Prefabricated blade root manufacturing method

Abstract

The present application discloses a method for manufacturing a prefabricated blade root, which includes providing a mold, wherein the mold wall has a barrel-shaped profile, and the outer surface has a plurality of annular steps connected and distributed along the axial direction of the mold; winding fiber filaments containing resin on the mold demoulding layer, and the fiber filaments are wound and filled with at least part of the plurality of steps to form a fiber layer with a smooth surface; curing the fiber layer to form a prefabricated molding; demoulding the prefabricated molding from the mold to form a prefabricated blade root. The prefabricated blade root manufacturing method of the present application can provide sufficient tension to the fiber to avoid the defect of axial wrinkles in the fiber, and can accurately control the length of the laid fiber layer so that the manufactured prefabricated blade root can reach the required length.

Description

Technical Field

[0001] The present application belongs to the technical field of wind power generation, and in particular relates to a method for manufacturing a prefabricated blade root. Background Art

[0002] A wind turbine generator set includes a fixed tower, a nacelle supported by the tower, a hub fixedly connected to the main shaft of the nacelle, and blades installed on the hub. The part of the blade that is fixedly connected to the hub is the blade root, and the part of the blade farthest from the hub is the blade tip. The blade is one of the most important components of a wind turbine, and the performance of the blade will directly affect the quality of the entire machine. As far as blade research is concerned, the blade root part is the priority part of the structural design, because the blade root part not only bears the weight of the entire blade and various loads, but also is the most direct connection part between the blade and other parts of the wind turbine generator set.

[0003] As the power generation increases, the length of wind turbine blades increases. The blade root is the key load-bearing part of the blade. As the blade length continues to increase, the blade root load increases, and the number of blade root fiber layers increases greatly. In order to improve manufacturing efficiency, prefabricated blade roots are often used. To manufacture prefabricated blade roots, it is necessary to lay the shaft cloth in the mold, and then vacuum-introduce the resin and solidify it.

[0004] However, inevitable errors will occur in the process of laying the prefabricated blade root. When laying the shaft cloth, it is impossible to apply sufficient tension to the end of the shaft cloth, which will cause the fibers of the shaft cloth to have axial wrinkles. Even if a fiber tensioning machine is used to tension the fibers, the sticky resin coated on the fibers will affect the arrangement of the fibers. Therefore, the machine cannot accurately control the length of the final fiber layer. Summary of the invention

[0005] The embodiment of the present application provides a method for manufacturing a prefabricated blade root, which can provide sufficient tension to the fibers to avoid the defect of axial wrinkles in the fibers, and can accurately control the length of the laid fiber layer so that the manufactured prefabricated blade root can reach the required length.

[0006] The present application provides a method for manufacturing a prefabricated blade root, wherein the method for manufacturing a prefabricated blade root comprises: providing a mold, wherein the mold wall profile is barrel-shaped, and the outer surface has a plurality of annular steps connected and distributed along the axial direction of the mold; winding fiber filaments containing resin on a mold release layer, wherein the fiber filaments are wound around and fill at least a portion of the plurality of steps to form a fiber layer with a smooth surface; curing the fiber layer to form a prefabricated molded body; and demolding the prefabricated molded body from the mold to form a prefabricated blade root.

[0007] In the method for manufacturing a prefabricated blade root as described above, in the step of providing a mold, the mold includes an outer peripheral surface parallel to its own axial direction, and the step includes a side surface parallel to the axial direction and an end surface perpendicular to the axial direction.

[0008] In the method for manufacturing a prefabricated blade root as described above, the side surface of one step of two adjacent steps among the multiple steps is connected to the end surface of the other step, and the distances between the side surfaces of the multiple steps distributed axially along the mold and the outer peripheral surface increase successively.

[0009] The method for manufacturing a prefabricated blade root as described above, wherein, in the step of winding fiber filaments containing resin on a mold release layer, when winding the fiber filaments on one of the steps, the fiber filaments are wound along the axial direction from any position of the outer peripheral surface along the axial direction to the end face of the step to form a layer of the fiber layer, and the outer surface of the layer of the fiber layer is arranged flush with the side face of the step.

