RU2688603C1 - Blade and method of its production - Google Patents

Abstract

FIELD: machine building.SUBSTANCE: invention relates to design of blades intended for operation in multi-bladed fans of aerodynamic tube or wind generators. Blade represents a prefabricated structure in form of profiled feather to be installed at fan or wind generator sleeve flap. Power element of the profiled blade feather is a spar made in the form of a composite conical tube, the root part of which is attached to the sleeve flap of the fan or wind generator. Spar of profiled blade feather provides the required angle of attack of the profiled blade feather. Blade feather is made from polymer composite materials. Spar is made of steel and polymer composite materials. Polymer composite materials included in the blade design ensure stability of geometrical sizes and constant weight of the blade operating under conditions of wet air flow.EFFECT: blade design allows increasing service life.20 cl, 31 dwg

Description

The invention relates to the construction of large-sized blades, designed to work as part of multi-blade fans or wind turbines.

In the construction of large-sized multi-blade fans, which are used in wind tunnels or wind tunnels, the blades are installed and fastened by putting them on the corresponding max (conical shaft mounted on a rotating hub of a fan or wind generator).

As a rule, the loads from the aerodynamic forces acting on the profiled feather blade are transmitted to the max through the spar.

Known blade (RF patent No. 2407925, IPC F04D29 / 38, 11/05/2009).

According to the patent, the blade is made in the form of a hollow shell and contains the butt part, which is a round rod and designed for mounting to the hub of the fan impeller with the possibility of setting the required working angle of the blade, the feather and the transition part from the butt to its pen.

The disadvantage of this blade is the use of a round monolithic rod designed to fasten the blade to the impeller hub, which, due to the absence of a longitudinal hole, cannot be put on a hard swing and thereby relieve the feather blades from bending and centrifugal loads.

Known design of the blade containing the spar, the ribs connected to it (SU patent No. 244895, IPC VS64C 27/46, 01/15/1981).

This blade cannot be used as a fan blade, since it works as a cantilever beam and has unsatisfactory rigidity and aerodynamic characteristics, since bending and torsion stresses increase in the blade elements.

The closest technical solution is the blade, presented in the patent of the Russian Federation №2145004, IPC F04D 29/00, 16.09.1998.

According to the description of this patent, the blade feather is made of a composite material in the form of a thin-walled shell forming the wing profile of the blade, the transitional and butt parts of the blade, which is a round rod (spar) and is made with direct attachment to the hub of the fan impeller. In the inner cavity of the blade formed by a thin-walled shell, there is a reinforcing element made of composite material and consisting of at least two power profiles of variable height, the power profiles are connected to the thin-walled shell and divide the internal cavity of the blade into parts, each of which is filled with filler from the self-foaming material.

The disadvantage of this blade is the use of a round monolithic rod designed to fasten the blade to the impeller hub, which, due to the absence of a longitudinal hole, cannot be put on a hard swing and thereby relieve the feather blades from bending loads.

A known method of manufacturing a composite blade (patent 2058250, B64F 5/00, WS64C 27/46, VS64C 11/26) according to which the manufacture of composite propeller blades consists in molding a spar with a butt in the molds of the blade shells by laying layers of filler followed by impregnation with a binder, hot polymerization and finishing operations.

A known method of manufacturing a blade with an arrow-shaped end part (patent number 2043947, B64F 5/00, VS64C 27/46) consists in separately cutting the material of the regular and irregular zones, in layer-by-layer assembly with their mutual overlap and fixation into composite packages, pre-pressing them and assembly to a rubber bag with further molding in the press chamber.

The disadvantage of these methods is that they can produce small-sized blades in high-volume production conditions, and for the technological process it is necessary to have an expensive heated metal mold that allows you to create significant excess pressure in the molding process. It is technically and technologically difficult for small-scale production of large-sized blade.

Known blade wind wheel of composite materials and method of its manufacture (patent SU 1807960, 27.02.91, VS 27/46). According to the above method, the molding of the spar is performed by winding fibers on a special mandrel, and the outer shell is molded by the method of spiral winding glass tape on a mandrel obtained by foaming the foam in a closed form, the working surface of which corresponds to the inner shape of the outer shell. After winding, curing in the furnace follows, and then docking of the spar with the profiled aggregates in the mold. The final operation of obtaining the outer skin is winding a tape impregnated with a polymer binder, followed by curing of the entire material in the mold, when heated in an oven.

The disadvantage is that this method can produce small blades using a winding machine with numerical control. This is difficult for small-scale large-size products.

The disadvantages of the method include the high probability of wrinkling or entanglement of unidirectional tapes in different parts of the blade as a result of winding and, as a result, the appearance of stress concentrators and a decrease in the strength and service life of the blade.

A known method of manufacturing blades, described in patent No. 96120605, from 11/20/1998, IPC B64F 5/00; W64C 27/46; VS64C 11/26, which consists in using a special mandrel for winding a tape from a composite material with the subsequent molding of this mandrel in a metal mold in order to manufacture the blade spar.

The disadvantages of this method are: the use of a winding machine, a special mandrel, a metal mold, a device for extracting a mandrel, a device for creating excessive pressure during molding, which leads to a long preparatory stage associated with the manufacture of technological equipment of complex design, setting up winding modes, creating pressure, and exposure of the product during polymerization and the increased cost of the process of manufacturing small blades series.

A known method of manufacturing fan blades (RF patent 2576744, IPC: F04D 29/38, 03/10/2016) according to which a preform of a fiberglass material is placed into an epoxy-impregnated matrix, a preform is made from a fiberglass material and the workpiece is processed by pressure. In the process of placing the workpiece in the matrix, it is impregnated with a mixture of elastolite and isocyanate.

