CN113942252B - Method for integrally pouring and forming adhesive flange mold and blade skin - Google Patents
Method for integrally pouring and forming adhesive flange mold and blade skin Download PDFInfo
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- CN113942252B CN113942252B CN202111219539.2A CN202111219539A CN113942252B CN 113942252 B CN113942252 B CN 113942252B CN 202111219539 A CN202111219539 A CN 202111219539A CN 113942252 B CN113942252 B CN 113942252B
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- 239000000853 adhesive Substances 0.000 title claims abstract description 73
- 230000001070 adhesive effect Effects 0.000 title claims abstract description 73
- 238000000034 method Methods 0.000 title claims abstract description 47
- 239000004744 fabric Substances 0.000 claims abstract description 93
- 239000000463 material Substances 0.000 claims abstract description 30
- 239000011152 fibreglass Substances 0.000 claims abstract description 25
- 238000002955 isolation Methods 0.000 claims abstract description 11
- 238000004381 surface treatment Methods 0.000 claims abstract description 11
- 239000010410 layer Substances 0.000 claims description 138
- 230000003014 reinforcing effect Effects 0.000 claims description 24
- 238000005498 polishing Methods 0.000 claims description 19
- 239000011162 core material Substances 0.000 claims description 17
- 239000011248 coating agent Substances 0.000 claims description 16
- 238000000576 coating method Methods 0.000 claims description 16
- 239000004593 Epoxy Substances 0.000 claims description 14
- 238000000465 moulding Methods 0.000 claims description 14
- 238000000605 extraction Methods 0.000 claims description 13
- 239000012945 sealing adhesive Substances 0.000 claims description 12
- 238000001514 detection method Methods 0.000 claims description 10
- 239000003365 glass fiber Substances 0.000 claims description 10
- 238000004519 manufacturing process Methods 0.000 claims description 10
- 239000002131 composite material Substances 0.000 claims description 9
- 230000001965 increasing effect Effects 0.000 claims description 9
- 230000008859 change Effects 0.000 claims description 8
- 239000012790 adhesive layer Substances 0.000 claims description 7
- 239000002390 adhesive tape Substances 0.000 claims description 6
- 239000003795 chemical substances by application Substances 0.000 claims description 6
- 238000004140 cleaning Methods 0.000 claims description 6
- 238000010438 heat treatment Methods 0.000 claims description 5
- 239000002356 single layer Substances 0.000 claims description 4
- 240000007182 Ochroma pyramidale Species 0.000 claims description 3
- 238000005520 cutting process Methods 0.000 claims description 3
- 230000008439 repair process Effects 0.000 claims description 3
- 238000007790 scraping Methods 0.000 claims description 3
- 238000005266 casting Methods 0.000 claims 8
- 238000009966 trimming Methods 0.000 abstract description 3
- 239000003292 glue Substances 0.000 abstract 1
- 238000002360 preparation method Methods 0.000 abstract 1
- 238000004088 simulation Methods 0.000 abstract 1
- 239000011347 resin Substances 0.000 description 11
- 229920005989 resin Polymers 0.000 description 11
- 238000001802 infusion Methods 0.000 description 10
- 230000000694 effects Effects 0.000 description 8
- 238000007493 shaping process Methods 0.000 description 7
- 230000008569 process Effects 0.000 description 6
- 230000009471 action Effects 0.000 description 3
- 230000007547 defect Effects 0.000 description 3
- 230000008595 infiltration Effects 0.000 description 3
- 238000001764 infiltration Methods 0.000 description 3
- 230000002035 prolonged effect Effects 0.000 description 2
- 230000005611 electricity Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000002708 enhancing effect Effects 0.000 description 1
- 238000005429 filling process Methods 0.000 description 1
- 238000001746 injection moulding Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000005086 pumping Methods 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
- B29C70/34—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
- B29C70/342—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation using isostatic pressure
-
- 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
- B29C33/00—Moulds or cores; Details thereof or accessories therefor
- B29C33/56—Coatings, e.g. enameled or galvanised; Releasing, lubricating or separating agents
- B29C33/68—Release sheets
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
Abstract
The invention belongs to the technical field of wind power blades, and particularly discloses a method for integrally pouring and forming an adhesive flange die and a blade skin, which comprises the following steps of S1, PS surface forming, namely, die preparation, laying of a PS skin structure layer of the blade, auxiliary material arrangement, cloth layer isolation, glue layer simulation, laying of a PS surface adhesive flange die structure layer, parting surface treatment, optimizing the arrangement of pouring auxiliary materials, integrally pouring and forming, and die closing joint glass fiber reinforced plastic treatment of the PS surface skin and the adhesive flange die; s2, forming an SS surface, namely preparing a mold, processing a mold parting surface and a vacuum port, laying a blade SS skin structural layer, arranging auxiliary materials, isolating a cloth layer, laying an SS surface bonding flange mold structural layer, optimizing the arrangement of filling auxiliary materials at the parting surface, integrally filling and forming, and processing the SS surface skin and bonding flange mold die joint glass fiber reinforced plastics; and S3, die bonding, die trimming, surface treatment and setting a limiting pultrusion block. The method can solve the problem that the forming period of the blade is influenced in the prior art.
Description
Technical Field
The invention belongs to the technical field of wind power blades, and particularly relates to a method for integrally pouring and forming an adhesive flange die and a blade skin.
Background
Wind energy is widely used as a sustainable, pollution-free energy source. Wind power plants are power machines, also called windmills, that convert wind energy into mechanical work. Broadly, it is a thermal energy utilization launch apparatus that uses the sun as a heat source and the atmosphere as a working medium. The wind power is utilized to drive the blades of the windmill to rotate, and then the rotating speed is increased through the speed increaser so as to promote the generator to generate electricity.
