GB2611677A - Main beam for use in wind-driven generator blade and manufacturing method therefor - Google Patents
Main beam for use in wind-driven generator blade and manufacturing method therefor Download PDFInfo
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- GB2611677A GB2611677A GB2300368.4A GB202300368A GB2611677A GB 2611677 A GB2611677 A GB 2611677A GB 202300368 A GB202300368 A GB 202300368A GB 2611677 A GB2611677 A GB 2611677A
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- carbon fiber
- fiber pultrusion
- plates
- glass fiber
- pultrusion plates
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 19
- 229920000049 Carbon (fiber) Polymers 0.000 claims abstract description 203
- 239000004917 carbon fiber Substances 0.000 claims abstract description 203
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 claims abstract description 202
- 239000003365 glass fiber Substances 0.000 claims abstract description 180
- 239000000463 material Substances 0.000 claims abstract description 86
- 230000001808 coupling effect Effects 0.000 claims abstract description 8
- 230000000694 effects Effects 0.000 claims abstract description 8
- 238000000034 method Methods 0.000 claims description 41
- 239000004744 fabric Substances 0.000 claims description 33
- 229920005989 resin Polymers 0.000 claims description 21
- 239000011347 resin Substances 0.000 claims description 21
- 238000009736 wetting Methods 0.000 claims description 12
- 229920005992 thermoplastic resin Polymers 0.000 claims description 10
- 239000004745 nonwoven fabric Substances 0.000 claims description 6
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 claims description 5
- 239000003822 epoxy resin Substances 0.000 claims description 5
- 229920001568 phenolic resin Polymers 0.000 claims description 5
- 239000005011 phenolic resin Substances 0.000 claims description 5
- 229920000647 polyepoxide Polymers 0.000 claims description 5
- 229920001187 thermosetting polymer Polymers 0.000 claims description 5
- 229920006337 unsaturated polyester resin Polymers 0.000 claims description 5
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 claims description 5
- 229920002554 vinyl polymer Polymers 0.000 claims description 5
- 239000004696 Poly ether ether ketone Substances 0.000 claims description 3
- 239000004734 Polyphenylene sulfide Substances 0.000 claims description 3
- 239000004743 Polypropylene Substances 0.000 claims description 3
- 229920002530 polyetherether ketone Polymers 0.000 claims description 3
- 229920013716 polyethylene resin Polymers 0.000 claims description 3
- 229920001721 polyimide Polymers 0.000 claims description 3
- 239000009719 polyimide resin Substances 0.000 claims description 3
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- 229920001155 polypropylene Polymers 0.000 claims description 3
- 229920005990 polystyrene resin Polymers 0.000 claims description 3
- 229920002635 polyurethane Polymers 0.000 claims description 3
- 239000004814 polyurethane Substances 0.000 claims description 3
- 229920000915 polyvinyl chloride Polymers 0.000 claims description 3
- 239000004800 polyvinyl chloride Substances 0.000 claims description 3
- XQUPVDVFXZDTLT-UHFFFAOYSA-N 1-[4-[[4-(2,5-dioxopyrrol-1-yl)phenyl]methyl]phenyl]pyrrole-2,5-dione Chemical compound O=C1C=CC(=O)N1C(C=C1)=CC=C1CC1=CC=C(N2C(C=CC2=O)=O)C=C1 XQUPVDVFXZDTLT-UHFFFAOYSA-N 0.000 claims 2
- 229920003192 poly(bis maleimide) Polymers 0.000 claims 2
- 239000000835 fiber Substances 0.000 description 20
- 230000008569 process Effects 0.000 description 18
- 230000007704 transition Effects 0.000 description 10
- 239000011521 glass Substances 0.000 description 7
- 239000002131 composite material Substances 0.000 description 6
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- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 2
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- 238000000429 assembly Methods 0.000 description 2
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
- F03D—WIND MOTORS
- F03D1/00—Wind motors with rotation axis substantially parallel to the air flow entering the rotor
- F03D1/06—Rotors
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
- F03D—WIND MOTORS
- F03D1/00—Wind motors with rotation axis substantially parallel to the air flow entering the rotor
- F03D1/06—Rotors
- F03D1/065—Rotors characterised by their construction elements
- F03D1/0675—Rotors characterised by their construction elements of the blades
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- 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
- B29C70/06—Fibrous reinforcements only
- B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
- B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
-
- 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
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/50—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
- B29C70/52—Pultrusion, i.e. forming and compressing by continuously pulling through a die
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D99/00—Subject matter not provided for in other groups of this subclass
- B29D99/0025—Producing blades or the like, e.g. blades for turbines, propellers, or wings
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05B—INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
- F05B2280/00—Materials; Properties thereof
- F05B2280/20—Inorganic materials, e.g. non-metallic materials
- F05B2280/2006—Carbon, e.g. graphite
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05B—INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
- F05B2280/00—Materials; Properties thereof
- F05B2280/60—Properties or characteristics given to material by treatment or manufacturing
- F05B2280/6003—Composites; e.g. fibre-reinforced
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/70—Wind energy
- Y02E10/72—Wind turbines with rotation axis in wind direction
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
- Y02P70/50—Manufacturing or production processes characterised by the final manufactured product
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Life Sciences & Earth Sciences (AREA)
- Sustainable Development (AREA)
- Sustainable Energy (AREA)
- Combustion & Propulsion (AREA)
- General Engineering & Computer Science (AREA)
- Composite Materials (AREA)
- Textile Engineering (AREA)
- Moulding By Coating Moulds (AREA)
- Wind Motors (AREA)
Abstract
A main beam (100) for use in a wind-driven generator blade (1) and a manufacturing method therefor. The main beam comprises: one or more carbon fiber pultrusion plates (101) that are arranged along the length direction of the blade (1); one or more glass fiber pultrusion plates (102) that are arranged along the length direction of the blade (1), wherein each carbon fiber pultrusion plate (101) and each glass fiber pultrusion plate (102) are arranged in a mixing mode, so that the carbon fiber pultrusion plate (101) and the glass fiber pultrusion plate (102) that are mixed have a forward hybrid effect and/or a bending-torsion coupling effect; and a first pouring material that wets the carbon fiber pultrusion plate (101) and the glass fiber pultrusion plate (102).
Description
MAIN BEAM FOR USE IN WIND-DRIVEN GENERATOR BLADE AND MANUFACTURING METHOD THEREOF
FIELD OF TECHNOLOGY
The present invention relates to the field of wind-driven generators, and in particular to a main beam for use in a wind-driven generator blade. In addition, the present invention also relates to a method for manufacturing such a main beam.
BACKGROUND
In recent years, as countries pay more attention to the environment, the field of clean energy has rapidly developed worldwide. As a new energy, clean energy has the advantages of wide distribution, renewability and less environmental pollution compared with traditional fossil fuels. Wind-driven generators are increasingly used as the most promising representative of clean energy, and are expected to further replace traditional fossil energy. Wind power is a typical clean energy, and is more and more valued by all parties due to the environmental protection problem in recent years. The core and soul of the wind power is blade design, and the key of blade design depends on the design of a main load-bearing structure, namely, a main beam.
