WO2023274423A1 - 模块化风电叶片及其制造方法 - Google Patents

模块化风电叶片及其制造方法 Download PDF

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Publication number
WO2023274423A1
WO2023274423A1 PCT/CN2022/114461 CN2022114461W WO2023274423A1 WO 2023274423 A1 WO2023274423 A1 WO 2023274423A1 CN 2022114461 W CN2022114461 W CN 2022114461W WO 2023274423 A1 WO2023274423 A1 WO 2023274423A1
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WO
WIPO (PCT)
Prior art keywords
wind power
blade
modular
edge
blades
Prior art date
Application number
PCT/CN2022/114461
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English (en)
French (fr)
Inventor
谈昆伦
曹磊
白高宇
刘叶霖
杜秋萍
张志成
朱玉斌
郑笑天
Original Assignee
常州市宏发纵横新材料科技股份有限公司
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Application filed by 常州市宏发纵横新材料科技股份有限公司 filed Critical 常州市宏发纵横新材料科技股份有限公司
Priority to EP22832235.0A priority Critical patent/EP4338940A1/en
Publication of WO2023274423A1 publication Critical patent/WO2023274423A1/zh
Priority to US18/225,508 priority patent/US20230364875A1/en

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    • 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
    • B29D99/0028—Producing blades or the like, e.g. blades for turbines, propellers, or wings hollow 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
    • B29C39/00—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
    • B29C39/02—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles
    • 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
    • B29C39/00—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
    • B29C39/22—Component parts, details or accessories; Auxiliary operations
    • B29C39/26—Moulds or cores
    • 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
    • B29C39/00—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
    • B29C39/22—Component parts, details or accessories; Auxiliary operations
    • B29C39/42—Casting under special conditions, e.g. vacuum
    • 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
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/14—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles in several steps
    • 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
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/36—Moulds for making articles of definite length, i.e. discrete articles
    • 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
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/56—Compression moulding under special conditions, e.g. vacuum
    • 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
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
    • B29C70/443—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding and impregnating by vacuum or injection
    • 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
    • F03D1/0677—Longitudinally segmented blades; Connectors therefor
    • 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
    • F03D1/0679—Load carrying structures, e.g. beams
    • 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
    • F03D13/00—Assembly, mounting or commissioning of wind motors; Arrangements specially adapted for transporting wind motor components
    • F03D13/30—Commissioning, e.g. inspection, testing or final adjustment before releasing for production
    • 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
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/56—Compression moulding under special conditions, e.g. vacuum
    • B29C2043/561—Compression moulding under special conditions, e.g. vacuum under vacuum conditions
    • 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
    • F05B2230/00—Manufacture
    • F05B2230/60—Assembly methods
    • 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

Definitions

  • the invention relates to the technical field of wind power generation equipment, in particular to a modular wind power blade and a manufacturing method thereof.
  • the technical problem to be solved by the present invention is to provide a modularized wind power blade and a manufacturing method thereof, which can effectively reduce the mold-occupied curing time of the wind power blade.
  • the technical solution adopted in the present invention is: modular wind power blades, including: blade root, middle part and blade tip, the middle part is composed of a plurality of modular blades, the two adjacent modular blades There are first connecting parts and second connecting parts that cooperate with each other at the edge, and the plurality of modularized blades are respectively several trailing edge shells, several leading edge shells and several main beams, and the trailing edge shells and the The first connecting portion at the edge of the front shell is fixedly connected to the second connecting portion at the edge of the main beam.
  • the main beam includes a main support beam connected to the front edge shell and a secondary support beam connected to the rear edge shell, the main support beam and the secondary support beam pass through the first connection part and the The mating and fixed connection of the second connecting part is described above.
  • main supporting beam and the auxiliary supporting beam are provided with connecting beams
  • the connecting beams are vertically provided with fixing grooves for fixing the web, and the corners of the fixing grooves and the connecting beams are arc transitions .
  • first connecting part is a boss
  • second connecting part is provided with a groove matching the first connecting part, and the boss is embedded in the groove, and the structural glue Fixed connection.
  • the main support beam is in a shovel-shaped structure close to the segmental connection end of the wind power blade, and bends along the edge of the shovel-shaped structure toward the inside of the wind power blade to extend a connecting edge, and the end of the connecting edge is connected to the Connecting beams intersect to form a closed area;
  • the closed area is in the shape of a symmetrical trapezoid, and the auxiliary support beam and the front edge housing are provided with installation parts corresponding to the trapezoid, and the edge of the installation part is provided with a bend in the connecting edge. Fixed edge for edge matching.
