A novel method for manufacturing a megawatt-class wind turbine blade trailing edge pasting corner mold

Abstract

The invention belongs to the technical field of wind power blade manufacturing, and provides a novel manufacturing method of a trailing edge pasting corner mold of a megawatt-class wind power blade, the manufacturing method of the trailing edge pasting corner mold of the blade comprising the following steps: curing and removing auxiliary materials, placing a pad, manufacturing a trailing edge pasting corner contour, trial mold fitting, manufacturing a trailing edge pasting corner mold, demoulding and trimming the mold, placing a pad in a trailing edge pasting corner manufacturing area of ​​a trailing edge pasting corner manufacturing surface shell, laying a layer of vacuum film and a layer of demoulding cloth on the inner side of the pad in sequence, which can be fixed by spraying glue, and then using hand-laid resin to completely soak X layers of fiber cloth, laying them on the inner side of the pad and the trailing edge pasting corner manufacturing surface shell, and auxiliary heating until completely cured; by using polyurethane foam glue to shape the trailing edge pasting corner mold, the degree of conformity is high, the process design is reasonable, the operation is simple, the cost is low, and there is no need to perform mold bonding, which greatly improves the quality of the trailing edge pasting corner and the trailing edge bonding of the blade.

Description

Technical Field

[0001] The invention belongs to the technical field of wind power blade manufacturing, in particular to a method for manufacturing a novel megawatt-class wind power blade trailing edge pasting corner mould. Background Art

[0002] With the reduction of non-renewable energy, renewable energy, such as wind power, photovoltaic and other energy sources, has gradually begun to occupy the mainstream, which can effectively reduce the dependence on non-renewable energy. Among them, wind power energy units mainly rely on wind power to drive the blades to rotate, and then the blades drive the generator to generate electricity. The blades are one of the most important components of the wind turbine and play an irreplaceable role. A wind turbine blade with excellent design, reliable quality and high-efficiency performance is the key factor to ensure the normal operation of the entire wind turbine.

[0003] At present, in the manufacturing process of wind turbine blades, the trailing edge bonding angle is an important structure of the wind turbine blades. Its function is to increase the bonding width between the trailing edge bonding angle manufacturing surface (generally the SS surface, hereinafter referred to as the SS surface) and the PS surface, and reduce the bonding gap between the SS surface and the PS surface. Therefore, the trailing edge bonding angle will directly affect the bonding quality of the wind turbine blades. The manufacturing of the trailing edge bonding angle is generally to shape the trailing edge bonding angle by placing a vacuum trailing edge bonding angle mold in the first layer of the laying process. The current manufacturing method of the trailing edge bonding angle mold in the industry is: hand-laying several layers of fiber cloth on the trailing edge boss and flange platform of the SS surface and the inner side of the PS surface shell and the trailing edge boss in the trailing edge bonding angle manufacturing area, and trial mold fitting is performed after curing. After matching, the hand-laid fiber cloths on the two surfaces are bonded together at the trailing edge boss position with adhesive, and then demolded, cut, polished, trimmed, and weighted.

[0004] Although the trailing edge bonding angle of the fan blade can be completed in the above production process, the following problems still exist:

[0005] 1. The mold making method requires two curings during production, and several trial molds are performed to verify the matching of the two hand-laid fiber cloths. The production process is cumbersome;

[0006] 2. Due to the limited width of the blade trailing edge boss, it is difficult to ensure the bonding quality; during the blade production process, if the trailing edge pasting corner mold cannot meet the current process requirements, it will take a lot of time to make it again. Summary of the invention

[0007] In order to solve the above technical problems, the present invention provides a method for manufacturing a new megawatt-class wind turbine blade trailing edge pasting corner mold, which solves the problems of complicated steps and low trailing edge bonding quality in the prior art of blade trailing edge pasting corner mold manufacturing by increasing the width of the trailing edge boss and other technologies.

[0008] The specific technical solutions of the present invention are as follows:

[0009] A novel method for manufacturing a corner mold for pasting the trailing edge of a megawatt-class wind power generation blade, the method comprising the following steps:

[0010] S1: Curing and removing auxiliary materials. After the blade is pre-cured, the vacuum auxiliary materials used to make the surface shell of the trailing edge adhesive corner are torn off, leaving only the demoulding cloth;

[0011] S2: placing a pad, placing a pad in the rear edge pasting angle production area of ​​the rear edge pasting angle production surface shell, the angle α between the pad and the rear edge pasting angle production surface shell is less than the theoretical value of the angle between the rear edge pasting angle and the rear edge pasting angle production surface shell; to ensure the stability of the pad placement, it can be bonded to the rear edge boss;

