A method for manufacturing a wind turbine blade trailing edge mold core material

Abstract

The application provides a kind of production method of wind power blade trailing edge mold core material, comprising steps 1: prefabricated shell and SS shell of blade, then respectively in the inside of PS shell and SS shell sequentially lay release cloth, wrapping cloth and carry out pouring solidification;2: in the trailing edge mold core material area of SS shell, adhesive is coated;3: rubber gasket is set at the trailing edge bonding area of PS shell, PS shell and SS shell are aligned and extruded, after adhesive solidification, the male die of trailing edge mold core material is obtained;4: the male die is cut into multiple sections, and the edge of each section is shaped, so that the outer dimension meets the design requirements;5: glass fabric is laid on the surface of the male die, then resin is coated on the glass fabric, and after the resin solidifies, the female die is formed;6: inject foaming liquid into the female die for foaming, after complete foaming, solidification and cooling, demolding can be carried out, and the required mold core material is obtained;The production method described in the application has high production and processing efficiency, and the size precision of the mold core material is high.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of sample preparation methods, in particular to a method for manufacturing a wind turbine blade trailing edge mold core material. BACKGROUND

[0002] A wind turbine blade is one of the important components of a wind turbine generator system, mainly used for capturing wind energy. The wind turbine blade is usually bonded by two halves, namely the windward surface (PS surface) and the leeward surface (SS surface). The bonding process of the blade is called the mold closing process. In the mold closing process of the blade, the bonding area mainly includes the leading edge, trailing edge and web of the blade. The trailing edge bonding area is one of the difficulties in the mold closing process of the blade and is a key problem affecting the quality of the blade because of its large bonding width and the existence of a cavity in the trailing edge area. The bonding gap between the two halves needs to be controlled within 2mm-10mm in the mold closing process of the blade. If the bonding gap is too small, there is a risk of blade top mold, and if the bonding gap is too large, it will cause the bonding strength to decrease, affecting the quality and operation safety of the blade.

[0003] Currently, a mold closing core material is used to fill the trailing edge area of the blade to ensure that the mold closing gap meets the design requirements. The design process of the mold closing core material is as follows: first, the airfoil of the trailing edge area of the blade is extracted, then the layup of the trailing edge area is simulated on the airfoil section drawing, the contour of the mold closing core material is drawn according to the simulated layup, the mold closing core material is processed, and finally the processed core material is applied to the blade production. However, due to the deviation between the theoretical design and the actual production and the error in the processing of the core material, the initially processed trailing edge mold closing core material still has the problem of inappropriate size when applied to the blade, resulting in a mold closing gap that does not meet the requirements. Both too large and too small mold closing gaps will affect the quality and production efficiency of the blade, and in severe cases, it will lead to the scrapping of the blade. Therefore, it is necessary to develop an effective method for preparing a blade mold closing core material. SUMMARY

[0004] Therefore, the present application aims to provide a method for manufacturing a wind turbine blade trailing edge mold closing core material to solve the problems of inaccurate size and low efficiency in manufacturing the wind turbine blade trailing edge mold closing core material in the prior art.

[0005] To achieve the above-mentioned purposes, the technical scheme of the present application is as follows:

[0006] A method for manufacturing a wind turbine blade trailing edge mold closing core material, comprising the following steps:

[0007] Step 1: Preparing the PS shell and the SS shell of the blade, then sequentially laying the release cloth and wrapping cloth inside the PS shell and the SS shell respectively and performing pouring and curing;

[0008] Step 2: Applying an adhesive to the trailing edge mold closing core material area of the SS shell;

[0009] Step 3: A rubber gasket is arranged at the rear edge bonding area of the PS shell, the PS shell and the SS shell are aligned and pressed, and after the adhesive is cured, a male mold of the rear edge mold core material is obtained;

[0010] Step 4: The male mold is cut into multiple sections, and then the edges of each section of the male mold are shaped to make the outer dimensions of the male mold meet the design requirements;

[0011] Step 5: A glass fabric is laid on the surface of the male mold, and then a hand lay-up or vacuum infusion resin is laid on the glass fabric, and after the resin is solidified, a female mold is formed, the female mold comprising a cavity and a cover plate;

[0012] Step 6: The cover plate is placed on the cavity, after the cavity and the cover plate are firmly fixed, the foaming liquid is injected into the female mold for foaming, and after the foaming liquid is completely foamed, solidified and cooled, the mold is demolded, and the required rear edge mold core material is obtained;

[0013] Wherein, PS is the windward surface, and SS is the leeward surface.

