Manufacturing method of a floating buoy and the floating buoy

Abstract

The present invention discloses a manufacturing method of a floating buoy and the floating buoy, including the steps: S1, manufacturing a buoy prefabricated part; S2, performing anti-corrosion treatment on the surface of the central steel cylinder; S3, splicing the buoy prefabricated part and the central steel cylinder; S4, manufacturing a cast-in-place surface of the buoy; S5, demolding and painting treatment. By reasonably formulating the process route of the floating buoy, the mass production and popularization of the buoy can be quickly achieved in the present invention.

Description

Technical Field

[0001] The present invention relates to the technical field of floating wind turbine pontoons, in particular to a manufacturing method of a floating pontoon and a floating pontoon. Background Art

[0002] In recent years, with the gradual development of wind power technology, people have gradually extended from onshore to offshore. Since the current offshore wind power installation areas are mainly concentrated in shallow sea areas, with the gradual saturation of the installed capacity in shallow sea areas, in order to develop faster and better, the installation areas need to extend to the deep and far sea areas, and the research on deep and far sea floating wind turbines has become essential. The production of deep and far sea floating wind turbines involves one of the most important components - the floating pontoon, whose main function is to use its own buoyancy to balance the gravity of the wind turbine platform itself, thereby ensuring that the floating wind turbine can operate stably in the deep and far sea. Therefore, the manufacturing technology of the floating pontoon is particularly important. Among many floating pontoon structures, for the pontoon structure using a combination of steel frames, foams, and fiberglass reinforced plastics, it currently only stays at the drawing stage. Therefore, there is an urgent need to design a manufacturing method of a floating pontoon to realize the mass production and popularization of the pontoon. Summary of the Invention

[0003] The purpose of the present invention is to overcome the deficiencies of the prior art and provide a manufacturing method of a floating pontoon and a floating pontoon, which can quickly realize the mass production and popularization of the pontoon by reasonably formulating the process route of the floating pontoon.

[0004] The first purpose of the present invention is to provide a manufacturing method of a floating pontoon.

[0005] The second purpose of the present invention is to provide a floating pontoon.

[0006] The first purpose of the present invention can be achieved by adopting the following technical solutions:

[0007] A manufacturing method of a floating pontoon includes the steps:

[0008] S1. Manufacturing of pontoon prefabricated parts

[0009] On the upper surface of the core of the pontoon prefabricated part mold, vacuum infusion auxiliary materials, fiberglass cloth, and small foam blocks are sequentially laid, and a PU foam integral is obtained through the first vacuum infusion. After curing, the vacuum infusion auxiliary materials on the surface of the PU foam are torn off. Then, inner fiberglass cloth, PVC foam, outer fiberglass cloth, and vacuum infusion auxiliary materials are sequentially laid on the outer surface of the PU foam, and an outer contour sandwich structure is formed on the outer surface of the PU foam through the second vacuum infusion, thereby obtaining a pontoon prefabricated part. After the pontoon prefabricated part is demolded, it is placed on a supporting demolding platform for standby; another pontoon prefabricated part is manufactured according to the above operations and placed on a supporting demolding platform for standby;

[0010] S2. Anticorrosion treatment of the surface of the central steel cylinder

[0011] Sandblast the surface of the central steel cylinder, lay a fiberglass cloth on its surface, arrange a plurality of ohmic tubes for vacuum infusion at intervals along the circumferential direction of the central steel cylinder, lay vacuum infusion auxiliary materials along the axial direction of the central steel cylinder between every two adjacent ohmic tubes, lay an air extraction bag for vacuum infusion air extraction on the upper surface of the vacuum infusion auxiliary materials, and obtain the central steel cylinder with surface anticorrosion treatment through vacuum infusion;

[0012] S3. Splicing of the floating cylinder prefabricated parts and the central steel cylinder

