Blade spar and method of manufacturing same, blade, and wind turbine generator system

Abstract

The application provides a blade main beam and a manufacturing method thereof, a blade and a wind turbine generator set. The manufacturing method of the blade main beam comprises laying of a main beam plate material and a core material and resin infusion molding. The laying of the main beam plate material and the core material comprises: stacking a plurality of main beam plate materials in a main beam mold to form a main beam plate body; measuring a gap on one side of the main beam plate body to obtain a gap size; filling the gap of the plate material with a filler; and laying the core material on one side of the main beam plate body, so that the core material is connected with the filler to obtain a main beam layup, and the laying of the main beam plate material and the core material is completed. The blade main beam and the manufacturing method thereof, the blade and the wind turbine generator set provided by the application reduce resin enrichment on the edge of the main beam, and improve the strength and rigidity of the main beam. The method can effectively improve the strength and rigidity of the main beam, thereby being beneficial to guaranteeing the structural strength of the blade and the stability of the operation of the entire wind turbine generator set.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of wind power, and particularly relates to a main beam of a blade, a manufacturing method of the main beam, a blade and a wind turbine generator. BACKGROUND

[0002] Wind energy is a clean and renewable energy, and a wind turbine generator is widely used at home and abroad as a necessary device for converting wind energy into electric energy. The blade of the wind turbine generator is a main component for converting wind energy into kinetic energy, and the performance stability of the blade in use has a key influence on the overall performance of the wind turbine generator.

[0003] The main beam and the web plate are arranged in the blade as load-bearing components of the blade structure, and ensuring the structural strength and rigidity of the main beam is the basis for ensuring the stable operation of the blade. Therefore, how to improve the structural strength and rigidity of the main beam is a problem to be solved by those skilled in the art. SUMMARY

[0004] The present application provides a main beam of a blade, a manufacturing method of the main beam, a blade and a wind turbine generator, which can improve the structural strength and rigidity of the main beam of the blade.

[0005] In one aspect, the present application provides a manufacturing method of a main beam of a blade, which comprises laying a main beam plate and a core material and resin infusion molding, and the laying of the main beam plate and the core material comprises:

[0006] stacking a plurality of main beam plates in a main beam mold to form a main beam plate body;

[0007] measuring a gap on one side of the main beam plate body to obtain a gap size;

[0008] filling the gap of the plate with a filler;

[0009] laying the core material on one side of the main beam plate body, the core material being connected with the filler, obtaining a main beam layup, and completing the laying of the main beam plate and the core material.

[0010] In some embodiments, the step of measuring the gap on one side of the main beam plate body to obtain a gap size comprises:

[0011] marking the main beam plate at the bottom layer as a first plate, and marking the main beam plate adjacent to the first plate as a second plate;

[0012] the part of the side edge of the second plate protruding from the side edge of the first plate is a first misalignment part;

[0013] measuring the size of the first misalignment part in the width direction of the second plate to obtain a first gap size W1.

[0014] In some embodiments, the step of filling the gap of the plate with the filler comprises:

[0015] Obtaining the thickness H1 of the first plate;

[0016] Manufacturing the first filler according to the thickness H1 of the first plate and the first gap width W1, the thickness of the first filler being H1, and the width of the first filler being W1 / N, N being a positive integer;

[0017] Placing the at least one first filler on the side of the first plate facing the core material.

[0018] In some embodiments, the first filler is made of the same material as the core material.

[0019] In some embodiments, the filler and the core material are bonded.

[0020] In some embodiments, the core material is laid on one side of the girder plate body, the core material is connected with the filler, and the girder layer is obtained, and the step of completing the laying of the girder plate and the core material comprises:

[0021] Cutting the side of the core material facing the girder plate to form an inclined portion with gradually decreasing thickness;

[0022] Placing the core material on one side of the girder plate body, and the inclined portion abuts against the first filler, and the inclined portion and the girder plate body form an observation slot;

[0023] Placing the second filler in the observation slot to obtain the girder layer.

[0024] In some embodiments, the step of cutting the side of the core material facing the girder plate to form an inclined portion with gradually decreasing thickness comprises:

[0025] Obtaining the included angle α between the plane where the side wall of the girder plate body is located and the plane where the bottom wall of the girder plate body is located;

[0026] Obtaining the inclination angle β of the inclined portion according to the included angle α, and cutting the core material according to the inclination angle β to form the inclined portion.