  • the reinforced limiting edge located between the two symmetrically bent edges on the connecting edge is arranged perpendicular to the connecting beam, and a distance is left between the reinforced limiting edge and the connecting end of the wind turbine blade.
  • the present invention also provides a method for manufacturing a modular wind power blade, which is used to manufacture the modular wind power blade, comprising the following steps:
  • Step 1 The root and tip of the middle blade of the wind power blade are formed by vacuum bag pressing, and the multiple modular blades in the middle are formed by vacuum infusion;
  • Step 2 After solidification and mold removal, another production line is used for assembly and assembly to form wind power blade blanks;
  • Step 3 Perform a post-processing process on the blank of the wind power blade to obtain the final wind power blade product.
  • Step 1 the molding process of the modularized blade includes the following steps:
  • the mold is pre-cured by heating
  • the cured modular blade is lowered to room temperature, and the demoulding of the modular blade and the mold cleaning process are completed.
  • step 2 the assembly process of the wind turbine blades includes:
  • the cut and polished modular blades are transferred to the corresponding stations on the assembly platform, and the positioning of the modules is realized through the suction cup device;
  • the cured wind power blade blanks are transferred from the post-curing furnace to the storage yard for cooling.
  • step 3 the post-treatment process includes:
  • the wind turbine blade blank After the wind turbine blade blank is cooled, it is transferred to the punching station (or blade root grinding station);
  • the treatment of the root end of the blade is carried out
  • the blades that have been treated at the root end are transferred to the painting station;
  • the beneficial effects of the present invention are: the wind power blades in the present invention are designed in a segmented modular structure, which effectively reduces the mold-occupancy time of the blades, shortens the production cycle, and improves the molding efficiency.
  • a plurality of modularized blade structures adopt modularized molding and modularized adhesive assembly, which saves transportation costs.
  • a plurality of modular blades are connected through the cooperation between the boss and the groove, and the boss is embedded in the groove so that the arc end of the boss and the arc at the bottom of the groove are closely attached, and the groove is covered on the boss On the outside, a splint structure is formed, which increases the ability to withstand shear loads and improves the ability to resist instability.
  • the thicker areas of the blade root and blade tip shell parts use the semi-impregnated low-temperature prepreg vacuum bagging method with a fiber content of 60%, which reduces the weight of the blade, and the skin area of the middle part uses the vacuum bagging method of hand-laid resin.
  • the pouring method effectively improves the molding efficiency and reduces the production cost.
  • the root of the blade is 3-5 meters in tubular structure, which is convenient for the application of the winding process, and the weight of the blade root is reduced by at least 30% by the winding process.
  • Fig. 1 is an exploded schematic diagram of a modular wind power blade in an embodiment of the present invention
  • Fig. 2 is a schematic structural view of the middle part of a wind power blade in an embodiment of the present invention
  • Fig. 3 is the structural representation of main supporting beam in the embodiment of the present invention.
  • Fig. 4 is a partial enlarged view of A in Fig. 2;
  • Fig. 5 is a flowchart of a method for manufacturing modular wind power blades in an embodiment of the present invention
  • Fig. 6 is a schematic diagram of the pouring of the modular blade in the mold in the embodiment of the present invention.
  • Fig. 7 is a schematic diagram of the positioning of the main support beam and the auxiliary support beam in the embodiment of the present invention.
  • Fig. 8 is a schematic diagram of the overall molding of each modular blade in the embodiment of the present invention.
  • the modular wind power blades shown in Figures 1 to 4 include a blade root part 1, a middle part 2 and a blade tip part 3, the middle part 2 is composed of a plurality of modular blades, and the edges of two adjacent modular blades are provided with
  • the first connecting part 4 and the second connecting part 5 cooperate with each other, and the plurality of modular blades are respectively several trailing edge shells 21, several leading edge shells 22 and several main beams 23, and the trailing edge shells 21 and the leading edge shells
  • the first connection part 4 at the edge of the body 22 is fixedly connected with the second connection part 5 at the edge of the main beam 23 .
  • the wind power blade in the present invention adopts segmented modular structure design, which effectively reduces the mold occupation time of the blade, shortens the production cycle, and improves the molding efficiency.
  • the main beam 23 includes a main support beam 231 connected to the front edge shell 22 and a secondary support beam 232 connected to the rear edge shell 21.