The disadvantage of this technical solution is the use of a mixture of elastolite and isocyanate as a binder, which hardens over a very short period of time, which can cause premature curing of the binder of large-sized blade blanks and the impossibility of laying large-sized layers of woven blanks.

In SU patent No. 1807769 dated February 10, 1997 IPC G01M 9/08; BC64C 27/46 describes a method consisting in the manufacture of a propeller blade consisting of a shell in the form of a closed loop, made of unidirectional high-modulus fibers, impregnated with a binder, a continuous spar from a unidirectional facet, located inside the shell and foam foam nasal and tail parts of a polyplate. .

The disadvantages of this method are: the use of a special device for the manufacture of foam blocks designed to fill the internal cavity, which, consequently, will increase the cost of manufacturing the blades of a small series, as well as the inability to control the geometrical characteristics of the blade in the molding process.

In US patent No. 3,967,996 of July 6, 1976, IPC V29S 17/00; В29С 27/00; BC64C 27/04 describes a method for manufacturing a blade consisting in separate cutting of the material of the spar and skins from prepreg, their layer-by-layer assembly into separate composite packages, followed by vacuum and mechanical pressing of each package on special mandrels, followed by the final pneumatic molding of the spar and skins in metal mold. At the same time, to create the molding pressure, internal rubber bags are used, which create the molding pressure in the hollow tubular structures of the spar and tail section.

The disadvantages of this method are: the use of multiple mandrels, metal molds, rubber press chambers to create pressure during molding in the spar and tail section, which ultimately leads to a long preparatory stage associated with conducting numerous operations to set up the creation process modes pressure and endurance, and as a result - to the appreciation of the process of manufacturing small blades series.

A known method of manufacturing blades described in US patent No. 5,041,182, 08/20/1991, IPC VS29C 65/02, consists in using a single mold, in the cavity of which the process linings are first installed with the process insert of the tail section used in molding the spar geometry. Then, the process platings and the process liner of the tail section are removed from the mold dies, and in their place the molded spar, the molded plating of the tail section and the profiled liner of the tail section are placed in the mold. The spar, skin and liner are applied with glue, and the whole structure is glued together in a closed mold.

The disadvantages of this method are the use of a molded spar of non-tubular shape, which is why it is impossible to install this blade on the max.

The closest to the technical nature of this invention is a method of manufacturing the blades, described in patent RU 2444716 C1, IPC: G01M 9/08 10.03.2012, consisting in the creation of casings of polymer composite material, nasal lining of the spar, tail section filler, end, end ribs, nasal influx with the subsequent gluing of all elements into a single structure.

The disadvantages of this method are the use of a monolithic spar without a longitudinal hole, which will not allow installing such a blade on the max of a multi-blade wind tunnel fan or wind generator and provide the required angle of attack.

Analysis of the known technical solutions associated with the methods of manufacturing blades from composite materials, allows us to conclude that there are no signs in them that are similar to the significant distinguishing features in the claimed method of manufacturing blades.

The technical result consists in the possibility of establishing the blade on the max sleeve of the fan or wind generator and providing the necessary angle of attack of the profiled blade feather.

The technical result is to ensure the sustainability of the geometric dimensions and the constancy of the weight of the blade operating in a humid air flow.

The technical result is to increase the service life of the blade.

The technical result is achieved by the fact that in a blade containing a spar and a profiled feather connected to the spar, the spar is made of at least two parts, the root part being made in the form of a conical tube attached to the bushing of a fan sleeve or a wind generator.

The root part of the spar is made of a metal alloy, for example, high-strength steel, and the end part is made of a polymer composite material, for example, glass-reinforced plastic.

The root part of the side member on the side with a stroke has a flange, and on the other hand, an internal ledge, while the end part is made with an external ledge, joined with the internal ledge of the root part.

The connection between the root part and the end part of the spar is made permanent with glue.

In places of contact of the root part of the spar with a stroke, a root liner is installed, and an end liner is installed on the opposite side.

A bandage consisting of at least two halves made of a polymer composite material, for example, fiberglass, covering both parts of the spar is glued to the outer surface of the root part and the end part of the spar.

On the outer side of the root part of the side member there is a circular groove and one or several rows of circular shoulders with longitudinal slots.

The blade additionally contains upper and lower power belts connected to each other and to the surface of the band using adhesive and bolted joints.

Lightweight aggregate is glued between the surfaces of the bandage, so that the bandage with the aggregate is joined to the upper and lower power belts.

The blade additionally contains spouts and tails of the ribs.

The profiled upper and lower lattice panels are attached to the upper and lower power belts.

The noses and tails of one or more ribs are box-shaped.

The blade additionally contains front and rear stringers mounted, respectively, on the nozzles and tails of the ribs.

The profiled blade feather consists of the upper plating, lower plating, front edge fairing, trailing edge fairing, upper root fairing plating, root fairing lower plating, end fairing.

The technical result is also achieved by the fact that the method of manufacturing the blade, which consists in the fact that all elements of the blade are prefabricated and then fixed between them, the spar is made of at least two parts, one of which is the root of a metal alloy and the second The end of the polymer composite material, interconnected by glue.

Each molded part of the profiled feather blade from a polymer composite material is subjected to milling processing.

Power belts are molded using preformed and machined casings and profiled lattice panels.

The band is molded using preformed casings, profiled lattice panels and power belts, laid in the appropriate tooling.

The bandage is molded sequentially in at least two parts, and after molding and curing the upper part of the bandage, longitudinal windows are made in it to pass through them a specially cut fabric impregnated with a polymeric binder for subsequent molding of the lower part of the bandage of the desired shape from this fabric and covering the composite bandage spar blades on both sides.

