A method for manufacturing a web mold for a wind turbine blade

Abstract

The present invention relates to the technical field of wind turbine blade manufacturing, and specifically provides a method for manufacturing a web plate mold for a wind turbine blade, comprising the following steps: S1: obtaining a three-dimensional model of a wind turbine blade shell mold and wind turbine blade design parameters, and designing the web plate mold based on this; S2: using three-dimensional software for simulation, laying glass fiber cloth and sandwich core; S3: after the simulation is completed, extracting the suction surface shell inner profile and the pressure surface shell inner profile respectively; using the extracted suction surface shell inner profile and pressure surface shell inner profile to simulate actual production, and making the suction surface and pressure surface; S4: making the leading edge web plate mold plane and the trailing edge web plate mold plane according to the positioning line positions of the pressure surface and the suction surface web; S5: making the web plate plane according to the three-dimensional model of the web plate mold, welding the web plate side and reserving the mold gap, and completing the making of the web plate mold. The web plate mold in this scheme has high precision and reliable bonding quality, can reduce material costs, and shorten construction period.

Description

Technical Field

[0001] The invention relates to the technical field of wind turbine blade manufacturing, and in particular to a method for manufacturing a web mold for a wind turbine blade. Background Art

[0002] Green, clean and environmentally friendly energy has become the key development direction in the future. As a pollution-free, renewable green development energy, wind energy has huge development potential, especially for coastal islands, remote mountainous areas, grasslands and pastures, as well as rural and border areas far away from the power grid and difficult to reach by the power grid in the short term. As a reliable way to solve the production and living energy, it is of great significance. Wind energy has the advantages of low energy consumption, environmental protection and large reserves. The way to use wind energy is usually to convert wind energy into electrical energy through wind turbines, so as to generate electricity through wind power.

[0003] Wind turbine blades are the core components of wind power generation systems. Their conception, development, molding quality and overall performance are the guarantee for the stable operation of the generator set and the continuous supply of electricity. As the key structural component of wind turbine blades, the blade web is mainly used to connect and transfer loads to the SS shell and PS shell. The quality and performance of the web directly determine whether the bonding quality meets the requirements. The web is mainly composed of a bottom panel and bonding edges on both sides. The bottom panel follows the blade contour and is the main load-bearing component; the bonding edge is the bonding component between the shell and the web. The web product is made of a web mold. The platform and bonding rib of the web mold are used to provide the overall contour and bonding edge shape of the web product. When using a web mold to make a web product, it is easy to cause the adhesive to be too thick due to the large mold gap, or the top mold phenomenon due to the small mold gap, which will seriously affect the bonding quality of the wind turbine blade. Therefore, when making wind turbine blades, it is necessary to design the web mold.

[0004] At present, the conventional design and manufacturing method of the web mold is: cut a section on the blade 3D model, calculate the shell ply thickness at the section, reserve a mold clearance, and then calculate the web shape coordinates of the corresponding section to generate a web 3D model. The existing web mold manufacturing method has the following problems: due to the different number of plies at different positions of the blade, the cross section cannot perfectly represent the shell ply thickness of the entire web bonding area, resulting in a difference between the web mold 3D model and the actual situation.

[0005] Therefore, in order to ensure a good mold clearance, it is usually necessary to first make a process web according to normal production requirements, and then simulate the bonding of this process web to the shell on which the fiberglass cloth and sandwich have been laid to test the mold clearance, and then reversely optimize the web mold according to the mold clearance. However, this method has complex procedures, time-consuming operations, long production cycles, and requires the use of shell molds; and the same blade type, different factories and workshops need to make process webs, and the web molds are not very versatile; at the same time, the produced process webs need to be discarded after testing the mold clearance, and are not actually bonded to the blades, which increases the time and material costs.

[0006] In summary, how to design a web mold for wind turbine blades that can simulate the actual production process and directly extract the simulated surface without occupying the mold and extending the construction period is a problem that needs to be solved urgently. Summary of the invention

[0007] In order to solve the above problems, the present invention provides a method for manufacturing a web mold for a wind turbine blade. The method simulates the actual production process of the blade such as glass fiber cloth and sandwich laying through three-dimensional simulation, reserves a suitable mold gap, designs a three-dimensional model of the web mold and manufactures the web mold according to the three-dimensional model, thereby improving the versatility of the web mold, improving the accuracy of the web mold, shortening the production period, and ensuring the bonding quality.