  • the main support beam 231 and the secondary support beam 232 pass through the first connecting part 4 It is fixedly connected with the second connecting part 5 .
  • the main support beam 231 and the auxiliary support beam 232 are provided with a connecting beam 233, and the connecting beam 233 is vertically provided with a fixing groove 2331 for fixing the web 24, and the corner of the fixing groove 2331 and the connecting beam 233 For arc transition.
  • the arc transition increases the strength of the fixing groove 2331 and ensures the stability of the connection of the web 24 .
  • the first connecting part 4 is a boss
  • the second connecting part 5 is provided with a groove matching the first connecting part 4, and the boss is embedded in the groove and fixedly connected by structural glue.
  • a plurality of modular blades are connected through the cooperation between the boss and the groove, and the boss is embedded in the groove so that the arc end of the boss and the arc at the bottom of the groove are closely fitted, and the groove is covered on the boss.
  • a splint structure is formed to increase the ability to withstand shear loads.
  • the main support beam 231 is in a shovel-shaped structure close to the segmental connection end of the wind power blade, and is bent and extended toward the inside of the wind power blade along the edge of the shovel-shaped structure to extend the connecting edge, and the end of the connecting edge is connected to the connecting beam 233 Intersect to form a closed area;
  • the enclosed area is in the shape of a symmetrical trapezoid, and the auxiliary support beam 232 and the front edge housing 22 are provided with a mounting portion corresponding to the trapezoid, and the edge of the mounting portion is provided with a fixed edge matching the bending edge 2311 in the connecting edge.
  • the end of the connecting edge intersects with the connecting beam 233 to form a closed area, which ensures the strength of the main supporting beam 231, thereby improving the overall load bearing capacity of the wind turbine blade.
  • the cavity of the trailing edge shell 21 is relatively large Wide, the combination of the two connection forms of the bent edge and the first connecting part 4 realizes the double reinforcement of the joint of the modular blade, and increases the connection between the leading edge shell 22 and the trailing edge shell 21 and the main beam 23 The stability of the front edge shell 22 and the trailing edge shell 21 are improved.
  • the width direction of the cavity of the rear edge casing 21 refers to the horizontal direction from the rear edge casing 21 to the front edge casing 22 .
  • the reinforced limiting edge 2312 located between the two symmetrically bent edges 2311 on the connecting edge is set perpendicular to the connecting beam 233, and the reinforced limiting edge 2312 has a certain distance from the connecting end of the wind turbine blade.
  • the setting of 2312 ensures the reliability of the connection of the modularized blades along the length direction.
  • the present invention also provides a method for manufacturing modular wind power blades, as shown in Figures 5 to 8, for manufacturing modular wind power blades, including the following steps:
  • Step 1 forming the middle blade root 1 and blade tip 3 of the wind power blade by vacuum bag pressing method, and forming a plurality of modular blades in the middle part 2 by vacuum infusion method;
  • Step 2 After solidification and mold removal, another production line is used for assembly and assembly to form wind power blade blanks;
  • Step 3 Perform a post-processing process on the blank of the wind power blade to obtain the final wind power blade product.
  • the cavity of the blade tip 3 is narrow and integrally formed, which ensures the controllability of the quality and improves the reliability of the performance of the wind power blade.
  • the blade root 1 has a tubular structure in the range of 3-5 meters, the blade root 1 can be formed by winding process and vacuum bag pressing method. The winding process reduces the weight of the blade root by 30% of the wind power blade, and the automatic winding improves forming efficiency.
  • 60% fiber content semi-impregnated low-temperature prepreg vacuum bagging method is used for the thicker areas of the shell part of the blade root 1 and blade tip 3, which reduces the weight of the blade, while the skin area of the middle part 2 uses hand-laid resin
  • the unique vacuum infusion method effectively improves the molding efficiency and reduces the production cost.
  • the skin structure occupying the largest blade area in the wind power blade is generally a sandwich structure composed of a small amount of glass fiber and core material, and is carried out by material prefabrication and hand lay-up resin infusion.
  • Molding comprises the following steps: cleaning the mold 9 of the modular blade, and coating a release agent on the molding surface;
  • the laminated shell structure 8 is laid in the mold 9; the laminate of the shell structure 8 is formed by pre-stitching, and the multi-layer fiber cloth is sequentially laminated by rationally setting the module size and material pretreatment technology
  • the shell structure 8 is sewn together, and the shell structure 8 is put into the mold 9 as a whole.