Blades of the wind-driven generator are its important components to capture wind energy, wherein the blades mounted on a hub of the wind-driven generator rotate under the driving of wind energy to generate a lift force, and the lift force is further converted into a torque through a transmission chain in an engine room to drive the wind-driven generator to generate electricity. in the same case, the larger the impeller constituted by the blades is, the more the wind energy can be captured, and therefore the blades of the wind-driven generator tend to be longer and longer. With the blade getting longer and longer, a clearance (it refers to a distance between a tip of the wind-driven generator blade and a tower, which is an important safety index) is becoming a bottleneck, so that it is urgent to develop novel blade materials or blade designs to increase the clearance. The blade main beam, which contributes to about 90% of the flapping rigidity, thus basically determines the magnitude of the clearance.
Carbon fiber is a high modulus, high strength material, but at the same time is also relatively expensive. Therefore, how to reasonably introduce carbon fibers into the blade to achieve the goal of increasing the clearance and increasing the blade cost as little as possible is a current important research topic of major wind power companies Since the cost of a pure carbon fiber main beam is too high, and it takes too long to pay back the cost at one time, hybrid fiber materials came into being. The hybrid fiber material is a composite material formed by hybrid weaving or hybrid laying a certain amount of carbon fiber and glass fiber. The hybrid fiber material can balance the performance and the cost as much as possible.
However, the current hybrid fiber material mainly has the following limitations.
I. The mixing modes of the hybrid fiber materials are mostly carried out at a material scale, for example, a mixing mode in which carbon fiber and glass fiber are mixed and woven in the same fabric layer in different proportions of fiber bundles, or one layer of carbon fiber and one layer of glass fiber are mixed and laid; such a hybrid form is extremely short of design freedom, the ratio of fiber mixing is completely restricted by material suppliers, and for different models of blades, only materials in fixed mixing ratios can be selected, so that the demand of customization for each model cannot be met.
2. The final mechanical property of carbon fiber is greatly influenced by a process, so that a stable process route is crucial to the performance stability of a final product. Hybrid fiber materials (that is, hybrid materials of carbon fiber and glass fiber) generally often adopt a pouring process, that is, the carbon-glass mixed fabrics are stacked in multiple layers and poured together, or several layers of carbon fiber and several layers of glass fiber cloth are stacked and poured together. However, the pouring process of this material is easy to produce defects such as bubbles and wrinkles, which greatly compromises the final performance.
At present, there is a need for a novel wind-driven generator main beam or main beam material that at least partially eliminates the above limitations.
SUMMARY
A purpose of the present invention is to provide a main beam for use in a wind-driven generator blade and a manufacturing method thereof Through the main beam and/or the method, a hybrid form with more economy, better performance and higher operability can be proposed under the condition of reducing the amount of carbon fiber, so as to improve and prolong the required rigidity and service life of the main beam.
In a first aspect of the present invention, the purpose is achieved by a main beam for use in a wind-driven generator blade, wherein the main beam comprises: one or more carbon fiber pultrusion plates that are arranged along a length direction of the blade; one or more glass fiber pultrusion plates that are arranged along the length direction of the blade, wherein the carbon fiber pultrusion plates and the glass fiber pultrusion plates are combined in one or more ways and mixed in one or more proportions such that the carbon fiber pultrusion plates and the glass fiber pultrusion plates that are mixed have a forward hybrid effect and/or bending-torsion coupling effect; and a first pouring material that wets the carbon fiber pultrusion plates and the glass fiber pultrusion plates.
In the present invention, the term "main beam-refers to a long and narrow structure used to reinforce a blade in a housing on two sides of the blade. Generally, the main beams at two sides are connected with a web located inside the blade to support an inner space of the blade. The term 'carbon fiber pultrusion plate" refers to a material made of carbon fiber which is formed by curing after resin wetting and pultrusion processes, and the term "glass fiber pultntsion plate-refers to a material made of glass fiber which is formed by curing after resin wetting and pultrusion processes. Preferably, the carbon fiber pultrusion plates and the glass fiber pultrusion plates in the main beam together form a continuous main beam surface, and the main beam surface has a desired curvature when necessary. The term "wetting" means that a pouring material is poured into a pouring object and at least partially combined with the pouring object and finally cured. In addition, the second pouring material forming the carbon fiber pultrusion plates can be the same as the first pouring material or may be other pouring materials, and similarly, the third pouring material fonning the glass fiber pultrusion plates can be the same as the first pouring material or may be other pouring materials; and the carbon fiber pultrusion plates and the glass fiber pultrusion plates can be arranged adjacent to each other in a direction perpendicular to the thickness of the main beam, such as in the length direction and a width direction of the main beam, to Constitute a coverage area of the main beam. In the case that the carbon fiber pultrusion plates and the glass fiber pultrusion plates are of a strip structure, the carbon fiber pultrusion plates and the glass fiber pultrusion plates can be arranged adjacent to each other in a chord direction of the main beam Here, the term "chord direction" refers to a direction perpendicular to the thickness of the main beam and the length direction of the blade.
In an extended solution of the present invention, it is provided that the cross section of a main body of the glass fiber pultrusion plate is rectangular. According to different application scenarios, glass fiber pultrusion plates in different sizes can be adopted. For example, the size of the glass fiber pultrusion plate can be determined according to a desired final shape of the main beam.
In an extended solution of the present invention, it is provided that the cross section of a main body the carbon fiber pultrusion plate is rectangular. According to different application scenarios, carbon fiber pultrusion plates in different sizes can be adopted. For example, the size of the carbon fiber pultntsion plate can be determined according to the desired final shape of the main beam in an extended solution of the present invention, it is provided that in a certain area of the main beam, m carbon fiber pultrusion plates are stacked along a thickness direction of the blade, and/or n carbon fiber pultrusion plates are stacked along a chord direction of the blade, wherein m and n are both integers from Ito 100. The carbon fiber pultrusion plates extend for 0.1%-99.9% of the blade length. A starting point of the blade length is a connecting part between a blade root and a hub, and an end point of the blade length is a blade tip.
In another extended solution of the present invention, it is provided that in a certain area of the main beam, p glass fiber pultrusion plates are stacked along the thickness direction of the blade, and/or q glass fiber pultrusion plates are stacked along the chord direction of the blade, wherein p and q are both integers from 1 to 100.
For example, one or more glass fiber pultrusion plates and/or one or more carbon fiber pultrusion plates can be arranged on the top, bottom, left and right, front and back of each carbon fiber pultrusion plate. Similarly, one or more glass fiber pultrusion plates and/or one or more carbon fiber pultrusion plates can be arranged on the top, bottom, left and right, front and back of each glass fiber pultrusion plate. By adjusting different mixing schemes, mixing sizes and mixing ratios of the carbon fiber pultrusion plates and the glass fiber pultrusion plates, the rigidity of the main beam can be adjusted, so that the glass fiber pultrusion plates and the carbon fiber pultrusion plates together can achieve the desired flapping rigidity after secondary pouring and better form a desired curved surface.