[0010] The method for manufacturing a prefabricated blade root as described above, wherein the step of winding fiber filaments containing resin on a mold release layer further includes, when winding the fiber filaments on the step adjacent to the first step, winding the fiber filaments on the outer surface of the fiber layer that has been wound, until the fiber filaments abut against the outer surface of the step to be wound, thereby forming another fiber layer.

[0011] The method for manufacturing a prefabricated blade root as described above, wherein the step of winding fiber filaments containing resin on the mold demolding layer also includes winding the fiber filaments on a plurality of continuously arranged steps to form an inner fiber layer formed by multiple fiber layers; an embedded part is provided on the outer surface of the inner fiber layer, the width of the end face of the step abutting against the embedded part along the direction perpendicular to the axial direction is greater than the width of the remaining part of the step, one end of the embedded part is abutted against one of the steps, and the embedded part is fixedly connected to the outer surface of the inner fiber layer; the fiber filaments are continued to be wound on the outer surface of the embedded part, and the fiber filaments are sequentially wound around the embedded part along a plurality of continuously arranged steps to form an outer fiber layer.

[0012] The method for manufacturing the prefabricated blade root as described above, wherein, after the step of forming the outer fiber layer, it further comprises providing a protective layer on the outer surface of the outer fiber layer.

[0013] The method for manufacturing the prefabricated blade root as described above, wherein the method for manufacturing the prefabricated blade root further comprises: assembling and fixing the prefabricated blade root to a wind turbine blade body.

[0014] The method for manufacturing a prefabricated blade root as described above, wherein the mold includes a fixing device, and the fixing device is arranged at both ends of the mold. The step of tensioning and winding the fiber filaments on the outer wall of the mold includes: hanging the fiber filaments on the fixing device at one end of the mold; winding the fiber filaments along one end of the mold to the other end and setting them on the outer peripheral surface of the mold; and hanging the fiber filaments on the fixing device at the other end of the mold.

[0015] In the method for manufacturing a prefabricated blade root as described above, in the step of winding the fiber filaments containing resin on the mold release layer, the winding method is one of dry winding, semi-dry winding or wet winding.

[0016] The present application provides a method for manufacturing a prefabricated blade root, comprising providing a mold and winding fiber filaments containing resin on a mold release layer, wherein the mold wall profile is barrel-shaped, and the fiber filaments are mechanically tensioned and wound around the outer wall of the barrel-shaped mold to form a barrel-shaped fiber layer with a smooth appearance. The fiber filaments will not wrinkle during the winding process, thereby avoiding axial wrinkles in the fiber layer formed by the fiber filaments. Compared with the manufacturing method of manually laying the shaft cloth, the fiber layer formed by this method has a smoother surface. The outer surface of the mold provided by the prefabricated blade root manufacturing method of the present application has a plurality of annular steps connected and distributed along the axial direction of the mold. In the process of winding the fiber filaments on the mold release layer, the fiber filaments are wound and filled around at least part of the plurality of steps until the fiber filaments are wound to a suitable length along the axial direction of the mold to form a fiber layer. The steps have a blocking effect on the fiber filaments, and the fiber filament winding process can be effectively controlled. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] In order to more clearly illustrate the technical solution of the embodiments of the present application, the following is a brief introduction to the drawings required for use in the embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without any creative work.

[0018] Figure 1 A flow chart of a method for manufacturing a prefabricated blade root according to an embodiment of the present application;

[0019] Figure 2 A schematic diagram of the structure of a fiber layer of a method for manufacturing a prefabricated blade root according to an embodiment of the present application;

[0020] Figure 3 This is a schematic structural diagram of a mold for a prefabricated blade root manufacturing method according to an embodiment of the present application.

[0021] Description of Figure Numbers:

[0022] 10. Fiber layer; 20. Mold; 21. Step. DETAILED DESCRIPTION

[0023] The features and exemplary embodiments of various aspects of the present application will be described in detail below. In order to make the purpose, technical solutions and advantages of the present application clearer, the present application will be further described in detail below in conjunction with the accompanying drawings and specific embodiments. It should be understood that the specific embodiments described herein are only intended to explain the present application, rather than to limit the present application. For those skilled in the art, the present application can be implemented without the need for some of these specific details. The following description of the embodiments is only to provide a better understanding of the present application by illustrating the examples of the present application.