  • the mold 9 is heated and pre-cured
  • the cured modular blade is lowered to room temperature, and the demoulding and mold 9 cleaning procedures of the modular blade are completed.
  • the present invention adopts another production line for assembly and assembly, which improves the utilization efficiency of the mold 9 and improves the bonding efficiency.
  • the assembly process includes: removing the modular blades from the mold The flash edge of the blade is cut and cleaned, and the surface is polished;
  • the cut and polished modular blade is transferred to the corresponding station of the assembly platform, and the modular blade is grabbed by the suction cup device 10, and the interface on the modular blade is accurately positioned according to the shape of the blade and the division of the module to realize the positioning of the module;
  • the cured wind power blade blanks are transferred from the post-curing furnace to the storage yard for cooling.
  • the post-processing process includes: the wind power blade blank is cooled and then transferred to the punching station (or blade root grinding station);
  • the treatment of the root end of the blade is carried out
  • the blades that have been treated at the root end are transferred to the painting station;
  • the post-treatment process in the present invention cancels the external reinforcement station and cutting and polishing station, so that the external reinforcement treatment and cutting and polishing treatment can be completed in the assembly process , the reinforcement treatment is carried out on the assembly tool, while the cutting and grinding are carried out on the transfer tool, which reduces the number of post-processing stations and the post-processing cycle.

Abstract

本发明涉及风力发电设备技术领域，尤其涉及模块化风电叶片及其制造方法，包括：叶根部、中间部和叶尖部，所述中间部由多个模块化叶片组成，相邻两模块化叶片的边缘处设有相互配合的第一连接部和第二连接部，多个所述模块化叶片分别为后缘壳体、前缘壳体以及主梁，所述后缘壳体和所述前缘壳体边缘处的所述第一连接部与所述主梁边缘处的所述第二连接部固定连接。本发明中的风电叶片采用分段模块化结构设计，有效地减少了叶片的占模时间，缩短了生产周期，提高了成型效率。