[0027] In some embodiments, the step of placing the filler in the observation slot to obtain the girder layer comprises:

[0028] Obtaining the size of each direction of the observation slot;

[0029] Manufacturing the second filler according to the size of each direction of the observation slot;

[0030] Placing the second filler in the observation slot.

[0031] In some embodiments, the second filler is made of the same material as the core material.

[0032] In some embodiments, the core material is arranged on one side of the main beam plate body, and the inclined portion is in abutment with the first filler. After the step of forming the observation slot by the inclined portion and the main beam plate body, the method further comprises:

[0033] Measuring the second gap on the side edge of the beam plate body to obtain a second gap width W2;

[0034] Manufacturing a third filler according to the second gap width W2;

[0035] Arranging the third filler in the second gap.

[0036] In some embodiments, the step of measuring the second gap on the side edge of the beam plate body to obtain a second gap width W2 comprises:

[0037] Marking any two adjacent beam plate materials as lower plate materials close to the first plate material and as upper plate materials away from the first plate material;

[0038] The part of the upper plate material protruding from the lower plate material in the width direction of the upper plate material is a second misalignment part;

[0039] Measuring the width of the second misalignment part to obtain the second gap width W2.

[0040] In some embodiments, the step of manufacturing a third filler according to the second gap width W2 comprises:

[0041] Obtaining a thickness H2 of the lower plate material;

[0042] Manufacturing the third filler according to the thickness H2 of the lower plate material and the second gap width W2, the thickness of the third filler being H2, and the width of the third filler being W2 / M, M being a positive integer.

[0043] In a second aspect, the embodiments of the present application provide a main beam of a blade, manufactured by the manufacturing method provided in any of the above embodiments.

[0044] In a third aspect, the embodiments of the present application provide a blade comprising the main beam of the blade provided in the above embodiments.

[0045] In a fourth aspect, the embodiments of the present application provide a wind turbine generator comprising the blade provided in the above embodiments.

[0046] The main beam of the blade and the manufacturing method thereof, the blade and the wind turbine generator set provided by the embodiments of the present application can obtain accurate size of the notch by measuring the edge notch of the main beam plate body after the main beam plate body is formed, improve the accuracy and efficiency of the measurement. Then, the filler is used to fill the notch width, and after the core material is laid, the resin is injected and molded. The above method can effectively reduce the gap size between the core material and the main beam plate body, reduce the probability of resin enrichment at the gap, and thus reduce the reduction of the strength and rigidity of the main beam caused by the resin enrichment at the edge of the main beam plate body. The above method can effectively improve the strength and rigidity of the main beam, and thus is conducive to ensuring the structural strength of the blade and the stability of the operation of the entire wind turbine generator set. BRIEF DESCRIPTION OF DRAWINGS

[0047] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings needed to be used in the embodiments of the present application will be briefly introduced as follows. Obviously, the drawings in the following description are only some embodiments described in the present application, and other drawings can also be obtained according to these drawings without creative labor for those skilled in the art.

[0048] Fig. 1 is a flow chart of the laying method of the main beam plate and the core material provided by the embodiments of the present application;

[0049] Fig. 2 is a structural schematic diagram of the laying of the main beam plate and the core material provided by the embodiments of the present application;

[0050] Fig. 3 is a flow chart of the first notch measurement method of the main beam plate provided by the embodiments of the present application;

[0051] Fig. 4 is a structural schematic diagram of the first notch of the main beam plate provided by the embodiments of the present application;

[0052] Fig. 5 is a flow chart of the filling method of the first filler provided by the embodiments of the present application;

[0053] Fig. 6 is a structural schematic diagram of the integrated structure of the first filler and the core material provided by the embodiments of the present application;

[0054] Fig. 7 is a flow chart of the method of setting the second filler in the observation slot provided by the embodiments of the present application;

[0055] Fig. 8 is a structural schematic diagram of the observation slot of the main beam plate provided by the embodiments of the present application;

[0056] Fig. 9is a flow chart of a manufacturing method of the inclined part of the core material provided by the embodiment of the present application;

[0057] Fig. 10 is a structural schematic diagram of the third filler provided by the embodiment of the present application;

