CN114953508A

CN114953508A - Composite material prefabricated structural part, manufacturing method and sectional type blade

Info

Publication number: CN114953508A
Application number: CN202210613070.9A
Authority: CN
Inventors: 左刘洋; 齐志攀; 王晨伟; 路旭恒; 白宏伟; 王国军
Original assignee: Shanghai Electric Wind Power Group Co Ltd
Current assignee: Shanghai Electric Wind Power Group Co Ltd
Priority date: 2022-05-31
Filing date: 2022-05-31
Publication date: 2022-08-30

Abstract

The invention provides a composite material prefabricated structural part which is used for connecting blade sections to form a sectional type blade and comprises a first prefabricated part and a second prefabricated part, wherein the first prefabricated part is a hollow structure; one end of the first prefabricated member is provided with a bolt piece, and one end of the second prefabricated member is provided with an enveloping type socket cavity matched with the bolt piece. Still provide a sectional type blade, including two at least blade subsections, first prefab and second prefab are buried in two blade subsection's that are connected each other covering subsection department respectively, through vacuum infusion two blade subsections of shaping back, carry out the bolt connection by bolt spare and envelope formula socket cavity again. The method for manufacturing the prefabricated part by vacuum die pressing comprises the following steps: providing a molding die and a profile die; laying prepreg and placing a mould pressing mould on the molded surface mould according to a set mode; and (3) carrying out vacuum pressurization and heating to form the first prefabricated member or the second prefabricated member. The invention adopts a light and reliable connection mode to prevent the weight and the cost of the sectional type blade from being greatly increased.

Description

Composite material prefabricated structural part, manufacturing method and sectional type blade

Technical Field

The invention relates to the technical field of wind power blades, in particular to a composite material prefabricated structural part, a manufacturing method and a sectional type blade.

Background

Wind energy is a high-quality renewable energy source, and is very suitable for coastal islands, grassland pastoral areas, mountain areas and plateau areas with water shortage, fuel shortage and inconvenient traffic to generate electricity by utilizing wind power according to local conditions. Wind power is an important field of renewable energy development, wind energy resources are abundant in China, construction of wind power projects is accelerated, and the method has important significance for adjusting energy structures and changing economic development modes in China.

With the wind power blades becoming longer and longer, the manufacturing and transporting cost and difficulty of the wind power blades are increased remarkably, and in order to reduce the difficulty of the transporting and manufacturing processes, the transporting cost is saved greatly, the forming quality is improved, and the sectional type fan blades are the subsequent main development trend. In the prior art, two sections of blades are connected at a section by adopting metal bolts, so that the weight and the cost of the blades are greatly increased; and the connecting structure is more complicated, and the wind field assembly of the blade is inconvenient, so the light and reliable connecting mode is the most required technology of the sectional type fan blade.

Disclosure of Invention

Aiming at the defects in the prior art, the invention provides a composite material prefabricated structural part, a manufacturing method thereof and a sectional type blade, wherein a light and reliable connection mode is adopted, so that the weight and the cost of the sectional type blade are prevented from being greatly increased.

To achieve the above and other related objects, the present invention provides a composite prefabricated structural member for connecting blade segments to form a segmented blade, comprising a first prefabricated member and a second prefabricated member; one end of the first prefabricated member is provided with a plug pin piece, and one end of the second prefabricated member is provided with an enveloping type socket cavity matched with the plug pin piece.

Furthermore, first prefab with the second prefab is divided into chamfer district, uniform thickness district and grafting district along length direction, chamfer district along length direction thickness increases gradually, the thickness in uniform thickness district equals, the grafting district sets up bolt spare or envelope type socket cavity.

Further, the chamfering ratio of the chamfering area is 1: 50-1: 100.

Further, the first prefabricated member and the second prefabricated member are made of carbon fiber epoxy resin.

Further, an end of the latch piece is provided with a chamfer at upper and lower surfaces in a thickness direction.

