JP2003042056A - Method of manufacturing component for wind power generation device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method of manufacturing a component for the wind power generation capable of significantly improving the work efficiency and providing a high-quality, lightweight product with high strength. SOLUTION: The method of manufacturing the component for wind power generation comprises a cloth material disposing process for disposing a cloth-like glass fiber material 10, a base disposing process for disposing a lower base 20, a cloth material disposing process for disposing the cloth-like glass fiber material 10 on the surface of the lower base 20, a covering/sealing process for covering the cloth-like glass fiber material 10 with a vacuum bag 70 and sealing the space formed by the vacuum bag 70 and the lower base 20, a discharging process for discharging air inside the sealed space formed by the vacuum bag 70 and the lower base 20, a resin impregnating process for introducing a polyester resin into the sealed space with the vacuum pressure and impregnating the cloth-like glass fiber material 10 with the polyester resin, and a resin hardening process for hardening the impregnating polyester resin.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a component part of a wind turbine generator, and more particularly to a so-called VARTM.
(Vacuum Assist Resin Transfer Molding) method for manufacturing main components such as blades, spinners and nacelles of wind power generators.

[0002]

2. Description of the Related Art In recent years, research on wind power generation technology for obtaining stable power from natural wind has progressed, and as a wind power generation device, a wind turbine that obtains torque from lift acting on blades (turbine type) is generally used. Has been adopted. This wind turbine has a structure in which blades are rotatably attached to a hub above the tower, and components having a complicated structure such as a nacelle and a spinner are attached to the hub. In recent years, in order to reduce the weight and increase the strength of the components of such a wind turbine, a method of manufacturing main components such as a blade, a nacelle, and a spinner of the wind turbine with a fiber-reinforced composite material has been proposed.

As the above-mentioned method, for example, as shown in FIG. 4, a cloth-like glass fiber material for forming a blade outer plate portion is prepared (a cloth material preparing step: S10), and a lower mold for forming the blade outer plate portion is prepared. The mold is placed (jig placement step: S20), the surface of the lower mold is washed with a solvent, and a release agent is applied (release processing step: S3).
0), and laminating the required number of cloth-like glass fiber materials thereon while impregnating the polyester resin (layup step: S4
0), the roller is pressed against the outer surface of the laminate to discharge excess resin and defoam inside the laminate (defoaming step: S5
0), a hand lay-up method has been proposed which goes through a series of steps of curing by leaving it to stand (curing step: S60). An outer plate portion and a girder portion of the blade were prepared by this hand layup method, and these were joined to manufacture a blade.

[0004]

However, according to the above-mentioned hand lay-up method, the cloth-like glass fiber material is laminated by hand while impregnating the polyester resin with the polyester resin. Since it was necessary to wear protective equipment such as a gas mask and goggles, work efficiency was extremely low. In addition to the lay-up process, the defoaming process is also performed manually, so that the size, weight, internal quality, etc. of the product may differ depending on the technical skill of the worker. Therefore, there is also a problem that a skilled worker is required to stabilize the quality.

Further, since the product manufactured by the above hand lay-up method has a low reinforcing fiber volume ratio of about 30% at the maximum, the wall thickness of parts is increased when manufacturing the above-mentioned blade. Therefore, a method of expressing high strength is adopted, but as a result, there is a problem that the weight of the component increases.

An object of the present invention is to provide a method of manufacturing a component part of a wind turbine generator capable of significantly improving work efficiency and obtaining a product of stable quality, light weight and high strength.

[0007]

In order to solve the above-mentioned problems, the invention according to claim 1 is a cloth for manufacturing components of a wind turbine generator as shown in, for example, FIGS. 1 to 3. A cloth material preparing step of preparing a glass fiber material, a jig arranging step of arranging a lower jig, a cloth arranging step of arranging the cloth glass fiber material on a surface of the lower jig, A covering and sealing step of covering a cloth-like glass fiber material with a vacuum bag to seal a space formed by the vacuum bag and the lower jig, and a sealing formed by the vacuum bag and the lower jig. An exhausting step of discharging air in the space, a resin impregnating step of introducing polyester resin into the closed space by vacuum pressure to impregnate the cloth-like glass fiber material,
And a resin curing step of curing the impregnated polyester resin.