[0058] Fig. 11 is a flow chart of a method of filling the third filler in the second gap of the girder plate provided by the embodiment of the present application;

[0059] Fig. 12 is a structural schematic diagram of the second misaligned part of the girder plate provided by the embodiment of the present application;

[0060] Fig. 13 is a flow chart of a method of obtaining the second gap width of the girder plate provided by the embodiment of the present application;

[0061] Fig. 14 is a structural schematic diagram of the third filler of the girder plate provided by the embodiment of the present application;

[0062] Fig. 15 is a flow chart of a manufacturing method of the third filler of the girder plate provided by the embodiment of the present application;

[0063] Fig. 16 is a structural schematic diagram of the wind turbine generator provided by the embodiment of the present application.

[0064] In the drawings, the drawings are not necessarily drawn according to scale.

[0065] The reference signs in the detailed description are as follows:

[0066] 10, blade; X, first direction; Y, second direction; 20, girder plate; 201, first plate; 202, second plate; 203, first misaligned part; 204, lower plate; 205, upper plate; 206, second misaligned part; 30, girder mold; 40, girder plate body; 401, gap; 402, filler; 50, core material; 501, main body part; 502, inclined part; 503, observation groove; 504, third filler. Detailed Description

[0067] The features and exemplary embodiments of various aspects of the present application will be described in detail below, in order to make the purposes, technical solutions and advantages of the present application more clear and apparent, the present application will be further described in detail below in combination with the drawings and specific embodiments. It should be understood that the specific embodiments described herein are only intended to explain the present application, but not to limit the present application. The present application can be implemented without some of these specific details by those skilled in the art. The following description of the embodiments is only to provide a better understanding of the present application by showing examples of the present application.

[0068] It should be pointed out that, in this document, relational terms such as first and second and the like can only be used to distinguish one entity or action from another entity or action, without necessarily requiring or implying that there is any such relationship or order between or among the respective entities or actions. Moreover, the terms "comprises", "comprising", or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but can include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element proceeded by "comprises... a" does not, without more constraints, exclude the existence of additional identical elements in the process, method, article, or apparatus that comprises the element.

[0069] It should be pointed out that the terms "upper", "lower", "front", "back", and the like indicate the orientation or positional relationship shown in the drawings, which are only for the convenience of description, and do not indicate or imply that the device or element referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as a limitation on the patent.

[0070] It should also be pointed out that, unless otherwise explicitly specified and limited, the terms "arranged", "mounted", "connected", "linked" should be understood broadly, for example, it can be fixedly connected, or detachably connected, or integrally connected; it can be mechanically connected, or electrically connected; it can be directly connected, or indirectly connected through an intermediate medium; it can be the internal communication of two elements. For those skilled in the art, the specific meaning of the above terms in this application can be understood according to the specific circumstances.

[0071] With the rapid development of the wind power market and the continuous progress of wind power technology, the single machine capacity is getting larger and larger, and the blade is getting longer and longer. Good design, reliable quality and superior performance of the blade are the decisive factors to ensure the normal and stable operation of the unit. In order to adapt to the above changes, the main beam in the blade for bearing load also needs to be improved to ensure the structural strength of the blade and improve the operation stability of the wind turbine generator unit.

[0072] The blade is usually composed of an upper and lower shell to form the external contour, and a main beam-web structure is used for internal bearing. The main beam is the main bearing component. When manufacturing the main beam of the blade, the main beam is usually laid in the cavity of the main beam mold, and the two sides of the main beam are filled with light core material, which is cured and formed between the core material and the main beam by resin.

[0073] The main beam plate is usually selected from a pultruded plate. The pultruded plate has a flat plate structure. A plurality of pultruded plates are stacked in the main beam mold along a first direction. For example, the first direction is the thickness direction of the main beam plate. The bottom wall of the main beam mold is arc-shaped. After the main beam plate is laid, two adjacent main beam plates will be misaligned in a second direction. The second direction can be the width direction of the main beam plate. At this time, laying the core material will cause a gap between the main beam plate and the core material. If the above layer is directly injected, the gap will be rich in resin. After the resin is cured and formed, its strength is less than that of the core material and the main beam plate. Therefore, the strength and stiffness of the main beam at the resin-rich position are lower than the design standard, which reduces the overall structural strength and stiffness of the main beam.

