A wind turbine nacelle production process

Abstract

The application provides a wind power generator cabin production process and relates to the field of wind power generator cabin forming. The process comprises the following steps: spraying glue on a production mold and curing to form a glue layer; arranging auxiliary components in the production mold; covering a vacuum bag film on the production mold after the arrangement is completed and sealing; performing a vacuumizing operation on the space in the vacuum bag film through a flow guide pipe; injecting a forming injection material into the production mold through a glue injection pipe; plugging the air outlet and the glue injection port after the glue injection is completed, maintaining a vacuum environment, and curing; controlling the vacuum degree in stages based on the parameters of the forming injection material; removing the vacuum bag film after the curing is completed; and taking out the formed wind power generator cabin from the production mold. The application can adapt to the process requirements of different stages by controlling the vacuum degree in stages, so as to ensure the quality of the formed wind power generator cabin.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of wind turbine nacelle forming technology, in particular to a wind turbine nacelle production process. BACKGROUND

[0002] Wind power generation is currently a very important power generation technology, and a wind turbine generally includes a tower, a blade, a hub and a nacelle cover. The nacelle cover is arranged at the top of the generator set and protects the wind turbine. The reliability of the wind turbine nacelle cover determines the stability and service life of the wind turbine.

[0003] The existing wind turbine nacelle production process, such as CN110778465B, a wind turbine nacelle manufacturing process, and CN104589665B, a wind turbine nacelle cover one-step forming process, both disclose that the pressure value of the vacuum system during injection is kept at -0.09±0.005MPa. However, the process does not disclose the staged pressure regulation during the injection and curing process, which cannot dynamically adjust the pressure according to the different process requirements at different stages, and the production quality of the wind turbine nacelle cover may be unqualified due to the mismatch of the pressure. SUMMARY

[0004] The present application provides a wind turbine nacelle production process to solve the technical problems in the background art.

[0005] To solve the above technical problems, the present application discloses a wind turbine nacelle production process, comprising:

[0006] Step S1: spraying glue on the production mold and curing to form a glue layer;

[0007] Step S2: arranging auxiliary components in the production mold;

[0008] Step S3: covering the production mold with a vacuum bag film after the arrangement in step S2 and sealing;

[0009] Step S4: performing a vacuum operation on the space in the vacuum bag film through a flow guide pipe;

[0010] Step S5: injecting a molding injection material into the production mold through an injection pipe; after the injection is completed, the air outlet and the injection port are blocked, and the vacuum environment is maintained for curing;

[0011] In step S5, the vacuum degree is regulated in stages based on the parameters of the molding injection material;

[0012] Step S6: after curing is completed, the vacuum bag film is removed;

[0013] Step S7: taking out the molded wind turbine nacelle from the production mold.

[0014] Preferably, it further comprises step S8: corner polishing and inner gel coating spraying are performed on the shaped wind turbine nacelle.

[0015] Preferably, the auxiliary components comprise embedded parts and reinforcing materials, and the reinforcing materials comprise glass cloth and reinforcing ribs.

[0016] Preferably, the vacuum operation is performed to a pressure of -0.08 to -0.1 MPa.

[0017] Preferably, the wet gel film thickness in step S1 is 0.5 to 0.8 mm.

[0018] Preferably, before step S5, the batch of the to-be-applied injection material further comprises the following steps based on the batch of the to-be-applied injection material:

[0019] Step S051: obtaining a control gel time and a control curing time of the to-be-applied injection material;

[0020] Step S052: collecting an actual injection viscosity and an actual pH of the to-be-applied injection material;

[0021] Step S053: determining a viscosity-curing coupling characteristic factor based on the actual injection viscosity and a curing agent addition ratio of the to-be-applied injection material, correcting the control gel time based on the viscosity-curing coupling characteristic factor to obtain a corrected gel time;

[0022] Step S054: determining a predicted gel rate based on the corrected gel time, determining a gel rate deviation coefficient based on the predicted gel rate, and determining a pH deviation coefficient based on the actual pH of the to-be-applied injection material; correcting the control curing time based on the gel rate deviation coefficient and the pH deviation coefficient to obtain a corrected curing time;

[0023] Step S055: dividing the injection gel starting time to the curing process of the to-be-applied injection material into a first vacuum period, a second vacuum period, and a third vacuum period based on the corrected gel time and the corrected curing time;

[0024] Step S056: obtaining a target vacuum degree of the first vacuum period based on the viscosity deviation coefficient and a control vacuum degree of the first vacuum period; obtaining a target vacuum degree of the second vacuum period based on the pH deviation coefficient and a control vacuum degree of the second vacuum period; and obtaining a target vacuum degree of the third vacuum period based on the gel rate deviation coefficient and a control vacuum degree of the third vacuum period;

[0025] When the batch of the to-be-applied injection material performs step S05, the actual vacuum degree of the vacuum period is controlled to be the corresponding target vacuum degree.