In another preferred solution of the present invention, it is provided that the carbon fiber pultrusion plates are fonned by curing with a second pouring material, and the glass fiber pultrusion plates are formed by curing with a third pouring material. The first pouring material, the second pouring material and the third pouring material may be pairwise the same or different from each other, or they may all be the same or different from one another, and each comprises one or more of thermosetting epoxy resin, vinyl resin, unsaturated polyester resin, phenolic resin, bi sm al ei m i de and thermoplastic resin. Other pouring materials are also conceivable under the teaching of the present invention.
in yet another preferred embodiment of the present invention, it is provided that the thermoplastic resin comprises one or more of polypropylene resin, polyethylene resin, polyvinyl chloride resin, polystyrene resin, polyacrylonitrilebutadiene-styrene resin, polyurethane, polyimide resin, polyetheretherketone resin, and polyphenylene sulfide. Other thermoplastic resins are also conceivable under the teaching of the present invention.
In another extended solution of the present invention, it is provided that on one or more layers in the thickness direction of the blade, a first end of each of the carbon fiber pultrusion plates is connected with a second end of each of the glass fiber pultrusion plates, and/or the first end of each of the carbon fiber pultrusion plates is inserted between two of the glass fiber pultrusion plates, and/or the second end of each of the glass fiber pultrusion plates is inserted into two of the carbon fiber pultrusion plates. The first end and the second end may be ends located in the longitudinal direction of the glass fiber pultrusion plate and the carbon fiber pultrusion plate, or ends located in the width direction of the glass fiber pultrusion plate and the carbon fiber pultrusion plate.
Through the preferred solution, a better passive load reduction of the main beam can be realized. For example, at a certain layer in the thickness direction of the blade, a specific hybrid arrangement is designed along the chord direction; the first carbon fiber pultrusion plates and the first glass fiber pultrusion plates that are locally connected are distributed in a first chord direction coordinate position, the second carbon fiber pultrusion plates and the first carbon fiber pultrusion plates that are locally connected are distributed in a second chord direction coordinate position, and by analogy, the Nth carbon fiber pultrusion plates and the Nth glass fiber pultrusion plates that are locally connected are distributed in an Nth chord direction coordinate position, then a connection in the first chord direction coordinate position, a connection in the second chord direction coordinate position and a connection in the Nth chord direction coordinate position can be distributed in a staggered manner, so that the blade can have a bending-torsion coupling effect, that is, it generates torsional deformation under bending, and this response of the structure is used for passive load reduction.
In yet another preferred solution of the present invention, it is provided that at connections of the glass fiber pultrusion plates and the carbon fiber pultrusion plates, one or more connecting parts cover the first ends of the carbon fiber pultrusion plates and/or the second ends of the glass fiber pultrusion plates.
Through the preferred solution, better local strength of the main beam can be achieved, and a smooth geometric transition can be provided. The reason is that, first of all, starting from the connection, two sides of the carbon fiber pultrusion plate and the glass fiber pultrusion plate have chamfers which transition from 0 to full thickness, and multiple layers of fiber cloth are laid above and below a blank area of the connection, a staggered size of the fiber cloth is matched with slope angles of the pultrusion plates at the two sides, the carbon fiber pultrusion plate and glass fiber pultrusion plate that are locally connected are connected by the cloth layer at the connection, so that the requirement of strength and the requirement of smooth geometric transition are both met; and when chamfer sides of the two pultrusion plates face one side, the size of the fiber cloth is gradually changed from small to large when the fiber cloth is completely transited to full thickness from the connecting part closest to the two pultrusion plates. When the chamfers of the two pultrusion plates face two sides, the two pultrusion plates are butted to form slope angle matching, multiple layers of fiber cloth are arranged between the two plates, a gap between the two pultrusion plates is absent, the fitting degree is better, and the friction coefficient is increased, so that the two pultrusion plates do not move in a staggered manner, and the local rigidity is enhanced; in addition, a layers of fiber cloth and b layers of fiber cloth are arranged on an upper surface of the previous plate and a lower surface of the next plate respectively to form a local connection design as a whole, so that the upper and lower surfaces of the two pultntsion plates are smoother. Because in the thickness direction of the main beam there are main bodies of two types of pultrusion plates and connections of the two types of pultrusion plates, so that more mobility is provided in a direction perpendicular to the thickness direction of the main beam, such as the chord direction; and the mobility is beneficial for the main beam material to form a desired surface shape, such as a curved surface, before pouring, so that the surface shape can kept by curing after pouring.
In another preferred solution of the present invention, it is provided that the connecting part comprises one or more of glass fiber fabric, carbon fiber fabric, glass fiber non-woven fabric, carbon fiber non-woven fabric and glass fiber roving, and other materials of the connecting part are also conceivable under the teaching of the present invention. j connecting parts are stacked along the thickness direction of the blade, and/or k connecting parts are stacked along the chord direction of the blade, wherein j and k are both integers from Ito 100.
In a second aspect of the present invention, the aforementioned purpose is achieved by a method for manufacturing a main beam for use in a wind-driven generator blade, wherein the method comprises the following steps: providing one or more carbon fiber pultrusion plates, and arranging the carbon fiber pultrusion plates along a length direction of the blade; providing one or more glass fiber pultrusion plates, and arranging the glass fiber pultrusion plates along the length direction of the blade; combining the carbon fiber pultrusion plates and the glass fiber pultrusion plates in one or more ways and mixing them in one or more proportions such that the carbon fiber pultrusion plates and the glass fiber pultrusion plates that are mixed have a forward hybrid effect and/or bending-torsion coupling effect; and wetting the carbon fiber pultrusion plates and the glass fiber pultrusion plates with a first pouring material.
In a preferred solution of the present invention, it is provided that providing one or more carbon fiber pultrusion plates and providing one or more glass fiber pultrusion plates comprise the following steps: wetting and curing the carbon fiber pultrusion plates with a second pouring material, and wetting and curing the glass fiber pultrusion plates with a third pouring material; arranging one or more carbon fiber pultrusion plates and/or glass fiber pultrusion plates in a mutually stacked manner, and arranging a pouring layer around each carbon fiber pultrusion plate for pouring for the second time; and arranging a pouring layer around each glass fiber pultrusion plate for pouring for the second time The present invention has at least the following beneficial effects (1) the present invention adopts a mixture of carbon fiber pultrusion and glass fiber pultrusion, so that the disadvantage of insufficient rigidity of a pure glass fiber main beam and the defect of high price of pure carbon fiber are overcome; and the mixed ratio of carbon fiber and glass fiber can be arbitrarily adjusted to achieve the overall optimal cost performance; (2) carbon fiber and glass fiber composites exist in their respective optimal technological ways, namely, pultrusion; hybrid materials have a forward hybrid effect, that is, the stiffness of the materials is improved by the existence of each other, which is superior than a theoretical value of a pure mixing relationship; and compared with a pure carbon fiber pultrusion blade, due to mixing and buffering effects of the glass fiber, the process sensitivity of the carbon fiber will be reduced and the carbon fiber process and the quality robustness will be improved; and (3) a special local connection design can make it possible for the carbon fiber pultrusion plate to start from the blade, and the local connection design has two functions, one is to ensure that the local strength of the connection meets the requirements, and the other is to provide a gentle geometric transition to avoid defects such as resin enrichment caused by suspension of the pultrusion plate; the carbon fiber pultrusion plates and the glass fiber pultrusion plates can be mixed in the same layer or different layers according to the design, and can be arranged in any combination to the greatest extent with the local connection design; and the local connection design is realized by a composite cloth layer, and a soft laid layer is used to connect two hard structures, which is very flexible and appropriate.