The main components of the blade are divided into PS skin, SS skin, web and girder, and the bonding flanges at the front and rear edges of the skin are used as important components for bonding and forming the PS skin and the SS skin of the wind turbine blade, so that the bonding flange is a main bearing component for bonding the wind turbine blade. The shaping of skin front and back edge bonding flange needs to use bonding flange mould, bonding flange's shape-following degree and bonding clearance are guaranteed by the flange mould, and the flange mould plays vital effect to blade shaping, however flange mould is general to pour into the shaping on the skin product, and shaping time is usually 40-48h, and bonding flange is poured into after bonding flange mould is poured into the shaping, and this shaping technology seriously influences blade shaping cycle, causes the serious waste of resource.
Disclosure of Invention
The invention aims to provide a method for integrally pouring and forming an adhesive flange die and a blade skin, which aims to solve the problem that the forming period of a blade is influenced in the prior art.
In order to achieve the above purpose, the technical scheme of the invention is as follows: a method for integrally pouring and molding an adhesive flange mold and a blade skin comprises the following steps:
s1, PS surface molding; the method specifically comprises the following steps:
s1.1, preparing a mould, namely cleaning a blade mould, coating a release agent on the surface of the mould, paving release cloth on the surface of the mould, paving a primary vacuum sealing adhesive tape and a secondary vacuum sealing adhesive tape on the parting surface of the mould;
s1.2, laying a PS skin structure layer of a blade, namely firstly laying an outer skin large cloth, an outer skin reinforcing layer and an outer skin reinforcing layer, secondly laying a prefabricated rear edge beam, placing a main beam, laying a core material, laying a rear edge UD on the core material, and finally laying an inner skin reinforcing layer, an inner skin reinforcing layer and an inner skin large cloth; after the PS skin structure layer is laid, laying release cloths of a front edge bonding area and a rear edge bonding area;
s1.3, auxiliary material arrangement, namely laying release cloth on the surface of a PS skin structure layer and bonding the release cloth on the lower side of a flange die;
s1.4, cloth layer isolation, namely paving porous isolating films on a front edge area and a rear edge area of a die for manufacturing the bonding flange, and covering the cloth layer of the die for manufacturing the bonding flange on the porous isolating films;
s1.5, simulating an adhesive layer, namely simulating an adhesive gap between a PS surface skin and an SS surface skin, calculating the adhesive gap between the PS skin and the SS skin, simulating the thickness of the adhesive layer according to the adhesive gap and the thickness of a single-layer glass fiber fabric after being poured and molded, and paving glass fiber fabrics with corresponding layers;
s1.6, laying a PS surface bonding flange mold structure layer: laying an adhesive flange mold structure layer in the PS surface adhesive flange area;
s1.7, mold parting surface treatment, namely arranging a circumferential airfelt and airfelt bridging on a PS surface mold parting surface, wherein one side of the airfelt bridging is overlapped and paved with an adhesive flange mold cloth layer, and the other side is pressed below the circumferential airfelt;
s1.8, optimizing the arrangement of pouring auxiliary materials, namely extending a composite diversion net and a pouring runner to an adhesive flange mold area, and adding an external air extraction spiral pipe in the adhesive flange mold structural layer area; after the arrangement of the filling auxiliary materials is finished, the PS surface skin is integrally sealed with a primary vacuum bag film and a secondary vacuum bag film, and the primary vacuum bag film and the secondary vacuum bag film are arranged along with the PS skin surface;
s1.9, integrally pouring and forming, namely checking the vacuum degree of the primary vacuum bag film and the vacuum degree of the secondary vacuum bag film before pouring, and integrally pouring and forming the bonding flange die and the PS surface skin after the vacuum degree is checked to be qualified;
s1.10, PS surface skin and bonding flange die closing seam glass fiber reinforced plastic treatment, namely after the PS surface skin and bonding flange die are poured and pre-cured, removing vacuum bag films, pouring auxiliary materials and pouring runners of the PS surface skin and the bonding flange die; polishing and repairing the die closing seam terrace region of the bonding flange die region;
s2, forming an SS surface; the method specifically comprises the following steps:
s2.1, preparing a mould, namely cleaning a blade mould, coating a release agent on the surface of the mould, paving release cloth on the surface of the mould, paving a primary vacuum sealing adhesive tape and a secondary vacuum sealing adhesive tape on the parting surface of the mould;
s2.2, mold parting surfaces and vacuum ports are treated, wherein all vacuum ports of the parting surfaces of the bonding flange mold areas are sealed by using a diversion net and a VAP film; firstly, a diversion net is placed, then a VAP film is placed, and the white surface of the VAP film faces upwards;
s2.3, paving a blade SS skin structure layer, namely firstly paving an outer skin large cloth, an outer skin reinforcing layer and an outer skin reinforcing layer, secondly paving a prefabricated rear edge beam, placing a main beam, paving a core material, paving a rear edge UD on the core material, and finally paving an inner skin reinforcing layer, an inner skin reinforcing layer and an inner skin large cloth; after the SS skin structure layer is laid, laying release cloths of a front edge bonding area and a rear edge bonding area;
s2.4, laying release cloth on the surface of the SS skin structure layer and bonding the release cloth on the lower side of the flange die;
s2.5, cloth layer isolation, namely paving hole isolation films in a front edge area and a rear edge area of a die for manufacturing the bonding flange; covering an adhesive flange die cloth layer on the porous isolating film;
s2.6, laying an SS surface bonding flange mold structure layer: paving an adhesive flange mold structure layer on the parting surface of the adhesive flange area of the SS surface;
