A method for quickly matching the web gap of large blades

Abstract

The present invention specifically discloses a method for quickly matching the web gap of large blades, which comprises the following steps: S1. Forming the profiled web includes calculating the height of the profiled web, welding the profiled web, manufacturing the profiled web, and assembling the profiled web; S2. Bonding the profiled web includes positioning the web bonding block on the PS surface, placing a thin rubber sheet in the web bonding area, placing the profiled web, welding and matching the lower pressing tool for the web, locking the lower pressing tool, fixing the web by hand lay-up, heating and curing the hand-laid cloth layer, placing the putty nails, collecting the trial mold closing data, and removing the profiled web; S3. Manufacturing the product web includes analyzing the data of the profiled web, modifying the web mold, and flanging and sealing the web mold. The beneficial effects of the present invention are as follows: It can achieve the quick matching of the web gap, shorten the trial production cycle of the blade and improve the production efficiency of blade mass production; it can save the amount of mold closing glue, thereby reducing the blade weight and mass moment, and ultimately reducing the load of the wind turbine blade on the unit.

Description

Technical Field

[0001] The present invention belongs to the technical field of large wind turbine blades, and particularly relates to a method for quickly matching the web gap of large blades. Background Art

[0002] The main components of a wind turbine blade are divided into a PS shell, an SS shell, and a web. The web is an important component for connecting and supporting the PS surface and the SS surface. If the web gap is too large, the peel strength of the adhesive layer will be reduced. If the web adhesive layer is too small, there will be a risk of anti-mode delamination.

[0003] With the advent of the era of grid parity, in order to maintain a cost advantage, reduce the manufacturing cost of blades, and enhance the competitiveness in the blade type industry, the matching of the web gap is the top priority in blade molding. Stable web gap can improve the bonding quality of blades, save blade manufacturing costs, and improve blade molding efficiency. At present, during the trial production of blades, there are problems such as difficult web gap matching and large amount of mold closing adhesive used. Summary of the Invention

[0004] The purpose of the present invention is to provide a method for quickly matching the web gap of large blades, which can achieve quick matching of the web gap, reduce the amount of mold closing adhesive used, improve the bonding quality of blades, and shorten the trial production cycle of blades.

[0005] In order to achieve the above object, the technical solution of the present invention is as follows:

[0006] A method for quickly matching the web gap of large blades includes the following steps:

[0007] S1. Forming the profiled web includes calculating the height of the profiled web, welding the profiled web, manufacturing the profiled web, and assembling the profiled web;

[0008] S2. Bonding the profiled web includes positioning the web bonding block on the PS surface, placing a thin rubber sheet in the web bonding area, placing the profiled web, welding and matching the web pressing tooling, locking the pressing tooling, hand-laying and fixing the web, heating and curing the hand-laid cloth layer, placing oil mud nails, collecting trial mold closing data, and removing the profiled web;

[0009] S3. Manufacturing the product web includes analyzing the data of the profiled web, modifying the web mold, and flanging and sealing the web mold;

[0010] In the step S1, the method for calculating the height of the profiled web is as follows: in the three-dimensional model of the blade, according to the requirements of the design document, simulate the shell ply structure and the main beam thickness, and measure the theoretical height dimension and the theoretical angle of the web; the method for welding the profiled web is as follows: according to the theoretically calculated height and angle, with the mold central axis as the reference, weld the web flange according to the theoretical height of the web;

[0011] In the step S2, the method for bonding the web positioning block to the PS surface includes: according to the horizontal distance from the web to the parting line and the outer spacing of the web given in the process document, use a plumb line and a spirit level to make marks, bond the positioning blocks according to the marks, and place an axial positioning tooling for the web at the starting position of the web;

[0012] In the step S3, the method for flanging and sealing the web die: includes after the flanging and welding of the web die are completed, cleaning the welding spots and impurities, scraping a fillet with a radius of 2 mm at the inner corner of the web die with an adhesive and bonding a transparent tape, and pasting a sealing strip at the outer corner of the web die for sealing.