The present invention also provides a method for manufacturing a wind-driven generator blade, wherein the method comprises the following steps: prefabricating a main beam by the aforementioned method, placing the main beam in a housing, and pouring with the housing for the third time; or providing one or more carbon fiber pultrusion plates, and arranging the carbon fiber pultrusion plates in the housing along a length direction of the blade; providing one or more glass fiber pultrusion plates, and an-anging the glass fiber pultrusion plates in the housing along the length direction of the blade; and pouring for the second time, so that the carbon fiber pultrusion plates, the glass fiber pultrusion plates and other materials are integrally formed. The hybrid main beam can be used as a prefabricated main beam to be molded earlier than the housing, and then placed in the housing for secondary pouring; or at the beginning, the two types of pultrusion plates are placed into the housing to be molded with other parts of the housing at one time.
In the main beam for use in the wind-driven generator blade and the manufacturing method thereof provided by the present invention, carbon fiber is a material with high specific strength and high specific modulus, and its high price limits its wide application. Therefore, the present invention realizes the most efficient use of carbon fiber materials. Mixing carbon fiber and glass fiber is a more optimal design mode. Compared with the mixing of materials at levels of carbon-glass hybrid weaving or carbon-glass hybrid laying, the present invention will bring a larger design space by mixing from a higher dimension, and is not limited by a customized mixing ratio of materials. In addition, the properties of the carbon fiber are very sensitive to the process stability, and a pultrusion process is currently recognized as a process that can stably exert the properties of carbon fiber materials to the greatest extent. Similarly, glass fiber pultrusion can also stabilize and solidify the properties of the glass fiber materials. To sum up, the main beam mixed with the carbon fiber pultrusion and glass fiber pultrusion materials will exert the greatest potential of the blade design and create products with the best cost performance.
BRIEF DESCRIPTION OF THE DRAWINGS
Figs. IA to 1G show several embodiments of a main beam according to the present invention; Figs. 2A to 2C show schematic diagrams of connection of various components in the main beam; and Figs. 3A to 3B show a schematic diagram of a wind-driven generator adopting the main beam according to the present invention; and Fig. 4 shows a process flow of manufacturing the main beam for use in the wind-driven generator blade according to the present invention.
As shown in the figure: 100, main beam; 101, carbon fiber pultrusion plate; 102, glass fiber pultrusion plate; 103, connecting part; 104, connection.
DESCRIPTION OF THE EMBODIMENTS
It should be noted that the components in the figures may be shown exaggerated for illustrative purposes and are not necessarily to scale. In the figures, identical or functionally identical components are provided with the same reference numerals.
In the present invention, unless otherwise specified, "arranged on...", "arranged over... and "arranged above do not exclude the existence of an intervening element therebetween. In addition, "arranged on or above..." merely means the relative positional relationship between two components, but it can also be converted into "arranged under or below..." under certain circumstances, such as after a direction of a product is reversed, and vice versa.
In the present invention, the embodiments are only intended to illustrate the solution of the present invention, and should not be construed as limiting.
in the present invention, the terms "a" and "an" do not exclude the presence of a plurality of elements, unless otherwise specified.
it should also be noted here that in the embodiment of the present invention, only some components or assemblies may be shown for clarity and simplicity, but those of ordinary skill in the art can understand that, under the teaching of the present invention, the required components or assemblies can be added according to the needs of specific scenarios.
It should also be noted here that within the scope of the present invention, expressions such as "same", "equal" and "equal to" do not mean that their values are absolutely equal, but allow certain reasonable errors, that is, the expressions also cover "substantially the same", "substantially equal-and "substantially equal to". By analogy, in the present invention, the terms "perpendicular to", "parallel to" and so on with respect to a direction also cover the meanings of "substantially perpendicular to" and "substantially parallel to".
In addition, the number of steps of each method of the present invention does not limit the execution order of the method steps. Unless otherwise specified, the method steps can be performed in a different order.
Most traditional main beams are formed by pouring a glass fiber reinforced plastic composite (GFRP) in a separate main beam mold to form a prefabricated part, and then placing the prefabricated part into a shell mold to be assembled with other materials to form an integral blade housing.
At present, most of the main beams in the market are pure glass fiber main beams. When a blade is over 80 in, the glass fiber material cannot meet the requirement of the long blade for rigidity, leading to the extremely heavy glass fiber blade. The rigidity problem can be extremely efficiently solved by adding a carbon fiber material. However, only pure carbon fiber pultrusion main beams or pure carbon fiber poured main beams are available at present and are extremely expensive. Even carbon-glass hybrid main beams are mostly in a material-level hybrid form of carbon-glass hybrid weaving or hybrid laying, and there is no hybrid arrangement of carbon materials and glass fiber materials in a higher structural design dimension. In addition, even though individual patents mentioned the pultrusion hybrid design of carbon fiber and glass fiber, the detailed design problem of actual connection between the two materials has not been solved, and the operability is to be improved.
A purpose of the present invention is to provide a main beam for use in a wind-driven generator blade and a manufacturing method thereof Through the main beam and/or the method, a hybrid form with more economy, better performance and higher operability can be proposed under the condition of reducing the amount of carbon fiber, so as to improve and prolong the required rigidity and service life of the main beam In order to realize the above idea, the present invention provides a main beam for use in a wind-driven generator blade and a manufacturing method thereof The main beam comprises: one or more carbon fiber pultrusion plates that are arranged along the length direction of the blade; one or more glass fiber pultntsion plates that are arranged along the length direction of the blade, wherein each carbon fiber pultrusion plate and each glass fiber pultrusion plate are arranged in a mixing mode, so that the carbon fiber pultrusion plate and the glass fiber pultrusion plate that are mixed have a forward hybrid effect and/or bending-torsion coupling effect; and a first pouring material that wets the carbon fiber pultntsion plate and the glass fiber pultruded plate.
The main beam for use in a wind-driven generator blade and its manufacturing method proposed by the present invention will be further explained in detail with reference to the following drawings and specific embodiments. The advantages and features of the present invention will be more apparent from the following description and claims. It should be noted that the drawings are all in a very simplified form and not to precise scale, and are only used to facilitate and clearly explain the purpose of the embodiments of the present invention.
Whether the carbon plate is arranged on an outermost side of the blade or on an intermediate layer (in a dimension in the thickness direction of the main beam) can be decided according to a design optimization result. See a first embodiment and a second embodiment. Fig. lA shows a first embodiment according to the present invention.
In the first embodiment, the main beam comprises: one or more carbon fiber pultrusion plates 101 that are arranged along a length direction z of the blade; and one or more glass fiber pultrusion plates 102 that are also arranged along the length direction z of the blade, wherein the arrangement along the length direction z of the blade means that several plates can be spliced to form 0.1%-99.9% of the blade length, or a whole plate can constitute 0.1%-99.9% of the blade length. A starting point of the blade length is a connecting part between a blade root and a hub, and an end point of the blade length is a blade tip. The carbon fiber pultrusion plates 101 and the glass fiber pultrusion plates 102 extend for 0.1%-99.9% of the blade length. According to the teaching of the present invention, the carbon fiber pultrusion plates 101 and the glass fiber pultrusion plates 102 start at 0.1%-99.9% of the blade length, and the carbon fiber pultrusion plates 101 and the glass fiber pultrusion plates 102 stop at 0.1%-99.9% of the blade length.
