Wind power blade web hand lay-up auxiliary flange positioning tool

Abstract

A wind power blade web hand lay-up auxiliary flange positioning tool comprises an L-shaped main body structure formed by welding a side arm, a bonding base and a supporting plate. The side arm is a metal tubular component, the top of the supporting plate (3) is provided with a pre-bent arc-shaped structure, the bonding base is fixed to the inner skin of the blade through a bonding agent, and an operable gap with the width larger than or equal to 70 mm and the height larger than or equal to 140 mm is formed between the supporting plate and the outer surface of the web. The gap allows the scraper blade to go deep into a finishing glue layer and guarantees continuous glass fabric laying operation of the auxiliary flange. Through the operable gap design, the glass fiber fault defect caused by a traditional D-shaped positioning block is thoroughly eliminated, and the interlayer bubble rate is reduced by 83%; and in cooperation with an AB glue rapid bonding system (the curing time is less than or equal to 10 minutes), the working time of a single blade is saved by more than or equal to 200 minutes, the repair cost is reduced by 62%, and the percent of pass is increased to 95% or above. The tool is compatible with the combined application of the D-shaped positioning block, the application range is expanded by 40%, and the chordwise positioning precision is controlled within + / -1.5 mm.

Description

Technical Field

[0001] The present invention relates to the technical field of wind power generation equipment manufacturing, and in particular to a positioning device for assisting flange forming in the web bonding process of a wind turbine blade, which is particularly suitable for solving problems such as glass fiber faults and secondary repairs caused by traditional D-type positioning blocks. Background Art

[0002] In the current wind turbine blade web bonding process, D-shaped positioning blocks are commonly used to achieve chord-wise positioning of the web. The positioning block needs to form hard contact with the main bonding flange, the edge of the auxiliary bonding side flange, or the trailing edge of the web, and remain fixed before the bonding cures. The existing technology has the following significant defects: First, the glue collection operation cannot be performed in the blocking area of ​​the D-shaped positioning block, resulting in a step-like protrusion in the glue layer at the contact surface between the positioning block and the web flange, requiring a second glue collection after the positioning block is removed; second, when hand-laying the auxiliary flange, the glass fiber cloth layer must be disconnected in the positioning block area, and the disconnected area must be repaired after the web is cured, which seriously affects the continuity of the glass fiber and the operation efficiency.

[0003] To address these issues, application publication number CN207630561U proposed a rounded corner positioning block, but this solution still has technical limitations: First, the scraper blade cannot penetrate the contact surface between the positioning block and the flange to achieve adhesive transition treatment, requiring adhesive rework after removing the positioning block. Second, this solution does not address the process defect that requires the hand lay-up auxiliary flange to be disconnected in the positioning block area. Existing technology results in an additional post-processing time of 200 minutes or more required for the production of a single blade, and the rework process results in additional consumption of materials such as adhesives and fiberglass cloth, significantly increasing production costs.

[0004] More seriously, the glue layer step formed after the positioning block is removed in the traditional process can cause stress concentration, posing a potential threat to the reliability of the blade structure. The industry urgently needs a new positioning tool that can achieve precise chord-wise positioning while meeting the process requirements of the glue collection process and the continuous forming of the hand lay-up auxiliary flange, fundamentally improving blade manufacturing quality and production efficiency. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to provide a wind turbine blade web hand lay-up auxiliary flange positioning tool with a simple structure, low cost and easy operation.

[0006] In order to solve the above technical problems, this application provides the following technical solutions:

[0007] The present invention provides a wind turbine blade web hand lay-up auxiliary flange positioning tool, which comprises:

[0008] The L-shaped main structure is formed by welding the side arm (1), the bonding base (2) and the support plate (3) into one body;

[0009] The side arm (1) is a metal tubular component;

[0010] The top of the support plate (3) is provided with a pre-bent arc structure;

[0011] The bonding base (2) is a polygonal plate structure and is fixed to the inner skin (5) of the blade by means of an adhesive;

[0012] An operable gap is formed between the support plate (3) and the outer surface of the web (6), and the width of the operable gap is ≥70 mm and the height is ≥140 mm.

[0013] Preferably, the metal tubular member is a stainless steel round tube with a diameter of 25 to 35 mm; the curvature radius R of the pre-bent arc structure is ≥ 15 mm; and the polygonal plate structure is a square with a side length of 45 to 55 mm.

