A secondary mold closing method for large offshore wind turbine blades

Abstract

The application discloses a secondary mold closing method for large offshore wind power blades, which comprises the following steps: setting a leading edge positioning tool on the SS surface main beam of the blade mold and on the left and right sides of the preset installation position of the leading edge web, drawing a glue scraping auxiliary line on the SS surface main beam according to the preset installation position of the leading edge web and applying glue, positioning the leading edge web to the SS surface main beam and bonding, turning over the mold to perform the first mold closing; opening the mold, setting a trailing edge positioning tool on the SS surface auxiliary beam of the blade mold and on the left and right sides of the preset installation position of the trailing edge web, drawing a glue scraping auxiliary line on the SS surface auxiliary beam according to the preset installation position of the trailing edge web and applying glue, positioning the trailing edge web to the SS surface auxiliary beam and bonding, setting an adjusting support tool for adjusting the perpendicularity of the trailing edge web between the leading edge web and the trailing edge web, and turning over the mold to perform the second mold closing. The application can effectively solve the problem of difficult bonding and fixing of the leading edge web and the trailing edge web in the blade mold closing process.

Description

Technical Field

[0001] This invention relates to the technical field of offshore wind turbine blades, and in particular to a secondary molding method for large offshore wind turbine blades. Background Technology

[0002] With the development of wind power technology, the single-unit capacity of wind turbine generators is constantly expanding. To meet the ever-increasing single-unit capacity, the root pitch circle diameter and blade length of wind turbine blades are also continuously increasing, leading to the continuous lengthening and heightening of the shear-resistant main web of the wind turbine blade. At the same time, the original double-set "C-shaped" web has been adjusted to an "I-shaped" single web (leading edge web), which is also heightened and lengthened. Furthermore, a "C-shaped" single web (tailing edge small web) is added to the trailing edge auxiliary beam. In the actual blade production process, the traditional double-set "C-shaped" web has a small spacing, making it easy to assemble, hoist, and transport. However, for large offshore wind turbine blades using both leading edge and trailing edge small webs, the spacing between the leading edge and trailing edge small webs is much larger, exceeding 1000mm. The two webs cannot be connected together as in the traditional double-set "C-shaped" web, resulting in the two webs standing and being fixed separately, creating a new mold-making problem and posing significant difficulties for hoisting and transport.

[0003] Currently, in the actual production of large offshore wind turbine blades, the leading-edge web and trailing-edge small web need to be hoisted and transported separately to the blade shell. The secondary hoisting of the leading-edge web and trailing-edge small web, as well as the positioning of the web, requires a considerable amount of time, making it difficult to meet the curing time of the structural adhesive, thus increasing the risk of structural adhesive curing. The original one-time mold-closing process can no longer meet the production requirements of the blades. Furthermore, when hoisted separately to the blade shell, the independent web has no support points, making it prone to tipping over. During mold closing, the web is also prone to displacement and sliding, posing a significant challenge to offshore blade mold closing and easily leading to other quality problems, such as excessive gaps between the web and the shell, insufficient web verticality, and web displacement. Currently, the industry mostly uses web pressing fixtures for web positioning and bonding fixation. The advantages are high efficiency and convenient and quick positioning; the disadvantages are high overall equipment investment. For example, for a 100-meter-class offshore blade, the overall web pressing fixture costs approximately 1.8 to 2 million yuan. In addition, there are additional requirements for factory height and floor space. Therefore, given the limited factory space, it is necessary to develop new mold-making methods to meet the needs of large-blade production at sea. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of the prior art and provide a secondary molding method for large offshore wind turbine blades, which can effectively solve the problem of difficult bonding and fixing of the leading edge web and trailing edge web in the blade molding process, and ensure that the blade can be molded and produced normally.

