Segmented blade and manufacturing method thereof

Abstract

The present invention discloses a segmented blade and a manufacturing method thereof. The segmented blade includes: a first blade segment, the first blade segment includes a first barrel-shaped support, the first coupling portion of the first barrel-shaped support is provided with a first inclined surface; a second blade segment, the second blade segment includes a second barrel-shaped support, the second coupling portion of the second barrel-shaped support is provided with a second inclined surface, the first coupling portion is inserted into the second coupling portion, and adhesive is filled between the first inclined surface and the second inclined surface; a connecting member, which fastens the first coupling portion and the second coupling portion; a reinforcing member, which includes an inner sleeve and / or an outer sleeve. The first inclined surface and the second inclined surface facilitate positioning and installation, which helps to effectively transmit the axial load of the segmented blade; the combination of fastening connection and bonding makes it possible to accurately position the blade segment by fastening connection without the need for external tooling during bonding, thereby ensuring bonding and curing; and the reinforcement member is provided to share the local stress of the connecting member on the blade segment.

Description

Technical Field

[0001] The present invention relates to the technical field of blades, and in particular to a segmented blade and a manufacturing method thereof. Background Art

[0002] As blades get longer, the cost and difficulty of transporting them increase significantly. In order to reduce the difficulty of transportation and significantly save transportation costs, segmented blades are the main development trend in the future. The main purpose of connecting segmented blades is to ensure the continuous and effective load transmission of the main load-bearing structure. Generally, the connection of segmented blades is achieved through bonding, pinning, bolting and other connection methods. The existing structural design, molding method, coupling assembly positioning method of the segmented coupling position, etc., all have implementation defects in different aspects, for example:

[0003] Prior art CN110177933A discloses controlling the coupling accuracy of segmented blades through the forward, backward, upward, and downward, and left-right adjustments of tooling. However, this prior art, due to limitations such as the blade's aerodynamic shape and the thickness of the adhesive, requires a mobile plant with very high control precision. Furthermore, the complex and ever-changing terrain of wind farms severely limits the mobile plant's environmental adaptability. Furthermore, the time required to maintain various states of the mobile plant during blade bonding and curing significantly limits its efficiency. This prior art, therefore, suffers from weak self-positioning capabilities and requires the use of high-precision tooling to ensure the precise connection of the segmented blades.

[0004] The prior art CN101463795B and CN111051693A both disclose that only the main beams are overlapped at an angle, but since the prior art only overlaps the main beams at an angle, the load transfer capacity in all directions is relatively weak.

[0005] Prior art CN112955647A discloses connecting adjacent blade segments via a segmented connection structure. The segmented connection structure is a plug-in box girder structure, with both the root and tip sections being butt-jointed box girder structures. The root and tip box girders are not directly coupled but instead are coupled to the root and tip box girders, respectively, via a third box girder component. The third box girder is glued to the tip box girder, and the third box girder is pinned to the root box girder via a longitudinal pin. However, this prior art requires external tooling to stabilize the relative position of the blade segments and ensure the curing of the glue, resulting in a long construction period. Furthermore, to ensure accurate connection of the blade segments, the two blade segments are typically co-molded, then disassembled and post-processed in-plant before being reconnected outside the plant, resulting in poor interchangeability of the blade segments. Summary of the Invention

[0006] Therefore, the technical problem to be solved by the present invention is to overcome the above-mentioned defects in the prior art, thereby providing a segmented blade and a manufacturing method thereof.

[0007] A segmented blade comprising:

[0008] a first blade segment, the first blade segment comprising a first shell and a first barrel-shaped support member, a portion of the first barrel-shaped support member being located within and connected to the first shell, a first coupling portion of the first barrel-shaped support member being exposed from the first shell, each outer wall surface of the first coupling portion being provided with a first inclined surface, the first inclined surface being inclined toward an inner side of the first coupling portion in a direction approaching an adjacent end of the first blade segment;

[0009] a second blade segment, the second blade segment comprising a second outer shell and a second barrel-shaped support member, a portion of the second barrel-shaped support member being located within and connected to the second outer shell, a second coupling portion of the second barrel-shaped support member being exposed from the second outer shell, each inner wall surface of the second coupling portion being provided with a second inclined surface, the second inclined surface being inclined toward the outside of the second coupling portion in a direction close to an adjacent end of the second blade segment, the first coupling portion being inserted into the second coupling portion, and an adhesive being filled between the first inclined surface and the second inclined surface;

[0010] a connecting member, the connecting member fasteningly connecting the first coupling portion and the second coupling portion;

[0011] The reinforcement member includes an inner sleeve and / or an outer sleeve, wherein the inner sleeve is arranged on the inner side of the first coupling portion, and the outer sleeve is arranged on the outer side of the second coupling portion.