[0026] Preferably, the first vacuum period is from the injection gel starting time to the injection gel completion time plus 0.5 times the corrected gel time.

[0027] Vacuum period two: "glue injection completion time + 0.5 times the modified gel time" to "glue injection completion time + 1.5 times the modified gel time";

[0028] Vacuum period three: "glue injection completion time + 1.5 times the modified gel time" to "glue injection completion time + modified curing time".

[0029] Preferably, the target glue injection speed of the batch injection material to be applied is determined before step S5 when the batch hatch cover to be produced is produced, and the glue injection is performed at the target glue injection speed when the batch hatch cover to be produced is produced.

[0030] Preferably, the target glue injection speed of the batch injection material to be applied includes:

[0031] Step S01: detecting the actual glue layer hardness, actual glue layer thickness, and actual glue layer temperature of the glue layer when the batch hatch cover to be produced is produced;

[0032] Step S02: detecting the actual viscosity and temperature of the batch injection material to be applied, and performing dimensionless processing on the actual glue layer hardness, actual glue layer thickness, and actual viscosity of the batch injection material to be applied to obtain a hardness coefficient, a thickness coefficient, and a viscosity coefficient, respectively, and determining a current "glue-substrate adaptation factor" based on the hardness coefficient, the thickness coefficient, and the viscosity coefficient;

[0033] Step S03: determining a current interface expansion stress characteristic factor based on the actual glue layer temperature, the temperature of the batch injection material to be applied, the thermal expansion coefficient of the glue, and the thermal expansion coefficient of the batch injection material to be applied;

[0034] Step S04: determining a target glue injection speed range corresponding to the current "glue-substrate adaptation factor" and the current interface expansion stress characteristic factor based on a "glue-substrate adaptation factor range-interface expansion stress characteristic factor range-infiltration section glue injection speed range" model;

[0035] Step S05: obtaining a comparison "single hatch cover production glue injection time-glue injection amount-glue injection speed" matrix of the batch injection material to be applied, and dividing the matrix into an infiltration section matrix, a filling section matrix, and a densification section matrix; and respectively determining an average glue injection speed and a glue injection speed fluctuation coefficient corresponding to the filling section matrix and the densification section matrix, determining a filling section target glue injection speed range based on the average glue injection speed and the glue injection speed fluctuation coefficient of the filling section, and determining a densification section target glue injection speed range based on the average glue injection speed and the glue injection speed fluctuation coefficient of the densification section.

[0036] The technical solutions of the present application will be further described in detail below with reference to the drawings and examples.

[0037] Compared with the prior art, the present application has the following beneficial effects:

[0038] The staged regulation of the vacuum degree can adapt to the process requirements of different stages: in the glue injection stage, the reasonable vacuum degree is used to ensure that the formed injection material fully fills the mold cavity and avoids material shortage in dead corners; in the gelation stage, the vacuum degree is adjusted separately to balance the local shrinkage and prevent surface depression and internal micro-cracks, according to the characteristics of the material viscosity sharply rising and the flowability sharply dropping; in the curing stage, the pressure is regulated to reduce stress concentration and delamination and improve the uniformity and stability of the cabin structure, thereby reducing the rejection rate of the cabin production.

[0039] The wet film thickness of the gel coat (0.5-0.8 mm) and the configuration of auxiliary components (pre-embedded parts and reinforcing materials) are determined, which not only ensures the surface quality of the cabin (uniform thickness of the gel coat layer), but also improves the structural strength of the cabin through the reinforcing materials, thereby further optimizing the performance of the finished product. BRIEF DESCRIPTION OF DRAWINGS

[0040] The accompanying drawings are included to provide a further understanding of the application, and constitute a part of the specification, illustrate the application, and are used to explain the application together with the embodiments of the application, and do not constitute a limitation on the application. In the drawings:

[0041] Figure 1 The flowchart of the application is shown. DETAILED DESCRIPTION

[0042] The preferred embodiments of the application are described below in conjunction with the accompanying drawings, and it should be understood that the preferred embodiments described herein are only used to illustrate and explain the application, and not to limit the application.

[0043] In addition, the description of "first", "second" and the like in the present application is only for the purpose of description, and does not mean to specially indicate the order or sequence, nor to limit the application, which is only to distinguish the components or operations described by the same technical terms, and cannot be understood as indicating or implying the relative importance of the indicated technical features or implicitly indicating the number of the indicated technical features. Therefore, the features limited by "first" and "second" can explicitly or implicitly include at least one of the features. In addition, the technical solutions and technical features of various embodiments can be combined with each other, but it must be based on the realization of ordinary skilled in the art, when the combination of technical solutions appears contradictory or unachievable, it should be considered that the combination of technical solutions does not exist, nor within the scope of protection required by the application.

