A large wind power blade pultrusion glass plate girder interlayer pouring system and pouring method

Abstract

This invention relates to an interlayer grouting system and method for the main beam of a large wind turbine blade pultruded glass sheet. The system includes a blade mold, an outer skin fiberglass fabric layer, a continuous felt, multi-layer pultruded glass sheets, two sets of core materials, an inner skin fiberglass fabric layer, a release cloth, a porous isolation membrane, a flow guide net, and grouting channels. The grouting method is as follows: (1) Laying the outer skin fiberglass fabric layer; (2) Laying the continuous felt on top of the outer skin fiberglass fabric layer; (3) Stacking 2-10 sets of pultruded glass sheets into a main beam; (4) Laying the inner skin fiberglass fabric layer; (5) Laying the upper release cloth and porous isolation membrane; (6) Laying the woven flow guide net; (7) Laying the grouting channels; (8) Sealing the mold with a vacuum membrane; (9) Vacuuming to ≤25mbar; (10) Starting the grouting operation. This invention achieves complete interlayer wetting of the main beam without any grouting defects by designing the width and laying position of the bottom continuous felt, the spacing of the glue injection ports, and the grouting time, thereby reducing grouting time and improving grouting efficiency and quality.

Description

Technical Field

[0001] This invention belongs to the field of wind power equipment manufacturing technology, and relates to an interlayer grouting system and grouting method for the main beam of pultruded glass plate of large wind turbine blades. Background Technology

[0002] As blade length increases, so does blade weight. As the load-bearing component of wind turbine blades, selecting higher-performance materials for the main beam is beneficial for blade weight reduction. The pultrusion process, compared to vacuum infusion, can increase the tensile and compressive moduli of fiberglass products from 54 GPa to 62 GPa, an increase of 14.8%, meeting the structural design requirements of large-size blades and representing a mainstream design trend for future wind turbine blades.

[0003] The existing grouting process involves laying a continuous felt under the main beam and a flow guide net on top. The grouting time meets the curing window of the epoxy grouting adhesive. However, due to the excessively fast flow rate of the adhesive layers on the upper and lower surfaces, an envelope is formed in the middle. In the later stages, the adhesive slowly and completely wets the layers through capillary action, which easily leads to defects such as poor wetting of the interlayer fiber fabric.

[0004] Application publication number CN 114953503 A discloses an integrated injection molding system and method for wind turbine blades, which mainly provides an auxiliary material solution for the injection of pultruded main beams. However, because the upper surface of the pultruded main beam lacks a flow guide and uses a semi-permeable membrane for assisted air extraction, the injection time exceeds 3 hours, which easily causes the epoxy gel to solidify exothermically, leading to product scrap. Secondly, the cost of the semi-permeable membrane is relatively high, at 50 yuan / ㎡, with a single blade requiring approximately 100㎡, costing about 5000 yuan; the flow guide medium costs 3 yuan / ㎡, costing about 150 yuan, a cost difference of more than 30 times. Thirdly, there is no detailed description of the control points in the injection process, which may lead to poor wetting of the envelope due to differences in injection operation. Based on the above, it is necessary to control the arrangement of injection auxiliary materials, the setting of injection channels and the spacing of injection ports, and the injection switching time to solve problems such as poor wetting of interlayer fiber fabrics between pultruded glass plates. Summary of the Invention

[0005] The purpose of this invention is to provide an interlayer grouting system and method for the main beam of pultruded glass sheets for large wind turbine blades. By designing the width and laying position of the bottom continuous felt, the arrangement of the glue injection port spacing and the control of the grouting time, the interlayer wetting of the pultruded glass sheet main beam is completed without grouting defects, thereby reducing the grouting time and improving the interlayer grouting efficiency of the pultruded glass sheet main beam.