[0024] like Figures 1 to 3 As shown, an embodiment of the present application provides a method for manufacturing a prefabricated blade root, wherein the method for manufacturing a prefabricated blade root comprises:

[0025] S110, providing a mold 20, wherein the wall profile of the mold 20 is barrel-shaped, and the outer surface has a plurality of annular steps 21 connected and distributed along the axial direction of the mold 20;

[0026] S120, winding fiber filaments containing resin on the demoulding layer of the mold 20, and the fiber filaments are wound and filled at least part of the plurality of steps 21 to form a fiber layer 10 with a smooth surface;

[0027] S130, curing the fiber layer 10 to form a prefabricated molding;

[0028] S140, demoulding the prefabricated molded body from the mold 20 to form a prefabricated blade root.

[0029] In steps S110 and S120, when the fiber filaments are wound around the outer surface of the mold 20, a machine for winding the fiber filaments, such as a fiber roving frame, is used to tension the fiber filaments and wind them around the barrel-shaped outer surface of the mold 20 to avoid wrinkles during the winding process, thereby avoiding axial wrinkles in the fiber layer 10 formed by the fiber filaments. The fiber layer 10 formed in this way has a smoother surface than the manufacturing method of manually laying the axial cloth.

[0030] When the manufacturing method of manually laying the shaft cloth is adopted, the shaft cloth is usually a single-axis cloth arranged along the axial direction or a double-axis cloth with a fixed angle. However, by adopting the method of winding fiber filaments in the embodiment of the present application, the winding angle of the fiber filaments can be freely adjusted, and more different structures can be formed.

[0031] In the process of manually laying the shaft cloth, two semicircular prefabricated blade roots are first formed, and then the two semicircles are spliced ​​together to form a complete prefabricated blade root. Since residual stress will be released during the resin curing process and rebound will occur at the splicing position, this manufacturing method will cause the prefabricated blade root to warp at the splicing position. The prefabricated blade root formed by winding in the present application is a complete rotating body that can be constrained as a whole. Compared with the spliced ​​prefabricated blade roots, the splicing position will not warp.

[0032] In steps S110 and S120, the fiber filaments are wound and filled around at least a portion of the multiple steps 21 until the fiber filaments are wound to a suitable axial length along the mold 20 to form a fiber layer 10. At this time, the steps 21 act as a barrier to the fiber filaments, so that the fiber filaments can be stopped when they are wound around a certain step 21, thereby effectively controlling the winding process of the fiber filaments. It can be understood that since the fiber filaments are coated with a sticky resin, the prefabricated blade root manufacturing method of the embodiment of the present application can stop winding in time compared to using a machine to set a preset fiber filament length, so that the manufactured prefabricated blade root can reach the required length.

[0033] In step S130, the fiber layer 10 formed in step S120 is cured to form a prefabricated body having a hardness that meets the requirements, and in step S140, the prefabricated body is demolded from the mold 20 to form a prefabricated blade root that meets the use requirements.

[0034] Specifically, during the curing process of the fiber layer 10 in step S130, the fiber layer 10 and the mold 20 need to be placed in a curing furnace as a whole for rotational curing to finally form a prefabricated molding; each fiber filament of the fiber layer 10 is coated with a resin, and the resin is viscous, so that the fiber filaments can be firmly bonded to each other to form an overall fiber layer 10. During the rotational curing process, the rotating action allows the resin to be evenly dispersed on the fiber filaments, and heating is required during the rotational curing. The heating will cause the resin to undergo a curing reaction, and the bonding between the fiber filaments will be more firm, and the formed prefabricated molding will be more stable.

[0035] During specific implementation, in step S120, winding the fiber filaments on the demolding layer of the mold 20 requires the use of a four-axis linkage or more advanced winding machine. First, the mold 20 is installed on the winding machine, and the shape and size of the mold 20 and the data of the required fiber layer 10 are input into the CNC system. Then, the winding machine winds the fiber filaments on the demolding layer of the mold 20 according to the data to form a fiber layer 10 that meets the requirements.