According to the first aspect of the present invention, since it is not necessary to manually laminate the cloth-like glass fiber material while impregnating the polyester resin, the quality of the product may differ depending on the skill level of the worker. It is possible to obtain a product of extremely stable quality. Further, by omitting the above-mentioned manual work, it is possible to shorten the working time and the labor cost, and as a result, the manufacturing cost can be remarkably reduced.

Further, according to the first aspect of the present invention, the polyester resin is sealed in the vacuum bag, so that the harmful gas generated when the polyester resin is cured is diffused to the outside (in the workplace). And does not pollute the work environment.

Further, according to the invention described in claim 1, since a lightweight and high-strength product having a high reinforcing fiber volume ratio can be obtained, the method of the present invention is extremely suitable for the production of large-sized components. .

According to a second aspect of the present invention, in the method of manufacturing a component part of the wind turbine generator according to the first aspect, as shown in FIG. 2, for example, a polyester resin is applied to the surface of the lower jig. And is cured to form a resin film.

According to the invention described in claim 2, in addition to the function and effect of the invention described in claim 1, the surface of the lower jig is
By forming the polyester resin film in advance, it is possible to reliably perform vacuuming in the exhaust process. That is, it is possible to prevent minute cracks from being generated on the surface of the lower jig and prevent the vacuum degree from lowering.
Further, it is possible to manufacture a high quality product having an extremely good surface condition.

The invention according to claim 3 is the invention according to claim 1 or 2.
In the method of manufacturing a component part of the wind power generator described,
For example, as shown in FIG. 2, a resin introducing pipe is provided around the cloth glass fiber material, and the polyester resin is introduced into the cloth glass fiber material through the resin introducing pipe.

According to the third aspect of the present invention, in addition to the effect of the first or second aspect of the present invention, the cloth-like glass fiber material can be impregnated with the polyester resin uniformly and rapidly. In this case, the impregnation rate can be adjusted to be almost constant. As a result, a high quality product can be manufactured while shortening the manufacturing time.

According to a fourth aspect of the present invention, in the method of manufacturing a component part of the wind turbine generator according to the first, second or third aspect, as shown in FIG. 2, for example, the vacuum bag is made of a silicon sheet. It is characterized by

According to the invention of claim 4, claim 1,
In addition to the function and effect of the invention described in 2 or 3, since a vacuum bag prepared by a silicon sheet having excellent flexibility is used, even when manufacturing a product having a complicated shape, a cloth-like glass fiber material ( And the polyester resin impregnated therein can be reliably sealed, and a high-quality product can be manufactured. Further, since the silicone sheet also has excellent mold releasability from the polyester resin, it can be easily released from the mold after manufacturing and can be reused in the subsequent manufacturing process, so that the manufacturing cost can be reduced.

[0017]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described in detail below with reference to FIGS. In the present embodiment, by the method of manufacturing a component of the wind power generation device according to the present invention, the back side skin portion and the ventral side skin portion of the blade are manufactured separately, and these are bonded to form the blade. The steps will be described. Here, since the steps of manufacturing the back-side outer plate portion and the ventral-side outer plate portion are substantially the same, in the present embodiment, the step of manufacturing the belly-side outer plate portion will be mainly described.

First, as shown in FIG. 1, a cloth-like glass fiber material 10 having a planar shape of the ventral outer plate portion of the blade is prepared (cloth material preparing step S1: see FIG. 3). This cloth-like glass fiber material 10 is composed of glass fiber weaving, knitting, twisting,
It is a thin plate-like body configured in a woven shape, a knitted shape, a non-woven shape, a mat shape, a felt shape or the like by bonding, and by impregnating the cloth-like glass fiber material 10 with a polyester resin (described later) and curing it, Blades made of lightweight, high strength fiber reinforced composite materials can be manufactured. The thickness of the cloth-shaped glass fiber material 10 can be appropriately determined according to the size of the blade to be manufactured.