[0012] Furthermore, the ratio of the maximum thickness of the first inclined surface to the length of the first inclined surface is greater than or equal to and less than or equal to The ratio of the maximum thickness of the second inclined surface to the length of the second inclined surface is greater than or equal to and less than or equal to

[0013] Furthermore, the connecting member includes a bolt and a rivet nut, the rivet cap of the rivet nut is located between the first inclined surface and the second inclined surface, and the bolt is connected to the threaded rod of the rivet nut.

[0014] Furthermore, the outer sleeve is an outer lining frame, the outer lining frame is integrally formed or separately formed, and the outer lining frame and the second coupling portion are integrally formed or separately formed.

[0015] Furthermore, the inner liner sleeve includes an inner liner frame and an inner liner end cover, the inner liner end cover is arranged at the port of the inner liner frame, and the inner liner frame and the inner liner end cover are integrally formed or separately arranged.

[0016] Furthermore, the reinforcement member includes the inner sleeve and the outer sleeve; a limiting member is provided in the second barrel-shaped bearing member, and the limiting member limits the inner sleeve.

[0017] Furthermore, the limiting member is provided with a drainage hole.

[0018] A method for manufacturing a segmented blade comprises the following steps:

[0019] Molding: forming a first blade segment: forming the first blade segment by a first barrel-shaped carrier and a first outer shell, wherein each outer wall surface of a first coupling portion of the first barrel-shaped carrier is formed with a first inclined surface; forming the second blade segment by a second barrel-shaped carrier and a second outer shell, wherein each inner wall surface of a second coupling portion of the second barrel-shaped carrier is formed with a second inclined surface, and reinforcement members are connected to corresponding coupling portions;

[0020] Assembly: inserting the first coupling part into the second coupling part, fastening the first coupling part and the second coupling part through a connector, and filling adhesive between the first inclined surface and the second inclined surface.

[0021] Furthermore, the assembling further comprises: connecting a third shell to the first coupling portion and the second coupling portion, so that the first shell, the second shell and the third shell form an aerodynamic profile of the segmented blade.

[0022] Furthermore, the forming of the first blade segment by the first barrel-shaped carrier and the first shell includes: the first suction surface main beam of the first barrel-shaped carrier and the first suction surface shell of the first shell are integrally formed and located on the first mold, the first pressure surface main beam of the first barrel-shaped carrier and the first pressure surface shell of the first shell are integrally formed and located on the second mold, the first leading edge web of the first barrel-shaped carrier and the inner sides of the first trailing edge web of the first barrel-shaped carrier are connected by the inner sleeve of the reinforcement; the first leading edge web and the first trailing edge web are connected to one of the first suction surface shell and the first pressure surface shell and connected to the other of the first suction surface shell and the first pressure surface shell by closing the first mold and the second mold to form the first blade segment.

[0023] Furthermore, the formation of the first blade segment by the first barrel-shaped carrier and the first shell includes: chord-wise positioning of the first suction surface main beam, the first pressure surface main beam, the first leading edge web, and the first trailing edge web by chord-wise positioning members, and axial positioning of the first suction surface main beam, the first pressure surface main beam, the first leading edge web, and the first trailing edge web by axial positioning members, and the first mold and the second mold are both provided with the chord-wise positioning members and the axial positioning members.

[0024] Furthermore, the forming of the second blade segment by the second barrel-shaped carrier and the second shell includes: the second suction surface main beam of the second barrel-shaped carrier and the second suction surface shell of the second shell are integrally formed and located on the first mold, the second pressure surface main beam of the second barrel-shaped carrier and the second pressure surface shell of the second shell are integrally formed and located on the second mold, the second leading edge web of the second barrel-shaped carrier and the second trailing edge web of the second barrel-shaped carrier are connected by the limiting piece of the second barrel-shaped carrier, and the outer sleeve of the reinforcement is connected to the outside of the second coupling part; the second leading edge web and the second trailing edge web are connected to one of the second suction surface shell and the second pressure surface shell and connected to the other of the second suction surface shell and the second pressure surface shell by closing the first mold and the second mold to form the second blade segment.

[0025] Furthermore, the forming of the second blade segment by the second barrel-shaped carrier and the second shell also includes: chord-wise positioning of the second suction surface main beam, the second pressure surface main beam, the second leading edge web, and the second trailing edge web by chord-wise positioning members, and axial positioning of the second suction surface main beam, the second pressure surface main beam, the second leading edge web, and the second trailing edge web by axial positioning members, and the first mold and the second mold are both provided with the chord-wise positioning members and the axial positioning members.

[0026] Furthermore, fastening the first coupling part and the second coupling part by a connector includes: inserting the first coupling part into the second coupling part, and drilling a hole through the outer bushing, the first coupling part, the second coupling part, and the inner bushing to form a mounting hole.

[0027] Furthermore, the fastening connection between the first coupling part and the second coupling part by a connecting member also includes: separating the first blade segment and the second blade segment, expanding the mounting holes on the first coupling part and the inner sleeve, installing the rivet nut of the connecting member on the first coupling part and the inner sleeve, and connecting the second coupling part and the rivet nut by the bolt of the connecting member.

[0028] Further, based on the above segmented blade.