[0014] The method for manufacturing the rear edge mold core material of the wind power blade provided by the application is simple to operate, can improve the production and processing efficiency, and the rear edge mold core material prepared has high dimensional accuracy, which can improve the product quality and installation precision.

[0015] Further, in step 3, the thickness of the rubber gasket is H1, and 4.5mm≤H1≤5.5mm.

[0016] This arrangement can not only reserve the coating thickness of the adhesive, but also avoid the tight fit between the PS shell and the SS shell due to the improper tolerance when the rear edge mold core material is installed in the shell, and can also adjust the mold gap by changing the thickness of the rubber gasket, facilitating installation and production.

[0017] Further, in step 4, the length of each section of the male mold is H2, and 0.8m≤H2≤1.2m.

[0018] This arrangement facilitates the shaping, handling and assembly of the male mold, improving the production and processing efficiency.

[0019] Further, in step 6, the cavity and the cover plate edge are provided with a vent groove, the vent groove comprising a first vent groove and a second vent groove, and the vent groove is used to prevent the foaming liquid from leaking outside the female mold when foaming.

[0020] This structure not only facilitates the discharge of the foaming gas in the female mold, but also avoids the leakage of the foaming foam to the outside of the female mold.

[0021] Further, in step 6, the gap between the cavity and the cover plate at the vent groove is H3, and H3<1mm.

[0022] The structure can guarantee the size precision of the rear edge mold core material and facilitate the discharge of the foaming gas in the female mold.

[0023] Further, in step 6, the cover plate is provided with a glue injection port for injecting the foaming liquid into the female mold.

[0024] The structure facilitates the injection of the foaming liquid into the female mold.

[0025] Further, in step 6, the amount of the foaming liquid is calculated according to the volume of the female mold.

[0026] The method can effectively control the density of the rear edge mold core material and adjust the weight and mechanical properties of the rear edge mold core material, control the weight of the blade, and realize the designable control of the rear edge mold core material.

[0027] Further, in step 6, the thickness of the cavity and the cover plate is H4, and H4>5cm.

[0028] The arrangement can ensure the strength of the cavity and the cover plate and avoid deformation in the foaming process, thereby affecting the quality of the rear edge mold core material.

[0029] Further, in step 6, the cavity and the cover plate are fixed together by screws or F clamps.

[0030] The arrangement facilitates the assembly and production and reduces the cost.

[0031] Further, the cavity and the cover plate are made of glass steel.

[0032] The arrangement can improve the strength of the cavity and the cover plate, reduce the weight, and facilitate the handling and production.

[0033] Compared with the prior art, the method for manufacturing the rear edge mold core material of the wind power blade has the following advantages:

[0034] 1. Simple operation, which can improve the production and processing efficiency;

[0035] 2. The rear edge mold core material has high size precision, which can improve the product quality and installation precision. DETAILED DESCRIPTION

[0036] Figure 1 The structure of the wind power blade is shown in the embodiment of the application.

[0037] Figure 2 The structure of the female mold is shown in the embodiment. Figure 1 The local enlarged structure of A in the embodiment is shown in the structure.

[0038] Figure 3 The structure of the female mold is shown in the embodiment.

[0039] Reference signs:

[0040] 11, PS shell; 12, SS shell; 2, wrapping cloth; 3, negative mold; 31, cavity; 32, cover plate; 320, glue injection port; 4, back edge mold core material; 5, anti-bubbling groove; 51, first anti-bubbling groove; 52, second anti-bubbling groove; 100, back edge bonding area; 200, adhesive. DETAILED DESCRIPTION

[0041] In order to make the above-mentioned purposes, features and advantages of the present application more obvious and easy to understand, the specific embodiments of the present application will be described in detail below with reference to the drawings.

[0042] Example 1

[0043] As shown in the drawings, a method for manufacturing a back edge mold core material of a wind power blade includes the following steps: Figures 1 to 3 Step 1: Preparing a PS shell 11 and a SS shell 12 of the blade, and then laying a release cloth, a wrapping cloth 2 in the PS shell 11 and the SS shell 12 respectively and performing pouring and curing;

[0044] Step 2: Coating an adhesive 200 on the back edge mold core material area 4 of the SS shell 12;

[0045] Step 3: Setting a rubber gasket at the back edge bonding area 100 of the PS shell 11, aligning and pressing the PS shell 11 and the SS shell 12, and obtaining a male mold of the back edge mold core material 4 after the adhesive 200 is cured;