s2.7, die-parting surface treatment, namely arranging a circumferential airfelt and airfelt bridging on the SS surface die-parting surface, wherein one side of the airfelt bridging is overlapped and laid with the bonding flange die cloth layer, and the other side of the airfelt bridging is pressed below the circumferential airfelt;
s2.8, optimizing the arrangement of pouring auxiliary materials, namely arranging an air extraction spiral pipe on the outer side of a flange die cloth layer bonded on a parting surface, wherein the spiral pipe is connected with an external air extraction pipeline for air extraction; the chord direction of the composite diversion net is increased to the bonding flange die cloth layer on the parting plane; extending the pouring runner to the bonding flange mold area; an independent pouring runner is added in the structural layer area of the bonding flange die; after the arrangement of the filling auxiliary materials is finished, the SS surface skin is integrally sealed with a primary vacuum bag film and a secondary vacuum bag film, and the primary vacuum bag film and the secondary vacuum bag film are arranged along with the SS surface skin;
s2.9, integrally pouring and forming, namely checking the vacuum degree of the primary vacuum bag film and the vacuum degree of the secondary vacuum bag film before pouring, and integrally pouring and forming the bonding flange mold and the SS surface skin after the vacuum degree is checked to be qualified;
s2.10, carrying out glass fiber reinforced plastic treatment on the mold closing joints of the SS surface skin and the bonding flange mold, namely removing vacuum bag films, pouring auxiliary materials and pouring runners of the SS surface skin and the bonding flange mold after pouring pre-curing of the SS surface skin and the bonding flange mold is finished; polishing and repairing the die closing seam terrace region of the bonding flange die region;
s3, bonding and molding by a mold; the method specifically comprises the following steps:
s3.1, bonding a bonding flange die, namely after the PS surface skin and the SS surface skin and the bonding flange die are subjected to qualified glass fiber reinforced plastic treatment at the die closing joint position, coating the PS surface skin and the SS surface skin by vacuum, and paving an airfelt in a die surface area during coating the vacuum, wherein the airfelt completely covers the glass fiber reinforced plastic burrs; stripping the release cloth of the bonding areas of the PS surface and the front edge and the rear edge of the SS surface; uniformly coating a bi-component epoxy structural adhesive on the bonding area of the front edge and the rear edge; the PS surface die is turned over to be clamped and bonded, and the PS surface and the SS surface bonding flange die are bonded; starting a PS surface and SS surface mould heating system to heat; after curing, testing Tg values of Tg sample blocks of the structural adhesive;
s3.2, repairing the bonding flange mold, namely opening a PS surface of the mold after bonding of the bonding flange mold is completed, drawing lines on the bonding flange mold according to the axial position and the chord direction width of the bonding flange, drawing lines on the axial position and the chord direction width, cutting and polishing the bonding flange mold according to the drawn lines, and then carrying out finishing treatment on the bonding flange mold;
and S3.3, performing surface treatment, namely performing leveling treatment and polishing treatment on the bonding flange die after the bonding flange die is repaired and reinforced.
The technical effect of the technical scheme is as follows: (1) according to the technical scheme, the integral pouring molding of the bonding flange mold and the blade skin can be realized, the molding time of the flange mold (40-48 h is estimated), the molding time of the bonding flange of the blade is reduced, and the production period of the blade is prolonged. (2) The material for bonding the flange mold can be saved, and the consumption of filling auxiliary materials and auxiliary materials of an air extraction system used in independent filling molding is reduced. (3) The follow-up degree and matching degree of the bonding flange and the skin can be realized, and the bonding quality is improved. (4) Optimizing the arrangement of filling auxiliary materials, guaranteeing the impregnating resin infiltration of the bonding flange mold structural layer, carrying out regional enhancement air guide capacity on the bonding flange mold structural layer, and increasing the filling effect of the bonding flange mold structural layer region.
And step S3.4, setting a limiting pultrusion block, namely arranging and positioning the split die surfaces of the manufactured bonding flange die at the positions of the bonding flanges at the front and rear edges of the PS face and the SS face die along the axial direction and the chord direction, and bonding the axial limiting pultrusion block and the chord direction limiting pultrusion block on the split die surfaces for fixing the following positioning of the bonding flange die.
Further, the PS-side bonding flange mold structure layer and the SS-side bonding flange mold structure layer are laid alternately by adopting biaxial fabrics and uniaxial fabrics or triaxial fabrics, and the number of layers of the PS-side bonding flange mold structure layer and the SS-side bonding flange mold structure layer is 10-14. The number of layers is less, so that the strength of the bonding flange die is affected, and the bonding flange die is deformed; the number of layers is more and can influence the bonding flange mould weight, causes bonding flange mould weight too big, and follow-up use is difficult.
Further, the Balsa wood core material is added in the middle of the SS surface bonding flange die structural layer, and the thickness is 8-10mm.
Further, the vacuum degree detection in the step S1.9 and the step S2.9 is carried out in a mode that the first vacuum bag film and the second vacuum bag film are vacuumized to be below 30mbar respectively to start vacuum degree detection, the change of the vacuum representation number within 15min is not more than 20mbar, and the vacuum degree detection is qualified.
Further, in step S1.10 and step S2.10, the specific polishing method is as follows: and (3) polishing and repairing the raised and uneven positions of the glass fiber reinforced plastics in the joint seam terrace region of the bonding flange mold region, wherein the terrace glass fiber reinforced plastics is kept for 2-3mm.
