CN115027076A - Manufacturing method of wind power blade bonding angle die - Google Patents
Manufacturing method of wind power blade bonding angle die Download PDFInfo
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- CN115027076A CN115027076A CN202210455408.2A CN202210455408A CN115027076A CN 115027076 A CN115027076 A CN 115027076A CN 202210455408 A CN202210455408 A CN 202210455408A CN 115027076 A CN115027076 A CN 115027076A
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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
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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
- B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
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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
- B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
- B29C70/545—Perforating, cutting or machining during or after moulding
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- 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
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- 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 invention discloses a manufacturing method of a wind power blade bonding angle die, which comprises the steps of manufacturing a front edge bonding angle die, manufacturing a rear edge bonding angle die, installing a bonding angle die positioning block, manufacturing a front edge bonding angle and a rear edge bonding angle and bonding; the manufacturing method of the front edge bonding angle die and the rear edge bonding angle die sequentially comprises the steps of die cleaning preparation, structural layer laying, auxiliary material laying, forming, bonding and shaping; the manufacturing and bonding of the front and rear bonding angles comprises the following steps: the method comprises the following steps of blade structure layer laying, bonding angle transition layer laying, bonding angle mould laying, bonding angle forming, bonding angle repair, bonding angle gap testing and bonding. The bonding angle die manufactured by the method has good matching performance with the blade main die, high strength, uniform gap of the bonding angle die manufactured by the bonding angle die, high gap control precision, good bonding angle forming effect, smooth transition at the central line position of the bonding angle and no wrinkle.
Description
Technical Field
The invention belongs to the technical field of wind power blades, and particularly relates to a manufacturing method of a wind power blade bonding angle die and a bonding angle manufacturing method.
Background
In order to achieve the aims of 'carbon neutralization and carbon peak reaching', the wind power generation industry enters a new development stage, and the proportion of wind power generation in the social power consumption is also improved year by year. The quality of the wind power blade serving as a core component of the wind driven generator directly influences whether the wind driven generator can continuously and effectively operate or not, so that continuous electric quantity is more smoothly provided. The main structure of the wind power blade in the wind power generator comprises a windward shell, a leeward shell, a main beam structure embedded in the shell and a reinforcing rib plate structure between the main beams. And finally, coating adhesives with certain characteristics on the bonding angles at the front edge and the rear edge of the shell and the bonding flanges of the reinforcing rib plates in a scraping mode, and bonding the windward shell, the leeward shell and the reinforcing rib plate together to form the blade with stable structural characteristics.
Disclosure of Invention
In order to overcome the defects in the prior art, the invention provides a manufacturing method of a wind power blade bonding angle die and a bonding angle manufacturing method, which are reasonable in design, so that a windward shell and a leeward shell of a blade are bonded together through front and rear edge bonding angles, and a good bonding effect is ensured, so that the product quality of the blade is ensured.
The invention is realized by the following technical scheme: the invention discloses a manufacturing method of a wind power blade bonding angle die, which comprises the steps of manufacturing a front edge bonding angle die, manufacturing a rear edge bonding angle die, installing a bonding angle die positioning block, manufacturing a front edge bonding angle and a rear edge bonding angle and bonding; the manufacturing method of the front edge bonding angle die and the rear edge bonding angle die sequentially comprises the steps of die cleaning preparation, structural layer laying, auxiliary material laying, forming, bonding and shaping; the manufacturing and bonding of the front and rear bonding angles comprises the following steps: the method comprises the following steps of blade structure layer laying, bonding angle transition laying, bonding angle mould laying, bonding angle forming, bonding angle shaping, bonding angle gap testing and bonding angle bonding.
The manufacturing method of the front edge bonding angle mold comprises the following steps: the manufacturing range of the front edge bonding angle of the fan blade starts at a position which is dozens of meters away from the root part of the blade until the position of the tip part of the blade is finished, according to the operation habits and the process requirements of different blade manufacturing manufacturers, the front edge bonding angle can be manufactured on a windward shell or a leeward shell, the blade structure layer corresponding to the front edge bonding angle position only comprises two layers to 4 layers of glass fiber structures, a core material structure is laid between glass fiber cloth, the whole structure layer is relatively simple and uniform in thickness, and the front edge bonding angle mold is manufactured in a main blade mold empty state.