[0029] The technical solution of the present invention has the following advantages:

[0030] 1. The present invention provides a segmented blade, comprising: a first blade segment, the first blade segment comprising a first shell and a first barrel-shaped support member, a portion of the first barrel-shaped support member being located within and connected to the first shell, a first coupling portion of the first barrel-shaped support member being exposed from the first shell, each outer wall surface of the first coupling portion being provided with a first inclined surface, the first inclined surface being inclined toward the inner side of the first coupling portion in a direction close to an adjacent end of the first blade segment; a second blade segment, the second blade segment comprising a second shell and a second barrel-shaped support member, a portion of the second barrel-shaped support member being located within and connected to the second shell. Two shells, the second coupling part of the second barrel-shaped support is exposed in the second shell, and each inner wall surface of the second coupling part is provided with a second inclined surface, and the second inclined surface is inclined toward the outer side of the second coupling part along the direction close to the end of the adjacent second blade segment, and the first coupling part is inserted into the second coupling part, and the first inclined surface and the second inclined surface are filled with adhesive; a connecting part, the connecting part fastens the first coupling part and the second coupling part; a reinforcement part, the reinforcement part includes an inner sleeve and / or an outer sleeve, wherein the inner sleeve is arranged on the inner side of the first coupling part, and the outer sleeve is arranged on the outer side of the second coupling part. A segmented blade of this structure is provided with a first barrel-shaped support member having a first inclined surface and a second barrel-shaped support member having a second inclined surface, so that the first inclined surface and the second inclined surface are overlapped and connected, which is convenient for positioning and installing the first coupling part and the second coupling part, and helps to effectively transmit the axial load of the segmented blade; through the cooperation of fastening connection and bonding, it is not necessary to use external tooling to position the blade segment during bonding, but the blade segment is accurately positioned by means of fastening connection, ensuring bonding and curing, ensuring the connection accuracy and connection strength of the segmented blade, which is beneficial to wind farm construction; by providing reinforcement parts, the local stress of the connecting parts on the blade segment is shared, providing sufficient strength.

[0031] 2. In a segmented blade provided herein, the connecting member comprises a bolt and a rivet nut, the rivet cap of the rivet nut being located between the first and second inclined surfaces, and the bolt being connected to the threaded rod of the rivet nut. In a segmented blade of this structure, the rivet cap has a thickness, which provides space for adhesive bonding.

[0032] 3. In a segmented blade provided by the present invention, the reinforcement member comprises the inner sleeve and the outer sleeve; a stopper is provided within the second barrel-shaped support member to limit the position of the inner sleeve. This segmented blade structure facilitates the initial positioning of the first and second blade segments through the cooperation of the stopper and the inner sleeve.

[0033] 4. In the segmented blade provided by the present invention, the limiting member is provided with a drainage hole. The segmented blade of this structure is provided with a drainage hole, which is beneficial to the drainage of the interior of the first blade segment.

[0034] 5. The present invention provides a method for manufacturing a segmented blade, comprising the following steps: molding: forming a first blade segment: forming the first blade segment by a first barrel-shaped carrier and a first outer shell, wherein a first inclined surface is formed on each outer wall surface of the first coupling portion of the first barrel-shaped carrier; forming a second blade segment by a second barrel-shaped carrier and a second outer shell, wherein a second inclined surface is formed on each inner wall surface of the second coupling portion of the second barrel-shaped carrier, and a reinforcement member is connected to the corresponding coupling portion; assembling: inserting the first coupling portion into the second coupling portion, fastening the first coupling portion and the second coupling portion through a connecting member, and filling adhesive between the first inclined surface and the second inclined surface. In this step, a method for manufacturing segmented blades is provided, in which the first inclined surface of the first barrel-shaped support member is overlapped and connected to the second barrel-shaped support member having a second inclined surface, so as to facilitate the positioning and installation of the first coupling part and the second coupling part, and contribute to the effective transmission of the axial load of the segmented blade; through the coordination of fastening connection and bonding, it is not necessary to use external tooling to position the blade segment during bonding, but the blade segment is accurately positioned with the help of fastening connection, thereby ensuring the curing of the adhesive, and ensuring the connection accuracy and connection strength of the segmented blade, which is beneficial to the construction of the wind farm; by connecting with reinforcement parts, the local stress of the connecting parts on the blade segment is shared, and sufficient strength is provided.

[0035] 6. The present invention provides a method for manufacturing a segmented blade, wherein forming a first blade segment using the first barrel-shaped carrier and the first outer shell includes: chordwise positioning of the first suction side main beam, the first pressure side main beam, the first leading edge web, and the first trailing edge web using chordwise positioning members, and axially positioning the first suction side main beam, the first pressure side main beam, the first leading edge web, and the first trailing edge web using axial positioning members, wherein both the first mold and the second mold are provided with the chordwise positioning members and the axial positioning members. Forming a second blade segment using the second barrel-shaped carrier and the second outer shell also includes: chordwise positioning of the second suction side main beam, the second pressure side main beam, the second leading edge web, and the second trailing edge web using chordwise positioning members, and axially positioning the second suction side main beam, the second pressure side main beam, the second leading edge web, and the second trailing edge web using axial positioning members, wherein both the first mold and the second mold are provided with the chordwise positioning members and the axial positioning members. In this step, a method for manufacturing a segmented blade can realize different-mold forming of two blade segments through a first mold and a second mold, which can improve the interchangeability of the blade segments; and when the segmented blade needs to be extended, the blade tip can be replaced and then other blade segments can be plugged in to achieve this; and by providing chordal positioning parts and axial positioning parts, the molding accuracy can be ensured.