[0014] in addition:

[0015] The width X of the bonding base (2) from the web (6) satisfies: X=W+Δw, wherein W is the maximum width of the auxiliary flange (8) on the inner skin (5), and Δw≥10mm;

[0016] The height Y of the support plate (3) from the inner skin (5) satisfies: Y=H+Δh, where H is the maximum height of the web hand lay-up auxiliary flange (8), and Δh=10-30 mm;

[0017] The width X and height Y are set so that the operable gap formed between the support plate (3) and the outer surface of the web (6) satisfies a width of ≥70 mm and a height of ≥140 mm.

[0018] In addition, the contact surface between the support plate (3) and the web (6) is provided with anti-slip grooves, the groove depth is 0.5 to 1 mm, and the groove spacing is 3 to 5 mm;

[0019] The contact surface of the support plate (3) is further provided with an elastic buffer layer, which is made of silicone rubber material with a thickness of 1 to 3 mm and a Shore hardness of 40 to 50 HA (measured according to ISO 7619-1:2010). At the same time, preferably, the side arm (1) and the bonding base (2) are welded by V-groove welding with a weld height of 3 to 4 mm, and the non-destructive testing meets the requirements of NB / T47013.2-2015 Level II.

[0020] The four corners of the bonding base (2) are provided with chamfers, with a chamfer radius of R3-R5mm, a mounting surface flatness ≤0.05mm, and a surface roughness Ra ≤1.6μm. Preferably, the back of the support plate (3) is provided with reinforcing ribs, with a rib height of 4 to 6mm, a spacing of 15 to 25mm, and a material yield strength ≥250MPa. The surface of the positioning fixture can be passivated, with a passivation film thickness ≥10μm and a salt spray resistance test ≥500 hours. The contact surface of the support plate (3) is provided with an elastic buffer layer with a thickness of 1 to 3mm and a Shore hardness of 40-50HA.

[0021] The present invention provides a wind turbine blade web hand lay-up auxiliary flange positioning tool, wherein the positioning tool is equipped with a positioning fixture with an accuracy of ±0.1mm and comprises a laser alignment device and a magnetic table base.

[0022] Compared with the prior art, the wind turbine blade web hand lay-up auxiliary flange positioning tool of the present invention has at least the following beneficial effects:

[0023] (1) Structural innovation: The continuous operating space (height Y ≥ 60 mm, width X ≥ 70 mm) formed by the L-shaped positioning fixture and the web enables continuous fiberglass cloth laying for the hand lay-up auxiliary flange, reducing the fiberglass cloth breakage rate by 100% and increasing the shear strength of the web auxiliary bonding side flange by 15% to 20%;

[0024] (2) Process compatibility: The pre-bent arc structure design with R ≥ 20mm on the top of the support plate (3) allows the scraper to penetrate 3 to 5mm into the gap between the tooling and the web to trim the glue layer. The surface roughness Ra value of the glue layer is reduced from 12.5μm in the original process to 3.2μm, effectively eliminating stress concentration points;

[0025] (3) Significant economic benefits: When the positioning fixture is used in combination with the D-type positioning block, the adhesive consumption of a single blade is reduced by 2.3 to 2.8 kg, the post-processing time is saved by ≥ 200 minutes, and the comprehensive cost is reduced by 500-800 yuan per blade. Based on an annual production of 1,000 blades, it can generate direct economic benefits of 500,000 to 800,000 yuan;

[0026] (4) Improved quality stability: The stainless steel positioning fixture (elastic modulus ≥ 200 GPa) has a deformation of less than 0.2 mm in an 80°C curing environment, which is 5 times more stable than the traditional fiberglass positioning block, allowing the web chord-wise positioning accuracy to be controlled within the range of ±1.5 mm.

[0027] (5) Improved surface quality: The bonding base (2) is fixed with non-residual AB glue (peel strength ≥ 4N / mm), which reduces the number of skin surface repair points per tooling by 12 to 16 compared with the traditional bolt connection method, and improves the surface roughness compliance rate of the blade cavity to 98.5%;

[0028] (5) The interlayer bubble rate is reduced by 88%;

[0029] (7) Eliminate process breakpoints:

[0030] After the D-block is removed, the tooling immediately provides physical support to prevent the web from shifting (measured offset ≤ 0.3 mm);

[0031] By using the preset operable gap, adhesive layer repair and glass fiber continuous layering can be completed simultaneously without waiting for the tooling to be removed

[0032] This invention leverages an L-shaped spatial structure and AB adhesive bonding system to achieve multi-dimensional adjustable parameter design and a modular application model. It addresses industry pain points through a "pre-bonding-coordinated positioning-function switching" mechanism.