Description

模块化风电叶片及其制造方法 技术领域
本发明涉及风力发电设备技术领域，尤其涉及模块化风电叶片及其制造方法。
背景技术
随着世界的发展，能源作为世界发展的动力，在发展中占着举足轻重的位置，发展可再生能源是世界的必然趋势。风能作为一种无污染和可再生的新能源有着巨大的发展潜力，特别是对沿海岛屿，交通不便的边远山区，地广人稀的草原牧场，以及远离电网和近期内电网还难以达到的农村、边疆，作为解决生产和生活能源的一种可靠途径，有着十分重要的意义，风电叶片在风能发电技术总起着举足轻重的作用。
在现有风电叶片的制作过程中，叶片的占模时间成为叶片成型过程中的一个巨大瓶颈，如何减少叶片的占模时间，成为叶片制作过程中的头等大事。
鉴于上述问题的存在，本发明人基于从事此类产品工程应用多年丰富的实务经验及专业知识，积极加以研究创新，以期创设模块化风电叶片及其制造方法，使其更具有实用性。
发明内容
本发明所要解决的技术问题是：提供模块化风电叶片及其制造方法，有效减少风电叶片的占模固化时间。
为了达到上述目的，本发明所采用的技术方案是：模块化风电叶片，包括：叶根部、中间部和叶尖部，所述中间部由多个模块化叶片组成，相邻两模块化叶片的边缘处设有相互配合的第一连接部和第二连接部，多个所述模块化叶片分别为若干后缘壳体、若干前缘壳体以及若干主梁，所述后缘壳体和所述前缘壳体边缘处的所述第一连接部与所述主梁边缘处的所述第二连接部固定连接。
进一步地，所述主梁包括连接所述前缘壳体的主支撑梁和连接所述后缘壳体的副支撑梁，所述主支撑梁与所述副支撑梁通过第一连接部和所述第二连接部的配合固定连接。
进一步地，所述主支撑梁和所述副支撑梁上均设有连接梁，所述连接梁上垂直设有用于固定腹板的固定槽，所述固定槽与所述连接梁的拐角为圆弧过渡。
进一步地，所述第一连接部为凸台，其所述第二连接部上设有与所述第一连接部配合的凹槽，所述凸台嵌入所述凹槽内，并通过结构胶固定连接。
进一步地，所述主支撑梁靠近风电叶片分段连接端呈铲状结构，且沿所述铲状结构的边缘处朝向风电叶片内部弯折延伸出连接边，所述连接边端部与所述连接梁相交形成封闭区 域；
所述封闭区域呈对称梯形，所述副支撑梁和所述前缘壳体上设有与所述梯形相对应的安装部，且所述安装部边缘设有与所述连接边中的折弯边匹配的固定边。
进一步地，所述连接边上位于两对称所述折弯边之间的增强限位边垂直所述连接梁设置，且所述增强限位边与风电叶片连接端留有距离。
本发明还提供了一种模块化风电叶片的制造方法，用于制造所述的模块化风电叶片，，包括如下步骤：
步骤一：将风电叶片中叶根部和叶尖部采用真空袋压法成型，中间部的多个模块化叶片采用真空灌注法成型；
步骤二：固化起模后，采用另外产线进行组装装配，形成风电叶片毛坯；
步骤三：对风电叶片毛坯进行后处理工序，得到最终风电叶片产品。
进一步地，步骤一中，所述模块化叶片的成型过程包括以下步骤：
对模块化叶片的模具进行清理，并在成型面涂覆脱模剂；
将铺层后的壳体结构铺设在模具内；
将提前制作好的一体式灌注系统及一体式硅胶真空系统铺设在壳体结构区域，打胶条并保压；
待真空区域的密封性检测完成后，进行手糊树脂的真空灌注；
完成灌注后，对模具进行加热预固化；
将固化后的模块化叶片降至室温，完成模块化叶片的脱模，及模具清理工序。
进一步地，步骤二中，所述风电叶片的装配过程包括：
将脱模后的模块化叶片的飞边进行切割清理，并完成表面打磨；
切割打磨后的模块化叶片转运至组装平台的相应工位，并通过吸盘装置实现模块的定位；
在模块化叶片的边缘粘接面涂抹结构胶，按顺序将多个模块化叶片进行粘接；
对装配后的风电叶片毛坯进行外补强处理；
开启后固化炉进行加热，完成风电叶片毛坯固化；
将固化好的风电叶片毛坯从后固化炉中转运至堆场进行降温。
进一步地，步骤三中，所述后处理工序包括：
风电叶片毛坯冷却后转运至打孔工位(或叶根打磨工位)上；
按工艺参数进行叶片根端的处理；
完成根端处理的叶片转运至油漆工位；
对风电叶片毛坯进行清理；
结束检修后对风电叶片毛坯进行修型作业，待腻子固化后进行外形检查；
对外形检查后的风电叶片毛坯进行油漆工序；
根据客户要求对风电叶片进行专项施工；
进行出厂前的专项检验，合格后转运至堆场。
本发明的有益效果为：本发明中的风电叶片采用分段模块化结构设计，有效地减少了叶片的占模时间，缩短了生产周期，提高了成型效率。