Based on the same invention concept, the invention also provides a segmented blade, which comprises at least two blade segments, wherein the blade segments are spliced two by two to form a blade whole, the segmented blade comprises the composite material prefabricated structural part, the first prefabricated part and the second prefabricated part are respectively embedded in the skin segments of the two blade segments connected with each other in advance, and after the two blade segments are formed through vacuum infusion, the bolt piece of the first prefabricated part is connected with the enveloping socket cavity of the second prefabricated part in a bolt mode.

Further, the upper surface and the lower surface of the first prefabricated member and the second prefabricated member are both curved surfaces matched with the profile of the blade segment.

The composite material prefabricated structural member comprises a plurality of groups of composite material prefabricated structural members, wherein the plurality of groups of composite material prefabricated structural members are arranged at intervals and are adjacent to each other, and core materials are filled between the adjacent composite material prefabricated structural members.

Based on the same invention conception, the invention also provides a vacuum die-pressing manufacturing method of a prefabricated part, which is used for manufacturing the composite material prefabricated structural part, and comprises the following steps:

s1, providing a molding die and a molded surface die;

s2, laying prepreg and placing the mould pressing mould on the molded surface mould according to a set mode;

s3, vacuum pressurizing and heating to form the first prefabricated member or the second prefabricated member.

Further, the chamfer area and the equal-thickness area in the first prefabricated part and the second prefabricated part are formed in the following mode:

when the prepreg is laid, the equal-thickness area is laid in an equal-thickness mode, and the chamfer area is laid in an axial staggered mode; or

When the prepreg is laid, equal-thickness laying is adopted for an equal-thickness area and a chamfer area, and the first prefabricated member and the second prefabricated member are ground out after molding to form the chamfer area.

Further, the prepreg is made of a carbon fiber material.

Further, the mould pressing mould comprises a first mould for manufacturing the first prefabricated part and a second mould for manufacturing the second prefabricated part, wherein the first mould comprises an upper mould and a lower mould, the shapes and the sizes of the two parts are consistent, and the second mould is in a cuboid shape with a certain thickness.

Further, when the first prefabricated member is manufactured, the setting mode is as follows:

laying lower surface demolding cloth on the molded surface mold, and placing a lower mold of the first mold on the lower surface demolding cloth;

circularly laminating and paving a plurality of layers of prepregs on the lower die according to a 45-degree symmetrical paving mode;

and placing an upper die of the first die on the laid prepreg, and then laying an upper surface demolding cloth.

Further, when the second prefabricated member is manufactured, the setting mode is as follows:

laying a lower surface demolding cloth on the molded surface mold;

circularly laminating and laying a plurality of layers of prepregs according to a 45-degree symmetrical laying mode;

placing the second mould on the laid prepreg, and then circularly laying and laying a plurality of layers of prepregs on the second mould again according to a 45-degree symmetrical laying mode;

and finishing the laying of the prepreg cloth and laying the upper surface demolding cloth.

Furthermore, a glue absorption felt, a pressing plate and a vacuum bag film are sequentially paved on the upper surface demolding cloth.

Compared with the prior art, the invention has the following advantages:

according to the composite material prefabricated structural part and the manufacturing method thereof as well as the sectional type blade, the first prefabricated part and the second prefabricated part are provided with the plug pin part and the enveloping socket cavity, the plug pin part and the enveloping socket cavity are inserted and connected to connect the first prefabricated part and the second prefabricated part into a whole, so that the force transmission of the sectional type blade in the using process is mainly realized through the first prefabricated part and the second prefabricated part, and the stress in the shearing direction can be better borne, so that the connection strength between the sections is effectively improved; in addition, the vacuum die-pressing manufacturing method of the prefabricated structural part is provided, and batch production of the first prefabricated part and the second prefabricated part is realized.

Drawings

In order to more clearly illustrate the technical solution of the present invention, the drawings used in the description will be briefly introduced, and it is obvious that the drawings in the following description are an embodiment of the present invention, and other drawings can be obtained by those skilled in the art without creative efforts according to the drawings:

FIG. 1 is a schematic view of a first preform provided in accordance with an embodiment of the present invention;

FIG. 2 is a schematic view of a second preform provided in accordance with an embodiment of the present invention;

FIG. 3 is a schematic view of vacuum compression molding of a first preform according to an embodiment of the present invention;

FIG. 4 is a schematic view of vacuum compression molding of a second preform according to an embodiment of the present invention;

FIG. 5 is a schematic view of a molding die according to an embodiment of the present invention;

FIG. 6 is a schematic view of a prepreg layup provided by an embodiment of the present invention;

FIG. 7 is a schematic view of a segmented blade provided in accordance with an embodiment of the present invention;

FIG. 8 is a schematic view of another sectional blade according to an embodiment of the present invention.