[0036] like Figure 3As shown, in the method for manufacturing a prefabricated blade root in an embodiment of the present application, as an example, the mold 20 includes an outer peripheral surface parallel to its own axial direction, and the step 21 includes a side surface parallel to the axial direction and an end surface perpendicular to the axial direction. The end surface of the step 21 is perpendicular to the axial direction of the step 21, so that when the fiber filaments are wound to the end surface of a certain step 21, they can be blocked by the end surface of the step 21, so that the fiber filaments stop winding in time, and a fiber layer 10 with precise size is obtained. In this process, the step 21 plays a role in positioning and blocking.

[0037] like Figure 3 As shown, the side surface of one step 21 of two adjacent steps 21 in the multiple steps 21 of the mold 20 is connected to the end surface of the other step 21, and the distance between the side surface of the multiple steps 21 distributed along the axial direction of the mold 20 and the outer peripheral surface increases successively. When the fiber filaments are sequentially wound around the mold 20 along the multiple steps 21, each step 21 is correspondingly wound with a layer of fiber layer 10. Since the distance between the side surface of the multiple steps 21 and the outer peripheral surface increases successively, as the number of fiber filaments wound around the steps 21 increases, the thickness of the formed overall fiber layer 10 perpendicular to the axial direction becomes thicker.

[0038] The prefabricated blade root manufacturing method of the embodiment of the present application, wherein, in the step of winding fiber filaments containing resin on the demolding layer of the mold 20, when winding the fiber filaments on a step 21, the fiber filaments are axially wound from any position along the axial direction of the outer peripheral surface to the end face of the step 21 to form a fiber layer 10, and the outer surface of the fiber layer 10 is arranged flush with the side surface of the step 21, thereby ensuring that the thickness of this fiber layer 10 in the direction perpendicular to the axial direction is fixed.

[0039] In this step, when the fiber filaments are wound from the outer periphery of the mold 20 to the end face of the step 21, the fiber filaments stop winding immediately when they reach the end face, forming a fiber layer 10 fixed along the axial length of the mold 20. Therefore, the end face of the step 21 plays a role in positioning and blocking the winding of the fiber filaments.

[0040] The prefabricated blade root manufacturing method of an embodiment of the present application, wherein, in the step of winding fiber filaments containing resin on the demolding layer of the mold 20, also includes, when winding the fiber filaments on the step 21 adjacent to the first step 21, winding the fiber filaments on the outer surface of the already wound fiber layer 10 until the fiber filaments abut against the outer surface of the step 21 to be wound, thereby forming another fiber layer 10.

[0041] In this step, the outer surface of the first fiber layer 10 is flush with the side of the first step 21, so the fiber filaments are wound around the second step 21 adjacent to the first step 21 to form a fiber layer 10 with a smooth inner surface. Since the end face of the second step 21 is located at a different position from the end face of the first step 21 in the axial direction of the mold 20, the axial length of the second fiber layer 10 is greater than the axial length of the first fiber layer 10. The length of the overall fiber layer 10 formed by the first fiber layer 10 and the second fiber layer 10 is the length of the second fiber layer 10.

[0042] The method for manufacturing a prefabricated blade root in an embodiment of the present application, wherein, in the step of winding fiber filaments containing resin on the demolding layer of the mold 20, it also includes winding the fiber filaments on a plurality of continuously arranged steps 21 to form an inner fiber layer formed by the multi-layer fiber layer 10; an embedded part is arranged on the outer surface of the inner fiber layer, the width of the end face of the step 21 that is against the embedded part along the axis perpendicular to the axis is greater than the width of the remaining part of the step 21, one end of the embedded part is against a step 21, and the embedded part is fixedly connected to the outer surface of the inner fiber layer; the fiber filaments continue to be wound on the outer surface of the embedded part, and the fiber filaments are sequentially wound around the embedded part along a plurality of continuously arranged steps 21 to form an outer fiber layer.

[0043] The wind turbine blades are installed and connected to the wind turbine hub through the embedded parts in the blade roots. The embedded parts have the function of enhancing the connection strength of the prefabricated blade roots. Inner fiber layers and outer fiber layers are arranged on both sides of the embedded parts to wrap the embedded parts so that the embedded parts can be stably arranged inside the prefabricated blade roots.