The specific manufacturing process for manufacturing the front edge bonding angle die comprises the following steps:
(1) cleaning and preparing a die: cleaning the flange at the front edge of the blade mould and the surface of the corresponding bonding angle position, wherein the flange is free of dust and foreign matters, the bonding angle mould is separated from the main mould after the manufacture is finished, and a release agent is wiped on the surface of the mould;
(2) laying a structural layer: glass fiber cloth and core materials are laid on a front edge flange and an inner cavity of a blade mould, two layers of biaxial glass fiber cloth are laid in the front edge flange and the inner cavity of the windward side of the blade mould, then PVC or PET is laid as a core material, the thickness of the core material on the front edge flange is lower than the height of a boss of the front edge flange, and the width of the core material is smaller than the distance from the boss to the lower part of the mould for air extraction; finally, two layers of biaxial glass fiber cloth are laid above the sandwich material, the sandwich material is completely covered by the glass fiber cloth, and the glass fiber cloth is laid flatly to avoid the phenomena of suspension and folding; firstly laying two layers of biaxial glass fiber cloth on a front edge flange on the leeward side of a blade mould, then laying PVC or PET as a core material, wherein the thickness of the core material on the front edge flange is less than the height of a boss of the front edge flange, and the width of the core material is less than the distance from the boss to the lower part of the mould for air suction;
(3) paving auxiliary materials: the bonding angle mould is formed by resin infusion, a layer of demoulding cloth is laid firstly when the diversion auxiliary materials are required to be arranged, and the demoulding cloth completely covers the glass fiber cloth; the function of the demoulding cloth is to ensure that the surface of the glass fiber is rough; sequentially laying an isolation film and a flow guide net on the demoulding cloth, wherein the isolation film has the function of ensuring that the auxiliary materials on the demoulding cloth are easy to clean, and the flow guide net has the function of conducting resin; laying a glue injection pipeline and a glue injection seat on the front edge side of the mold, wherein the glue injection pipeline and the glue injection seat are used as runners of resin glue; a spiral overflow pipe is laid on the rear edge side for air extraction, and the spiral overflow pipe is connected with a negative pressure vacuum pump; finally, laying a vacuum bag film, and sealing the vacuum bag film by using an adhesive tape so as to ensure that the whole system is in a negative-pressure vacuum state and the sealing effect is good;
(4) molding: when a certain negative pressure state is achieved, resin infusion is carried out, resin used for bonding the corner mould is blade epoxy resin or mould special resin, the resin is mixed with a main agent and a curing agent according to the technical requirements of product TDS, the uniformly mixed resin is guided into a glass fiber area through a glue injection pipeline, the complete infiltration of the whole glass fiber area is ensured, and the whole operation area is heated after the infusion is finished, so that the resin is rapidly cured;
(5) bonding: after curing is finished, removing a vacuum bag film, an isolating film, a flow guide net, an adhesive injection pipeline and a vacuum pipeline auxiliary material above a bonding angle mould, polishing a rugged area on the surface of the bonding angle mould, ensuring that no interference phenomenon occurs, tearing off all demolding cloth, ensuring that the whole bonding area is rough and the surface is clean and free of dust, scraping and coating an adhesive on a flange bonding surface of a leeward side, turning a windward side mould by a main mould turning system for 180 degrees to trial mould, ensuring that two bonding angle moulds are completely bonded together, heating the bonding angle mould, and promoting the adhesive to be rapidly cured;
(6) modifying: after the solidification is finished, the bonding angle die is separated from the blade main die, the edge of the bonding angle die is cut and removed, the bonding angle die is subjected to coordinate calibration according to the coordinate of the blade main die, the whole bonding angle die is cut into a plurality of sections according to the actual production use condition, each section is subjected to digital calibration, and the bonding angle die is easy to transport and use.
In the step (2), the thickness of the sandwich material in the inner cavity is 6-8 mm, the thickness influences the die assembly gap of the blade bonding angle, a core material with proper thickness is selected according to actual conditions during production, and the width of the sandwich material in the inner cavity exceeds 20-30 mm of the process width of the front edge bonding angle.
The manufacturing method of the rear edge bonding angle die comprises the following steps: the manufacturing range of the rear edge bonding angle of the blade is within a range of a few meters or dozens of meters at the maximum chord length, the rear edge bonding angle can be manufactured in a windward shell or a leeward shell according to the operation habits and process requirements of different blade manufacturing manufacturers, the blade structure layer corresponding to the rear edge bonding angle position generally has a plurality of layers of glass fiber structures, some blades are designed in structures such as glass fiber cloth laying core materials or rear edge beams, the whole structure layer is complex, and the rear edge bonding angle mold is manufactured in the molding state of the glass fiber reinforced plastic structure layer of the blade.
The specific manufacturing process for manufacturing the rear edge bonding angle die comprises the following steps:
(1) cleaning and preparing a die: bonding an area made of an angle mold on the rear edge of the blade, polishing glass fiber reinforced plastics of a blade layer, polishing the glass fiber reinforced plastics at a flange boss to be flat, and cleaning dust on the surface of the mold; vacuumizing the blade structure layer and a blade main mold to ensure that the blade structure layer is not separated from the main mold in the mold turning process, turning the windward side of the blade for 180 degrees to perform trial mold assembly, and ensuring that the mold assembly gap between the leeward side and the windward side of the blade meets the process requirement; opening the blade mould, separating the blade mould from the main mould after the manufacture of the bonding angle mould is finished, and paving a layer of non-porous isolating membrane in the manufacturing area of the bonding angle mould;
(2) laying a structural layer: laying glass fiber cloth and a core material on a flange at the rear edge of a flange of the blade mould, and laying the glass fiber cloth in an inner cavity; firstly laying two layers of biaxial glass fiber cloth on a rear edge flange on the windward side and in an inner cavity, then laying PVC or PET as a core material on the rear edge flange, wherein the thickness of the core material on the rear edge flange is less than the height of a boss of the rear edge flange, and the width of the core material is less than the distance from the boss to the lower part of a mould for air extraction; laying a plurality of layers of glass fiber cloth in the inner cavity, ensuring that the thickness of the formed glass fiber reinforced plastic is controlled to be 6-10 mm, wherein the thickness mainly influences the die assembly clearance of the bonding angle of the blade, and selecting the specific number of the layers of the cloth layer according to the actual condition in production; the width of the cloth layer in the inner cavity exceeds the process width of the rear edge bonding angle by 20-30 mm. Finally, two layers of biaxial glass fiber cloth are integrally laid, the glass fiber cloth completely covers the core clamping material, and the glass fiber cloth is laid flatly to avoid the phenomena of suspension and folding; laying two layers of biaxial glass fiber cloth on a rear edge flange on a leeward side, and then laying PVC or PET as a core clamping material, wherein the thickness of the core clamping material on the rear edge flange is lower than the height of a boss of the rear edge flange, and the width of the core clamping material is smaller than the distance from the boss to air exhaust below a mold; finally, two layers of biaxial glass fiber cloth are laid above the sandwich material, the sandwich material is completely covered by the glass fiber cloth, and the glass fiber cloth is laid flatly to avoid the phenomena of suspension and folding;
(3) the auxiliary material arrangement, forming, bonding and modification processes are the same as the manufacturing method of the front edge bonding angle die in the claim 3.