[0074] In related technologies, common control methods for main beam resin-rich defects include: method 1, in the core material design stage, the inclination angle of the core material on the side of the main beam is consistent with the design angle of the pultruded main beam. During the production of the pultruded main beam, the main beam plate angle is controlled by means of tensioning tooling and shape foam + binding tape. The core material is attached to the main beam during the integral forming of the core material, the main beam and the blade. Method 2, in the core material design stage, the inclination angle of the core material on the side of the main beam is consistent with the design angle of the main beam. The main beam is separately injected and formed by using a mold. The angle of the mold stopper is consistent with the design angle of the main beam. The main beam is injected in the mold. After demolding, the main beam is polished and shaped. The core material is attached to the main beam during the laying of the main beam plate.

[0075] However, the above methods have certain problems, resulting in low production efficiency and high production cost of the main beam of the blade. For example, the tensioning tooling and the shape foam in the above method 1 cannot effectively ensure the angle of the main beam. The misalignment of the main beam plate is more likely to cause the generation of resin-rich defects on the side of the pultruded main beam. The main beam plate in method 2 is separately injected and formed, which is time-consuming and laborious, has high cost, and seriously affects the forming period of the blade.

[0076] Therefore, as shown in the Figs. 1-2 The embodiments of the present application provide a manufacturing method of a main beam of a blade, which includes laying of a main beam plate 20 and a core material 50 and resin injection forming. The resin injection forming can be manufactured by using the related technology disclosed in the wind power blade 10 main beam manufacturing, which is not limited herein.

[0077] In the embodiments of the present application, the laying of the main beam plate 20 and the core material 50 in the manufacturing method of the blade 10 includes the following steps:

[0078] S01, a plurality of main beam plates 20 are stacked in a main beam mold 30 to form a main beam plate body 40;

[0079] S02, measuring the gap 401 on one side of the main beam plate body 40 to obtain the width of the gap 401;

[0080] S03, filling the gap 401 of the plate with the filler 402;

[0081] S04, laying the core material 50 on one side of the girder plate body 40, the core material 50 being connected with the filler 402, obtaining a girder layer, and completing the laying of the girder plate 20 and the core material 50.

[0082] In the above technical solution, the girder plate 20 is arranged in layers in the girder mold 30, and the edge gap 401 of the girder plate body 40 is measured after the girder plate body 40 is formed, so that the size of the gap 401 can be accurately obtained, and the measurement accuracy and efficiency are improved. Then, the gap 401 is filled with the filler 402, and after the core material 50 is laid, resin infusion molding is performed. The above method can effectively reduce the gap size between the core material 50 and the girder plate body 40, avoid resin enrichment at the gap, and reduce the reduction of the strength and stiffness of the girder caused by resin enrichment. The above method can effectively improve the strength and stiffness of the girder, and thus help to ensure the structural strength of the blade 10 and the stability of the entire wind turbine generator set.

[0083] Moreover, compared with the prior art, the method of the present application can effectively avoid the strength defects caused by resin enrichment on both sides of the girder plate, and does not need to separately infuse the girder plate 20, thereby improving the structural strength and stiffness of the girder while ensuring the production efficiency of the blade.

[0084] As shown in Fig. 3 and Fig. 4 In some embodiments of the present application, step S2 specifically comprises:

[0085] S201, marking the girder plate 20 arranged at the bottom layer as a first plate 201, and marking the girder plate 20 adjacent to the first plate 201 as a second plate 202;

[0086] S202, the part of the side edge of the second plate 202 protruding from the side edge of the first plate 201 is a first misalignment part 203;

[0087] S203, measuring the size of the first misalignment part 203 along the width direction of the second plate 202 to obtain a first gap 401 width W1.

[0088] In the embodiments of the present application, the gap 401 formed by the misalignment between the first plate 201 and the second plate 202 is accurately measured to obtain the gap 401 width, which can accurately set the matching filler material for filling, improve the structural strength and stiffness at the gap 401, avoid resin enrichment at the bottom of the girder plate body 40, and ensure the structural strength and stiffness of the girder as a whole.

