Wind turbine blade web wire pre-embedding forming process

Abstract

The application discloses a wind power blade web wire embedding forming process, characterized in that: the branch wire of the web is connected with the main wire in parallel and is sealed and wrapped, and the part of the branch wire connected with the main wire in parallel is embedded in the web together with the main wire when the web is formed. Before the main wire is embedded, the branch wire of the web is connected with the main wire in parallel and is effectively sealed, and the part of the branch wire connected with the main wire in parallel is embedded in the web together with the main wire when the web is formed, so that the process of protecting the branch wire connection embedding area and the branch wire connection operation in the web assembly process is omitted, the branch wire is connected on the web through filling, hand laying and other operations is avoided, the connection reliability of the branch wire on the web is improved, the connection mode of the branch wire is simplified, the forming process is simple and practical, convenient operation is achieved, the work efficiency of the web assembly forming is improved, the practicability is high, the quality problems caused by the filling and hand laying process in the operation process of the blade are reduced, and the quality of the blade is improved.

Description

Technical Field

[0001] This invention relates to a process for pre-embedding conductors in the web of wind turbine blades, belonging to the field of wind turbine blade web manufacturing technology. Background Technology

[0002] The main structural components of a wind turbine blade include the semi-shell, main beam, web, trailing edge beam, blade root connection bolts, lightning protection system, and surface protective coating. The lightning protection system includes the main lightning conductor, blade branch conductors, blade lightning arrester base, and blade tip lightning arrester. Currently, the main lightning conductor is pre-embedded in the web and vacuum-cast integrally with it. The protection of the reserved area for the branch conductor connection and the connection operations are all completed on the assembly frame during the web assembly process. The branch conductor connection is fixed by hand lay-up in the reserved area. Hand lay-up has limited operating space, makes quality control difficult, and the hand lay-up molding is prone to falling off during blade operation, damaging the blade.

[0003] Relevant existing patent documents retrieved:

[0004] 1. CN201310104643.6 - A pre-embedded process for lightning protection conductors on wind turbine blades;

[0005] 2. CN201910281915.7 - A conductor arrangement system for wind turbine blades; wind turbine blades and their manufacturing method;

[0006] 3. CN202110614148.4 - A lightweight main beam for wind turbine blades with a concave structure, and a method for manufacturing the main beam structure combined wind turbine blade;

[0007] 4. CN202120658078.8 - A fixing structure for lightning protection conductors of wind turbine blades. Summary of the Invention

[0008] The wind turbine blade web conductor pre-embedding molding process provided by this invention connects and effectively seals the branch conductors of the web with the main conductor before pre-embedding the main conductor. During web molding, the portion where the branch conductors are connected to the main conductor is pre-embedded in the web along with the main conductor. This eliminates the need for protection of the branch conductor connection pre-embedding area and branch conductor connection operations during web assembly. It also avoids connecting branch conductors to the web through filling, hand lay-up, or other operations. This not only improves the reliability of the branch conductor connection on the web but also simplifies the connection method. The molding process is simple, practical, and easy to operate, improving the efficiency of web assembly and molding. It is highly practical, reduces quality problems caused by filling and hand lay-up processes during blade operation, and improves blade quality.

[0009] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0010] The process for pre-embedding conductors in the web of a wind turbine blade is characterized by: connecting the branch conductors and the main conductors of the web in parallel and sealing them together; and pre-embedding the portion of the branch conductors connected to the main conductors along with the main conductors in the web during the web forming process.

[0011] Preferably, it includes the following steps:

[0012] First, connect one end of the branch conductor to the main conductor to form a conductor parallel connection segment;

[0013] Next, the wire parallel connection section is sealed and wrapped with thermoplastic tubing and sealing strip, and the sealed wire parallel connection section is placed in the fiber cloth layer of the molded web.

[0014] Then, the web is vacuum-cast, and the conductor parallel connection section is pre-embedded in the web together with the main conductor.

[0015] Preferably, "connecting one end of the branch conductor to the main conductor to form a conductor parallel connection segment" means using a parallel clamp to clamp one end of the branch conductor to the main conductor, and then wrapping the branch conductor to the main conductor with sealing tape to form a conductor parallel connection segment.

[0016] Preferably, the phrase "sealing and wrapping the wire parallel connection section with thermoplastic tube and sealing strip" means putting a thermoplastic tube over the wire parallel connection section and sealing the end of the thermoplastic tube with a sealing strip.

[0017] Preferably, the thermoplastic tube is sleeved outside the parallel clamp, the parallel clamp is located in the middle of the thermoplastic tube, the thermoplastic tube is multi-layered, and the sealing strip that binds the branch wire to the main wire is located inside the thermoplastic tube and is wrapped and bound at only one position.