The specific operation steps for mounting the positioning block of the bonding angle die comprise: sequentially placing the front edge bonding angle die and the rear edge bonding angle die on the blade main die in an empty die state of the blade die to ensure that the bonding angle positions are correct; a positioning block is arranged at the starting and ending point of the bonding angle mould of each section, the positioning block is made of glass fiber pultrusion plates or other materials, and the positioning block and the blade main mould are bonded together by using an adhesive, so that the positioning block is firm and does not fall off; the corner of locating piece need be polished to the rounding off after the locating piece installation, avoids the comparatively sharp corner to appear in the locating piece.
The manufacturing and bonding process of the front and rear bonding angles specifically comprises the following steps:
(1) laying a blade structural layer: laying a blade structural layer according to the blade process requirement;
(2) paving a bonding angle transition layer: the bonding angle mould is placed on the blade mould, a certain distance of thickness difference exists between the corner position of the bonding angle mould and the blade structure layer, and if the bonding angle laying layer is directly laid, the bonding angle laying layer in the area can be wrinkled. In order to avoid the generation of related defects, a transition layer is required to be laid in the area, and a plurality of layers of fiber cloth are laid in a staggered manner from large to small in sequence by taking a flange boss of the mould as an upper starting point for transition;
(3) paving a bonding angle layer: laying bonding angle laying layers in staggered layers according to the process requirements, pre-laying the bonding angle laying layers on a platform in advance for the convenience of production operation, and then sewing the laid layers along the axial center line by using a sewing machine; laying a layer of demoulding cloth on the uppermost part of the bonding angle to ensure that the surface is a rough surface after the bonding angle is formed;
(4) placing a bonding angle mold: placing the front and rear edge bonding angle dies according to the coordinates and the serial numbers, ensuring that the placing positions of the bonding angle dies are correct, and the bonding angle dies are well matched with the positioning blocks;
(5) forming a bonding angle: according to the blade flow guiding mode, the blades and the bonding angles are poured, so that the integral forming effect is good;
(6) bonding angle modification: cutting the edge of the prefabricated bonding angle according to the width of the process requirement, and ensuring that the width of the bonding angle meets the process requirement;
(7) testing the bonding angle clearance: placing a piece of plasticine on the bonding angle at intervals, turning the windward side shell for 180 degrees to perform trial assembly, opening the mold, and then testing the thickness of the plasticine, wherein the thickness of the plasticine is a reserved gap between the bonding angle and the other side shell, and the gap is also the thickness of the bonding glue; and checking whether the thickness of the plasticine meets the process requirements, and polishing or cloth supplementing the bonding corners which do not meet the requirements to ensure that the plasticine meets the requirements.
(8) Bonding the bonding corners: cleaning dust on the surface of the bonding corner, and removing the release cloth on the surface of the bonding corner; coating adhesive with a certain thickness on the surface of the bonding angle in a scraping way, and turning the windward side shell 180 degrees for die assembly and bonding; the blade is heated and cured, so that the curing effect of the adhesive is good, and all performances meet the requirements.
The invention has the beneficial effects that: the invention provides a manufacturing method of a wind turbine blade bonding angle die and a bonding angle manufacturing method, the bonding angle die manufactured by the method is good in matching performance with a blade main die, the bonding angle die is high in strength, the bonding angle die manufactured by the bonding angle die is uniform in die assembly gap, high in gap control precision and good in bonding angle forming effect, transition is smooth at the position of a bonding angle center line, and wrinkles do not exist. The manufacturing method of the wind power blade bonding angle die and the manufacturing method of the bonding angle can ensure that the windward shell and the leeward shell of the blade are bonded together through the front and rear edge bonding angles, and ensure good bonding effect, thereby ensuring the product quality of the blade.
Drawings
FIG. 1 is a schematic cross-sectional view of a structural layer laid by a leading edge bonding angle mold;
FIG. 2 is a schematic cross-sectional view of a leading edge bond angle die bond;
FIG. 3 is a schematic cross-sectional view of a bond angle mold;
FIG. 4 is a schematic cross-sectional view of a structural layer laid by the trailing edge bonding angle mold;
FIG. 5 is a cross-sectional structural schematic view of a trailing edge bond angle die bond;
FIG. 6 is a schematic cross-sectional view of the positioning of the bond angle die;
FIG. 7 is a schematic cross-sectional view of a bonded corner lay-up;
FIG. 8 is a schematic cross-sectional view of a corner bond;
in the figure: 1-windward side of blade mould; 2-leeward side of the blade mould; 3-glass fiber cloth; 4-sandwiching a core material; 5-adhesive; 6-leading edge bonding angle mould; 7-bonding the corner mould at the rear edge; 8-blade structure layer; 9-blade mould trailing edge flange; 10-leading edge flange of blade mould; 11-positioning blocks; 12-trailing edge adhesive; 13-bonding a corner transition layer; 14-bonding the corner lay; 15-layering the blade leading edge structure; 16-leading edge bond angle; 17-leading edge adhesive; 18-structural layering of the trailing edge of the blade; 19-trailing edge bond angle.