The filler with a small allowance is first glued to the bandage or the transition part, then the seam allowance is removed by milling.

Polymer composite elements of profiled feather are glued to the blade in the following sequence: first, the nozzles and tails of the ribs are glued to the power belts previously glued to the bandage and the side member, then the nose and tail stringers are glued to the nozzles and tails of the ribs, then glued to the stringers and further fixed with mechanical fasteners. lattice panels, through the windows of which the visual control of gluing is carried out, then gluing the skins and skirt panels to the lattice panels and stringers and.

The design of the blade and the method of manufacture is illustrated graphic materials, which depict the following:

FIG. 1 General view of the attachment of the blade on the swing of a fan or wind generator.

FIG. 2 Fastening the side member blade to the fly.

FIG. 3 The design of the blade version 1.

FIG. 4 Section of the profile in the middle part of the blade of option 1.

FIG. 5 The design of the brace and power belts of the blade variant 2.

FIG. 6 The design of the blade version 2.

FIG. 7 Section of the profile in the middle part of the blade of option 2.

FIG. 8 A set of basic tooling for the manufacture of the blade.

FIG. 9 The device of the root of the spar.

FIG. 10 The formation scheme of the end part of the spar.

FIG. 11 Scheme assembly spar.

FIG. 12 Cladding molding scheme.

FIG. 13 Diagram of the forming of profiled lattice panels.

FIG. 14 The scheme of forming power belts on the surface of profiled lattice panels.

FIG. 15 The formation of the bandage on the spar and the power belt.

FIG. 16 Installation scheme in the bandage of lightweight aggregate.

FIG. 17 Scheme of fastening of power belts on the bandage and spar.

Fig. 18 A molding scheme for one of the halves of the band on the spar and on the auxiliary technological lodgment.

FIG. 19 The formation scheme of the second half of the band on the spar.

FIG. 20 Gluing and reinforcement of bolts with spar.

FIG. 21 Diagram of the formation of transition parts.

FIG. 22 Installation diagram in the cavity of the transitional parts of lightweight aggregate.

FIG. 23 Diagram of the formation of power belts on the surface of the skins.

FIG. 24 Diagram of the molding of noses and tails of box ribs.

FIG. 25 Diagram of the formation of stringers and radomes blades.

FIG. 26 Scheme of assembly of power belts with transitional parts and a bandage of a spar blade.

FIG. 27 Scheme of assembly of a bandage with power belts of the blade.

FIG. 28 Scheme of assembling the frame of the blade without covering option 1.

FIG. 29 Diagram of the assembly of nozzles and tails of the ribs between the power belts, bandage and stringers in half-mold.

FIG. 30 Scheme of assembly of the frame of the blade without skinings for option 2.

FIG. 31 The frame of the blade assembly with skins and fairings.

The blade contains a spar and profiled pen.

The shaped feather of the blade 1 is mounted on the max 2 bushings of the fan or wind generator 3 (Fig. 1). The power element of the profiled feather blade is the spar 4.

The spar 4 has a flange 5 (Fig. 2). The flange 5 of the side member is attached to the fly 2 with the help of the power ring 6 and the required number of bolts 7, perceiving centrifugal force.

There are several variants of the design of the profiled feather blade 1. One of such variants is shown in disassembled form in FIG. 3. The spar of this profiled feather blade is made of a composite of at least two parts, while the root part 8 is made in the form of a conical tube attached to the fan sleeve of the fan or wind generator.

The root part 8 is made of a metal alloy, for example, high-strength steel. The end part 9 of the spar is made of a polymer composite material, for example, glass-reinforced plastic. The connection between the root part 8 and the end part 9 of the spar is made permanent with glue.

A bandage consisting of at least two halves, for example, the upper half 10 and lower half 11, made of a polymeric composite material, for example, fiberglass, is glued to the outer surface of the root part 8 and the end part 9 of the spar. Both halves of the bandage cover both sides of the spar.

Parts 10 and 11 of the bandage are molded areas into which, after gluing together parts of the bandage with a side member, bolted fasteners 12 are installed.

The upper transitional part 13 is glued to the upper half of the bandage 10, and the lower transitional part 14 is glued to the lower half of the bandage 11. Both transitional parts are obtained by molding from a polymeric composite material, for example, glass-carbon plastic.

The upper power belt 15 is attached to the upper transitional part 13 and at the same time to the upper half of the band 10, and the lower power belt 16 is attached to the lower transitional part 14 and simultaneously to the lower part of the bandage by means of glue and bolt connection. Power belts 15 and 16 are also interconnected by means of glue and bolt joints.

The nozzles and tails of the ribs are installed in the profiled feather blade 1, and the nozzles and tails of one or more ribs are box-shaped.

In the root of the profiled feather blade are fixed: the nose of the root box-shaped rib 17 and the tail of the root box-shaped rib 18, made of a polymer composite material, for example, fiberglass. The spout of the root box-shaped rib 17 is connected on glue and screws to the root nasal gutter 19 made of a polymer composite material, for example, fiberglass. The tail of the root box-shaped rib 18 is connected on glue and screws with a root tail chute 20 made of a polymeric composite material, for example, fiberglass.

In the end part of the profiled feather blade, there are: a spout of a terminal box-shaped rib 21 and a tail of the terminal box-shaped rib 22, made of a polymer composite material, for example, fiberglass.

In the regular (central) part of the blade, nozzles of regular box-shaped ribs 23 and tails of regular box-shaped ribs 24, made of a polymer composite material, for example, fiberglass, are installed.