[0006] The technical solution of this invention is: a large wind turbine blade pultruded glass sheet main beam interlayer injection system, comprising a blade mold, an outer skin fiberglass fabric layer, a continuous felt, a multi-layer pultruded glass sheet, two sets of core materials, an inner skin fiberglass fabric layer, a release cloth, a porous isolation membrane, a flow guide net, and injection channels. The outer skin fiberglass fabric layer, continuous felt, pultruded glass sheet, inner skin fiberglass fabric layer, release cloth, porous isolation membrane, and flow guide net are arranged sequentially from bottom to top in the mold. The two sets of core materials are located at both ends, i.e., the leading edge side and the trailing edge side, respectively. The pultruded glass sheet is located between the two sets of core materials, and the injection channels are laid on top of the flow guide net. The continuous felt is displaced from the trailing edge side to the leading edge side, with a positioning distance of L3 = 10-20 mm to the core material on the trailing edge side, and a positioning distance of L4 = 10-30 mm to the core material on the leading edge side. The flow guide net is shortened from the leading edge side, with a shortening width of 1 / 5 of the width of the pultruded glass sheet.

[0007] The infusion channel is equipped with an injection port. The guide mesh is positioned above the pultruded glass sheet with a shortened distance L1 = 50-60 mm, and above the core material with a shortened distance L2 = 30-50 mm. Interlayer fiber fabric is provided between the pultruded glass sheets, with the width of the interlayer fiber fabric being the same as the width of the corresponding pultruded glass sheet layer. The system also includes a vacuum membrane for sealing the mold, and the vacuum port after mold sealing is connected to a vacuum pump.

[0008] The present invention relates to a method for interlayer grouting of pultruded glass plate main beams for large wind turbine blades, the grouting process of which is described as follows:

[0009] (1) Lay the outer skin fiberglass fabric layer on the main beam mold, and place the core material at both ends;

[0010] (2) Lay a continuous felt on top of the outer skin fiberglass fabric layer. The distance between the core material on the rear edge of the continuous felt is L3 = 10-20 mm, and the distance between the continuous felt inserted into the core material on the front edge is L4 = 10-30 mm.

[0011] (3) A main beam is formed by stacking 2-10 groups of pultruded glass sheets, with 5-10 layers of pultruded glass sheets in each group. Interlayer fiber fabric is provided between the pultruded glass sheets, and the width of the interlayer fiber fabric is the same as the width of the corresponding pultruded glass sheet.

[0012] (4) Lay an inner skin fiberglass layer on top of the pultruded glass plate to complete the structural fabric layer laying;

[0013] (5) Lay the upper release cloth 7 and the porous isolation film on the inner skin fiberglass fabric layer;

[0014] ⑹ Lay a woven flow guide net on the perforated isolation membrane. The flow guide net is positioned above the pultruded glass plate with a shortened distance L1 = 50-60 mm, and the flow guide net is positioned above the core material with a shortened distance L2 = 30-50 mm.

[0015] (7) Lay the injection channel above the flow guide net at the rear edge, and place the glue injection port in the middle of the injection channel. The spacing of the glue injection port should be controlled at 8-10m.

[0016] (8) Seal the mold with a vacuum membrane, the sealing membrane having a vacuum port, which is connected to a vacuum or vacuum pumping system;

[0017] (9) Start the vacuum machine and evacuate to ≤25mbar;

[0018] (10) Start the injection operation and open the injection channels in sequence. First, open the first injection port of the injection channel on the rear edge side. After the adhesive tangentially exceeds 1 / 2 of the main beam width or the flow time is 8-10 minutes, open the next injection port.

[0019] After the injection begins, the adhesive flows axially along the injection channel, and simultaneously, it flows chordally towards the rear edge on the guide net. Injection ports are placed at 10m intervals along the main channel. When the adhesive flows axially to the next injection port, it must be allowed to flow chordally to half the width of the main beam at that port before opening it. This ensures the adhesive fully flows and wets the materials. A time frame of 8-10 minutes is recommended and can be used as a site control measure.

[0020] The injection port is opened in a semi-open position to control the injection speed and avoid poor interlayer wetting. An oblique-push injection method is used, with the adhesive on the upper surface of the guide net reaching the next injection port. The injection port is opened when the chord length exceeds half the width of the main beam, or after 8-10 minutes based on comparative data. The continuous felt is 300g / ㎡, with foam as the core material. Multilayer pultruded glass sheets and interlayer fiber fabrics are interleaved and bundled to form the main beam, which is then hoisted into the mold and laid on the continuous felt.