[0013] Furthermore, in the step S1, the production of the profiled web includes grinding and removing the burrs at the welding position, and cleaning the surface of the die in place. Lay 2 layers of 800 g / ㎡ biaxial fabric under the core material, lay 2 layers of 800 g / ㎡ biaxial fabric and 2 layers of 1200 g / ㎡ uniaxial fabric at the flange edge, then lay a core material with a thickness of 25 mm - 30 mm on the large surface, and finally lay 2 layers of 800 g / ㎡ biaxial fabric on the core material, lay 2 layers of 800 g / ㎡ biaxial fabric and 2 layers of 1200 g / ㎡ uniaxial fabric at the flange edge, and perform vacuum infusion molding, and heat and cure until the glass transition temperature of the fiberglass Tg ≥ 70°C.

[0014] Furthermore, in the step S1, the assembly of the profiled web includes when the temperature of the profiled web drops below 45°C, use a demolding tooling for demolding. After demolding and cutting, according to the assembly width of the web, perform web assembly on the web assembly rack, bond connecting strips every 2 m, and hand lay 2 layers of 800 g / ㎡ biaxial fabric at the connecting strip position for fixation to prevent the web from falling apart due to the demolding of the connecting strip during the hoisting of the web.

[0015] Furthermore, in the step S2, the placement of a thin rubber sheet in the bonding area of the web is to start laying a rubber sheet with a thickness of 2 mm and a width of 120 mm from 1.5 m, and the rubber sheet is laid along the inner edge of the positioning block, and overlapping in the axial direction of the rubber sheet is prohibited.

[0016] Furthermore, in the step S2, the placement of the profiled web starts from 2 m, and place a web hoisting day-shaped tooling every 6 - 8 m. Use a lifting beam to transfer the assembled web to the die, fix the root end of the web with a locking belt, and remove the web hoisting tooling.

[0017] Furthermore, in the step S2, the hand lay and fixation of the web includes laying a chamfer of the web core material on the outer sides of the front and rear edge webs from 1.5 - 10 m. After the chamfer laying is completed, hand lay 2 layers of 800 g / ㎡ biaxial fabric with a width of 200 mm centered on the corner; start from 11 m and place a chamfer of the web core material with a length of 300 mm every 1 m. After the chamfer placement is completed, hand lay 2 layers of 800 g / ㎡ biaxial fabric with a width of 200 mm and a length of 300 mm centered on the corner.

[0018] Further, in the step S2, the heating and curing of the hand-laid cloth layer includes laying a layer of vacuum bag film on the upper surface of the hand-laid cloth layer, laying an electric heating blanket, and assisting in heating at a constant temperature of 80°C. After heating until the glass transition temperature (Tg) of the hand-laid cloth layer fiberglass is ≥70°C, the lower pressing tool for the web is removed.

[0019] Further, in the step S2, the placement of the putty nails includes placing putty nails on the web every half meter according to the mold meter scale. The putty nails cover three points: the auxiliary flange, the core material side, and the fiberglass side, and the height of the putty nails is not less than 25 mm.

[0020] Further, in the step S3, the analysis of the data of the profiled web includes collecting data according to the trial mold fitting. A glue layer of 6 mm is reserved for the SS surface, and the data for adjusting the flange edge and angle of the web mold are calculated.

[0021] Further, in the step S3, the modification of the web mold includes cleaning the resin-rich inner corners of the web mold, turning the inner flange of the web, and marking lines with white paint pens. After the removal of the web flange edge is completed, according to the data for adjusting the web flange edge, the offset line of the web flange edge is drawn, and the web mold is welded according to the offset line.

[0022] The beneficial effects of the present invention are as follows:

[0023] 1. It can achieve rapid matching of the web gap, shorten the trial production cycle of the blade, and improve the production efficiency of mass production of the blade.

[0024] 2. It can keep the glue layer stable at 3 - 6 mm, achieve an optimal bonding quality for mold closing and bonding, and improve the shear force and bonding strength of the bonding.