[0044] The application provides the following embodiments:

[0045] Embodiment 1: The application provides a wind turbine cabin production process, as shown in Figure 1 , which comprises:

[0046] Step S1: spraying gel coat on the production mold and curing to form a gel coat layer;

[0047] Step S2: arranging auxiliary components in the production mold;

[0048] Step S3: covering the production mold arranged in step S2 with a vacuum bag film and sealing;

[0049] Step S4: performing a vacuumizing operation on the space in the vacuum bag film through a flow guide pipe;

[0050] Step S5: injecting a molding injection material into the production mold through an injection pipe; after the injection is completed, the air outlet and the injection port are blocked, and a vacuum environment is maintained for curing;

[0051] In step S5, the vacuum degree is controlled in stages based on the parameters of the molding injection material;

[0052] Step S6: after the curing is completed, the vacuum bag film is removed;

[0053] Step S7: the molded wind turbine nacelle cover is taken out of the production mold.

[0054] The method further comprises step S8: edge polishing and inner layer gel coating of the molded wind turbine nacelle cover.

[0055] The auxiliary components include embedded parts and reinforcing materials, and the reinforcing materials include glass fiber cloth and reinforcing ribs.

[0056] In the vacuumizing operation, the pressure is-0.08 to-0.1 MPa.

[0057] In step S1, the wet gel film has a thickness of 0.5 to 0.8 mm.

[0058] In this embodiment, the production mold is a wind turbine nacelle molding mold.

[0059] In this embodiment, the molding injection material refers to a mixture of materials used to fill the mold and form the main body structure of the nacelle after curing.

[0060] The above technical solution has the following beneficial effects:

[0061] Controlling the vacuum degree in stages can adapt to the process requirements of different stages: in the injection stage, a reasonable vacuum degree is used to ensure that the molding injection material fully fills the mold cavity and avoids dead angles and material shortages; in the gelation stage, the vacuum degree is adjusted separately to balance the local shrinkage, prevent surface depression and internal micro-cracks, and match the material viscosity and flowability; in the curing stage, the pressure is controlled to match the material curing shrinkage, reduce stress concentration and delamination, and improve the uniformity and stability of the nacelle structure, thereby reducing the rejection rate of the nacelle production.

[0062] The thickness of the wet film (0.5-0.8 mm) and the configuration of auxiliary components (pre-embedded parts and reinforcing materials) are determined, which not only ensures the surface quality of the cabin cover (uniform thickness of the rubber layer), but also improves the structural strength of the cabin cover through the reinforcing materials, further optimizing the performance of the finished product.

[0063] In Example 2, based on Example 1, before performing step S5 based on the injection material batch to be applied, the following steps are further included:

[0064] Step S051: Obtain the control gel time and control curing time of the injection material batch to be applied;

[0065] Step S052: Collect the actual injection viscosity and actual pH of the injection material batch to be applied;

[0066] Step S053: Determine the viscosity-curing coupling characteristic factor based on the actual injection viscosity and the curing agent addition ratio of the injection material batch to be applied, correct the control gel time based on the viscosity-curing coupling characteristic factor to obtain the corrected gel time;

[0067] Step S054: Determine the predicted gel rate based on the corrected gel time, determine the gel rate deviation coefficient based on the predicted gel rate, and determine the pH deviation coefficient based on the actual pH of the injection material batch to be applied; correct the control curing time based on the gel rate deviation coefficient and the pH deviation coefficient to obtain the corrected curing time;

[0068] Step S055: Based on the corrected gel time and the corrected curing time, divide the injection material curing process of the injection material batch to be applied into vacuum period one, vacuum period two, and vacuum period three;

[0069] Step S056: Based on the viscosity deviation coefficient and the control vacuum degree of vacuum period one, obtain the target vacuum degree of vacuum period one (such as -0.09 to -0.1 MPa); based on the pH deviation coefficient and the control vacuum degree of vacuum period two, obtain the target vacuum degree of vacuum period two (such as -0.07 to -0.08 MPa); based on the gel rate deviation coefficient and the control vacuum degree of vacuum period three, obtain the target vacuum degree of vacuum period three (such as -0.08 to -0.09 MPa);

[0070] In the process development stage, for the molding injection material, based on the cabin cover production qualified data, the "deviation type-deviation amplitude-vacuum degree adjustment coefficient" correlation model corresponding to the three vacuum periods is preset:

[0071] Vacuum period one: establish a correlation model of "viscosity deviation coefficient → vacuum degree adjustment coefficient";

[0072] Vacuum period two: establish a correlation model of "pH deviation coefficient → vacuum degree adjustment coefficient";

[0073] Vacuum period three: establish the correlation model of "gel rate deviation coefficient → vacuum degree adjustment coefficient".

[0074] The correlation model can be a mapping table, and the mapping table can be obtained as follows:

[0075] Data collection: collect "viscosity / pH / gel rate deviation value" and "corresponding vacuum degree adjustment coefficient" of all qualified production (which can be trial production) of the same formula resin (molding injection material);

[0076] Correlation analysis: one-to-one correspondence between the deviation value and the vacuum degree adjustment value, statistics of the optimal adjustment coefficient corresponding to different deviation amplitudes, forming a preliminary mapping relationship.