Next, the lower jig 20 for forming the ventral outer plate portion of the blade is placed (jig placement step S2: see FIG. 3). The lower jig 20 in the present embodiment is made of a fiber-reinforced composite material composed of an epoxy resin and glass fibers, and has a concave portion on the surface thereof that matches the shape of the ventral outer plate portion of the blade to be manufactured. Are formed.

The lower jig 20 prepared by the fiber-reinforced composite material is lighter and easier to handle than a jig made of a metal material, but since minute cracks are easily generated on the surface, a polyester resin is applied to the surface. It is applied and cured to form a resin film 21 (see FIG. 2). This resin coating 21
As a result, it is possible to reliably perform vacuuming in the evacuation step described later, and it is possible to manufacture a high-quality ventral outer plate portion having an extremely good surface condition.

Next, the manufactured belly-side outer plate portion is attached to the lower jig 2.
For easy removal from 0, the surface of the recess of the lower jig 20 is washed with a solvent and then a release agent is applied (release process S3: see FIG. 3). After this step, the cloth-like glass fiber material 10 described above is arranged in the concave portion of the lower jig 20 (cloth material arrangement step S4: FIG. 3).

Next, around the cloth-like glass fiber material 10,
The blocking members 30 as shown in FIG. 1 are continuously arranged at regular intervals, and the resin introducing pipe 40 is arranged between the blocking members 30 and around the blocking member 30. The end of the resin introducing pipe 40 is connected to a resin tank 50 made of polyester resin, as shown in FIGS.

The resin introducing pipe 40 is a flow path through which the polyester resin is introduced into the cloth-like glass fiber material 10 in the resin introducing process described later.
When 0 is provided, the cloth-like glass fiber material 10 can be uniformly and quickly impregnated with the polyester resin. Further, since the impregnation rate of the polyester resin can be adjusted to be substantially constant, while shortening the manufacturing time,
A high quality ventral skin part can be manufactured.

Next, a dam 60 for preventing the outflow of resin is provided between the cloth glass fiber material 10 and the resin tank 50.
(See FIG. 2), the cloth-like glass fiber material 10 is covered with a vacuum bag 70, and the vacuum bag 70 and the lower jig 20 are covered.
The space formed by and is sealed with the sealing material 80 (coating sealing step S5: see FIG. 3). At this time, in order to easily remove the vacuum bag 70 from the manufactured abdominal outer plate portion,
A release film 90 is placed between the cloth glass fiber material 10 and the vacuum bag 70 (see FIG. 2).

The vacuum bag 70 in this embodiment is
I am using the one made of silicon sheet. Since the vacuum bag 70 made of a silicon sheet has excellent flexibility, the cloth-like glass fiber material 10 having the shape of the ventral outer plate portion to be manufactured can be reliably sealed.

Next, the air in the closed space formed by the vacuum bag 70 and the lower jig 20 is discharged (exhaust step S6: see FIG. 3). At this time, as shown in FIGS. 1 and 2, a plurality of exhaust holes 71 are provided in the vacuum bag 70, and an exhaust pipe 72 is connected to the exhaust holes 71. It is connected to a vacuum device such as a vacuum pump (not shown) so that the air in the closed space is discharged by vacuuming by the vacuum device.

The polyester resin introduced into the closed space in the resin impregnation step described below may enter the exhaust pipe 72 due to vacuum pressure. Such an exhaust pipe 72
If the polyester resin in the exhaust pipe 72 is left unattended, the cloth glass fiber material 10 cannot be sufficiently impregnated with the vacuum resin so that the excess resin trap 73 for removing the polyester resin in the exhaust pipe 72 is provided with an exhaust pipe. 7
It is provided in the middle of 2 (see FIG. 2).