[0036] 7. The present invention provides a method for manufacturing a segmented blade, wherein the method of fastening the first coupling portion and the second coupling portion with a connector further comprises: separating the first and second blade segments, enlarging the mounting holes on the first coupling portion and the inner sleeve, installing a rivet nut of the connector on the first coupling portion and the inner sleeve, and connecting the second coupling portion and the rivet nut with a bolt of the connector. This step of the method for manufacturing a segmented blade involves enlarging the mounting holes to accommodate the bolts of the connector. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] In order to more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the specific embodiments or the description of the prior art. Obviously, the drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0038] Figure 1 A cross-sectional view of the first tub-shaped carrier and the second tub-shaped carrier provided in Example 1 of the present invention when connected;

[0039] Figure 2 for Figure 1The first barrel-shaped carrier and the second barrel-shaped carrier are shown as schematic structural diagrams without bolts;

[0040] Figure 3 for Figure 1 The schematic structural diagram of the first blade segment shown;

[0041] Figure 4 for Figure 3 The first blade section shown is a schematic diagram showing the structure of the inner liner;

[0042] Figure 5 for Figure 1 A schematic structural diagram of the second blade segment shown;

[0043] Figure 6 for Figure 5 The second blade segment shown shows a schematic structural diagram of the outer liner;

[0044] Figure 7 for Figure 5 A schematic structural diagram of the second blade segment, the first mold and the second mold shown;

[0045] Figure 8 for Figure 7 A cross-sectional view of the first mold and the second mold being molded together;

[0046] Figure 9 for Figure 7 A schematic structural diagram of the first blade segment and the second mold shown;

[0047] Figure 10 for Figure 1 The schematic structural diagram of the first blade segment and the second blade segment when plugged in is shown;

[0048] Figure 11 for Figure 10 The schematic diagram of the structure of the first blade segment and the second blade segment when plugged in does not show part of the housing;

[0049] Figure 12 for Figure 10 The first blade segment and the second blade segment are shown as schematic structural diagrams showing mounting holes;

[0050] Figure 13 for Figure 12 The first blade segment and the second blade segment are schematic structural diagrams showing the stopper and the inner sleeve;

[0051] Description of reference numerals:

[0052] 11-first shell, 111-first suction surface shell, 112-first pressure surface shell, 12-first barrel-shaped bearing member, 121-first suction surface main beam, 122-first pressure surface main beam, 123-first leading edge web, 124-first trailing edge web, 13-first coupling portion, 131-first inclined surface, 21-second shell, 211-second suction surface shell, 212-second pressure surface shell, 22-second barrel-shaped bearing member, 221- Second suction surface main beam, 222-second pressure surface main beam, 223-second leading edge web, 224-second trailing edge web, 23-second coupling part, 231-second inclined surface, 31-bolt, 32-rivet nut, 321-rivet cap, 41-inner sleeve, 42-outer sleeve, 5-limiting part, 61-first mold, 62-second mold, 71-chordal positioning part, 72-axial positioning part, 73-positioning hole, 74-positioning column, 8-mounting hole. DETAILED DESCRIPTION

[0053] The technical solution of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the embodiments described are only some embodiments of the present invention, not all embodiments. All other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention without making any creative efforts shall fall within the scope of protection of the present invention.

[0054] In the description of the present invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings and are intended solely to facilitate and simplify the description of the present invention. They are not intended to indicate or imply that the devices or components referred to must have, be constructed, or operate in a specific orientation, and therefore should not be construed as limitations on the present invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0055] In the description of the present invention, it should be noted that, unless otherwise expressly specified or limited, the terms "mounted," "connected," and "connected" should be understood in a broad sense. For example, they may refer to fixed, detachable, or integral connections; mechanical or electrical connections; direct or indirect connections through an intermediate medium; and internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on the specific circumstances.

[0056] In addition, the technical features involved in the different embodiments of the present invention described below can be combined with each other as long as they do not conflict with each other.

[0057] Example 1

[0058] This embodiment provides Figures 1 to 13 A segmented blade shown in FIG. 1 includes a first blade segment, a second blade segment, a connector, and a reinforcement. The first blade segment includes a first outer shell 11 and a first tubular support 12. A portion of the first tubular support 12 is located within and connected to the first outer shell 11, with a first coupling portion 13 of the first tubular support 12 exposed outside the first outer shell 11. The second blade segment includes a second outer shell 21 and a second tubular support 22. A portion of the second tubular support 22 is located within and connected to the second outer shell 21, with a second coupling portion 23 exposed outside the second outer shell 21. The connector securely connects the first coupling portion 13 and the second coupling portion 23.