Further, in step S2.2, the size of the flow-guiding mesh is 100mm x 70mm, and the size of the vap film is 140mm x 100mm; the diversion net and the VAP film are fixed by using a vacuum adhesive tape, and the vacuum adhesive tape is arranged more than 30mm away from the edge of the vacuum port.
Further, in step S2.8, the composite diversion net is 50-70mm from the edge of the bonded flange die cloth layer on the parting plane.
Further, in the step S3.1, the coating thickness of the bi-component epoxy structural adhesive is 10-15mm, and a strong light flashlight is used for checking whether obvious bubbles exist in the bi-component epoxy structural adhesive; and collecting the redundant bi-component epoxy structural adhesive extruded from the bonding areas of the front edge and the rear edge by using a scraping plate after die assembly.
Further, in step S3.2, after finishing the repair, 4 layers of 808 g/square meter biaxial fabric are laid by pasting with the die joint of the bonding flange die as a central symmetry hand. The molded surface strength of the bonding flange mold can be enhanced, and the bonding flange mold is prevented from deforming in the use process.
Drawings
FIG. 1 is a flow chart of a method of integrally injection molding an adhesive flange mold and a blade skin according to the present invention.
Detailed Description
The following is a further detailed description of the embodiments:
the following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
An example is substantially as shown in figure 1: a method for integrally pouring and molding an adhesive flange mold and a blade skin comprises the following steps:
s1, PS surface molding; the method specifically comprises the following steps:
s1.1, preparing a mould, namely cleaning a blade mould, coating a release agent on the surface of the mould, paving release cloth on the surface of the mould, paving a primary vacuum sealing adhesive tape and a secondary vacuum sealing adhesive tape on the parting surface of the mould;
s1.2, laying a PS skin structure layer of a blade, namely firstly laying an outer skin large cloth, an outer skin reinforcing layer and an outer skin reinforcing layer, secondly laying a prefabricated rear edge beam (or a lower rear edge UD of a core material), placing a main beam, laying a core material, laying a rear edge UD on the core material, and finally laying an inner skin reinforcing layer, an inner skin reinforcing layer and an inner skin large cloth; after the PS skin structure layer is laid, laying release cloths of a front edge bonding area and a rear edge bonding area, wherein the release cloths must completely cover the axial chord bonding area to prevent the bonding area from being smooth and causing bonding failure;
s1.3, auxiliary material arrangement, namely laying release cloth on the surface of a PS skin structure layer and bonding the release cloth on the lower side of a flange die;
s1.4, cloth layer isolation, namely paving hole isolation films in a front edge area and a rear edge area of a die for manufacturing an adhesive flange; the porous isolating film is covered with the adhesive flange mould cloth layer, and the porous isolating film can prevent the adhesive flange mould cloth layer and the PS skin structure layer from being unable to be separated;
s1.5, simulating an adhesive layer, namely simulating an adhesive gap between a PS surface skin and an SS surface skin, calculating the adhesive gap between the PS skin and the SS skin, simulating the thickness of the adhesive layer according to the adhesive gap and the thickness of a single-layer glass fiber fabric after being poured and molded, and paving glass fiber fabrics with corresponding layers; if the bonding gap is 6-8mm, the single-layer glass fiber fabric (taking 808 g/square meter double-shaft fabric as an example) is 0.6mm, and 10-13 layers of glass fiber fabrics can be paved in corresponding areas when the thickness of the bonding adhesive layer is simulated;
s1.6, laying a PS surface bonding flange mold structure layer: laying an adhesive flange mold structure layer in the PS surface adhesive flange area; the PS surface bonding flange die structure layer is formed by alternately laying single-axis fabrics (or triaxial fabrics) and double-axis fabrics, so that the strength of the die can be increased, and the die is prevented from deforming in the subsequent trial; the number of the structural layers of the PS-surface bonding flange mold is 10-14, the mold strength and the weight factors are mainly considered, and the strength of the bonding flange mold is affected by fewer layers, so that the bonding flange mold is deformed; the number of layers is large, so that the weight of the bonding flange die is influenced, the bonding flange die is overlarge in weight, and the subsequent use is difficult;
s1.7, mold parting surface treatment, namely arranging a circumferential airfelt and airfelt bridging on a PS surface mold parting surface, wherein one side of the airfelt bridging is overlapped and paved with an adhesive flange mold cloth layer, and the other side is pressed below the circumferential airfelt;
s1.8, optimizing the arrangement of pouring auxiliary materials, namely extending a composite diversion net and a pouring runner to the bonding flange mold area so as to ensure the pouring resin of the bonding flange mold structural layer to infiltrate; the externally connected air extraction spiral pipe is added in the area of the bonding flange die structural layer so as to locally strengthen air guide capacity and increase the pouring effect of the die structural layer area; after the arrangement of the filling auxiliary materials is finished, the PS surface skin is integrally sealed with a primary vacuum bag film and a secondary vacuum bag film, and the primary vacuum bag film and the secondary vacuum bag film are arranged along with the PS skin surface; the PS skin structure layer and the bonding flange die have larger area with larger change of the molded surface, and the primary vacuum bag film and the secondary vacuum bag film are adjusted according to the change of the molded surface, so that the situation of tightening and suspending the vacuum bag films is prevented;
s1.9, integrally pouring and forming, namely checking the vacuum degree of the primary vacuum bag film and the secondary vacuum bag film before pouring, wherein the vacuum degree detection mode is that the primary vacuum bag film and the secondary vacuum bag film are respectively vacuumized to be lower than 30mbar and start vacuum degree checking, the change of the vacuum representation number is not more than 20mbar within 15min, and the vacuum degree checking is qualified; after the vacuum degree is checked to be qualified, the bonding flange mold and the PS surface skin are integrally poured and molded; the pouring resin must be defoamed to prevent the defects of bubble and blushing of the glass fiber reinforced plastic layer after pouring molding. The structural layer of the bonding flange mold is added, so that the flow rate of the infusion resin in the region needs to be controlled in the infusion process, the infusion flow rate is reduced, the infusion resin infiltration effect of the structural layer of the bonding flange mold is increased, and the end of infusion after the glass fiber cloth layer is completely infiltrated is confirmed;