[0077] The correlation model can also be a formula, and the "deviation value-vacuum degree adjustment coefficient" data collected is fitted to obtain a mathematical formula;

[0078] The target vacuum degree of the current vacuum period = the reference vacuum degree of the current vacuum period × (1 + the corresponding vacuum degree adjustment coefficient of the current vacuum period);

[0079] When the batch of injection material to be applied performs step S05, the actual vacuum degree of the vacuum period is controlled to be the corresponding target vacuum degree.

[0080] Viscosity deviation coefficient = (actual injection viscosity of the batch of injection material to be applied - reference viscosity of the batch of injection material to be applied) ÷ reference viscosity of the batch of injection material to be applied;

[0081] Viscosity-curing coupling characteristic factor = viscosity deviation coefficient ÷ curing agent addition ratio of the batch of injection material to be applied;

[0082] Gel is the process of resin changing from "liquid flowable" to "semi-solid unflowable", and viscosity will affect the speed of gel through "resin molecular motion resistance": the higher the viscosity, the greater the "initial resistance" of intermolecular crosslinking, and the slower the gel rate; at the same time, the curing agent addition ratio determines the "theoretical rate basis" of crosslinking reaction, so it is necessary to combine the influence of curing agent ratio and viscosity deviation.

[0083] The coupling factor is positive → the gel rate is slower than the standard case; otherwise, the gel rate is faster.

[0084] Corrected gel time = reference gel time × (1 + "viscosity-curing coupling characteristic factor" × time correction coefficient 1);

[0085] Time correction coefficient one: First, measure the ratio of theoretical and actual gel time under different conditions through laboratory test; then, iterate and optimize combined with production data, or refer to the same industry data. The value range of time correction coefficient one is 0.05-0.5 (0.05-0.2 for small deviation / simple structure; 0.2-0.3 for conventional scene; 0.3-0.5 for large deviation / thick structure);

[0086] Predicted gel rate = (the viscosity of the injection material to be applied to reach the gel state - the actual injection viscosity of the injection material to be applied) ÷ correction gel time;

[0087] Gel rate deviation coefficient = (predicted gel rate - control gel rate of the injection material to be applied) ÷ control gel rate of the injection material to be applied;

[0088] pH deviation coefficient = (control pH of the injection material to be applied - actual pH of the injection material to be applied) ÷ control pH of the injection material to be applied;

[0089] Corrected curing time = control curing time × (1 + (pH deviation coefficient - gel rate deviation coefficient) × time correction coefficient two);

[0090] Curing time is a key parameter for resin to change from "gel state" to "fully cured state": pH deviation will affect the activity of curing agent (and then change the curing rate; high alkalinity → strong activity of curing agent → accelerated curing), and gel rate deviation reflects the rhythm difference of the early gel process (for example, fast gel rate → early curing start → actual curing time will be shortened), and both determine the adaptability of the final curing time.

[0091] Time correction coefficient two: measure the ratio of theoretical and actual curing time through laboratory test, fine-tune combined with production data, or refer to the same industry data. Value: 0.1-0.5 (0.05-0.2 for small deviation / simple structure; 0.2-0.3 for conventional scene; 0.3-0.5 for large deviation / complex structure);

[0092] Among them, vacuum period one: the moment of starting injection to "injection completion time + 0.5 times correction gel time";

[0093] Vacuum period two: "injection completion time + 0.5 times correction gel time" to "injection completion time + 1.5 times correction gel time";

[0094] Vacuum period three: "injection completion time + 1.5 times correction gel time" to "injection completion time + correction curing time".

[0095] In this embodiment, the "control" corresponds to the parameter set obtained by standard condition testing of the same type (formula, model completely consistent) molding injection material in the qualified state of "the performance of the finally molded cabin cover reaching the production index (such as strength, appearance, etc. meet the quality requirements of the cabin cover)".

[0096] Control gel time: the time required for the same type of material to change from a liquid mixture to a gel state that loses flowability under standard conditions with "qualified performance" (it is the benchmark length to ensure that the material gelation process meets the qualified requirements);

[0097] Control solidification time: the total time required for the same type of material to change from a liquid mixture to a solid structure under standard conditions with "qualified performance" (it is the benchmark length to ensure that the material performance meets the standard after solidification);

[0098] Control gel rate: the gel rate benchmark value of the same type of material in the "qualified performance" state (the calculation method is "(the gel viscosity of the material in the qualified state-injection viscosity) ÷ control gel time", which is a reference scale to measure whether the material gelation rhythm meets the qualified requirements);

[0099] Control pH: the pH benchmark value of the same type of material under standard conditions with "qualified performance" (it is the pH reference value to ensure that the material reaction is stable and the final performance meets the standard).

