each plate have the same curvature radius.
In other embodiments, the second surface of the conformable sheet is planar and the plurality of non-conformable sheets are planar. That is, only the surface connected to the blade shell is curved, the other surfaces are flat, and the flat surfaces of the plurality of plates are stacked, and the surface contacted with the web 30 is flat, so that the connection between the plates and the web 30 is tighter.
In this embodiment, each of the laminated board 11 and the non-laminated board 12 further has a clamping portion, and the adjacent laminated boards 11 and the non-laminated board 12 are matched and butted through the clamping portion.
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 of the upper surface and the lower surface of the plate is used as a dividing line.
As shown in fig. 4, the cross section of each plate is, for example, circular arc, the concave-convex shape of the opposite surfaces of the circular arc plates is used as the engaging portions 13, and when stacked along the first direction, the engaging portions 13 of adjacent plates are matched with each other, so that the adjacent plates are closely attached to each other, and offset is avoided.
As shown in fig. 5, the two ends of the plates in the second group and the fourth group have cambered surfaces protruding outwards, the two ends of the plates in the third group have cambered surfaces recessed inwards, and the one ends of the plates in the first group and the fifth group have cambered surfaces recessed inwards, so that the plates in adjacent groups are matched and butted with each other to form interlocking, and the adjacent plates are combined more accurately and tightly.
It should be understood that the number and arrangement of the plates is only schematically illustrated, and that the outer circumferences of the plates on both sides may have a snap-fit portion 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 two adjacent groups of plates are reversed, so that the plates are matched and aligned. The cross section of the plates on both sides is right trapezoid, so that a flush periphery is formed.
In fig. 9, each plate has a right trapezoid cross section, the shapes of two adjacent groups of plates are reversed, so that the plates are matched and aligned, and the periphery of the beam cap is flush.
In fig. 11, the cross section of the sheet material includes a right trapezoid and a parallelogram, and in the second direction, the sheet materials having the cross section of the parallelogram overlap each other to form an interlock, and the sheet materials having the cross section of the right trapezoid are positioned at both sides to form a flush outer circumference.
In fig. 7, the cross section of the plate is zigzag, and two ends of the plate are each formed with an engaging portion 13. Along the second direction, the plates are placed in the same direction and overlap each other to form an interlock. In this embodiment, the peripheries of the plates located on two sides are flush, that is, the two types of pultruded plates are included, the cross section of one type of pultruded plates is in the shape of the Z-shaped, the shape of the clamping part of the Z-shaped is square, the cross section of the other type of pultruded plates is square, and the two types of pultruded plates are buckled together to form a main beam prefabricated member with a rectangular cross section. 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 with the cross section of the clamping part of the Z-shaped plate. The two pultruded panels are combined together to form a rectangular or rectangle-like girder cap cross section with uniform thickness and width on the upper and lower surfaces.
The embodiment shown in fig. 8 is similar to the embodiment shown in fig. 7, in this embodiment, the section of the plate is zigzag, and the engaging portions 13 at two ends of the plate are triangular and formed into a hook shape, so that adjacent plates are more tightly aligned and combined.
The embodiment shown in fig. 12 is similar to the embodiment shown in fig. 7 in that it includes two cross-sectional sheets. The difference is that in this embodiment, at least two adjacent plates arranged along the second direction are placed opposite to each other, the engaging portions 13 at the upper ends of the two plates are abutted, 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. In the next layer of plates, the gap is filled through the upper end of one plate, and the gap between the plates of the next layer is filled through the plate. Thereby, not only in the second large direction, the plates arranged side by side are interlocked, but also in the first direction, the stacked plates are interlocked, that is, the plates are simultaneously clamped and locked in the two directions, so that the whole structure of the beam cap is more stable.
The shapes mentioned in the above embodiments are not strictly defined, and they cover similar shapes, for example, the upper and lower surfaces of the plate material have radians, and the cross section thereof is substantially zigzag, parallelogram, triangle, circular arc or trapezoid.
The plate materials described in the above embodiments are only schematically illustrated, and the shape and arrangement of the plate materials are not limited thereto, and for example, the outer periphery of the beam cap may have other shapes, and the corners of the plate materials may have circular arc-shaped or wedge-shaped chamfers or may have no chamfers. In other embodiments, a sheet of material may be included in a variety of combinations of shapes.
The application also provides a manufacturing method of the wind power blade, which comprises the following steps:
forming a laminated sheet 11 and a non-laminated sheet 12 to be stacked to form spar caps 10, 20, wherein the laminated sheet 11 and the non-laminated sheet 12 can be formed by a pultrusion process;
providing a blade shell mold (not shown), placing the laminated sheet material 11 and the non-laminated sheet material 12 in predetermined positions of the blade shell mold, and curing and molding at least one pair of spar caps 10, 20 and a blade shell 40 by pouring resin through a vacuum pouring process; a kind of electronic device with high-pressure air-conditioning system
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 blade;
wherein, each laminated board 11 has a first surface S1 and a second surface opposite to each other, the non-laminated board 12 is stacked and combined on the second surface of the laminated board 11, the first surface S1 of each laminated board 11 is connected with the blade shell 40, and the radius of curvature of the circle where the cross section of the first surface S1 of each laminated board 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 in which the cross section of the first surface S1 of each laminated board 11 is located; r is the section curvature radius of the blade shell mould; l is the cross-sectional arc length of the first surface S1 of each laminated board 11; sita, a_2, sita and S are process parameters; fabs are absolute 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 a clearance 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 clearance volume is selected as the curvature radius of a circle where the section of the first surface of each bonding plate is located.