[0044] Specifically, the embedded parts include materials such as a yarn-wrapped bolt sleeve and a wedge block. The bolt sleeve is used to connect the fan hub, and the wedge block is used to position the bolt sleeve. The embedded parts are bonded to the surface of the inner fiber layer by manual bonding, and one end of the embedded parts abuts against the end face of the step 21. Since the thickness of the embedded parts along the direction perpendicular to the axial direction of the mold 20 is relatively thick, when setting the step 21 against which the embedded parts abut, it is necessary to set the width of its end face along the direction perpendicular to the axial direction to be greater than the width of the remaining part of the step 21.

[0045] The method for manufacturing a prefabricated blade root in an embodiment of the present application further includes, after the step of forming the outer fiber layer, providing a protective layer on the outer surface of the outer fiber layer.

[0046] Since the fiber filaments in the formed fiber layer 10 are not firmly bonded after being wound around the mold 20, a protective layer needs to be provided on the outer surface of the outer fiber layer so that the fiber layer 10 as a whole can maintain its shape after winding to avoid deformation of the fiber layer 10, thereby avoiding deformation of the appearance of the manufactured prefabricated blade root.

[0047] The prefabricated blade root manufacturing method of the embodiment of the present application, wherein the prefabricated blade root manufacturing method further includes: assembling and fixedly connecting the prefabricated blade root with the wind turbine blade body to form an integral wind turbine blade.

[0048] In specific implementation, before the step of manufacturing the mold 20, the prefabricated blade root manufacturing method also includes setting the size parameters of the fiber layer 10; setting the size parameters of the mold 20, and designing a plurality of steps 21 according to the size parameters of the fiber layer 10, so that the fiber layer 10 obtained by winding the mold 20 can meet the use requirements.

[0049] The prefabricated blade root manufacturing method of the embodiment of the present application, wherein the mold 20 includes a fixing device, the fixing device is arranged at both ends of the mold 20, and the steps of tensioning and winding the fiber filaments on the outer wall of the mold 20 include: hanging the fiber filaments on the fixing device at one end of the mold 20; winding the fiber filaments along the outer peripheral surface of the mold 20 from one end to the other end of the mold 20; hanging the fiber filaments on the fixing device at the other end of the mold 20.

[0050] During the process of winding the fiber filaments on the barrel-shaped mold 20, since there is no fixed base, when the fiber filaments contact the outer surface of the mold 20, they cannot be fixed on the outer surface of the mold 20, which affects the winding. Therefore, in this step, by setting fixing devices at both ends of the mold 20, one end of the fiber filaments is fixed on the fixing device, so that the fiber filaments have a fixed base, and the fiber filaments will not be offset during the winding process. After the fiber layer 10 is wound, the other end of the fiber filaments is hung on the fixing device at the other end of the mold 20, and the fiber layer 10 is fixed as a whole.

[0051] In a specific implementation, after the fiber layer 10 is wound, the fixing devices at both ends of the mold 20 can be disassembled, and the fiber filaments fixed to the fixing devices can be removed at the same time to form a complete fiber layer 10 .

[0052] Specifically, the fixing device is a yarn hanging device, which can fix the fiber filaments.

[0053] In the method for manufacturing a prefabricated blade root according to an embodiment of the present application, in the step of winding fiber filaments containing resin on the demoulding layer of the mold 20, the winding method is one of dry winding, semi-dry winding or wet winding.

[0054] Specifically, dry winding makes it easy to control the glue content of the entire prefabricated blade root. Since the resin on the surface of the fiber layer 10 wound by dry winding is not in a completely melted state, rotation curing is not required. Only heating is required to cure the fiber layer 10 as a whole. If semi-dry winding or wet winding is adopted, rotation curing is required while heating to evenly diffuse the melted resin to each fiber filament.

[0055] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device. In the absence of further restrictions, the elements defined by the statement "include..." do not exclude the presence of other identical elements in the process, method, article or device including the elements.

[0056] The above is only a specific implementation of the present application. Those skilled in the art can clearly understand that for the convenience and simplicity of description, the specific working processes of the systems, modules and units described above can refer to the corresponding processes in the aforementioned method embodiments, and will not be repeated here. It should be understood that the protection scope of the present application is not limited to this. Any technician familiar with the technical field can easily think of various equivalent modifications or replacements within the technical scope disclosed in this application, and these modifications or replacements should be included in the protection scope of this application.