Detailed Description
The invention is described in detail below with reference to the drawings and the detailed description, but is not intended to be limited or restricted by the invention, and various materials used below are commercially available.
As shown in fig. 1 to 8, the invention discloses a manufacturing method of a wind power blade bonding angle die, which comprises the steps of manufacturing a front edge bonding angle die 6, manufacturing a rear edge bonding angle die 7, installing a bonding angle die positioning block 11, manufacturing front and rear edge bonding angles 16 and 19 and bonding; the manufacturing of the front edge bonding angle die 6 and the rear edge bonding angle die 7 sequentially comprises the steps of die cleaning preparation, structural layer laying, auxiliary material laying, forming, bonding and shape repairing; the manufacture and bonding of the front and rear bonding angles 16, 19 comprises the following steps: the method comprises the steps of blade structure layer 8 laying, bonding angle transition laying, bonding angle laying 14 laying, bonding angle mould laying, bonding angle forming, bonding angle shaping, bonding angle gap testing and bonding angle bonding.
Manufacturing a front edge bonding angle die 6:
a typical blade leading edge bond angle 16 is made in a range starting at a distance of a few tenths of a meter from the blade root and ending at the blade tip. The leading edge bonding angle 16 may be made on either the windward side shell or the leeward side shell according to the operating habits and process requirements of different blade manufacturers. Considering that the blade structure layer 8 corresponding to the position of the front edge bonding angle 16 generally only contains two to 4 layers of glass fiber cloth 3, the core material clamping layer 4 is laid between the glass fiber cloth 3, the whole structure layer is relatively simple and uniform in thickness, and the front edge bonding angle mold 6 is manufactured under the empty mold state of the blade main mold.
The specific manufacturing process of the front edge bonding angle die 6 is as follows:
(1) preparing for cleaning a die: cleaning the surfaces of the front edge flange 10 of the blade mould and the corresponding bonding angle position, and avoiding impurities such as dust, foreign matters and the like; to facilitate separation of the corner mold from the master mold after fabrication, it is recommended to wipe the mold surface once with release agent.
(2) Laying a structural layer: glass fiber cloth 3 and sandwich materials 4 are laid on the flange 10 of the front edge of the blade mould and the inner cavity, as shown in figure 1: two layers of biaxial glass fiber cloth 3 are firstly paved on a front edge flange and an inner cavity of a windward side 1 of a blade mould, then sandwich materials 4 such as PVC or PET are paved, the thickness of the sandwich materials 4 on the front edge flange is lower than the height of a boss of the front edge flange, and the width is smaller than the distance from the boss to the lower part of the mould for air extraction. The thickness of the sandwich material 4 in the inner cavity is generally controlled to be 6-8 mm, the thickness mainly influences the mold closing gap of the blade bonding angle, the sandwich material 4 with proper thickness can be selected according to actual conditions, and the width of the sandwich material 4 in the inner cavity exceeds the process width of the front edge bonding angle 16 by 20-30 mm. Finally, two layers of biaxial glass fiber cloth 3 are laid above the sandwich material 4, the sandwich material 4 is covered by the glass fiber cloth 3 completely, and the glass fiber cloth 3 is laid flatly to avoid the phenomena of suspension and folding; two layers of biaxial glass fiber cloth 3 are paved on a front edge flange of the leeward side 2 of the blade mould. Then, sandwich materials 4 such as PVC or PET are laid, the thickness of the sandwich materials 4 on the front edge flange is lower than the height of a boss of the front edge flange, and the width of the sandwich materials is smaller than the distance between the boss and the lower part of the mould for air suction. And finally, laying two layers of biaxial glass fiber cloth 3 above the sandwich material 4, wherein the sandwich material 4 is completely covered by the glass fiber cloth 3, and the glass fiber cloth 3 is laid to be flat, so that the phenomena of suspension and folding are avoided.
(3) Paving auxiliary materials: the bonding angle die is formed by resin infusion, so that the arrangement of the flow guide auxiliary materials is required. Firstly, laying a layer of demoulding cloth which is required to completely cover the glass fiber cloth 3, wherein the demoulding cloth is used for ensuring that the surface of the glass fiber cloth 3 is a rough surface; sequentially laying an isolation film and a flow guide net on the demoulding cloth, wherein the isolation film has the function of ensuring that the auxiliary materials on the demoulding cloth are easy to clean, and the flow guide net has the function of conducting resin; laying a glue injection pipeline and a glue injection seat on the front edge side of the mold, wherein the glue injection pipeline and the glue injection seat are used as a flow channel for resin glue solution; a spiral overflow pipe is laid on the rear edge side for air extraction, and the spiral overflow pipe is connected with a negative pressure vacuum pump; and finally, laying a vacuum bag film, wherein the vacuum bag film is sealed by using an adhesive tape, so that the vacuum state of the whole system under negative pressure is ensured, and the sealing effect is good.