According to the wind power blade manufactured by the method, the curved beam cap plate has the optimal curvature radius, so that the gap volume between the first surface of the beam cap plate and the blade shell is minimum, and therefore, 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.
Wherein, the plate material can be formed with a clamping part. The form of the engaging portion is described above, and thus will not be described again.
Wherein, the step of forming the beam cap comprises:
providing a girder mould, and paving the laminated plate and the non-laminated plate in the girder mould to form the girder cap.
In an embodiment, specifically, the bonding plate and the non-bonding plate are laid in the main beam mold, fibers are laid between the bonding plate and the non-bonding plate of the adjacent layers, and then the bonding plate, the non-bonding plate and the fibers are bound and fixed by using fiber strips to form the beam cap.
In this embodiment, the method for manufacturing a wind power blade may include:
cutting and surface treatment are carried out on the plate according to the design requirements, wherein the plate is designed into a specific curvature radius and a clamping part in the mode; for example, the cross section of the plate is circular arc. The thickness of the pultruded plate is 5mm, the arc length is 150mm or 50mm, and the curvature radius is 2000mm.
Laying the plate in a girder mould; and the clamping parts of each layer of plate are connected with the clamping parts of the adjacent plates, and fibers are paved among the stacked plates along the first direction, so that the paving of the wind power blade main beam prefabricated member is circularly completed. And then the fiber strips are used for binding and fixing the girder prefabricated members for later use.
After the girder prefabricated member is placed in the position of the girder in the blade shell mold, resin is poured into the area between the pultruded plates and the fiber area according to the vacuum pouring process of the wind power blade or the girder, and the manufacturing of the wind power blade girder or the wind power blade shell 40 is completed by solidifying the resin.
In one embodiment, referring to fig. 7, the step of laying the sheet material in the girder die is specifically:
first layer lay-up order: in the second direction, a plurality of Z-shaped plates are mutually adjacent and interlocked together, and are circularly connected until the total width of the plates is consistent with the width of the main beam; then, two ends of the plate are respectively connected with a plate with square section, so that the periphery of the main beam is flush.
According to the mode, the plates of other layers are sequentially paved, fiber fabrics are paved between the plates of each layer and between the plates of the adjacent layers, and paving of wind power blade main beam prefabricated parts is completed in a circulating mode. And then the fiber strips are used for binding and fixing the girder prefabricated members 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 in the 90-degree direction or a biaxial fabric in the 0/90 degree or +/-45 degree direction.
For example, the plate can be made of 0-degree glass fiber or carbon fiber through a pultrusion process, and a layer of fiber fabric with the direction of +/-45 degrees can be added into a 0-degree glass fiber yarn middle layer or not. The fabric gram weight can be 100-300 g/square meter.
In some embodiments, the laying of glass fibers between the sheets may be omitted.
In summary, the application provides an automatic method for searching the optimal curvature radius of the radian of the section of the sheet, and the plate with the arc-shaped section is adopted, so that the clearance volume between the plate and the blade shell is minimum, and therefore, the clearance between the beam cap plate and the blade shell after molding is as small as possible, even no clearance exists, and the risk of defects such as cavities, bubbles or resin-rich areas of the wind power blade is greatly reduced. Therefore, the manufacturing efficiency of the wind power generation blade can be improved, and the blade manufacturing cost can be reduced.
It should be understood that the application is not limited in its application to the details of construction and the arrangement of components set forth in the specification. The application is capable of other embodiments and of being practiced and carried out in various ways. The foregoing variations and modifications are intended to fall within the scope of the present application. It should be understood that the application 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 various alternative aspects of the present application. The embodiments described in this specification illustrate the best mode known for carrying out the application and will enable those skilled in the art to make and use the application.

Claims (24)

1. The processing method of the wind power blade plate is characterized by comprising the following steps of:
s1, selecting a wind power blade plate, which comprises a first surface and a second surface which are opposite and are used for being attached to a blade shell, wherein the arc length of the cross section of the first surface is a fixed value L;
s2, determining the attaching position of the plate relative to the blade shell, wherein the curvature radius of the attaching position is a fixed value R;
s3, determining the volume of a gap between the surface of the blade shell and the first surface 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))；
integrating the S to obtain the gap volumes corresponding to each r;
wherein: r is the radius of curvature of the circle in which the cross section of the first surface is located; sita, a_2, sita and S are process parameters; fabs are absolute functions;
s4, selecting r corresponding to the minimum value of the gap volume as the curvature radius of a circle where the section of the first surface is located;
s5, processing to obtain the plate with the size.