Claims

1. A method for manufacturing a prefabricated blade root, It is characterized in that The prefabricated blade root manufacturing method comprises: A mold (20) is provided, wherein the wall profile of the mold (20) is barrel-shaped, and the outer surface has a plurality of annular steps (21) connected and distributed along the axial direction of the mold (20); Winding fiber filaments containing resin on the demoulding layer of the mold (20), wherein the fiber filaments wind and fill at least a portion of the plurality of steps (21) to form a fiber layer (10) with a smooth surface; Winding fiber filaments containing resin on the demoulding layer of the mold (20) includes winding the fiber filaments on a plurality of continuously arranged steps (21) to form an inner fiber layer formed by multiple fiber layers (10); arranging an embedded part on the outer surface of the inner fiber layer, one end of the embedded part is abutted against one of the steps (21), the width of the end face of the step (21) abutted against the embedded part along the axis direction is greater than the width of the remaining part of the step (21), and the embedded part is fixedly connected to the outer surface of the inner fiber layer; continuing to wind the fiber filaments on the outer surface of the embedded part, the fiber filaments are sequentially wound around the embedded part along the plurality of continuously arranged steps (21) to form an outer fiber layer; curing the fiber layer (10) to form a prefabricated molding; The prefabricated molded body is demoulded from the mold (20) to form a prefabricated blade root.

2. The method for manufacturing a prefabricated blade root according to claim 1, It is characterized in that In the step of providing the mold (20), the mold (20) includes an outer peripheral surface parallel to its own axial direction, and the step (21) includes a side surface parallel to the axial direction and an end surface perpendicular to the axial direction.

3. The method for manufacturing a prefabricated blade root according to claim 2, It is characterized in that The side surface of one of two adjacent steps (21) in the plurality of steps (21) is connected to the end surface of the other step (21), and the distances between the side surfaces of the plurality of steps (21) distributed axially along the mold (20) and the outer peripheral surface increase successively.

4. The method for manufacturing a prefabricated blade root according to claim 2, It is characterized in that In the step of winding the fiber filaments containing resin on the demoulding layer of the mold (20), when the fiber filaments are wound on one of the steps (21), the fiber filaments are wound along the axial direction from any position of the outer peripheral surface along the axial direction to the end face of the step (21) to form a layer of the fiber layer (10), and the outer surface of the layer of the fiber layer (10) is arranged flush with the side face of the step (21).

5. The method for manufacturing a prefabricated blade root according to claim 4, It is characterized in that The step of winding the fiber filaments containing resin on the demoulding layer of the mold (20) also includes winding the fiber filaments on the outer surface of the already wound fiber layer (10) when winding the fiber filaments on the step (21) adjacent to the first step (21), until the fiber filaments abut against the outer surface of the step (21) to be wound, thereby forming another layer of the fiber layer (10).

6. The method for manufacturing a prefabricated blade root according to claim 1, It is characterized in that After the step of forming the outer fiber layer, the method further includes disposing a protective layer on the outer surface of the outer fiber layer.

7. The method for manufacturing a prefabricated blade root according to claim 1, It is characterized in that The prefabricated blade root manufacturing method further comprises: The prefabricated blade root is assembled and fixedly connected with the wind turbine blade body.

8. The method for manufacturing a prefabricated blade root according to claim 1, It is characterized in that The mold (20) comprises a fixing device, wherein the fixing device is arranged at two ends of the mold (20), and the step of tensioning and winding the fiber filaments and setting them on the outer wall of the mold (20) comprises: The fiber filament is hung on the fixing device at one end of the mold (20); Winding the fiber filaments along one end of the mold (20) to the other end thereof and arranging them on the outer peripheral surface of the mold (20); The fiber filaments are hung on the fixing device at the other end of the mold (20).

9. The method for manufacturing a prefabricated blade root according to claim 1, It is characterized in that In the step of winding the fiber filaments containing resin on the demoulding layer of the mold (20), the winding method is one of dry winding, semi-dry winding or wet winding.

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