[0018] Preferably, the thermoplastic tube comprises a first layer of thermoplastic tube, a second layer of thermoplastic tube, a third layer of thermoplastic tube, and a fourth layer of thermoplastic tube stacked sequentially from the inside out. The first and second layers of thermoplastic tube are disposed on one side of the parallel clamp, and the sealing strip for binding the branch conductor to the main conductor is disposed on the other side of the parallel clamp. The sealing strip for binding the branch conductor to the main conductor and the parallel clamp are both located in the third layer of tube. The outer end of the first layer of thermoplastic tube extends from the outer end of the second layer of thermoplastic tube, the outer end of the second layer of thermoplastic tube extends from the outer end of the third layer of thermoplastic tube, and the end of the third layer of thermoplastic tube extends from the end of the fourth layer of thermoplastic tube. The outer ends of the first, second, and third layers of thermoplastic tube are all sealed with sealing strips.

[0019] Preferably, "setting the sealed and wrapped wire parallel connection section in the fiber cloth layer of the molding web" means that after laying multiple layers of fiber cloth in the injection mold, the sealed and wrapped wire parallel connection section is placed on the fiber cloth, and then fiber cloth is laid on the sealed and wrapped wire parallel connection section.

[0020] Preferably, a pressure-resistant foam layer is sandwiched between the sealed wire parallel connection section and the fiber cloth, so that the sealed wire parallel connection section is sandwiched between two pressure-resistant foam layers.

[0021] The beneficial effects of the invention are:

[0022] The wind turbine blade web conductor pre-embedding molding process of the present invention connects the branch conductors of the web with the main conductor and effectively seals them before pre-embedding the main conductor. During web molding, the portion of the branch conductor connected to the main conductor is pre-embedded in the web along with the main conductor. This eliminates the need for protection of the branch conductor connection pre-embedding area and branch conductor connection operations during web assembly. It also avoids connecting branch conductors to the web through filling, hand lay-up, or other operations. This not only improves the reliability of the branch conductor connection on the web but also simplifies the connection method. The molding process is simple, practical, and easy to operate, improving the efficiency of web assembly and molding. It is highly practical, reduces quality problems caused by filling and hand lay-up processes during blade operation, and improves blade quality. Attached Figure Description

[0023] Figure 1 This is a schematic diagram showing the wire parallel connection section sealed and wrapped by thermoplastic tubing and sealing strips.

[0024] Figure 2 for Figure 1 A magnified view of the left side.

[0025] Figure 3 for Figure 1 Enlarged schematic diagram of the right-hand side. Detailed Implementation

[0026] The following is combined Figures 1-3 The embodiments of the present invention will be described in detail below.

[0027] The process for pre-embedding conductors in the web of a wind turbine blade is characterized by: connecting the branch conductor 1 and the main conductor 2 in parallel and sealing them together; and pre-embedding the part of the branch conductor 1 and the main conductor 2 together in the web during the forming of the web.

[0028] The above-described wind turbine blade web conductor pre-embedding molding process involves connecting the branch conductor 1 of the web to the main conductor 2 in parallel and effectively sealing them before pre-embedding the main conductor 2. During web molding, the portion where the branch conductor 1 is connected to the main conductor 2 in parallel is pre-embedded in the web along with the main conductor 2. This eliminates the need for protecting the pre-embedded area of ​​the branch conductor connection and the branch conductor connection operation during web assembly. It also avoids connecting the branch conductor to the web through filling, hand lay-up, or other operations. This not only improves the reliability of the branch conductor connection on the web but also simplifies the connection method. The molding process is simple, practical, and easy to operate, improving the efficiency of web assembly and molding. It is highly practical, reduces quality problems caused by filling and hand lay-up processes during blade operation, and improves blade quality.

[0029] This includes the following steps:

[0030] First, connect one end of the branch conductor 1 to the main conductor 2 to form the conductor parallel connection segment 3;

[0031] Next, the wire parallel connection section 3 is sealed and wrapped with thermoplastic tube 4 and sealing strip 5, and the sealed wire parallel connection section 3 is placed in the fiber cloth layer of the molded web.

[0032] Then, the web is vacuum-injected and formed, and the conductor parallel connection section 3 and the main conductor 2 are pre-embedded in the web.