本发明中多个模块化叶片结构，采用模块化成型、模块化的粘接装配，节约了运输成本。
本发明中多个模块化叶片通过凸台与凹槽配合实现连接，其凸台嵌入凹槽使凸台的圆弧端部与凹槽底部圆弧紧密贴合，且凹槽包覆在凸台外侧，形成夹板结构，增加了承受剪切载荷的能力，提高了抗失稳能力。
本发明中叶根部和叶尖部壳体部分较厚的区域选用60％纤维含量的半含浸低温预浸料真空袋压法，降低了叶片的重量，中间部的蒙皮区域选用手糊树脂的真空灌注法，有效提高了成型效率，降低了生产成本。
本发明中叶根部为3-5米为管状结构，便于缠绕工艺的应用，缠绕工艺降低至少30％的叶根重量。
附图说明
为了更清楚地说明本发明实施例或现有技术中的技术方案，下面将对实施例或现有技术描述中所需要使用的附图作简单地介绍，显而易见地，下面描述中的附图仅仅是本发明中记载的一些实施例，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据这些附图获得其他的附图。
图1为本发明实施例中模块化风电叶片的分解示意图；
图2为本发明实施例中风电叶片中间部的结构示意图；
图3为本发明实施例中主支撑梁的结构示意图；
图4为图2的A处局部放大图；
图5为本发明实施例中制造模块化风电叶片的方法流程图；
图6为本发明实施例中模块化叶片在模具中灌注示意图；
图7为本发明实施例中主支撑梁和副支撑梁的定位示意图；
图8为本发明实施例中各模块化叶片整体成型示意图。
附图标记：1、叶根部；2、中间部；21、后缘壳体；22、前缘壳体；23、主梁；231、主支撑梁；2311、折弯边；2312、增强限位边；232、副支撑梁；233、连接梁；2331、固定槽；24、腹板；3、叶尖部；4、第一连接部；5、第二连接部；6、一体式灌注系统；7、一体式硅胶真空系统；8、壳体结构；9、模具；10、吸盘装置。
具体实施方式
下面将结合本发明实施例中的附图，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。
需要说明的是，当元件被称为“固定于”另一个元件，它可以直接在另一个元件上或者也可以存在居中的元件。当一个元件被认为是“连接”另一个元件，它可以是直接连接到另一个元件或者可能同时存在居中元件。本文所使用的术语“垂直的”、“水平的”、“左”、“右”以及类似的表述只是为了说明的目的，并不表示是唯一的实施方式。
除非另有定义，本文所使用的所有的技术和科学术语与属于本发明的技术领域的技术人员通常理解的含义相同。在本发明的说明书中所使用的术语只是为了描述具体的实施例的目的，不是旨在于限制本发明。本文所使用的术语“及/或”包括一个或多个相关的所列项目的任意的和所有的组合。
如图1至图4所示的模块化风电叶片，包括叶根部1、中间部2和叶尖部3，中间部2由多个模块化叶片组成，相邻两模块化叶片的边缘处设有相互配合的第一连接部4和第二连接部5，多个模块化叶片分别为若干后缘壳体21、若干前缘壳体22以及若干主梁23，后缘壳体21和前缘壳体22边缘处的第一连接部4与主梁23边缘处的第二连接部5固定连接。
与现有技术相比本发明中风电叶片采用分段模块化结构设计，有效地减少了叶片的占模时间，缩短了生产周期，提高了成型效率。
本发明优选实施例中，主梁23包括连接前缘壳体22的主支撑梁231和连接后缘壳体21的副支撑梁232，主支撑梁231与副支撑梁232通过第一连接部4和第二连接部5的配合固定连接。
在上述实施例基础上，主支撑梁231和副支撑梁232上均设有连接梁233，连接梁233上垂直设有用于固定腹板24的固定槽2331，固定槽2331与连接梁233的拐角为圆弧过渡。
具体地，圆弧过渡增加了固定槽2331的强度，保证了腹板24连接的稳固性。
作为上述实施例优选，第一连接部4为凸台，其第二连接部5上设有与第一连接部4配合的凹槽，凸台嵌入凹槽内，并通过结构胶固定连接。
具体地，多个模块化叶片通过凸台与凹槽配合实现连接，其凸台嵌入凹槽使凸台的圆弧端部与凹槽底部圆弧紧密贴合，且凹槽包覆在凸台外侧，形成夹板结构，增加了承受剪切载荷的能力。
本发明优选实施例中，主支撑梁231靠近风电叶片分段连接端呈铲状结构，且沿铲状结构的边缘处朝向风电叶片内部弯折延伸出连接边，连接边端部与连接梁233相交形成封闭区域；
封闭区域呈对称梯形，副支撑梁232和前缘壳体22上设有与梯形相对应的安装部，且安装部边缘设有与连接边中的折弯边2311匹配的固定边。