[0012] S3: Make the rear edge pasting corner contour, lay a layer of vacuum film and a layer of demoulding cloth on the inner side of the pad in sequence, which can be fixed by spray glue, and then use hand lay-up resin to completely soak X layers of fiber cloth, lay them on the inner side of the pad and the rear edge pasting corner production surface shell, and assist heating until completely cured, wherein X is preferably 4-8 layers;

[0013] S4: Test mold closing. After the rear edge pasting corner profile is solidified, the pad is removed, polyurethane foam glue is sprayed on the rear edge pasting corner profile, and the test mold closing is performed;

[0014] S5: making a rear edge pasting corner mold, after the polyurethane foam glue is cured, laying a vacuum film and a demoulding cloth on the polyurethane foam glue in sequence, the rear edges of the vacuum film and the demoulding cloth are turned over beyond the rear edge boss, and then laying N layers of fiber cloth soaked with hand paste resin, and then laying a layer of demoulding cloth on the N layers of fiber cloth, and auxiliary heating until completely cured;

[0015] S6: demoulding, demoulding the main part of the corner mold with the rear edge, tearing off the inner demoulding cloth, hand-laying M layers of fiber cloth inside, and then laying a layer of demoulding cloth, and auxiliary heating until completely cured;

[0016] S7: Finishing the mold. After the mold is made, the mold is polished and finished to meet the use requirements.

[0017] As a further improvement of the present solution, in step S2, the width D of the inner edge of the shell body made by the backing plate beyond the rear edge pasting angle is equal to the theoretical width of the rear edge pasting angle + 50 mm.

[0018] As a further improvement of this solution, in step S3, the width of the fiber cloth is D+200mm, and the width d of the fiber cloth on the shell body of the trailing edge pasting corner production surface is 200mm. After the trailing edge pasting corner mold is completed, the trailing edge pasting corner contour can be cut off, which will not affect the subsequent production of the blade.

[0019] As a further improvement of the present scheme, in step S4, the polyurethane foam glue is sprayed with a thickness of 3 times of the mold clearance, and its function is to shape; the shape of the polyurethane foam glue after the trial mold is that of the rear edge pasting corner, and the rear edge pasting corner mold made by shaping the polyurethane foam glue can be integrally formed without bonding, and has a very high degree of conformity.

[0020] As a further improvement of the present solution, in step S5, the main part of the rear edge pasting corner mold is made of N layers of fiber cloth soaked with hand-paste resin and then laid on the polyurethane foam glue and the rear edge flange platform.

[0021] As a further improvement of the present scheme, the width D of the N layers of fiber cloth in the direction of the shell body made at the rear edge pasting angle = the theoretical width of the rear edge pasting angle + 50 mm, and the width d of the fiber cloth flange beyond the rear edge boss is 200 mm; wherein N is preferably 20-25 layers, and the hand-laid thickness of a single layer of fiber cloth is 0.8 mm.

[0022] As a further improvement of the present solution, in step S5, the rear edge flanges of the vacuum film and the release cloth extend beyond the rear edge boss by 300 mm.

[0023] As a further improvement of the present solution, in step S6, the thickness of the hand-laid M layers of fiber cloth is equal to the mold gap at the rear edge, and the mold gap is calculated as 6±4 mm; wherein M is preferably 3-12 layers, and the thickness of a single layer of fiber cloth is 0.8 mm.

[0024] Compared with the prior art, the present invention has the following beneficial effects:

[0025] 1. The present invention uses polyurethane foam glue to shape the trailing edge sticking angle mold, which has high conformability, reasonable process design, simple operation, low cost, and no need for mold bonding, which greatly improves the quality of the trailing edge sticking angle and the trailing edge bonding of the blade. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 It is a manufacturing flow chart of the blade trailing edge pasting corner mold of the present invention;

[0027] Figure 2 It is a schematic diagram of the laying structure of the blade trailing edge pasting angle profile of the present invention;

[0028] Figure 3 It is a schematic diagram of laying the main part of the blade trailing edge pasting corner mold of the present invention;

[0029] Figure 4 It is a schematic diagram of laying M layers of fiber cloth of the corner pasting mold of the trailing edge of the blade of the present invention.

[0030] In the figure:

[0031] 1. Making the surface shell of the rear edge pasting corner; 2. The rear edge boss; 3. The pad; 4. The rear edge pasting corner profile; 5. The polyurethane foam; 6. The main part of the rear edge pasting corner mold; 7. The M-layer fiber cloth. DETAILED DESCRIPTION

[0032] The following embodiments of the present invention are described in further detail in conjunction with the accompanying drawings and examples. The following examples are used to illustrate the present invention, but are not intended to limit the scope of the present invention.