[0013] Move the central steel cylinder with the surface anticorrosion treatment to the designated position, lay a diversion plate on the lower surface of the central steel cylinder, move the two floating cylinder prefabricated parts to the corresponding positions on the left and right sides below the central steel cylinder respectively through a demolding platform, and then splice the two floating cylinder prefabricated parts with the lower surface of the central steel cylinder, lay vacuum infusion auxiliary materials, and bond the two floating cylinder prefabricated parts and the central steel cylinder into a whole through vacuum infusion;

[0014] S4. Production of the cast-in-place surface of the floating cylinder

[0015] Lay a fiberglass cloth, small foam pieces and vacuum infusion auxiliary materials on the upper surfaces of the two floating cylinder prefabricated parts and the central steel cylinder in sequence, conduct the first vacuum infusion to obtain the PU foam layer structure of the cast-in-place surface, then lay an inner fiberglass cloth, PVC foam, an outer fiberglass cloth and vacuum infusion auxiliary materials on the outer surface of the PU foam layer structure in sequence, conduct the second vacuum infusion to obtain the outer contour sandwich layer structure of the cast-in-place surface, and complete the perfusion molding of the cast-in-place surface;

[0016] S5. Demolding and painting treatment

[0017] After demolding, a floating cylinder product is prepared, and then painting operation is carried out on the surface of the floating cylinder product.

[0018] Furthermore, in step S1 and step S4, cross-shaped shallow grooves facilitating resin flow are processed on each contact surface of each small foam piece, and a fiberglass cloth for enhancing the bonding strength of the small foam pieces is laid between every two adjacent small foam pieces.

[0019] Furthermore, in step S1 and step S4, epoxy spray adhesive is used to fix the laying positions of the inner fiberglass cloth and the outer fiberglass cloth respectively.

[0020] Furthermore, in step S1, the fiberglass cloth is laid along the circumferential direction of the mold core, and during the laying process, the cloth layers are required to overlap by 50 - 70 mm.

[0021] Furthermore, in step S2, epoxy spray adhesive is used to fix the laying position of the fiberglass cloth.

[0022] Further, in step S3, a fiberglass cloth is laid at the splicing joint position of the two pontoon prefabrications.

[0023] Further, during the vacuum infusion process, a colorant is added to the infused resin to facilitate observing the flow of the resin.

[0024] The second object of the present invention can be achieved by adopting the following technical solutions:

[0025] A floating pontoon is formed by using the manufacturing method of the above floating pontoon.

[0026] Compared with the prior art, the present invention has the following advantages and beneficial effects:

[0027] The present invention first uses the vacuum infusion process to form a whole PU foam from several foam small pieces, then conducts secondary vacuum infusion on the PU foam to produce pontoon prefabrications, and then adhesively bonds the center steel cylinder after surface anti-corrosion treatment and the two pontoon prefabrications into a whole by the vacuum infusion process. Finally, a pontoon cast-in-place surface is made on the upper surfaces of the two pontoon prefabrications and the center steel cylinder by the vacuum infusion process, thereby preparing a complete pontoon product, which has the advantages of simple process, low cost, high efficiency, etc. By reasonably formulating the process route of the floating pontoon, mass production and popularization of the pontoon can be quickly realized; by adding a colorant to the infused resin, the infusion situation inside the large-volume foam can be well judged, thereby ensuring the infusion quality of the whole PU foam; by using the demolding platform to effectively splice the pontoon prefabrication and the center steel cylinder, the bonding quality between the pontoon prefabrication and the center steel cylinder is ensured. Description of the Drawings

[0028] Figure 1 It is a schematic diagram of the internal structure of the pontoon prefabrication in the present invention.

[0029] Figure 2 It is a schematic diagram of laying an ohmic tube on the surface of the center steel cylinder in the present invention.

[0030] Figure 3 It is the front view of the center steel cylinder and the two pontoon prefabrications after splicing in the present invention.