[0008] To achieve the above object, the present invention proposes the following technical solution: a method for manufacturing a web mold for a wind turbine blade, comprising the following steps:

[0009] S1: Obtain the three-dimensional model of the wind turbine blade shell mold and the wind turbine blade design parameters, and design the web mold based on them;

[0010] S2: Use 3D software to simulate, lay out the fiberglass cloth and sandwich core, and display the fiberglass cloth and sandwich core in the 3D model of the blade shell mold;

[0011] S3: After the simulation is completed, the suction surface shell inner profile and the pressure surface shell inner profile are extracted respectively; the actual production is simulated with the extracted suction surface shell inner profile and pressure surface shell inner profile, and the suction surface and the pressure surface are manufactured;

[0012] S4: according to the positioning line positions of the pressure surface and the suction surface webs, a leading edge web mold plane and a trailing edge web mold plane are manufactured;

[0013] S5: Make the web plane according to the three-dimensional model of the web mold, weld the web side and reserve a mold gap to complete the production of the web mold.

[0014] Preferably, in step S3, after extracting the suction face shell inner profile and the pressure face shell inner profile, the suction face shell inner profile and the pressure face shell inner profile need to be trimmed according to bonding width requirements, and web mold sides are formed respectively.

[0015] Preferably, the suction surface shell inner profile and the pressure surface shell inner profile extracted in step S3 respectively include the suction surface main beam area inner profile, the suction surface auxiliary beam area inner profile and the pressure surface main beam area inner profile, and the pressure surface auxiliary beam area inner profile.

[0016] Preferably, after the inner profiles of the suction face shell and the pressure face shell are trimmed according to the bonding width requirements, the inner profile of the suction face main beam area forms the side of the web mold at the front edge of the suction face, the inner profile of the suction face auxiliary beam area forms the side of the web mold at the rear edge of the suction face, the inner profile of the pressure face main beam area forms the side of the web mold at the front edge of the pressure face, and the inner profile of the pressure face auxiliary beam area forms the side of the web mold at the rear edge of the pressure face.

[0017] Preferably, the leading edge web mold plane in step S4, together with the suction surface front edge web mold side and the pressure surface front edge web mold side constitute the leading edge web mold three-dimensional model; the trailing edge web mold plane, together with the suction surface trailing edge web mold side and the pressure surface trailing edge web mold side constitute the trailing edge web mold three-dimensional model.

[0018] Preferably, pads are provided inside the front edge web mold side of the suction surface, the rear edge web mold side of the suction surface, the front edge web mold side of the pressure surface and the rear edge web mold side of the pressure surface to reserve the mold closing gap in step S5.

[0019] Preferably, the thickness of the backing plate is 5-10 mm.

[0020] Preferably, when laying the glass fiber cloth and the sandwich core in step S2, it is necessary to simulate the actual production process and perform simulated laying based on the design parameter requirements of the glass fiber cloth and the sandwich core.

[0021] Preferably, the design parameter requirements of the glass fiber cloth and the sandwich core include design positioning requirements and design size requirements.

[0022] Preferably, the wind turbine blade design parameters in step S1 include glass fiber cloth laying requirements, sandwich laying requirements, and mold clearance requirements.

[0023] The beneficial effects of the present invention are:

[0024] 1. In the present invention, different shell molds of the same blade type can use the same set of web mold models. The web mold has high adaptability and versatility, which can reduce material costs and shorten working hours and production period.

[0025] 2. The present invention arranges a pad on the inner side of the web side, which eliminates the need for testing the mold clearance during the web manufacturing process, and can optimize the pad thickness according to actual production needs.

[0026] 3. The web plate mold in the present invention has high precision, has excellent matching and excellent mold clearance with the blade shell mold, can ensure the bonding quality, and does not occupy the shell mold. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 It is an isometric schematic diagram of a blade shell mold provided by an embodiment of the present invention.

[0028] Figure 2 It is an isometric schematic diagram of the pressure surface shell after the inner surface is extracted provided by an embodiment of the present invention.

[0029] Figure 3 It is an isometric schematic diagram of the suction surface shell after the inner surface is extracted provided by an embodiment of the present invention.