[0089] As shown in Fig. 4And as shown in 5, in some embodiments of the present application, step S03 specifically comprises:

[0090] S301, obtain the thickness H1 of the first plate material 201;

[0091] S302, according to the thickness H1 of the main beam plate material 20 and the first gap 401 width W1, manufacture the first filler 402, the thickness of the first filler 402 is H1, the width of the first filler 402 is W1 / N, N is a positive integer;

[0092] S303, set at least one first filler 402 to the side of the first plate material 201 facing the core material 50.

[0093] In the embodiments of the present application, the thickness of the plurality of main beam plate materials 20 can be set to be equal, and the thickness of the first plate material 201 and other main beam plate materials 20 is H1. The thickness of the first filler 402 in the first direction X is H1, the width of the first filler 402 in the second direction Y is W1, and the length of the first filler 402 in the third direction is equal to the length of the core material 50. For example, the third direction can be the length direction of the main beam. The above-mentioned first filler 402 can be prefabricated according to the thickness H of the main beam plate material 20, and then cut according to the first gap 401 width W1 measured in step S302 to match the size of the first gap 401. For example, it can be cut to 1 / N of the width of W1, so N number of first fillers 402 need to be cut.

[0094] Optionally, the first filler 402 is prefabricated into a filler strip of a fixed width, and the filler strip can be used to fill the gap 401 of the main beam plate material 20. For example, the thickness of the main beam plate material 20 is 7mm, a plurality of 7mm*5mm strip-shaped fillers 402 can be manufactured, and when the first gap 401 width is 10mm, two strip-shaped fillers 402 can be set to fill. It can be understood that when the first gap 401 width size cannot match the width of an integer number of strip-shaped fillers 402, one more strip-shaped filler 402 can be set. For example, when the first gap 401 width size is 12mm, three 7mm*5mm strip-shaped fillers 402 can be filled, and the excess part can be cut or the width of the upper core material 50 is widened to improve the fit between the core material 50 and the main beam plate material 20 and reduce resin enrichment.

[0095] In some optional embodiments, the first filler 402 and the core material 50 are made of the same material. The core material 50 is usually made of a material with high structural strength and low density, and the first filler 402 is made of the same material as the core material 50, which can minimize the weight while ensuring that the structural strength and stiffness of the main beam meet the standards.

[0096] In some optional embodiments, the filler 402 and the core material 50 are connected by adhesion. For example, after the filler 402 is arranged in the notch 401 of the beam plate, the side of the filler 402 facing the core material 50 is sprayed with glue, and then the core material 50 is laid, the core material 50 is abutted with the filler 402 and pressure is applied, so that the filler 402 and the core material 50 are glued. The above technical solution can improve the connection strength between the core material 50 and the filler 402, further reduce the gap between the core material 50 and the beam plate, reduce the defect of resin enrichment of the main beam, and ensure the structural strength and rigidity of the main beam.

[0097] As shown in Fig. 6 In some optional embodiments, the first filler 402 and the core material 50 are integrally formed. The above structure can reduce the step of adhesion between the first filler 402 and the core material 50, while ensuring the connection strength of the first filler 402 and the core material 50.

[0098] As shown in Fig. 7 In some embodiments of the present application, step S4 specifically includes:

[0099] S401, cutting the side of the core material 50 facing the main beam plate 20, and forming an inclined portion 502 with gradually decreasing thickness on one side of the core material 50;

[0100] S402, arranging the core material 50 on one side of the main beam plate 40, and abutting the inclined portion 502 with the first filler 402, and the inclined portion 502 and the main beam plate 40 form an observation slot 503;

[0101] S403, arranging the second filler 402 in the observation slot 503 to obtain the main beam layer.

[0102] The core material 50 includes a main body portion 501 and an inclined portion 502 connected in sequence along the second direction Y. The inclined portion 502 is arranged close to the main beam plate 40. The thickness of the main body portion 501 is substantially uniform, and the thickness of the inclined portion 502 gradually decreases along the direction of the main body portion 501 towards the main beam plate 40. The side wall of the inclined portion 502 facing the main beam plate 40 is inclined towards the main body portion 501, so as to form a wedge-shaped observation slot 503 at the top of the core material 50.