[0031] Figure 4 It is the top view of the center steel cylinder and the two pontoon prefabrications after splicing in the present invention. Detailed Embodiments

[0032] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the following will clearly and completely describe the technical solutions in the embodiments of the present invention with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are some, but not all, of the embodiments of the present invention. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts fall within the scope of protection of the present invention.

[0033] This embodiment provides a manufacturing method for a floating buoy, including the steps of:

[0034] S1. Manufacturing of buoy prefabricated parts

[0035] Each prefabricated part is formed by two-stage pouring. The first stage pours PU foam, and the second stage pours the outer contour sandwich structure on the outer surface of the PU foam.

[0036] The specific process of the first-stage pouring of PU foam is as follows: Lay vacuum infusion auxiliary materials on the upper surface of the mold core of the buoy prefabricated part mold, and then lay a layer of 808 g / m 2 biaxial fiberglass cloth on the surface of the vacuum infusion auxiliary materials. The fiberglass cloth is laid circumferentially along the mold core. During the laying process, it is required that the cloth layers overlap by 50 - 70 mm. Then, use a suction cup tooling to lift small pieces of foam to the corresponding positions on the upper surface of the fiberglass cloth, and at the same time splice the small pieces of foam 1 in sequence. Through the first-stage vacuum infusion, an overall PU foam is obtained. After curing, tear off the vacuum infusion auxiliary materials on the surface of the PU foam.

[0037] The specific process of the second-stage pouring of the outer contour sandwich structure on the outer surface of the PU foam is as follows: Lay a certain number of layers of inner fiberglass cloth 2, 20-mm-thick PVC foam 3, a certain number of layers of outer fiberglass cloth 4, and vacuum infusion auxiliary materials on the outer surface of the PU foam in sequence. Both the inner fiberglass cloth and the outer fiberglass cloth are composed of biaxial fiberglass cloth and triaxial fiberglass cloth. Among them, the inner fiberglass cloth is laid in the order of first biaxial fiberglass cloth and then triaxial fiberglass cloth, and the outer fiberglass cloth is laid in the order of first triaxial fiberglass cloth and then biaxial fiberglass cloth. Each laying layer is laid circumferentially along the PU foam. In addition, to ensure the pouring quality, lay a VAP air extraction bag on the surface of the vacuum infusion auxiliary materials for air extraction. Through the second-stage vacuum infusion, an outer contour sandwich structure is formed on the outer surface of the PU foam, thereby obtaining a buoy prefabricated part. Its specific structure is as Figure 1 shown. After demolding the buoy prefabricated part, place it on a supporting demolding platform for standby;

[0038] Manufacture another buoy prefabricated part according to the above operations and place it on a supporting demolding platform for standby;

[0039] S2. Anticorrosion treatment of the surface of the central steel cylinder

[0040] The surface of the central steel cylinder is sandblasted, and the central steel cylinder is transported to the designated work station by a flatbed truck. A layer of fiberglass cloth is laid on the surface of the central steel cylinder. The fiberglass cloth is an 808g / m 2 biaxial fiberglass cloth, which is laid circumferentially along the central steel cylinder. The lap between cloth layers is 50 - 70mm. To prevent the fiberglass cloth from slipping on the surface of the central steel cylinder, epoxy spray adhesive is used to fix the fiberglass cloth; as Figure 2 shown, a plurality of ohmic tubes 6 for vacuum infusion are arranged at intervals circumferentially along the central steel cylinder 5. Vacuum infusion auxiliary materials are laid axially along the central steel cylinder between every two adjacent ohmic tubes. An air extraction bag for vacuum infusion air extraction is laid on the upper surface of the vacuum infusion auxiliary materials. The width of the air extraction bag is smaller than the width of the vacuum infusion auxiliary materials. At the same time, the valves of all ohmic tubes are opened, and the central steel cylinder with surface anti-corrosion treatment is obtained through vacuum infusion;

[0041] S3. Splicing of two buoy prefabricated parts and the central steel cylinder