Then, the polyester resin is introduced into the closed space by the vacuum pressure in the evacuation step to impregnate the cloth glass fiber material 10 with the polyester resin (resin impregnation step S7: see FIG. 3). At this time, as described above, the polyester resin is introduced into the cloth-like glass fiber material 10 through the resin introducing pipe 40 so that the cloth-like glass fiber 10 is uniformly and quickly impregnated with the polyester resin. You can

The polyester resin used in the present embodiment is a two-liquid mixed type which can be cured at room temperature. The temperature of the polyester resin introduced by vacuum pressure is 15 ° C.
It is set to about 35 ° C. If it is lower than this range, it takes a long time to cure, and if it is higher than this range, it may be cured during the introduction.

Next, the polyester resin impregnated in the cloth-shaped glass fiber material 10 is left to stand to be cured (resin curing step S8: see FIG. 3). This time to leave it naturally
Although it depends on the concentration of the polyester resin and the temperature environment, it can be about 3 hours at room temperature (25 ° C.). After this,
The sealing material 80 is peeled off to release the sealed state, the vacuum bag 70 is removed from the abdominal outer plate portion manufactured, and the abdominal outer plate portion is removed from the lower jig 20 to manufacture the abdominal outer plate portion. finish. The blade is manufactured by manufacturing the dorsal side skin part of the blade through the same steps as above and joining the dorsal side and ventral side skin parts.

According to the manufacturing method of the present embodiment, the blade can be easily manufactured by the so-called VARTM method. Therefore, like the conventional hand layup method, the cloth-like glass fiber material is manually attached to the polyester resin. It is not necessary to laminate while impregnating. Therefore, the quality of the product does not differ depending on the skill of the worker, and it is possible to manufacture a blade of extremely stable quality. Further, since the work time and labor cost can be reduced by omitting the manual work as described above, the manufacturing cost of the blade can be remarkably reduced.

Further, according to the manufacturing method of the present embodiment, since the polyester resin is sealed in the vacuum bag, the harmful gas generated when the polyester resin is left to stand and hardened is kept outside (workplace). It does not disperse into the interior) and does not pollute the work environment.

Further, according to the manufacturing method of the present embodiment, since a lightweight and high-strength blade having a high volume fraction of reinforcing fibers can be manufactured, the thickness of the blade is increased to reinforce it as in the conventional case. You don't have to. Therefore, the manufacturing method according to the present embodiment is extremely effective especially for manufacturing a large blade.

The girder portion of the blade is manufactured through the same steps as the manufacturing method adopted in the above-described embodiment, and the girder portion is arranged between the back side outer plate part and the ventral side outer plate part and bonded. By doing so, it is possible to construct a blade having higher strength. Further, it is possible to manufacture other main constituent parts of the wind turbine such as nacelle and spinner through similar steps.

[0035]

According to the first aspect of the present invention, since it is not necessary to manually laminate the cloth-like glass fiber material while impregnating it with the polyester resin, the quality of the product varies depending on the skill level of the worker. It is possible to produce a product of extremely stable quality without any trouble. Further, by omitting the above-mentioned manual work, it is possible to shorten the working time and the labor cost, and as a result, the manufacturing cost can be remarkably reduced.

According to the first aspect of the invention, since the polyester resin is sealed in the vacuum bag, the harmful gas generated when the polyester resin is cured (by allowing it to stand) is exposed to the outside ( It is not released into the workplace) and does not pollute the work environment.

Further, according to the invention described in claim 1, since a lightweight and high-strength product having a high reinforcing fiber volume ratio can be obtained, the method of the present invention is extremely suitable for the production of large-sized components. .

According to the invention described in claim 2, not only the effect of the invention described in claim 1 can be obtained, but also by forming a polyester resin film on the surface of the lower jig in advance, the exhaust gas can be exhausted. It is possible to reliably perform vacuuming in the process. That is, it is possible to prevent minute cracks from being generated on the surface of the lower jig and prevent the vacuum degree from lowering. Further, it is possible to manufacture a high quality product having an extremely good surface condition.