[0059] like Figure 1 and Figure 2 As shown, each outer wall surface of the first coupling part 13 is provided with a first inclined surface 131, and the first inclined surface 131 is inclined toward the inner side of the first coupling part 13 along the direction close to the end of the adjacent first blade segment; each inner wall surface of the second coupling part 23 is provided with a second inclined surface 231, and the second inclined surface 231 is inclined toward the outer side of the second coupling part 23 along the direction close to the end of the adjacent second blade segment. The first coupling part 13 is inserted into the second coupling part 23, and an adhesive is filled between the first inclined surface 131 and the second inclined surface 231, wherein the second inclined surface 231 is adapted to the first inclined surface 131.

[0060] The ratio of the maximum thickness of the first inclined surface 131 to the length of the first inclined surface 131 is greater than or equal to and less than or equal to The ratio of the maximum thickness of the second inclined surface 231 to the length of the second inclined surface 231 is greater than or equal to and less than or equal to It should be noted that the maximum thickness of the first inclined surface 131 refers to the maximum thickness of the first inclined surface 131 at Figure 1 The thickness at the rightmost position of the first bevel 131 is greater than the thickness at other positions of the first bevel 131, and is the maximum thickness of the first bevel 131. The length of the first bevel 131 refers to the thickness of the first bevel 131 at the rightmost position of the first bevel 131. Figure 1 The length from the rightmost position to the leftmost position; and the maximum thickness of the second inclined surface 231 refers to the second inclined surface 231 in Figure 1 The thickness at the leftmost position of the second slope 231 is greater than the thickness at other positions of the second slope 231, and is the maximum thickness of the second slope 231. The length of the second slope 231 refers to the thickness of the second slope 231 at the leftmost position of the second slope 231. Figure 1 The length from the leftmost position to the rightmost position in .

[0061] like Figure 1 、 Figure 2 、 Figure 4 and Figure 6 As shown, the reinforcement member includes an inner sleeve 41 and an outer sleeve 42, wherein the inner sleeve 41 is provided on the inner side of the first coupling portion 13 and the outer sleeve 42 is provided on the outer side of the second coupling portion 23. As an alternative embodiment, the reinforcement member may include the inner sleeve 41 or the outer sleeve 42.

[0062] Specifically, the outer lining sleeve 42 is an outer lining frame, which is integrally formed or split, and the outer lining frame and the second coupling part 23 are integrally formed or split; and the inner lining sleeve 41 includes an inner lining frame and an inner lining end cover, which is arranged at the port of the inner lining frame, and the inner lining frame and the inner lining end cover are integrally formed or split.

[0063] like Figure 1 and Figure 2 As shown, the connecting member includes a bolt 31 and a rivet nut 32. The rivet cap 321 of the rivet nut 32 is located between the first inclined surface 131 and the second inclined surface 231. The bolt 31 is connected to the screw rod of the rivet nut 32. Since the rivet cap 321 has a thickness, this thickness can provide space for the adhesive to bond.

[0064] like Figure 4 、 Figure 7 and Figure 13 As shown, a stopper 5 is provided within the second barrel-shaped support member 22, which limits the position of the inner sleeve 41. The cooperation between the stopper 5 and the inner sleeve 41 facilitates the initial positioning of the first and second blade segments. The stopper 5 is provided with a drainage hole, which facilitates drainage from within the first blade segment.

[0065] In this embodiment, a segmented blade is provided with a first barrel-shaped support member 12 having a first inclined surface 131 and a second barrel-shaped support member 22 having a second inclined surface 231, so that the first inclined surface 131 and the second inclined surface 231 are overlapped and connected, which is convenient for positioning and installing the first coupling part 13 and the second coupling part 23, and helps to effectively transmit the axial load of the segmented blade; through the cooperation of fastening connection and bonding, there is no need to use external tooling to position the blade segment during bonding, but the blade segment is accurately positioned by means of fastening connection, ensuring bonding and curing, ensuring the connection accuracy and connection strength of the segmented blade, and thus facilitating wind farm construction; by providing a reinforcement, the local stress of the connecting member on the blade segment is shared, providing sufficient strength.