2. A wind power blade comprising:
a primary load bearing structure comprising at least one pair of spar caps and a web supported between the at least one pair of spar caps, each spar cap comprising at least one conformable sheet material obtained by the sheet material processing method of claim 1 and at least one non-conformable sheet material, each conformable sheet material having opposed first and second surfaces, the non-conformable sheet material being stacked and bonded to the second surface of the conformable sheet material; and a blade housing surrounding the at least one pair of spar caps, wherein the first surface of each bonding plate is connected with the blade housing.
3. The wind power blade of claim 2, wherein each spar cap comprises a plurality of bonded and non-bonded sheets stacked and bonded in a first direction, each bonded and non-bonded sheet being formed by a pultrusion process.
4. A wind power blade according to claim 3, wherein each spar cap comprises a plurality of sets of side-by-side and adjacent sheet elements along a second direction, each set of sheet elements comprising a plurality of bonded and non-bonded sheets stacked and bonded along a first direction, the first direction being perpendicular to the second direction.
5. The wind power blade of claim 4, wherein the second surface of the conformable sheet is planar and the plurality of non-conformable sheets are planar sheets.
6. The wind power blade of claim 4, wherein the second surface of the conformable sheet is curved and the plurality of non-conformable sheets are curved sheets.
7. The wind turbine blade of claim 6, wherein the radius of curvature of the conformable sheet and the non-conformable sheet of each set of sheet elements is the same.
8. The wind power blade of claim 2, wherein each of the conformable sheet material and the non-conformable sheet material has a snap-fit portion,
adjacent laminated plates and non-laminated plates are matched and butted through the clamping parts.
9. The wind turbine blade of claim 8, wherein each of the plurality of laminated sheets and non-laminated sheets of each layer are mutually aligned
The adjacent laminated plates and the non-laminated plates are matched and butted through the clamping parts.
10. The wind turbine blade of claim 8, wherein each set of the plurality of bonded and non-bonded sheets are mutually bonded
The adjacent laminated plates and the non-laminated plates are matched and butted through the clamping parts.
11. A wind power blade according to claim 9 or 10, wherein opposite sides of each of the conformable sheet material and the non-conformable sheet material protrude away from each other forming a pair of detents.
12. The wind power blade of claim 11, wherein each of the conformable sheet material and the non-conformable sheet material has a cross-section that is zig-zag, parallelogram, triangle, circular arc, or trapezoid.
13. A wind power blade according to claim 9 or 10, wherein each of the conformable sheet material and the non-conformable sheet material is right trapezoid in cross-section.
14. A wind power blade according to claim 9 or 10, wherein one of two adjacent bonded or non-bonded sheets has a right trapezoid cross section, and the other bonded or non-bonded sheet has an isosceles trapezoid cross section.
15. A method of manufacturing a wind power blade, comprising:
forming a bonded panel and a non-bonded panel obtained by the panel processing method of claim 1 to be stacked to form a spar cap;
providing a blade shell mould, putting the laminated plate and the non-laminated plate into a preset position 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 blade;
wherein, each laminating panel has relative first surface and second surface, and non-laminating panel piles up the second surface that combines in laminating panel, and the first surface and the blade casing of each laminating panel are connected.
16. The method for manufacturing a wind power blade according to claim 15, wherein,
the step of forming the spar cap includes:
providing a girder mould, and paving the laminated plate and the non-laminated plate in the girder mould to form the girder cap.
17. The method for manufacturing a wind power blade according to claim 16, wherein,
the step of forming the spar cap further comprises:
paving the laminated plates and the non-laminated plates in the girder die, and binding and fixing the laminated plates, the non-laminated plates and the fibers by using fiber strips to form the girder cap.
18. The method of manufacturing a wind power blade according to claim 15, wherein each spar cap comprises a plurality of bonded and non-bonded sheets stacked and bonded in a first direction.
19. The method of claim 18, wherein each spar cap comprises a plurality of sets of adjacent plate units side by side in a second direction, each set of plate units comprising a plurality of bonded plates and non-bonded plates stacked and bonded in a first direction, the first direction being perpendicular to the second direction.
20. The method of claim 19, wherein each of the laminated sheet material and the non-laminated sheet material has a engaging portion, and adjacent laminated sheet material and non-laminated sheet material are mated and butted by the engaging portion.
21. The method for manufacturing a wind power blade according to claim 19, wherein adjacent laminated plates and non-laminated plates among the plurality of laminated plates and non-laminated plates of each layer are mated and butted by the engaging portion.
22. The method for manufacturing a wind power blade according to claim 19, wherein, of the plurality of laminated plates and non-laminated plates in each group, adjacent laminated plates and non-laminated plates are mated and butted by the engaging portion.
23. A method of manufacturing a wind turbine blade according to claim 21 or 22, wherein opposite sides of each of the laminated and non-laminated plates protrude away from each other to form a pair of engaging portions.
24. The method for manufacturing a wind power blade according to claim 23, wherein each of the laminated sheet material and the non-laminated sheet material has a zigzag, parallelogram, triangle, circular arc or trapezoid cross section.
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