[0005] The objective of this invention is achieved through the following technical solution:

[0006] A secondary molding method for a large offshore wind turbine blade involves first setting leading edge positioning fixtures on the SS surface main beam of the blade mold, on both sides of the preset installation position of the leading edge web. Then, adhesive application is performed on the bonding surface of the SS surface main beam according to the preset installation position of the leading edge web. The leading edge web is accurately positioned onto the bonding surface of the SS surface main beam using the leading edge positioning fixtures, bonding the leading edge web to the SS surface main beam. The verticality of the leading edge web is adjusted to meet requirements. The mold is then flipped for the first molding and heat-curing is completed. Next, the mold is opened, and the blade is positioned on the SS surface auxiliary beam and on the trailing edge web... A trailing edge positioning fixture is set on both the left and right sides of the preset installation position. A scraping guide line is drawn on the bonding surface of the SS surface auxiliary beam according to the preset installation position of the trailing edge web and glue is applied. The trailing edge web is accurately positioned on the bonding surface of the SS surface auxiliary beam according to the trailing edge positioning fixture, so that the trailing edge web and the SS surface auxiliary beam are bonded. Multiple adjustment support fixtures are evenly spaced between the leading edge web and the trailing edge web along the blade span. The verticality of the trailing edge web is adjusted to meet the requirements by adjusting the support fixtures. Glue is applied to all bonding surfaces of the PS surface. The mold is flipped over for a second mold closing. All structural glue in the bonding area is scraped and filled, and the heat curing molding is completed.

[0007] Furthermore, including steps,

[0008] S1. On the SS surface main beam of the blade mold, set a row of leading edge positioning fixtures on the left and right sides of the preset installation position of the leading edge web plate. The spacing between the two rows of leading edge positioning fixtures is adapted to the thickness of the leading edge web plate. Hoist the leading edge web plate into the space between the two rows of leading edge positioning fixtures, and test the mold to measure the upper and lower gap of the leading edge web plate. If the gap meets the requirements, proceed to the next step; otherwise, adjust the gap until it meets the requirements.

[0009] S2. Lift the front edge web plate and draw the glue scraping auxiliary line on the bonding surface of the main beam on the SS surface according to the preset installation position of the front edge web plate.

[0010] S3. Apply adhesive to the SS surface main beam according to the adhesive scraping auxiliary line, lift the front edge web plate, and position the front edge web plate to the bonding surface of the SS surface main beam according to the front edge positioning fixture, so that the front edge web plate is bonded to the SS surface main beam. Turn the mold over and press down the front edge web plate, adjust the verticality of the front edge web plate, and collect the adhesive after the mold is opened.

[0011] S4. Flip the mold for the first mold closing, reinforce the front edge web by hand lay-up, and heat the mold to solidify and form the mold.

[0012] S5. Mold opening: On the SS surface auxiliary beam of the blade mold, set a row of rear edge positioning fixtures on the left and right sides of the preset installation position of the rear edge web plate. The spacing between the two rows of rear edge positioning fixtures is adapted to the thickness of the rear edge web plate. Hoist the rear edge web plate into the space between the two rows of rear edge positioning fixtures, test close the mold and measure the mold gap. If the mold gap meets the requirements, proceed to the next step; otherwise, adjust the mold gap until it meets the requirements.

[0013] S6. Lift the rear edge web plate and draw the glue scraping auxiliary line on the bonding surface of the SS surface auxiliary beam according to the preset installation position of the rear edge web plate.

[0014] S7. Apply adhesive to the SS surface auxiliary beam according to the adhesive scraping guide line in step S6, lift the rear edge web plate, and position the rear edge web plate to the bonding surface of the SS surface auxiliary beam according to the rear edge positioning fixture, so that the rear edge web plate is bonded to the SS surface auxiliary beam.

[0015] S8. Multiple adjustment support fixtures are evenly spaced between the leading edge web and the trailing edge web along the blade span. The trailing edge web is fixed by adjusting the support fixtures to prevent the trailing edge web from sliding, shifting, or tilting. At the same time, the verticality of the trailing edge web is adjusted by adjusting the support fixtures.