Detailed Description

The composite prefabricated structural member, the manufacturing method thereof and the segmented blade according to the present invention will be described in further detail with reference to fig. 1 to 8 and the following detailed description. The advantages and features of the present invention will become more apparent from the following description. It is to be noted that the drawings are in a very simplified form and are all used in a non-precise scale for the purpose of facilitating and distinctly aiding in the description of the embodiments of the present invention. To make the objects, features and advantages of the present invention comprehensible, reference is made to the accompanying drawings. It should be understood that the structures, ratios, sizes, and the like shown in the drawings and described in the specification are only used for matching with the disclosure of the specification, so as to be understood and read by those skilled in the art, and are not used to limit the implementation conditions of the present invention, so that the present invention has no technical significance, and any structural modification, ratio relationship change or size adjustment should still fall within the scope of the present invention without affecting the efficacy and the achievable purpose of the present invention.

Referring to fig. 1 and 2, an embodiment of the present invention provides a prefabricated structural member made of a composite material for connecting blade segments to form a segmented blade, including a first prefabricated member 10 and a second prefabricated member 20; one end of the first prefabricated member 10 is provided with a plug piece 13, and one end of the second prefabricated member 20 is provided with an enveloping socket cavity 23 matched with the plug piece.

In specific implementation, the first prefabricated member 10 and the second prefabricated member 20 are respectively fixed to two blade segments, the plug member 13 is inserted into the enveloping socket 23 to connect the two blade segments, and a bonding fixing manner may be adopted to make the connection between the plug member 13 and the enveloping socket 23 tighter, for example, structural glue is applied to the outer surface of the plug member 13 and the inner wall of the enveloping socket 23.

In this embodiment, as shown in fig. 1 and fig. 2, the first preform 10 is divided into a chamfer area 11, an equal-thickness area 12 and an insertion area along the length direction, the chamfer area 11 is gradually increased in thickness along the length direction, the equal-thickness area 12 is equal in thickness, and the insertion area is provided with the plug piece 13; similarly, the second prefabricated member 20 is also divided into a chamfer area 21, an equal-thickness area 22 and a plug area along the length direction, and the plug area is provided with the enveloping socket cavity 23. The

chamfered regions

11, 21 prevent stress concentration in the connection region for guiding and transferring the load of the connection region to the blade main beam; furthermore, the chamfer ratio of the

chamfer areas

11, 21 is generally 1: 50-1: 100, which facilitates the staggered layer laying operation of the reinforcing material when two prefabricated parts are manufactured. The equal thickness regions 12, 22 are the main bearing regions of the two preforms for better fixing the preforms at the blade segments; the first preform 10 and the second preform 20 are generally made of carbon fiber epoxy resin, and are lightweight and structurally strong. Finally, for convenience of insertion, the end of the latch piece 13 is provided with chamfers on the upper and lower surfaces in the thickness direction.

Based on the same invention concept, referring to fig. 3-6, the invention further provides a manufacturing method of the composite prefabricated structural member, in particular to a vacuum die-pressing manufacturing method of a prefabricated member, which is used for manufacturing the composite prefabricated structural member and comprises the following steps:

s1, providing a molding die 30 and a profile die 40;

s2, laying the prepreg 50 and placing the molding die 30 on the molded surface die 40 according to a set mode;

s3, vacuum pressure heating to form the first preform 10 or the second preform 20.