[0066] Example 2

[0067] This embodiment provides a method for manufacturing a segmented blade, which may be based on the segmented blade in Embodiment 1 and includes the following steps:

[0068] Molding: Forming the first blade segment: The first blade segment is formed by the first barrel-shaped carrier 12 and the first outer shell 11, wherein each outer wall surface of the first coupling portion 13 of the first barrel-shaped carrier 12 is formed with a first inclined surface 131; the second blade segment is formed by the second barrel-shaped carrier 22 and the second outer shell 21, wherein each inner wall surface of the second coupling portion 23 of the second barrel-shaped carrier 22 is formed with a second inclined surface 231, and reinforcement members are connected to the corresponding coupling portions;

[0069] Specifically, forming the first blade segment by the first barrel-shaped carrier 12 and the first shell 11 includes: Figure 3 and Figure 4 As shown, the first suction side main beam 121 of the first tub-shaped carrier 12 and the first suction side shell 111 of the first outer shell 11 are integrally cast and positioned in the first mold 61; the first pressure side main beam 122 of the first tub-shaped carrier 12 and the first pressure side shell 112 of the first outer shell 11 are integrally cast and positioned in the second mold 62; the first leading edge web 123 of the first tub-shaped carrier 12 and the first trailing edge web 124 of the first tub-shaped carrier 12 are bonded together via the inner liner 41 of the first tub-shaped carrier 12; the first leading edge web 123 and the first trailing edge web 124 are bonded together to one of the first suction side shell 111 and the first pressure side shell 112 and then bonded together to the other of the first suction side shell 111 and the first pressure side shell 112 by closing the first mold 61 and the second mold 62 to form a first blade segment;

[0070] The first suction surface main beam 121, the first pressure surface main beam 122, the first leading edge web 123, and the first trailing edge web 124 are chord-wise positioned on the first mold 61 and the second mold 62 by the chord-wise positioning member 71, and the first suction surface main beam 121, the first pressure surface main beam 122, the first leading edge web 123, and the first trailing edge web 124 are axially positioned on the first mold 61 and the second mold 62 by the axial positioning member 72. The first mold 61 and the second mold 62 are both provided with the chord-wise positioning member 71 and the axial positioning member 72. The first mold 61 and the second mold 62 can realize different-molding of the two blade segments, thereby improving the interchangeability of the blade segments. When the segmented blade needs to be extended, the blade tip can be replaced and then other blade segments can be plugged in to achieve this. The chord-wise positioning member 71 and the axial positioning member 72 can ensure the molding accuracy.

[0071] See Figure 7 and Figure 8The chord-wise positioning member 71 includes chord-wise positioning blocks that are relatively arranged, and the axial positioning member 72 is an axial positioning plate. The axial positioning plate is connected to the chord-wise positioning block. The chord-wise positioning block of one of the first mold 61 and the second mold 62 is provided with a positioning column 74 and the chord-wise positioning block of the other of the two is provided with a positioning hole 73. When the first mold 61 and the second mold 62 are closed, the positioning column 74 is inserted into the positioning hole 73.

[0072] In addition, first inclined surfaces are respectively processed at the first coupling portions formed on the first suction surface main beam, the first pressure surface main beam, the first leading edge web, and the first trailing edge web.

[0073] And, forming the second blade segment by the second barrel-shaped carrier 22 and the second shell 21 includes: Figures 5 to 9 As shown, the second suction side main beam 221 of the second tub-shaped carrier 22 and the second suction side shell 211 of the second shell 21 are integrally cast and located on the first mold 61; the second pressure side main beam 222 of the second tub-shaped carrier 22 and the second pressure side shell 212 of the second shell 21 are integrally cast and located on the second mold 62; the second leading edge web 223 of the second tub-shaped carrier 22 and the second trailing edge web 224 of the second tub-shaped carrier 22 are bonded together via the limiting member 5 of the second tub-shaped carrier 22; the second leading edge web 223 and the second trailing edge web 224 are bonded together to one of the second suction side shell 211 and the second pressure side shell 212 and bonded together to the other of the second suction side shell 211 and the second pressure side shell 212 by closing the first mold 61 and the second mold 62 to form a second blade segment;

[0074] Among them, such as Figure 7 and Figure 9 As shown, the second suction surface main beam 221, the second pressure surface main beam 222, the second leading edge web 223, and the second trailing edge web 224 are positioned chordwise by the chordwise positioning member 71, and the second suction surface main beam 221, the second pressure surface main beam 222, the second leading edge web 223, and the second trailing edge web 224 are positioned axially by the axial positioning member 72;

[0075] In addition, second inclined surfaces 231 are processed respectively on the second suction surface main beam 221 , the second pressure surface main beam 222 , the second leading edge web 223 , and the second trailing edge web 224 to form the second coupling portion 23 ; an outer bushing 42 is bonded and connected to the outside of the second coupling portion 23 .

[0076] Assembly: In a wind farm, the first coupling portion 13 of the first tub-shaped carrier 12 is inserted into the second coupling portion 23 of the second tub-shaped carrier 22. During this process, external tooling, a crane, etc. can be used to define the coupling posture. The first coupling portion 13 and the second coupling portion 23 are fastened together by connectors. At this time, the external tooling, crane, etc. can be removed, and the adhesive is filled between the first inclined surface 131 and the second inclined surface 231. The lowering process can be carried out without waiting for the curing to be completed. The third shell is then connected to the first coupling portion 13 and the second coupling portion 23 to seal the first coupling portion 13 and the second coupling portion 23, so that the first shell 11, the second shell 21 and the third shell form the aerodynamic profile of the segmented blade.