The profiled blade feather additionally contains front and rear stringers mounted, respectively, on the nozzles and tails of the ribs.

On the nose of the root box-shaped rib 17, on the nose of the terminal box-shaped rib 21 and on the nozzles of regular box-shaped ribs 23, there is a front stringer 25 made of a polymeric composite material, for example glass fiber plastic, on the glue. On the tail of the root box-shaped rib 18, on the tail of the terminal box-shaped rib 22 and on the tails of regular box-shaped ribs 24, a rear stringer 26 is installed on the glue, made of a polymeric composite material, for example, glass-carbon plastic.

To the upper power belt 15, the upper surface of the nozzle of the root box-shaped rib 17, the upper surface of the tail of the root box-shaped rib 18, the upper surface of the nozzle of the terminal box-shaped rib 21, the upper surface of the tail of the terminal box-shaped rib 22, the upper surface of the nozzles of regular box-shaped ribs 23, the upper surface of the regular tail tails box-shaped ribs 24, the upper surface of the front stringer 25, the upper surface of the rear stringer 26 are glued, and then additionally fixed, for example, on self-tapping screws or screws, upper lining 27.

To the lower power belt 16, the lower surface of the spout of the root box-shaped rib 17, the lower surface of the tail of the root box-shaped rib 18, the lower surface of the spout of the terminal box-shaped rib 21, the lower surface of the tail of the terminal box-shaped rib 22, the lower surface of the nozzles of regular box-shaped ribs 23, the lower surface of the regular tail tails box-shaped ribs 24, the bottom surface of the front stringer 25, the bottom surface of the rear stringer 26 is glued, and then additionally fixed, for example, on self-tapping screws or a screw , The lower shell 28.

The upper lining 27 and the lower lining 28 are made of a polymer composite material, for example, glass-carbon plastic.

To the upper power belt 15, the upper surface of the spout of the root box-shaped rib 17, the upper surface of the tail of the root box-shaped rib 18, the upper surface of the front stringer 25, the upper surface of the rear stringer 26, the upper surface of the root nasal groove 19, the upper surface of the root tail gutter 20 are glued, and then additionally secured, for example, on self-tapping screws or screws, the upper skin of the root fairing 29, which is made of a polymer composite material, for example fiberglass.

To the lower power belt 16, the lower surface of the spout of the root box-shaped rib 17, the lower surface of the tail of the root box-shaped rib 18, the lower surface of the front stringer 25, the lower surface of the rear stringer 26, the lower surface of the root nasal gutter 19, the lower surface of the root tail gutter 20 are glued, and then additionally secured, for example, on self-tapping screws or screws, the bottom plating of the root fairing 30, which is made of a polymeric composite material, for example fiberglass.

To the upper power belt 15, the lower power belt 16, the upper and lower surfaces of the spout of the terminal box-shaped rib 21, the upper and lower tail surfaces of the terminal box-shaped rib 22, the upper and lower surfaces of the front stringer 25, the upper and lower surfaces of the rear stringer 26 are glued, and then additionally secured, for example, on self-tapping screws or screws, a box-shaped end fairing 31, which is made of a polymer composite material, for example, fiberglass.

To the front surface of the upper casing 27 and the front surface of the lower casing 28 glued fairing front edge 32, made of polymer composite material, such as fiberglass.

To the rear surface of the upper casing 27 and the rear surface of the lower casing 28 glued rear edge 33, made of polymeric composite material, such as fiberglass.

The profiled blade feather assembly consists of an upper casing 27, a lower casing 28, a front lip fairing 32, a rear edge curling 33, an upper casing of the root fairing 29, a bottom casing of the root fairing 30, an end fairing 31.

Thanks to the box-shaped design of the nozzles and tails of the ribs, as well as the structural steps on the upper casing 27, the bottom casing 28, the spouts 21 and the tails 22 of the box-shaped ribs, all elements of polymer composites are glued together so that the external smooth contour of the feather blade is obtained during assembly (Fig. 4).

Consider the second version of the design of the profiled feather blade 1.

In the second version of the profiled feather blade 1, the bandage is made by molding the upper half 34 and the lower half 35 (Fig. 5) so that these halves in the assembled condition embrace the spar on both sides. At the edges of the upper half 34 and lower half 35, platforms for gluing with the upper power belt 36 and the lower power belt 37 are formed. The glue connection of the power belts with parts of the bandage is additionally reinforced with bolts 38 and 39.

Tails of flat ribs 40 and nozzles of flat ribs 41 made of sheet materials, for example, foam plastic or honeycomb, are glued to the halves of the bandage and power belts (Fig. 6). The front stringer 25 is glued to the nozzles of the flat ribs 41, and the rear stringer 26 is glued to the tails of the flat ribs 40.

To the upper surface of the front stringer 25, the upper surface of the rear stringer 26, to the upper sides of the nozzles of flat ribs 41, to the upper power belt 36 is glued the upper profiled lattice panel 42, made by molding from a polymer composite material, for example, fiberglass.

To the lower surface of the front stringer 25, to the lower surface of the rear stringer 26, to the underside of the nozzles of flat ribs 41, to the lower power belt 37 is glued the lower profiled lattice panel 43, made by molding from a polymer composite material, for example, fiberglass.

An upper skin 27 and an upper skin of the root fairing 29 are glued to the upper profiled lattice panel 42. A lower skin 28 and a lower skin of the root fairing 30 are glued to the lower profiled lattice panel 43. An end fairing 31 is glued to the upper profiled lattice panel 42 and the lower profiled lattice panel 43 .

To the upper casing 27, to the lower casing 28, the front edge guard 32 and the rear edge guard 33 are glued. After gluing all the blade parts, an external smooth contour of the feather blade is obtained (Fig. 7).