[0021] In practical application of the technical solution of this invention, the positioning data L1, L2, L3, and L4 can be fine-tuned. Ultimately, adjustments are made in real-time based on the adhesive pioneer oblique-push injection method and phased array scanning detection results, and the scheme is solidified to form a standardized solution. The advantages of this invention are: ① The continuous felt at the bottom of the mold is shortened near the rear edge, slowing down the wetting speed of the bottom adhesive and reducing the risk of bottom adhesive backflow. ② The distance between the upper surface guide net and the air extraction side is shortened, reducing the width to 1 / 5 of the main beam width, allowing for more thorough downward wetting of the adhesive and solving the problem of incomplete wetting of the interlayer fiberglass fabric. ③ The setting of the injection port spacing ensures the supply of injection adhesive, solving interlayer defects caused by insufficient adhesive. ④ The standardization of injection time enables an oblique-push injection process, improving the process's error tolerance.

[0022] This invention relates to an interlayer grouting system and method for large wind turbine blade pultruded glass sheet main beams. By controlling the width and placement of the bottom continuous felt, the spacing of the injection ports, and the grouting time, it achieves complete interlayer wetting of the pultruded glass sheet main beam, eliminating grouting defects, reducing grouting time, and improving the efficiency and quality of interlayer grouting for the pultruded glass sheet main beam. Compared with existing technologies, the advantages of this invention are: ① By optimizing the continuous felt, the guide net, and the grouting arrangement, defects such as poor interlayer adhesive wetting are effectively controlled. ② Reduction of rework and repair costs, saving more than 500 yuan per blade. ③ Grouting of the main beam area can be completed in 60-80 minutes, and the overall grouting time for large wind turbine blades of 90-100m size is controlled within 120 minutes. Attached Figure Description

[0023] Figure 1 This is a structural schematic diagram (cross-sectional view) of the interlayer grouting system for the main beam of the large wind turbine blade pultruded glass plate of the present invention;

[0024] Figure 2 for Figure 1 A side top view;

[0025] Figure 3 Schematic diagram of interlayer adhesive impregnation for pultruded glass plates;

[0026] Figure 4 This is a schematic diagram showing the flow of adhesive and valve opening requirements.

[0027] Wherein: 1—Outer skin fiberglass fabric layer, 2—Continuous mat, 3—Pultruded glass plate, 4—Interlayer fiber fabric, 5—Core material, 6—Inner skin fiberglass fabric layer, 7—Mold release cloth, 8—Porous release membrane, 9—Flow guide mesh, 10—Injection channel, 11—Injection port, 12—Potentially defective location Detailed Implementation

[0028] The present invention will now be described in detail with reference to the embodiments and accompanying drawings. The scope of protection of the present invention is not limited to the embodiments, and any modifications made by those skilled in the art within the scope defined by the claims also fall within the scope of protection of the present invention.

[0029] This invention relates to an interlayer grouting system for the main beam of a large wind turbine blade pultruded glass plate, such as... Figure 1As shown, the mold includes a blade mold, an outer skin fiberglass fabric layer 1, a continuous mat 2, a multi-layer pultruded glass plate 3, two sets of core materials 5, an inner skin fiberglass fabric layer 6, a release cloth 7, a porous release membrane 8, a flow guide net 9, and an injection channel 10. The outer skin fiberglass fabric layer, continuous mat, pultruded glass plate, inner skin fiberglass fabric layer, release cloth, porous release membrane, and flow guide net are arranged sequentially from bottom to top in the mold. The injection channel 10 is placed on top of the flow guide net and has an injection port 11. The core material is foam, and the two sets of core materials are located at opposite ends of the mold, namely the leading edge and the trailing edge. The pultruded glass plate is located between the two sets of core materials. The continuous mat is displaced from the trailing edge to the leading edge, with a positioning distance of L3 = 15 mm to the trailing edge core material and a positioning distance of L4 = 20 mm to the leading edge core material. The flow guide net 9 is positioned above the pultruded glass plate 3 with a shortened distance L1 = 60 mm, and above the core material 5 with a shortened distance L2 = 40 mm. Interlayer fiber fabric 4 is provided between the pultruded glass plates 3, and the width of the interlayer fiber fabric is the same as the width of the corresponding pultruded glass plate. The system is equipped with a vacuum membrane for sealing the mold, and the vacuum port after the mold is sealed is connected to a vacuum pump.