[0033] like Figure 1-4 As shown, the present invention proposes a novel method for manufacturing a corner mold for pasting the trailing edge of a megawatt-class wind power generation blade. The method for manufacturing the corner mold for pasting the trailing edge of the blade is specifically as follows:

[0034] Step 1: Curing and removing auxiliary materials

[0035] First, after the pre-curing of the blade is completed, the vacuum auxiliary material of the trailing edge adhesive corner production surface 1 (generally the SS surface, hereinafter referred to as the SS surface) is torn off, leaving only the demoulding cloth.

[0036] Step 2: Pad placement

[0037] A pad 3 is placed in the rear edge pasting angle production area of ​​the SS surface shell 1, and the angle α between the pad 3 and the rear edge pasting angle production surface shell 1 is less than the theoretical value of the angle between the rear edge pasting angle and the rear edge pasting angle production surface shell 1; the width D of the pad 3 beyond the inner edge of the SS surface shell 1 = the theoretical width of the rear edge pasting angle + 50mm;

[0038] In order to ensure the stability of the placement of the pad 3, it can be bonded to the rear edge boss 2.

[0039] Step 3: Make the back edge gluing corner outline

[0040] The rear edge pasting angle profile 4 is formed by impregnating X layers of fiber cloth with hand-paste resin, laying them on the inner side of the pad 3 and the SS surface shell 1 and curing them; a layer of vacuum film and a layer of demoulding cloth are laid on the inner side of the pad 3 in sequence, and can be fixed by spraying glue, and then the X layers of fiber cloth are completely impregnated with hand-paste resin, laid on the inner side of the pad 3 and the SS surface shell 1, and auxiliary heating is performed until they are completely cured;

[0041] The width of the fiber cloth is D+200 mm, the width d of the fiber cloth on the SS surface shell 1 is 200 mm, and X is generally 4-8 layers.

[0042] Step 4: Test mold

[0043] After the rear edge pasting corner contour 4 is cured, the pad 3 is removed, polyurethane foam glue 5 is sprayed on the top of the rear edge pasting corner contour 4 and a trial mold is performed. The spraying thickness of the polyurethane foam glue 5 is generally 3 times the mold gap, and its main function is shaping; the shape of the polyurethane foam glue 5 after the trial mold is the shape of the rear edge pasting corner. The rear edge pasting corner mold made by shaping the polyurethane foam glue 5 can be formed in one piece without bonding, and has a very high degree of conformity.

[0044] Step 5: Make the back edge sticking corner mold

[0045] The rear edge pasting corner mold main body 6 is made of N layers of fiber cloth soaked with hand paste resin and laid on the polyurethane foam glue 5 and the rear edge flange platform; specifically, after the polyurethane foam glue 5 is cured, a vacuum film and a demoulding cloth are laid on the polyurethane foam glue 5 in sequence, and the rear edge flanges of the vacuum film and the demoulding cloth exceed the rear edge boss 2 by 300mm, and then N layers of fiber cloth soaked with hand paste resin are laid, and then a layer of demoulding cloth is laid on the N layers of fiber cloth, and auxiliary heating is performed until it is completely cured; wherein N is preferably 20-25 layers;

[0046] It should be noted that: the width D of the fiber cloth in the direction of the SS surface shell 1 = the theoretical width of the rear edge bonding angle + 50 mm; the width d of the fiber cloth flange beyond the rear edge boss 2 is 200 mm.

[0047] Step 6: Demolding

[0048] After the main part 6 of the rear edge corner mold is cured, the main part 6 of the rear edge corner mold is demolded, the inner demoulding cloth is torn off, and M layers of fiber cloth 7 are hand-laid inside. The thickness of the hand-laid M layers of fiber cloth 7 is equal to the mold gap of the rear edge, and the mold gap is calculated as 6±4mm; wherein M is preferably 3-12 layers; and then a layer of demoulding cloth is laid, and auxiliary heating is performed until it is completely cured.

[0049] It should be noted that the thickness of the X-layer, N-layer and M-layer fiber cloths is about 0.8 mm for each single layer of fiber cloth.

[0050] Step 7: Trimming the mold

[0051] After the hand-laid M layers of fiber cloth 7 are solidified on the inner side of the main part 6 of the rear edge pasting corner mold, they are cut and trimmed to obtain a rear edge pasting corner mold with excellent performance, so that it meets the use requirements.