To implement the method of manufacturing the blade (Fig. 8), consisting of a profiled pen 1 and a tubular spar 4, use a set of basic tooling, including:

- steel mandrel 44 - for the manufacture of the spar;

- the upper half of the mold 45 and the lower half of the mold 46 of polymer composite material, for example, fiberglass - for the manufacture of: casings, transitional parts, profiled lattice panels, power belts, bandage;

- the form 47 of a polymer composite material, for example, fiberglass - for the manufacture of the front stringer;

- the form 48 of a polymer composite material, for example, fiberglass - for the manufacture of the rear stringer;

- the form 49 of a polymer composite material, for example, fiberglass - for the manufacture of the leading edge radome;

- the form 50 of a polymer composite material, for example, fiberglass - for the manufacture of the trailing edge trailing,

- form 51 of a polymer composite material, for example, fiberglass - for the manufacture of the skins of the root fairing,

- the form 52 of a polymer composite material, for example, fiberglass-form for the manufacture of the end fairing,

- a set of forms 53 of a polymer composite material for the manufacture of box-shaped rib nozzles,

- a set of forms 54 of polymer composite material for the manufacture of tails of box-shaped ribs.

The method is as follows. Pre-made all the elements of the blade, followed by fastening them together.

The spar 4 is made of at least two parts, the metal (steel) root part 8 by turning and milling and the end part 9 of a polymer composite material, such as fiberglass, which is first molded, on a steel mandrel 44, and then grind on a lathe. Then both parts are interconnected with glue.

In the root part 8 of the side member on the side of the connection with the stroke 2 they grind the flange 5, and under the flange 5 they bore the inner seat under the root insert 55 (Fig. 9 view A), which is installed at the points of contact of the root part 8 with the side member 4. On the opposite side the root part 8 of the spar is boring an internal seat, where the end insert 56 is installed (Fig. 9 view B).

On the outer side of the root part 8 of the spar, a circular groove 57 and a flange 58 are pierced through (FIG. 9 view B). On the inner side of the root portion, a ledge 59 is machined. On the outer side of the root portion of the spar, one or several rows of circular shoulders 60 are also pierced, in which longitudinal slots 61 are made (Fig. 9, section B-B).

Thanks to the shoulder 58 and the circular shoulder 60, the circular groove 57 and the longitudinal slots 61 provide a fixed connection of the spar with parts of the bandage of the profiled feather blade.

The end part 9 is made of a polymer composite material, for example, fiberglass by winding the required number of layers of fabric, for example glass or glassy carbon, impregnated with a binder on a steel mandrel 44 (Fig. 10). A fabric impregnated with a liquid, for example, epoxy binder, is wound in a wet form on a steel mandrel 44, then is wrapped on top first with a collage 62 and then with an elastic, for example, rubber tape 63, to create external pressure (Fig. 10 sec A-A). In this condition, the end portion 9 is cured.

After curing the end part 9, the elastic band 63 and the tackle 62 are removed from it. The end part 9 located on the steel mandrel 44 is turned on a lathe on the outer surface to an appropriate geometrical shape and formation of an external protrusion 64, which allows to ensure a one-piece mating with the steel root part 8 .

The machined end part 9 is removed from the steel mandrel 44 and subjected to control for compliance with geometric dimensions and weight, as well as for the absence of internal defects. After the control operations, the root part 8 and the end part 9 are glued together on a steel mandrel 44 (Fig. 11) to ensure a permanent connection.

Technological inserts 65, 66, 67, 68, which were previously made, for example, of fiberglass, are installed in the upper mold half 45 to form the upper casing 27 with steps along the leading and trailing edges, as well as with steps in the butt and end parts (FIG. 12). In the bottom mold 46, technological inserts 69, 70, 71, 72 are installed, which are made, for example, of fiberglass, in order to form the bottom casing 28 with steps along the front and rear edges, as well as with steps in the butt and tail parts.

The skins 27 and 28 are made of a polymer composite material, for example, glass-reinforced plastic by cutting the required number of layers of the appropriate fabric and styling. In the root zone of the profiled feather blade, more layers are laid than in the end zone, thereby increasing the strength in the root portion of the blade.

Each molded part of the profiled feather blade from a polymer composite material is subjected to milling processing.

The molded skins 27 and 28, after the final polymerization of the binder, are milled to the required geometrical dimensions on the equipment with numerical program control and subjected to a weight control and monitoring cycle for the absence of internal defects.

After passing the cycle of control operations, the casing 27 and 28 are re-placed into the corresponding molds 45 and 46, to form on their surface profiled lattice panels 42 and 43 (Fig. 13).

The profiled lattice panels 42 and 43 are made of a polymer composite material, for example glass fiber plastic, by cutting and laying the required number of layers of fabric impregnated with, for example, epoxy binder fabric. Molded profiled lattice panels 42 and 43 after the final polymerization of the binder is separated from the skins 27 and 28, removed from the half-form 45 and 46 and processed mechanically on the equipment with numerical control in the required geometrical dimensions, and then subjected to a cycle of weight control and control for the absence of internal defects .

After passing the cycle of control operations, the profiled lattice panels 42 and 43 are repositioned into the corresponding half-molds 45 and 46 on the casing 27 and 28, to form power belts 36 and 37 on their surface (Fig. 14).