[0016] S9. Flip the mold and press down the rear edge web plate, open the mold and collect the glue, and at the same time apply glue to all bonding surfaces of the PS surface.

[0017] S10. Flip the mold to close it for the second time, scrape off the structural adhesive filling all the bonding areas, and complete the heating and curing process.

[0018] Furthermore, the two ends of the adjusting support fixture are respectively connected to the front edge web and the rear edge web, and it includes a support rod, an adjusting rod, a trapezoidal nut, a U-shaped hinge, and a pressure plate. There are two support rods, which are coaxially and symmetrically arranged on the left and right sides of the adjusting rod. Each support rod has a trapezoidal nut at the end near the adjusting rod, and the trapezoidal nut is threaded to the adjusting rod. Each support rod has a U-shaped hinge at the end away from the adjusting rod, and each U-shaped hinge is connected to a pressure plate through a hinge shaft. The two pressure plates are respectively connected to the front edge web and the rear edge web.

[0019] Furthermore, before hoisting the leading and trailing edge webs, multiple Ω-shaped tubular ears are arranged at intervals along the blade span for adjusting the positioning of the support fixtures, and the Ω-shaped tubular ears on the trailing edge web and the leading edge web are horizontally corresponding one to one.

[0020] Furthermore, both the leading edge positioning fixture and the trailing edge positioning fixture are composed of multiple positioning blocks arranged at equal intervals.

[0021] Compared with the prior art, the present invention has the following advantages and beneficial effects:

[0022] 1. This invention adopts a two-stage mold closing process, which can effectively shorten the time for applying structural adhesive during a single mold closing, reduce the risk of structural adhesive curing, reduce the difficulty of hoisting and transportation, reduce the occupation of production space, and improve product quality.

[0023] 2. This invention provides an adjustment support fixture between the front and rear web plates. The adjustment support fixture has a simple structure, is easy to install, easy to process, and reusable. It can effectively prevent the web plates from shifting, sliding, and tipping over during mold closing. Furthermore, the verticality of the web plates is easy to adjust, and the fixture has a low cost of less than 1,000 yuan, which greatly reduces costs and makes it highly practical. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the structure of the present invention, which includes an adjustment support fixture between the leading and trailing web plates.

[0025] Figure 2 This is a schematic diagram of the structure of the present invention, showing the glue scraping auxiliary lines drawn on the SS surface main beam.

[0026] Figure 3 This is a schematic diagram of the structure of the positioning rear edge web of the present invention.

[0027] Figure 4 This is a schematic diagram of the structure of the present invention, showing the glue scraping auxiliary lines drawn on the SS surface auxiliary beam.

[0028] Figure 5 This is a schematic diagram of the adjustment support tooling of the present invention. Detailed Implementation

[0029] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are some embodiments of the present invention, but not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0030] like Figure 1As shown, this embodiment provides a secondary molding method for large offshore wind turbine blades. The method first sets up leading edge positioning fixtures on the SS surface main beam of the blade mold, on both sides of the preset installation position of the leading edge web. On the bonding surface of the SS surface main beam, according to the preset installation position of the leading edge web, an auxiliary line for applying adhesive is drawn and adhesive is applied. The leading edge web is accurately positioned onto the bonding surface of the SS surface main beam according to the leading edge positioning fixtures, so that the leading edge web is bonded to the SS surface main beam. The verticality of the leading edge web is adjusted to meet the requirements. The mold is flipped over for the first molding and heat curing is completed. Then, the mold is opened, and on the SS surface auxiliary beam of the blade mold, at the trailing edge... Rear edge positioning fixtures are set on the left and right sides of the preset installation position of the web plate. On the bonding surface of the SS surface auxiliary beam, the glue scraping auxiliary line is drawn according to the preset installation position of the rear edge web plate and glue is applied. The rear edge web plate is accurately positioned on the bonding surface of the SS surface auxiliary beam according to the rear edge positioning fixtures, so that the rear edge web plate and the SS surface auxiliary beam are bonded. Multiple adjustment support fixtures 8 are evenly spaced between the front edge web plate 7 and the rear edge web plate 3 along the blade span. The verticality of the rear edge web plate is adjusted to meet the requirements by adjusting the support fixtures 8. Glue is applied to all bonding surfaces of the PS surface. The mold is flipped over for the second mold closing. All structural glue in the bonding area is scraped and filled, and the heat curing molding is completed.