In this embodiment, the first preform 10 and the second preform 20 may be formed in two ways, namely, a chamfer region and an equal-thickness region: the first method is that when the prepreg is laid in step S2, the prepreg is laid by using equal thickness in the equal thickness region, and axial staggered ply laying is used in the chamfered region, the staggered ply size is determined according to the chamfer ratio, and may be, for example, 50mm to 100mm, so that the first preform 10 or the second preform 20 after molding has the equal thickness region and the chamfered region; and secondly, when the prepreg is laid, the equal-thickness area and the chamfer area are laid by adopting equal thickness, and then the first prefabricated member and the second prefabricated member are ground to form the chamfer area after molding.

In this embodiment, as shown in fig. 5, the molding die 30 includes a first die 31 and a second die 32, wherein the first die 31 includes an upper die and a lower die, and the two parts have the same shape and size and are used for manufacturing the first preform 10, please refer to fig. 3, which specifically includes the following steps:

1) when the first prefabricated member 10 is manufactured, a piece of demolding cloth 61 is laid on the molded surface mold 40 to serve as lower surface demolding cloth, and a lower mold of the first mold 31 is placed on the lower surface demolding cloth;

2) as shown in fig. 6, a plurality of layers of the prepregs 50 are cyclically stacked and laid on the lower die in a 45-degree symmetrical laying manner; the mode of symmetrically laying at 45 degrees is favorable for the interlayer combination stability of the prefabricated member. Specifically, the yarns can be laid in a manner of +/-45 °, 0 °, 90 °, 0 °, -45 °, 0 ° ] n circular lamination, wherein 45 °, 0 °, 90 ° and 0 ° refer to the knitting angle of the single-axis yarns, and are defined as 0 ° along the length direction of the blade. Starting the laying with 45 ° as the first layer is only an example here, and in other embodiments, the laying can also be started with 0 ° or 90 ° as the first layer, as long as: the yarns with the angle of 45 degrees are symmetrically laid, the yarns with the angle of 0 degree account for 50 percent, the yarns with the angle of +/-45 degrees account for 33 percent to 35 percent, the yarns with the angle of 90 degrees account for 15 percent to 17 percent, and the yarns with the angle of 45 degrees are positioned on the outer sides of the yarns with other angles.

3) And placing an upper die of the first die 31 on the laid prepreg, and laying a release cloth 61 as an upper surface release cloth, wherein the release cloth 61 is convenient for taking out the first prefabricated member 10 after the manufacture is finished.

In this embodiment, the second mold 32 is generally a rectangular parallelepiped with a certain thickness, and the thickness of the second mold is the same as the thickness of the enveloping socket 23 of the second preform 20, so as to manufacture the second preform 20, please refer to fig. 4, which specifically includes the following steps:

1) laying a demoulding cloth 61 on the molded surface mould as a lower surface demoulding cloth;

2) as shown in fig. 6, multiple layers of the prepregs 50 are cyclically laid up in a 45-degree symmetrical manner; for example, it can be laid in a cyclic stack of [ +45 °, 0 °, 90 °, 0 °, -45 °, 0 ° ] n;

3) placing the second mold 32 on the laid prepreg, and then circularly laying a plurality of layers of the prepreg 50 on the second mold 32 in a 45-degree symmetrical laying manner; for example, it can be laid in a cyclic stack of [ +45 °, 0 °, 90 °, 0 °, -45 °, 0 ° ] n;

4) and finishing the laying of the prepreg cloth, and laying a release cloth 61 as an upper surface release cloth, wherein the release cloth 61 is convenient for taking out the second prefabricated member 20 after the completion of the manufacture.

The specific laying manner is shown in the following table 1:

TABLE 1

Layer number	Initiation of	End 1	Initiation of	End 2	Angle of rotation	Layer number	Initiation of	End 1	Initiation of	End 2	Angle of rotation
												1	0	1800	-	-	+45	25	-	-	200	1800	+45
2	0	1800	-	-	0	26	-	-	200	1800	0
												3	0	1800	-	-	90	27	-	-	200	1800	90
4	0	1800	-	-	0	28	-	-	200	1800	0
												5	0	1800	-	-	-45	29	-	-	200	1800	-45
6	0	1800	-	-	0	30	-	-	200	1800	0
												7	0	1800	-	-	+45	31	-	-	200	1800	+45
8	0	1800	-	-	0	32	-	-	200	1800	0
												9	0	1800	-	-	90	33	-	-	200	1800	90
10	0	1800	-	-	0	34	-	-	200	1800	0
												11	0	1800	-	-	-45	35	-	-	200	1800	-45
12	0	1800	-	-	0	36	-	-	200	1800	0
												13	-	-	200	1800	+45	37	0	1800	-	-	+45
14	-	-	200	1800	o	38	0	1800	-	-	0
												15	-	-	200	1800	90	39	0	1800	-	-	90
16	-	-	200	1800	0	40	0	1800	-	-	0
												17	-	-	200	1800	-45	41	0	1800	-	-	-45
18	-	-	200	1800	0	42	0	1800	-	-	0
												19	-	-	200	1800	+45	43	0	1800	-	-	+45
20	-	-	200	1800	0	44	0	1800	-	-	0
												21	-	-	200	1800	90	45	0	1800	-	-	90
22	-	-	200	1800	0	46	0	1800	-	-	0
												23	-	-	200	1800	-45	47	0	1800	-	-	-45
24	-	-	200	1800	0	48	0	1800	-	-	0

In this embodiment, the upper surface release fabric is further laid with a glue absorbing felt 62, a pressing plate 63 and a vacuum bag film 64 in sequence. The glue absorption felt 62 is used for absorbing resin overflowing during heating, the pressing plate 63 is used for ensuring the profile of the upper surfaces of the first prefabricated member 10 and the second prefabricated member 20, and the vacuum bag film 64 is used for sealing structural paving. Preferably, the first mold 31 and the second mold 32 are generally made of a light-weight and non-deformable material, and preferably made of an aluminum alloy. In addition, the periphery is sealed by a sealing rubber strip 67, and a vacuum pump 65 is connected to the periphery through an air exhaust channel 66, and the vacuum pump 65 performs an operation of evacuating through the air exhaust channel 66.

Based on the same invention concept, as shown in fig. 7 and 8, the invention further provides a sectional type blade, which comprises at least two blade sections, wherein the blade sections are spliced two by two to form a blade whole, and the sectional type blade comprises the composite material prefabricated structural member. Referring to fig. 7, the first prefabricated member 10 and the second prefabricated member 20 are respectively pre-embedded at the sections of the skins 70 of the two blade sections connected with each other, and after the two blade sections are formed by vacuum infusion, the plug member 13 of the first prefabricated member 10 is connected with the enveloping socket 23 of the second prefabricated member 20 through a plug.

In specific implementation, referring to fig. 7, a group of composite prefabricated structural members are provided, and are pre-embedded at the section of the blade skin 70, two sections of the sectional blade are formed by vacuum infusion, and the bolt member 13 of the first prefabricated member 10 is in bolt connection with the enveloping socket cavity 23 of the second prefabricated member 20 and is further fixed by using structural adhesive 80, so as to obtain the sectional blade. The first prefabricated member 10 and the second prefabricated member 20 are respectively embedded at two ends of the section of the broken part of the sectional type blade, wherein a skin 70 is wrapped on the first prefabricated member 10 and the second prefabricated member 20, the connecting area of the first prefabricated member 10 protrudes out of the connecting surface, and the end surface of the second prefabricated member 20 is flush with the connecting surface, namely the enveloping type socket cavity 23 is arranged in the skin 70. After the first prefabricated member 10 and the second prefabricated member 20 are respectively formed with two blade segments by vacuum resin infusion, the structural adhesive 80 is filled and coated after the bolt connection, and the two blade segments are connected to obtain a complete blade after the structural adhesive 80 is cured.

In this embodiment, the upper and lower surfaces of the first preform 10 and the second preform 20 are curved surfaces matching the profile of the blade segment. During manufacturing, the upper and lower surfaces of the second mold 32 are preferably curved surfaces, and the lower surface of the upper mold and the upper surface of the lower mold of the first mold 31 are also curved surfaces.

In the embodiment, in order to improve the tightness of the connection, the segmented blade includes a plurality of sets of the composite prefabricated structural members, as shown in fig. 8, the plurality of sets of the composite prefabricated structural members are arranged at intervals, and the adjacent composite prefabricated structural members are filled with a core material 90.