s1.10, PS surface skin and bonding flange die closing seam glass fiber reinforced plastic treatment, namely after the PS surface skin and bonding flange die are poured and pre-cured, removing vacuum bag films, pouring auxiliary materials and pouring runners of the PS surface skin and the bonding flange die; polishing and repairing the die closing seam terrace region of the bonding flange die region; polishing and trimming the raised and uneven positions of the glass fiber reinforced plastic in the edge table area of the die closing seam of the bonding flange die area, and keeping the glass fiber reinforced plastic in the edge table for 2-3mm, so as to prevent the die from being jacked during die closing and bonding, thereby causing the deviation of the die surface of the bonding flange die and further causing the deviation of the die surface of the bonding flange;
s2, forming an SS surface; the method specifically comprises the following steps:
s2.1, preparing a mould, namely cleaning a blade mould, coating a release agent on the surface of the mould, paving release cloth on the surface of the mould, paving a primary vacuum sealing adhesive tape and a secondary vacuum sealing adhesive tape on the parting surface of the mould;
s2.2, mold parting surfaces and vacuum ports are treated, namely all vacuum ports of the parting surfaces of the bonding flange mold areas are sealed by using a guide net and a VAP film, so that the phenomenon that the vacuum system is invalid due to pipeline blockage caused by overflow of filling resin into the vacuum pumping system in the filling process can be prevented; the size of the diversion net is 100mm by 70mm, and the size of the VAP film is 140mm by 100mm; the diversion net and the VAP film are fixed by using a vacuum adhesive tape, and the vacuum adhesive tape is arranged more than 30mm away from the edge of the vacuum port; firstly, a diversion net is placed, then a VAP film is placed, and the white surface of the VAP film faces upwards;
s2.3, paving a blade SS skin structure layer, namely firstly paving an outer skin large cloth, an outer skin reinforcing layer and an outer skin reinforcing layer, secondly paving a prefabricated rear edge beam (or a core material lower rear edge UD), placing a main beam, paving a core material, paving a rear edge UD on the core material, and finally paving an inner skin reinforcing layer, an inner skin reinforcing layer and an inner skin large cloth; after the SS skin structure layer is laid, laying demolding cloth of a front edge bonding area and a rear edge bonding area, wherein the demolding cloth is required to completely cover an axial chord bonding area and a parting surface area of a bonding flange area, so that bonding failure and failure of a bonding flange die due to a smooth surface of the bonding area are prevented;
s2.4, laying release cloth on the surface of the SS skin structure layer and bonding the release cloth on the lower side of the flange die;
s2.5, cloth layer isolation, namely paving hole isolation films in a front edge area and a rear edge area of a die for manufacturing the bonding flange; the porous isolating film is covered with the adhesive flange mould cloth layer, and the porous isolating film can prevent the adhesive flange mould cloth layer and the SS skin structure layer from being unable to be separated;
s2.6, laying an SS surface bonding flange mold structure layer: paving an adhesive flange mold structure layer on the parting surface of the adhesive flange area of the SS surface; the SS surface bonding flange die structural layer is formed by alternately laying single-axis fabrics (or triaxial fabrics) and double-axis fabrics, so that the strength of the die can be increased, and the deformation of the die in the subsequent trial can be placed; the number of the structural layers of the SS surface adhesive flange mold is 10-14; the Balsa wood core material capable of enhancing the strength of the SS surface bonding flange mold structure layer is added in the middle of the SS surface bonding flange mold structure layer, and the thickness is 8-10mm;
s2.7, die-parting surface treatment, namely arranging a circumferential airfelt and airfelt bridging on the SS surface die-parting surface, wherein one side of the airfelt bridging is overlapped and laid with the bonding flange die cloth layer, and the other side is pressed below the circumferential airfelt;
s2.8, optimizing the arrangement of pouring auxiliary materials, namely arranging an air extraction spiral pipe on the outer side of a flange die cloth layer bonded on a parting surface, wherein the spiral pipe is connected with an external air extraction pipeline for air extraction; because the bonding flange mold structural layer is paved on the SS parting surface, the original pouring auxiliary material arrangement needs to be optimized again, the chord direction of the composite diversion net is increased to the bonding flange mold cloth layer on the parting surface, and the distance between the composite diversion net and the bonding flange mold cloth layer on the parting surface is 50-70mm; the pouring runner is prolonged to the bonding flange mold area so as to ensure that the pouring resin of the bonding flange mold structural layer is soaked; the independent pouring flow channels are added in the structural layer area of the bonding flange die so as to regional strengthen the flowing capability of pouring resin and increase the pouring effect of the structural layer area of the bonding flange die; after the arrangement of the filling auxiliary materials is finished, the SS surface skin is integrally sealed with a primary vacuum bag film and a secondary vacuum bag film, and the primary vacuum bag film and the secondary vacuum bag film are arranged along with the SS surface skin; the SS skin and the bonding flange die have larger areas with larger change of the profiles, and the primary vacuum bag film and the secondary vacuum bag film are adjusted according to the change of the profiles, so that the conditions of tightening and suspending the primary vacuum bag film and the secondary vacuum bag film are prevented;