(4) Molding: when a certain negative pressure state is reached, resin infusion can be carried out, and the resin used for bonding the angle die adopts blade epoxy resin or die special resin. And (3) mixing the main agent and the curing agent with the resin according to the TDS technical requirements of the product, and introducing the uniformly mixed resin into the area of the glass fiber cloth 3 through a glue injection pipeline to ensure that the whole area of the glass fiber cloth 3 is completely soaked. And heating the whole operation area after the guiding injection is finished, so as to promote the resin to be quickly cured.
(5) Bonding: and after the curing is finished, removing auxiliary materials such as the vacuum bag film, the isolating film, the flow guide net, the glue injection pipeline, the vacuum pipeline and the like above the bonding angle mould. And polishing the uneven area on the surface of the bonding angle mold to ensure that no interference phenomenon occurs. All the demolding cloth is torn off, and the whole bonding area is guaranteed to be a rough surface, and the surface is clean and free of dust. And (3) coating an adhesive 5 on the flange bonding surface of the leeward side, wherein the adhesive 5 is a mold closing adhesive for the blade. As shown in fig. 2: and (3) turning the windward side die by 180 degrees through a main die turning system to carry out die assembly, ensuring that the two bonding angle dies are completely bonded together, and heating the bonding angle dies to promote the adhesive 5 to be quickly cured.
(6) Modifying: after curing is completed, the bonding angle mold is separated from the blade main mold, as shown in fig. 3: the method comprises the following steps of cutting and removing the edge of the bonding angle die, calibrating the coordinates of the bonding angle die according to the coordinates of the blade main die, cutting the whole bonding angle die into a plurality of sections according to the actual use condition of production, and carrying out digital calibration on each section, wherein the bonding angle die is easy to transport and use.
(II) manufacturing a rear edge bonding angle die 7:
typical blade trailing edge bond angles 19 are made in the range of a few or a dozen meters at the maximum chord length. According to the operation habits and the process requirements of different blade manufacturers, the rear edge bonding angle 19 can be manufactured on the windward side shell or the leeward side shell. Considering that the blade structure layer 8 corresponding to the position of the rear edge bonding angle 19 generally has more glass fiber cloth 3, and some blades are designed in the structure that core materials or rear edge beams are laid on the glass fiber cloth 3, the whole structure layer is more complex, the rear edge bonding angle mold 7 is manufactured under the forming state of the glass fiber reinforced plastic structure layer of the blade;
the specific manufacturing process of the rear edge bonding angle die 7 is as follows:
(1) cleaning and preparing a die: in the area made by the blade rear edge bonding angle mould 7, polishing the blade paving glass fiber reinforced plastics, polishing the glass fiber reinforced plastics at the flange boss, and cleaning dust on the surface of the mould. The blade structure layer 8 and the blade main die are vacuumized, the blade structure layer 8 is not separated from the main die in the die turning process, the windward side of the blade is turned for 180 degrees to perform trial die assembly, and the die assembly gap between the leeward side and the windward side of the blade is ensured to meet the process requirements. And opening the blade mould, and paving a layer of non-porous isolating membrane in the manufacturing area of the bonding angle mould so as to be convenient for the bonding angle mould to be separated from the main mould after the manufacturing is finished.
(2) Laying a structural layer: and laying glass fiber cloth 3 and sandwich materials 4 on a flange at the rear edge of the flange of the blade mould, and laying the glass fiber cloth 3 in the inner cavity. As shown in fig. 4 and 5: two layers of biaxial glass fiber cloth 3 are paved in the rear edge flange of the windward side and the inner cavity. Then, a sandwich material 4 such as PVC or PET is laid on the rear edge flange, the thickness of the sandwich material 4 on the rear edge flange is lower than the height of a boss of the rear edge flange, and the width of the sandwich material is smaller than the distance from the boss to the lower air exhaust of the mold. A plurality of layers of glass fiber cloth 3 are laid in the inner cavity, the thickness of the formed glass fiber reinforced plastic is controlled to be 6-10 mm, the thickness mainly influences the die assembly gap of the bonding angle of the blade, the specific number of the cloth layer layers can be selected according to the actual condition in production, and the width of the cloth layer in the inner cavity exceeds the process width of the rear edge bonding angle 19 by 20-30 mm. Finally, two layers of biaxial glass fiber cloth 3 are integrally laid, the glass fiber cloth 3 completely covers the core material clamping 4, and the glass fiber cloth 3 is laid flatly to avoid the phenomena of suspension and wrinkling; two layers of biaxial glass fiber cloth 3 are paved on a flange 9 at the rear edge of the blade mould on the leeward side. Then, sandwich materials 4 such as PVC or PET are laid, the thickness of the sandwich materials 4 on the flange 9 at the rear edge of the blade die is lower than the height of a boss of the flange 9 at the rear edge of the blade die, and the width of the sandwich materials is smaller than the distance from the boss to the lower air exhaust of the die. And finally, laying two layers of biaxial glass fiber cloth 3 above the sandwich material 4, wherein the sandwich material 4 is completely covered by the glass fiber cloth 3, and the glass fiber cloth 3 is laid to be flat, so that the phenomena of suspension and folding are avoided.