[0031] The specific steps of this method are as follows:

[0032] S1. On the SS surface main beam of the blade mold, a row of leading edge positioning fixtures is set on the left and right sides of the preset installation position of the leading edge web plate. The spacing between the two rows of leading edge positioning fixtures is adapted to the thickness of the leading edge web plate. Each row of leading edge positioning fixtures consists of multiple positioning blocks set at equal intervals. The leading edge web plate is hoisted and placed between the two rows of leading edge positioning fixtures. The mold is closed for trial to measure the upper and lower gap of the leading edge web plate. If the gap meets the requirements, proceed to the next step. Otherwise, adjust the gap until it meets the requirements.

[0033] S2. Lift the leading edge web, such as Figure 2 As shown, draw the glue scraping auxiliary line 2 on the bonding surface of the SS surface main beam 1 according to the preset installation position of the front edge web plate, clean the auxiliary materials, and ensure the cleanliness of the bonding surface.

[0034] S3. Apply a certain thickness of structural adhesive to the SS surface main beam according to the adhesive application guide line to ensure that the adhesive thickness meets the process requirements. Lift the inspected and qualified front edge web plate and quickly and accurately position the front edge web plate onto the bonding surface of the SS surface main beam according to the front edge positioning fixture to bond the front edge web plate to the SS surface main beam. Turn the mold over and press down the front edge web plate to ensure the verticality of the front edge web plate. After opening the mold, scrape and squeeze out the excess structural adhesive and fill the missing adhesive areas.

[0035] S4. Flip the mold for the first mold closing to ensure that the position and perpendicularity of the leading edge web meet the requirements. Hand lay up the leading edge web reinforcement and turn on the mold heating system to ensure that the structural adhesive cures to meet the process requirements.

[0036] S5. Mold opening: On the SS surface auxiliary beam of the blade mold, a row of trailing edge positioning fixtures is set on both the left and right sides of the preset installation position on the trailing edge web. The spacing between the two rows of trailing edge positioning fixtures is adapted to the thickness of the trailing edge web. Each row of trailing edge positioning fixtures consists of multiple positioning blocks arranged at equal intervals. To facilitate the installation of the adjustment support fixture, multiple Ω-shaped ears for adjusting the support fixture can be arranged at intervals along the blade spanwise on the leading and trailing edge webs, ensuring that the Ω-shaped ears on the trailing edge web and the leading edge web are horizontally aligned. The adjustment support fixture can be quickly installed by using the Ω-shaped ears for positioning. Then, as follows... Figure 3 As shown, the rear edge web plate 3 is hoisted and placed between the two rows of positioning blocks 4. The mold is closed for trial and the gap between the mold joints is measured. Specifically, the gap between the upper and lower parts of the rear edge web plate, the PS surface of the front edge web plate, the front edge bonding angle, and the rear edge bonding surface is measured. If the gap between the mold joints meets the requirements, proceed to the next step; otherwise, adjust the gap between the mold joints until it meets the requirements.

[0037] S6. Lift the rear edge web, as follows: Figure 4 As shown, draw the glue scraping auxiliary line 6 on the bonding surface of the SS surface auxiliary beam 5 according to the preset installation position of the rear edge web plate, clean the auxiliary material, and ensure the cleanliness of the bonding surface.