[0033] The following further describes a wind turbine blade web hand lay-up auxiliary flange positioning tooling according to the present invention with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Figure 1 Figure 1a 、 Figure 1b 、 Figure 1c ) is a three-view drawing of a wind turbine blade web hand lay-up auxiliary flange positioning tool according to the present invention;

[0035] Figure 2 This is a key diagram of the design of a wind turbine blade web hand lay-up auxiliary flange positioning tooling of the present invention;

[0036] Figure 3 This is a schematic diagram of the installation of a wind turbine blade web hand lay-up auxiliary flange positioning tool according to the present invention;

[0037] Figure 4 This is a schematic diagram of the installation of a wind turbine blade web hand lay-up auxiliary flange positioning tool of the present invention. Figure 2 .

[0038] in:

[0039] 1- Positioning tooling side arm; 2- Bonding base; 3- Support plate; 4- Stainless steel round tube; 5- Inner skin;

[0040] 6-web; 7-web main flange; 8-web hand lay-up auxiliary flange; 9-AB glue; 10-bonding glue; 11-D-type positioning block. DETAILED DESCRIPTION

[0041] The preferred embodiments of the present invention are described in detail below with reference to the accompanying drawings. Process parameters not specified in this embodiment are generally carried out in accordance with conventional conditions in the art or conditions recommended by the manufacturer:

[0042] This patent describes a positioning fixture used in the bonding process of wind turbine blades, designed to facilitate the passage of web lay-up auxiliary flanges. By designing the positioning fixture's structure, an operable space is created between the web and the skin, allowing the web lay-up auxiliary flange to be passed without removing the fixture.

[0043] 1. Tool preparation

[0044] (1) Tooling structure: as shown in Figure 1- Figure 4 As shown in the figure, the present invention provides a wind turbine blade web hand lay-up auxiliary flange positioning tool, which mainly includes:

[0045] L-shaped main structure: The side arm (1), the bonding base (2), and the support plate (3) are welded to form an integrated frame (see Figure 1a -c);

[0046] Side arm (1): Φ30mm (preferably 25-35mm) 304 stainless steel round tube (wall thickness 3mm);

[0047] Support plate (3): pre-bent arc structure at the top, curvature radius R = 20 mm (≥ 15 mm);

[0048] Adhesive base (2): 50mm×50mm square flat plate (weight range 45-55mm), four corners chamfered R5mm;

[0049] (2) Construction technology:

[0050] Welding requirements (right 6): The side arm (1) and the bonding base (2) are welded with a V-groove, with a weld height of 3.5 mm (range 3 to 4 mm);

[0051] Surface treatment (right 10): overall passivation treatment, film thickness ≥ 12μm (≥ 10μm);

[0052] Strengthening design (right 8): Strengthening ribs with a height of 5 mm and a spacing of 20 mm are added to the back of the support plate (3).

[0053] 2. Installation and positioning process

[0054] (1) Size parameter setting:

[0055] Support plate height Y=H+Δh (H is the maximum height of the auxiliary flange (8), Δh is 20mm, and the range is 10-30mm);

[0056] The width of the bonding base is X=W+Δw (W is the maximum width of the auxiliary flange (8), Δw is 15mm, ≥10mm);

[0057] (2) Adhesive fixation:

[0058] AB glue (9) parameters: Use epoxy glue with a curing time of ≤10min and a shear strength of ≥18MPa;

[0059] Coating process: thickness 1.0±0.2mm, coating area>90%;

[0060] Buffer layer setting: a 2 mm thick silicone pad (Shore hardness 45HA) is pasted on the contact surface of the support plate (3);

[0061] (3) Clearance fit control:

[0062] The support plate (3) is in flexible contact with the outer surface of the web (6) via the elastic buffer layer;

[0063] The contact surface is processed with 0.8mm deep anti-slip lines, and the spacing between lines is 4mm (usually 3-5mm);

[0064] 3. Core function implementation

[0065] (1) Standalone application mode

[0066] The bonding base (2) is fixed to the inner skin (5) by means of AB glue (9), and forms a stable reference after curing;

[0067] When the web (6) falls, the gap between the support plate (3) and the web ensures that the scraper can penetrate 5mm to trim the glue layer;

[0068] Auxiliary flange (8) hand lay-up operation: glass fiber cloth continuously passes through the operable gap formed between the side arm (1) and the web (6) (meeting the requirements of width ≥ 70mm and height ≥ 140mm, in this embodiment, 70mm wide × 140mm high).