s2.9, integrally pouring and forming, namely checking the vacuum degree of the vacuum bag film before pouring, wherein the vacuum degree detection mode is that the primary vacuum bag film and the secondary vacuum bag film are respectively vacuumized to be lower than 30mbar and start vacuum degree detection, the change of the vacuum representation number is not more than 20mbar within 15min, and the vacuum degree detection is qualified; after the vacuum degree is checked to be qualified, the bonding flange mold and the SS surface skin are integrally poured and molded; the pouring resin must be defoamed to prevent the defects of bubble and blushing of the glass fiber reinforced plastic layer after pouring molding; the structural layer of the bonding flange mold is added, so that the flow rate of the infusion resin in the region needs to be controlled in the infusion process, the infusion flow rate is reduced, the infusion resin infiltration effect of the structural layer of the bonding flange mold is increased, and the end of infusion after the glass fiber cloth layer is completely infiltrated is confirmed;
s2.10, carrying out glass fiber reinforced plastic treatment on the mold closing joints of the SS surface skin and the bonding flange mold, namely removing vacuum bag films, pouring auxiliary materials and pouring runners of the SS surface skin and the bonding flange mold after pouring pre-curing of the SS surface skin and the bonding flange mold is finished; polishing and repairing the die closing seam terrace region of the bonding flange die region; polishing and trimming the raised and uneven positions of the glass fiber reinforced plastic in the edge table area of the die closing seam of the bonding flange die area, and keeping the glass fiber reinforced plastic in the edge table for 2-3mm, so as to prevent the die from being jacked during die closing and bonding, thereby causing the deviation of the die surface of the bonding flange die and further causing the deviation of the die surface of the bonding flange;
s3, bonding and molding by a mold; the method specifically comprises the following steps:
s3.1, bonding a bonding flange die, namely after the PS surface skin, the SS surface skin and glass fiber reinforced plastics at the die closing joint positions of the bonding flange die are treated to be qualified, wrapping the PS surface skin and the SS surface skin by vacuum, laying an airfelt on the die surface area when the wrapping die is in vacuum, and completely covering glass fiber reinforced plastics burrs by the airfelt to prevent the glass fiber reinforced plastics burrs from puncturing a primary vacuum bag film and a secondary vacuum bag film to cause the failure of a vacuum system; the vacuum degree of the PS and SS surface skins is pumped to less than-81 KPa, and the die overturning and bonding operation can be performed; tearing off release cloth in the bonding areas of the PS surface and the front edge and the rear edge of the SS surface, wherein the tearing-off time of the release cloth is not more than 2 hours; uniformly coating a bi-component epoxy structural adhesive on the bonding area of the front edge and the rear edge, wherein the coating thickness of the bi-component epoxy structural adhesive is 10-15mm, and checking whether obvious bubbles exist in the bi-component epoxy structural adhesive by using a strong light flashlight (whether the obvious bubbles exist indicates that the bi-component epoxy structural adhesive is qualified); the PS surface die is turned over to carry out die assembly bonding, the PS surface and the SS surface bonding flange die are bonded, and after die assembly, a scraping plate is used for collecting redundant bi-component epoxy structural adhesive extruded from bonding areas of the front edge and the rear edge; starting a PS surface and SS surface mold heating system to heat, setting the temperature of a heater to 80-85 ℃, and heating and curing the double-component epoxy structural adhesive; heating for 5-6h, and after curing, testing the Tg value of the Tg sample block of the structural adhesive, wherein the Tg value is more than or equal to 70 ℃ and is qualified;
s3.2, repairing the bonding flange mold, namely opening a PS surface of the mold after bonding of the bonding flange mold is completed, drawing lines on the bonding flange mold according to the axial position and the chord direction width of the bonding flange, drawing lines on the axial position and the chord direction width, cutting and polishing the bonding flange mold according to the drawn lines, and then carrying out finishing treatment on the bonding flange mold; after finishing the repair, using the die joint of the bonding flange die as a center to lay 4 layers of 808 g/square meter double-shaft fabrics by hand lay. The molded surface strength of the bonding flange die can be enhanced, and the bonding flange die is prevented from deforming in the use process;
s3.3, performing mold surface treatment, namely polishing burrs, bulges, folds and other defects on the inner surface and the outer surface of the bonding flange mold by using a disc polisher after the bonding flange mold is repaired and reinforced, and performing leveling treatment and polishing treatment on the bonding flange mold; uniformly coating a layer of special gel coat protection mold for the mold on the surface of the bonding flange mold, and completing the manufacturing of the bonding flange mold;
and S3.4, setting a limiting pultrusion block, namely arranging and positioning the split die surfaces of the manufactured bonding flange die at the bonding flange positions of the front edge and the rear edge of the PS face die and the SS face die along the axial direction and the chord direction, and bonding the axial limiting pultrusion block and the chord direction limiting pultrusion block on the split die surfaces for fixing the along-the-direction positioning of the bonding flange die.
It is noted that relational terms such as first and second, and the like are used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Moreover, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.
The foregoing is merely an embodiment of the present invention, and a specific structure and characteristics of common knowledge in the art, which are well known in the scheme, are not described herein, so that a person of ordinary skill in the art knows all the prior art in the application day or before the priority date of the present invention, and can know all the prior art in the field, and have the capability of applying the conventional experimental means before the date, so that a person of ordinary skill in the art can complete and implement the present embodiment in combination with his own capability in the light of the present application, and some typical known structures or known methods should not be an obstacle for a person of ordinary skill in the art to implement the present application. It should be noted that modifications and improvements can be made by those skilled in the art without departing from the structure of the present invention, and these should also be considered as the scope of the present invention, which does not affect the effect of the implementation of the present invention and the utility of the patent. The protection scope of the present application shall be subject to the content of the claims, and the description of the specific embodiments and the like in the specification can be used for explaining the content of the claims.