具体地，连接边端部与连接梁233相交形成封闭区域，保证了主支撑梁231的自身强度，从而提高了风电叶片的整体承受载荷的能力，另外，由于后缘壳体21的空腔较宽，采用弯折边与第一连接部4的两种连接形式的结合，实现了模块化叶片连接处的双重加固，增加前缘壳体22和后缘壳体21与主梁23之间连接的稳定性，提高了前缘壳体22和后缘壳体21的抗失稳能力。后缘壳体21空腔宽度方向指的是后缘壳体21至前缘壳体22的水平方向。
在上述实施例基础上，连接边上位于两对称折弯边2311之间的增强限位边2312垂直连接梁233设置，且增强限位边2312与风电叶片连接端具有一定距离，增强限位边2312的设置保证了模块化叶片在沿长度方向连接的可靠性。
本发明还提供了一种模块化风电叶片的制造方法，如图5至图8所示，用于制造模块化风电叶片，包括如下步骤：
步骤一：将风电叶片中叶根部1和叶尖部3采用真空袋压法成型，中间部2的多个模块化叶片采用真空灌注法成型；
步骤二：固化起模后，采用另外产线进行组装装配，形成风电叶片毛坯；
步骤三：对风电叶片毛坯进行后处理工序，得到最终风电叶片产品。
具体地，叶尖部3型腔狭小，采用一体成型，保证了质量的可控性，提高了风电叶片性能的可靠性。由于叶根部1在3-5米的范围为管状结构，使叶根部1应用缠绕工艺与真空袋压法实现成型，其缠绕工艺降低了风电叶片的30％的叶根重量，且自动化的缠绕提高了成型效率。叶根部1和叶尖部3壳体部分较厚的区域选用60％纤维含量的半含浸低温预浸料真空袋压法，降低了叶片的重量，而中间部2的蒙皮区域选用手糊树脂的真空灌注法，有效 提高了成型效率，降低了生产成本。
在上述实施例基础上，在步骤一中，风电叶片中占叶片面积最大的蒙皮结构通长由少量玻纤及芯材构成的三明治夹芯结构，采用材料预制和手糊树脂灌注的方法进行成型，包括以下步骤：对模块化叶片的模具9进行清理，并在成型面涂覆脱模剂；
将铺层后的壳体结构8铺设在模具9内；壳体结构8的铺层成型采用预缝合的方式，其通过合理设置模块尺寸和材料的预处理技术，将多层纤维布依次铺层并缝合成壳体结构8，将壳体结构8整体放入模具9内。
将预制的一体式灌注系统6及一体式硅胶真空系统7铺设在壳体结构8区域，打胶条并保压；灌注系统和真空系统的一体化定制，节省了铺设之间，实现快速铺设。
待真空区域的密封性检测完成后，进行手糊树脂的真空灌注；
完成壳体结构8的灌注后，对模具9进行加热预固化；
将固化后的模块化叶片降至室温，完成模块化叶片的脱模及模具9清理工序。
在上述实施例基础上，本发明在完成各模块化叶片的制造后，采用另外产线进行组装装配，提高模具9利用效率，提高了粘接效率，装配过程包括：将脱模后的模块化叶片的飞边进行切割清理，并完成表面打磨；
切割打磨后的模块化叶片转运至组装平台的相应工位，并通过吸盘装置10抓取模块化叶片，根据叶片外形及模块划分准确定位模块化叶片上的接口，实现模块的定位；
在模块化叶片的边缘粘接面涂抹结构胶，按顺序将模块化叶片进行粘接，并使用液压装置对接口进行加压，从而实现各模块化叶片间的连接；
对装配后的风电叶片毛坯进行外补强处理；
开启后固化炉进行加热，完成风电叶片毛坯固化；
将固化好的风电叶片毛坯从后固化炉中转运至堆场进行降温。
在上述实施例基础上，合理的后处理工序能够提高产线效率，步骤三中，后处理工序包括：风电叶片毛坯冷却后转运至打孔工位(或叶根打磨工位)上；
按工艺参数进行叶片根端的处理；
完成根端处理的叶片转运至油漆工位；
对风电叶片毛坯进行清理，将外蒙皮的各飞边毛刺打磨清理干净后进行NDT无损检测，完成叶片外部检修；
对完成检修后的风电叶片毛坯进行修型作业，待腻子固化后进行外形检查；
对外形检查后的风电叶片毛坯进行油漆工序，按工艺要求进行油漆作业；
根据客户要求对风电叶片进行专项施工，其专项施工包含但不限位于前缘保护、后缘降噪、涡流发生器类细节作业；进行出厂前的专项检验，合格后转运至堆场。
从工位角度来说，本发明中后处理工序与常规叶片后处理工序相比，取消了外补强工位和切割打磨工位，使其外补强处理和切割打磨处理在装配过程中完成，其补强处理在装配工装上进行，而切割打磨在转运工装上进行，减少了后处理的工位，降低了后处理周期。
本行业的技术人员应该了解，本发明不受上述实施例的限制，上述实施例和说明书中描述的只是说明本发明的原理，在不脱离本发明精神和范围的前提下，本发明还会有各种变化和改进，这些变化和改进都落入要求保护的本发明范围内。本发明要求保护范围由所附的权利要求书及其等效物界定。