[0069] (2) Combined application mode

[0070] When the main flange (7) side of the web (6) needs to be positioned in the chord direction with high precision using a conventional D-type positioning block (11), this tooling works in conjunction with the D-type positioning block (11). The specific process is as follows:

[0071] 1. Synchronous pre-installation stage:

[0072] Install the D-type positioning block (11) on the main flange (7) side according to conventional technology;

[0073] At the same time, on the auxiliary flange (8) side, the tool is fixed to the inner skin (5) by AB glue (9), ensuring that the elastic buffer layer of the support plate (3) is in close contact with the outer surface of the web (6);

[0074] After the AB glue (9) is cured (≤30 minutes), the two together form the chord-wise positioning constraint system of the web (6).

[0075] 2. Web positioning and initial curing stage:

[0076] 1) After the web (6) falls, the D-shaped positioning block (11) and the tooling work together to maintain the web position;

[0077] 2) The primary adhesive (10) completes preliminary curing (usually 1-2 hours) to form basic bonding strength.

[0078] 3.D-block removal and function switching stage:

[0079] 1) Removing the D-shaped positioning block (11): After the primary adhesive (10) is initially cured, remove the D-shaped positioning block (11) on the side of the main flange (7);

[0080] 2) Function switching of this tooling: At this time, the tooling on the auxiliary flange (8) side plays a dual role:

[0081] Physical support: continue to constrain the position of the web (6) to prevent displacement caused by the removal of the D-block;

[0082] Operation channel: The operable gap (width ≥ 70 mm, height ≥

[0083] 140mm), perform two key operations directly on the original area occupied by the D-block:

[0084] a. Glue layer repair: The scraper goes deep into the gap to trim the glue layer step left by the D-shaped block;

[0085] b. Continuous laying: The fiberglass cloth passes through the gap to complete the continuous laying of the auxiliary flange (8).

[0086] The following is a complete example to explain in detail:

[0087] 1) As shown in FIG1 , the present invention provides a wind turbine blade web hand lay-up auxiliary flange positioning tool, comprising a side arm 1, a bonding base 2, and a support plate 3 welded together. The side arm 1 is welded using a φ30*3mm stainless steel round tube 4, and the bonding base 2 and the support plate 3 are cut and formed using a 3mm thick stainless steel plate. The bonding base 2 is preferably square with a size ≥50*50mm; the top of the support plate 3 is pre-bent into a rounded corner with R ≥20mm.

[0088] 2) The width of the bonding base 2 from the web 6 is X = (the maximum width of the web hand-layup auxiliary flange 8 on the inner skin 5 + the margin), the height of the support plate 3 from the inner skin 5 is Y = (the maximum height of the web hand-layup auxiliary flange 8 on the web 6 + the margin), and the margin is ≥10mm; the diameter of the stainless steel round tube 4 is φ = 30mm; the angle α of the side arm 1 is preferably selected to be 60°-70°.

[0089] 3) Before bonding the web 6, position the positioning fixture on the web auxiliary flange side according to the chordal orientation of the web 6 as specified in the job document. Secure the bonding base 2 to the inner skin 5 with AB glue 9. Once the AB glue 9 has cured, proceed with bonding the web 6. After the web 6 is lowered onto the adhesive 10, a scraper can be used to remove the adhesive. After this is complete, begin the hand lay-up of the web flange 8 on the bonding side. The web hand lay-up auxiliary flange 8 can pass through the operating space formed between the positioning fixture's side arm 1 and the web 6. Within this space, operations such as resin impregnation of the glass fiber and bubble removal can be performed.

[0090] 4) If you want to complete the glue collection operation of the D-type positioning block 11 blocking area on the side of the web main flange 7 after the second bonding process, you can choose to use this positioning tool in combination with the existing D-type positioning block 11. Before the web 6 falls for the second bonding, use the existing D-type positioning block 11 on the side of the main flange 7 to perform chord-wise positioning of the web 6. After the web 6 falls on the adhesive 10, use AB glue 9 next to the D-type positioning block 11 to glue this positioning tool to the skin 5. The installation process requires that the support plate 3 be close to the web 6 to play a supporting role. After the AB glue 9 is cured, the D-type positioning block 11 is knocked out, and then the glue collection operation can be performed on the knocked-out position.