Claims (9)
1. A method for integrally pouring and forming an adhesive flange mold and a blade skin is characterized by comprising the following steps of: the method comprises the following steps:
s1, PS surface molding; the method specifically comprises the following steps:
s1.1, preparing a mould, namely cleaning a blade mould, coating a release agent on the surface of the mould, paving release cloth on the surface of the mould, paving a primary vacuum sealing adhesive tape and a secondary vacuum sealing adhesive tape on the parting surface of the mould;
s1.2, laying a PS skin structure layer of a blade, namely firstly laying an outer skin large cloth, an outer skin reinforcing layer and an outer skin reinforcing layer, secondly laying a prefabricated rear edge beam, placing a main beam, laying a core material, laying a rear edge UD on the core material, and finally laying an inner skin reinforcing layer, an inner skin reinforcing layer and an inner skin large cloth; after the PS skin structure layer is laid, laying release cloths of a front edge bonding area and a rear edge bonding area;
s1.3, auxiliary material arrangement, namely laying release cloth on the surface of a PS skin structure layer and bonding the release cloth on the lower side of a flange die;
s1.4, cloth layer isolation, namely paving porous isolating films on a front edge area and a rear edge area of a die for manufacturing the bonding flange, and covering the cloth layer of the die for manufacturing the bonding flange on the porous isolating films;
s1.5, simulating an adhesive layer, namely simulating an adhesive gap between a PS surface skin and an SS surface skin, calculating the adhesive gap between the PS skin and the SS skin, simulating the thickness of the adhesive layer according to the adhesive gap and the thickness of a single-layer glass fiber fabric after being poured and molded, and paving glass fiber fabrics with corresponding layers;
s1.6, laying a PS surface bonding flange mold structure layer: laying an adhesive flange mold structure layer in the PS surface adhesive flange area;
s1.7, mold parting surface treatment, namely arranging a circumferential airfelt and airfelt bridging on a PS surface mold parting surface, wherein one side of the airfelt bridging is overlapped and paved with an adhesive flange mold cloth layer, and the other side is pressed below the circumferential airfelt;
s1.8, optimizing the arrangement of pouring auxiliary materials, namely extending a composite diversion net and a pouring runner to an adhesive flange mold area, and adding an external air extraction spiral pipe in the adhesive flange mold structural layer area; after the arrangement of the filling auxiliary materials is finished, the PS surface skin is integrally sealed with a primary vacuum bag film and a secondary vacuum bag film, and the primary vacuum bag film and the secondary vacuum bag film are arranged along with the PS skin surface;
s1.9, integrally pouring and forming, namely checking the vacuum degree of the primary vacuum bag film and the vacuum degree of the secondary vacuum bag film before pouring, and integrally pouring and forming the bonding flange die and the PS surface skin after the vacuum degree is checked to be qualified;
s1.10, PS surface skin and bonding flange die closing seam glass fiber reinforced plastic treatment, namely after the PS surface skin and bonding flange die are poured and pre-cured, removing vacuum bag films, pouring auxiliary materials and pouring runners of the PS surface skin and the bonding flange die; polishing and repairing the die closing seam terrace region of the bonding flange die region;
s2, forming an SS surface; the method specifically comprises the following steps:
s2.1, preparing a mould, namely cleaning a blade mould, coating a release agent on the surface of the mould, paving release cloth on the surface of the mould, paving a primary vacuum sealing adhesive tape and a secondary vacuum sealing adhesive tape on the parting surface of the mould;
s2.2, mold parting surfaces and vacuum ports are treated, wherein all vacuum ports of the parting surfaces of the bonding flange mold areas are sealed by using a diversion net and a VAP film; firstly, a diversion net is placed, then a VAP film is placed, and the white surface of the VAP film faces upwards;
s2.3, paving a blade SS skin structure layer, namely firstly paving an outer skin large cloth, an outer skin reinforcing layer and an outer skin reinforcing layer, secondly paving a prefabricated rear edge beam, placing a main beam, paving a core material, paving a rear edge UD on the core material, and finally paving an inner skin reinforcing layer, an inner skin reinforcing layer and an inner skin large cloth; after the SS skin structure layer is laid, laying release cloths of a front edge bonding area and a rear edge bonding area;
s2.4, laying release cloth on the surface of the SS skin structure layer and bonding the release cloth on the lower side of the flange die;
s2.5, cloth layer isolation, namely paving hole isolation films in a front edge area and a rear edge area of a die for manufacturing the bonding flange; covering an adhesive flange die cloth layer on the porous isolating film;
s2.6, laying an SS surface bonding flange mold structure layer: paving an adhesive flange mold structure layer on the parting surface of the adhesive flange area of the SS surface;
s2.7, die-parting surface treatment, namely arranging a circumferential airfelt and airfelt bridging on the SS surface die-parting surface, wherein one side of the airfelt bridging is overlapped and laid with the bonding flange die cloth layer, and the other side of the airfelt bridging is pressed below the circumferential airfelt;
s2.8, optimizing the arrangement of pouring auxiliary materials, namely arranging an air extraction spiral pipe on the outer side of a flange die cloth layer bonded on a parting surface, wherein the spiral pipe is connected with an external air extraction pipeline for air extraction; the chord direction of the composite diversion net is increased to the bonding flange die cloth layer on the parting plane; extending the pouring runner to the bonding flange mold area; an independent pouring runner is added in the structural layer area of the bonding flange die; after the arrangement of the filling auxiliary materials is finished, the SS surface skin is integrally sealed with a primary vacuum bag film and a secondary vacuum bag film, and the primary vacuum bag film and the secondary vacuum bag film are arranged along with the SS surface skin;