[0103] By setting the observation groove 503, the misalignment of the main beam plate 20 can be observed from the top of the core material 50, and the beam edge defect of the main beam plate 20 can be identified. Specifically, the above-mentioned misalignment is caused by many factors, including the misalignment caused by the unevenness of the bottom of the mold in the height direction, and the misalignment caused by the transfer process of the stacked main beam plate 20. In order to further reduce the gap between the core material 50 and the main beam plate 20, and reduce the defect caused by the main beam resin enrichment, by observing the misalignment through the observation groove 503, the filler 402 can be arranged in the gap 401 caused by the misalignment in time, improve the structural strength and rigidity of the gap 401, and ensure the structural stability of the main beam.

[0104] Please continue to refer to Fig. 8 and Fig. 9 In some embodiments of the present application, step S401 specifically comprises:

[0105] S401A, obtaining the included angle a between the plane where the side wall of the main beam plate body 40 is located and the plane where the bottom wall of the main beam plate body 40 is located;

[0106] S401B, obtaining the inclination angle b of the inclined part 502 according to the included angle a, and cutting the core material 50 according to the inclination angle b to form the inclined part 502.

[0107] The above technical solution can ensure the accuracy of the inclination angle of the inclined part 502 by accurately measuring the included angle a, and then calculating the inclination angle b according to the included angle a, and cutting the core material 50 according to the above calculation result to obtain the inclined part 502, which can ensure that the observation groove 503 has a better observation field of view, fully fill the gap between the main beam plate 20 and the core material 50, improve the structural strength of the gap 401, and ensure the structural stability of the main beam.

[0108] In some optional embodiments, step S401A comprises:

[0109] Obtaining a main beam plate body 40 model by modeling the main beam plate 20 stacked in the main beam mold 30;

[0110] Measuring the included angle between the side of the main beam plate body 40 model and the bottom wall of the main beam mold 30, which is the included angle a.

[0111] The above technical solution can improve the efficiency of obtaining the included angle a by modeling the main beam plate body 40.

[0112] In some optional embodiments, the step S401B comprises: calculating the inclination angle β between the side of the core material 50 and the bottom wall of the main beam mold 30, the inclination angle β being the inclination angle of the inclined part 502, wherein the inclination angle β is calculated by the following formula: β = a - θ, 0 < θ ≤ 15°. For example, θ is 8°, 9°, 10°, 11° or 12°.

[0113] In the above technical solution, the angle of the included angle a is increased by an angle θ to obtain the inclination angle β, and the increased angle θ is the angle of the observation groove 503. Therefore, the inclination angle β can be flexibly set according to the included angle a of the main beam plate body 40, the angle θ of the observation groove 503 is reasonable, a better observation field of view is obtained, and the accuracy of the size measurement of the gap 401 is improved.

[0114] In some embodiments of the present application, the step S402 specifically comprises:

[0115] S402A, obtaining the size of each direction of the observation groove 503;

[0116] S402B, manufacturing the second filler 402 according to the size of each direction of the observation groove 503;

[0117] S402C, setting the second filler 402 in the observation groove 503.

[0118] The shape of the observation groove 503 can be a triangular column, including three rectangular sides, a triangular top surface and a triangular bottom surface. The above structure is easy to manufacture and stable in structure, and any one of the rectangular sides is also convenient for firmly bonding with the core material 50 or the main beam plate body 40. Therefore, the second filler 402 can further reduce the gap between the core material 50 and the main beam plate 20, avoid the formation of resin enrichment in the observation groove 503, and ensure the overall structural strength and stability of the main beam after forming.

[0119] In some embodiments of the present application, the second filler 402 is manufactured by using the same material as the core material 50. The core material 50 is usually manufactured by using a material with high structural strength and low density, and the second filler 402 is manufactured by using the same material as the core material 50, so as to minimize the weight while ensuring that the structural strength and rigidity of the main beam meet the standards.

[0120] For reference Figs. 10-12 In some embodiments of the present application, after the step S402, the step S402.5 is further included:

[0121] S402.5a, measuring the second gap 401 of the beam plate body side through the observation groove 503 to obtain the width W2 of the second gap 401;

[0122] S402.5b, manufacturing the third filler 504 according to the width W2 of the second gap 401;

[0123] S402.5c, The third filler 504 is placed in the second notch 401.

[0124] In the above technical solution, by observing the defects on the side of the main beam plate 40 through the observation slot 503, a better field of view can be obtained, and all gaps 401 can be filled, improving the filling efficiency of gaps 401. Furthermore, by manufacturing a third filler 504 according to the width W2 of the second gap 401, the filling effect can be guaranteed, further reducing the gaps 401 between the core material 50 and the side of the main beam plate 40, thus ensuring the overall structural stability of the main beam.