[0030] Figure 4 It is a cross-sectional schematic diagram after the inner surface is extracted provided by an embodiment of the present invention.

[0031] Figure 5 It is a schematic diagram of the web mold model design provided by an embodiment of the present invention.

[0032] Figure 6 It is an isometric schematic diagram of a web mold model provided by an embodiment of the present invention.

[0033] Figure markings: pressure face shell 1, suction face shell 2, suction face main beam area inner surface 3, suction face auxiliary beam area inner surface 4, pressure face main beam area inner surface 5, pressure face auxiliary beam area inner surface 6, leading edge web mold plane 7, trailing edge web mold plane 8, suction face leading edge web mold side 9, suction face trailing edge web mold side 10, pressure face leading edge web mold side 11, pressure face trailing edge web mold side 12, pressure face leading edge web positioning line 13, suction face leading edge web positioning line 14, pressure face trailing edge web positioning line 15, suction face trailing edge web positioning line 16. DETAILED DESCRIPTION

[0034] In order to make the purpose, technical solutions and advantages of the present invention more clearly understood, the following Figure 1-6 It should be understood that the specific embodiments described herein are only used to explain the present invention and do not constitute a limitation of the present invention.

[0035] A method for manufacturing a web mold for a wind turbine blade comprises the following steps:

[0036] S1: Obtain the 3D model of the wind turbine blade shell mold, wind turbine blade design parameters, and design drawings to ensure the perfect match between the web mold and the blade shell mold, and design the web mold based on this; the design parameters of the wind turbine blade include glass fiber cloth laying requirements, sandwich core laying requirements, and mold clearance requirements.

[0037] S2: Use 3D software to simulate. According to the design drawings, 3D models and related design parameters provided by the designer, lay the glass fiber cloth and sandwich core and display them in the 3D model of the blade shell mold. When laying the glass fiber cloth and sandwich core, it is necessary to simulate the actual production process and simulate the laying based on the design parameter requirements of the glass fiber cloth and sandwich core. The design parameter requirements of the glass fiber cloth and sandwich core include design positioning requirements and design size requirements. After laying, perform 3D simulation and display the glass fiber cloth and sandwich core on the 3D blade shell model.

[0038] S3: After the simulation is completed, the suction surface shell inner profile and the pressure surface shell inner profile are extracted respectively; the actual production is simulated with the extracted suction surface shell inner profile and pressure surface shell inner profile, and the suction surface and the pressure surface are manufactured.

[0039] After extracting the suction surface shell inner profile and the pressure surface shell inner profile, the suction surface shell inner profile and the pressure surface shell inner profile need to be trimmed according to the bonding width requirements, and form the web mold side edges respectively; the extracted suction surface shell inner profile and the pressure surface shell inner profile include the suction surface main beam area inner profile 3, the suction surface auxiliary beam area inner profile 4 and the pressure surface main beam area inner profile 5, and the pressure surface auxiliary beam area inner profile 6 respectively; after trimming the suction surface shell inner profile and the pressure surface shell inner profile according to the bonding width requirements, the suction surface main beam area inner profile 3 forms the suction surface front edge web mold side edge 9, the suction surface auxiliary beam area inner profile 4 forms the suction surface rear edge web mold side edge 10, the pressure surface main beam area inner profile 5 forms the pressure surface front edge web mold side edge 11, and the pressure surface auxiliary beam area inner profile 6 forms the pressure surface rear edge web mold side edge 12.

[0040] S4: According to the positioning lines of the pressure surface and the suction surface web, the leading edge web mold plane 7 and the trailing edge web mold plane 8 are manufactured; the positioning lines of the pressure surface and the suction surface web include Figure 1-3 The pressure face front edge web positioning line 13, the suction face front edge web positioning line 14, the pressure face trailing edge web positioning line 15 and the suction face trailing edge web positioning line 16 shown in the figure; the leading edge web mold plane 7 and the suction face front edge web mold side 9 and the pressure face front edge web mold side 11 together constitute the leading edge web mold three-dimensional model; the trailing edge web mold plane 8 and the suction face trailing edge web mold side 10 and the pressure face trailing edge web mold side 12 together constitute the trailing edge web mold three-dimensional model.