s2.9, integrally pouring and forming, namely checking the vacuum degree of the primary vacuum bag film and the vacuum degree of the secondary vacuum bag film before pouring, and integrally pouring and forming the bonding flange mold and the SS surface skin after the vacuum degree is checked to be qualified;
s2.10, carrying out glass fiber reinforced plastic treatment on the mold closing joints of the SS surface skin and the bonding flange mold, namely removing vacuum bag films, pouring auxiliary materials and pouring runners of the SS surface skin and the bonding flange mold after pouring pre-curing of the SS surface skin and the bonding flange mold is finished; polishing and repairing the die closing seam terrace region of the bonding flange die region;
s3, bonding and molding by a mold; the method specifically comprises the following steps:
s3.1, bonding a bonding flange die, namely after the PS surface skin and the SS surface skin and the bonding flange die are subjected to qualified glass fiber reinforced plastic treatment at the die closing joint position, coating the PS surface skin and the SS surface skin by vacuum, and paving an airfelt in a die surface area during coating the vacuum, wherein the airfelt completely covers the glass fiber reinforced plastic burrs; stripping the release cloth of the bonding areas of the PS surface and the front edge and the rear edge of the SS surface; uniformly coating a bi-component epoxy structural adhesive on the bonding area of the front edge and the rear edge; the PS surface die is turned over to be clamped and bonded, and the PS surface and the SS surface bonding flange die are bonded; starting a PS surface and SS surface mould heating system to heat; after curing, testing Tg values of Tg sample blocks of the structural adhesive;
s3.2, repairing the bonding flange mold, namely opening a PS surface of the mold after bonding of the bonding flange mold is completed, drawing lines on the bonding flange mold according to the axial position and the chord direction width of the bonding flange, drawing lines on the axial position and the chord direction width, cutting and polishing the bonding flange mold according to the drawn lines, and then carrying out finishing treatment on the bonding flange mold;
s3.3, performing die surface treatment, namely performing leveling treatment and polishing treatment on the bonding flange die after the bonding flange die is repaired and reinforced;
and S3.4, setting a limiting pultrusion block, namely arranging and positioning the split die surfaces of the manufactured bonding flange die at the bonding flange positions of the front edge and the rear edge of the PS face die and the SS face die along the axial direction and the chord direction, and bonding the axial limiting pultrusion block and the chord direction limiting pultrusion block on the split die surfaces for fixing the along-the-direction positioning of the bonding flange die.
2. The method for integrally casting an adhesive flange mold and a blade skin according to claim 1, wherein the method comprises the steps of: the PS-side bonding flange mold structure layer and the SS-side bonding flange mold structure layer are laid alternately by adopting biaxial fabrics and uniaxial fabrics or triaxial fabrics, and the number of layers of the PS-side bonding flange mold structure layer and the SS-side bonding flange mold structure layer is 10-14.
3. The method for integrally casting an adhesive flange mold and a blade skin according to claim 2, wherein the method comprises the steps of: the Balsa wood core material is added in the middle of the structural layer of the bonding flange die of the SS surface, and the thickness is 8-10mm.
4. The method for integrally casting an adhesive flange mold and a blade skin according to claim 1, wherein the method comprises the steps of: the vacuum degree detection in the step S1.9 and the step S2.9 is carried out by respectively vacuumizing the first vacuum bag film and the second vacuum bag film to be below 30mbar and starting vacuum degree detection, wherein the change of the vacuum representation number is not more than 20mbar within 15min, and the vacuum degree detection is qualified.
5. The method for integrally casting an adhesive flange mold and a blade skin according to claim 1, wherein the method comprises the steps of: in the step S1.10 and the step S2.10, the specific polishing method is as follows: and (3) polishing and repairing the raised and uneven positions of the glass fiber reinforced plastics in the joint seam terrace region of the bonding flange mold region, wherein the terrace glass fiber reinforced plastics is kept for 2-3mm.
6. The method for integrally casting an adhesive flange mold and a blade skin according to claim 1, wherein the method comprises the steps of: in step S2.2, the size of the flow-guiding mesh is 100mm x 70mm, and the size of the vap film is 140mm x 100mm; the diversion net and the VAP film are fixed by using a vacuum adhesive tape, and the vacuum adhesive tape is arranged more than 30mm away from the edge of the vacuum port.
7. The method for integrally casting an adhesive flange mold and a blade skin according to claim 1, wherein the method comprises the steps of: in step S2.8, the distance between the composite diversion net and the edge of the adhesive flange die cloth layer on the parting surface is 50-70mm.
8. The method for integrally casting an adhesive flange mold and a blade skin according to claim 1, wherein the method comprises the steps of: in the step S3.1, the smearing thickness of the bi-component epoxy structural adhesive is 10-15mm, and a strong light flashlight is used for checking whether obvious bubbles exist in the bi-component epoxy structural adhesive; and collecting the redundant bi-component epoxy structural adhesive extruded from the bonding areas of the front edge and the rear edge by using a scraping plate after die assembly.
9. The method for integrally casting an adhesive flange mold and a blade skin according to claim 1, wherein the method comprises the steps of: in the step S3.2, after finishing the repair, 4 layers of 808 g/square meter biaxial fabric are laid by using the joint of the bonding flange die as a central symmetry hand lay.
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