In a certain area of the main beam, 3 carbon fiber pultrusion plates 101 are stacked along the thickness direction x of the blade, and in a certain area of the main beam, 7 glass fiber pultrusion plates 102 are stacked along the thickness direction x of the blade, and it can be seen from this side view that the carbon fiber pultrusion plates 101 are arranged at an outermost side of the blade, and the glass fiber pultrusion plates 102 are arranged at an inner side of the blade; the carbon fiber pultrusion plates 101 and the glass fiber pultrusion plates 102 are combined in one or more ways and mixed in one or more proportions; a second pouring material wets the carbon fiber pultrusion plates 101; and a third pouring material wets the glass fiber pultrusion plates 102.
The cross section of a main body of the glass fiber pultrusion plate 102 is rectangular. According to different application scenarios, glass fiber pultrusion plates 102 in different sizes can be adopted. For example, the size of the glass fiber pultrusion plate 102 can be determined according to a desired final shape of the main beam. The cross section of a main body of the carbon fiber pultrusion plate 101 is rectangular. According to different application scenarios, carbon fiber pultrusion plates 101 in different sizes can be adopted. For example, the size of the carbon fiber pultrusion plate 101 can be determined according to the desired final shape of the main beam.
Fig. 1B shows a second embodiment according to the present invention.
In the second embodiment, one or more glass fiber pultntsion plates 102 are arranged above and below each carbon fiber pultrusion plate 101. The carbon fiber pultrusion plates are arbitrarily embedded into the glass fiber pultrusion plates, and by adjusting the different mixing schemes, mixing sizes and mixing ratios of the carbon fiber pultrusion plates 101 and the glass fiber pultrusion plates 102, the rigidity of the main beam can be adjusted, so that the glass fiber pultrusion plates 102 and the carbon fiber pultrusion plates 101 can achieve the desired flapping rigidity and better form a desired curved surface after pouring for the second time.
In another preferred solution of the present invention, it is provided that the carbon fiber pultrusion plates 101 are formed by curing with a second pouring material, and the glass fiber pultrusion plates 102 are formed by curing with a third pouring material. The first pouring material, the second pouring material and the third pouring material each comprise one or more of thermosetting epoxy resin, vinyl resin, unsaturated polyester resin, phenolic resin, bi sm al eim i de and thermoplastic resin. Other pouring materials are also conceivable under the teaching of the present invention.
In yet another preferred embodiment of the present invention, it is provided that the thermoplastic resin comprises one or more of polypropylene resin, polyethylene resin, polyvinyl chloride resin, polystyrene resin, polyactylonitrilebutadiene-styrene resin, polyurethane, polyimide resin, polyetheretherketone resin, and polyphenylene sulfide. Other thermoplastic resins are also conceivable under the teaching of the present invention.
In another extended solution of the present invention, it is provided that on one or more layers in the thickness direction x of the blade, a first end of each of the carbon fiber pultrusion plates 101 is connected with a second end of each of the glass fiber pultrusion plates 102, and/or the first end of each of the carbon fiber pultrusion plates 101 is inserted between two of the glass fiber pultrusion plates 102, and/or the second end of each of the glass fiber pultrusion plates 102 is inserted into two of the carbon fiber pultmsion plates 101. The first end and the second end may be ends located in the longitudinal direction z of the glass fiber pultrusion plate 102 and the carbon fiber pultrusion plate 101, or ends located in the width direction of the glass fiber pultrusion plate 102 and the carbon fiber pultrusion plate 101.
Whether the carbon plate is arranged at the most tip portion of the blade (in a dimension in the length direction of the blade) may be decided according to a design optimization result. See a third embodiment and a fourth embodiment.
Fig. IC shows a third embodiment according to the present invention.
In the third embodiment, the carbon fiber pultrusion plates 101 are inserted and connected at the same sides of the glass fiber pultrusion plates 102. The carbon fiber pultrusion plates 101 are only arranged in a blade tip region, and the carbon fiber pultrusion plates 101 and the glass fiber pultrusion plates 102 are mixed in layers.
Fig. 1D shows a fourth embodiment according to the present invention.
In the fourth embodiment, each short carbon fiber pultrusion plate 101 is inserted between two layers of long glass fiber pultrusion plates 102. The carbon fiber pultrusion plates 101 are only arranged in the blade tip region, and the carbon fiber pultrusion plates 101 and the glass fiber pultrusion plates 102 are mixed between layers.
Fig. lE shows a fifth embodiment according to the present invention.
in the fifth embodiment, 3 carbon fiber pultrusion plates 101 are placed on the first layer, 2 carbon fiber pultrusion plates 101 are placed on the second layer, and 1 carbon fiber pultrusion plate 101 is placed on the third layer. Different numbers of carbon fiber pultrusion plates 101 are arranged in the chord direction, in this way, a torsion and shear center of each layer will generate chordwise deviation which can cause the main beam to be deformed by torsion when subjected to a bending load, and the negative increase of the torsion will lead to the decrease of an attack angle of the blade, so that a function of reducing the load is exerted.
Fig. IF shows a sixth embodiment according to the present invention.
In the sixth embodiment, On each layer of the fifth embodiment (this layer shall have a plurality of carbon fiber pultrusion plates 101), the carbon fiber pultrusion plates 101 and the glass fiber pultrusion plates 102 are linearly butted on the macro level.
Fig. 10 shows a seventh embodiment according to the present invention.
Unlike the sixth embodiment, in the seventh embodiment, the carbon fiber pultrusion plates 101 and the glass fiber pultrusion plates 102 are in macroscopic zigzag butt joint, and the zigzag butt joint can reduce the harm caused by a sudden change of local stress.
Through the fifth embodiment, the sixth embodiment and the seventh embodiment, a better passive load reduction of the main beam can be realized For example, at a certain layer in the thickness direction x of the blade, a specific hybrid arrangement is designed along the chord direction y; the first carbon fiber pultrusion plates 101 and the first glass fiber pultrusion plates 102 that are locally connected are distributed in a first chord direction y coordinate position, the second carbon fiber pultrusion plates 101 and the first carbon fiber pultrusion plates 102 that are locally connected are distributed in a second chord direction y coordinate position, and by analogy, the Nth carbon fiber pultrusion plates 101 and the Nth glass fiber pultrusion plates 102 that are locally connected are distributed in an Nth chord direction y coordinate position, then a connection 104 in the first chord direction y coordinate position, a connection 104 in the second chord direction y coordinate position and a connection 104 in the Nth chord direction y coordinate position can be distributed in a staggered manner, so that the blade can have a bending-torsion coupling effect, that is, it generates torsional deformation under bending, and this response of the structure is used for passive load reduction.