[0100] The control vacuum degree of each stage is the actual vacuum pressure of the same type of molding injection material in the "qualified performance" standard condition during the injection to solidification of each stage (vacuum period one, vacuum period two, vacuum period three);

[0101] "Standard conditions" refers to the uniform and stable environment and operating parameters in the laboratory that simulate the conventional production scene of the molding injection material, which usually includes the following core elements: temperature conditions; pressure conditions; material state: the molding injection material is accurately proportioned according to the formula requirements and uniformly stirred (stirring rate, time fixed, such as 1000 r / min, stirring for 5 minutes); test container: use small standard sample molds consistent with the material and shape of the actual production mold (such as uniformly sized glass steel molding small test molds).

[0102] The beneficial effects of the above technical solutions are:

[0103] 1. Traditional process usually covers all batches with "fixed reference time / vacuum degree", but viscosity and pH of different batches of materials naturally fluctuate (such as raw material batches, storage environment differences). This process links actual viscosity → viscosity-curing coupling characteristic factor → correction of gel time, actual pH + gel rate deviation → correction of curing time, so that the core time parameter is directly anchored to the "real state of the current batch of materials", avoiding the problem of "gel too fast / slow, curing insufficient / excessive" caused by "using standard parameters to fit individual materials".

[0104] Vacuum degree regulation is more refined into three vacuum periods, corresponding to "viscosity deviation coefficient, pH deviation coefficient, gel rate deviation coefficient" to correct the reference vacuum degree:

[0105] Vacuum period one (initial gelation): use viscosity deviation coefficient to adapt vacuum degree, more accurately solve the problem of "different viscosity materials have different exhaust difficulties" (high viscosity materials need higher vacuum degree to exhaust, low viscosity materials avoid excessive vacuum extraction leading to material splashing);

[0106] Vacuum period two (mid-gelation): use pH deviation coefficient to adapt vacuum degree, match the difference in material crosslinking rate at this stage (pH fluctuation will affect the activity of curing agent, corresponding adjustment of vacuum degree can maintain the uniformity of crosslinking);

[0107] Vacuum period three (curing stage): use gel rate deviation coefficient to adapt vacuum degree, ensure the stability of material form and performance during curing (avoid uneven internal stress caused by fluctuation of curing rate).

[0108] The division of three vacuum periods is not "fixed time length", but based on "gel injection completion time + multiple of corrected gel / curing time": period one covers "gel initiation period", adapting to the initial needs of material transition from liquid to gel state (emphasis on exhaust); period two covers "gel critical period", adapting to the stage of fastest crosslinking rate of material (emphasis on maintaining form); period three covers "curing and shaping period", adapting to the stage of material transition from gel state to solid state (emphasis on mechanical properties). This division makes the vacuum degree of each period accurately match the "physical / chemical state requirements" of the material, rather than "process time requirements".

[0109] If the viscosity of a batch of materials is too high, the corrected gel time will be adjusted accordingly, and the length of the three vacuum periods will also be dynamically changed (such as period one is extended to adapt to the longer exhaust time of high viscosity materials), without the need for manual re-setting of process nodes, achieving a closed loop of "batch difference → parameter automatic adaptation → process automatic adjustment".

[0110] The traditional process needs to manually adjust parameters such as time and vacuum degree repeatedly (even 1-2 batches of trial production) when changing batches. Through the logic of "actual parameters-automatic correction of parameters", the process only needs to collect viscosity and pH when changing batches, and can automatically generate adaptive parameters, reducing the adjustment time from several hours to several minutes, and reducing the waste of trial production materials.

[0111] In embodiment 3, on the basis of embodiment 2, further comprising:

[0112] Step S057: Based on the target vacuum degrees corresponding to the vacuum period one, the vacuum period two and the vacuum period three, an initial "time-vacuum degree polyline" is constructed with time as the horizontal coordinate and vacuum degree as the vertical coordinate, and the transition time range of the vacuum period one to the vacuum period two and the transition time range of the vacuum period two to the vacuum period three are labeled (the time interval of the vacuum degree switching of the adjacent two periods can be 10-20 min);

[0113] The vacuum period one, the vacuum period two and the vacuum period three are represented as horizontal platform segments in the polyline;

[0114] Step S058: Determine the corresponding transition slope range (the end point is known and the time range is known, and the transition slope range can be calculated) in combination with each transition time range; divide each transition slope range into a first slope segment, a second slope segment and a third slope segment;

[0115] The transition curve slope range is divided into three segments, the first slope segment has the largest slope, the third slope segment has the smallest slope, and the second slope segment is the remaining one;

[0116] Obtain the "time-contrast vacuum degree" curve of the batch of injection materials to be applied (the curve comes from the actual production data of a typical qualified batch of the same type of injection materials, including the vacuum degrees of each vacuum stable segment and the slope of the transition between the segments), and determine the average transition slope (the average slope of the transition segment) of the vacuum period one to the vacuum period two and the average transition slope of the vacuum period two to the vacuum period three of the "time-contrast vacuum degree";

[0117] The average transition slope of the vacuum period one to the vacuum period two is selected as the target slope segment in which the average transition slope is located, and the average transition slope of the vacuum period two to the vacuum period three is selected as the target slope segment in which the average transition slope is located;

[0118] The corresponding target slope segment median is used as the corresponding transition slope, and finally the "time-vacuum degree polyline" is determined, and the actual step S5 process is controlled based on the "time-vacuum degree polyline".