[0125] like Fig. 12 As shown in Figure 13, in some embodiments of this application, step S402.5a includes:

[0126] In any two adjacent beam plates, the one closer to the first plate 201 is marked as the lower plate 204, and the one farther away from the first plate 201 is marked as the upper plate 205.

[0127] The portion of the side of the upper plate 205 that protrudes from the side of the lower plate 204 forms a second misaligned portion 206;

[0128] Measure the length of the second misaligned portion 206 along the width direction of the upper plate 205 to obtain the width W2 of the second notch 401.

[0129] For example, the width direction can be the second direction Y in the figure. In the embodiments of this application, by observing the second misaligned part 206, the misaligned part on the side of the main beam plate 20 is measured to ensure that the size of the third filler 504 matches the second misaligned part 206, thereby further improving the dimensional accuracy of the third filler 504 and improving production efficiency.

[0130] like Fig. 14 as well as Fig. 15 As shown, in some embodiments of this application, step S402.5b includes:

[0131] Obtain the thickness H2 of the 204 sheet material;

[0132] The third filler 504 is made according to the thickness H2 of the lower plate 204 and the width W2 of the second notch 401. The thickness of the third filler 504 is H2, and the width of the third filler 504 is W2 / M, where M is a positive integer.

[0133] In the technical solution, the thickness of the plurality of main beam plates 20 can be equal, and the thickness of the lower plate 204 and the other main beam plates 20 is H2. The third filler 504 has a thickness of H2 in the first direction X, a width of W2 in the second direction Y, and a length in the third direction equal to the length of the core material 50. For example, the third direction can be the length direction of the main beam. The third filler 504 can be prefabricated according to the thickness H2 of the main beam plate 20, and then cut according to the width W2 of the second gap 401 to a size matching the second gap 401. For example, the width of the prefabricated filler can be cut to 1 / N of W2, and then M third fillers 504 need to be cut, where M is any positive integer, for example, 1, 3, or 6.

[0134] Optionally, the third filler 504 is prefabricated into a filler strip of a fixed width, and the filler strip is used to fill the gap 401 of the main beam plate 20. For example, the thickness of the main beam plate 20 is 7 mm, and a plurality of 7 mm*5 mm strip-shaped fillers 402 can be manufactured. When the width of the second gap 401 is 10 mm, two strip-shaped fillers 402 can be arranged to fill the gap. It can be understood that when the width of the second gap 401 cannot match the width of an integer number of strip-shaped fillers 402, one more strip-shaped filler 402 can be arranged. For example, when the width of the second gap 401 is 12 mm, three 7 mm*5 mm strip-shaped fillers 402 can be arranged to fill the gap. The excess part can be cut, or the width of the upper core material 50 can be widened to improve the fit between the core material 50 and the main beam plate 20, reduce resin enrichment, and improve the overall stability of the main beam.

[0135] The main beam of the blade 10 provided in the embodiments of the present application is manufactured by using the manufacturing method of the main beam of the blade 10 in any of the above embodiments. In the embodiments of the present application, the gap 401 between the main beam and the core material 50 is filled by using the filler 402, and the core material 50 is laid and then resin infusion molding is performed. The above method can effectively reduce the gap size between the core material 50 and the main beam plate 40, avoid resin enrichment at the gap, and thus reduce the reduction of the strength and rigidity of the main beam caused by resin enrichment. The above method can effectively improve the strength and rigidity of the main beam, and thus is conducive to ensuring the structural strength of the blade 10 and the stability of the entire wind turbine generator system.

[0136] For reference Fig. 16 The blade provided in the embodiments of the present application includes the main beam of the blade provided in the above embodiments. The wind turbine generator system 100 provided in the embodiments of the present application includes the blade 10 provided in any of the above embodiments.

[0137] The blade and the wind turbine generator set 100 provided by the embodiments of the present application include the blade main beam provided by the above embodiments, and thus have the same technical effects, which will not be described herein again.