In summary, the invention has the advantages that the designed composite material prefabricated structural part, the manufacturing method thereof and the sectional type blade are characterized in that the first prefabricated part and the second prefabricated part are provided with the pin piece and the enveloping socket cavity, the pin piece and the enveloping socket cavity are inserted and connected to connect the first prefabricated part and the second prefabricated part into a whole, so that the force transmission of the sectional type blade in the use process is mainly realized through the first prefabricated part and the second prefabricated part, and the force in the shearing direction can be better borne, thereby effectively improving the connection strength between the sections; in addition, the vacuum die-pressing manufacturing method of the prefabricated structural part is provided, and batch production of the first prefabricated part and the second prefabricated part is realized.

While the present invention has been described in detail with reference to the preferred embodiments, it should be understood that the above description should not be taken as limiting the invention. Various modifications and alterations to this invention will become apparent to those skilled in the art upon reading the foregoing description. Accordingly, the scope of the invention should be limited only by the attached claims.

Claims

1. A prefabricated structural part made of composite materials is characterized by being used for connecting blade sections to form a sectional type blade and comprising a first prefabricated part and a second prefabricated part; one end of the first prefabricated member is provided with a plug pin piece, and one end of the second prefabricated member is provided with an enveloping type socket cavity matched with the plug pin piece.

2. The composite precast structure of claim 1, wherein the first precast member and the second precast member are divided into a chamfer area, an equal thickness area and a plug area along a length direction, the chamfer area is gradually increased in thickness along the length direction, the equal thickness area is equal in thickness, and the plug area is provided with the plug member or the enveloping socket cavity.

3. The composite precast structural member according to claim 2, wherein the chamfer ratio of the chamfer area is 1: 50-1: 100.

4. The composite precast structural member of claim 1, wherein the first and second precast members are made of carbon fiber epoxy resin.

5. The composite precast structural member of claim 1, wherein the end portion of the pin member is provided with chamfers at upper and lower surfaces in a thickness direction.

6. A segmented blade, comprising at least two blade segments, which are spliced two by two to form a blade whole, comprising the prefabricated structural member of composite material as claimed in any one of claims 1 to 5, wherein the first prefabricated member and the second prefabricated member are respectively embedded in skin segments of the two blade segments connected with each other, and after the two blade segments are formed by vacuum infusion, the plug member of the first prefabricated member is connected with the enveloping socket cavity of the second prefabricated member by a plug.

7. The segmented blade of claim 6, wherein the upper and lower surfaces of the first and second preforms are curved surfaces that match the profile of the blade segment.

8. The segmented blade according to claim 6, comprising a plurality of sets of the composite prefabricated structural members, wherein the plurality of sets of the composite prefabricated structural members are arranged at intervals and are filled with core materials between adjacent sets of the composite prefabricated structural members.

9. A preform vacuum-embossing production method for producing a composite material preform structure according to any one of claims 1 to 5, comprising the steps of:

s1, providing a molding die and a molded surface die;

10. The preform vacuum mold fabrication method of claim 9, wherein the chamfer region and the equal thickness region in the first preform and the second preform are formed as follows:

11. The preform vacuum mold manufacturing method according to claim 9, wherein the prepreg is made of a carbon fiber material.

12. The vacuum mold pressing method for manufacturing a preform according to claim 9, wherein the mold pressing mold comprises a first mold for manufacturing the first preform and a second mold for manufacturing the second preform, wherein the first mold comprises an upper mold part and a lower mold part, the upper mold part and the lower mold part are identical in shape and size, and the second mold is a cuboid having a certain thickness.

13. The preform vacuum mold pressing method as claimed in claim 12, wherein said setting is such that when said first preform is manufactured:

14. The preform vacuum mold pressing method as claimed in claim 12, wherein said setting is such that when said second preform is manufactured:

laying a lower surface demolding cloth on the molded surface mold;

15. The vacuum die pressing manufacturing method of the prefabricated member according to claim 13 or 14, wherein the upper surface demolding cloth is sequentially paved with a glue absorption felt, a pressing plate and a vacuum bag film.