[0119] The beneficial effects of the above technical solutions are:

[0120] Through "slope range calculation + control curve matching", the vacuum degree transition is transformed from "empirical parameter adjustment" to "data-driven segmented control", the fluctuation range of the vacuum degree change rate is reduced, and the glue solution flow disorder caused by the sudden change of the vacuum degree is avoided.

[0121] In any one of embodiments 1-3, on the basis of any one of embodiments 1-3, before the production of the to-be-produced batch of fairings, a to-be-applied batch of injection materials (the injection materials applied by the to-be-produced batch of fairings) target injection speed determination process is performed, and the injection is performed at the target injection speed when the to-be-produced batch of fairings is produced.

[0122] The to-be-applied batch of injection materials target injection speed determination process comprises:

[0123] Step S01: detecting the actual glue layer hardness, the actual glue layer thickness, and the actual glue layer temperature of the glue layer when the to-be-produced batch of fairings is produced;

[0124] Step S02: detecting the actual viscosity and the temperature of the to-be-applied batch of injection materials, performing dimensionless processing on the actual glue layer hardness, the actual glue layer thickness, and the actual viscosity of the to-be-applied batch of injection materials to obtain a hardness coefficient, a thickness coefficient, and a viscosity coefficient, respectively, and determining a current "glue layer-substrate adaptation factor" based on the hardness coefficient, the thickness coefficient, and the viscosity coefficient;

[0125] Step S03: determining a current interface expansion stress characteristic factor based on the actual glue layer temperature, the temperature of the to-be-applied batch of injection materials, the thermal expansion coefficient of the glue layer, and the thermal expansion coefficient of the to-be-applied batch of injection materials;

[0126] Step S04: determining a current "glue layer-substrate adaptation factor" and a current interface expansion stress characteristic factor corresponding to a wetting section target injection speed range based on a "glue layer-substrate adaptation factor range-interface expansion stress characteristic factor range-wetting section injection speed range" model;

[0127] Step S05: obtaining a control "single fairing production injection time-injection amount-injection speed" matrix of the to-be-applied batch of injection materials, and dividing the matrix into a wetting section matrix, a filling section matrix, and a densification section matrix; and determining an average injection speed and an injection speed fluctuation coefficient (the standard deviation of the injection speed corresponding to the matrix ÷ the average value of the injection speed corresponding to the matrix) corresponding to the filling section matrix and the densification section matrix, respectively, determining a filling section target injection speed range based on the filling section average injection speed and the injection speed fluctuation coefficient, and determining a densification section target injection speed range based on the densification section average injection speed and the injection speed fluctuation coefficient.

[0128] The wetting section (the actual total injection amount is 0-25% of the required total injection amount): the target injection speed range is 8-12 ml / s;

[0129] Filling section (actual total injection amount is 25% to 75% of the total injection amount required): the target injection speed range is 5 to 7 ml / s;

[0130] Compact section (actual total injection amount is 75% to 100% of the total injection amount required): the target injection speed range is 2 to 4 ml / s;

[0131] Hardness coefficient = actual glue layer hardness ÷ control glue layer hardness;

[0132] Thickness coefficient = actual glue layer thickness ÷ control glue layer thickness;

[0133] Viscosity coefficient = actual viscosity of the batch to be applied ÷ control viscosity of the batch to be applied;

[0134] Glue-substrate adaptation factor = (hardness coefficient x thickness coefficient) ÷ viscosity coefficient;

[0135] Among them, "hardness coefficient x thickness coefficient" reflects the carrying capacity of the glue, and the viscosity coefficient reflects the "flow impact" of the injection material;

[0136] The essence is the matching state of "glue carrying capacity" and "injection material impact";

[0137] Interface expansion stress characteristic factor = (actual temperature of the batch to be applied - actual glue layer temperature) x |thermal expansion coefficient of the glue - thermal expansion coefficient of the batch to be applied|;

[0138] The greater the absolute value of the interface expansion stress characteristic factor: the greater the difference in expansion / contraction deformation between the glue and the injection material due to the temperature difference, the stronger the tensile / compressive stress at the interface, and the higher the risk of cracking and delamination;

[0139] The interface expansion stress characteristic factor approaches 0: the temperature difference is small or the expansion coefficient is close, the interface deformation synchronization is good, and the stress risk is low.