(3) The auxiliary material arrangement, forming, bonding and shaping process refers to the manufacturing mode of the front edge bonding angle die 6.
(III) installing a bonding angle die positioning block 11:
and under the empty die state of the blade die, sequentially placing the front and rear edge bonding angle dies 7 on the blade main die to ensure that the bonding angle position is correct. As shown in fig. 6: the positioning block 11 is installed at the starting and ending point of the bonding angle mold of each section, the positioning block 11 can be made of glass fiber pultrusion plates or other materials, the positioning block 11 and the blade main mold are bonded together by using the adhesive 5, and the positioning block 11 is guaranteed to be firm and does not fall off. After the positioning block 11 is installed, the corners of the positioning block 11 need to be polished to smooth transition, so that the sharp corners of the positioning block 11 are avoided.
The manufacturing and bonding of the front and rear edge bonding angles 19 specifically comprise the following steps;
(1) and (3) laying a blade structure layer 8: as shown in fig. 7, the blade structure layer 8 is laid according to the blade process requirements.
(2) Laying an adhesive angle transition layer 13: as shown in FIG. 7, the bonding angle mould is placed on the blade mould, and there is a thickness difference with a certain distance between the corner position of the bonding angle mould and the blade structure layer 8, and if the bonding angle paving layer 14 is directly laid, the bonding angle paving layer 14 in the area has a wrinkle defect. In order to avoid the generation of related defects, a bonding angle transition layer 13 needs to be laid in the region, and specifically, a plurality of layers of glass fiber cloth 3 are sequentially laid from large to small in a staggered manner by taking a flange boss of the mold as an upper starting point for transition.
(3) Laying of the bonding angle paving layer 14: as shown in fig. 7, the adhesive angle ply 14 is laid in a staggered manner according to the process requirements, so that the adhesive angle ply 14 can be pre-laid on a platform in advance for production operation, and then the laid ply is sewn along the axial center line by using a sewing machine. And laying a layer of demoulding cloth on the uppermost part of the bonding angle to ensure that the surface is a rough surface after the bonding angle is formed.
(4) Placing a bonding angle mold: the front and rear edge bonding angle molds 7 are placed according to coordinates and serial numbers, so that the correct placement positions of the bonding angle molds are ensured, and the bonding angle molds are well matched with the positioning blocks 11.
(5) Forming a bonding angle: according to the blade flow guide mode, the blades and the bonding angles are filled, and the integral forming effect is ensured to be good.
(6) And (3) trimming the bonding angle, namely performing edge cutting on the prefabricated bonding angle according to the width of the process requirement, and ensuring that the width of the bonding angle meets the process requirement.
(7) Testing the bonding angle clearance: placing a piece of plasticine on the bonding angle at intervals, turning the windward side shell by 180 degrees to perform trial assembly, opening the die and then testing the thickness of the plasticine, wherein the thickness of the plasticine is the reserved gap between the bonding angle and the other side shell, and the gap is also the thickness of the bonding glue. And checking whether the thickness of the plasticine meets the process requirements, and polishing or paving the bonding angle which does not meet the requirements to ensure that the bonding angle meets the requirements.
(8) Bonding the bonding angle: as shown in FIG. 8, the structural laminates include a blade leading edge structural laminate 15 and a blade trailing edge structural laminate 18, the bonded corner surfaces are cleaned of dust, and the release cloth of the bonded corner surfaces is removed. And (3) scraping and coating front and rear edge adhesives 17 and 12 with certain thickness on the surface of the bonding angle, and turning the windward side shell 180 degrees for die assembly and bonding. The blade is heated and cured, so that the curing effect of the front and rear edge adhesives 17 and 12 is good, and all performances meet the requirements.
Finally, it should be noted that the above-mentioned contents are only used for illustrating the technical solutions of the present invention, and do not limit the protection scope of the present invention, and those skilled in the art can make simple modifications or equivalent substitutions on the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention.
Claims (10)
1. A manufacturing method of a wind power blade bonding angle die is characterized by comprising the following steps: the manufacturing method of the wind power blade bonding angle die comprises the steps of manufacturing a front edge bonding angle die, manufacturing a rear edge bonding angle die, installing a bonding angle die positioning block, manufacturing a front edge bonding angle and a rear edge bonding angle and bonding; the manufacturing of the front edge bonding angle die and the rear edge bonding angle die sequentially comprises die cleaning preparation, structural layer laying, auxiliary material laying, forming, bonding and shaping; the manufacturing and bonding of the front and rear edge bonding angles comprises the following steps: the method comprises the following steps of blade structure layer laying, bonding angle transition laying, bonding angle mould laying, bonding angle forming, bonding angle shaping, bonding angle gap testing and bonding angle bonding.
2. The manufacturing method of the wind power blade bonding angle mold according to claim 1, characterized in that: the manufacturing method of the front edge bonding angle die comprises the following steps: the manufacturing range of the front edge bonding angle of the fan blade is from a position which is dozens of meters away from the root part of the blade to a position which is finished at the tip part of the blade, the front edge bonding angle can be manufactured on a windward shell or a leeward shell according to the operation habits and process requirements of different blade manufacturing manufacturers, and the front edge bonding angle die is manufactured in an empty die state of a blade main die.