According to the invention of claim 3, not only the effect of the invention of claim 1 or 2 can be obtained, but also the cloth-like glass fiber material can be impregnated with the polyester resin uniformly and rapidly. It is possible to adjust the impregnation speed at this time to be substantially constant. As a result, a high quality product can be manufactured while shortening the manufacturing time.

According to the invention of claim 4, claim 1,
It goes without saying that the effects of the invention described in 2 or 3 are achieved,
Uses a vacuum bag prepared with a highly flexible silicone sheet, so even when manufacturing products with complicated shapes, it reliably seals the cloth-like glass fiber material (and the polyester resin impregnated into it) It is possible to manufacture high quality products. In addition, since the silicone sheet also has excellent mold releasability from the polyester resin, it can be easily released from the mold after manufacturing and can be reused in the subsequent manufacturing process, so that the manufacturing cost can be reduced.

[Brief description of drawings]

FIG. 1 is an explanatory view for explaining a manufacturing process of a blade according to the present embodiment, in which a cloth-like glass fiber material is placed in a lower jig and covered with a vacuum bag to be hermetically sealed as seen from above. It is a figure.

FIG. 2 is an explanatory view for explaining the manufacturing process of the blade according to the present embodiment, and is a side view schematically showing the vicinity of the connection portion between the resin tank of FIG. 1 and the cloth-like glass fiber material. .

FIG. 3 is a flowchart for explaining a manufacturing process of the blade according to the present embodiment.

FIG. 4 is a flowchart for explaining a hand layup method.

[Explanation of symbols]

10 Cloth-shaped glass fiber material 20 Lower jig 21 Resin coating 30 Closing member 40 resin introduction pipe 50 resin tank 60 dam 70 vacuum bag 71 Exhaust hole 72 Exhaust pipe 73 Surplus resin trap 80 sealing material 90 Release film S1 cloth material preparation process S2 jig placement process S3 mold release process S4 cloth material placement process S5 coating and sealing process S6 exhaust process S7 resin impregnation process S8 resin curing process S10 Fabric material preparation process S20 jig placement process S30 mold release process S40 layup process S50 defoaming process S60 curing process

Front page continuation (51) Int.Cl. ⁷ Identification code FI theme code (reference) B29K 105: 08 B29K 105: 08 B29L 31:34 B29L 31:34 F term (reference) 3H078 AA02 BB12 BB18 BB21 CC02 4F204 AA41 AD04 AD08 AH33 AM28 EA03 EB01 EB11 EF01 EF05 EF23 EK09

Claims (4)

[Claims] 1. A method of manufacturing a component for a wind turbine generator, comprising: a cloth material preparing step for preparing a cloth glass fiber material; a jig arranging step for arranging a lower jig; A cloth material arranging step of arranging the cloth-like glass fiber material on the surface, and a covering and sealing for covering the cloth-like glass fiber material with a vacuum bag and sealing a space formed by the vacuum bag and the lower jig. A step, an exhaust step of discharging air in a closed space formed from the vacuum bag and the lower jig, and a polyester resin is introduced into the closed space by vacuum pressure to the cloth-like glass fiber material. A method for manufacturing a component part of a wind power generation device, comprising: a resin impregnation step of impregnating the resin; and a resin curing step of curing the impregnated polyester resin. 2. A method of manufacturing a component part of a wind turbine generator according to claim 1, wherein a polyester resin is applied and cured on the surface of the lower jig to form a resin film. . 3. The cloth-like glass fiber material is provided with a resin introduction pipe around the cloth-like glass fiber material, and the polyester resin is introduced into the cloth-like glass fiber material through the resin introduction pipe. A method for manufacturing a component part of the wind power generator described. 4. The vacuum bag is made of a silicone sheet.
Alternatively, the method for manufacturing a component part of the wind turbine generator according to the item 3.