[0030] The present invention relates to a method for interlayer grouting of pultruded glass plate main beams for large wind turbine blades, the grouting process of which is as follows:

[0031] (1) Lay the outer skin fiberglass fabric layer 1 on the main beam mold, and place the core material 5 at both ends. The core material is foam.

[0032] (2) Lay a 300g / ㎡ continuous felt 2 on top of the outer skin fiberglass fabric layer 1. The distance L3 from the core material on the rear edge of the continuous felt is 15mm, and the distance L4 from the insertion of the continuous felt into the core material 5 on the front edge is 20mm.

[0033] (3) For example Figure 3 As shown, a main beam is formed by stacking 5 groups of pultruded glass sheets 3, with 50 layers of pultruded glass sheets in each group. Interlayer fiber fabric 4 is provided between the pultruded glass sheets, and the width of the interlayer fiber fabric is the same as the width of the corresponding layer of pultruded glass sheet. The multiple layers of pultruded glass sheets 3 and interlayer fiber fabric 4 are laid in an alternating manner and tied together to form a main beam. The main beam is then hoisted into a mold and laid on a continuous felt.

[0034] (4) The inner skin fiberglass fabric layer 6 is laid on top of the pultruded glass plate 3 to complete the structural fabric layer laying;

[0035] (5) Lay the upper release cloth 7 and the porous isolation film 8 on the inner skin fiberglass fabric layer;

[0036] (6) Lay a woven flow guide net 9 on top of the perforated isolation membrane 8, such as... Figure 1 , Figure 2 As shown, the flow guide net 9 is located above the pultruded glass plate 3 with a shortened distance L1 = 60 mm, and the flow guide net 9 is located above the core material 5 with a shortened distance L2 = 450 mm;

[0037] (7) Lay the injection channel 10 above the rear edge guide net 9, and place the glue injection port 11 in the middle of the injection channel 10. The spacing of the glue injection port 11 is controlled at 10m.

[0038] (8) Seal the mold with a vacuum membrane, the sealing membrane having a vacuum port, which is connected to a vacuum or vacuum pumping system;

[0039] (9) Start the vacuum machine and evacuate to ≤25mbar;

[0040] (10) Start the injection operation and open the injection channel 10 in sequence. First, open the first injection port of the injection channel on the rear edge side. After the glue tangentially exceeds 1 / 2 of the main beam width or the flow time is 8-10 minutes, open the next injection port.

[0041] After the injection begins, the adhesive flows axially along the injection channel, and simultaneously, it flows chordally towards the rear edge on the guide net. Injection ports are placed at 10m intervals along the main channel. When the adhesive flows axially to the next injection port, it must be allowed to flow chordally to half the width of the main beam at that port before opening it. This ensures the adhesive fully flows and wets the materials. A time frame of 8-10 minutes is recommended and can be used as a site control measure.

[0042] To obtain a better product, the filling process should follow these steps:

[0043] ① Injection speed control: In order to ensure more complete and sufficient impregnation of the board and board fiber, the injection port 11 in the main beam area is opened by half-opening the valve to control the injection speed and better avoid poor interlayer impregnation from the operation.

[0044] ②Standard for injection pipe opening time: The injection method using a slanted approach is as follows: Figure 4 As shown, the opening standard is: when the adhesive vane on the upper surface of the guide net reaches the next injection port position, and the chord direction exceeds 1 / 2 the width of the main beam, or after 8-10 minutes according to the comparison data, the corresponding injection port is opened to ensure the supply of adhesive.