[0025] 3. It can save the amount of glue used for mold closing, thereby reducing the weight and mass moment of the blade, and ultimately reducing the load of the wind turbine blade on the unit. Description of the Drawings

[0026] Figure 1 It is a flow chart of a method for rapid matching of the web gap of a large blade according to the present invention. Detailed Embodiments

[0027] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0028] As shown in the Figure 1 drawings: The present invention provides a method for rapid matching of the web gap of a large blade, including the following steps:

[0029] S1. Forming of corrugated web:

[0030] S101. Method for calculating the height of the corrugated web: In the three-dimensional model of the blade, according to the requirements of the design document, simulate the shell ply structure and the thickness of the main beam (calculated as 0.5 mm for a single-layer pultruded plate and 0.8 mm for a 1250 g / ㎡ unidirectional cloth), and measure the theoretical height dimension and the theoretical angle of the web;

[0031] S102. Method for welding the corrugated web: Based on the theoretical calculated height and angle, with the mold central axis as the reference, and according to the theoretical height of the web, weld the flange edge of the web (the flange edge is smooth, without waves, and there are no steps at the butt joint);

[0032] S103. Manufacturing the corrugated web: Grind and remove the burrs at the welding position, and clean the mold surface thoroughly. Lay 2 layers of 800 g / ㎡ biaxial cloth under the core material, lay 2 layers of 800 g / ㎡ biaxial cloth and 2 layers of 1200 g / ㎡ unidirectional cloth at the flange edge, then lay a core material with a thickness of 25 mm - 30 mm on the large surface, and finally lay 2 layers of 800 g / ㎡ biaxial cloth on the core material, lay 2 layers of 800 g / ㎡ biaxial cloth and 2 layers of 1200 g / ㎡ unidirectional cloth at the flange edge, and perform vacuum infusion molding, heating and curing until the glass transition temperature of the fiberglass Tg ≥ 70 °C;

[0033] S104. Assembly of the corrugated web: Cool the corrugated web to below 45 °C, and use a demolding tooling for demolding. After demolding and cutting, according to the assembly width of the web, perform web assembly on the web assembly rack, bond connecting strips every 2 m, and hand lay 2 layers of 800 g / ㎡ biaxial cloth at the connecting strip position for fixation to prevent the web from falling apart due to the demolding of the connecting strip during the hoisting process of the web;

[0034] S2. Bonding of the corrugated web:

[0035] S201. Method for bonding the web positioning block on the PS surface includes: According to the horizontal distance from the web to the parting line and the outer spacing of the web given in the process document, use a plumb line and a spirit level to mark points, bond the positioning blocks according to the points, and place an axial positioning tooling for the web at the starting position of the web;

[0036] S202. Place thin rubber sheets in the bonding area of the web: Start laying rubber sheets with a thickness of 2 mm and a width of 120 mm from 1.5 m, lay the rubber sheets along the inner edge of the positioning block, and no overlapping is allowed in the axial direction of the rubber sheets;

[0037] S203. Place the corrugated web: Start from 2 m, place the day-shaped lifting tooling for the web every 6 - 8 m, use a lifting beam to transfer the assembled web to the mold, fix the root end of the web with a locking belt, and remove the web lifting tooling;

[0038] S204. Welding and pressing tool for the web: After the web is properly placed, use a spirit level or inclinometer to check the perpendicularity of the web and ensure that the perpendicularity of the web is 90° ± 0.5°. After passing the inspection, hoist the split pressing tool for the web. According to the profile and position of the bonding surface of the web, weld the pressing plate and the lock of the pressing tool for the web. The pressing plate should fit the flange edge of the web and the stress point should be on the core material side;

[0039] S205. Locking the pressing tool for the web: After the welding of the pressing tool for the web is completed, lock the lock of the flange edge, tighten the pressing plate of the web with a wrench, and use a feeler gauge to measure whether the pressing plate of the web is tightened to ensure that the PS surface of the web and the adhesive layer are in contact;

[0040] S206. Hand lay-up and fixation of the web: Lay the chamfer of the web core material on the outer sides of the front and rear edge webs at a distance of 1.5 - 10 m. After the chamfer laying is completed, hand lay up 2 layers of 800 g / ㎡ biaxial fabric with a width of 200 mm centered on the corner; Starting from 11 m, place the chamfer of the web core material with a length of 300 mm every 1 m. After the chamfer placement is completed, hand lay up 2 layers of 800 g / ㎡ biaxial fabric with a width of 200 mm and a length of 300 mm centered on the corner;

[0041] S207. Heating and curing of the hand-laid fabric layer: Lay a layer of vacuum bag film on the upper surface of the hand-laid fabric layer, lay an electric blanket, and assist in heating at a constant temperature of 80 °C. After heating until the glass transition temperature (Tg) of the hand-laid fabric layer of fiberglass is ≥ 70 °C, remove the pressing tool for the web;