In yet another preferred solution of the present invention, it is provided that at connections 104 of the glass fiber pultrusion plates 102 and the carbon fiber pultrusion plates 101, one or more connecting parts 103 cover the first ends of the carbon fiber pultrusion plates 101 and/or the second ends of the glass fiber pultrusion plates 102.
In another preferred solution of the present invention, it is provided that the connecting part comprises one or more of glass fiber fabric, carbon fiber fabric, glass fiber non-woven fabric, carbon fiber non-woven fabric and glass fiber roving, and other materials of the connecting part are also conceivable under the teaching of the present invention. j connecting parts are stacked along the thickness direction x of the blade, and/or k connecting parts are stacked along the chord direction y of the blade, wherein j and k are both integers from 1 to 100.
Through the preferred solution, better local strength of the main beam can be achieved, and a smooth geometric transition can be provided. The reason is that, first of all, starting from the connection 104, two sides of the carbon fiber pultrusion plate 101 and the glass fiber pultrusion plate 102 have chamfers which transition from 0 to full thickness, and multiple layers of fiber cloth (the connecting part 103) are laid above and below a blank area of the connection 104, a staggered size of the fiber cloth (the connecting part 103) is matched with slope angles of the pultrusion plates at the two sides, the carbon fiber pultrusion plate 101 and glass fiber pultrusion plate 102 that are locally connected are connected by the cloth layer at the connection 104, so that the requirement of strength and the requirement of smooth geometric transition are both met; and when chamfer sides of the two pultrusion plates face one side, the size of the fiber cloth (the connecting part 103) is gradually changed from small to large when the fiber cloth (the connecting part 103) is completely transited to full thickness from the connecting part closest to the two pultrusion plates. When the chamfers of the two pultrusion plates face two sides, the two pultrusion plates are butted to form slope angle matching, multiple layers of fiber cloth are arranged between the two plates, a gap between the two pultrusion plates is absent, the fitting degree is better, and the friction coefficient is increased, so that the two pultrusion plates do not move in a staggered manner, and the local rigidity is enhanced; in addition, a layers of fiber cloth and b layers of fiber cloth are arranged on an upper surface of the previous plate and a lower surface of the next plate respectively to form a local connection design as a whole, so that the upper and lower surfaces of the two pultrusion plates are smoother. Because in the thickness direction x of the main beam there are main bodies of two types of pultrusion plates and connections 104 of the two types of pultrusion plates, so that more mobility is provided in a direction perpendicular to the thickness direction x of the main beam, such as the chord direction y; and the mobility is beneficial for the main beam material to form a desired surface shape, such as a curved surface, before pouring, so that the surface shape can kept by curing after pouring.
Two sides of the carbon fiber pultrusion plate 101 and the glass fiber pultrusion plate 102 have chamfers which transition from full thickness to 0, x layers of fiber cloth are laid above and below the middle blank area, the staggered size of the fiber cloth is matched with the slope angle of the pultrusion plates at the two sides, and the left pultrusion plate and the right pultrusion plate are connected by the mi ddle cloth layer, so that both the requirement of strength and the requirement of smooth geometric transition are met.
Fig. 2A shows an eighth embodiment according to the present invention.
In the eighth embodiment, the chamfer sides of the carbon fiber pultrusion plate 101 and the glass fiber pultrusion plate 102 face one side, that is, in a first connection mode when the carbon fiber pultrusion plate 101 and the glass fiber pultrusion plate 102 are mixed in layers in the third, fifth, sixth and seventh embodiments; Fig. 2B shows a ninth embodiment according to the present invention.
In the ninth embodiment, the chamfers of the carbon fiber pultrusion plate 101 and the glass fiber pultrusion plate 102 face two sides, that is, in a second connection mode when the carbon fiber pultrusion plate 101 and the glass fiber pultrusion plate 102 are mixed in layers in the third, fifth, sixth and seventh embodiments; x layers of fiber cloth are arranged between the carbon fiber pultrusion plate 101 and the glass fiber pultrusion plate 102, and additional y and z layers of fiber cloth (connecting parts 103) are arranged on the upper side of the carbon fiber pultrusion plate 101 and the lower side of the glass fiber pultrusion plate 102, respectively, which form a local connection design as a whole.
Fig. 2C shows a tenth embodiment according to the present invention.
In the tenth embodiment, the carbon fiber pultrusion plate 101 has a chamfer and the glass fiber pultrusion plates 102 are smooth, that is, in a first connection mode when the carbon fiber pultrusion plate 101 is inserted between the glass fiber pultrusion plates 102 during mixing between layers in the fourth embodiment; before the carbon fiber pultrusion plate 101 is inserted between the glass fiber pultrusion plates 102, it is also necessary to make a reliable and gentle connection design, that is y and x layers of cloth (connecting parts 103) are placed above and below the carbon fiber pultrusion plate 101, respectively, to play a function of local connection.
In a second aspect of the present invention, the aforementioned purpose is achieved by a method of manufacturing a main beam for use in a wind-driven generator blade, wherein the method comprises the following steps: providing one or more carbon fiber pultrusion plates 101, and arranging the carbon fiber pultrusion plates 101 along a length direction z of the blade; providing one or more glass fiber pultrusion plates 102, and arranging the glass fiber pultrusion plates 102 along the length direction z of the blade; combining the carbon fiber pultrusion plates 101 and the glass fiber pultrusion plates 102 in one or more ways and mixing them in one or more proportions; and wetting the carbon fiber pultrusion plates 101 and the glass fiber pultrusion plates 102 with a first pouring material.
In a preferred solution of the present invention, it is provided that providing one or more carbon fiber pultrusion plates 101 and providing one or more glass fiber pultrusion plates 102 comprise the following steps: wetting and curing the carbon fiber pultrusion plates 101 with a second pouring material, and wetting and curing the glass fiber pultrusion plates 102 with a third pouring material; arranging one or more carbon fiber pultrusion plates 101 and/or glass fiber pultrusion plates 102 in a mutually stacked manner, and arranging a glass fiber pouring layer around each carbon fiber pultrusion plate 101 for pouring for the second time; and arranging a glass fiber pouring layer around each glass fiber pultrusion plate 102 for pouring for the second time.
The present invention also provides a method for manufacturing a wind-driven generator blade, wherein the method comprises the following steps: prefabricating a main beam by the aforementioned method, placing the main beam in a housing, and pouring with the housing for the third time; or providing one or more carbon fiber pultrusion plates 101, and arranging the carbon fiber pultnsion plates 101 in the housing along a length direction z of the blade; providing one or more glass fiber pultrusion plates 102, and arranging the glass fiber pultrusion plates 102 in the housing along the length direction z of the blade; and pouring for the second time, so that the carbon fiber pultrusion plates 101, the glass fiber pultrusion plates 102 and other materials are integrally formed. The hybrid main beam can be used as a prefabricated main beam to be molded earlier than the housing, and then placed in the housing for secondary pouring; or at the beginning, the two types of pultrusion plates are placed into the housing to be molded with other parts of the housing at one time.