[0038] S7. Apply adhesive to the SS auxiliary beam according to the adhesive scraping guide line in step S6, lift the rear edge web plate, and vertically position the rear edge web plate to the bonding surface of the SS auxiliary beam according to the rear edge positioning fixture, so that the rear edge web plate is bonded to the SS auxiliary beam.

[0039] S8. Multiple adjustment support fixtures are evenly spaced between the leading edge web and the trailing edge web along the blade span through Ω-shaped ears. The trailing edge web is fixed by the adjustment support fixtures to prevent the trailing edge web from sliding, shifting, or tilting. At the same time, the verticality of the trailing edge web is adjusted by the adjustment support fixtures.

[0040] S9. Flip the mold and press down the rear edge web plate, open the mold and collect the glue. Apply glue to all bonding surfaces of the PS surface (including the front edge bonding corner, the PS surface of the front edge web plate, the PS surface edge of the rear edge web plate and the rear edge bonding surface). The thickness and width of the glue application must meet the process requirements.

[0041] S10. Flip the mold and close it for the second time to ensure the perpendicularity of the front and rear web plates. Scrape and fill all the structural adhesive in the bonding areas. Turn on the mold heating system to ensure that the structural adhesive cures to meet the process requirements.

[0042] like Figure 5As shown, the adjusting support fixture 8 includes a support rod 801, an adjusting rod 802, a trapezoidal nut 803, a U-shaped hinge 804, a pressure plate 805, and a hinge shaft 806. There are two support rods, which are coaxially and symmetrically arranged on the left and right sides of the adjusting rod. Each support rod has a trapezoidal nut at the end near the adjusting rod, and the trapezoidal nut is threaded to the adjusting rod. Each support rod has a U-shaped hinge at the end away from the adjusting rod. Each U-shaped hinge is connected to a pressure plate through a hinge shaft (i.e., a hexagonal bolt and a nut). The two pressure plates are connected to the front web plate and the rear web plate, respectively.

[0043] The above description is merely a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope disclosed in the present invention, based on the technical solution and inventive concept of the present invention, shall fall within the scope of protection of the present invention.

Claims

1. A method for secondary molding of large offshore wind turbine blades, characterized in that, The method first involves setting leading edge positioning fixtures on the SS surface main beam of the blade mold, on both sides of the preset installation position of the leading edge web. Then, auxiliary lines for applying adhesive are drawn on the bonding surface of the SS surface main beam according to the preset installation position of the leading edge web, and adhesive is applied. The leading edge web is accurately positioned onto the bonding surface of the SS surface main beam using the leading edge positioning fixtures, allowing the leading edge web to bond with the SS surface main beam. The perpendicularity of the leading edge web is adjusted to meet the requirements. The mold is then flipped for the first mold closing and heat curing. Next, the mold is opened, and the leading edge web is positioned on the SS surface auxiliary beam of the blade mold, on both sides of the preset installation position of the trailing edge web. Both sides are equipped with rear edge positioning fixtures. On the bonding surface of the SS surface auxiliary beam, draw the glue scraping auxiliary line according to the preset installation position of the rear edge web and apply glue. According to the rear edge positioning fixtures, accurately position the rear edge web onto the bonding surface of the SS surface auxiliary beam, so that the rear edge web and the SS surface auxiliary beam are bonded. Along the blade span, set multiple adjustment support fixtures evenly at intervals between the leading edge web and the trailing edge web. Adjust the verticality of the trailing edge web to meet the requirements by adjusting the support fixtures. Apply glue to all bonding surfaces of the PS surface. Turn the mold over for a second mold closing. Scrape and fill all the structural glue in the bonding area and complete the heat curing molding.