Power belts are molded using preformed and machined casings and profiled lattice panels. The power belts 36 and 37 are made of a polymer composite material, for example, glass-reinforced plastic by cutting and stacking the required number of layers of a fabric impregnated with, for example, epoxy binder. Due to the additional location of the required number of layers, for example, in the root zone, a local increase in strength is achieved in this part of the power belts. Molded power belts 36 and 37 after the final polymerization of the binder is separated from the profiled lattice panels 42 and 43 and casings, removed from the half-form 45 and 46 and processed on the equipment with numerical program control in the required geometrical dimensions, and then they are subjected to weight control and control for the absence internal defects.

After passing the cycle of control operations, the power belts 36 and 37 are re-placed into the corresponding molds 45 and 46 on the corresponding profiled lattice panels 42 and 43, which in turn are pre-laid onto the shells 27 and 28. After this, the steel mandrel 44 is laid into the mold 45, on which is placed the blade spar consisting of a steel root part 8 and an end part 9 assembled with a power ring 6 (Fig. 15).

The band is molded using preformed casings, profiled lattice panels and power belts, laid in the appropriate tooling.

The bandage is molded sequentially in at least two parts, and after molding and curing the upper part of the bandage, longitudinal windows are made in it to pass through them a specially cut fabric impregnated with a polymeric binder for subsequent molding of the lower part of the bandage of the desired shape from this fabric and covering the composite bandage spar blades on both sides.

In advance of the mold half 45, under the steel root part 8 and the end part 9 on the power belt 36 a process insert 73 is installed (Fig. 15 a). Thanks to this liner, the upper part of the band 35 is molded from a polymer composite material, for example, fiberglass, and at the same time it is glued to the steel root part 8 and the end part 9 of the spar. The upper part of the band 35 is made of a polymer composite material, for example, fiberglass by cutting and laying the required number of layers impregnated with, for example, epoxy binder, fabric.

The molded upper part of the band 35 after the final polymerization and gluing to the steel root part 8 and the end part 9 of the spar is separated from the process liner 73. Then, in the walls of the upper part of the band 35, the longitudinal openings (holes) 74 are formed, for example, by milling The treated upper part of the band 35 passes the cycle of weight control and monitoring for the absence of internal defects.

Then, a steel mandrel 44 with a fixed steel root part 8 and an end part 9 of the side member is mounted into the mold 46, to which the upper part of the band 35 is already glued. Previously, the lower shell 28, the lower grid panel 43 and the lower power belt 37 are laid in the half-mold 46. Between the lower the power belt and the outer surface of the upper part of the band 35 establish a process liner 75. Thanks to this liner, the lower part of the band 34 is molded from a polymeric composite material, for example, fiberglass. The lower part of the bandage 34, as well as the upper part of the bandage 35, is made of a polymer composite material, for example, fiberglass, by cutting and laying the necessary amount of impregnated, for example, epoxy binder, fabric.

The lower part of the band 34 is glued to the steel root part 8 and the end part 9 of the spar (Fig. 15 b). For gluing the lower part of the bandage 34 to the upper part of the bandage 35, longitudinal windows (holes) 74 are used (Fig. 15c). Through the longitudinal window (hole) 74 pave the sheets of fabric impregnated with a polymeric binder. After curing the polymer binder the lower part of the bandage 34 remove the technological insert 75.

Thus, a bandage is obtained, consisting of the upper part 35 and the lower part 34, which covers the composite spar on both sides, thereby providing this assembly structure with the necessary strength after curing. In the fully molded bandage, longitudinal legs are formed from the upper and lower sides, which exactly follow the contact surface of the power belts 36 and 37.

The filler with a small allowance is first glued to the bandage or the transition part, then the seam allowance is removed by milling. Between the surfaces of the bandage - the longitudinal legs of the upper part of the bandage 35 form a surface where the lightweight filler 76 is glued. In the same way, between the surfaces of the bandage-longitudinal legs of the lower part of the bandage form a surface onto which the lightweight aggregate 77 is glued (Fig. 16). Light aggregates 76 and 77 are made, for example, of foam with a small allowance to ensure, after machining, that they fit perfectly not only to the parts of the bandage, but also to the upper 36 and lower 37 power belts.

The upper power belt 36 and the lower power belt 37 are glued to the parts 35 and 34 of the bandage, with lightweight aggregates 76 and 77 (Fig. 17). To increase the reliability of gluing, power belts 36 and 37 between themselves and with parts 35 and 34 of the bandage are fastened with the help of mechanical fasteners 38 and 41.

The bandage for this profiled feather blades are made in another way.

To this end, an auxiliary technological cradle 79 is mounted on a flat surface 78 (Fig. 18). A spar is laid on these cradles, which is pre-glued from a steel root part 8 and an end part 9. A force ring 6 is put on the spar. The spar is coated with several layers of a polymer composite material consisting of, for example, a glass fabric impregnated with, for example, an epoxy binder fabric. The polymer composite material is cured and forms the upper half of the 10 bandage on the surface of the spar.

Then the spar with the upper half 10 of the bandage is separated from the surface of the auxiliary technological lodgement 79 and transferred to the auxiliary technological lodgement 80 (Fig. 19).

The spar with the upper half of the bandage 10 is coated with several layers of a polymer composite material consisting of a glass fabric impregnated with, for example, an epoxy binder. The polymer composite material is cured and forms the lower half of the 11th bandage on the surface of the spar. For greater strength and reliability, the upper half 10 and the lower half 11 of the bandage are fastened with a mechanical connection, for example, bolted 12 (Fig. 20). After fastening the halves 10 and 11 of the bandage, mechanical processing of the outer sides of B and C is carried out on a machine with numerical program control in order to prepare the outer surface of the bandage for gluing with other parts.

Auxiliary forms 81 and 82 are used to form the upper transition part 13 and the lower transition part 14 (Fig. 21). Several layers of a polymer composite material consisting of a fabric, for example glass, impregnated with, for example, an epoxy binder, are placed in these auxiliary forms.