[0138] Finally, it should be noted that: the above embodiments are only used to illustrate the technical solutions of the present application, but not to limit them; although the present application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that: it can still modify the technical solutions recorded in the foregoing embodiments, or make equivalent replacement for part or all of the technical features; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the scope of the technical solutions of the embodiments of the present application, and they should be covered in the scope of the claims and the description of the present application. Especially, as long as there is no structural conflict, each technical feature mentioned in each embodiment can be combined in any way. The present application is not limited to the specific embodiments disclosed herein, but includes all technical solutions falling within the scope of the claims.

Claims

1. A method of manufacturing a blade spar, characterized by, The method comprises the following steps: laying and resin infusion forming of a main beam plate and a core material, the laying of the main beam plate and the core material comprising: stacking a plurality of main beam plates in a main beam mold to form a main beam plate body; measuring a gap on one side of the main beam plate body to obtain a gap size; filling the gap with a filler; laying a core material on one side of the main beam plate body, the core material being connected to the filler to obtain a main beam layup, completing the laying of the main beam plate and the core material, and the step specifically comprising: cutting one side of the core material facing the main beam plate body, one side of the core material forming an inclined portion with gradually decreasing thickness; placing the core material on one side of the main beam plate body, and the inclined portion abutting against the filler, the inclined portion and the main beam plate body enclosing an observation slot; measuring a second gap on the side edge of the main beam plate body to obtain a second gap width W2; manufacturing a third filler according to the second gap width W2; placing the third filler in the second gap; and placing a second filler in the observation slot to obtain the main beam layup.

2. The method of manufacturing a blade spar according to claim 1, characterized in that The step of measuring the gap on one side of the main beam plate body to obtain a gap size comprises: marking the main beam plate at the bottom layer as a first plate, and marking the main beam plate adjacent to the first plate as a second plate; the part of the side edge of the second plate protruding from the side edge of the first plate is a first misalignment portion; measuring the size of the first misalignment portion along the width direction of the second plate to obtain a first gap size W1.

3. The method of manufacturing a blade spar according to claim 2, wherein The step of filling the gap with a filler comprises: obtaining the thickness H1 of the first plate; manufacturing a first filler according to the thickness H1 of the first plate and the first gap width W1, the thickness of the first filler being H1, and the width of the first filler being W1 / N, N being a positive integer; placing at least one first filler on the side of the first plate facing the core material.

4. The method of manufacturing a blade spar according to claim 3, wherein The first filler and the core material are made of the same material.

5. The method of manufacturing a blade spar according to any of claims 1-4, characterized in that, The filler and the core material are adhesively connected.

6. The method of manufacturing a blade spar according to claim 5, wherein The step of cutting one side of the core material facing the main beam plate body, one side of the core material forming an inclined portion with gradually decreasing thickness, comprises: obtaining the included angle α between the plane where the side wall of the main beam plate body is located and the plane where the bottom wall of the main beam plate body is located; obtaining the inclination angle β of the inclined portion according to the included angle α, and cutting the core material according to the inclination angle β to form the inclined portion.

7. The method of manufacturing a blade spar according to claim 6, wherein The step of placing a second filler in the observation slot to obtain the main beam layup comprises: obtaining the size of each direction of the observation slot; manufacturing a second filler according to the size of each direction of the observation slot; placing the second filler in the observation slot.

8. The method of manufacturing a blade spar according to claim 7, wherein The second filler and the core material are made of the same material.

9. The method of manufacturing a blade spar according to any of claims 2-4, characterized in that, The step of measuring the second gap on the side edge of the main beam plate body to obtain a second gap width W2 comprises: marking any two adjacent main beam plates closer to the first plate as lower plates, and marking the main beam plates farther away from the first plate as upper plates; The part of the upper plate protruding in the width direction of the lower plate is a second misalignment part; The width of the second misalignment part is measured to obtain a second gap width W2.

10. The method of manufacturing a blade spar according to claim 9, wherein, The step of manufacturing a third filler according to the second gap width W2 comprises: The thickness H2 of the lower plate is obtained; A third filler is manufactured according to the thickness H2 of the lower plate and the second gap width W2, the thickness of the third filler being H2, and the width of the third filler being W2 / M, M being a positive integer.

11. A main spar for a blade, characterised in that Manufactured using the manufacturing method of the blade spar according to any one of claims 1-10.

12. A vane, characterized by A spar comprising a blade according to claim 11.

13. A wind power unit, characterized in that A blade according to claim 12.

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