[0077] Specifically, fastening the first coupling portion 13 and the second coupling portion 23 by the connecting member includes: Figure 10 and Figure 11 As shown, the first coupling portion 13 of the first tub-shaped carrier 12 is inserted into the second coupling portion 23 of the second tub-shaped carrier 22, as shown in FIG. Figure 12 As shown, a hole is drilled through the outer sleeve 42, the first coupling portion 13, the second coupling portion 23, and the inner sleeve 41 to form the mounting hole 8. The first and second blade segments are separated, and the mounting hole 8 located on the first coupling portion 13 and the inner sleeve 41 is enlarged. The rivet nut 32 of the connecting member is installed on the first coupling portion 13 and the inner sleeve 41, and the second coupling portion 23 and the rivet nut 32 are connected by the bolt 31 of the connecting member. The enlarged hole makes the mounting hole 8 fit the bolt 31 of the connecting member.

[0078] It should be noted that the first suction surface main beam 121, the first pressure surface main beam 122, the second suction surface main beam 221, and the second pressure surface main beam 222 can be made of pultruded plates or other materials, the first outer shell 11 and the second outer shell 21 can be made of skin or other materials, the area where the first leading edge web 123 and the first trailing edge web 124 form the first coupling part 13 and the area where the second leading edge web 223 and the second trailing edge web 224 form the second coupling part 23 can be made of pultruded plates or other materials, the other areas where the first leading edge web 123 and the first trailing edge web 124 do not form the first coupling part 13 and the other areas where the second leading edge web 223 and the second trailing edge web 224 do not form the second coupling part 23 can be made of fiberglass sandwich composite or other materials, the inner liner 41 can be made of glass fiber, resin or other materials, and the outer liner 42 can be made of glass fiber, resin or other materials.

[0079] In this embodiment, a method for manufacturing a segmented blade is provided, in which the first inclined surface 131 of the first barrel-shaped support member 12 is overlapped and connected to the second barrel-shaped support member 22 having the second inclined surface 231, so as to facilitate the positioning and installation of the first coupling portion 13 and the second coupling portion 23, and contribute to the effective transmission of the axial load of the segmented blade; through the coordination of fastening connection and bonding, it is not necessary to use external tooling to position the blade segment during bonding, but the blade segment is accurately positioned by means of fastening connection, thereby ensuring the curing of the adhesive, and ensuring the connection accuracy and connection strength of the segmented blade, which is beneficial to the construction of the wind farm; by connecting with a reinforcement member, the local stress of the connection member on the blade segment is shared, and sufficient strength is provided.

[0080] Obviously, the above embodiments are merely examples for clarity of explanation and are not intended to limit the implementation methods. Those skilled in the art will readily appreciate that other variations or modifications based on the above descriptions are possible. It is not necessary and impossible to enumerate all implementation methods here. Obvious variations or modifications arising therefrom remain within the scope of protection of the present invention.

Claims

1. A segmented blade, characterized in that: include: a first blade segment, the first blade segment comprising a first shell and a first barrel-shaped support member, a portion of the first barrel-shaped support member being located within and connected to the first shell, a first coupling portion of the first barrel-shaped support member being exposed from the first shell, each outer wall surface of the first coupling portion being provided with a first inclined surface, the first inclined surface being inclined toward an inner side of the first coupling portion in a direction approaching an adjacent end of the first blade segment; a second blade segment, the second blade segment comprising a second outer shell and a second barrel-shaped support member, a portion of the second barrel-shaped support member being located within and connected to the second outer shell, a second coupling portion of the second barrel-shaped support member being exposed from the second outer shell, each inner wall surface of the second coupling portion being provided with a second inclined surface, the second inclined surface being inclined toward the outside of the second coupling portion in a direction close to an adjacent end of the second blade segment, the first coupling portion being inserted into the second coupling portion, and an adhesive being filled between the first inclined surface and the second inclined surface; a connecting member, the connecting member fasteningly connecting the first coupling portion and the second coupling portion; The reinforcement member includes an inner sleeve and / or an outer sleeve, wherein the inner sleeve is arranged on the inner side of the first coupling portion, and the outer sleeve is arranged on the outer side of the second coupling portion.

2. A segmented blade according to claim 1, characterized in that: The ratio of the maximum thickness of the first inclined surface to the length of the first inclined surface is greater than or equal to and less than or equal to the ratio of the maximum thickness of the second inclined surface to the length of the second inclined surface is greater than or equal to and less than or equal to.

3. A segmented blade according to claim 1 or 2, characterized in that: The connecting member includes a bolt and a rivet nut, the rivet cap of the rivet nut is located between the first inclined surface and the second inclined surface, and the bolt is connected to the screw rod of the rivet nut.

4. A segmented blade according to claim 1 or 2, characterized in that: The outer sleeve is an outer lining frame, the outer lining frame is integrally formed or separately formed, and the outer lining frame and the second coupling part are integrally formed or separately formed.