[0045] Compared with existing technologies: ① When the woven guide net 9 is positioned at L1=0 and L2=0mm, after the pre-curing is completed, a phased array scan of the pultruded glass plate main beam is performed. A defect of poor interlayer wetting appears in the pultruded plate area near the leading edge, with an area of ​​approximately 200*30mm. This is an unacceptable defect (acceptable standard area ≤100*20mm), affecting product quality. This indicates that if the woven guide net 9 on the upper surface is fully laid, the adhesive front pouring on the upper surface is too fast, quickly exceeding the main beam area, causing an envelopment between the lower plates, resulting in insufficient wetting of the interlayer fiber fabric 4 between the plates, leading to poor interlayer wetting. ② Referring to the spacing of the previous pouring channels 10 and the injection ports 11, with an injection port spacing L=15-20mm, after the pre-curing is completed, a phased array scan of the pultruded glass plate main beam is performed. A defect of poor interlayer wetting appears near the middle of the two injection ports 11. The explanation is that the spacing of the injection nozzles 11 affects the occurrence of defects. The analysis is that if the spacing of the injection nozzles 11 is set too long at the edge of the two injection nozzles (i.e., near the middle of the two injection nozzles 11), the glue supply will be insufficient, resulting in poor interlayer wetting defects.

[0046] Compared with existing technologies, the interlayer grouting method for the main beam of large wind turbine blade pultruded glass sheets in this invention is as follows: ① After the continuous felt is positioned with an inward shrinkage of L3 = 10-20mm, the adhesive quickly flows from the core material gap to the bottom continuous felt. The adhesive front is supplied to the front edge through the bottom continuous felt at a slower speed, which is beneficial for the adhesive to penetrate and wet the interlayer fiber fabric between the sheets, reducing the occurrence of defects such as poor interlayer wetting. The positioning data of the continuous felt 2 on the front edge side is L4 = 10-30mm, which ensures that the adhesive is fully supplied at the bottom, wetting the outer skin fiberglass fabric layer 1 of the main beam assembled from the pultruded glass sheets 3. ② The use of the porous isolation membrane 8 is beneficial for removing the woven guide net 9 from the release cloth 7 after the shell pre-curing is completed, reducing labor intensity. At the same time, removing the woven guide net 9 helps quality inspectors to quickly complete the inspection. ③ Lay out the woven guide net 9. The positioning data above the pultruded glass plate 3 is L1, where L1 = 1 / 2 the width of a single pultruded plate (e.g., if the width of a single pultruded glass plate is 120mm, L1 = 1 / 2 * 120 = 60mm), with a tolerance of ±20mm; the positioning data above the core material 5 is L2, where L2 = 30-50mm. ④ Lay the injection channel 10 above the guide net at the trailing edge. The channel at the trailing edge should not be interrupted to ensure a continuous supply of adhesive.

Claims

1. A large wind turbine blade pultruded glass plate main beam interlayer injection system, comprising a blade mold, an outer skin fiberglass fabric layer (1), a continuous felt (2), a multilayer pultruded glass plate (3), two sets of core materials (5), an inner skin fiberglass fabric layer (6), a release cloth (7), a porous isolation membrane (8), a flow guide net (9), and an injection channel (10); the outer skin fiberglass fabric layer, continuous felt, pultruded glass plate, inner skin fiberglass fabric layer, release cloth, porous isolation membrane, and flow guide net are arranged sequentially from bottom to top in the mold; the two sets of core materials (5) are located on the leading edge side and the trailing edge side respectively, the pultruded glass plate is located between the two sets of core materials (5), and the injection channel (10) is laid on top of the flow guide net; characterized in that: The continuous felt is displaced from the rear edge to the front edge, and the core material positioning distance from the rear edge is L3=10-20mm. The core material (5) inserted into the front edge is positioned at a distance of L4=10-30mm. The guide net (9) is shortened from the front edge, and the shortened width is 1 / 5 of the width of the pultruded glass plate. The guide net (9) is located above the pultruded glass plate (3) with a shortened distance L1=50-60mm, and the guide net is located above the core material (5) with a shortened distance L2=30-50mm.