2. The secondary molding method for large offshore wind turbine blades according to claim 1, characterized in that, Including steps, S1. On the SS surface main beam of the blade mold, set a row of leading edge positioning fixtures on the left and right sides of the preset installation position of the leading edge web plate. The spacing between the two rows of leading edge positioning fixtures is adapted to the thickness of the leading edge web plate. Hoist the leading edge web plate into the space between the two rows of leading edge positioning fixtures, and test the mold to measure the upper and lower gap of the leading edge web plate. If the gap meets the requirements, proceed to the next step; otherwise, adjust the gap until it meets the requirements. S2. Lift the front edge web plate and draw the glue scraping auxiliary line on the bonding surface of the main beam on the SS surface according to the preset installation position of the front edge web plate. S3. Apply adhesive to the SS surface main beam according to the adhesive scraping auxiliary line, lift the front edge web plate, and position the front edge web plate to the bonding surface of the SS surface main beam according to the front edge positioning fixture, so that the front edge web plate is bonded to the SS surface main beam. Turn the mold over and press down the front edge web plate, adjust the verticality of the front edge web plate, and collect the adhesive after the mold is opened. S4. Flip the mold for the first mold closing, reinforce the front edge web by hand lay-up, and heat the mold to solidify and form the mold. S5. Mold opening: On the SS surface auxiliary beam of the blade mold, set a row of rear edge positioning fixtures on the left and right sides of the preset installation position of the rear edge web plate. The spacing between the two rows of rear edge positioning fixtures is adapted to the thickness of the rear edge web plate. Hoist the rear edge web plate into the space between the two rows of rear edge positioning fixtures, test close the mold and measure the mold gap. If the mold gap meets the requirements, proceed to the next step; otherwise, adjust the mold gap until it meets the requirements. S6. Lift the rear edge web plate and draw the glue scraping auxiliary line on the bonding surface of the SS surface auxiliary beam according to the preset installation position of the rear edge web plate. S7. Apply adhesive to the SS surface auxiliary beam according to the adhesive scraping guide line in step S6, lift the rear edge web plate, and position the rear edge web plate to the bonding surface of the SS surface auxiliary beam according to the rear edge positioning fixture, so that the rear edge web plate is bonded to the SS surface auxiliary beam. S8. Multiple adjustment support fixtures are evenly spaced between the leading edge web and the trailing edge web along the blade span. The trailing edge web is fixed by adjusting the support fixtures to prevent the trailing edge web from sliding, shifting, or tilting. At the same time, the verticality of the trailing edge web is adjusted by adjusting the support fixtures. S9. Flip the mold and press down the rear edge web plate, open the mold and collect the glue, and at the same time apply glue to all bonding surfaces of the PS surface. S10. Flip the mold to close it for the second time, scrape off the structural adhesive filling all the bonding areas, and complete the heating and curing process.

3. The secondary molding method for large offshore wind turbine blades according to claim 2, characterized in that: The adjusting support fixture has two ends connected to the front and rear web plates, respectively. It includes a support rod, an adjusting rod, a trapezoidal nut, a U-shaped hinge, and a pressure plate. There are two support rods, which are coaxially and symmetrically arranged on the left and right sides of the adjusting rod. Each support rod has a trapezoidal nut at the end near the adjusting rod, and the trapezoidal nut is threaded to the adjusting rod. Each support rod has a U-shaped hinge at the end away from the adjusting rod. Each U-shaped hinge is connected to a pressure plate through a hinge shaft. The two pressure plates are connected to the front and rear web plates, respectively.

4. The secondary molding method for large offshore wind turbine blades according to claim 2, characterized in that: Before hoisting the leading and trailing edge webs, multiple Ω-shaped tubular ears are arranged at intervals along the blade span for adjusting the limiting position of the support fixture, and the Ω-shaped tubular ears on the trailing edge web and the Ω-shaped tubular ears on the leading edge web are horizontally corresponding one to one.

5. The secondary molding method for large offshore wind turbine blades according to claim 2, characterized in that: Both the leading edge positioning fixture and the trailing edge positioning fixture are composed of multiple positioning blocks arranged at equal intervals.

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