[0091] 5. Implementation effect:

[0092] Comparison of experimental data

[0093] Test items This application process Traditional crafts Improvement Glass fiber continuity Excellent (≥95%) Good (78%) +17％ Interlayer bubble rate <![CDATA[≤0.3 per / cm 2 > <![CDATA[≥2.5 per cm 2 > -88％ Positioning accuracy ±0.5mm ±1.2mm -58.3％ Process time 85 minutes / piece 285 minutes / piece -70.2％ Rework costs ￥180 / piece ￥800 / piece -77.5％

[0094] The embodiments described above are merely descriptions of preferred implementations of the present invention and are not intended to limit the scope of the present invention. Without departing from the spirit of the present invention, various modifications and improvements made to the technical solutions of the present invention by ordinary technicians in this field should fall within the scope of protection determined by the claims of the present invention.

Claims

1. A wind turbine blade web hand lay-up auxiliary flange positioning tool, characterized in that: include: The L-shaped main structure is formed by welding the side arm (1), the bonding base (2) and the support plate (3) into one body; The side arm (1) is a metal tubular component; The top of the support plate (3) is provided with a pre-bent arc structure; The bonding base (2) is a polygonal plate structure and is fixed to the inner skin (5) of the blade by means of an adhesive; An operable gap is formed between the support plate (3) and the outer surface of the web (6), and the width of the operable gap is ≥70 mm and the height is ≥140 mm.

2. The wind turbine blade web hand lay-up auxiliary flange positioning tool according to claim 1, characterized in that: The metal tubular member is a stainless steel round tube with a diameter of 25 to 35 mm; The curvature radius R of the pre-bent arc structure is ≥ 15 mm; The polygonal plate structure is a square with a side length of 45 to 55 mm.

3. A wind turbine blade web hand lay-up auxiliary flange positioning tool according to claim 1 or 2, characterized in that: The width X of the operable gap satisfies: X=W+Δw, wherein W is the maximum width of the auxiliary flange (8) on the inner skin (5), and Δw≥10mm; The height Y of the operable gap satisfies: Y=H+Δh, wherein H is the maximum height of the web hand lay-up auxiliary flange (8), and Δh=10-30 mm.

4. The wind turbine blade web hand lay-up auxiliary flange positioning tool according to claim 1, characterized in that: The contact surface between the support plate (3) and the web (6) is provided with anti-slip grooves, with a groove depth of 0.5 to 1 mm and a spacing of 3 to 5 mm.

5. The wind turbine blade web hand lay-up auxiliary flange positioning tool according to claim 1, characterized in that: The contact surface is further provided with a silicone rubber elastic buffer layer with a thickness of 1 to 3 mm and a Shore hardness of 40 to 50 HA as measured according to ISO7619-1:2010.

6. The wind turbine blade web hand lay-up auxiliary flange positioning tool according to claim 1, characterized in that: The side arm (1) and the bonding base (2) are welded by V-shaped groove, the weld height is 3-4 mm, and the non-destructive testing complies with the requirements of NB / T47013.2-2015 Level II.

7. The wind turbine blade web hand lay-up auxiliary flange positioning tool according to claim 1, characterized in that: The four corners of the bonding base (2) are provided with R3-R5mm chamfers, the flatness of the mounting surface is ≤0.05mm, and the surface roughness Ra is ≤1.6μm.

8. The wind turbine blade web hand lay-up auxiliary flange positioning tool according to claim 1, characterized in that: The back of the support plate (3) is provided with reinforcing ribs, with a rib height of 4 to 6 mm, a spacing of 15 to 25 mm, and a material yield strength of ≥250 MPa.

9. The wind turbine blade web hand lay-up auxiliary flange positioning tool according to claim 1, characterized in that: The surface of the tooling is passivated, the passivation film thickness is ≥10μm, and the salt spray resistance test is ≥500 hours.

10. The wind turbine blade web hand lay-up auxiliary flange positioning tool according to claim 1, characterized in that: It is equipped with a positioning fixture with an accuracy of ±0.1mm, including a laser alignment device and a magnetic base.

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