2. The interlayer grouting system for the main beam of a large wind turbine blade pultruded glass plate according to claim 1, characterized in that: The injection channel (10) is provided with an injection port (11).

3. The interlayer grouting system for the main beam of a large wind turbine blade pultruded glass plate according to claim 1, characterized in that: Interlayer fiber fabric (4) is provided between the pultruded glass plates (3), and the width of the interlayer fiber fabric is the same as the width of the corresponding pultruded glass plate.

4. The interlayer grouting system for the main beam of a large wind turbine blade pultruded glass plate according to claim 1, characterized in that: The core material (5) is foam.

5. The interlayer grouting system for the main beam of a large wind turbine blade pultruded glass plate according to claim 1, characterized in that: The system also includes a vacuum membrane for sealing the mold, and the vacuum port of the sealed mold is connected to a vacuum pump.

6. A grouting method for the interlayer grouting system of the large wind turbine blade pultruded glass plate main beam as described in claim 1, characterized in that: The infusion process is as follows: (1) Lay the outer skin fiberglass fabric layer (1) on the main beam mold and place the core material (5) at both ends; (2) Lay a continuous felt (2) on top of the outer skin fiberglass fabric layer (1). The distance between the core material on the rear edge of the continuous felt is L3=10-20mm, and the distance between the continuous felt on the front edge and the core material (5) is L4=10-30mm. (3) A main beam is formed by stacking 2-10 groups of pultruded glass plates (3), each group having 5-10 layers of pultruded glass plates, with interlayer fiber fabric (4) between the pultruded glass plates (3), the width of the interlayer fiber fabric being the same as the width of the corresponding layer of pultruded glass plate; (4) Lay the inner skin fiberglass fabric layer (6) on top of the pultruded glass plate (3) to complete the structural fabric layer laying; (5) Lay the upper release cloth (7) and the porous isolation film (8) on the inner skin fiberglass fabric layer; ⑹ A woven flow guide net (9) is laid on the porous isolation membrane (8). The flow guide net is located above the pultruded glass plate (3) with a shortened distance L1=50-60mm, and the flow guide net is located above the core material (5) with a shortened distance L2=30-50mm. (7) Lay an injection channel (10) above the rear edge guide net (9), and place an injection port (11) in the middle of the injection channel (10). The spacing of the injection ports is controlled at 8-10m. (8) Seal the mold with a vacuum membrane, the sealing membrane having a vacuum port, which is connected to a vacuum or vacuum pumping system; (9) Start the vacuum machine and evacuate to ≤25mbar; (10) Start the injection operation and open the injection channels (10) in sequence. First, open the first injection port of the injection channel on the rear edge side. After the glue tangentially exceeds 1 / 2 of the main beam width or the flow time is 8-10 minutes, open the next injection port.

7. The grouting method for the interlayer grouting system of the pultruded glass plate main beam of a large wind turbine blade according to claim 6, characterized in that: The opening of the injection port (11) is in a half-open state to control the injection speed and avoid poor interlayer wetting.

8. The grouting method for the interlayer grouting system of the pultruded glass plate main beam of a large wind turbine blade according to claim 6, characterized in that: The grouting adopts a slanted push grouting method. When the adhesive on the upper surface of the guide net (9) reaches the next grouting port position, the corresponding grouting port is opened when the chord direction exceeds 1 / 2 of the main beam width or after 8-10 minutes according to the comparison data.

9. The grouting method for the interlayer grouting system of the pultruded glass plate main beam of a large wind turbine blade according to claim 6, characterized in that: The continuous felt (2) is a 300g / ㎡ continuous felt.

10. The grouting method for the interlayer grouting system of the pultruded glass plate main beam of a large wind turbine blade according to claim 6, characterized in that: Multilayer pultruded glass sheets (3) and interlayer fiber fabrics (4) are laid in an alternating manner and tied together to form a beam. The beam is then hoisted into a mold and laid on a continuous felt (2).

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