[0140] In this embodiment, "control" corresponds to the same type (formula, model completely consistent) molding injection material in the "final molded cabin performance reaches the production index (such as strength, appearance, etc. meet the cabin quality requirements)", through standard condition test to get the parameter set (the type of material qualified standard sample test data, the actual production parameters corresponding to the past batches of qualified products (take each type of parameter in the qualified batch interval value and typical mean value)) of the qualified state; The parameter set includes control glue layer hardness, control glue layer thickness, control "single cabin production injection time-injection amount-injection speed" matrix.

[0141] The "glue-substrate adaptation factor range" - interface expansion stress characteristic factor range - immersion section injection speed range" model can be a mapping table;

[0142] Row element: interval division of glue coat-matrix adaptation factor;

[0143] Column element: interval division of interface expansion stress characteristic factor;

[0144] Cell element: glue injection speed range under corresponding working condition (corresponding glue coat-matrix adaptation factor interval and corresponding interface expansion stress characteristic factor interval).

[0145] First, the factor interval of row / column is divided based on the "control parameter of qualified product", and then the glue injection speed range corresponding to each interval is filled out through parameter statistics of qualified working condition.

[0146] The "control matrix" is an "glue injection time-glue injection amount-glue injection speed" correlation matrix established separately by selecting the actual production data of a "typical qualified batch" (the cabin cover produced by the batch completely meets the quality index). Row dimension: glue injection stage (infiltration section, filling section, and densification section); column dimension: three key process parameters (glue injection time interval, glue injection amount interval, and glue injection speed range); cell: specific value / range of each "glue injection stage" corresponding to "each key process parameter item".

[0147] Step S05 specifically comprises: first, obtaining the average glue injection speed of the infiltration section matrix, and then determining the target ratio;

[0148] Target ratio = average glue injection speed of infiltration section matrix ÷ median value of infiltration section target glue injection speed range;

[0149] Median value of filling section target glue injection speed = average glue injection speed of filling section × ;

[0150] Filling section target glue injection speed = median value of filling section target glue injection speed × (1 ± filling section glue injection speed fluctuation coefficient);

[0151] Median value of densification section target glue injection speed = average glue injection speed of densification section × ;

[0152] Densification section target glue injection speed = median value of densification section target glue injection speed × (1 ± densification section glue injection speed fluctuation coefficient);

[0153] Correction coefficient one (value is 0.9-1.1) and correction coefficient two (value is 0.8-1) are obtained based on process matching experiment / historical qualified data fitting (statistical regression fitting) of actual production;

[0154] The beneficial effects of the above technical solutions are:

[0155] The scheme builds a quantitative correlation mechanism between the state of gel coat (hardness, thickness) and the characteristics of injected material (viscosity, temperature) through dimensionless representation + multi-factor coupling calculation:

[0156] Based on the product of the hardness coefficient and the thickness coefficient to represent the "load-cushion comprehensive performance" of the gel coat, combined with the flow impact quantification of the viscosity coefficient, the quantitative evaluation of the mechanical adaptability of the gel coat-injected material is realized;

[0157] The product of the temperature difference and the thermal expansion coefficient difference is introduced as the interface thermal stress characteristic factor to realize the pre-judgment of the interface thermal-mechanical coupling risk.

[0158] Finally, the gel injection speed of the infiltration section is accurately matched with the mechanical adaptability of the gel coat-substrate and the interface thermal stress state, solving the empirical blind area of the "material characteristics-injection parameter" matching in the traditional process, and the interface bonding strength discrete coefficient can be reduced.

[0159] The scheme realizes the hierarchical management and control of the quality risk of the whole injection process through phased matrix splitting + statistical fluctuation constraint:

[0160] The "factor-speed" mapping model is used in the infiltration section to ensure the permeability of resin to fiber substrate and reduce the dry spot defect rate;

[0161] The average speed and the fluctuation coefficient based on the control matrix are used to determine the speed range in the filling section and the densification section, so that the cavity filling rate is increased, the bubble residual equivalent diameter in the densification section is reduced, and the mechanical property loss rate is reduced.

[0162] Obviously, those skilled in the art can make various modifications and variations to the present application without departing from the spirit and scope of the present application. Thus, if these modifications and variations of the present application fall within the scope of the claims of the present application and their equivalent technologies, the present application also intends to include these modifications and variations.