In the main beam for use in the wind-driven generator blade and the manufacturing method thereof provided by the present invention, carbon fiber is a material with high specific strength and high specific modulus, and its high price limits its wide application. Therefore, the present invention realizes the most efficient use of carbon fiber materials. Mixing carbon fiber and glass fiber is a more optimal design mode. Compared with the mixing of materials at levels of carbon-glass hybrid weaving or carbon-glass hybrid laying, the present invention will bring a larger design space by mixing from a higher dimension, and is not limited by a customized mixing ratio of materials. In addition, the properties of the carbon fiber are very sensitive to the process stability, and a pultrusion process is currently recognized as a process that can stably exert the properties of carbon fiber materials to the greatest extent. Similarly, glass fiber pultrusion can also stabilize and solidify the properties of the glass fiber materials. To sum up, the main beam mixed with the carbon fiber pultntsion and glass fiber pultrusion materials will exert the greatest potential of the blade design and create products with the best cost performance.
Fig. 3A shows a schematic cross-sectional view in a vertical blade thickness direction of the wind-driven generator blade 1 adopting the main beam 100 according to the present invention.
Fig. 3B shows a schematic cross-sectional view in a vertical blade length direction of the wind-driven generator blade 1 adopting the main beam 100 according to the present invention.
As shown in Fig. 3B, the blade 1 has a blade leading edge 2 and a blade trailing edge 8, and a part of the blade 1 in front of the blade leading edge 2 and the blade trailing edge 8 is divided into a windward side 5 and a leeward side 6. Trailing edge beams 7 are arranged near the trailing edge 8 to improve the strength of the trailing edge. Main beams 100 are respectively arranged on the windward side 5 and the leeward side 6, between the blade leading edge 2 and the blade trailing edge 8. The main beams 100 are connected by a web 4 to improve the stability of the blade and prevent inward collapse. With the main beams 100 of the present invention, the rigidity of the blade 1 can be improved, and the conformability of a main beam material can be enhanced, thereby improving and prolonging the aerodynamic performance and service life of the blade.
Fig. 4 shows a process flow 400 of manufacturing the main beam for use in the wind-driven generator blade according to the present invention.
At step 402, one or more carbon fiber pultrusion plates are provided, the carbon fiber pultrusion plates being stacked along the thickness direction, the length direction and/or the chord direction, wherein the carbon fiber pultrusion plates are formed by curing with a second pouring material, and a glass fiber pouring material is arranged between every two carbon fiber pultrusion plates; At step 404, one or more glass fiber pultrusion plates are provided, the glass fiber pultrusion plates being stacked along the thickness direction, the length direction and/or the chord direction, wherein the glass fiber pultrusion plates are formed by curing with a third pouring material, a glass fiber pouring material is arranged between every two glass fiber pultrusion plates, and the glass fiber pultrusion plates can be arranged adjacent to the carbon fiber pultrusion plates; In step 406, one or more covering layers are arranged on the carbon fiber pultrusion plates and/or the glass fiber pultrusion plates on two sides in the thickness direction of the main beam; and In step 408, the carbon fiber pultrusion plates, the glass fiber pultrusion plates and the covering layers are wet with a first pouring material.
The present invention has at least the following beneficial effects: (1) the present invention adopts a mixture of carbon fiber pultrusion and glass fiber pultrusion, so that the disadvantage of insufficient rigidity of a pure glass fiber main beam and the defect of high price of pure carbon fiber are overcome; and the mixed ratio of carbon fiber and glass fiber can be arbitrarily adjusted to achieve the overall optimal cost performance; (2) carbon fiber and glass fiber composites exist in their respective optimal technological ways, namely, pultrusion; hybrid materials have a forward hybrid effect, that is, the stiffness of the materials is improved by the existence of each other, which is superior than a theoretical value of a pure mixing relationship; and compared with a pure carbon fiber pultrusion blade, due to mixing and buffering effects of the glass fiber, the process sensitivity of the carbon fiber will be reduced and the robustness of the carbon fiber process and quality will be improved; and (3) a special local connection design can make it possible for the carbon fiber pultrusion plate to start from the blade, and the local connection design has two functions, one is to ensure that the local strength of the connection meets the requirements, and the other is to provide a gentle geometric transition to avoid defects such as resin enrichment caused by suspension of the pultrusion plate; the carbon fiber pultrusion plates 101 and the glass fiber pultrusion plates 102 can be mixed in the same layer or different layers according to the design, and can be an-anged in any combination to the greatest extent with the local connection design; and the local connection design is realized by a composite cloth layer, and a soft laid layer is used to connect two hard structures, which is very flexible and appropriate.
To sum up, the above-mentioned embodiments have explained in detail different configurations of the main beam for use in the wind-driven generator blade and a manufacturing method thereof. Certainly, the present invention includes, but is not limited to, the configurations listed in the above-mentioned embodiments, and any changes based on the configurations provided in the above-mentioned embodiments are within the protection scope of the present invention. Those skilled in the art can draw inferences from the above-described embodiments.
In this specification, the various embodiments are described in a progressive way, each embodiment focuses on differences from other embodiments, and the same and similar parts among the embodiments are referred to each other. As for a system disclosed in the embodiment, the description is relatively simple because the system corresponds to the method disclosed by the embodiment, and relevant points can be referred to the description of the method part.
The above description is only for the purpose of describing the preferred embodiment of the present invention, and is not intended to limit the scope of the present invention, and any variations and modifications made by those of ordinary skill in the art based on the above disclosure are intended to fall within the protection scope of the appended claims.
Claims (14)
- WHAT IS CLAIMED IS: 1. A main beam for a wind-driven generator blade, wherein the main beam comprises: one or more carbon fiber pultrusion plates that are arranged along a length direction of the blade; one or more glass fiber pultrusion plates that are arranged along the length direction of the blade, wherein the carbon fiber pultrusion plates and the glass fiber pultrusion plates are arranged in a mixing mode, so that the carbon fiber pultrusion plates and the glass fiber pultnision plates that are mixed have a forward hybrid effect and/or bending-torsion coupling effect; and a first pouring material that wets the carbon fiber pultrusion plates and the glass fiber pultrusion plates.
- 2. The main beam of claim 1, wherein in a certain area of the main beam, m carbon fiber pultrusion plates are stacked along a thickness direction of the blade, and/or n carbon fiber pultnision plates are stacked along a chord direction of the blade, wherein in and n are both integers from 1 to 100.
- 3. The main beam of claim 1, wherein in a certain area of the main beam, p glass fiber pultrusion plates are stacked along the thickness direction of the blade, and/or q glass fiber pultrusion plates are stacked along the chord direction of the blade, wherein p and q are both integers from 1 to 100.
- 4. The main beam of claim 1, wherein the carbon fiber pultrusion plates are formed by curing with a second pouring material, and the glass fiber pultrusion plates are formed by curing with a third pouring material.
- 5. The main beam of claim 4, wherein the first pouring material comprises one or more of thermosetting epoxy resin, vinyl resin, unsaturated polyester resin, phenolic resin, bismaleimide and thermoplastic resin; the second pouring material comprises one or more of thermosetting epoxy resin, vinyl resin, unsaturated polyester resin, phenolic resin, bi sm al eim i de and thermoplastic resin; and the third pouring material comprises one or more of thermosetting epoxy resin, vinyl resin, unsaturated polyester resin, phenolic resin, bismaleimide and thermoplastic resin.