[0042] As Figure 3 、 Figure 4 shown, the central steel cylinder 5 with surface anti-corrosion treatment is moved to the designated position in the workshop. The flatbed truck is used to move the two buoy prefabricated parts 8 to the corresponding positions on the left and right sides below the central steel cylinder 5 through the demolding platform 7 respectively. The vacuum infusion auxiliary materials on the surface of the central steel cylinder are torn off, and a flow guide plate is laid on the lower surface of the central steel cylinder. Then, the two buoy prefabricated parts are spliced with the lower surface of the central steel cylinder. To ensure the splicing effect of the two buoy prefabricated parts, fiberglass cloth is laid at the splicing seam position, and then vacuum infusion auxiliary materials are laid. The two buoy prefabricated parts and the central steel cylinder are bonded into a whole through vacuum infusion; during the splicing process, the positions of the two buoy prefabricated parts can be adjusted at any time through the flatbed truck to achieve precise splicing of the prefabricated parts and the central steel cylinder.

[0043] S4. Fabrication of the cast-in-place surface of the buoy

[0044] Fiberglass cloth, small pieces of foam and vacuum infusion auxiliary materials are sequentially laid on the upper surfaces of the two buoy prefabricated parts and the central steel cylinder. The first vacuum infusion is carried out to obtain the PU foam layer structure of the cast-in-place surface. Then, inner fiberglass cloth, PVC foam, outer fiberglass cloth and vacuum infusion auxiliary materials are sequentially laid on the outer surface of the PU foam layer structure. The second vacuum infusion is carried out to obtain the outer contour sandwich layer structure of the cast-in-place surface, completing the infusion molding of the cast-in-place surface. The shape and size of the cast-in-place surface are consistent with the shape and size after the splicing of the two buoy prefabricated parts.

[0045] S5. Demolding and painting treatment

[0046] After demolding, the buoy product is prepared, and then painting operation is carried out on the surface of the buoy product.

[0047] Specifically, in steps S1 and S4, since the PU foam and the PU foam layer are large in volume and are each composed of multiple small foam pieces, and the volume of a single small foam piece is large (length * width * height is 4.2 m * 2.1 m * 1.2 m), in order to ensure the perfusion quality between the small foam pieces, cross-shaped shallow grooves are pre-opened on each contact surface during the processing of the small foam pieces. The cross-shaped shallow grooves serve as the flow channels for the resin. Compared with laying Ohm tubes on the surface of the PU foam as the glue injection channels, the operation is simple, the cost is low, the perfusion effect is better, and it is more suitable for the perfusion of large-volume foams. Additionally, after laying the small foam pieces, a biaxial fiberglass cloth with a gram weight of 400 g / m 2 can be laid between the foam seams to increase the bonding strength between the small foam pieces.

[0048] Specifically, in steps S1 and S4, epoxy spray glue is used to fix the laying positions of the inner fiberglass cloth and the outer fiberglass cloth respectively to prevent them from sliding down at the arc surface position.

[0049] Specifically, in this embodiment, a colorant is added to the perfusion resin to facilitate observing the flow of the resin, which is beneficial for on-site operators to judge the accurate end time of the perfusion.

[0050] This embodiment also provides a floating buoy, which is prepared and formed by using the above-mentioned manufacturing method of the floating buoy.

[0051] As mentioned above, only the preferred embodiments of this invention patent are described, but the protection scope of this invention patent is not limited thereto. Any person skilled in the art within the scope disclosed by this invention patent, according to the technical solution of this invention patent and its inventive concept, makes equivalent substitutions or changes, and all belong to the protection scope of this invention patent.