The polymer composite material is cured and forms the upper transition part 13 and the lower transition part 14. Thereafter, a lightweight aggregate 83 is glued into the free cavity of the upper transitional part 13, and a lightweight aggregate 84 is pasted into the free cavity of the upper transition part 14. from polyfoam or sotoplast with a small allowance. After gluing of lightweight aggregates, the surface “A” is machined to allow for the upper transition part 13 and the surface “B” for the lower transition part 14 (Fig. 22).

To form the upper power belt 15, the upper half-form 45 is used, in which the casing 27 is pre-laid.

The upper power belt 15 and the lower power belt 16 are made of a polymer composite material, for example, glass-carbon plastic by cutting and stacking fabrics, for example, glass, impregnated with, for example, epoxy binder. An additional number of layers are laid in the root zone for a local increase in strength in this part. Molded upper power belt 15 and lower power belt

16 after polymerization, the binder is separated from the skins 27 and 28, extracted from the half-molds 45 and 46. Then they are processed on the equipment with numerical program control to the required geometrical dimensions, and then subjected to a cycle of weight control and control for the absence of internal defects.

The nozzles of the regular box-shaped ribs 23 and the tails of the regular box-shaped ribs 24 are made from a polymer composite material, for example, by molding plastic with a set of forms 53 and 54 (Fig. 24).

In such sets of forms, a spout of a root box-shaped rib 17 and a tail of a root box-shaped rib 18, a root nasal chute 19, a root tail chute 20, a spout of a terminal box-shaped rib 21, a tail of a terminal box-shaped rib 22 are made. In similar sets of forms they form spouts of flat ribs 39, tails flat ribs 40, blanks of which are made from sheet materials, for example, foam plastic or honeycomb, followed by pasting them along the contour, in several layers, for example, glass fabric impregnated with, for example, epoxy nym binder.

The front stringer 25 is made by molding from a polymer composite material, for example, glass-carbon plastic using form 47 (Fig. 25). The rear stringer 26 is made by molding from a polymer composite material, for example, glass-carbon plastic using form 48.

Fairing the front edge 32 is made by molding from a polymer composite material, for example, glass-carbon plastic using form 49. The fairing of the trailing edge 33 is made by molding from a polymer composite material, for example, glass carbon plastic using form 50.

The upper casing of the root fairing 29 and the bottom casing of the root fairing 30 are made by molding from a polymer composite material, for example, fiberglass using form 51. A box-shaped end fairing 31 is made by molding from a polymer composite material, for example, fiberglass using form 52 (Figure 25).

Each of the molded stringers and fairings passes a cycle of mechanical processing on equipment with numerical program control to obtain the required geometrical dimensions, weight control and control procedures for the absence of internal defects.

The assembly of any of the variants of the profiled feather blade begins with the assembly of the spar. For example, if the upper half of the bandage 10 is glued to the spar, then the upper transitional part 13 with aggregate 83 is glued to it (Fig. 26 sec. A-A). Accordingly, when the lower half of the bandage 11 is glued to the upper half of the bandage 10, the lower transitional part 14 with aggregate 84 is glued to it. The aggregate 83 or 84 with a small allowance is first glued to the bandage or transitional part, then the aggregate allowance is removed by milling.

The upper power belt 15 is glued to the upper transitional part 13, and the lower power belt 16 is glued to the lower transitional part 14. Between them, the upper and lower power belts are glued and additionally fixed, for example, with bolts 12 and 85 (Fig. 26 view B).

In the event that the upper part of the band 35 with the filler 76 is glued to the spar, then the upper power belt 36 is glued to it. Accordingly, if the lower part of the band 34 with the filler 77 is glued to the spar, then the lower power belt 37 is glued to it. the upper and lower power belts are glued together and additionally fixed, for example, with bolts 38 and 39 (Fig. 27).

Fully glued spar passes the procedure of checking the geometric dimensions, the procedure of weight control and control for the absence of internal defects.

Polymer composite elements of profiled feather are glued to the blade in the following sequence: first, the nozzles and tails of the ribs are glued to the power belts previously glued to the bandage and the side member, then the front and rear stringers are glued to the nozzles and tails of the ribs, then glued to the stringers and additionally fixed with mechanical fasteners. trellised panels, through the windows of which they carry out a visual inspection of gluing, then glue and fairings are glued to the trellised panels and stringers.

The spar with the upper power belt 15 and the lower power belt 16 glue the nozzles of regular box-shaped ribs 23, the tails of regular box-shaped ribs 24, the nose of the root box-shaped rib 17, the tail of the root box-shaped rib 18, the root nasal groove 19, the root tail groove 20, the nose of the box end ribs 21, tail box-shaped rib ribs 22 (Fig. 28). After that, they glue the front stringer 25 and the rear stringer 26. To control the gluing of such a set of profile elements, use the top half of the form 45, in which the top casing 27 is installed on the technological inserts 66 and 67.

When the spar is glued to the upper power belt 36 and the lower power belt 37 (Fig. 29a), then tails of flat ribs 40 and tips of flat ribs 41 are glued to them. Then the front stringer 25 is glued to the tips of flat ribs 41, and to tails of flat ribs 40 glue back stringer 26.

The blades are assembled in the upper mold half 45, in which technological liners 66 and 67 are retained in their places. A molded upper casing 27 is laid on them. The upper profiled lattice panel 42 is laid on the casing 27.

The upper power belt 36, the upper edges of the nozzles of flat ribs 39, the upper edges of the tails of the flat ribs 40, the upper side of the stringer of the leading edge 25, the upper side of the stringer of the trailing edge 26 are glued to the upper profiled lattice panel 42.