- 6. The main beam of claim 5, wherein the thermoplastic resin comprises one or more of polypropylene resin, polyethylene resin, polyvinyl chloride resin, polystyrene resin, polyacrylonitrile-butadiene-styrene resin, polyurethane, polyimide resin, polyetheretherketone resin, and polyphenylene sulfide resin.
- 7. The main beam of claim 1, wherein on one or more layers in the thickness direction of the blade, ends of the carbon fiber pultrusion plates are connected with ends of the glass fiber pultrusion plates, and/or the ends of the carbon fiber pultrusion plates are inserted between every two glass fiber pultrusion plates, and/or the ends of the glass fiber pultrusion plates are inserted between every two carbon fiber pultrusion plates.
- 8. The main beam of claim 7, wherein at connections of the glass fiber pultrusion plates and the carbon fiber pultrusion plates, one or more connecting parts cover the ends of the carbon fiber pultrusion plates and/or the ends of the glass fiber pultrusion plates.
- 9. The main beam of claim 8, wherein the connecting parts comprise one or more of glass fiber fabric, carbon fiber fabric, glass fiber non-woven fabric, carbon fiber non-woven fabric and glass fiber roving, j connecting parts are stacked along the thickness direction of the blade, and/or k connecting parts are stacked along the chord direction of the blade, wherein j and k are both integers from 1 to 100.
- 10. The main beam of claim 1, wherein each of the carbon fiber pultrusion plates starts at 0.1%-99.9% of a blade length, and each of the carbon fiber pultrusion plates stops at 0.1%-99.9% of the blade length.
- 11. A method for manufacturing a main beam for a wind-driven generator blade, wherein the method comprises the following steps: providing and arranging one or more carbon fiber pultrusion plates along a length direction of the blade; providing and arranging one or more glass fiber pultrusion plates along the length direction of the blade; arranging the carbon fiber pultrusion plates and the glass fiber pultrusion plates in a mixing mode, so that the carbon fiber pultrusion plates and the glass fiber pultrusion plates that are mixed have a forward hybrid effect and/or bending-torsion coupling effect; and wetting the carbon fiber pultnision plates and the glass fiber pultrusion plates with a first pouring material.
- 12. The method of claim 11, wherein providing the one or more carbon fiber pultrusion plates and providing the one or more glass fiber pultrusion plates comprise the following steps: wetting the carbon fiber pultrusion plates with a second pouring material and curing, and wetting the glass fiber pultrusion plates with a third pouring material and curing; arranging one or more carbon fiber pultrusion plates and/or glass fiber pultrusion plates in a mutually stacked manner, and arranging a pouring layer around each of the carbon fiber pultrusion plates for pouring for the second time; and arranging a pouring layer around each of the glass fiber pultrusion plates for pouring for the second time
- 13. A method for manufacturing a wind-driven generator blade, wherein the method comprises the following steps: prefabricating a main beam by using the method of claim 11, placing the main beam in a housing, and pouring with the housing for the third time; or providing and arranging one or more carbon fiber pultrusion plates in the housing along a length direction of the blade; providing and arranging one or more glass fiber pultrusion plates in the housing along the length direction of the blade; pouring for the second time, so that the carbon fiber pultrusion plates, the glass fiber pultrusion plates and other materials are integrally formed.
- 14. A wind-driven generator having the main beam of claims 1-10.
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| PCT/CN2020/105013 WO2022021039A1 (en) | 2020-07-28 | 2020-07-28 | Main beam for use in wind-driven generator blade and manufacturing method therefor |
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| GB2611677A true GB2611677A (en) | 2023-04-12 |
| GB2611677B GB2611677B (en) | 2024-04-03 |
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| CN (1) | CN114286891B (en) |
| GB (1) | GB2611677B (en) |
| MX (1) | MX2023000890A (en) |
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| CN115054952B (en) * | 2022-07-22 | 2023-08-08 | 合肥茂腾环保科技有限公司 | Stripping liquid wastewater treatment atomization treatment device |
| CN117162561B (en) * | 2023-11-02 | 2024-03-22 | 中材科技风电叶片股份有限公司 | Thermoplastic composite girder forming method and wind power blade girder |
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| CN102465844A (en) * | 2010-11-04 | 2012-05-23 | 三一电气有限责任公司 | Wind driven generator blade |
| CN103921457A (en) * | 2014-04-28 | 2014-07-16 | 连云港中复连众复合材料集团有限公司 | Method for manufacturing main beam or auxiliary beam of fan blade by unidirectional sheets manufactured by use of pultrusion process |
| CN106368894A (en) * | 2015-07-22 | 2017-02-01 | 通用电气公司 | Rotor blade root assembly for wind turbine |
| US20180156202A1 (en) * | 2016-12-05 | 2018-06-07 | Nordex Energy Gmbh | Spar cap assembly for a wind turbine rotor blade |
| CN109094075A (en) * | 2017-06-21 | 2018-12-28 | 通用电气公司 | Wind turbine blade and related production with mixing spar caps |
| CN109098929A (en) * | 2017-06-21 | 2018-12-28 | 通用电气公司 | The associated method of wind turbine blade and manufacture with hybrid spar caps |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB2497578B (en) * | 2011-12-16 | 2015-01-14 | Vestas Wind Sys As | Wind turbine blades |
| CN210859042U (en) * | 2019-10-15 | 2020-06-26 | 中材科技风电叶片股份有限公司 | Main beam cap splicing structure and fan rotor blade |
-
2020
- 2020-07-28 CN CN202080003490.4A patent/CN114286891B/en active Active
- 2020-07-28 MX MX2023000890A patent/MX2023000890A/en unknown
- 2020-07-28 GB GB2300368.4A patent/GB2611677B/en active Active
- 2020-07-28 WO PCT/CN2020/105013 patent/WO2022021039A1/en active Application Filing
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Patent Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102465844A (en) * | 2010-11-04 | 2012-05-23 | 三一电气有限责任公司 | Wind driven generator blade |
| CN103921457A (en) * | 2014-04-28 | 2014-07-16 | 连云港中复连众复合材料集团有限公司 | Method for manufacturing main beam or auxiliary beam of fan blade by unidirectional sheets manufactured by use of pultrusion process |
| CN106368894A (en) * | 2015-07-22 | 2017-02-01 | 通用电气公司 | Rotor blade root assembly for wind turbine |
| US20180156202A1 (en) * | 2016-12-05 | 2018-06-07 | Nordex Energy Gmbh | Spar cap assembly for a wind turbine rotor blade |
| CN109094075A (en) * | 2017-06-21 | 2018-12-28 | 通用电气公司 | Wind turbine blade and related production with mixing spar caps |
| CN109098929A (en) * | 2017-06-21 | 2018-12-28 | 通用电气公司 | The associated method of wind turbine blade and manufacture with hybrid spar caps |
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| Publication number | Publication date |
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| ZA202300355B (en) | 2024-02-28 |
| GB2611677B (en) | 2024-04-03 |
| WO2022021039A1 (en) | 2022-02-03 |
| CN114286891A (en) | 2022-04-05 |
| CN114286891B (en) | 2023-10-20 |
| MX2023000890A (en) | 2023-02-22 |
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