[0046] Step 4: Cutting the male mold into multiple segments, and then shaping the edges of each segment of the male mold to make the outer dimensions of the male mold meet the design requirements;

[0047] Step 5: Laying a glass fabric on the surface of the male mold, and then hand-pasting or vacuum pouring resin on the glass fabric, and forming a negative mold 3 after the resin is solidified, the negative mold 3 including a cavity 31 and a cover plate 32;

[0048] Step 6: Covering the cover plate 32 on the cavity 31, and after the cavity 31 and the cover plate 32 are fixed firmly, injecting foaming liquid into the negative mold 3 for foaming, and after the foaming liquid is completely foamed and solidified and cooled, demolding can be performed, and the required back edge mold core material 4 is obtained;

[0049] Wherein, PS is the windward surface, and SS is the leeward surface.

[0050]

[0051] ​The method for manufacturing the wind power blade trailing edge mold core material provided by the application comprises the following steps: coating adhesive 200 in the blade shell, pressing a positive mold of the conformal trailing edge mold core material, laying glass fabric and resin on the surface of the positive mold to prepare a negative mold 3, and injecting foaming liquid into the negative mold 3 to prepare the required trailing edge mold core material 4. The method is simple in operation, can improve the production and processing efficiency, and has high size precision of the prepared trailing edge mold core material 4, thereby improving the product quality and installation precision.

[0052] As a preferred example of the application, in step 2, the excess adhesive 200 is coated on the trailing edge bonding area 100 of the PS shell 11.

[0053] Specifically, the method can ensure the size precision of the pressed positive mold and avoid the existence of depressions on the surface of the positive mold.

[0054] As a preferred example of the application, in step 3, the thickness of the rubber gasket is H1, 4.5mm≤H1≤5.5mm.

[0055] Specifically, the setting can reserve the coating thickness of the adhesive, avoid the improper tolerance between the PS shell 11 and the SS shell 12 when the trailing edge mold core material 4 is installed in the shell, and adjust the mold gap by changing the thickness of the rubber gasket, thereby facilitating the installation and production.

[0056] As a preferred example of the application, in step 4, the length of each positive mold is H2, 0.8m≤H2≤1.2m.

[0057] Specifically, the setting facilitates the profiling, handling and assembly of the positive mold, thereby improving the production and processing efficiency.

[0058] As a preferred example of the application, in step 6, the mold cavity 31 and the cover plate 32 are provided with an anti-bubbling groove 5, the anti-bubbling groove 5 comprises a first anti-bubbling groove 51 and a second anti-bubbling groove 52, and the anti-bubbling groove 5 is used to prevent the foaming liquid from leaking outside the negative mold 3 when the foaming liquid is foamed.

[0059] Specifically, the structure facilitates the discharge of the foaming gas in the negative mold 3 and avoids the leakage of the foaming foam to the outside of the negative mold 3.

[0060] As a preferred example of the application, in step 6, the gap between the mold cavity 31 and the cover plate 32 at the anti-bubbling groove 5 is H3, H3<1mm.

[0061] Specifically, the structure can ensure the size precision of the trailing edge mold core material 4 and facilitate the discharge of the foaming gas in the negative mold 3.

[0062] As a preferred example of the present invention, in step 6, the cover plate 32 is provided with a glue injection port 320, which is used to inject foaming liquid into the female mold 3.

[0063] Specifically, this structure facilitates the injection of foaming liquid into the female mold 3.

[0064] Preferably, a rubber plug is provided on the injection port 320 to seal the injection port 320 and prevent foam from leaking from the injection port 320 to the outside of the female mold 3.

[0065] As a preferred example of the present invention, in step 6, the amount of foaming liquid is calculated based on the volume of the female mold 3.

[0066] Specifically, this method can effectively control the density of the trailing edge mold core material 4, as well as adjust the weight and mechanical properties of the trailing edge mold core material 4, control the blade weight, and achieve the designable controllability of the trailing edge mold core material 4.

[0067] As a preferred example of the present invention, in step 6, the thickness of both the cavity 31 and the cover plate 32 is H4, where H4 > 5cm.

[0068] Specifically, this setup ensures the strength of the cavity 31 and the cover plate 32, preventing deformation during the foaming process and affecting the quality of the rear edge mold core material 4.

[0069] As a preferred example of the present invention, in step 6, the cavity 31 and the cover plate 32 are fixed together by screws or F-clamps.

[0070] Specifically, this setup facilitates assembly and production, reducing costs.