After curing of the glue, operations are performed to control the gluing of this structure. After that, glue is applied to the lower power belt 37, the lower edges of the tails of the flat ribs 40, the lower edges of the nozzles of the flat ribs 41, the lower side of the front stringer 25, the lower side of the rear stringer 26. The lower profiled grating panel 43 is glued to this glue (Fig. 29 b ). Through the holes in the lower profiled lattice panel 43, visual inspection of the gluing of the entire structure is carried out (Fig. 30).

In a similar way, the glued part of the structure of the profiled feather blade is checked for the achievement of the required geometrical dimensions, weight and for the absence of internal defects.

The final assembly of the profiled feather blade is carried out in half-shapes 45 and 46, from which all technological inserts are extracted (Fig. 31). The glued parts of the structure of the profiled feather blade glue: the upper casing 27, the lower casing 28. Then glue the casing: the front edge trimmer 32 and the back edge 33 trimming, the upper root cover plating 29, the lower cover of the root fairing 30, the end fairing 31. the profiled feather blades of the place of docking of the fairings with casings are additionally reinforced with screws.

A fully assembled blade is pasted over with several layers of glass cloth impregnated with, for example, epoxy glue, and then plastered and painted.

The presented various designs and the method of manufacturing the blades make it possible to ensure the production of the required number of blades of stable size and weight to changes in the humidity of the air flow. Blades, inside of which is placed a tubular spar, thanks to which the blades can be installed and securely fastened to the corresponding max fan or wind generator. In this case, the blades are able to rotate at the desired angle relative to the axis of the mach for wind tunnel fans or wind turbines.

The proposed method is made mock blades, in which the elements of the frame of the blade blades are made of polymer composite materials. Due to the absence of holes for rivets in the design of the side member and the use of a combined adhesive and screw connection, the blades turned out to have an increased service life.

Claims (20)

1. A blade containing a spar and a profiled feather connected to it, comprising an upper and lower casing, characterized in that the spar is made of at least a root and an end parts, the root part being made in the form of a conical tube attached to the vents of a fan sleeve or wind turbine, and the profiled feather contains the fairing of the front and rear edges, the root fairing with the upper and lower skins, the end fairing, the upper and lower power belts. 2. The blade according to claim. 1, characterized in that the root part of the spar is made of a metal alloy, for example, high-strength steel, and the end part is made of a polymer composite material, for example glass-carbon plastic. 3. The blade under item 1, characterized in that the root part of the spar on the side of the connection with the stroke has a flange, and on the other hand - the inner ledge, while the end part is made with an outer ledge, joined with the internal ledge of the root part. 4. The blade under item 1, characterized in that the connection between the root part and the end part of the spar is made permanent with glue. 5. The blade according to claim. 1, characterized in that at the points of contact of the root part of the spar with a stroke, a root insert is installed, and an end insert is installed on the opposite side. 6. A blade according to claim 1, characterized in that a bandage consisting of at least two halves made of a polymer composite material, for example fiberglass, covering both sides of the spar is glued to the outer surface of the root part and the end part of the spar. 7. A blade according to claim. 1, characterized in that on the outer side of the root of the spar there is a circular groove and one or several rows of circular shoulders, on which there are longitudinal slots. 8. The blade according to claim. 6, characterized in that the upper and lower power belts are interconnected with each other and with the surface of the bandage by means of glue and bolt joint. 9. The blade according to claim. 8, characterized in that a lightweight aggregate is glued between the surfaces of the bandage in such a way that the bandage with the aggregate is joined with the power upper and lower belts. 10. The blade on p. 1, characterized in that it further contains nozzles and tails of the ribs. 11. A blade according to claim. 8, characterized in that profiled upper and lower lattice panels are attached to the upper and lower power belts. 12. The blade on p. 10, characterized in that the nozzles and tails of one or more ribs are box-shaped. 13. The blade on p. 10, characterized in that it further contains front and rear stringers, installed, respectively, on the nozzles and tails of the ribs. 14. A method of manufacturing the blade, which consists in the fact that all elements of the blade are prefabricated and then fixed between them, characterized in that the spar is made of at least two parts, one of which is the root of a metal alloy, and the second is the end of a polymer composite material, interconnected by glue. 15. The method according to p. 14, characterized in that each molded part of the profiled feather blades of polymer composite material is subjected to milling. 16. The method according to p. 15, characterized in that the power belt is formed using preformed and machined casings and profiled lattice panels. 17. The method according to p. 15, characterized in that the molded bandage with preformed casings, profiled lattice panels and power belts, stacked in the appropriate tooling. 18. The method according to p. 17, characterized in that the bandage is molded sequentially in at least two parts, and after molding and curing the upper part of the bandage, longitudinal windows are made in it to pass through them a specially cut fabric impregnated with a polymeric binder for subsequent molding from this the fabric of the lower part of the bandage of the desired shape and the banding of the composite spar of the blade on both sides. 19. The method according to p. 18, characterized in that the aggregate with a small allowance is first glued to the bandage or the transition part, then the allowance from the aggregate is removed by milling. 20. The method according to p. 14, characterized in that they glue the polymer composite elements of the profiled feather blade in the following sequence: first glue the nozzles and tails of the ribs to the power belts, pre-glued to the bandage and the spar, then to the spouts and tails of the ribs glue the nose and tail Stringers, then glued to the stringers and additionally fix the profiled lattice panels with mechanical fasteners, through the windows of which they carry out a visual inspection of gluing, then to the lattice panels and strins Heram sticking sheathing and fairings.

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