[0042] S208. Placing putty nails: On the web, according to the mold meter scale, place putty nails every half meter. The putty nails should cover three points: the auxiliary flange, the core material side, and the fiberglass side. The height of the putty nails should not be less than 25 mm;

[0043] S209. Data collection during trial mold closing: After the mold is closed, check that the mold hooks are in place. After checking for no abnormalities, open the mold, measure the thickness of the putty with a vernier caliper, and record it in detail in the gap record form;

[0044] S210. Removing the profiled web: After the data collection is completed, use a utility knife to cut the first layer of the web on both sides after demolding and pry open the hand-laid fabric layer. Use a lifting tool to hoist out the web and clean the debris in the inner cavity of the shell;

[0045] S3. Manufacturing the product web:

[0046] S301. Data analysis of the profiled web: According to the data collected during the trial mold closing, reserve a 6-mm adhesive layer on the SS surface and calculate the data for adjusting the flange edge and angle of the web mold;

[0047] S302. Modifying the web mold: Clean the resin-rich corners inside the web mold, draw a marking line along the inner turned edge of the web. After the flange edge of the web is removed, draw an offset line for the flange edge of the web according to the data for adjusting the flange edge of the web, and weld the web mold according to the offset line;

[0048] S303. Method for Flanging and Sealing of Web Die: After the flanging and welding of the web die are completed, clean the welding spots and impurities. Use an adhesive to scrape a fillet with a radius of 2 mm at the inner corner of the web die and bond a transparent tape. Paste a sealing strip at the outer corner of the web die for sealing.

[0049] The method of the present invention can fundamentally solve the problem of difficult web gap matching, reduce the amount of mold closing glue, improve the bonding quality of the blade, and shorten the blade trial production cycle.

[0050] It should be noted that in this article, relational terms such as first and second are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the terms "including", "comprising" or any other variant thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements not only includes those elements, but also includes other elements not expressly listed, or also includes elements inherent to such process, method, article or device.

[0051] The above are only embodiments of the present invention. Common knowledge such as the specific structures and characteristics known in the art are not described in detail here. Those of ordinary skill in the art know all the common technical knowledge in the technical field to which the invention belongs before the application date or priority date, can know all the prior arts in this field, and have the ability to apply the conventional experimental means before this date. Those of ordinary skill in the art can, under the inspiration given in this application, combine their own abilities to improve and implement this solution. Some typical well-known structures or well-known methods should not become an obstacle for those of ordinary skill in the art to implement this application. It should be pointed out that for those skilled in the art, without departing from the structure of the present invention, several deformations and improvements can still be made, and these should also be regarded as the protection scope of the present invention, and these will not affect the implementation effect of the present invention and the practicality of the patent. The protection scope required by this application should be based on the content of its claims, and the specific implementation manners described in the specification can be used to interpret the content of the claims.