[0071] Preferably, the anti-outburst groove 5 is provided with a fixing position for installing screws or F-clamps.

[0072] As a preferred example of the present invention, the cavity 31 and the cover plate 32 are made of fiberglass.

[0073] Specifically, this design can improve the strength of the cavity 31 and the cover plate 32, reduce weight, and facilitate handling and manufacturing.

[0074] In summary, the method for manufacturing the trailing edge mold core material of the wind turbine blade described in this application has the following advantages: First, by coating the inside of the blade shell with adhesive 200, a male mold of the conformal trailing edge mold core material is pressed out. Fiberglass fabric and resin are then laid on the surface of the male mold to prepare a female mold 3. Foaming liquid is injected into the female mold 3 to prepare the required trailing edge mold core material 4. The operation is simple, which can improve production efficiency. Moreover, the prepared trailing edge mold core material 4 has high dimensional accuracy, which can improve product quality and installation accuracy. Second, the amount of foaming liquid is calculated based on the volume of the female mold 3, which can control the density of the trailing edge mold core material 4 to meet the design requirements and save costs. Third, by setting anti-escape grooves 5 at the edges of the cavity 31 and the cover plate 32, it is not only convenient to discharge the foaming gas in the female mold 3, improving the manufacturing accuracy of the trailing edge mold core material 4, but also to prevent the foam from leaking to the outside of the female mold 3.

[0075] While the present invention has been disclosed above, it is not limited thereto. Any person skilled in the art can make various modifications and alterations without departing from the spirit and scope of the invention; therefore, the scope of protection of the present invention should be determined by the scope defined in the claims.

Claims

1. A method for manufacturing a core material for the trailing edge molding of a wind turbine blade, characterized in that, Including the following steps: Step 1: Prefabricate the PS shell (11) and SS shell (12) of the blade, and then lay the release cloth and wrapping cloth (2) in sequence inside the PS shell (11) and SS shell (12) respectively and perform injection curing; Step 2: Apply adhesive (200) to the rear edge mold core material area (4) of the SS housing (12); Step 3: Set a rubber pad at the rear edge bonding area (100) of the PS shell (11), align the PS shell (11) and SS shell (12) and press them together. After the adhesive (200) has cured, the male mold of the rear edge mold core material (4) is obtained. Step 4: Cut the male mold into multiple segments, and then trim the edges of each segment to ensure that the external dimensions of the male mold meet the design requirements. Step 5: Lay fiberglass fabric on the surface of the male mold, and then hand lay up or vacuum inject resin on the fiberglass fabric. After the resin solidifies, a female mold (3) is formed. The female mold (3) includes a cavity (31) and a cover plate (32). Step 6: Cover the cavity (31) with a cover plate (32). After the cavity (31) and the cover plate (32) are firmly fixed, inject foaming liquid into the female mold (3) for foaming. After the foaming liquid has completely foamed, solidified and cooled, it can be demolded to obtain the required rear edge mold core material (4). PS represents the windward side, and SS represents the leeward side. The cavity (31) and cover plate (32) are provided with anti-leakage grooves (5), the anti-leakage grooves (5) include a first anti-leakage groove (51) and a second anti-leakage groove (52), the anti-leakage grooves (5) are used to prevent the foaming liquid from leaking to the outside of the female mold (3) when foaming; The gap between the cavity (31) and the cover plate (32) at the anti-overflow groove (5) is H3, where H3 < 1 mm.

2. The manufacturing method according to claim 1, characterized in that, In step 3, the thickness of the rubber gasket is H1, where 4.5mm ≤ H1 ≤ 5.5mm.

3. The manufacturing method according to claim 1, characterized in that, In step 4, the length of each male mold segment is H2, where 0.8m ≤ H2 ≤ 1.2m.

4. The manufacturing method according to claim 1, characterized in that, In step 6, the cover plate (32) is provided with a glue injection port (320), which is used to inject foaming liquid into the female mold (3).

5. The manufacturing method according to claim 1, characterized in that, In step 6, the amount of foaming liquid is calculated based on the volume of the negative mold (3).

6. The manufacturing method according to claim 1, characterized in that, In step 6, the thickness of both the cavity (31) and the cover plate (32) is H4, where H4 > 5cm.

7. The manufacturing method according to claim 1, characterized in that, In step 6, the cavity (31) and the cover plate (32) are fixed together by screws or F-clamps.

8. The manufacturing method according to claim 1, characterized in that, The cavity (31) and cover plate (32) are made of fiberglass.

Images