3. The manufacturing method of the wind power blade bonding angle mold according to claim 2, characterized in that: the specific manufacturing process for manufacturing the front edge bonding angle die comprises the following steps of:
(1) cleaning and preparing a die: cleaning the flange at the front edge of the blade mould and the surface of the corresponding bonding angle position, wherein no dust or foreign matters exist, the blade mould is conveniently separated from the main mould after the manufacturing of the bonding angle mould is finished, and a release agent is wiped on the surface of the mould once;
(2) laying a structural layer: glass fiber cloth and core materials are laid on a front edge flange and an inner cavity of a blade mould, two layers of biaxial glass fiber cloth are laid in the front edge flange and the inner cavity of the windward side of the blade mould, then PVC or PET is laid as a core material, the thickness of the core material on the front edge flange is lower than the height of a boss of the front edge flange, and the width of the core material is smaller than the distance from the boss to the lower part of the mould for air extraction; finally, two layers of biaxial glass fiber cloth are laid above the sandwich material, the sandwich material is completely covered by the glass fiber cloth, and the glass fiber cloth is laid flatly to avoid the phenomena of suspension and folding; firstly laying two layers of biaxial glass fiber cloth on a front edge flange on the leeward side of a blade mould, then laying PVC or PET as a core material, wherein the thickness of the core material on the front edge flange is less than the height of a boss of the front edge flange, and the width of the core material is less than the distance from the boss to the lower part of the mould for air suction;
(3) laying auxiliary materials: the bonding angle mould is formed by resin infusion, a layer of demoulding cloth is laid firstly when the diversion auxiliary materials are arranged, and the demoulding cloth completely covers the glass fiber cloth; sequentially laying an isolation film and a flow guide net on the demoulding cloth, laying an adhesive injection pipeline and an adhesive injection seat on the front edge side of the mould, laying a spiral overflow pipe on the rear edge side for air extraction, and connecting the spiral overflow pipe with a negative pressure vacuum pump; finally, laying a vacuum bag film, and sealing the vacuum bag film by using an adhesive tape;
(4) molding: when a certain negative pressure state is achieved, resin infusion is carried out, resin used for bonding the corner mold is blade epoxy resin or mold special resin, the resin is mixed with a main agent and a curing agent according to the TDS technical requirements of the product, the uniformly mixed resin is guided into a glass fiber area through an infusion pipeline, the complete infiltration of the whole glass fiber area is ensured, and the whole operation area is heated after infusion is completed, so that the resin is rapidly cured;
(5) bonding: after curing is finished, removing a vacuum bag film, an isolating film, a flow guide net, an adhesive injection pipeline and a vacuum pipeline auxiliary material above a bonding angle mould, polishing a rugged area on the surface of the bonding angle mould, ensuring that no interference phenomenon occurs, tearing off all demolding cloth, ensuring that the whole bonding area is rough and the surface is clean and free of dust, scraping and coating an adhesive on a flange bonding surface of a leeward side, turning a windward side mould by a main mould turning system for 180 degrees to trial mould, ensuring that two bonding angle moulds are completely bonded together, heating the bonding angle mould, and promoting the adhesive to be rapidly cured;
(6) modifying: after the solidification is finished, the bonding angle die is separated from the blade main die, the edge of the bonding angle die is cut and removed, the bonding angle die is subjected to coordinate calibration according to the coordinate of the blade main die, the whole bonding angle die is cut into a plurality of sections according to the actual production use condition, each section is subjected to digital calibration, and the bonding angle die is easy to transport and use.
4. The manufacturing method of the wind power blade bonding angle mold according to claim 3, characterized in that: in the step (2), the thickness of the sandwich material in the inner cavity is 6-8 mm, the thickness influences the die assembly gap of the blade bonding angle, a core material with proper thickness is selected according to actual conditions during production, and the width of the sandwich material in the inner cavity exceeds 20-30 mm of the process width of the front edge bonding angle.
5. The manufacturing method of the wind power blade bonding angle mold according to claim 1, characterized in that: the manufacturing method of the rear edge bonding angle die comprises the following steps: the manufacturing range of the bonding angle of the rear edge of the blade is within a range of a few meters or a dozen meters at the maximum chord length, the bonding angle of the rear edge can be manufactured on a windward shell or a leeward shell according to the operation habits and process requirements of different blade manufacturing manufacturers, and the die of the bonding angle of the rear edge is manufactured in the molding state of the glass fiber reinforced plastic structure layer of the blade.