[0033] Before the web is formed, the parallel connection of the branch conductor 1 and the main conductor 2 is formed. After the parallel connection section 3 is formed, the parallel connection section 3 is sealed in the thermoplastic tube 4 with a thermoplastic tube 4 and a sealing strip 5. This ensures that the parallel connection section 3 is in a relatively independent sealed space during the web injection molding process. The vacuum injection will not affect the parallel connection of the branch conductor 1 and the main conductor 2, effectively ensuring the reliability of the connection between the branch conductor 1 and the main conductor 2 in the formed web. After sealing the parallel connection section 3, the sealed parallel connection section 3 and the main conductor 2 are placed in the fiber cloth layer of the formed web. Then, the web is vacuum injected and molded, so that the parallel connection section 3 is pre-embedded in the web along with the main conductor 2. The parallel connection between the main conductor 2 and the branch conductor 1 in the web has high reliability. Moreover, by pre-embedding it in the web, the overall quality of the web is improved, and the reliability of the connection of the branch conductor 1 in the web is also guaranteed.

[0034] The phrase "connecting one end of the branch conductor 1 to the main conductor 2 to form a parallel connection section 3" refers to using a parallel clamp 6 to clamp one end of the branch conductor 1 to the main conductor 2, and then wrapping the branch conductor with a sealing strip 5 to bind it to the main conductor, thus forming a parallel connection section. As shown in the attached diagram, the parallel clamp 6 clamps one end of the branch conductor 1 together with the main conductor 2. A sealing strip 5 is wrapped around the main conductor and the branch conductor on one side of the parallel clamp 6 to extend the parallel connection length, forming the parallel connection section 3. The parallel clamp 6 ensures the reliability of the parallel connection between the main conductor and the branch conductor. The sealing strip extends the length of the parallel connection section 3 for sealing and wrapping. At the same time, the sealing strip 5 wrapped around the main conductor 2 and the branch conductor 1 seals with the thermoplastic tube 4 to form a sealed support, so that the parallel clamp 6 is wrapped in a sealed enclosure, reducing the pressure on the parallel clamp 6 during the vacuum filling process and ensuring that the parallel connection position of the branch conductor and the main conductor is not damaged during the vacuum filling process.

[0035] The phrase "sealing and wrapping the wire parallel connection section 3 with thermoplastic tube 4 and sealing strip 5" refers to fitting thermoplastic tube 4 onto the wire parallel connection section 3 and sealing the end of the thermoplastic tube with sealing strip 5. Simply fitting thermoplastic tube 4 onto the parallel connection section 3 and sealing the end of the thermoplastic tube 4 with sealing strip 5 effectively seals the wire parallel connection section 3 within the thermoplastic tube 6, making the operation convenient and simple.

[0036] The thermoplastic tube 4 is fitted over the parallel clamp 6, which is located in the middle of the thermoplastic tube. The thermoplastic tube 4 is multi-layered. The sealing strip 5, which binds the branch conductor 1 to the main conductor 2, is located inside the thermoplastic tube 4 and is wrapped and bound only at one position. The sealing strip 5, which binds the branch conductor 1 to the main conductor 2, is located on one side of the parallel clamp 6 and is wrapped and bound only at one position. The wrapping and binding is simple and does not affect the normal heat conduction of the main conductor 2 and the branch conductor 1.

[0037] The thermoplastic tube 4 comprises a first layer thermoplastic tube 41, a second layer thermoplastic tube 42, a third layer thermoplastic tube 43, and a fourth layer thermoplastic tube 44 stacked sequentially from the inside out. The first layer thermoplastic tube 44 and the second layer thermoplastic tube 42 are located on one side of the parallel clamp 6, and the sealing strip 5 that binds the branch conductor 1 to the main conductor 2 is located on the other side of the parallel clamp 6. The sealing strip 5 that binds the branch conductor 1 to the main conductor 2 and the parallel clamp 6 are both located in the third layer thermoplastic tube 43. The outer end of the first layer thermoplastic tube 41 extends from the outer end of the second layer thermoplastic tube 42, the outer end of the second layer thermoplastic tube 42 extends from the outer end of the third layer thermoplastic tube 43, and the end of the third layer thermoplastic tube 43 extends from the end of the fourth layer thermoplastic tube 44. The outer ends of the first layer thermoplastic tube 41, the second layer thermoplastic tube 42, and the third layer thermoplastic tube 43 are all sealed with sealing strips. As shown in the attached diagram, the thermoplastic tube 4 has four layers. The second layer thermoplastic tube 42 and the first layer thermoplastic tube 41 are located on one side of the parallel clamp 6. The third layer thermoplastic tube 43 is fitted over the second layer thermoplastic tube 42, the parallel clamp 6, and the sealing strip 5 that binds the branch conductor 1 to the main conductor 2. The fourth layer thermoplastic tube 44 is fitted over the third layer thermoplastic tube 43. The layered stacking of multiple thermoplastic tubes forms a sealed space with a certain supporting force, ensuring that the parallel connection section 3 of the conductor is not damaged during the vacuum casting of the web. The sealing strip 5 that binds the branch conductor 1 to the main conductor 2 is connected to the inner layer of the third layer thermoplastic tube 43. The wall seals contact with the third layer of thermoplastic tube 43, which serves as a sealing and support. The first layer of thermoplastic tube 41 and the second layer of thermoplastic tube 42 support the third layer of thermoplastic tube 43, creating a small gap between the parallel clamp and the inner wall of the third layer of thermoplastic tube 43. This reduces the pressure on the parallel clamp during vacuum injection and ensures that the wire parallel connection section 3 will not be damaged during web forming. The sealing strips at the ends of each layer of thermoplastic tubes seal the thermoplastic tubes and simultaneously bind and position each layer of thermoplastic tubes, forming a sealed whole that encapsulates the wire parallel connection section 3. This provides reliable support and sealing protection for the wire parallel connection section 3 during the web forming process.