5. A segmented blade according to claim 1 or 2, characterized in that: The inner liner sleeve includes an inner liner frame and an inner liner end cover. The inner liner end cover is arranged at the port of the inner liner frame. The inner liner frame and the inner liner end cover are integrally formed or separately arranged.

6. A segmented blade according to claim 1 or 2, characterized in that: The reinforcement member includes the inner sleeve and the outer sleeve; a limiting member is provided in the second barrel-shaped bearing member, and the limiting member limits the position of the inner sleeve.

7. A segmented blade according to claim 6, characterized in that: The limiting member is provided with a drainage hole.

8. A method for manufacturing a segmented blade, characterized in that: For manufacturing the segmented blade according to any one of claims 1 to 7, the method comprises the following steps: Molding: forming a first blade segment: forming the first blade segment by a first barrel-shaped carrier and a first outer shell, wherein each outer wall surface of a first coupling portion of the first barrel-shaped carrier is formed with a first inclined surface; forming the second blade segment by a second barrel-shaped carrier and a second outer shell, wherein each inner wall surface of a second coupling portion of the second barrel-shaped carrier is formed with a second inclined surface, and reinforcement members are connected to corresponding coupling portions; Assembly: inserting the first coupling part into the second coupling part, fastening the first coupling part and the second coupling part through a connector, and filling adhesive between the first inclined surface and the second inclined surface.

9. A method for manufacturing a segmented blade according to claim 8, characterized in that: The assembling further includes connecting a third shell to the first coupling portion and the second coupling portion such that the first shell, the second shell, and the third shell form an aerodynamic profile of the segmented blade.

10. The method for manufacturing a segmented blade according to claim 8, characterized in that: The forming of the first blade segment by the first tub-shaped carrier and the first shell includes: the first suction surface main beam of the first tub-shaped carrier and the first suction surface shell of the first shell are integrally formed and located on a first mold; the first pressure surface main beam of the first tub-shaped carrier and the first pressure surface shell of the first shell are integrally formed and located on a second mold; the inner sides of the first leading edge web of the first tub-shaped carrier and the first trailing edge web of the first tub-shaped carrier are connected by the inner sleeve of the reinforcement; the first leading edge web and the first trailing edge web are connected to one of the first suction surface shell and the first pressure surface shell and are connected to the other of the first suction surface shell and the first pressure surface shell by closing the first mold and the second mold to form the first blade segment.

11. A method for manufacturing a segmented blade according to claim 10, characterized in that: The formation of the first blade segment by the first barrel-shaped carrier and the first shell includes: chord-wise positioning of the first suction surface main beam, the first pressure surface main beam, the first leading edge web, and the first trailing edge web by chord-wise positioning members, and axial positioning of the first suction surface main beam, the first pressure surface main beam, the first leading edge web, and the first trailing edge web by axial positioning members, and the first mold and the second mold are both provided with the chord-wise positioning members and the axial positioning members.

12. The method for manufacturing a segmented blade according to claim 10, characterized in that: The forming of the second blade segment by the second barrel-shaped carrier and the second shell includes: the second suction surface main beam of the second barrel-shaped carrier and the second suction surface shell of the second shell are integrally formed and located on the first mold, the second pressure surface main beam of the second barrel-shaped carrier and the second pressure surface shell of the second shell are integrally formed and located on the second mold, the second leading edge web of the second barrel-shaped carrier and the second trailing edge web of the second barrel-shaped carrier are connected by the limiting piece of the second barrel-shaped carrier, and the outer side of the second coupling portion is connected with the outer sleeve of the reinforcement; the second leading edge web and the second trailing edge web are connected to one of the second suction surface shell and the second pressure surface shell, and are connected to the other of the second suction surface shell and the second pressure surface shell by closing the first mold and the second mold to form the second blade segment.

13. A method for manufacturing a segmented blade according to claim 12, characterized in that: The forming of the second blade segment by the second barrel-shaped carrier and the second shell also includes: chord-wise positioning of the second suction surface main beam, the second pressure surface main beam, the second leading edge web, and the second trailing edge web by chord-wise positioning members, and axial positioning of the second suction surface main beam, the second pressure surface main beam, the second leading edge web, and the second trailing edge web by axial positioning members, and the first mold and the second mold are both provided with the chord-wise positioning members and the axial positioning members.

14. A method for manufacturing a segmented blade according to claim 13, characterized in that: The fastening connection between the first coupling part and the second coupling part by the connector includes: inserting the first coupling part into the second coupling part, and drilling a hole through the outer bushing, the first coupling part, the second coupling part, and the inner bushing to form a mounting hole.

15. A method for manufacturing a segmented blade according to claim 14, characterized in that: The fastening connection between the first coupling part and the second coupling part by a connecting member further includes: separating the first blade segment and the second blade segment, expanding the mounting holes on the first coupling part and the inner sleeve, installing the rivet nut of the connecting member on the first coupling part and the inner sleeve, and connecting the second coupling part and the rivet nut by the bolt of the connecting member.

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