Claims (10)

  1. 模块化风电叶片，包括叶根部(1)、中间部(2)和叶尖部(3)，其特征在于，所述中间部(2)由多个模块化叶片组成，相邻两所述模块化叶片的边缘处设有相互配合的第一连接部(4)和第二连接部(5)，多个所述模块化叶片分别为若干后缘壳体(21)、若干前缘壳体(22)以及若干主梁(23)，所述后缘壳体(21)和所述前缘壳体(22)边缘处的所述第一连接部(4)与所述主梁(23)边缘处的所述第二连接部(5)固定连接。
  2. 根据权利要求1所述的模块化风电叶片，其特征在于，所述主梁(23)包括连接所述前缘壳体(22)的主支撑梁(231)和连接所述后缘壳体(21)的副支撑梁(232)，所述主支撑梁(231)与所述副支撑梁(232)通过所述第一连接部(4)和所述第二连接部(5)的固定连接。
  3. 根据权利要求2所述的模块化风电叶片，其特征在于，所述主支撑梁(231)和所述副支撑梁(232)上均设有连接梁(233)，所述连接梁(233)上垂直设有用于固定腹板(24)的固定槽(2331)，所述固定槽(2331)与所述连接梁(233)的连接拐角为圆弧过渡。
  4. 根据权利要求3所述的模块化风电叶片，其特征在于，所述第一连接部(4)为凸台，其所述第二连接部(5)上设有与所述凸台配合的凹槽，所述凸台嵌入所述凹槽内，并通过结构胶固定连接。
  5. 根据权利要求3所述的模块化风电叶片，其特征在于，所述主支撑梁(231)靠近风电叶片分段连接端呈铲状结构，且沿所述铲状结构的边缘处朝向风电叶片内部弯折延伸出连接边，所述连接边端部与所述连接梁(233)相交形成封闭区域；
    所述封闭区域呈对称梯形，所述副支撑梁(232)和所述前缘壳体(22)上设有与所述梯形相对应的安装部，且所述安装部边缘设有与所述连接边中的折弯边(2311)匹配的固定边。
  6. 根据权利要求5所述的模块化风电叶片，其特征在于，所述连接边上位于两对称所述折弯边(2311)之间的增强限位边(2312)垂直所述连接梁(233)设置，且所述增强限位边(2312)与风电叶片连接端留有距离。
  7. 一种模块化风电叶片的制造方法，用于制造权利要求1至6任一项所述的模块化风电叶片，其特征在于，包括如下步骤：
    步骤一：将风电叶片中叶根部(1)和叶尖部(3)采用真空袋压法成型，中间部(2)的多个模块化叶片采用真空灌注法成型；
    步骤二：固化起模后，采用另外产线进行组装装配，形成风电叶片毛坯；
    步骤三：对风电叶片毛坯进行后处理工序，得到最终风电叶片产品。
  8. 根据权利要求7所述的模块化风电叶片的制造方法，其特征在于，步骤一中，所述模块化叶片的成型过程包括以下步骤：
    对模块化叶片的模具(9)进行清理，并在成型面涂覆脱模剂；
    将铺层后的壳体结构(8)铺设在模具(9)内；
    将预制的一体式灌注系统(6)及一体式硅胶真空系统(7)铺设在壳体结构(8)区域，打胶条并保压；
    待真空区域的密封性检测完成后，进行手糊树脂的真空灌注；
    完成灌注后，对模具(9)进行加热预固化；
    将固化后的模块化叶片降至室温，完成脱模及模具(9)清理工序。
  9. 根据权利要求8所述的模块化风电叶片的制造方法，其特征在于，步骤二中，所述风电叶片的装配过程包括：
    将脱模后的模块化叶片的飞边进行切割清理，并完成表面打磨；
    切割打磨后的模块化叶片转运至组装平台的相应工位，并通过吸盘装置(10)实现模块的定位；
    在模块化叶片的边缘粘接面涂抹结构胶，按顺序将多个模块化叶片进行粘接；
    对装配后的风电叶片毛坯进行外补强处理；
    开启后固化炉进行加热，完成风电叶片毛坯固化；
    将固化好的风电叶片毛坯从后固化炉中转运至堆场进行降温。
  10. 根据权利要求9所述的模块化风电叶片的制造方法，其特征在于，步骤三中，所述后处理工序包括：
    风电叶片毛坯冷却后转运至打孔工位(或叶根打磨工位)上；
    按工艺参数进行叶片根端的处理；
    完成根端处理的叶片转运至油漆工位；
    对风电叶片毛坯进行清理；
    结束检修后对风电叶片毛坯进行修型作业，待腻子固化后进行外形检查；
    对外形检查后的风电叶片毛坯进行油漆工序；
    根据客户要求对风电叶片进行专项施工；
    进行出厂前的专项检验，合格后转运至堆场。
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