Claims

1. A method for quickly matching the web gap of large blades, characterized in that It includes the following steps: S1. The forming of the profiled web includes the calculation of the height of the profiled web, the welding of the profiled web, the fabrication of the profiled web and the assembly of the profiled web. The fabrication of the profiled web includes grinding and removing the burrs at the welding position and cleaning the surface of the mold in place. Lay 2 layers of 800 g / ㎡ biaxial fabric under the core material, lay 2 layers of 800 g / ㎡ biaxial fabric and 2 layers of 1200 g / ㎡ uniaxial fabric at the flange edge, then lay the core material with a thickness of 25 mm - 30 mm on the large surface, and finally lay 2 layers of 800 g / ㎡ biaxial fabric on the core material, lay 2 layers of 800 g / ㎡ biaxial fabric and 2 layers of 1200 g / ㎡ uniaxial fabric at the flange edge, and perform vacuum infusion molding, and heat and cure until the glass transition temperature of the fiberglass Tg≥70°C. The assembly of the profiled web includes demolding with a demolding tooling when the profiled web cools down to below 45°C. After demolding and cutting, according to the width of the web assembly, perform web assembly on the web assembly rack, bond connecting strips every 2 m, and hand-lay 2 layers of 800 g / ㎡ biaxial fabric at the connecting strip position for fixation to prevent the web from falling apart due to the demolding of the connecting strip during the lifting of the web; S2. The bonding of the profiled web includes bonding the web positioning block on the PS surface, placing a thin rubber sheet in the web bonding area, placing the profiled web, welding and assembling the lower pressing tooling for the web, locking the lower pressing tooling, hand-laying and fixing the web, heating and curing the hand-laid fabric layer, placing oil mud nails, collecting trial fitting die data and removing the profiled web; S3. The fabrication of the product web includes the data analysis of the profiled web, the modification of the web mold and the flanging and sealing of the web mold; In the step S1, the method for calculating the height of the profiled web is as follows: In the three-dimensional model of the blade, according to the requirements of the design document, simulate the cloth layer structure of the shell and the thickness of the main beam, and measure the theoretical height dimension and the theoretical angle of the web; the method for welding the profiled web is as follows: According to the theoretically calculated height and angle, with the axis of the mold as the reference, weld the flange edge of the web according to the theoretical height of the web; In the step S2, the method for bonding the web positioning block on the PS surface includes: According to the horizontal distance from the web to the parting line and the outer spacing of the web given in the process document, use a plumb line and a spirit level to make marks, bond the positioning blocks according to the marks, and place the axial positioning tooling for the web at the starting position of the web; In the step S3, the method for flanging and sealing the web mold: includes cleaning the welding points and welding impurities after the flanging welding of the web mold, scraping a fillet with a radius of ² mm with an adhesive at the inner corner of the web mold and bonding a transparent tape, and pasting a sealing strip at the outer corner of the web mold for sealing.

2. A method for quickly matching the web gap of large blades according to claim 1, characterized in that: In the step S2, the placement of the thin rubber sheet in the web bonding area is to start laying the rubber sheet with a thickness of 2 mm and a width of 120 mm from 1.5 m, and the rubber sheet is laid along the inner edge of the positioning block, and lap joint is prohibited in the axial direction of the rubber sheet.

3. A method for quickly matching the web gap of a large blade, according to claim 2, characterized in that: In the step S2, the placement of the profiled web is to start from 2 m, place the I-shaped lifting tooling for the web every 6 - 8 m, use a lifting beam to transfer the assembled web to the mold, fix the root end of the web with a locking belt, and remove the web lifting tooling.

4. A method for quickly matching the web gap of large blades according to claim 3, characterized in that: In the step S2, the manual lay-up fixation of the web includes laying a chamfer of the web core material on the outer sides of the front and rear edge webs at a distance of 1.5 - 10 m. After the chamfer laying is completed, two layers of 800 g / ㎡ biaxial fabric with a width of 200 mm are manually laid up with the corner as the center; starting from 11 m, chamfers of the web core material with a length of 300 mm are placed every 1 m. After the chamfer placement is completed, two layers of 800 g / ㎡ biaxial fabric with a width of 200 mm and a length of 300 mm are manually laid up with the corner as the center.

5. A method for quickly matching the web gap of large blades according to claim 4, characterized in that: In the step S2, the heating and curing of the manually laid-up fabric layer includes laying a layer of vacuum bag film on the upper surface of the manually laid-up fabric layer, laying an electric heating blanket, and performing auxiliary heating at a constant temperature of 80 °C. After heating until the glass transition temperature (Tg) of the fiberglass of the manually laid-up fabric layer is ≥ 70 °C, the web pressing tooling is removed.

6. A method for quickly matching the web gap of large blades according to claim 5, characterized in that: In the step S2, the placement of putty nails includes placing putty nails on the web at intervals of half a meter according to the mold meter scale. The putty nails cover three points: the auxiliary flange, the core material side, and the fiberglass side, and the height of the putty nails is not less than 25 mm.

7. A method for quickly matching the web gap of large blades according to claim 6, characterized in that: In the step S3, the data analysis of the profiled web includes collecting data according to the trial mold fitting, reserving a glue layer of 6 mm on the SS surface, and calculating the data for adjusting the flange edge and angle of the web mold.

8. A method for quickly matching the web gap of large blades according to claim 7, characterized in that: In the step S3, the modification of the web mold includes cleaning the resin-rich corner inside the web mold, marking a line with a white paint pen along the inner flange of the web. After the web flange edge is completely removed, according to the data for adjusting the web flange edge, draw an offset line for the web flange edge, and weld the web mold according to the offset line.

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