[0038] Specifically, "setting the sealed and wrapped wire parallel connection segment 3 within the fiber cloth layer of the formed web" involves laying multiple layers of fiber cloth in the injection mold, placing the sealed and wrapped wire parallel connection segment on top of the fiber cloth, and then continuing to lay fiber cloth on top of the sealed and wrapped wire parallel connection segment. The sealed and wrapped wire parallel connection segment 3 is sandwiched within the fiber cloth layer and is pre-embedded within the web as it is formed.

[0039] Specifically, a pressure-resistant foam layer is sandwiched between the sealed wire parallel connection section 3 and the fiber cloth, so that the sealed wire parallel connection section 3 is sandwiched between two pressure-resistant foam layers. The pressure-resistant foam layer is used to prevent pressure marks and wrinkles in the fiber cloth layer during vacuum infusion, ensuring the quality of the web material molding.

[0040] The technical solutions of the embodiments of the present invention have been fully described above with reference to the accompanying drawings. It should be noted that the described embodiments are only a part of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

Claims

1. A process for pre-embedding conductors in the web of wind turbine blades, characterized in that: The branch line of the web is connected to the main line and sealed and wrapped. During the web forming process, the part where the branch line is connected to the main line is pre-embedded in the web along with the main line. Includes the following steps: First, use a wire clamp to clamp one end of the branch conductor onto the main conductor, and then use sealing tape to wrap and bind the branch conductor onto the main conductor to form a wire parallel connection section. Next, a thermoplastic tube is fitted onto the wire parallel connection section, and the end of the thermoplastic tube is sealed with a sealing strip. The sealed wire parallel connection section is then placed in the fiber cloth layer of the molded web. Then, the web is vacuum-injected and formed, and the conductor parallel connection section is pre-embedded in the web together with the main conductor. The thermoplastic tube is sleeved outside the parallel clamp, which is located in the middle of the thermoplastic tube. The thermoplastic tube is multi-layered, and the sealing strip that binds the branch wire to the main wire is located inside the thermoplastic tube and is only wrapped and bound at one position. The thermoplastic tube comprises a first layer of thermoplastic tube, a second layer of thermoplastic tube, a third layer of thermoplastic tube, and a fourth layer of thermoplastic tube stacked sequentially from the inside out. The first and second layers of thermoplastic tube are located on one side of the parallel clamp, and the sealing strip for binding the branch conductor to the main conductor is located on the other side of the parallel clamp. The sealing strip for binding the branch conductor to the main conductor and the parallel clamp are both located in the third layer of tube. The outer end of the first layer of thermoplastic tube extends from the outer end of the second layer of thermoplastic tube, the outer end of the second layer of thermoplastic tube extends from the outer end of the third layer of thermoplastic tube, and the end of the third layer of thermoplastic tube extends from the end of the fourth layer of thermoplastic tube. The outer ends of the first, second, and third layers of thermoplastic tube are all sealed with sealing strips. The sealing strip that binds the branch conductor to the main conductor makes a sealing contact with the inner wall of the third layer of thermoplastic tube, which plays a role in sealing and supporting. The first and second layers of thermoplastic tube support the third layer of thermoplastic tube, so that a small gap is formed between the parallel clamp and the inner wall of the third layer of thermoplastic tube, reducing the pressure of the parallel clamp during vacuum injection and ensuring that the parallel connection section of the conductor will not be damaged during the molding of the web material.

2. The wind turbine blade web conductor pre-embedding forming process according to claim 1, characterized in that: "Placing the sealed wire parallel connection section in the fiber cloth layer of the molding web" means that after laying multiple layers of fiber cloth in the injection mold, the sealed wire parallel connection section is placed on the fiber cloth, and then fiber cloth is laid on the sealed wire parallel connection section.

3. The wind turbine blade web conductor pre-embedding forming process according to claim 2, characterized in that: A pressure-resistant foam layer is sandwiched between the sealed wire parallel connection section and the fiber cloth, so that the sealed wire parallel connection section is sandwiched between two pressure-resistant foam layers.

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