6. The manufacturing method of the wind power blade bonding angle mold according to claim 5, characterized in that: the specific manufacturing process for manufacturing the rear edge bonding angle die comprises the following steps:
(1) cleaning and preparing a die: bonding an area made of an angle mold on the rear edge of the blade, polishing glass fiber reinforced plastics of a blade layer, polishing the glass fiber reinforced plastics at a flange boss to be flat, and cleaning dust on the surface of the mold; vacuumizing the blade structure layer and a blade main mold to ensure that the blade structure layer is not separated from the main mold in the mold turning process, turning the windward side of the blade for 180 degrees to perform trial mold assembly, and ensuring that the mold assembly gap between the leeward side and the windward side of the blade meets the process requirement; opening the blade mould, separating the blade mould from the main mould after the manufacture of the bonding angle mould is finished, and paving a layer of non-porous isolating membrane in the manufacturing area of the bonding angle mould;
(2) laying a structural layer: laying glass fiber cloth and a core material on a flange at the rear edge of a flange of the blade mould, and laying the glass fiber cloth in an inner cavity; firstly laying two layers of biaxial glass fiber cloth on a rear edge flange on the windward side and in an inner cavity, then laying PVC or PET as a core material on the rear edge flange, wherein the thickness of the core material on the rear edge flange is less than the height of a boss of the rear edge flange, and the width of the core material is less than the distance from the boss to the lower part of a mould for air extraction; finally, two layers of biaxial glass fiber cloth are integrally laid, the glass fiber cloth completely covers the core material, and the glass fiber cloth is laid flatly to avoid the phenomena of suspension and folding; laying two layers of biaxial glass fiber cloth on a rear edge flange on the leeward side, and then laying PVC or PET as a core material, wherein the thickness of the core material on the rear edge flange is less than the height of a boss of the rear edge flange, and the width of the core material is less than the distance from the boss to the lower part of a mould for air extraction; finally, two layers of biaxial glass fiber cloth are laid above the sandwich material, the sandwich material is completely covered by the glass fiber cloth, and the glass fiber cloth is laid flatly to avoid the phenomena of suspension and folding;
(3) the procedures of arranging, forming, bonding and modifying the auxiliary materials are the same as the manufacturing method of the front edge bonding angle die in the claim 3.
7. The manufacturing method of the wind power blade bonding angle mold according to claim 1, characterized in that: the specific operation steps for mounting the positioning block of the bonding angle die are as follows: sequentially placing the front edge bonding angle die and the rear edge bonding angle die on the blade main die in an empty die state of the blade die to ensure that the bonding angle positions are correct; installing a positioning block at the starting and ending point of the bonding angle mold of each section, wherein the positioning block is a plate pulled and extruded by glass fiber, and the positioning block and the blade main mold are bonded together by using an adhesive, so that the positioning block is firm and does not fall off; the corner of locating piece need be polished to the rounding off after the locating piece installation, avoids the comparatively sharp corner to appear in the locating piece.
8. The manufacturing method of the wind power blade bonding angle mold according to claim 1, characterized in that: the manufacturing and bonding process of the front and rear edge bonding angles specifically comprises the following steps:
(1) laying a blade structure layer: laying a blade structural layer according to the blade process requirement;
(2) paving a bonding angle transition layer: the bonding angle mould is placed on the blade mould, a transition layer is laid in the area, and a plurality of layers of fiber cloth are laid in a staggered manner from large to small in sequence by taking a flange boss of the mould as an upper starting point for transition;
(3) paving a bonding angle layer: paving bonding angle paving layers in a staggered mode according to the process requirements, pre-paving the bonding angle paving layers on a platform in advance, and then sewing the paved paving layers along the axial center line by using a sewing machine; laying a layer of demoulding cloth on the uppermost part of the bonding angle to ensure that the surface is a rough surface after the bonding angle is formed;
(4) placing a bonding angle mold: placing the front and rear edge bonding angle dies according to the coordinates and the serial numbers, ensuring that the placing positions of the bonding angle dies are correct, and the bonding angle dies are well matched with the positioning blocks;
(5) forming a bonding angle: according to the blade flow guiding mode, the blades and the bonding angles are poured, so that the integral forming effect is good;
(6) bonding angle modification: cutting the edge of the prefabricated bonding angle according to the width of the process requirement, and ensuring that the width of the bonding angle meets the process requirement;
(7) testing the bonding angle clearance: placing a piece of plasticine on the bonding angle at intervals, turning the windward side shell by 180 degrees for trial assembly, opening the die and then testing the thickness of the plasticine, wherein the thickness of the plasticine is the reserved gap between the bonding angle and the shell on the other side, and the gap is also the thickness of the bonding glue;
(8) bonding the bonding angle: cleaning dust on the surface of the bonding corner, and removing the release cloth on the surface of the bonding corner; coating an adhesive with a certain thickness on the surface of the bonding angle in a scraping way, and turning the windward side shell by 180 degrees to carry out die assembly bonding; the blade is heated and cured, so that the curing effect of the adhesive is good, and all performances meet the requirements.
9. The manufacturing method of the wind power blade bonding angle mold as claimed in claim 6, wherein: in the process of laying the structural layer in the step (2): laying a plurality of layers of glass fiber cloth in the inner cavity, ensuring that the thickness of the formed glass fiber reinforced plastic is controlled to be 6-10 mm, and selecting the specific number of the layers of the cloth layer according to the actual condition; the width of the cloth layer in the inner cavity exceeds the process width of the rear edge bonding angle by 20-30 mm.
10. The manufacturing method of the wind power blade bonding angle mold according to claim 8, characterized in that: and (7) in the bonding angle gap test in the step (7), checking whether the thickness of the plasticine meets the process requirement, and polishing or cloth supplementing the bonding angle which does not meet the requirement to ensure that the bonding angle meets the requirement.
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN115612427A (en) * | 2022-09-23 | 2023-01-17 | 明阳智慧能源集团股份公司 | Thermoplastic resin, preparation method thereof and wind power blade |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN115612427A (en) * | 2022-09-23 | 2023-01-17 | 明阳智慧能源集团股份公司 | Thermoplastic resin, preparation method thereof and wind power blade |
| CN115612427B (en) * | 2022-09-23 | 2024-03-26 | 明阳智慧能源集团股份公司 | Thermoplastic resin, preparation method thereof and wind power blade |
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