Claims

1. A manufacturing process for a wind turbine nacelle cover, characterized in that: include: Step S1: Apply gel coat to the production mold and allow it to cure to form a gel coat layer; Step S2: Arrange auxiliary components inside the production mold; Step S3: Cover the production mold arranged in step S2 with a vacuum bag film and seal it; Step S4: Vacuum the space inside the vacuum bag membrane through the guide tube; Step S5: Inject molding material into the production mold through the injection tube; after injection, seal the air extraction port and injection port to maintain a vacuum environment for curing; In step S5, the vacuum level is adjusted in stages based on the molding injection parameters; Step S6: After curing is complete, remove the vacuum bag film; Step S7: Remove the formed wind turbine nacelle cover from the production mold; Before step S5, which involves batch processing of the batch of materials to be applied, the following is also included: Step S051: Obtain the control gel time and control curing time of the batch injection to be applied; Step S052: Collect the actual injection viscosity and actual pH of the batch feed to be applied; Step S053: Combine the actual injection viscosity and the curing agent addition ratio of the batch injection material to be applied, determine the viscosity-curing coupling characteristic factor, and correct the control gel time based on the viscosity-curing coupling characteristic factor to obtain the corrected gel time; Step S054: Determine the predicted gel rate based on the corrected gel time, determine the gel rate deviation coefficient based on the predicted gel rate, and determine the pH deviation coefficient based on the actual pH of the batch to be injected; correct the control curing time based on the gel rate deviation coefficient and the pH deviation coefficient to obtain the corrected curing time. Step S055: Based on the corrected gel time and corrected curing time, the process from the start of dispensing to the application batch dispensing and curing is divided into three vacuum periods: Vacuum Period 1, Vacuum Period 2, and Vacuum Period 3. Step S056: Obtain the target vacuum level for vacuum period one based on the viscosity deviation coefficient and the control vacuum level for vacuum period one; obtain the target vacuum level for vacuum period two based on the pH deviation coefficient and the control vacuum level for vacuum period two; obtain the target vacuum level for vacuum period three based on the gel rate deviation coefficient and the control vacuum level for vacuum period three. When performing the batch execution step S05 of the batch injection, the actual vacuum level during the vacuum period is controlled to be the corresponding target vacuum level.

2. The manufacturing process for a wind turbine nacelle according to claim 1, characterized in that: It also includes step S8: grinding the edges and corners of the formed wind turbine nacelle and spraying the inner layer of gel coat.

3. The manufacturing process for a wind turbine nacelle according to claim 1, characterized in that: The auxiliary components include embedded parts and reinforcing materials, the reinforcing materials including fiberglass cloth and reinforcing ribs.

4. The manufacturing process for a wind turbine nacelle cover according to claim 1, characterized in that: The vacuuming operation is performed until the pressure is -0.08 to -0.1 MPa.

5. The manufacturing process for a wind turbine nacelle cover according to claim 1, characterized in that: In step S1, the wet film thickness of the gel coat is 0.5–0.8 mm.

6. The manufacturing process for a wind turbine nacelle according to claim 1, characterized in that: Vacuum Period 1: From the start of glue application to the completion of glue application + 0.5 times the correction gel time; Vacuum Period Two: from "Time of completion of glue application + 0.5 times correction gel time" to "Time of completion of glue application + 1.5 times correction gel time"; Vacuum Period 3: from "dip filling completion time + 1.5 times correction gel time" to "dip filling completion time + correction curing time".

7. The manufacturing process for a wind turbine nacelle according to claim 1, characterized in that: When the batch of chamber covers to be produced is being manufactured, the target injection speed for the batch to be applied is determined before step S5. During the production of the batch of chamber covers to be produced, the injection is performed at the target injection speed.

8. The manufacturing process for a wind turbine nacelle according to claim 7, characterized in that: The process of determining the target injection speed for the batch to be applied includes: Step S01: Detect the actual gel coat layer hardness, actual gel coat layer thickness, and actual gel coat layer temperature during the production of the batch of chamber covers to be produced; Step S02: Detect the actual viscosity and temperature of the batch material to be applied, and perform dimensionless processing on the actual gel coat layer hardness, actual gel coat layer thickness, and actual viscosity of the batch material to be applied to obtain the hardness coefficient, thickness coefficient, and viscosity coefficient respectively. Determine the current "gel coat-matrix compatibility factor" based on the hardness coefficient, thickness coefficient, and viscosity coefficient. Step S03: Based on the actual gel coat temperature, the temperature of the batch to be applied, the coefficient of thermal expansion of the gel coat, and the coefficient of thermal expansion of the batch to be applied, determine the current interface expansion stress characteristic factor. Step S04: Based on the model of "gel coat-matrix compatibility factor range - interface expansion stress characteristic factor range - impregnation section injection speed range", determine the target injection speed range of the impregnation section corresponding to the current "gel coat-matrix compatibility factor" and the current interface expansion stress characteristic factor. Step S05: Obtain the reference matrix of "single chamber production injection time - injection volume - injection speed" for the batch injection to be applied, and divide it into the impregnation section matrix, the filling section matrix, and the dense section matrix; and determine the average injection speed and injection speed fluctuation coefficient corresponding to the filling section matrix and the dense section matrix respectively. Based on the average injection speed and injection speed fluctuation coefficient of the filling section, determine the target injection speed range of the filling section; and based on the average injection speed and injection speed fluctuation coefficient of the dense section, determine the target injection speed range of the dense section.

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