[0041] S5: Make the web plane according to the three-dimensional model of the web mold, weld the web side and reserve the mold gap to complete the production of the web mold. Specifically, a pad is set inside the front edge web mold side 9 of the suction surface, the rear edge web mold side 10 of the suction surface, the front edge web mold side 11 of the pressure surface and the rear edge web mold side 12 of the pressure surface to reserve the mold gap in step S5, and the thickness of the pad is 5-10mm; technicians in this field can also optimize the thickness of the pad according to actual needs during the production process.

[0042] Although the embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and cannot be understood as limiting the present invention. Those skilled in the art may change, modify, replace and modify the above embodiments within the scope of the present invention.

[0043] The above specific implementations of the present invention do not constitute a limitation on the protection scope of the present invention. Any other corresponding changes and modifications made based on the technical concept of the present invention should be included in the protection scope of the claims of the present invention.

Claims

1. A method for manufacturing a web mold for a wind turbine blade, characterized in that: The steps include: S1: Obtain the three-dimensional model of the wind turbine blade shell mold and the wind turbine blade design parameters, and design the web mold based on them; S2: Use 3D software to simulate, lay out the fiberglass cloth and sandwich core, and display the fiberglass cloth and sandwich core in the 3D model of the blade shell mold; S3: After the simulation is completed, the suction surface shell inner profile and the pressure surface shell inner profile are extracted respectively; the actual production is simulated with the extracted suction surface shell inner profile and the pressure surface shell inner profile, and the suction surface and the pressure surface are manufactured; after the suction surface shell inner profile and the pressure surface shell inner profile are extracted, the suction surface shell inner profile and the pressure surface shell inner profile are trimmed according to the bonding width requirement, and the web mold side edges are formed respectively; the extracted suction surface shell inner profile and the pressure surface shell inner profile respectively include the suction surface main beam area inner profile (3), the suction surface auxiliary beam area inner profile (4) and the pressure surface main beam area inner profile (5), and the pressure surface auxiliary beam area inner profile (6); S4: According to the positioning line positions of the pressure surface and suction surface webs, a leading edge web mold plane (7) and a trailing edge web mold plane (8) are manufactured; after the suction surface shell inner profile and the pressure surface shell inner profile are trimmed according to the bonding width requirements, the suction surface main beam area inner profile (3) forms the suction surface leading edge web mold side (9), the suction surface auxiliary beam area inner profile (4) forms the suction surface trailing edge web mold side (10), and the pressure surface main beam area inner profile (5) forms the pressure surface front The front edge web mold side (11) and the inner profile (6) of the pressure surface auxiliary beam area form the pressure surface rear edge web mold side (12); the front edge web mold plane (7) and the suction surface front edge web mold side (9) and the pressure surface front edge web mold side (11) together form the front edge web mold three-dimensional model; the rear edge web mold plane (8) and the suction surface rear edge web mold side (10) and the pressure surface rear edge web mold side (12) together form the rear edge web mold three-dimensional model S5: Make the web plane according to the three-dimensional model of the web mold, weld the web side and reserve a mold gap to complete the production of the web mold.

2. The method for manufacturing a web mold for a wind turbine blade according to claim 1, characterized in that: Pads are provided inside the front edge web mold side (9) of the suction surface, the rear edge web mold side (10) of the suction surface, the front edge web mold side (11) of the pressure surface, and the rear edge web mold side (12) of the pressure surface, so as to reserve a mold closing gap in step S5.

3. The method for manufacturing a web mold for a wind turbine blade according to claim 2, characterized in that: The thickness of the pad is 5-10mm.

4. The method for manufacturing a web mold for a wind turbine blade according to any one of claims 1 to 3, characterized in that: When laying the glass fiber cloth and the sandwich core in step S2, it is necessary to simulate the actual production process and perform simulated laying based on the design parameter requirements of the glass fiber cloth and the sandwich core.

5. The method for manufacturing a web mold for a wind turbine blade according to claim 4, characterized in that: The design parameter requirements for glass fiber cloth and sandwich core include design positioning requirements and design size requirements.

6. The method for manufacturing a web mold for a wind turbine blade according to claim 5, characterized in that: The wind turbine blade design parameters in step S1 include glass fiber cloth laying requirements, sandwich core laying requirements, and mold clearance requirements.

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