[0052] The embodiments of the present invention are provided for the purpose of illustration and description, and are not intended to be exhaustive or to limit the present invention to the disclosed forms. Although the present invention has been described in detail with reference to the aforementioned embodiments, it is still possible for those skilled in the art to modify the technical solutions described in the aforementioned embodiments, or to make equivalent substitutions for some of the technical features therein.

Claims

1. A method for manufacturing a new type of megawatt-class wind turbine blade trailing edge pasting corner mold, characterized in that: The method for making the blade trailing edge pasting corner mold comprises the following steps: S1: curing and removing auxiliary materials. After the blade is pre-cured, the vacuum auxiliary materials for making the surface shell (1) at the trailing edge adhesive corner are torn off, leaving only the demoulding cloth; S2: placing a pad, placing a pad (3) in the rear edge pasting angle production area of ​​the rear edge pasting angle production surface shell (1), the angle α between the pad (3) and the rear edge pasting angle production surface shell (1) is smaller than the theoretical value of the angle between the rear edge pasting angle and the rear edge pasting angle production surface shell (1); S3: Making the rear edge pasting corner profile (4), laying a layer of vacuum film and a layer of demoulding cloth on the inner side of the pad (3) in sequence, which can be fixed by spraying glue, and then using hand-laid resin to completely soak X layers of fiber cloth, laying them on the inner side of the pad (3) and the rear edge pasting corner making surface shell (1), and auxiliary heating until completely cured; S4: Test mold closing, after the rear edge pasting angle profile (4) is solidified, the backing plate (3) is removed, polyurethane foam glue (5) is sprayed on the rear edge pasting angle profile (4) and the test mold closing is performed; S5: Making the rear edge pasting corner mold main part (6), after the polyurethane foam glue (5) is solidified, laying a vacuum film and a demoulding cloth on the polyurethane foam glue (5) in sequence, the rear edges of the vacuum film and the demoulding cloth are turned over beyond the rear edge boss (2), and then laying N layers of fiber cloth soaked with hand-paste resin, and then laying a layer of demoulding cloth on the N layers of fiber cloth, and auxiliary heating until completely solidified; S6: demoulding, demoulding the main part (6) of the corner mold with the rear edge, tearing off the inner demoulding cloth, hand-laying M layers of fiber cloth (7) inside, and then laying another layer of demoulding cloth, and auxiliary heating until completely cured; S7: Finishing the mold. After the mold is made, the mold is polished and finished to meet the use requirements.

2. A method for manufacturing a novel megawatt-class wind turbine blade trailing edge pasting corner mold as claimed in claim 1, characterized in that: In step S2, the width D of the inner edge of the surface shell (1) produced by the pad (3) extending beyond the rear edge pasting angle = the theoretical width of the rear edge pasting angle + 50 mm.

3. A method for manufacturing a novel megawatt-class wind turbine blade trailing edge pasting corner mold as claimed in claim 2, characterized in that: In step S3, the width of the X layers of fiber cloth is D+200 mm, and the width d of the fiber cloth on the rear edge pasting corner to make the surface shell (1) is 200 mm.

4. The method for manufacturing a novel megawatt-class wind turbine blade trailing edge pasting corner mold as claimed in claim 1, characterized in that: In step S4, the polyurethane foam glue (5) is sprayed to a thickness of 3 times the mold clearance, and its function is to shape.

5. The method for manufacturing a novel megawatt-class wind turbine blade trailing edge pasting corner mold as claimed in claim 1, characterized in that: In step S5, the rear edge pasting corner mold main body (6) is made of N layers of fiber cloth soaked with hand-paste resin and then laid on the polyurethane foam glue (5) and the rear edge flange platform.

6. A method for manufacturing a novel megawatt-class wind turbine blade trailing edge pasting corner mold as claimed in claim 5, characterized in that: The width D of the N layers of fiber cloth in the direction of the rear edge bonding angle to make the surface shell body (1) = the theoretical width of the rear edge bonding angle + 50 mm, and the width d of the fiber cloth flange beyond the rear edge boss (2) is 200 mm.

7. The method for manufacturing a novel megawatt-class wind turbine blade trailing edge pasting corner mold as claimed in claim 1, characterized in that: In step S5, the rear edge flanges of the vacuum film and the release cloth extend beyond the rear edge boss (2) by 300 mm.

8. The method for manufacturing a novel megawatt-class wind turbine blade trailing edge pasting corner mold as claimed in claim 1, characterized in that: In step S6, the thickness of the hand-laid M-layer fiber cloth (7) is equal to the mold clearance at the rear edge.

Images