Claims

1. A manufacturing method of a floating buoy, characterized in that, Including the steps: S1. Manufacturing of buoy prefabricates Vacuum infusion auxiliary materials, fiberglass cloth, and small foam pieces are sequentially laid on the upper surface of the core of the buoy prefabricate mold. A PU foam integral body is obtained through the first vacuum infusion. After curing, the vacuum infusion auxiliary materials on the surface of the PU foam are torn off. Then, inner fiberglass cloth, PVC foam, outer fiberglass cloth, and vacuum infusion auxiliary materials are sequentially laid on the outer surface of the PU foam. An outer contour sandwich structure is formed on the outer surface of the PU foam through the second vacuum infusion, thereby obtaining the buoy prefabricate. After demolding the buoy prefabricate, it is placed on a matching demolding platform for standby; another buoy prefabricate is manufactured according to the above operations and placed on a matching demolding platform for standby; S2. Surface anti-corrosion treatment of the central steel cylinder The surface of the central steel cylinder is sandblasted. Fiberglass cloth is laid on its surface. A plurality of ohmic tubes for vacuum infusion are arranged at intervals along the circumferential direction of the central steel cylinder. Vacuum infusion auxiliary materials are laid along the axial direction of the central steel cylinder between every two adjacent ohmic tubes. An air extraction bag for vacuum infusion air extraction is laid on the upper surface of the vacuum infusion auxiliary materials. The central steel cylinder with surface anti-corrosion treatment is obtained through vacuum infusion; S3. Splicing of the buoy prefabricate and the central steel cylinder The central steel cylinder with anti-corrosion treatment on the surface is moved to the designated position. A flow guide plate is laid on the lower surface of the central steel cylinder. The two buoy prefabricates are respectively moved to the corresponding positions on the left and right sides below the central steel cylinder through the demolding platform. Then, the two buoy prefabricates are spliced with the lower surface of the central steel cylinder. Vacuum infusion auxiliary materials are laid, and the two buoy prefabricates and the central steel cylinder are bonded into a whole through vacuum infusion; S4. Manufacturing of the cast-in-place surface of the buoy Fiberglass cloth, small foam pieces, and vacuum infusion auxiliary materials are sequentially laid on the upper surfaces of the two buoy prefabricates and the central steel cylinder. The first vacuum infusion is carried out to obtain the PU foam layer structure of the cast-in-place surface. Then, inner fiberglass cloth, PVC foam, outer fiberglass cloth, and vacuum infusion auxiliary materials are sequentially laid on the outer surface of the PU foam layer structure. The second vacuum infusion is carried out to obtain the outer contour sandwich layer structure of the cast-in-place surface, and the casting and molding of the cast-in-place surface are completed; S5. Demolding and painting treatment After demolding, the buoy product is prepared, and then painting operation is carried out on the surface of the buoy product.

2. The manufacturing method of the floating buoy according to claim 1, characterized in that, In steps S1 and S4, cross-shaped shallow grooves facilitating resin flow are processed on each contact surface of each small foam piece, and fiberglass cloth for enhancing the bonding strength of the small foam pieces is laid between two adjacent small foam pieces.

3. The manufacturing method of the floating buoy according to claim 1, characterized in that, In steps S1 and S4, epoxy spray adhesive is used to fix the laying positions of the inner fiberglass cloth and the outer fiberglass cloth respectively.

4. The manufacturing method of the floating buoy according to claim 1, characterized in that, In step S1, the fiberglass cloth is laid along the circumferential direction of the core, and the cloth layer lap is required to be 50 - 70 mm during the laying process.

5. The manufacturing method of the floating buoy according to claim 1, characterized in that, In step S2, epoxy spray adhesive is used to fix the laying position of the fiberglass cloth.

6. The manufacturing method of the floating buoy according to claim 1, characterized in that, In step S3, fiberglass cloth is laid at the splicing seam position of the two buoy prefabricates.

7. The manufacturing method of the floating buoy according to claim 1, characterized in that, During the vacuum infusion process, a colorant is added to the infused resin to facilitate observing the resin flow condition.

8. A floating buoy, characterized in that, It is prepared and formed by using the manufacturing method of the floating buoy according to any one of claims 1 - 7.

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